PVC AND CPVC PIPE AND FITTINGS MANUFACTURING PLANT

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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 and fittings 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. Our 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. For more information on the resistance of PVC for specific chemical(s), do not hesitate to let Interplast know. We inform you of the suitable pipe solution necessary. 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. 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 and Fittings 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. PVC was first developed in 1925 when a BF Goodrich employee, Dr. Waldo Semon, attempted to invent a method for bonding metal and rubber. After blending materials together to create a strong and flexible material, Semon discovered PVC. Nonetheless, the product remained virtually useless for another decade. In the late 1930’s, PVC was found to have great shock absorbing abilities. This discovery led to the creation of long lasting PVC tire treads, which were created with flexible forms of PVC. Two decades later, PVC pipe was invented. By heating the PVC material, a special machine called an extruder could be used to push the PVC into hollow pipes. This PVC pipe was extremely solid and virtually indestructible. Using PVC pipes for irrigation systems proved to be effective. PVC pipe has since been considered an affordable and reliable means for water piping. Due to the ability of PVC pipe to withstand extreme movement and bending, it is also increasingly used in earthquake prone areas. PVC pipe can withstand the rigorous shaking of the earth without experiencing any damage. The smooth surface of the PVC pipe is also resistant to bacterial contamination, such as E. coli. Therefore, many water companies rely on PVC pipe in their systems in order to keep them free of contamination. Unfortunately, the material used in PVC pipe appears to be detrimental to a person’s health and safety. Reported cases of PVC pipe shattering when used with high-pressured gases have increased drastically. The Federal Government has issued safety warnings, which strongly recommend using alternative piping material. In addition, the heavy metals used to create PVC pipe can leach out when heated. The vapors emitted from the heated PVC pipe are now being linked to certain forms of cancer, especially lung cancer. CPVC Pipes and Fittings are manufactured from compound, CPVC- Chlorinated polyvinyl chloride is a thermoplastic used for hot and cold water lines. Chlorinated polyvinyl chloride (CPVC) is a thermoplastic produced by chlorination of polyvinyl chloride (PVC) resin used for hot and cold water lines. CPVC is the first choice of material for potable water supply across the world and is in use across the world for more than 50 years.

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Description

INTRODUCTION
PROPERTIES OF PVC PIPES & FITTINGS
CHLORINATED POLYVINYL CHLORIDE (CPVC)
ADVANTAGES & LIMITATIONS
HANDLING & STORAGE:-
WIDE RANGE OF APPLICATIONS OF CPVC PIPE
IMPORTANT CPVC RELATED STANDARDS
STANDARD
TOPIC
ANSI/NSF STANDARD
CPVC PIPES-POTABLE WATER SUPPLY THIS IS A CRITICAL CERTIFICATION WITHOUT
WHICH CPVC PIPES CANNOT BE USED FOR CARRYING POTABLE WATER
ASTM D2840
CPVC HOT COLD WATER DISTRIBUTION SYSTEMS
ASTM F439
CPVC SCHEDULE 80 CPVC FITTINGS
ASTM F441
CPVC SCHEDULE 40 & 80 PIPES
DIN-8079
CPVC PIPES DIMENSION
DIN-8080
CPVC PIPES GENERAL QUALITY REQUIREMENTS AND TESTING
BS 7291/4
CPVC PIPES AND FITTINGS FOR HOT AND COLD WATER DISTRIBUTION
NFT 54-014-1/2
CPVC PIPES AND FITTINGS FOR HOT AND COLD WATER DISTRIBUTION
EN-ISO 15877:2003
PLASTICS PIPING SYSTEMS FOR HOT AND COLD WATER INSTALLATIONS –
CHLORINATED POLY VINYL CHLORIDE (PVC – C)
BUREAU OF INDIAN STANDARDS SPECIFICATIONS
PLASTIC PIPES & FITTINGS
PRESSURE PIPES FOR WATER SUPPLY & IRRIGATION
(TABLE OF DIMENSIONS OF PIPES TO IS : 4985-1968)
PLUMBING PIPES
APPLICATIONS OF PVC PIPES & FITTINGS
ADVANTAGES OF USING PVC PIPES
1. IT IS ECONOMICAL:
2. IT RESISTS CORROSION:
3. NON-ENRUSTATION:
4. LIGHT WEIGHT:
5. EASE OF INSTALLATION:
MARKET SURVEY
IMPACT OF GST, DEMONETISATION, RERA ON PIPES AND FITTINGS INDUSTRY
OPPORTUNITIES FOR THE PIPES AND FITTINGS SEGMENT FROM BUDGET 2018
IMPORTED OR INDIGENOUS PIPES
NEW VENTURE IN PIPES AND FITTING SEGMENT
PRODUCTION OF PVC AND CPVC PIPES FROM 2007 TO 2017
APPLICATION BREAK UP OF PVC IN INDIA
GLOBAL APPLICATION OF PVC
PRESENT CONSUMPTION PATTERN OF P.V.C. RIGID PIPES
PVC PIPES OFFERS THE FOLLOWING ADVANTAGES:-
TREND IN INCREASE IN DEMAND
TREND GROWTH RATE IN INCREASE OF DEMAND = 15%
ENHANCED RECYCLING PROPERTIES FOR PVC PIPES
OVERVIEW OF PVC
GLOBAL SCENARIO
GLOBAL PVC CAPACITY BREAK-UP (%)
PER CAPITA CONSUMPTION OF SUSPENSION PVC
GLOBAL PVC DEMAND BREAK-UP
INDIAN SCENARIO
FIGURE: PVC PRODUCTION AND IMPORTS IN INDIA
FIGURE: PVC DEMAND IN INDIA – HISTORY
FIGURE: APPLICATION BREAK-UP OF PVC – INDIA
FIGURE: APPLICATION BREAK-UP OF PVC – GLOBAL
FIGURE: PVC CONSUMPTION IN INDIA (2001-2015)
FIGURE: DOMESTIC MANUFACTURERS AND CAPACITIES (KT)
MANUFACTURERS/EXPORTERS 57
PVC PIPE MANUFACTURERS/EXPORTERS RAW MATERIAL SECTION
PVC RESIN:
DIMENSION OF PVC PIPE
PVC PIPE & FITTINGS DIMENSIONS (SCH 40 / SCH 80)
FORMULATION FOR PVC RIGID PIPES 65
PVC FLEXIBLE PIPES
PROCESS OF MANUFACTURE
PLUMBING PIPES
USES & APPLICABILITY OF PVC COMPOUNDS
BUILDING AND CONSTRUCTION:
PACKAGING:
MISCELLANEOUS:-
MANUFACTURING PROCESS OF PVC PIPES
PROCESS OF MANUFACTURE OF RIGID PIPES
TWIN SCREW EXTRUDERS
EXTRUSION DIES
EXTRUSION LINES:-
PVC PIPE FITTINGS:-
PLASTICIZER OF PVC
FILLERS OF PVC
STABILIZERS
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPES
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC FITTINGS
MANUFACTURING PROCESS OF PVC & CPVC PIPE FITTING
DETAILS OF PLASTIC EXTRUSION PROCESS
EXTRUDER HEATER
BLOCK DIAGRAM OF THE PLASTIC EXTRUSION PLANT
TEMPERATURE SECTION OF PVC PLANT
HEATER SPECIFICATION OF PLASTIC EXTRUSION SYSTEM
PLASTIC EXTRUSION SCREW
DETAILS OF INJECTION MOLDING FOR PIPE FITTINGS
PROCESS CYCLE
EQUIPMENT
INJECTION UNIT
INJECTION MOLDING MACHINE – INJECTION UNIT
CLAMPING UNIT
INJECTION MOLDING MACHINE – CLAMPING UNIT
MACHINE SPECIFICATIONS
INJECTION MOLDING MACHINE
TOOLING
MOLD OVERVIEW
MOLD BASE
MOLD BASE
MOLD CHANNELS
MOLD DESIGN
MOLD – CLOSED
MOLD – EXPLODED VIEW
THE NEW GENERATION OF PVC-O PIPES
MOLECULAR ORIENTATION, A REVOLUTION IN PVC TECHNOLOGY
A PLASTIC WITH UNBEATABLE PROPERTIES
CUTTING-EDGE TECHNOLOGY FOR WATER
MAXIMUM RELIABILITY AND SECURITY
HIGH SHORT AND LONG TERM HYDROSTATIC RESISTANCE
EXCELLENT RESPONSE TO WATER HAMMER
INCREASE HYDRAULIC CAPACITY
MAXIMUM FLEXIBILITY
COMPLETE CORROSION RESISTANCE
TOTAL WATER QUALITY
COMPLETELY WATER TIGHT
LOWER COST AND EASIER INSTALLATION
THE MOST ECO-FRIENDLY PIPES ON THE MARKET
ENERGY EFFICIENT
OPTIMAL USE OF WATER RESOURCES
100% RECYCLABLE
THE BEST MECHANICAL PROPERTIES
TENSILE RESISTANCE
LONG TERM HYDROSTATIC RESISTANCE
PIPING AND MATERIAL MECHANICAL PROPERTIES
OTHER MATERIAL CHARACTERISTICS
UNBEATABLE HYDRAULIC PROPERTIES
HYDRAULIC CAPACITY
WATER HAMMER
A RANGE FOR ALL KINDS OF APPLICATIONS
DIMENTIONS
PACKAGING
JOINTS AND WATER TIGHT SEALS
FITTINGS
TAPPING SADDLES
FLANGE WITH ANTI-TRACTION SYSTEM
FITTINGS WITH PLUGS EURO TYPE
APPLICATIONS
OTHER APPLICATIONS
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
MOULDS FOR PIPE FITTINGS
HIGH SPEED MIXER
EXTRUDER
PLASTIC SCRAP GRINDER MACHINE
PLASTIC INJECTION MOULDING MACHINE
GENERATOR SET
SUPPLIERS OF RAW MATERIALS
PVC RESIN
CALCIUM STEARATE
LEAD STEARATE
PRECIPITATED CALCIUM CARBONATE
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
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)

Additional information

Plant Capacity

13 MT/Day

Land and Building

(8000 sq.mt)

Plant & Machinery

US$.497143

Rate of Return

26%

Break Even Point

52%