project report on specialized coating div1

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PROJECT REPORT ON

COATING DIV & NDT INSPECTION DIV

Project Author:

This project report is authored by Mr. Vivek Naik.

Executive Summery:

This project report covers Setting up of a company in the field of Industrial Coating and Painting

Business and as well as NDT ( Non Destructive Testing ) Inspection Services Business. The Project

report also includes feasibility of the operations after careful estimation of man power expenses and

operational expenses besides investment on establishment.

The project report first talks of Specialized Coating Div and later of NDT Services. The project reportincludes Organization chart with details of services intend to provide under different divisions.

Separate flow chart is given for the different processes. The project report covers different options

available to the investor for additional services to give an edge to company over the competitors.

Prepared by Vivek Naik : 00919867899395

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INDEX

Sr.No.

Description Page

1 Operational Set Up 3

2 Operational Set Up (Details) 4

3 Market Definition 5

4 Major Competitors 6

5 General Set Up Coating Div 7

6 General Set Up NDT Inspection Div 8

7 Mile Stone chart 9

8 Organization Chart 10

9 Pipe Coating Flow Chart ( Coating Div) 11

10 Process Flow Chart (Coating Div) 12

11 Coating Div: Machinery Requirement 13

12 Coating Div: Manpower Requirement 14

13 Coating Div: Profitability chart 15

14 NDT Div: Machinery Requirement, Manpower Requirement 16

15 NDT Div: Profitability Chart 17

16 Feasibility Report 18

17 Plant Layout 19

18 Plant Layout Contd. 20


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OPERATION SET UP:

AREA OF OPERATIONS:

A. Specialized Coating Div:

B. NDT(Non Destructive Testing)Inspection and Quality Survey Services Div:

C. Future Expansion / Business Diversifications


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OPERATION SET UP (details):

A. Specialized Coating Div:

TRADING:1. Sales of Abrasive, Paints

2. Sales of Engineered Polymer product (e.g. Belzona)

SERVICES:a. External Pipe wrapping, ( Denso Tape)b. Blasting & Painting of Oil & gas Installations ( Storage Tanks, Pipelines etc)c. Internal coating of Pipes, Rig pipes, Casings & Tubingd. Fire Proof Coating, Intumescent coatingse. Coating of vessels, reactors, tanks

f. Maintenance of Painting & Coatingsg. Mobile coating services at Site

B. NDT Inspection and Quality Survey Services.

1. Equipment Rental Servicesa. Heat treatment Machine rental,

b. Pipeline Weld joint Robot,

c. Survey meters for Radio active substances ,d. X-Ray film viewer

2. Inspection Servicesa. Heat treatment servicesb. Inspection of Pipeline Weld joints with Robot,c. Radio active substancesd. X-Ray film viewer

C. Diversification Plans.1. Rubber Products and Services

2. Fireproof/ Explosion Proof Equipmentse. Blasting & Painting of Oil & gas Installations ( Storage Tanks,Pipelines etc)f. Internal coating of Pipes, Rig pipes, Casings & Tubing


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MARKET DEFINITION:

Markets for both divisions Specialized Coating Div, & Inspection and Quality SurveyServices Div is as follows,

Oman is one of the vibrant economy which has withstood adverse weather of globalfinancial crisis due to its very strength. Oman is a balanced mix of new developmentand already established infrastructure. We are addressing needs of maintenance ofinfrastructure already established as well as the new upcoming projects. Pipe line beinglifeline of the economy, the project related to pipelines are often treated as mostimportant from countrys economical development point of view.

Pipe line project is laid with long life consideration. As corrosion remains a major threat

to life of pipeline, special efforts are taken for protection of pipe line against possiblecorrosion be it internal or external. The same it true for the other equipment in Oil andGas e.g. Crude Oil storage or Diesel/ Petrol storage tank for refinery.

Major Market Sectors which will require our services as follows,

A. PDOB. Contractors of PDO e.g. Galfar, Arabian Ind, Al-Turki, GPS,C. City Municipality, Planning Dept (Water Supply)D. Airport, Sea PortE. Oil Trading Companies

F. Rural PlanningG. Cross Country PipelinesH. Private Oil Companies


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MAJOR COMPETITORS:

Major Players in Industrial Coating in Oman, UAE

Sr.No.

Name Year of Operations

Specialty Annual Turn Over

1 OICC OMAN 35 Competent in all sort of painting andcoating, Approved by PDO

RO.25 Millions

2 UES OMAN 15 Competent in all sort of painting andcoating, Approved by PDO

R.O.15 Millions

3 Asha Entp OMAN 10 Competent in specialized painting jobs R.O. 10 Millions

4 Nafal ContractingOMAN

5 Competent in specialized painting jobs R.O.10 Millions

5 ThyssencruppUAE

5 Competent in specialized painting jobs Dhs 150 Million

6 Gopinath UAE 10 Competent in specialized painting jobs Dhs 75 Millions

7 APC UAE 5 Competent in Pipeline coating Dhs 200 Millions

8 Bradero ShawUAE

5 Competent in Pipeline coating Dhs 200 Millions

Major players in NDT Services

Sr. No. Name Year of Operations

Specialty Annual Turn Over In R O

1 Sivert India 25 30 Specialist in all NDT ServicesAccepted all over world

50 Millions

2Hi Tech Inspection 10 Specialist in all NDT Services 10 Million

3 Al-Khaja Cooper Heat 25 Specialist in all NDT services 8 to 10 Millions

4 INSPEC ( International) 5 Specialist in all NDT services Dhs 50 Millions

5

6

Note: Turnover figures are approximate


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General Set up:

COATING DIV:

General Setup of the Coating Div includes a Closed shed for the Blasting and Painting

facilities. For the efficient mass production of the items for coating e.g. Structures, Tank

Shell plates, Pipes, valves etc coating plant design comes in play.

The coating factory with international specification is required. There are environmental

issues to be addressed while designing of the coating factory. The pollution issues like dust

clouds and paint over spray and paint dust in the atmosphere is major issues raised by the

authorities and hence effective measures to contain the pollutants is required to be in place.

The production of the coating unit depends on the efficient utility of the coating process and

the equipment. The efficiency of the coating unit depends on sophisticated coating

equipment, experienced & efficient workers and level of process automation.

Inspection and Quality Checks are required for the jobs carried in coating factory and

hence permanent appointment of QC personnel is mandatory for the coating factory.

The factory is required to practice general quality practices observed in coating industry

besides specific coating quality requirements bound by coating quality plan approved by

client.

Packing of the finished goods. Proper packing for the coated items is required as they are

prone to transportation and handling damages. Packing instruction of the client are to be

followed.

Transportation is crucial to all industrial work and hence its necessary to provide adequate

budget for transport facility or an arrangement with trustworthy transporter for hired

vehicle on requirement.


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General Set up:

NDT INSPECTION DIV:

General Setup of the NDT Inspection Div includes a specialized facilities, Highly trained and

experienced manpower for carrying out the sophisticated NDT inspection services.

International specification is used for most of the NDT Inspection services. There are also

environmental issues associated with NDT services like handling of Radio active substances.

These major issues are raised by the authorities and hence effective safety measures are

required to be enforced in the work place.

The NDT services required highly sophisticated machinery and equipment which provide

reliable results for clients. The efficiency of the equipment depends on proper handling ofthe equipment by experienced & efficient workers.

Often calibration of equipment is also major requirement. Inspection and Quality services

are provided through experienced personnel hence appointment of permanent qualified QC

personnel is required for NDT div. Its also required to be approved by client.

Transportation is crucial to all NDT services and special facility vehicles are used for

carrying radio active sources.


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MILE STONE CHART


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FOUNDATION

OF COMPANY

License , Other

formalities

Selection of Place,

Building, Staff and

Workmen

Operations of company

Increase customer base,

Increase Profitability of Company

complete customer satisfaction

INSPEECTIONINSPECTION

Purchase of Machinery

and Equipment

ISO Standards & otherCERTIFICATION

Building Completion

Set up of machines

Client approval formalities& CERTIFICATION

Other LegalFormalities

Annual assessment and Directors

approvals to future expansion plans

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ORGANIZATION CHART


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GOLDEN EAGLE

SP. COATING DIV NDT SERVICES

INTERNALPIPE COATING

EXTERNAL

PIPE COATING

STORAGE TANKS,

STRUCTURES PAINTING

EXTERNAL PIPE

WRAPPING (DENSO TAPE)

TRADING

SALES OF POLYMER

SALES OF DENSO TAPE

INTUMESCENT COATING

FOR BUILDING STRUCTURES

MOBILE COATING UNIT

FOR OIL INSTALLATIONS

SERVICES

INSPECTION SERVICES

HEAT TREATMENT SERVICES

INSPECTN, PIPE WELD JOINTS

EDDY CURRENT TEST

MPI , PT , UT, MFL (Flux Leakage)

EQUIPMENT RENTAL SERVICES

HEAT TREATMENT MACHINES

PIPE WELD JOINT INSP ROBOT

SURVEY METERS

X- RAY FILM VIEWERS

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PIPE COATING FLOW CHART


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RAW PIPE

INTERNAL BLASTING

EXTERNAL BLASTING

INTERNAL

COATING

EXTERNAL

COATING OR

WRAPPING

INTERNAL

PIPE

COATING

FINISHED PIPE

COATING

EXTERNAL

PIPE

COATING

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PROCESS FLOW CHART (Coating Div)


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RAW

MATREIAL

CLEANING

BLASTING

INSPECTION OF

FINISHED PRODUCTS

PRIMING

1ST COAT

INSPECTION

PAINTING

2ND COAT

PAINTING

3RD COAT

NO

YES

DELIVERY

INSPEECTION FAILED

INSPECTION PASSED

CORRECTION

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COATING DIV:

Machinery, Equipment and Manpower Requirement:

Sr.

No.

Machinery

Description

Specifications Qty Amount

In R.O.1 Blasting Booth for Manual

Blasting

100,000

2 Painting Booth for Manual

Painting

OPTIONAL ----

3 Paint Stores 25,0004 Electrical Compressor IR / CP/Atlas Copco 1 100,000

5 Portable compressors Atlas Copco 2 50,000

3 Automatic Blasting

Machine

4 Wheel (Wheelabrator)

2 Mt X 2Mt Entrance

1 100,000

4 Forklift 10 Ton ( CAT/Mitsubishi) 1 15,000

5 Over Head Crane for Shed 25 Ton 1 20,000

6 Blast Pots Air Blast / Blast-line 5 6,000

7 Spray Pump Blast-line 3 6,000

8 Inspection Equipment Whirling Hygrometer

DFT Gauge

Metal Temp thermometerTesting equipments

2

3

2

10,000

9 Auto wrapping machine

Manual Wrapping Machine

Specially Developed for

our requirement

1 50,000

10 Auto External Pipeline

Painting Machine


our requirement

1 50,000

11 Internal Pipeline Painting

Machine with controls


our requirement

1 50,000

12 Vehicles Truck, Pick up, Vans 20,000

TOTAL: 602,000


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COATING DIV:

Manpower Requirement:

Sr.

No.

Description Responsibility Yearly

Salary

Qty Annual

1 Production Manager(QC Inspector)

Managing Div

Handling QC issues

Communication to client

Communication to GM

Dealing with local authority

9000 1 9000

2 Stores Keeper,Document controller

Managing Stores,

In coming /Out going Mat

4000 1 4000

3 Accountant Managing local accounts,

Petty Cash,Generating Monthly Revenue

statement

Generating MIS

Generating DO/ Invoice

Dealing with Debtors

Dealing with Bank

Salary Management

4000 1 4000

4 Painting Supervisor Production SchedulingCommitment of Production

Communication with QC of

client

3600 1 3600

5 Painting Foreman Painting production,Work distribution, Work

progress

Efficient working of

Machinery,

Equipment/Machines

Maintenance

3000 2 6000

6 Painters 2400 3 7200

7 Blasters 2100 5 10500

8Helpers, Riggers 1800 10 18000

TOTAL 54900


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COATING DIV:

PROFITABILITY:

Sr. No. Description Amount Amount Amount

1 Annual Sales Revenue Forecast Annual 480,000

Annual Service Revenue Forecast Annual 120,000

2 Annual Machinery/ Equipment Cost

(Depreciated over 5 years)

120,000

3 Annual Manpower costing 60,000

4 Annual Other Over Heads 200,000

5 Raw Material, Consumables 120,000

TOTAL 600,000 500,000

100,000

Note: Figures are speculative

16% profit at the end of the year.

Sales figures will show rise as the operation is fully in swing.


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NDT INSPECTION SERVICES DIV:

Machinery, Equipment and Manpower Requirement:

Sr.

No.

Machinery

Description

Specifications Qty Amount

In R.O.1 Crawler Robot 6 2 75,000

10 1 100,000

24 1 150,000

2 Heat treatment Machine 6 Zone, 60 KV 1 25,000

9 Zone, 90 KV 1 30,000

12 Zone, 100 KV 1 35,000

3 X-Ray Tube 180 KV Panoramic 1 50,000

300 KV Panoramic 1 50,000

300 KV Directional 1 25,000

4

5 Vehicles Truck, Pick up, Vans 50,000

TOTAL: 590,000

Manpower Requirement:

Sr.

No.

Description Annual

Salary

Qty Annual

Cumulative

1 Qualified Inspector & Manager, 12000 1 12000

2 Quality Supervisor, Document controller 6000 1 6000

3 Stores Keeper 4000 1 4000

4 Accountant 4000 1 4000

5 Site Foreman 3000 2 6000

6 Machine Operators 2400 3 7200

7 Helpers, Riggers 2100 5 10500

TOTAL 41700


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NDT INSPECTION SERVICES DIV:

PROFITABILITY:Sr. No. Description Amount Amount Amount

1 Annual Service Revenue Forecast . 350,000

Annual Rental Revenue Forecast 200,000

2 Annual Machinery/ Equipment Cost

(Depreciated over 5 years)

120,000

3 Annual Manpower costing 50,000

4 Annual operating cost and Over Heads 200,000

5 Raw Material, Consumables 50,000

550,000 420,000

130,000

Note: Figures are speculative

23% profit at the end of the year.

Sales figures will show rise as the operation is fully in swing.


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FEASIBILITY REPORT FOR OPERATION:

Sr.

No.

Description Investment on

Establishment

Projected

Revenue

Yearly

Projected

Expense

Yearly

Projected

Profitability

Yearly

Projected

Profitability

%

1 Coating Div 600,000 600,000 500,000 100,000 16%

2 NDT

Inspection Div

600,000 550,000 420,000 130,000 23%

Investment on the Land Property is not considered for above profitability.

Yearly revenue figures are tentative figures and are fraction compared to lowest

competitors in the field. If proposed revenue is required to be increased multifold it necessitates further

investment in Infrastructure (Manpower and Machinery) for efficient production as per

requirement.

Operation Set up time for machinery will be 12 to 18 Months.


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PLANT LAY OUT

This is multi role plant lay out:

1. External Pipe coating Plant:

Salient Features:

A. Uniform Paint DFT ( dry Film Thickness) on the pipes.

B. Reduction in paint consumption

C. Better finish of the Painted pipes.

D. More production

1.

External/ Internal Pipe coating plant will reduce over thickness of the paint on the externalside of the pipe there by providing more quality product besides reducing paint consumption.


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2. Internal Pipe Coating Plant:


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project report on specialized coating div1

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