ERW ROLLING MILL
[CODE NO.3868]
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 In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.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, 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.
COST ESTIMATION
Plant Capacity 60 MT/Day
Land & Building (8000 sq.mt.) Rs. 5 Cr
Plant & Machinery Rs. 47.27 Cr
Working Capital for 2 Months Rs. 13.81 Cr
Total Capital Investment Rs. 66.62 Cr
Rate of Return 22%
Break Even Point 63%
INTRODUCTION
SIZE OF HOLLOW STEEL SECTIONS
MILD STEEL (SHS) SQUARE STEEL HOLLOW SECTION:
MILD STEEL (RHS) RECTANGULAR STEEL HOLLOW SECTION:
MILD STEEL (CHS) CIRCULAR STEEL HOLLOW SECTION:
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 (PLEASE REFER IS:5504:1997)
ULTRASONIC TESTING
EDDY-CURRENT TESTING
HYDROSTATIC TESTING
MAGNETIC PARTICLE TESTING
RADIOGRAPHIC (X-RAY) TESTING
DYE-PENETRANT TEST
14. MARKING
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
UNIQUE MODULE ROLL (ASSEMBLY ROLL) AND JUANTIE (EDGE GRADUALLY TO CENTER) FORMING TECHNOLOGY
(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
(7) ANNEALING FURNACE
(8) FLYING SAW
FLYING SAW
MAIN SPECIFICATION:
MAIN SPECIFICATION:
FLYING SAW ALL DIGITAL CONTROL SYSTEM
(9) FACING AND BEVELING MACHINE
(10) STRAIGHTNER MACHINE
(11) THREADING MACHINE
THREADING MACHINE FEATURES:
(12) HYDRAULIC TESTING MACHINE
ERW PIPE CURRENT MARKET ASPECTS
INDIAN MARKET
HUGE INVESTMENTS IN THE SOUTH/EAST INDIA
GLOBAL MARKET
TECHNOLOGY INSIGHTS
APPLICATION INSIGHTS
COUNTRIES INSIGHTS
STEEL PIPES & TUBES MARKET SHARE INSIGHTS
MARKET OVERVIEW
STEEL PIPES INDUSTRY OVERVIEW
STRUCTURE AND APPLICATION OF STEEL PIPES AND TUBES INDUSTRY
EBITDA/TONE AND LEVERAGE ACROSS PIPE SEGMENTS/PLAYERS
STEADY IMPROVEMENT IN SALE OF ERW STEEL PIPE
INCREASING DEMAND FOR STEEL PIPES
ERW PIPES
ERW PLAYERS PROFITABILITY
ERW PIPES GROWTH IN RECENT YEARS
HR COIL PRICES HAVE CORRECTED SHARPLY DUE TO EXCESS
GLOBAL SUPPLY, DRIVEN BY CHINA
UTILISATION UPTREND
ERW PIPES
UTILISATION LEVELS HEADED NORTH
ANNEXURE
LIST OF STEEL PIPE COMPANIES RATED BY CRISIL
PLANT LAYOUT
MANUFACTURES/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 PIPE GALVANISING PLANT
SUPPLIERS OF EOT CRANES
SUPPLIERS OF D.G. 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 PLATEFARM 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
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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