Detailed Project Report on UPVC AND CPVC PIPE AND FITTING

PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance to aggressive environments both naturally occurring and as a result of industrial activity. They are resistant to almost all types of corrosion, either chemical or electrochemical in nature. Since PVC is a non-conductor, galvanic and electro chemical effects do not occur in PVC pipes.

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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



UPVC AND CPVC PIPE AND FITTING
[EIRI/EDPR/4755] J.C.: 2975XL

PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance
to aggressive environments both naturally occurring and as a result of industrial
activity. They are resistant to almost all types of corrosion, either chemical or
electrochemical in nature. Since PVC is a non-conductor, galvanic and electro
chemical effects do not occur in PVC pipes.
PVC Pipes are a often used in the following circumstances:
• For drinking water pipe distribution systems, both main and supply lines
• Sewer and discharge pipe systems
Due to its non-metallic nature, the material used is totally resistant to all forms of
metallic corrosion.
Aggressive water resulting from high sulphate soils and low hardness water will
not attack PVC pipes.
PVC pipes are therefore resistant to a wide range of industrial waters and
chemicals and offer an advantage in long-term systems life and manufacture
costs.
Being made of a tasteless and odorless material, PVC pipes remain neutral to all
transported fluids.
PVC is completely inert and is widely used for transporting liquids made for
human consumption.

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Because of their mirror-smooth inside surface, PVC pipes have minimum flow
head loss. There is also no buildup of inside deposits, a particular advantage in
the construction of sewerage systems.
The physical properties of PVC pipes are not affected by neither direct sunshine,
nor wind or rain.
However, to avoid surface browning due to long exposure to direct sunlight, it is
recommended that the pipes are kept protected from direct sunlight.
Rigid PVC is not conductive to combustion. In the event of a fire, flames are
unable to travel on PVC pipes. They therefore offer added safety when used for
electrical installations, both domestic and industrial.
PVC pipes are relatively light. Their specific weight 1.43 is one- fifth that of steel
pipes. This cuts down transportation costs and facilitates installation when in
difficult and remote places. Installation is quick and easy with a complete line of
fittings either with the solvent glue weld sockets or the rubber seal socket joints.
In either case, a leak-proof joint is assured. Subsequent maintenance work is also
carried out with a minimum of complication and cost.
PVC pipe which is made from polymerized vinyl chloride, a synthetic resin, which
when plasticized or softened with other chemicals has some rubber-like
properties. Derived from acetylene and anhydrous hydrochloric acid. PVC pipe has
nominal sizes that are to be used with PVC socket fittings (schedule 40) and PVC
socket or threaded fittings (schedule 80).
PVC Pipe have got tremendous demand in India as well as in abroad. To
manufacture this, all the machinery and raw materials are available indigenously.
A polyvinyl chloride (PVC) pipe is made from a plastic and vinyl combination
material. The pipes are durable, hard to damage and long lasting. A PVC pipe does
not rust, rot, or wear over time. For that reason, PVC piping is most commonly
used in water systems, underground wiring, and sewer lines.

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CONTENTS

INTRODUCTION

PROPERTIES OF UPVC PIPES & FITTINGS

CHLORINATED POLYVINYL CHLORIDE (CPVC)

BUREAU OF INDIAN STANDARDS SPECIFICATIONS PLASTIC PIPES & FITTINGS

SPECIFICATION OF UPVC PIPES FOR POTABLE WATER

UNPLASTICIZED PVC PIPES FOR POTABLE WATER SUPPLIES-SPECIFICATION

1 SCOPE

2 NORMATIVE REFERENCES

3 TERMINOLOGIES

4 NOTATIONS

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5 CLASSIFICATIONS OF PIPES

6 COMPOSITIONS

7 DIMENSIONS

8 SEALING RINGS

9 PIPE ENDS

10 PHYSICAL AND CHEMICAL CHARACTERISTICS

11 MECHANICAL PROPERTIES

12 SAMPLING AND CRITERIA FOR CONFORMITY

13 MARKING

CPVC PIPES AND FITTING

TECHNICAL SPECIFICATIONS

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CPVC PIPES & FITTINGS

MARKET OVERVIEW OF INDIAN PLASTIC PIPES

MANUFACTURERS/EXPORTERS

UPVC PIPE MANUFACTURERS/EXPORTERS RAW MATERIAL SECTION

PVC RESIN:

DIMENSION OF UPVC PIPE

PVC PIPE & FITTINGS DIMENSIONS (SCH 40/SCH 80)

UPVC AND ITS BENEFITS

2.2 BENEFITS OF UPVC

COMPARISON BETWEEN CPVC AND PVC PIPES

BENEFITS OF CPVC

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PHYSICAL PROPERTIES

HEAT RESISTANCE

MECHANICAL PROPERTIES

PROPERTIES OF CPVC AND PVC

BONDING

FIRE PROPERTIES

COMPOSITION OF UPVC PIPE

ADVANTAGE AND SPECIFICATION OF CPVC PIPES AND FITTING

CPVC ADVANTAGES

CPVC APPLICATIONS

CPVC STANDARDS

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SPECIFICATION OF CPVC PIPES AND FITTINGD

CPVC SCHEDULE 40 & SCHEDULE 80 PIPE SPECIFICATIONS

APPLICATION

SCOPE

CPVC MATERIALS

DIMENSIONS

THE MAXIMUM SERIVCE TEMPERATURE FOR CPVC IS 200°F.

GENERAL SPECIFICATIONS FOR STANDARD CPVC SCHEDULE 40 AND
SCHEDULE 80 FABRICATED DRAINAGE FITTINGS

SCOPE

MATERIALS OF CONSTRUCTION

(CPVC) CHLORINATED POLYVINYL CHLORIDE

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SOLVENT CEMENT AND WELDING ROD (CPVC)

ASSEMBLY AND CONSTRUCTION PROCEDURES

GENERAL SPECIFICATIONS FOR STANDARD CPVC SCHEDULE 40 &
SCHEDULE 80 FABRICATED PRESSURE FITTINGS

SCOPE

MATERIALS OF CONSTRUCTION

(CPVC) CHLORINATED POLYVINYL CHLORIDE

SOLVENT CEMENT AND WELDING ROD (CPVC)

ASSEMBLY/CONSTRUCTION PROCEDURES

DIMENSIONAL SPECIFICATIONS

PRODUCT QUALITY

SEQUENCES IN UPVC PIPES MANUFACTURING

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RAW MATERIAL PREPARATION:

MIXING AND BLENDING:

EXTRUSION:

SHAPING:

COOLING AND SIZING:

SURFACE TREATMENT AND FINISHING:

QUALITY CONTROL:

PRODUCING UPVC PIPE

RAW MATERIAL PREPARATION:

MIXING AND COMPOUNDING:

EXTRUSION:

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SIZING AND CALIBRATION:

COOLING AND COOLING TANKS:

MARKING AND PRINTING:

QUALITY CONTROL:

PACKAGING AND STORAGE:

PIPE EXTRUSION PROCESS

PIPE EXTRUSION PROCESS

MATERIALS:

PVC COMPOUNDING IS USUALLY CARRIED OUT IN TWO STAGES

CONVERTING CPVC INTO PIPES AND FITTING

CPVC EXTRUSION

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CPVC INJECTION MOLDING

PROCESS FLOW DIAGRAM OF UPVC PIPE

MANUFACTURING PROCESS OF UPVC PIPES IN DETAILS

PVC COMPOUNDING

PVC COMPOUNDING IS USUALLY CARRIED OUT IN TWO STAGES

PVC PIPE FORMULATION:

PIPE EXTRUSION LINE:

PIPE EXTRUSION DIE:

SIZING EQUIPMENT:

COOLING WATER THROUGH:

PULLING MACHINES:

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CONTROLS:

CUTTING DEVICE:

COILING DEVICE:

PVC PIPE

DETAILS OF PLASTIC EXTRUSION

SECTIONAL VIEW OF A SIMPLE PLASTIC EXTRUDER

TYPES OF EXTRUDERS

SINGLE SCREW EXTRUDER:

SIMPLE PLASTIC SINGLE SCREW EXTRUDER

TWIN SCREW EXTRUDER:

TROUBLESHOOTING SHOOTING GUIDE FOR RVPC PIPE EXTRUSION

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ADDRESSES OF PLANT & MACHINERIES SUPPLIERS

SUPPLIERS OF MOULDS FOR PIPE FITTINGS

SUPPLIERS OF HIGH SPEED MIXER

SUPPLIERS OF EXTRUDER

SUPPLIERS OF PLASTIC SCRAP GRINDER MACHINE

SUPPLIERS OF PLASTIC INJECTION MOULDING MACHINE

SUPPLIERS OF GENERATOR SET

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PVC RESIN

SUPPLIERS OF CALCIUM STEARATE

SUPPLIERS OF LEAD STEARATE

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SUPPLIERS OF PRECIPITATED CALCIUM CARBONATE

SUPPLIERS OF PIGMENT DYE

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

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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)

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COST ESTIMATION
Plant Capacity 2.5 MT/Day
Land & Building (2000 sq.mt.) Rs. 2.75 Cr
Plant & Machinery Rs. 80.00 Lac
Working Capital for 1 Month Rs. 1.08 Cr
Total Capital Investment Rs. 4.85 Cr
Rate of Return 22%
Break Even Point 60%