Valve Manufacturing Plant

VALVE MANUFACTURING PLANT

[EIRI/EDPR/4781] J.C.: 3001XL

INTRODUCTION

A valve is a device that regulates controls or directs the flow of a fluid by opening, closing, or partially obstructing fluid flow. A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids or slurries) by opening, closing or partially obstructing various passageways. Valves are technically called as valves fittings, but are usually discussed as a separate category. In an open valve, fluid flows in a direction from higher to lower pressure. The word is derived from the Latin word “valva”, the moving part of a door, in turn from volvere, to turn, roll.

Valves have many uses, including controlling fluid flow for irrigation, industrial uses, controlling process and residential uses such as on/off and pressure control to dish and clothes washer and taps in the home. Even aerosols have a tiny valve built in valves are also used in the military and transport sectors.

Basically, it controls flow & pressure. Different types of valves are used to serve these functions. There are mainly about 9 Different Types of Valves used in Piping such as Gate Valve, Globe Valve, Check Valve, Plug valve, Ball Valve, Butterfly Valve, Needle Valve, Pinch Valve and Pressure Relief Valve. The item proposed is basically a casting, machined & assembled product. The castings of metals and alloys of copper, zinc, tin, aluminium, lead, alloy steel, CI etc. come under the group of non-ferrous & Ferrous castings. Some of the prominent valve castings are Brass, Bronze, Aluminium Bronze, Gun Metal, Stainless Steel; Cast Iron etc. are used to manufacture various types of valves for domestic and industrial applications.

The global industrial valves market size was valued at USD 48.1 billion in 2020 and is projected to reach USD 85.7 billion by 2025. It is expected to grow at a Compound Annual Growth Rate (CAGR) of 12.3% during the forecast period. Increasing demand for valves from the pharmaceuticals industry due to the outbreak of the COVID-19 pandemic, growing focus on the development of smart cities globally, rising need for connected networks to maintain and monitor industrial equipment, and surging requirement for establishing new nuclear power plants and revamping existing ones are the key driving factors for the industrial valves market.

The world is facing an economic crisis caused by the COVID-19 pandemic outbreak. The pandemic has affected the oil & gas industry badly, with oil prices slashing like never before. Major producers of oil are running out of storage space for extracted oil, and the demand is on a declining trend. This has resulted in a huge gap between supply and demand. Oil & gas is one of the key industries using valves. 

The water & wastewater treatment and energy & power industries are also among the key end-users of valves. These industries are also witnessing a shrinking demand due to the pandemic situation globally. There is a restriction on foreign trades due to the lockdown of international borders, non-operational distribution channels, and various government laws to take precautionary measures for public health and safety. However, it is expected that there will be an increasing focus on hygiene and sanitation due to the rise in people’s concern for a better and safer lifestyle. An increase in demand from the energy & power sector is also likely to drive the industrial valves market for the energy & power end-use industry gradually from 2021 to 2025. Metallic valves are non-ferrous & ferrous castings depending upon applications, are fast consuming items and the area of application for these items are vast due to their certain inherent advantages of mechanical and chemical properties.

COST ESTIMATION

Plant Capacity            300 Nos/Day

Land & Building (1 Acre)    Rs. 1.86 Cr

Plant & Machinery                    Rs. 2.69 Cr

Working Capital for 2 Months    Rs. 4.61 Cr

Total Capital Investment          Rs. 9.68 Cr

Rate of Return                          48%

Break Even Point                      39%

CONTENTS

INTRODUCTION

FIG. 1: BALL VALVE IN CLOSED POSITION

HSN CODE OF THE PRODUCT:

NIC CODE OF THE PRODUCT:

GOVERNING INTERNATIONAL SPECIFICATION:

VALVES ARE CATEGORIZED AS FOLLOWS:

WAYS OF OPERATING VALVES

HAND WHEEL & LEVER OPERATED:-

ACTUATOR OPERATED VALVES:-

LIMIT SWITCH OPERATED VALVES:-

THE INDIAN STANDARDS ARE MAINLY FOLLOWED ARE AS MENTIONED BELLOW:

DIFFERENT TYPES OF VALVES

TYPES OF VALVES & SPECIFICATIONS

DETAILS OF THE PRODUCT LICENCE TO BE OBTAINED

THE TECHNOLOGY EXISTING FOR MANUFACTURING OF THE PRODUCT

INDIA INDUSTRIAL VALVES APPLICATION AREA:

SUGGESTED MODERN TECHNOLOGY FOR IMPLEMENTATION OR AVAILABLE IN THE MARKET:

RAW MATERIAL REQUIRED AND AVAILABILITY COVERING RAW MATERIAL STANDARDS INDIAN/INTERNATIONAL STANDARDS

MATERIALS USED IN VALVES

SPECIFICATIONS:

A) BRASS VALVES

B) BRONZE VALVES:

C) CAST IRON VALVES:

D) STAINLESS STEEL:

MATERIALS FOR BALL VALVES

1. PVC

2. CPVC

3. BRONZE AND BRASS

4. IRON

5. STAINLESS STEEL

CONSTRUCTION OF A BALL VALVE

FIG. 2: LUBRICANT-SEAL SYSTEM IN A BALL VALVE

TYPES OF BALL VALVES

SPLIT-BODY BALL VALVE

FIG. 3: BALL VALVES, SPLIT BODY, REGULAR PORT, FLANGED ENDS

TOP-ENTRY BALL VALVE

FIG. 4: BALL VALVES, TOP ENTRY, REGULAR PORT, SOCKET WELD ENDS

END-ENTRY BALL VALVE

THREE-PIECE — BODY BALL VALVE

DOUBLE TRUNNION BALL VALVES

LUBRICATED OR NON-LUBRICATED BALL VALVES

ADVANTAGES OF BALL VALVES

THE FOLLOWING ARE THE ADVANTAGES OF BALL VALVES:

DISADVANTAGES OF BALL VALVES

TYPICAL APPLICATIONS OF BALL VALVES

B.I.S. SPECIFICATION

PROCESS FLOW CHART

MANUFACTURING PROCESS

THE MAIN STEPS ARE GIVEN BELOW:

1. PROCUREMENT OF BRASS BILLET

2. CUTTING THE BRASS BILLET FOR REQUIRED SIZE FOR BALL AND VALE BODY

3. HEATING THE BRASS BILLET UP TO FORGING TEMP.

4. CLOSE-DIE FORGING PROCESS

ADVANTAGES OF CLOSED DIE FORGING:

HIGH STRENGTH

LEAK RESISTANCE

CLOSE TOLERANCES

LOW OVERALL COST

5. TRIMMING AND CLIPPING

6. DIP FINISHING

7. HEAT TREATMENT

ANNEALING

ANNEALING (FULL)

STRESS RELIEVING

TEMPER ANNEALING

8. MACHINING

9. QUALITY CONTROL

ACTIVITIES

INSPECTION OF PACKING AND DISPATCH

INSPECTION OF IN-COMING MATERIALS

IN-PROCESS INSPECTION

FINAL INSPECTION

CONTROL OF MEASURING, INSPECTION TOOLS AND TEST EQUIPMENTS

10. TESTING

HYDROSTATIC TESTING

LOW PRESSURE GAS SEAT TESTING

HIGH PRESSURE GAS TESTING

HIGH TEMPERATURE TESTING

FUGITIVE EMISSION TESTING

ANTISTATIC TESTING

TORQUE TESTING

CAVITY RELIEF TESTING

DOUBLE BLOCK & BLEED (DBB) TESTING

11. PACKAGING

INDIAN MANUFACTURING INDUSTRY

INTRODUCTION

MARKET SIZE

INVESTMENT

GOVERNMENT INITIATIVES

ROAD AHEAD

MARKET POSITION

MARKET SIZE ESTIMATION

TOP KEY PLAYERS IN INDIA FOR INDUSTRIAL VALVE MARKET

MARKET OVERVIEW

KEY MARKET DRIVERS

GROWING INFRASTRUCTURE DEVELOPMENT

INCREASING DEMAND IN THE OIL AND GAS INDUSTRY

EMPHASIS ON WATER AND WASTEWATER MANAGEMENT

KEY MARKET CHALLENGES

ECONOMIC VOLATILITY AND POLITICAL UNCERTAINTY

INFRASTRUCTURE GAPS AND REGIONAL DISPARITIES

INTENSE COMPETITION AND PRICE PRESSURE

KEY MARKET TRENDS

INCREASING EMBRACE OF DIGITALIZATION AND SMART VALVES

SUSTAINABILITY AND ENVIRONMENTAL COMPLIANCE

SEGMENTAL INSIGHTS

MATERIAL TYPE INSIGHTS

APPLICATION INSIGHTS

BEST BUTTERFLY VALVE MANUFACTURERS

IN INDIA

DOMBOR

L&T VALVES

KIRLOSKAR VALVES

AMCO INDUSTRIAL VALVES

AMTECH VALVES

BRAY INDIA PVT. LTD.

VIP INDUSTRIAL VALVES

HAWA VALVES

SVR VALVES

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

KEY REGULATIONS AND POLICIES

BUREAU OF INDIAN STANDARDS ACT, 2016 (“BUREAU OF INDIAN STANDARDS ACT”)

BUREAU OF INDIAN STANDARDS RULES, 2018 (“BUREAU OF INDIAN STANDARDS RULES”)

STEEL AND STEEL PRODUCTS (QUALITY CONTROL) ORDER, 2020 (“QC ORDER”)

NATIONAL STEEL POLICY, 2017 (“NSP 2017”)

INDUSTRIAL AND LABOUR LAWS

THE FACTORIES ACT, 1948 (THE “FACTORIES ACT”)

ENVIRONMENTAL LAWS

THE ENVIRONMENT PROTECTION ACT, 1986 (THE “ENVIRONMENT PROTECTION ACT”) AND THE ENVIRONMENT (PROTECTION) RULES, 1986 (THE “ENVIRONMENT PROTECTION RULES”)

AIR (PREVENTION AND CONTROL OF POLLUTION) ACT, 1981 (THE “AIR ACT”)

THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974 (THE “WATER ACT”)

NOISE POLLUTION (REGULATION AND CONTROL) RULES, 2000 (“NOISE POLLUTION RULES”)

HAZARDOUS AND OTHER WASTES (MANAGEMENT AND TRANSBOUNDARY MOVEMENT) RULES, 2016 (THE “HAZARDOUS WASTE RULES”)

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT LAYOUT

VALVE MANUFACTURERS

DETAILS OF RAW MATERIALS SUPPLIERS

DETAILS OF MACHINERY SUPPLIERS

SUPPLIERS OF BRASS BALL VALVE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF BRASS BILLET

SUPPLIERS OF FKM O-RING AND PTFE SEAL

SUPPLIERS OF NICKEL INGOT

SUPPLIERS OF PICKLING ACIDS

SUPPLIERS OF PACKING MATERIALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF BILLET CUTTING MACHINE

SUPPLIERS OF ELECTROPLATING PLANT

SUPPLIERS OF ANNEALING FURNACES

SUPPLIERS OF HEAT TREATMENT FURNACE

SUPPLIERS OF HARDNESS TESTING MACHINE

SUPPLIERS OF CLOSE DIE HOT FORGING MACHINE

SUPPLIERS OF FORGING DIES

SUPPLIERS OF INDUCTION HEATING FURNACE

SUPPLIERS OF CNC LATHE MACHINE

SUPPLIERS OF CNC MACHINING CENTRE

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF DG SETS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

SUPPLIERS OF SUBMERSIBLE WATER PUMP

LIST OF DOCUMENTS REQUIRED TO GET FOR LICENSES

DOCUMENTS:

OTHER LICENSES REQUIRED FOR THE SETUP:

IMPLEMENTATION SCHEDULE

ORGANIZATION CHART

STATUTORY APPROVALS FROM GOVERNMENT

SCHEMES AND CONSULTANCY SERVICES

PROPOSED SCHEMES (IF EXISTING IS NOT SUITABLE)

DETAILS OF AGENCIES WHO CAN PROVIDE GUIDANCE (CSIR, MSME, SECTOR COUNCILS ETC.)

DETAILS OF TEST FACILITIES AVAILABLE IN INDIA

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

STEEL PRODUCTS MANUFACTURING CONSULTANT

LIST OF MACHINES

I. LATHES

II. DRILLING MACHINES

III. MILLING MACHINE

IV. BORING MACHINE

V. VERTICAL TURRET LATHE MACHINE

VI. TAPPING MACHINE

VII. CNC MACHINE (HORIZONTAL AXIS MACHINES)

VIII. VMC MACHINE 

IX. VTL CNC MACHINE

HMC - HORIZONTAL MACHINING CENTER

HORIZONTAL BORING MACHINE

X. AIR COMPRESSOR

XI. HYDRAULIC TEST RIGS

XII. GENERATOR

XII. LAPPING MACHINE 

XIII. OTHER MACHINES

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)