MS PIPE FOR SPIRAL AND ERW [3552]
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. 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 In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.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 galvanised 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. (1) Low-Frequency-Welded ERW (LF-ERW) Pipe: ERW pipe was introduced by Republic Steel in 1929 and variations of the original process are still in use today. Cans were formed continuously as described above, and welding was done with low-frequency alternating current (typically 120 cycles per second). Low-frequency electric resistance weld, LF-ERW is Electric resistance welded (ERW) pipe 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 1920s 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. (2) High-Frequency-Welded ERW (HF-ERW) Pipe: Between about 1960 and 1970, most manufacturers of low-frequency-welded ERW pipe either converted to high-frequency welding (450 kilocycles per second) or went out of business. The high-frequency welding process was easier to control, the equipment was easier to maintain, and it produced weld zones with better resistance to brittle fracture than the low-frequency process. (3) Direct-Current-Welded ERW (DC-ERW) Pipe: ERW pipe made with direct current was introduced around 1930 by Youngstown Sheet & Tube Company. Individual cans were cold formed from hot-rolled plates of more than 50 feet in length. Each pipe was thus welded as a separate unit compared to the continuous process.
COST ESTIMATION
Plant Capacity 30 MT/Day
Land & Building (16000 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)
