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)
