With its foundation strongly rooted in metallurgy transferred in manufacturing of superior quality Ductile Iron Pipe in When it comes to strength, durability and reliability of transporting water, Ductile Iron DI pipes have emerged as the defacto standard. Electrotherm is the only plant in the country to manufacture Centrifugally Cast Spun Ductile Iron Pressure pipes by melting solid charges in induction furnaces- which is a proven method to ensure the purest and cleanest form of metal. This integrated manufacturing process also comprises of several curing and treating operations that result in superior quality pipes with excellent dimensional stability, better strength and higher toughness.

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Major Production Process Metal Section Ductile Iron, also known as Spheroidal Graphite SG iron or nodular iron is made by treating liquid iron of suitable composition with pure magnesium before casting. This promotes the participation of graphite in the form of discrete nodules instead of interconnected flakes.

The nodular iron so formed has high ductility, allowing casting to be used for pipe making. The hot metal tapped from induction furnace is transferred into the turning ladle. Pure magnesium is then charged into the reaction chamber through a charging mouth. The hydraulic system provided will tilt the turning table into vertical position, thus allowing molten iron to react with Magnesium.

The reaction is allowed for 10 minutes. Once the reaction is complete, the hot metal is transferred to the pouring machine for casting the Ductile Iron Pipes. After the spheroidization process, the SG iron is directed towards the centrifugal pouring-cum-casting machine. Molten SG iron is transferred to a quadrant type ladle and from its bottom into a rotating pipe mould with a water jacket inside the centrifugal casting machine.

Core Making Section Head core made up of resin coated sand serves to seal the socket end of the mould and form the inside of the socket end of the pipe. As the mould rotates evenly, centrifugal force distributes the metal evenly, forming the pipe wall. Centrifugal casting machine containing the mould is mounted on a set of wheels, which move on a track. Spining Section Molten metal is poured into the spinning mould by the means of a pouring trough. As the spinning mould is retracted from the pouring trough, a uniform layer of metal is deposited on the mould.

Hydraulically operated extraction devices are provided for easy removal of the moulded pipe. Water jacket is provided for circulating water continuously around the mould thus cooling it uniformly. Heat Treatment Section The cast pipes are heat treated in an annealing furnace to optimize the strength impulses and ductility of the pipes.

The annealing furnace will be of a continuous chain type and will be LDO fired. Annealing furnace will have a pre-heating zone, soaking zone, fast cooling zone and controlled cooling zones. Pipes will be moving inside AF on casting iron rails and pushed by fingers on closed dog type chain. Zinc Coating Section Zinc coating is done with a spray process with the help of Zinc spray guns which ensure smooth and uniform Zinc deposition.

Zinc coating gives stable protective layer of insoluble zinc salt. It provides active protection due to the galvanizing effect, thus increasing corrosion resistance of the pipe in use.

Prior to the application of zinc, the pipe surface is kept dry and free from rust or non-adhering particles or foreign matter such as oil or grease. The metallic zinc coating covers the external surface of the pipe and provides a dense, continuous and uniform layer. The uniformity of the coating can be checked by 2 inspection. The purity of zinc is at least The finishing layer uniformly covers the whole surface of the metallic zinc layer and remains free from defects such as bare patches or lack of adhesion.

The thickness of the finishing layer remains 70 microns and the local minimum thickness not less than 50 microns. Special coating like extra zinc coating can also be provided. Internal Grinding Section Pipe grinding facilities are provided for cleaning the socket, spigot and the inner wall of the pipe. Spigot end cutting and chamfering is carried out during the grinding process. Hydrostatic Pressure Testing Section All the pipes are tested hydrostatically at a pressure depending on the size of Ductile Iron Pipe, as pressure depends on the class of the pipe.

Pipes are filled with water until they are full and are then pressurized to a predetermined value of pressure for a fixed duration of time. To perform the test, pressure is applied internally and is steadily maintained for a period of 10 seconds. The pipes withstand the pressure test and shall not show any sign of leakage, sweating or defects of any other kind.

The water used for hydro-testing is re-circulated after settling at settling tank 3 provided in this section. The mortar shall contain at least 1 part of cement to 3. Equipment required for cement lining of pipes consists of cement batching, mixing and material transfer equipment as well as cement and sand silos, cement lining machine along with traversing equipment etc. Internally lined Ductile Iron Pipe is cured in the curing oven.

Steam Curing Section Steam required for curing oven is drawn from the boiler envisaged exclusively for this purpose. Bituminous Coating Section The pipes are preheated in a hot chamber to dry any moisture from steam curing and to give better adherence to paint.

Bituminous paint is applied by a spraying machine which ensures uniform coating of the Ductile Iron Pipe. Coating is applied on clean surface i. For corrosive soils, excess bituminous coating can be provided.


Continuous Casting Machine & Induction Furnace Manufacturer

This enables us to fulfill requirements of various metal industry segments including investment casters, foundries, precious metal industry etc. These furnaces are ruggedly built with heavy structural steel for trouble free operation under harsh melt shop conditions. Thick walled rectangular coil sections are used to minimize coil losses. The higher coil efficiency ensures energy savings and higher productivity. Special coil insulation prevents inter turn sparking. Insulated furnace lid is provided to reduce heat loss through radiation.


Induction Furnace

Has capability to share the power with standby 3rd furnace, this system ensures uninterrupted continuation of metal production. Provides double output power supply, this system is appreciated for longer service life. Features: An ET Double-Track Plus is always a double track The seamless electronic integration completely eliminates need for any kind of mechanical switching If need arises at any given point of time for a larger quantum of metal to be made available, power can be given to all the three crucibles simultaneously in the required ratio, within the limits of overall rated power, and the metal from all the three furnaces can be tapped at a time to ensure larger single batch of liquid metal Other Details: ET Double-Track Plus is the most versatile double output power supply available in the market today. These systems allow simultaneous sharing of power between two furnaces in any ratio within the rated power. This feature makes ET Double-Track Plus a double output power supply in a real, complete and comprehensive sense of the word making it far superior than any of the competitive product. The seamless electronic integration completely eliminates need for any kind of mechanical switching for the selection of furnaces.

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