Detailed Project Report on DUCTILE IRON PIPE (DI PIPE) (PRODUCTION RATE – 50,000 TPA)

Ductile iron is a family of cast graphitic irons which possess high strength, ductility and resistance to shock. Annealed cast ductile iron can be bent, twisted or deformed without fracturing. Its strength, toughness and ductility duplicate many grades of steel and far exceed those of standard gray irons. Yet it possesses the advantages of design flexibility and low-cost casting procedures similar to gray iron. The difference between ductile iron and gray iron is in the graphite formation. Ordinary gray iron is characterized by a random flake graphite pattern in the metal. In ductile iron the addition of a few hundredths of 1 % of magnesium or cerium causes the graphite to form in small spheroids rather than flakes. These create fewer discontinuities in the structure of the metal and produce a stronger, more ductile iron. This nodular graphite structure inhibits the creation of linear cracks hence the ability to withstand distortion.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org





DUCTILE IRON PIPE (DI PIPE) (PRODUCTION
RATE – 50,000 TPA)
[EIRI/EDPR/4726] J.C.: 2946XL

Ductile iron is a family of cast graphitic irons which possess high strength,
ductility and resistance to shock. Annealed cast ductile iron can be bent, twisted
or deformed without fracturing. Its strength, toughness and ductility duplicate
many grades of steel and far exceed those of standard gray irons. Yet it possesses
the advantages of design flexibility and low-cost casting procedures similar to gray
iron. The difference between ductile iron and gray iron is in the graphite
formation. Ordinary gray iron is characterized by a random flake graphite pattern
in the metal. In ductile iron the addition of a few hundredths of 1 % of magnesium
or cerium causes the graphite to form in small spheroids rather than flakes. These
create fewer discontinuities in the structure of the metal and produce a stronger,
more ductile iron. This nodular graphite structure inhibits the creation of linear
cracks hence the ability to withstand distortion.

With ductile iron, the safety and reliability of process equipment is improved. The
improved mechanical properties increase its resistance to breakage from physical
load, or mechanical and thermal shock far above that of gray iron. The corrosion
resistance of ductile iron is equal or superior to gray cast iron and to cast steel in
many corrosives. Its wear resistance is comparable to some of the best grades of
steel and superior to gray iron in heavy load or impact load situations. Since it
can be cast with the same low-cost procedures used for gray cast iron, it is
considerably less expensive than cast steel and only moderately more expensive
than gray iron. The substantial advantages obtained from its high yield strength
and ductility make it an economical choice for many applications.

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CONTENTS

INTRODUCTION

TYPICAL MICRO STRUCTURE OF DUCTILE IRON

WHILE THERE ARE MANY DIFFERENT DUCTILE IRON SPECIFICATIONS,
FOUNDRIES ROUTINELY OFFER 3 COMMON GRADES;

PROPERTIES

PROPERTIES OF DUCTILE IRON PIPE

RANGES & DIMENSIONS

RANGES

DIMENSION OF PIPES THICKNESS OF DUCTILE IRON PIPES

BENEFITS

CHARACTERISTICS

THE FOLLOWING ARE THE TYPES OF JOINTS USUALLY USED FOR

DUCTILE IRON PIPES

THERE ARE MAINLY THREE SECTIONS OF DUCTILE IRON PIPE:

SOCKET

BARREL

SPIGOT

ADVANTAGES/DISADVANTAGES

ADVANTAGES

DISADVANTAGES

USES/APPLICATIONS

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BIS SPECIFICATION

MARKET OVERVIEW

INDIA DUCTILE IRON PIPES MARKET TRENDS

DUCTILE IRON PIPES MARKET DYNAMICS:

DUCTILE IRON PIPES MARKET REGIONAL INSIGHTS:

DUCTILE IRON PIPES MARKET KEY PLAYERS

MANUFACTURERS/SUPPLIERS

RAW MATERIALS SUPPLIERS

PIG IRON

CAST IRON SCRAP

STEEL SCRAP

SILICON CARBIDE

FERRO SILICON

MAGNESIUM INGOT

FERRO MANGANESE

FIRE CLAY

BENTONITE

COAL DUST

GRAPHITE POWDER

SILICA SAND

LIME STONE

MANUFACTURING PROCESS STEPS

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RAW MATERIAL SELECTION

DESULPHURISATION

MELTING AND COMPOSITION CONTROL

MAGNESIUM TREATMENT

NODULISING

INOCULATION

EFFECT OF INOCULATION

MOULD CONDITIONING

CORE MAKING

CASTING

CENTRIFUGAL CASTING

ESSENTIALLY, TWO WORKING METHODS ARE USED:

DE LAVAUD PROCESS

WET-SPRAY PROCESS

INTERNAL GRINDING

HEAT TREATMENT

ZINC COATING

CUT OFF AND CHAMFERING MACHINE

HYDROSTATIC PRESSURE TESTING

CEMENT MORTAR FEEDING AND LINING

STEAM CURING

INTERNAL POLISHING

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BITUMEN COATING

QUALITY CONTROL

MARKING AND STENCILING

STORAGE, PACKING AND DISPATCH

PROCESS FLOW

INDUCTION FURNACE & OPERATIONAL ASPECTS

RAW MATERIALS AND ENERGY SOURCE

IMPORTANT ASPECTS OF OPERATION

OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING

ENVIRONMENTAL EMISSIONS

SAFETY & INDUCTION FURNACE

REASONS OF MOST ACCIDENTS IN THE MELT SHOPS WITH INDUCTION
FURNACES ARE

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

UTILITY REQUIREMENT (ESTIMATED) - MONTH

PLANT & MACHINERY SUPPLIERS

ANNEALING FURNACE

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HEATREATMENT FURNACE

INDUCTION FURNACE

SAND MIXTURE AND MULLER

SAND SIEVING MACHINE

SQUEEZE MOLDING MACHINE

SHAKEOUT MACHINE

CORE SHOOTER MACHINE

DRYING OVEN

MOLDING BOXES

METAL TESTING MACHINE

PRECISION MEASURING TOOLS

PRECISION MEASURING TOOLS

NDT INSPECTION EQUIPMENT

DRILLING, LATHE, TAPING MACHINES

GRINDING MACHINE

EOT CRANE

POWER TRANSFORMERS

ELECTRICAL PANEL

ELECTRIC MOTOR

EFFULENT TREATMENT PLANT (ETP PLANT)

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

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AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

SHOT BLASTING MACHINE

JIGS AND FIXTURE

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

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COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

CONCLUSIONS



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

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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)

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COST ESTIMATION

Plant Capacity 167 MT/Day

Land & Building (13505 sq.mt.) Rs. 16.88 Cr

Plant & Machinery Rs. 110.63 Cr

Working Capital for 1 Month Rs. 20.22 Cr

Total Capital Investment Rs. 153.52 Cr

Rate of Return 41%

Break Even Point 54%