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    Detailed Project Report on erw pipes and tubes plant

    Detailed Project Report on erw pipes and tubes plant
    Detailed Project Report on erw pipes and tubes plant
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      ERW PIPES AND TUBES PLANT
      [CODE NO.3415]  


      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 In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.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 galvanized 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                                               :    320.00 MT/day   
      land & Building (36.960 Sq.Mtr)                  :    Rs.  30.04 Cr
      Plant & Machinery                                          :    Rs.  70.84 Cr
      Working Capital for 2 Months                       :    Rs.  51.58 Cr
      Total Capital Investment                                :    Rs.  195.32 Cr
      Rate of Return                                                  :    36%
      Break Even Point                                             :    44%

      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    
      B.I.S. SPECIFICATION    
      MARKET POSITION    
      DOMESTIC DEMAND DRIVERS    
      CAPACITY EXPANSION BY DOMESTIC PLAYERS    
      HUGE INVESTMENTS IN THE SOUTH/EAST INDIA    
      EXPORT DATA OF ERW STEEL PIPE    
      IMPORT DATA OF ERW STEEL PIPE    
      MANUFACTURERS/SUPPLIERS OF M.S ERW PIPE    
      PROCESS FLOW CHART    
      PROCESS FLOW CHART FOR HOT DIP GALVANISING    
      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    
      (15) HOT DIP GALVANISING PROCESS    
      (A) CONTINIOUS 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) LAVELER    
      (3) SHEAR AND WELDER    
      (4) ACCUMULATOR    
      (5) FORMING AND SIZING SECTION    
      (5) 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    
      MAIN SPECIFICATION:    
      FLYING SAW ALL DIGITAL CONTROL SYSTEM    
      (8) FACING AND BEVELING MACHINE    
      (9) STRAIGHTNER MACHINE    
      (10) THREADING MACHINE    
      (11) HYDRAULIC TESTING MACHINE    
      1) FOR ERW TUBE AND SEAMLESS TUBE    
      2) FOR LARGER DIAMETER PIPE (HSAW AND LSAW PIPES)    
      PLANT LAYOUT    
      SUPPLIERS OF RAW MATERIALS    
      M.S STRIP COILS    
      RESSISTANCE WELDING ELECTRODE    
      PICKLING CHEMICALS    
      ZINC INGOT    
      CASTIC SODA    
      HYDROCLORIC ACID    
      ZINC AMONIUM CLORIDE    
      DEGREASING CHEMICAL    
      PHOSPHATING CHEMICALS    
      SUPPLIERS OF PLANT AND MACHINERIES    
      ERW PIPE AND TUBE PLANT    
      HIGH FREQUENCY INDUCTION WELDER    
      EOT CRANE    
      DG SETS    
      POWER TRANSFORMERS    
      COOLING TOWER    
      ETP PLANTS    
      AIR POLLUTION CONTROL EQUIPMENTS    
      AIR COMPRESSORS    
      PLATFORM WEIGHING MACHINE    
      MATERIAL HANDLING EQUIPMENTS    
      NDT INSPECTION EQUIPMENT    
      FIRE FIGHTING EQUIPMENTS    
      ELECTRICAL MEASURING INSTRUMENTS    
      SUBMERSIBLE WATER PUMP    
      LIST OF PLANT & MACHINERY    
      UTILITY EQUIPMENTS    

      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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