M.S. PIPES
[EIRI/EDPR/1431] (J.C. 210)
INTRODUCTION
Pipes and tubes find use in almost all the industries/services in one way or the other. Automobile vehicles use metallic pipes, including steel pipes, of a large variety. Gas/water/liquids transporting pipes are spread everywhere. Irrigation, petroleum products, sewerage, chemicals transportation pipes and those used in mines, public water supply networks, are well known.
Hydraulic piping may be divided into (i) rigid & (ii) flexible classes.
Rigid piping of iron & steel is either seamless or welded type. Pipes have specified end-threading pipe-fittings in the piping net-work. The following common tube sizes, their bend=radii & other pertinent data, are taken care of by pipe manufacturers.
ERW processes uses tremendous amount of localized heating to bring the material to plastic state and above when it is just ready to melt. The ERW process joins two separate parts by passage of heavy current across the joint. Due to great electrical resistance of the circuit, heat generates locally at the joint surfaces which, when brought in contact at approximately the melting temperature, joint together to give a strong welded joint.
Either AC or DC current can be used but the use of AC current is felt convenient. It is so because the required high current can be supplied at a low voltage through a suitable transformer, if AC source is used. High current & proper "push-up" forces are the essential requirements in electric resistance welding.
Power requirement, for welding a given cross-section, varies widely with time-interval of current application to produce the weld. Low carbon steels are flash or butt resistance welded, requiring a heating period of several seconds. About 30 KVA or more is required per sq.inch of weld surface. If time-interval is decreased, the powder requirement increases, thus, welding is accomplished in a fraction of a second. 1500 to 2000 KVA/in2 of weld surface is required for fast resistance welding. The heated (above plastic state) edges, intended to be joined together, need a push-up force of approx. 5000 psi. Special equipments are required for ERW process and hence, this welding technique is suitable for mass production. A hard copper alloy electrode alongwith a soft copper alloy electrode makes a pair for use in ERW.
ERW flash welding is a modification of ERW butt welding. Contact edges are kept slightly apart and the flash or arcing occurs from edge-to-edge of the joint. The two joining edges are pressed together after the arc has heated-up the contact surfaces to required weld temperature.
ERW technique is made continuous for use in steel tubes/pipes manufacturing industry. This process requires less care in preparation of the joint surfaces. It requires smaller current density for satisfactory welding than resistance butt welding. Often a hydrogen-rich atmosphere can be maintained at the areas under welding process in order to avoid oxidation of the joint surfaces.
COST ESTIMATION
Plant Capacity 7.80 MT/Day
Land & Building (3000 sq.mt.) Rs. 1.68 Cr
Plant & Machinery Rs. 89.00 Lac
Working Capital for 2 Months Rs. 2.14 Cr
Total Capital Investment Rs. 4.94 Cr
Rate of Return 21%
Break Even Point 64%
CONTENTS
INTRODUCTION
USES & APPLICATIONS
B.I.S. SPECIFICATIONS
MARKET SURVEY
EXPORT POTENTIAL OF MILD STEEL PIPES
MANUFACTURERS/SUPPLIERS OF M.S. TUBES AND PIPES
TECHNICAL SPECIFICATONS OF M.S. PIPES
PROCESS OF MANUFACTURE
MANUFACTURING PROCESS STEEL TUBES/PIPES
PROCESS FLOW DIAGRAM
PLANT LAYOUT
COMPLETE PLANT AND MACHINERY SUPPLIERS OF M.S. PIPE AND TUBES
SUPPLIERS OF PLANT & MACHINERY
SUPPLIERS OF RAW MATERIALS
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)
