Industry Overview
Electric resistance welded (ERW) pipe is manufactured by cold-forming steel sheet or strip into a cylindrical shape and joining the edges through electric resistance or induction heating, without welding filler material. Early ERW pipe manufacturing used low-frequency A.C. current from the 1920s until 1970, after which high-frequency ERW technology became established because it produced higher-quality welds. Low-frequency ERW pipes were subsequently found susceptible to selective seam corrosion, hook cracks, and inadequate seam bonding and are no longer used for pipe manufacture.
High-frequency ERW technology continues to be used for pipeline and other industrial applications. ERW steel pipes and tubes are widely used in engineering, water, oil and gas distribution, line pipes, fencing, scaffolding, agriculture, drinking-water supply, thermal power, deep-boring hand pumps, and telecommunications cable protection. Products are manufactured in different diameters, wall thicknesses, and qualities according to end-user requirements, including line precision pipes, tubular poles, electric poles, and lightweight galvanized pipes for sprinkler irrigation.
Modern ERW pipes offer high strength, toughness, and corrosion resistance. Improved welding technology has expanded their application in the oil and gas sector, while demand from infrastructure and automobile industries has supported production growth. The sector also includes a number of production units operating in the SSI sector.
Cost Estimation
| Cost / Financial Parameter | Value |
|---|---|
| Plant Capacity | 60 MT/Day |
| Land & Building (1672.24 sq.mt.) | Rs. 2.07 Cr |
| Plant & Machinery | Rs. 10.85 Cr |
| Working Capital for 2 Months | Rs. 14.31 Cr |
| Total Capital Investment | Rs. 27.76 Cr |
| Rate of Return | 35% |
| Break Even Point | 45% |
Content Index
- INTRODUCTION
- IMPLEMENTATION OF SCHEDULE OF ACTIVITY OF PROJECT
- 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
- BENEFITS OF MSME REGISTRATION
- 1. COLLATERAL-FREE LOAN FACILITIES & PRIORITY LENDING
- 2. CREDIT LINKED CAPITAL SUBSIDIES FOR MSMES
- 3. LOW INTEREST RATE ON LOAN
- 4. ISO CERTIFICATION CHARGES REIMBURSEMENT
- 5. INCUBATION SCHEME FOR MSME
- 6. MARKET DEVELOPMENT ASSISTANCE SCHEME FOR MSME
- 7. SUBSIDY ON PATENT REGISTRATION
- 8. PROTECTION AGAINST DELAYED PAYMENTS
- 9. 100% TAX EXEMPTION FOR INNOVATIVE STARTUPS
- 10. CONCESSIONS ON ELECTRICITY BILLS
- 11. TENDER PREFERENCE TO MSME
- 12. PRIME MINISTER EMPLOYMENT GENERATION PROGRAMME FOR MSMES
- LABOUR LAWS APPLICABLE FOR MSMES
- ENVIRONMENTAL LAWS COMPLIANCES FOR MSMES
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- PROCESS FLOW CHART FOR HOT DIP GALVANISING
- MANUFACTURING PROCESS
- 1. UNCOILED, LEVELED 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
- 13. MARKING
- 14. HOT DIP GALVANISING PROCESS
- THERE ARE TWO TYPES OF HOT DIP GALVANIZING:
- (A) CONTINUOUS GALVANISING
- MAIN STEPS IN CONTINIOUS GALVANISING LINE
- (A) PREPARATION OF BLACK COILS
- (B) CLEANING
- (C) ANNEALING AND COOLING
- (D) ZINC BATH MANAGEMENT AND ALLOYING REACTIONS
- (E) COATING WEIGHT [MASS] CONTROL AND MEASUREMENT
- (F) POST TREATMENTS
- TEMPER PASSING
- LEVELING
- CHEMICAL TREATMENT
- INSPECTION
- OILING AND RECOILING
- (B) BATCH GALVANISING
- ZINC BATH COMPOSITION FOR BATCH PROCESS
- PART THICKNESS
- STEPS IN GALVANISING
- (A) PREPARATION
- CAUSTIC CLEANING –
- PICKLING –
- FLUXING –
- DRYING –
- (B) GALVANISING
- (C) POST TREATMENT
- SOURCES OF WASTE
- WASTE MANAGEMENT IN GALVANISING PROCESS
- TYPES OF WASTE
- I) ACID WASTE
- II) FLUX WASTE
- III) DROSS
- IV) ASH
- V) BAG FILTER DUST
- VI) GENERAL AND OTHER WASTES
- LIMIT OF POLLUTION IN HOT DIP GALVANISING PROCESS
- AIR POLLUTION CONTROL MEASURES FOR ACID FUMES
- PLANT AND MACHINERY
- (1) UNCOILER
- (2) LEVELER
- (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
- LEADING VENDORS IN THE MARKET ARE –
- SEGMENTATION BY END-USER AND ANALYSIS OF THE GALVANIZED STEEL TUBES MARKET
- SUPPLIERS OF M.S PIPE AND TUBE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF M.S STRIP COILS
- SUPPLIERS OF PACKING MATERIALS
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF RESSISTANCE WELDING ELECTRODE
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF ERW PIPE AND TUBE PLANT
- SUPPLIERS OF HIGH FREQUENCY INDUCTION WELDER
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMER
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- 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)
Frequently Asked Questions
An ERW pipe is a steel pipe manufactured by forming steel sheet or strip into a cylindrical shape and joining its edges using electrical heating and pressure. The process uses electric resistance or induction to generate the heat required to create the weld, without adding welding filler material. Modern high-frequency ERW technology provides improved weld quality and is used for a wide range of industrial and infrastructure applications, including water distribution, oil and gas, engineering, scaffolding, fencing, agriculture, and telecommunications cable protection.
The report identifies low-frequency-welded ERW (LF-ERW), high-frequency-welded ERW (HF-ERW), and direct-current-welded ERW (DC-ERW) pipe as the main types. High-frequency ERW technology is the modern process discussed for producing higher-quality welded pipe. Low-frequency ERW technology was historically used but is no longer used for pipe manufacture because of weld-related problems such as selective seam corrosion, hook cracks, and inadequate bonding. Different ERW products can also be manufactured in varying diameters, wall thicknesses, and qualities to meet application requirements.
ERW steel pipes are used across engineering, infrastructure, utilities, energy, agriculture, and industrial applications. The report lists water, oil and gas distribution, line pipes, fencing, scaffolding, agricultural applications, drinking-water supply, thermal power, deep-boring hand pumps, and protection of telecommunications cables among their uses. ERW products are also used for applications such as tubular poles, electric poles, line precision pipes, and lightweight galvanized pipes for sprinkler irrigation, with product specifications selected according to the requirements of the end-use industry.
ERW pipe manufacturing generally involves uncoiling and leveling the strip, forming it into a cylindrical section, welding the edges, sizing, cutting, finishing, and testing. The report covers operations including stripping, looping, edge trimming, forming, welding, bead trimming, sizing, cutting, normalising, end facing and bevelling, testing, and marking. Depending on the product and plant configuration, testing can include ultrasonic, eddy-current, hydrostatic, magnetic particle, radiographic, and dye-penetrant methods. Galvanizing may subsequently be carried out where corrosion protection is required.
High-frequency welding is used because it provides a higher-quality welded seam than the historical low-frequency ERW process. The high-frequency process generates the heat required to join the prepared edges while they are mechanically pressed together. Its adoption has supported the wider use of ERW pipes in demanding applications, including oil and gas. Modern ERW production lines can incorporate high-frequency solid-state welding equipment, cooling systems, control consoles, mechanical adjustment systems, and downstream operations for sizing, annealing, cutting, facing, bevelling, and testing.
An ERW pipe plant requires forming, welding, sizing, cutting, finishing, testing, and material-handling equipment. The report includes equipment such as an uncoiler, leveler, shear and welder, accumulator, forming and sizing mill, HF solid-state welder, annealing furnace, flying saw, facing and beveling machine, straightener machine, threading machine, and hydraulic testing machine. Supporting equipment can include cranes, transformers, electrical panels, cooling systems, compressors, material-handling equipment, and environmental-control systems, depending on the plant configuration and product range.
Hot dip galvanising is a zinc-coating process used to improve the corrosion protection of steel pipe and related products. The report covers continuous and batch galvanising methods. Preparation may involve caustic cleaning, pickling, fluxing, and drying, followed by immersion in a zinc bath and post-treatment. Continuous galvanising can additionally include cleaning, annealing and cooling, zinc-bath management, coating-weight control, temper passing, leveling, chemical treatment, inspection, oiling, and recoiling. The process requires appropriate management of acid waste, flux waste, dross, ash, bag-filter dust, and other wastes.
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