A CASE-STUDY REPORT On WAINGANGA SPUN PIPE

SUBMITTED TO THE UNIVERSITY OF NAGPUR, IN THE PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF DEGREE OF BACHELOR OF ENGINEERING (MECHANICAL) BY 1 Sujeet Kumar 2 Suraj P. Prajapati 3 Swapnil B. Berad 4 Vaibhav K. Barahate 5 Vishwajeet Nyaypati 6 Vishal R. Taware 7 Vishal Gupta 8 Vipul M. Sai 9 Yogesh K. Sahare

DEPARTMENT OF MECHANICAL ENGINEERING, S.S.P.A.C.E, COLLEGE OF ENGINEERING, RAM NAGAR, WARDHA 442001. Feb.-2011

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CERTIFICATE
This is to certify that the Industrial Case Study entitled ON WAINGANGA SPUN PIPE

For the partial fulfillment of the award of the degree of B.E.Mechanical Engineering of the University of Nagpur is approved. DatePlace-

Prof.R.K.Kulkarni (Case study Guide)

Prof. NITIN BORKAR (Case study Incharge)

Prof.C.B.KOTHARE (Head of the Mech.department)

Dr.B.B.GOGTE (Principal)

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ACKNOWLEDGEMENT

We would like to take this opportunity to express our honour, respect, deep gratitude and genuine towards our respected industrial case study Guide Prof. RAJESH K KULKARNI, H.O.D. of Mechanical Department Prof. C.B.KOTHARE & Principal Dr. B.B.GOGTE For giving us all guidance required for our case study apart for being constant source of inspiration and motivation. It was indeed our privilege to have a Prof. RAJESH KULKARNI and it is approved for the work under them. They have been our pillar of confidence and kept our spirits up in this endeavour. We would like to place on records our sincere thanks to all the staff members of Mechanical Department for their constant encouragement and kind help during our case study.

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CONTENTS
Name 1) Company profile 2) Introduction 3) Plant layout 4) Manufacturing process 5) Market potential 6) Various machine used 7) Advantage and Disadvantage 8) Application 9) Problem and Remedies 10) Conclusion 11) Reference

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COMPANY PROFILE
1) Name of company:- WAINGANGA SPUN PIPE INDUSTRIESPVT. LTD 2) Director 3) Year of Establishment 4) Location 5) Area 6) Annual Turn over :- B.N Dange :- 1979 :- A-41, M.I.D.C, Wardha-440006 :- 5 Acre :- 5 Crore(Approximately)

7) Number of Employees :- 50 8) Working Hours 9) Raw Material oil 10) Market :- 8hrs :- Cement, Steel, Coarse and fine aggregate, Mould

Grease and misc, sand :- All Maharashtra, Andhra Pradesh, Gujarat etc.

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Introduction

Reinforced cement concrete spun pipes upto 1000 mm dia. are exclusively reserved for manufacture in the SSI sector. These pipes are widely used for water drainage, sewerage, culverts and irrigation. RCC pipes are classified as pressure and non pressure pipes viz. NPI, NP2, NP3, P1, P2, P3 for use in specific conditions. These pipes are made from cement, coarse and fine aggregate, sand, mild steel and HT rods and bars. During this case study we observe that, the process of manufacturing like machining process, welding process etc. Helps to enhance the idea about the particular case study.

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Process of Manufacture

The reinforced cage is first prepared on the cage-winding machine by hand process. The cage is then placed inside the pipe mould which is then hoisted up and mounted horizontally on the turn unions. It is rotated by driving shaft with variable speed arrangement, the rotation is kept slow in the beginning and then the speed is increased. The concrete mixture for the RCC spun pipe is prepared in proportion of 1:2:5:2:5 of cement stone, metal and sand respectively. The cement concrete is fed into the moulds during rotation which spreads inside evenly. The time required for completion of this operation depends upon the diameter and class of the pipe. The pipes are kept in the mould for 24 hours. On the following day the pipes are removed from the moulds and submersed in water in the curing tank for about 15-20 days depending upon the class of the pipe. The specimen of the pipes are subject to the following tests viz: (1) Hydrostatic pressure test (2) Three edge bearing test (3) Absorption test.

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MARKET POTENTIAL
Public Health Engineering Department, Public Works Departments, Agriculture and Forest Department, National Highways, Environment Engineering Department,Panchayats Municipal Corporations are the bulk consumers of RCC spun pipes Most of the customers are approved civil contractors who are executing the works of the Government Department and Public Sector Undertakings. Presently government is giving stress on rural irrigation and improving methods of water supply scheme, so the demand for pipes is increasing.

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VARIOUS MACHINE USED

1. Concrete mixer 2. Gauge winding machine 3. Gas cutting machine 4. Welding machine 5. Testing equipments

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ADVANTAGES AND DISADVANTAGES

ADVANTAGES:(1) The pipes have durability, strength and realiability. (2) These pipes are non porous, extremely dense and have the ability to withstand great pressure. (3) Available in different sizes and lengths, these pipes find extensive application in construction industry. (4) In conformation with set industrial standards, these pipes can also be customized as per the requirement of clients. (5) These pipes are easy to install. (6) Exhibit highly efficient performance. (7) These pipes having corrosion resistance than metallic pipes DISADVANTAGES :(1) Noisy operation. (2) Dust produced during operation is hazardous to operators. (3) These pipes are bulky, heavy & require careful transportation & handling. (4) The layout process of these pipes is costlier than steel pipe.

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APPLICATION
These pipes are used for (1) Irrigation (2) Water supply lines (3) Sanitary sewers (4) culverts (5) storm drains (6) River bridges

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PROBLEM
1) In the Wainganga spun pipe manufacturing industries the mixture (concrete) is filled in the mould of pipe during its rotating motion. their is losses of mixture by manual process. 2) In this plant proper departments not made i.e. raw material, final products are not placed properly. 3) The dust are produced from this plant is hazardous for workers. 4) The proper track is not available for transferring the pipes from one place to other place so man power required is more and their can be result of cracking of pipes.

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REMEDIES
1) To prevent the wastage of concrete mixture during feeding the mixture into the mould of pipe during its rotation here we can use the AUTOMATIC FEEDER MACHINE. Using this machine we can reduce labour cost as well as wastage of concrete mixture. 2) We can made separate sections or departments for proper materials or final product. 3) We make the compulsion for workers to wearing the mask during working.by using the mask we prevent the entry of the dust particles into the human body so that we can control the breathing problems like asthma etc 4) By using CRANE we can prevent cracking of pipes.

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CONCLUSION
We visited the industry WAINGANGA SPUN PIPE and tried to look at all the aspects of the industry and tried to short out the problem after talking to all the operators, owner of the industry and our instructor and came to the foresaid solution. The case thus has been studied and the solution to the sorted out problem has been tried to be solved in the most optimal manner and all the details of the industry have been comprehensively studied.

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REFERENCES
(1) www.google.com. (2) www.wikipedia.com. (3) Manual of spun pipe.

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