INNER GROOVED COPPER TUBE

[EIRI/EDPR/4045] J.C.: 2178XL

INTRODUCTION

Inner grooved tube is enhanced with grooves by increasing the inner surface area.
Due to its high efficiency of heat transfer, it is used widely in power generation, air
conditioning and many other applications. Heat exchanger is one of the example
that uses inner grooved tube to enhance rate heat transfer. Precision in
production of inner grooved copper tube is very important because it affects the
tube's performance due to various tube parameters. Therefore, it is necessary to
carry out analysis in optimizing tube performance prior to production in order to
avoid unnecessary loss.

Ongoing rise of Air Conditioners and Refrigerators in the market and production
in GCC and other part of the world and Heat Transfer Systems in engineering
industries and automobile sectors all over the world, makes Copper tubes an
essential and unmatched engineering material as Copper possesses superior heat
transfer properties with excellent corrosion resistant. Seamless Copper Tubes
meeting the specification requirements of ASTM B68, ASTM B280 and JIS H3300
for ACR applications are in a commanding and challenging position in the market.
Conventional technology and tube mills are getting outdated as superior new
generation software based tube mills have already shaped up and proved their
efficiency and quality in production in this technology era and provides platform
for producing superior quality tubes. As old companies with conventional
machines struggle for their survival, as Quality and Cost are the prime concern
governing the market and business world today, new ventures are shaping up and
establishing bases to conquer the market. Process technology: An existing plant at
Sultanate of Oman cannot hold its position strong as far the market trend is
concerned as its lack of symmetry in the process equipments to produce tubes
meeting the requirements of primary users.

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INNER GROOVED COPPER TUBE SPECIFICATION

Outside Bottom Wall Groove Inclination Fin

Number of
Specification Diameter Thickness Depth Hf Angle Angle
Groove
(mm) (mm) (mm) (Degree) (Degree)

7.00*0.25+0.18 7 0.25 0.18 50 18 40

7.00*0.27+0.15 7 0.27 0.15 50 18 40

9.52*0.27+0.16 9.52 0.27 0.16 70 18 40

9.52*0.28+0.12 9.52 0.28 0.12 65 15 53

9.52*0.28+0.15 9.52 0.28 0.15 60 18 40

9.52*0.28+0.20 9.52 0.28 0.20 60 18 40

9.52*0.28+0.20 9.52 0.28 0.20 60 18 53

9.52*0.30+0.20 9.52 0.30 0.20 60 18 53

9.52*0.34+0.15 9.52 0.34 0.15 60 18 53

9.52*0.34+0.20 9.52 0.34 0.20 60 18 53

9.52*0.45+0.20 9.52 0.45 0.20 60 18 48

12.7*0.35+0.25 12.7 0.35 0.25 65 18 53

12.7*0.35+0.25 12.7 0.35 0.25 65 18 65

12.7*0.41+0.20 12.7 0.41 0.20 70 18 65

12.7*0.41+0.25 12.7 0.41 0.25 60 18 65

12.7*0.45+0.20 12.7 0.45 0.20 50 18 53

15.87*0.4+0.28 15.87 0.40 0.28 75 18 53

15.87*0.4+0.28 15.87 0.40 0.28 60 18 53

15.87*0.58+0.3 15.87 0.58 0.30 75 18 48

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 Internally Grooved Copper Tube Tolerances

Tolerances
Item Symbot Dimensions
(±)
Nominal Size (mm) 7×0.327.94×0.329×0.349.52×0.349.52×0.36
Nominal O.D. O.D.(mm)0.05 7.0 7.94 9.0 9.52 9.52
Nominal Wall
Tav(mm) 0.32 0.32 0.34 0.36 0.36
Thickness
Nominal I.D. I.D.(mm) 6.16 7.032 8.14 8.52 8.52
Bottom
TW(mm) 0.03 0.27 0.254 0.28 0.30 0.30
Thickness
Fin Height HF(mm) 0.02 0.15 0.20 0.16 0.20 0.20
Fin Width WI 0.05 0.188 0.270 0.246 0.255 0.220
Top Angle of Fin α 10° 40 40 44 44 53
Helix Angle β 2° 18 18 18 18 18
Number of Fins N 0 60 50 60 60 60
Fin Type C C C C C
Weight Per Meter (g) 62 75 88 90 95

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Benefits to use Inner Groove Copper Tube:

1. Leak Proof

2. Long Lasting

3. Accurate Groove Designs

4. Corrosion Resistant

5. High Metallurgical Strength

6. High Temperature Resistant

7. High Pressure Resistant

8. Excellent Heat Transfer Property

9. Good Electrical Conductivity etc.

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 CONTENTS

INTRODUCTION
INNER GROOVED COPPER TUBE SPECIFICATION
INTERNALLY GROOVED COPPER TUBE TOLERANCES
BENEFITS TO USE INNER GROOVE COPPER TUBE:
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW DIAGRAM
MANUFACTURING PROCESS
METHOD OF INNER GROOVE
REVOLUTION MECHANISM
FLOATING FRAME
UNWINDING BOBBIN
FIRST GUIDE CAPSTAN
FIRST DRAWING DIE
FIRST REVOLVING CAPSTAN
TURNING FLYER
SECOND REVOLVING CAPSTAN
SECOND DRAWING DIE
SECOND GUIDE CAPSTAN
WINDING BOBBIN
QUALITY CONTROL
QUALITY ASSURANCE PLAN
DESTRUCTIVE TESTS
1. TENSILE TEST
2. DRIFT EXPANDING TEST
NON-DESTRUCTIVE TESTING
1. EDDY-CURRENT TEST
2. HYDROSTATIC TEST
3. PNEUMATIC TEST
4. HYDROGEN EMBRITTLEMENT TEST (FOR CU-DHP AND CU-DPA GRADES)
PACKING
MARKING
MARKET POSITION
MARKET OVERVIEW
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE
PLANT LOCATION FACTORS
PRIMARY FACTORS

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1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF INNER GROOVED COPPER TUBE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COPPER BILLET
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF BILLET CUTTING MACHINE
SUPPLIERS OF BILLET STRAIGHTNING MACHINE
SUPPLIERS OF REHEATING FURNACE
SUPPLIERS OF COMPLELE TUBE PLANT
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL

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SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP

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)

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 COST ESTIMATION

Plant Capacity 35 MT/Day

Land & Building (15,000 sq.mt.) Rs. 18.58 Cr
Plant & Machinery Rs. 7.16 Cr
Working Capital for 2 Months Rs. 119.53 Cr
Total Capital Investment Rs. 146.22 Cr
Rate of Return 50%
Break Even Point 28%

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