M.S. PIPE MANUFACTURING PLANT [3517]
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 In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.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 20 MT/Day
Land & Building (4000 sq.mt) Rs. 3.17 Cr
Plant & Machinery Rs. 5.60 Cr
Working Capital for 1 Month Rs. 2.54 Cr
Total Capital Investment Rs. 11.84 Cr
Rate of Return 36%
Break Even Point 50%
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 (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
(4) ACCUMULATOR
(5) FORMING AND SIZING SECTION
(6) HF SOLID STATE WELDER
(7) ANNEALING FURNACE
(8) FLYING SAW
(9) FACING AND BEVELING MACHINE
(10) STRAIGHTNER MACHINE
(11) THREADING MACHINE
(12) HYDRAULIC TESTING MACHINE
MARKET POSITION
DOMESTIC DEMAND DRIVERS
CAPACITY EXPANSION BY DOMESTIC PLAYERS
HUGE INVESTMENTS IN THE SOUTH/EAST INDIA
MARKET SCENARIO: STEEL PIPES IN OIL & GAS INDUSTRY
LOCATION OF INDIA’S OIL AND GAS RESERVES – LARGELY OFFSHORE –
TO GENERATE HIGHER DEMAND FOR OCTG PIPES
CARBON SEAMLESS TUBES - ONGC/OIL TO CONTRIBUTE TOWARDS 80%
OF DOMESTIC DEMAND
CAPEX BUOYANCY IN REFINERIES – HUGE OPPORTUNITY FOR STAINLESS STEEL SEAMLESS PLAYERS
INDIAN REFINING MARKET: OPERATING AT >100% UTILIZATION
DETAILED EXPORT DATA OF MS ERW PIPE
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF M.S ERW PIPE
SUPPLIERS OF RAW MATERIALS
M.S STRIP COILS
PACKING MATERIALS
PICKLING CHEMICALS
RESSISTANCE WELDING ELECTRODE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF ERW PIPE AND TUBE PLANT
SUPPLIERS OF HIGH FREQUENCY INDUCTION WELDER
EOT CRANE
DG SETS
POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
AIR POLLUTION CONTROL EQUIPMENTS
AIR COMPRESSORS 103
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
NDT INSPECTION EQUIPMENT
FIRE FIGHTING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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