Detailed Project Report on lpg cylinder valves manufacturing plant

LPG CYLINDER VALVES MANUFACTURING PLANT
 [CODE NO.3422]


Valves are a type of mechanical device that are implemented to regulate flow, pressure, or both, within a system. They an integral aspect of any piping system that requires a fair amount of control. The primary functions of a conventional valve comprise flow control in the form of rate of flow and the direction of flow. Valves are thus used to prevent back flow, and relieving pressure. The various valve types, designs, and models can be functional in specific industrial, commercial, and residential applications.
 
 LPG valves may need to be designed especially for maintaining high pressure within the cylinder and to let out the gas at a rate specified and within regulatory permission. These valves are also designed to withstand the possible damage they may take during transportation. An additional cap is often screwed over the valve in order to further reduce the likelihood of gas leakage when the cylinder is not in use.

The gas cylinder valve is the primary safety mechanism on a gas cylinder and shall not be tampered with. It is a device used to contain the contents of the cylinder that is under pressure. Cylinder valves are fitted with pressure relief valves of different types (depending on the cylinder) to protect against catastrophic failure of the cylinder valve.

Cylinder valves open in an anticlockwise direction and close in a clockwise direction. Valves shall never be opened without a regulator attached. Always open cylinder valves slowly.

There two basic types of LP Gas cylinder valves for vapour service, namely, self-closing, clip-on valves and hand wheel operated valves. They can come with or without pressure relief valves depending on local regulations.

1 .Self-Closing, Clip-on Valve

 These are typically used for domestic cylinders where low cost and fit for service valves are required. Common types in the market are compact, bayonet, or snap on (snap tight) valves. They can be fitted with excess flow limiters and/or anti-dirt tubes (also called eduction tubes). Because these valves are open-topped, plastic dust caps are recommended to be fitted during storage and transportation to prevent entry of foreign matter

Performance requirements

i) The valve shall be of the self-closing type, closed by gas pressure in the cylinder assisted by a small stainless steel spring.

ii) The valve shall be completely gas-tight and shall have no regulating function that can restrict high filling rates.

iii) The 13kg and 50kg cylinder valves shall be with a safety relief valve. The 3kg and 6kg cylinder shall be fitted with camping valves

iv) If it is with a safety relief valve, then the safety relief valve shall be of pop-action type and shall have a set pressure of 2.55 MPa.



COST ESTIMATION

Plant  Capacity                                           :       6000.00 Nos./day                                           
land & Building (3000 Sq.mtr)                :    Rs.  1.80 Cr
Plant & Machinery                                     :    Rs.  1.81 Cr
Working Capital for 2 Months                 :    Rs.  1.77 Cr
Total Capital Investment                          :    Rs.  5.67 Cr
Rate of Return                                           :    32%
Break Even Point                                      :    51%

INTRODUCTION                                            
PARTS OF LPG VALVE                                        
B.I.S SPECIFICATION                                        
MARKET SURVEY                                            
LPG IN INDIA                                            
PRADHAN MANTRI UJJWALA YOJANA                            
INDIA LPG MARKET (2012-2026): INCREASING CONSUMPTION OF LPG TO
PRODUCE VARIOUS CHEMICAL COMPONENTS - RESEARCH AND MARKETS    
MAIN INDUSTRY                                            
INDIAN LPG SCENARIO                                        
ANALYSIS OF IMPORT OF LPG VALVE                            
ANALYSIS OF EXPORT OF LPG VALVE                            
MANFACTURERS/SUPPLIERS OF LPG CYLINDER VALVE                
MANUFACTURING PROCESS                                    
CLOSED DIE FORGING PROCESS OPERATIONS                        
ADVANTAGES OF CLOSED DIE FORGING:                        
INSPECTION OF PACKING AND DESPATCH.                        
FINAL INSPECTION                                        
CONTROL OF MEASURING, INSPECTION TOOLS AND TEST EQUIPMENTS    
PROCESS FLOW CHART                                    
PLANT LAYOUT                                            
CHINA SUPPLIERS FOR COMPLETE PLANT                        
SUPPLIERS OF PLANT AND MACHINERIES                        
BRASS BILLET CUTTING MACHINE                                
INDUCTION HEATING FURNACE                                
CNC LATHE                                                
CNC MACHINING CENTRE                                    
SHOT BLASTING MACHINE                                    
METAL TESTING MACHINE                                    
AIR POLLUTION CONTROL EQUIPMENTS                            
SUPPLIERS OF AIR COMPRESSOR                                
PLATFORM WEIGHING MACHINE                                
MATERIAL HANDLING EQUIPMENTS                            
FIRE FIGHTING EQUIPMENTS                                
SUPPLIERS OF RAW MATERIALS                                
BRASS BILLET                                            
NITRILE RUBBER SEAL                                        
VALVE SPRING                                            
PICKLING ACIDS                                            
PACKAGING MATERIALS                                    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET