Detailed Project Report on erw and spiral welded pipe

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ERW AND SPIRAL WELDED PIPE

[CODE NO.3553]

(A) SPIRAL WELDED PIPE

Spiral submerged arc welded pipe, a type of spirally welded steel pipe produced by using the double-sided submerged arc welding method.

Spiral welded pipes are formed using narrower plates or hot rolled coils, which lowers their production costs significantly. The spiral welding process permits the production of large-diameter pipes suitable for transporting large volumes of oil and gas. Traditional SSAW pipes were historically limited to low pressure applications; however, modern SSAW pipes have been used extensively in Russia, Canada and Asian countries in high pressure gas pipelines.

Spiral Weld Pipe, as the name implies, is a steel pipe which has a seam running its entire length in a spiral form. In the past, due to the method of manufacture, Spiral Welded pipe was relegated to low pressure and structural applications. With the development of the Submerged Arc Welding process, the production of large hot rolled coils of sufficient width and the development of dependable non-destructive testing methods, it is now possible to produce Spiral Weld pipe for high pressure service

Spiral welded pipe is an alternative process, spiral weld construction allows large diameter pipe to be produced from narrower plates or skelp. The defects that occur in spiral welded pipe are mainly those associated with the SAW weld, and are similar in nature to those for longitudinally welded SAW pipe.

COST ESTIMATION

Plant Capacity 30 MT/Day

Land & Building (16,000 sq.mt.) Rs. 8.32 Cr

Plant & Machinery Rs. 5.13 Cr

Working Capital for 2 Months Rs. 7.42 Cr

Total Capital Investment Rs. 21.95 Cr

Rate of Return 33%

Break Even Point 50%

INTRODUCTION
(A) SPIRAL WELDED PIPE
PROPERTIES
USES AND APPLICATION
OIL AND GAS PIPELINE
POWER PLANT
WATER & SEWERAGE
STRUCTURAL
OTHER INDUSTRIAL
(B) ERW PIPE
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
MANUFACTURING PROCESS
(A) FOR SPIRAL WELDED PIPE
PROCESS FLOW CHART FOR SPIRAL WELDED PIPE
MANUFACTURING PROCESS OF SPIRAL WELDED PIPE
STEPS ARE GIVEN BELOW
(1) PRODUCTION METHODOLOGY
(2) GEOMETRIC MONITORING
(3) END SHEARING, BUTT WELDING AND SIDE GUIDE ROLLERS
(4) THE MAKING OF SPIRAL WELD PIPES
(5) WELDING OF PIPE
(6) CUTTING OF PIPE
(7) TESTING OF PIPE
(8) FINAL INSPECTION, VISUAL CHECKING, WEIGHING AND MEASURING
(9) COATING OF PIPE
(10) FINAL MARKING
(B) FOR ERW PIPE
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
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
INDIAN SAW PIPE INDUSTRY
TABLE 1 – PRODUCT SUMMARY
INTERNATIONAL DEMAND DRIVERS
OIL
CHART 1 – GLOBAL CRUDE OIL PRODUCTION AND CONSUMPTION
CHART 2 – CRUDE OIL PRICE MOVEMENT VIS-À-VIS INVENTORY LEVELS
CHART 3 – GLOBAL NATURAL GAS PRODUCTION AND CONSUMPTION
CHART 4 – AVERAGE RIGS DEPLOYED
CHART 5 – WELDED TUBES PRODUCTION VIS-À-VIS CRUDE OIL PRICE
CHART 6 – MOVEMENT OF PLANNED PIPELINE PROJECTS VIS-À-VIS
CRUDE OIL PRICE
TABLE 2 – PIPELINES PLANNED AND UNDER CONSTRUCTION
DOMESTIC SCENARIO
TABLE 3 – EXISTING OIL & GAS PIPELINE NETWORK
NATURAL GAS
CHART 8 – DOMESTIC GAS AVAILABILITY VIS-À-VIS DEMAND
TABLE 4 – PLANNED DOMESTIC PIPELINE PROJECTS
WATER/SANITATION SECTOR
TABLE 5 – WATER/SANITATION PROJECTS
DOMESTIC TRENDS AND OUTLOOK
CHART 9 – PRODUCTION VIS-À-VIS DOMESTIC CONSUMPTION
INTRODUCTION TO PIPES – A PRIMER
SEAMLESS PIPES
SAW PIPES
LSAW PIPES
HSAW PIPES
WELDED (ELECTRIC RESISTANCE WELDED (ERW) AND ELECTRIC
FUSION WELDED
(EFW)) PIPES
DUCTILE IRON (DI) PIPES
GLOBAL PIPE INDUSTRY
DEMAND SCENARIO IN THE ENERGY SEGMENT
ENERGY DEMAND TO GROW AT A CAGR OF 1.4%
OVERALL OIL & GAS CAPEX EXPECTED TO INCREASE IN 2010 DRIVEN BY NOCS’ INVESTMENTS
ROBUST OUTLOOK FOR GLOBAL DEMAND FOR PIPELINES
REPLACEMENT DEMAND FROM THE US ALSO REMAINS STRONG
DEMAND SCENARIO IN THE WATER SEGMENT
GLOBAL DEMAND FOR PLASTIC PIPES TO RISE
WASTE & WATER PIPE DEMAND IN US
INDIAN PIPE INDUSTRY
INDIAN DEMAND FOR PIPES EXPECTED TO BE STRONG
ENERGY SEGMENT
LOW PIPELINE PENETRATION IN INDIA PROVIDES HUGE POTENTIAL
INCREASING SHARE OF NATURAL GAS IN ENERGY DEMAND
WITH PETROLEUM & NATURAL GAS REGULATORY BOARD IN ACTION,
TRUNK PIPELINES TO RECEIVE BOOST
SWOT – INDIAN PIPE INDUSTRY
SALIENT FEATURES OF THE INDIAN PIPE INDUSTRY
INDIAN MANUFACTURERS HAVE A COST ADVANTAGE
ORDER BOOK POSITION LOOKS ROBUST
CAPACITY UTILIZATION RANGES BETWEEN 25–60%
MARKET POSITION
DOMESTIC DEMAND DRIVERS
CAPACITY EXPANSION BY DOMESTIC PLAYERS
HUGE INVESTMENTS IN THE SOUTH/EAST INDIA
STEEL PIPES MARKET OVERVIEW
MARKET SIZE & FORECAST
GROWTH DRIVERS & CHALLENGES
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF M.S ERW PIPE
SUPPLIERS OF RAW MATERIALS
M.S STRIP COILS
RESSISTANCE WELDING ELECTRODE
WELDING ELECTRODES
PICKLING CHEMICALS
PACKING MATERIALS
SUPPLIERS OF PLANT AND EQUIPMENTS
TUBE MILL
SUBMERGED ARC WELDING EQUIPMENT
THREE ROLLER BENDING MACHINE
PLATE BENDING MACHINE
PIPE CUTTING MACHINE
PIPE STRAIGHTENING MACHINE
HYDROTESTING EQUIPMENT
BEND TESTING EQUIPMENT
POWDER COATING MACHINE
SUPPLIERS OF ERW PIPE AND TUBE PLANT
SUPPLIERS OF HIGH FREQUENCY INDUCTION WELDER
EOT CRANE
POWER TRANSFORMER
ELECTRICAL PANEL
ELECTRIC MOTOR
COOLING TOWER
EFFLUENT TREATMENT PLANT (ETP PLANT)
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE
JIGS AND FIXTURE
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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