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. The process initially used low-frequency alternating current from the 1920s until 1970, after which high-frequency ERW technology became predominant because it offered better weld quality and improved resistance to brittle fracture.
Low-frequency ERW pipes were subsequently associated with selective seam corrosion, hook cracks, and inadequate seam bonding, resulting in the discontinuation of this process for pipe manufacturing. High-frequency ERW technology continues to be used for applications including pipeline construction.
ERW steel pipes and tubes have extensive applications in engineering, water, oil and gas distribution, fencing, scaffolding, agriculture, drinking-water supply, thermal power, deep-boring hand pumps, and telecom cable protection. Products are manufactured in different diameters, wall thicknesses, and qualities, including line precision pipes, tubular poles, electric poles, and lightweight galvanized pipes for sprinkler irrigation. Growing requirements from the oil and gas, infrastructure, and automobile sectors have supported increased ERW pipe production.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1000 MT/Day |
| Land & Building (50,000 sq.mt.) | Rs. 30 Cr |
| Plant & Machinery | Rs. 60 Cr |
| Working Capital for 2 Months | Rs. 358.45 Cr |
| Total Capital Investment | Rs. 456.55 Cr |
| Rate of Return | 28% |
| Break Even Point | 48% |
Content Index
- 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
- 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
- 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
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 strip or sheet into a cylindrical shape and electrically welding the adjoining edges. The process generates heat through electrical resistance or induction, allowing the edges to bond without welding filler material. ERW pipes can be produced in different diameters, wall thicknesses, and grades according to application requirements. They are commonly used in water distribution, oil and gas, engineering, infrastructure, agriculture, scaffolding, fencing, and other industrial applications where welded steel tubular products are suitable.
The report identifies three main types of ERW pipe: low-frequency-welded ERW (LF-ERW), high-frequency-welded ERW (HF-ERW), and direct-current-welded ERW (DC-ERW). LF-ERW historically used low-frequency alternating current, while HF-ERW uses a higher-frequency electrical process that provides improved weld control and weld-zone performance. DC-ERW uses direct current and was introduced as an alternative manufacturing approach. Modern ERW pipe production commonly relies on high-frequency welding technology because of its process control and weld-quality advantages.
High-frequency ERW pipe is manufactured by progressively forming steel strip into a tubular shape and heating the adjoining edges using high-frequency electrical energy before pressing them together to create the weld. A typical production line includes uncoiling and leveling, strip preparation, looping, edge trimming, forming, welding, bead trimming, sizing, cutting, normalising, end facing and bevelling, followed by inspection and marking. Equipment selection depends on pipe dimensions, material specifications, production requirements, welding technology, and the required level of automation.
ERW pipes are used across water, oil and gas, engineering, infrastructure, agriculture, power, construction, and utility applications. Typical uses include water and fluid distribution, line piping, fencing, scaffolding, agricultural irrigation systems, tubular and electric poles, deep-boring hand pumps, and telecom cable protection. Their suitability depends on pipe grade, dimensions, weld quality, pressure requirements, corrosion conditions, and applicable product standards. The report also notes their increasing use in the oil and gas sector following improvements in welding technology.
ERW pipe quality can be evaluated using several non-destructive and pressure-testing methods. The report lists ultrasonic testing, eddy-current testing, hydrostatic testing, magnetic particle testing, radiographic or X-ray testing, and dye-penetrant testing. These methods serve different inspection purposes, including identifying weld discontinuities, surface defects, internal imperfections, and leakage or pressure-related problems. The appropriate inspection regime depends on the pipe specification, material, intended service, applicable standards, and purchaser requirements.
Important piping-material properties include malleability, ductility, brittleness, hardness, elasticity, conductivity, and resistance to chemical attack and corrosion. Malleability and ductility influence forming and fabrication, while hardness affects resistance to pressure and mechanical wear. Elasticity is relevant where dimensional changes occur because of temperature variations. Conductivity becomes important for applications involving heat transfer or electrical characteristics. Corrosion resistance is particularly significant because the service environment can strongly influence material selection, service life, fabrication requirements, and overall system cost.
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