UPVC AND CPVC PIPE PLANT

[EIRI/EDPR/3741] J.C.: 1834

INTRODUCTION

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 TERMINOLOGY
4 NOTATION
5 CLASSIFICATIONS OF PIPES
6 COMPOSITION
7 DIMENSIONS
8 SEALING RINGS
9 PIPE ENDS
10 PHYSICAL AND CHEMICAL CHARACTERISTICS
11 MECHANICAL PROPERTIES
12 SAMPLING AND CRITERIA FOR CONFORMITY
13 MARKING
OVERVIEW OF INDIAN PVC PIPE MARKET
SEGMENT REVIEW
INDIA PVC PIPES MARKET KEY SEGMENTS:
IMPACT OF GST, DEMONETISATION, RERA ON PIPES AND FITTINGS INDUSTRY
PRESENT CONSUMPTION PATTERN OF UPVC. RIGID PIPES
PVC PIPES OFFERS THE FOLLOWING ADVANTAGES:-
MANUFACTURERS/EXPORTERS
UPVC PIPE MANUFACTURERS/EXPORTERS RAW MATERIAL SECTION
PVC RESIN:
DIMENSION OF UPVC PIPE
UPVC AND ITS BENEFITS
2.2 BENEFITS OF UPVC
COMPARISON BETWEEN CPVC AND PVC PIPES
BENEFITS OF CPVC
PHYSICAL PROPERTIES
HEAT RESISTANCE
MECHANICAL PROPERTIES
PROPERTIES OF CPVC AND PVC
BONDING
FIRE PROPERTIES

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COMPOSITION OF UPVC PIPE
BASIS STEPS IN UPVC PIPES MANUFACTURE
FINAL INSPECTION AND PACKING
PROCESS FLOW DIAGRAM OF UPVC PIPE
MANUFACTURING PROCESS OF UPVC PIPES IN DETAILS
PIPE EXTRUSION PROCESS
MATERIALS:
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:
CONTROLS:
CUTTING DEVICE:
COILING DEVICE:
DETAILS OF PLASTIC EXTRUSION
TYPES OF EXTRUDERS
SINGLE SCREW EXTRUDER:
TWIN SCREW EXTRUDER:
TROUBLESHOOTING SHOOTING GUIDE FOR RVPC PIPE EXTRUSION
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

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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)

COST ESTIMATION
Plant Capacity 5 MT/Day
Land & Building (4000 sq.mt.) Rs. 1.53 Cr
Plant & Machinery Rs. 1.82 Cr
Working Capital for 2 Months Rs. 3.46 Cr
Total Capital Investment Rs. 7 Cr
Rate of Return 25%
Break Even Point 54%

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