Industry Overview
A Stainless Steel Tube Mill is an industrial facility designed for the manufacture of stainless steel tubes and pipes through a series of forming, welding, sizing, finishing, testing, and surface-treatment operations. The broader steel-making process may involve the conversion of iron ore or scrap into steel, followed by casting and rolling to produce semi-finished or finished products. Integrated steel production commonly uses iron ore, coal, and limestone, while secondary steel producers or mini mills primarily use recycled steel scrap.
In stainless steel tube manufacturing, strip is typically uncoiled, levelled, welded, formed, sized, cut, heat treated, straightened, tested, pickled, passivated, polished, and marked according to the required specifications. Quality control is important throughout the process, with inspection methods such as ultrasonic, eddy-current, hydrostatic, magnetic particle, radiographic, and dye-penetrant testing applied as appropriate.
The report also covers stainless steel tube sizes, raw materials, physical and chemical properties, applications, BIS specifications, manufacturing processes, plant and machinery, quality assurance, plant layout, market position, and supplier categories. Environmental considerations are relevant to steel and tube manufacturing, particularly emissions, process wastes, and effluents associated with production and surface treatment.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (10,000 sq.mt.) | Rs. 7.58 Cr |
| Plant & Machinery | Rs. 2.58 Cr |
| Working Capital for 2 Months | Rs. 30.60 Cr |
| Total Capital Investment | Rs. 41.86 Cr |
| Rate of Return | 35% |
| Break Even Point | 45% |
Content Index
- INTRODUCTION
- SIZES OF PIPES
- SIZES FOR STAINLESS STEEL TUBE
- RAW MATERIAL
- PHYSICAL PROPERTIES OF PIPING MATERIALS
- MALLEABILITY
- DUCTILITY
- BRITTLENESS
- ELASTICITY
- CONDUCTIVITY
- CHEMICAL RESISTANCE/ RESISTANCE TO CORROSION
- USES AND APPLICATION
- TYPICAL APPLICATIONS FOR STAINLESS STEEL PIPE:
- 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. STRAIGHTENING
- 12. END FACING AND BEVELLING
- 13. TESTING
- ULTRASONIC TESTING
- EDDY-CURRENT TESTING
- HYDROSTATIC TESTING
- MAGNETIC PARTICLE TESTING
- RADIOGRAPHIC (X-RAY) TESTING
- DYE-PENETRANT TEST
- 14. PICKLING
- 15. PASSIVATION
- POLISHING
- DIFFERENCE BETWEEN WET BRIGHT AND DRY BRIGHT:
- ADVANTAGES:
- ELECTROPOLISHING SUPERIOR THAN MECHANICAL POLISHING:
- ELECTROCHEMICAL POLISHING CHARACTERISTICS:
- 17. MARKING
- NOMINAL PIPE SIZE (NOMINAL BORE)
- QUALITY CONTROL
- QUALITY ASSURANCE PLAN
- A. INCOMING RAW MATERIAL
- B. STAGE WISE INSPECTION
- 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
- MARKET POSITION
- STEEL PIPE MARKET
- EBITDA/TONE AND LEVERAGE ACROSS PIPE SEGMENTS/PLAYERS
- STEADY IMPROVEMENT IN CREDIT PROFILES OF BOTH SEGMENTS
- INTEREST COVER ON UPTREND
- SO IS NET CASH ACCRUAL TO DEBT
- MOVEMENT IN OPERATING MARGINS VIS-À-VIS HR COIL PRICES
- EBITDA/TONNE FOR ERW
- EBITDA/TONNE FOR S & S
- UTILISATION LEVELS HEADED NORTH
- PLANT LAYOUT
- SUPPLIERS OF SS TUBES
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CR SS STRIPS
- SUPPLIERS OF PACKING MATERIALS
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF RESSISTANCE WELDING ELECTRODE
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF SS PIPE AND TUBE PLANT
- CHINA SUPPLIER
- SUPPLIERS OF METAL TESTING MACHINE
- SUPPLIERS OF PRECISION MEASURING TOOLS
- SUPPLIERS OF NDT INSPECTION EQUIPMENT
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
- 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 EFFULENT 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)
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