Factory Desing Mechanical Engineering University of Gaziantep

1. UNIVERSITY OF GAZIANTEP
DEPARTMENT OF MECHANICAL
ENGINEERING
ME 477
(_FACTORY DESIGN_)
SUBJECT : Feasibility Studies of Spiral Pipe
Factory
SUBMITTED TO : PROF. DR. Ömer EYERCİOĞLU
SUBMITTED BY : ERDİ KARAÇAL
OKAN UTANGAÇ
EMRE KARACA
JULY 2013
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2. CONTENTS
CHAPTER 1
1.INTRODUCTION 4
1.1 WHAT IS SPIRAL PIPE AND WHERE IT IS MOSTLY USED? 4
CHAPTER 2
2.MARKET ANALYSIS 5
2.1 WHERE CAN WE SELL OUR PRODUCT? 5
2.2 FACTORY LOCATION 6
CHAPTER 3
3.PIPE MANUFACTURING PROCESSES 9
3.1 PIPE MANUFACTURING FLOWCHART 10
3.2 EDGE MILLING 11
3.3 HOW TO FORM COIL AS SPIRAL? 12
3.4 WELDING OF PIPE 13
3.5 CUTTING PIPE 14
3.6 TESTING OF THE PIPE 14
3.6.1 ONLINE ULTRASONIC WELDING CONTROL 14
3.6.2 HYDROSTATIC TEST 15
3.7 COATING OF PIPE 16
3.7.1 EXTERNAL COATING 16
3.7.2 INTERNAL COATING 17
3.8 ACTIVITY RELATION CHART 18
3.9 FACTORY PLAN 19
3.10 TOTAL FACTORY AREA 19
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3. CHAPTER 4
4.COST ANALYSIS OF FACTORY 20
4.1 FACTORY MACHINERY REQUIREMENT 21
4.2 FIXED COST 23
4.3 INDIRECT COST 24
4.4 DIRECT LABOUR COST 25
4.5 DIRECT MATERIAL COST 26
4.6 FINANCIAL ANALYSIS 27
REFERENCES 29
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4. CHAPTER 1
INTRODUCTION
1.1 WHAT IS SPIRAL PIPE AND WHERE IT IS MOSTLY
USED?
Steel pipes through their protection methods against corrosion and their resistance in
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corrosive areas they are preferring initially.
In the production of spiral pipe (also known as helical seam pipe) sheet metal coil
(coil=saç rulo bobin) is continuously shaped into a tube by spiral forming facility applying a
constant bending radius, with also being continuosuly welded inline and outline.
Each pipe diameter requires a certain plate width of sheet metal.
A lot of types of pipes are producing in industry.Spiral pipe is the only one type which
we will produce.
İn the daily life spiral pipe is used for water distribution lines(figure 1), petroleum
pipelines (figure 2), industrial pipe network, compress air line, hydroelectric power plants
projects etc.
Figure (1) Figure(2)

5. CHAPTER 2
MARKET ANALYSIS
2.1 WHERE CAN WE SELL OUR PRODUCT?
When we investigating the market store we focused on the developing countries.
We have seen that Africa and Middle East is the best area where we can sell our product.
There is a big potential at Middle East and Africa about developing on all hands.
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Our export destinations are;
Figure (3):Export destinations
ALGERIA TURKMENISTAN PORTUGAL FRANCE CAMEROON USA ISRAEL SWEDEN ITALY ANGOLA
EGYPT ROMANIA PHILLIPINES IRAQ CROTIA QATAR SPAIN
SAUDI ARABIA BRAZIL MOROCCO JORDAN GREECE SYRİA AUSTRİA LİBYA TUNUSIA
U.A.E.NIGERIA
As it seen that in the figure (3) We will export our product mostly Middle East and
Africa.

6. 2.2 FACTORY LOCATION
Therefore after making this analyzes our factory location is slowly appeared..
And we asked ourself this question.Our raw material is coil (bobin=rulo) to produce spiral
pipe.
We will buy coil and transfer to our factory and we will produce spiral pipe…and so on..
Where is this coil mostly produced in our country?
On the other hand this location must have been nearer to sea for having minimum cost
of transportation..There must be railways,seaports etc..
Finally we find the best location to build our factory.
As a location of our factory We select Osmaniye Industrial Zone.From İskenderun to
Osmaniye a lot of steel factories are exist.for exaple İsdemir,Atakaş,Yolbulanbaştuğ,Rozak
which means that we can buy our raw material of coil easily.
Also we can export our product easily.
Red circle at the map in the Figure (4) refers to Osmaniye Industrial Zone.
Figure (4):Factory Location Map
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7. We can transfer and export our products by ship.
Figure (5):Loading of pipes to ship
Also We can transfer our product by train (doğu ekspresi inland)
Figure (6):Loading of pipes to train
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8. Red rectangular shape at the figure (7) is our factory location.And also red circles are
the factories where we can buy our important raw
material.(TOSÇELİK,YOLBULANBAŞTUĞ,ROZAK,KOÇ ÇELİK).
Figure (7):Osmaniye Industrial Zone Factory Locations
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9. CHAPTER 3
3.PIPE MANUFACTURING PROCESSES
Figure (8):Finished product
HOT ROLLED COIL
Figure (9):Main Raw Material of spiral pipe manufacturing
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10. 3.1 PIPE MANUFACTURING FLOWCHART
Figure(10):Flowchart
Figure (11):Uncoiling Figure(12):Leveling
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11. 3.2 EDGE MILLING
In the manufacturing of spiral pipe double Vee type of joints are used.
Figure(13): Basic Types of Weld and Joints
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In the figure (14) edge millers are shown
Figure (14) Edge Miller

12. 3.3 HOW TO FORM COIL AS SPIRAL?
Forming, or metal forming, is the metal working process of fashioning metal parts
and objects through mechanical deformation; the workpiece is reshaped without adding or
removing material, and its mass remains unchanged Forming operates on the materials
science principle of plastic deformation, where the physical shape of a material is
permanently deformed.
Forming angle is another important parameter for manufacturing spiral pipes as shown
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in figure (15).
Figure(15):Forming Angle
Forming angle can easily calculated from this Formula(.As it seen that in the figure16)
formula is function of width of plate and pipe diameter.
Figure(16):Calculation of forming angle

13. 3.4 WELDING OF PIPE
Submerged arc welding (SAW) is an arc welding process that uses a
continuous,consumable bare wire electrode. The molten weld and the arc zone are protected
from atmospheric contamination by being "submerged" under a blanket of granular fusible
flux consisting of lime, silica, manganese oxide, calcium fluoride, and other compounds.
Figure(15)When molten, the flux becomes conductive, and provides a current path between
the electrode and the work. This thick layer of flux completely covers the molten metal thus
preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and
fumes that are a part of the shielded metal arc welding (SMAW) process.The arc shielding is
provided by a cover of granular flux.
The electrode wire is fed automatically from a coil into the arc. The flux is introduced
into the joint slightly ahead of the weld arc by gravity from a hopper, as shown in the
figure(17).
Figure (17):Submerged Arc Welding
Figure(18):Piece of Slag
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14. 3.5 CUTTING PIPE
We use plasma cutting for our product which is spiral pipe. Plasma cutting is a
process that is used to cut steel and other metals of different thicknesses (or sometimes other
materials) using a plasm torch. In this process, an inert gas (in some units, compressed air) is
blown at high speed out of a nozzle; at the same time an electrical arc is formed through that
gas from the nozzle to the surface being cut, turning some of that gas to plasma.The plasma is
sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal
away from the cut
Figure(19):Pipe cuting
3.6 TESTING OF THE PIPE
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 Online ultrasonic welding control
 First eyes control
 Hydrostatic test machine
 Last eyes control
 Bending test
 Tensile test
3.6.1 Online Ultrasonic Welding Control
A system and method for providing multi-mode control of an ultrasonic welding
system. In one embodiment, the control modes include the energy of the weld, the time of the
welding process and the compression displacement of the parts being welded during the
welding process.

15. 3.6.2 HYDROSTATIC TEST
Hydrostatic testing has long been used to determine and verify pipeline integrity. Several
types of information can be obtained through this verification process.
However, it is essential to identify the limits of the test process and obtainable results.
There are several types of flaws that can be detected by hydrostatic testing, such as:
 Existing flaws in the material,
 Stress Corrosion Cracking (SCC) and actual mechanical properties of the pipe,
 Active corrosion cells, and
 Localized hard spots that may cause failure in the presence of hydrogen.
There are some other flaws that cannot be detected by hydrostatic testing. For
example, the sub-critical material flaws cannot be detected by hydro testing, but the test has
profound impact on the post test behavior of these flaws.
Given that the test will play a significant role in the nondestructive evaluation of pipeline,
it is important to determine the correct test pressure and then utilize that test pressure
judiciously, to get the desired results.
You see applied to check for leakage from welding area of pipes in fıgure (20)
Figure(20): Hydrostatic Test Machine
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16. 3.7 COATING OF PIPE
We can clasified the coating of pipe external and internal coating.
3.7.1 EXTERNAL COATING
The Fusion Bonded Epoxy (FBE) coating system is an externally-applied
thermosetting resin for pipe. It is applied in the form of a dry powder at thicknesses of 400-
600 microns onto the heated surface of the steel pipe. Once applied and cured, the epoxy film
exhibits an extremely hard surface with excellent adhesion to the steel surface. The FBE
protective surface is homogeneous and offers an excellent resistance to chemical reaction.
You can see how we can coating external of pipe figure (21) .
Figure(21): External Coating
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17. 3.7.2 INTERNAL COATING
The epoxy coating lining is made up from two parts, a base and a hardener. The pot
life is determined by the manufacturer to allow a reasonable time to perform the coating
application.
The internal pipeline coating desired film thickness is achieved through a
predetermined constant drive pressure and velocity throughout the pipeline.You can see in
figure (22) how we can sprey inside the pipe.
Figure(22): Internal Coating
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18. 3.8 ACTIVITY RELATION CHART
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19. 3.9 FACTORY PLAN
3.10 TOTAL FACTORY AREA
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20. CHAPTER 4
4.COST ANALYSIS OF FACTORY
First of all we started to calculate cost analysis with searching our necessary machines
and planing our working time then we tabulated our working plan at first.
Factory Hours
Hours Operational per day 8
DaysOperationalpermonth 25
DaysOperationalperyear 300
With this table we have eight hour working time per day . We have five day holiday
and have twenty five day working time per month. Totaly we have three hundred working day
per year.
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21. 4.1 FACTORY MACHINERY REQUIREMENTS
After planned our working time then we searched the internet for our machines and
took some prices.When calculated our machine cost we tried select our machines cheapest
and strongest as possible as.And we made logical assumptions some of them for their prices.
MachineryDescription Unit UnitPrice(TL) Total
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Cost(TL)
Decoiler Machine 1 2200 2200
Leveling Machine 1 10000 10000
Skalp End Cutting Machine 1 20000 20000
Spiral Pipe Welding Machine 1 1000000 1000000
Hydro Test Machine 1 250000 250000
End Milling Machine 1 80000 80000
Poliythene Coating Facilty 1 500000 500000
Pipe End Cleaning Machine 2 10000 20000
Ultrasonic Test Machine 2 5000 10000
Total Machinery Cost 1.892.200

22. Then we calculated our machine’s working time for one meter product. We tabulated
them and we chosed the biggest value for calculating our capacity.
Machinery Description Working Time(min pe rmeter)
Leveling Machine 1.22
Skalp End Cutting Machine 1.2
Spiral Pipe Welding Machine 1.4
Hydro Test Machine 1.1
End Beveling Machine 2
Poliythene CoveringFacilty 1.96(m^2)
Pipe End Cleaning Machine 1.1
Decoiler Machine 1.2
Total 2
Total Product Per Day at Full Capacity 8*60/2=240 meter (80 ton for 60 inch outer
diameter and 10 mm thickness)
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23. While calculating the total product per day at full capacity we got based our working
time per day which is eighth our and we converted it into minute then we divided in two
minute to calculate the total product for one day which is two hundered and forty meter. Then
we converted this value to ton under our standart. Our standarts are sixty inch outer diameter
and ten millimeter thickness.
4.2 FIXED COST
After our details became clear we calculated the our Project cost which means fixed
cost and we tabulated it.
Description Amount (TL)
Land for Factory 2.000.000
Building/Infastructure for Factory 500.000
Machinery Cost 1.892.220
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Office Equipment and
Mechanical Testing Equipment
400.000
Pre-Operating Costs 10.000
Tooling 20.000
Total Project Cost 4.822.220

24. 4.3 INDIRECT COST
We calculated indirect costs which are work overheads , Office overheads and sales
overheads. We added calculated electricity cost to work overheads. Then we tabulated the
man calculated total indirect cost at final stage of indirect cost analysis.
Overheads Amount(TL)
Work Overheads 3.000.000
Office Overheads 100.000
Sales Overheads 50.000
Total 3.150.000
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25. 4.4 DIRECT LABOUR COST
We made assumptions for our requirement workers then we tabulated the man
calculated total salary for one month and one year.
Workers Description No . MonthSalary(TL) Total
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AnnualSalary(TL)
Submerged arc Welding
Operator
2(inner ,
outer)
4000 48000
Testing Department 2 2500 30000
Manager 1 4000 48000
Engineer 6 18000 216000
Storage 3 3000 36000
Maintenance 8 10000 120000
Welding Department 7 14000 168000
Hydrostatic Testing 2 4000 48000
End Bevelling 2 2500 30000
Quality Control 2 4000 48000
Coating unit 8 8000 96000
Outer storge 2 2000 24000
Sales department and
others(secratary)
6 9000 108000
Total 49 85000 1,020,000

26. 4.5 DIRECT MATERIAL COST
Then we calculated direct material cost for our raw material , welding material and
coating material which is a hundred TL for one ton product for three hundered micron
polythenecoating thickness.
Material Amounth(TL per ton)
RawMaterial 1300
WeldingMaterial 100
CoatingMaterial 100
Total Materialcost 1500
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27. 4.6 FINANCIAL ANALYSIS
Finally we calculate the our whole costand our profit at full capacity then we decided
reduce our capaticy because it is impossible to sell all our product .
Full Capacity %70 Capacity
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Total
Direct cost
(1500*80*300)+1020000=37,020,000 (1500*56*300)+1020000=26,220,000
Total
indirect
cost
3,150,000 3150000
Fixed cost 4,822,000 4,822,000
Total cost
of factory
44,992,000 34,192,000
income 80*2150*300=51,600,000 36,120,000
Profit 6,628,000 1,940,000
After this calculation our amortizing time has occurred as approximately two year at
%70 capacity at final stage of cost analysis.

28. REFERENCES
Tosçelik Sheet Metal and Profile Industry
Yolbulan Baştuğ Metallurgy
Rozak Metallurgy
İSDEMİR Steel Factory
Erciyas Steel Manufacturing
Hall Longmore Steel Industry
İlhanlar Boru
Tosçelik Boru
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