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    Project Report On Steel Pipe Plant

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    EIRI Board of Consultants and Publishers
    Electric resistance welded (ERW) pipe is manufactured by cold-forming a sheet of steel into a cylindrical shape. Current is then passed between the two edges of the steel to heat the steel to a point at which the edges are forced together to form a bond without the use of welding filler material. Initially this manufacturing process used low frequency A.C. current to heat the edges. This low frequency process was used from the 1920’s until 1970. In 1970, the low frequency process was superseded

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    Project Report On Steel Pipe Plant

    Uploaded by

    EIRI Board of Consultants and Publishers
    273 views6 pages
    Electric resistance welded (ERW) pipe is manufactured by cold-forming a sheet of steel into a cylindrical shape. Current is then passed between the two edges of the steel to heat the steel to a point at which the edges are forced together to form a bond without the use of welding filler material. Initially this manufacturing process used low frequency A.C. current to heat the edges. This low frequency process was used from the 1920’s until 1970. In 1970, the low frequency process was superseded

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    PROJECT REPORT ON STEEL PIPE PLANT

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    Electric resistance welded (ERW) pipe is manufactured by cold-forming a sheet of steel into a cylindrical shape. Current is then passed between the two edges of the steel to heat the steel to a point at which the edges are forced together to form a bond without the use of welding filler material. Initially this manufacturing process used low frequency A.C. current to heat the edges. This low frequency process was used from the 1920’s until 1970. In 1970, the low frequency process was superseded

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    273 views6 pages

    Project Report On Steel Pipe Plant

    Uploaded by

    EIRI Board of Consultants and Publishers
    Electric resistance welded (ERW) pipe is manufactured by cold-forming a sheet of steel into a cylindrical shape. Current is then passed between the two edges of the steel to heat the steel to a point at which the edges are forced together to form a bond without the use of welding filler material. Initially this manufacturing process used low frequency A.C. current to heat the edges. This low frequency process was used from the 1920’s until 1970. In 1970, the low frequency process was superseded

    Copyright:

    © All Rights Reserved
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    of 6

    STEEL PIPE PLANT

    [EIRI/EDPR/3803] J.C.: 1902

    INTRODUCTION
    Electric resistance welded (ERW) pipe is manufactured by cold-forming a sheet of
    steel into a cylindrical shape. Current is then passed between the two edges of the
    steel to heat the steel to a point at which the edges are forced together to form a bond
    without the use of welding filler material. Initially this manufacturing process used
    low frequency A.C. current to heat the edges. This low frequency process was used
    from the 1920’s until 1970. In 1970, the low frequency process was superseded by a
    high frequency ERW process which produced a higher quality weld.

    Over time, the welds of low frequency ERW pipe was found to be susceptible to
    selective seam corrosion, hook cracks, and inadequate bonding of the seams, so low
    frequency ERW is no longer used to manufacture pipe. The high frequency process is
    still being used to manufacture pipe for use in new pipeline construction

    ERW steel pipes & tubes find widespread usage across industries and fields. In
    addition to various engineering industries, they are used for water, oil and gas
    distribution, line pipes, fencing, scaffolding, etc. They are also used for agricultural
    purposes, drinking water supply, and thermal power, for hand pumps for deep boring
    wells and also as protection for cables (telecom), among others. Depending on the
    requirement of the end user industry, ERW steel pipes & tubes are available in
    various wall thicknesses, diameters, and qualities. The different types include line
    precision pipes, tubular poles, electric poles, lightweight galvanised pipes for sprinkler
    irrigation, among others. The industry has sufficient capacity to manufacture the
    different types of pipes & tubes. High performance ERW steel pipes & tubes possess
    high strength, toughness and are corrosion resistant. In the manufacturing process of
    ERW steel pipes & tubes, the edges to be welded are mechanically pressed together
    and electric resistance or electric induction is used to generate the heat required for
    welding. With the adoption of better welding technology, ERW pipes & tubes are now
    widely used in the oil & gas sector. A number of ERW steel pipes & tubes production
    units are in the SSI sector. Higher demand from the oil & gas industry, infrastructure
    and automobile industries has led to a healthy increase in production of ERW steel
    pipes.

    www.eiriindia.org 1
    CONTENTS

    INTRODUCTION
    TYPES OF ERW PIPE
    (1) LOW-FREQUENCY-WELDED ERW (LF-ERW) PIPE
    (2) HIGH-FREQUENCY-WELDED ERW (HF-ERW) PIPE
    (3) DIRECT-CURRENT-WELDED ERW (DC-ERW) PIPE
    PHYSICAL PROPERTIES OF PIPING MATERIALS
    MALLEABILITY
    DUCTILITY
    BRITTLENESS
    ELASTICITY
    CONDUCTIVITY
    CHEMICAL RESISTANCE/ RESISTANCE TO CORROSION
    PROPERTIES
    ADVANTAGES OF ERW PIPE
    USES AND APPLICATION
    USES
    APPLICATION
    B.I.S. SPECIFICATION
    PROCESS FLOW CHART
    MANUFACTURING PROCESS
    1. UNCOILED, LAVELED AND WELDING OF STRIP
    2. STRIPPING
    3. LOOPING
    4. EDGE TRIMMING
    5. FORMING
    6. WELDING
    7. BEAD TRIMMING
    8. SIZING
    9. CUTTING
    10. NORMALISING
    11. END FACING AND BEVELLING
    12. TESTING
    ULTRASONIC TESTING
    EDDY-CURRENT TESTING
    HYDROSTATIC TESTING
    MAGNETIC PARTICLE TESTING
    RADIOGRAPHIC (X-RAY) TESTING
    DYE-PENETRANT TEST
    14. MARKING

    www.eiriindia.org 2
    PLANT AND MACHINERY
    (1) UNCOILER
    (2) LAVELER
    (3) SHEAR AND WELDER
    HIGH QUALITY WELDING SEAM.
    1. SWITCHGEAR RECTIFYING CABINET
    2. INVERTER OUTPUT CABINET
    3. CONNECTING OPTICAL FIBER
    4. CIRCULATION SOFT WATER COOLING SYSTEM
    5. CENTRAL OPERATION CONSOLE
    6. MECHANICAL ADJUSTMENT DEVICE
    (4) ACCUMULATOR
    ACCUMULATOR
    THE HORIZONTAL SPIRAL ACCUMULATOR FOR WELDED PIPE LINE
    (5) FORMING AND SIZING SECTION
    FORMING AND SIZING MILL
    MATURE TECHNOLOGY FOR ROLLER COMPATIBILITY
    OPTIMIZED FORMING
    EDGE BENDING
    W-FORMING ON FIRST STAND
    (6) HF SOLID STATE WELDER
    HIGH QUALITY WELDING SEAM.
    1. SWITCHGEAR RECTIFYING CABINET
    2. INVERTER OUTPUT CABINET
    3. CONNECTING OPTICAL FIBER
    4. CIRCULATION SOFT WATER COOLING SYSTEM
    5. CENTRAL OPERATION CONSOLE
    6. MECHANICAL ADJUSTMENT DEVICE
    (6) ANNEALING FURNACE
    (7) FLYING SAW
    FLYING SAW
    FLYING SAW ALL DIGITAL CONTROL SYSTEM
    (8) FACING AND BEVELING MACHINE
    (10) STRAIGHTNER MACHINE
    (11) THREADING MACHINE
    THREADING MACHINE FEATURES:
    (12) HYDRAULIC TESTING MACHINE
    1) FOR ERW TUBE AND SEAMLESS TUBE
    2) FOR LARGER DIAMETER PIPE (HSAW AND LSAW PIPES)
    MARKET POSITION
    DOMESTIC DEMAND DRIVERS
    CAPACITY EXPANSION BY DOMESTIC PLAYERS
    HUGE INVESTMENTS IN THE SOUTH/EAST INDIA
    PLANT LAYOUT

    www.eiriindia.org 3
    PRESENT MANUFACTURERS/SUPPLIERS OF M.S ERW PIPE
    SUPPLIERS OF RAW MATERIALS
    SUPPLIERS OF M.S STRIP COILS
    SUPPLIERS OF RESSISTANCE WELDING ELECTRODE
    SUPPLIERS OF PICKLING CHEMICALS
    SUPPLIERS OF ZINC INGOT
    SUPPLIERS OF CASTIC SODA
    SUPPLIERS OF HYDROCLORIC ACID
    SUPPLIERS OF ZINC AMONIUM CLORIDE
    SUPPLIERS OF DEGREASING CHEMICAL
    SUPPLIERS OF PHOSPHATING CHEMICALS
    SUPPLIERS OF PLANT AND MACHINERY
    SUPPLIERS OF ERW PIPE AND TUBE PLANT
    SUPPLIERS OF HIGH FREQUENCY INDUCTION WELDER
    SUPPLIERS OF EOT CRANES
    SUPPLIERS OF DG SETS
    SUPPLIERS OF POWER TRANSFORMERS
    SUPPLIERS OF COOLING TOWER
    SUPPLIERS OF ETP PLANTS
    SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
    SUPPLIERS OF AIR COMPRESSORS
    SUPPLIERS OF PLATFORM WEIGHING MACHINE
    SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
    SUPPLIERS OF NDT INSPECTION EQUIPMENT
    SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
    SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
    SUPPLIERS OF SUBMERSIBLE WATER PUMP
    LIST OF PLANT & MACHINERY

    www.eiriindia.org 4
    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)

    www.eiriindia.org 5
    COST ESTIMATION

    Plant Capacity 1000 MT/Day


    Land & Building (50,000 sq.mt.) Rs. 30.30 Cr
    Plant & Machinery Rs. 60.94 Cr
    Working Capital for 2 Months Rs. 358.44 Cr
    Total Capital Investment Rs. 456.55 Cr
    Rate of Return 28%
    Break Even Point 48%

    www.eiriindia.org 6

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