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7/31/2019 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
00971553067867
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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
Prepared by Vivek Naik : 00919867899395
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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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00971553067867
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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
Prepared by Vivek Naik : 00919867899395
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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
Prepared by Vivek Naik : 00919867899395
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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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00971553067867
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MILE STONE CHART
Prepared by Vivek Naik : 00919867899395
00971553067867
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
Prepared by Vivek Naik : 00919867899395
00971553067867
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
Prepared by Vivek Naik : 00919867899395
00971553067867
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)
Prepared by Vivek Naik : 00919867899395
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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
Specially Developed for
our requirement
1 50,000
11 Internal Pipeline Painting
Machine with controls
Specially Developed for
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
Prepared by Vivek Naik : 00919867899395
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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
Prepared by Vivek Naik : 00919867899395
00971553067867
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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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