Industry Overview
Spiral welded pipe, also known as spiral submerged arc welded (SSAW) pipe, is a steel pipe manufactured using the double-sided submerged arc welding method. The spiral welding process enables large-diameter pipes to be produced from narrower plates or hot rolled coils, offering significant production cost advantages while supporting applications requiring the transportation of large volumes of oil, gas, water, and other fluids.
Historically, spiral welded pipes were mainly associated with low-pressure and structural applications. Advances in submerged arc welding, the availability of large hot rolled coils, and dependable non-destructive testing methods have enabled their use in higher-pressure services. Spiral welded pipes have been used extensively in Russia, Canada, and Asian countries for high-pressure gas pipeline applications.
The project also covers electric resistance welded (ERW) pipes, including low-frequency, high-frequency, and direct-current welded varieties. The report examines pipe properties, applications, manufacturing processes, testing methods, plant and machinery, industry trends, domestic and international demand drivers, market outlook, plant layout, and suppliers of raw materials, equipment, and ancillary systems.
Cost Estimation
| Particulars | Cost / Value |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
Spiral welded pipe is a steel pipe manufactured with a continuous spiral seam using a submerged arc welding process. It is produced by forming narrower steel plates or hot rolled coils into a cylindrical shape and welding the adjoining edges. This manufacturing approach is particularly suitable for producing large-diameter pipes and can provide production cost advantages. Spiral welded pipes are used in applications such as oil and gas pipelines, water and sewerage systems, power plants, structural works, and other industrial services, subject to applicable design and quality requirements.
Spiral welded pipe is widely considered for large-diameter fluid transportation and industrial infrastructure applications. The report identifies oil and gas pipelines, power plants, water and sewerage systems, structural applications, and other industrial uses. Its suitability depends on pipe grade, dimensions, welding quality, pressure requirements, testing standards, coating requirements, and the operating environment. Proper engineering specifications and applicable standards are therefore essential when selecting spiral welded pipe for a particular service.
Spiral welded pipe is manufactured through a sequence of forming, welding, cutting, inspection, and finishing operations. The process described in the report includes production methodology, geometric monitoring, end shearing and butt welding, side guide control, spiral forming, submerged arc welding, pipe cutting, testing, final inspection, weighing and measurement, coating, and final marking. Manufacturing equipment and process controls are selected to maintain dimensional accuracy, weld integrity, surface quality, and compliance with the required product specifications.
Spiral welded pipe and ERW pipe differ primarily in their forming and welding methods. Spiral welded pipe is formed helically from steel strip or coil and uses a spiral submerged arc welded seam. ERW pipe is formed from strip and welded along a longitudinal seam using electrical resistance welding techniques. The report covers low-frequency, high-frequency, and direct-current ERW pipe types. Selection between these products depends on required diameter, wall thickness, application, material specification, production requirements, and applicable standards.
Welded pipes can undergo several non-destructive and performance tests to assess weld and pipe integrity. The report lists ultrasonic testing, eddy-current testing, hydrostatic testing, magnetic particle testing, radiographic testing, and dye-penetrant testing. The appropriate combination depends on the product specification, intended service, applicable standards, and quality-control requirements. Testing is supported by visual inspection, dimensional checks, weighing, measurement, and final marking to help verify that finished pipes meet the specified manufacturing and quality requirements.
A welded pipe manufacturing plant requires machinery covering material preparation, forming, welding, sizing, cutting, testing, and finishing. The report identifies equipment such as an uncoiler, leveler, shear and welder, accumulator, forming and sizing section, HF solid-state welder, annealing furnace, flying saw, facing and beveling machine, straightener machine, threading machine, and hydraulic testing machine. Supporting systems may include cooling, electrical, material handling, testing, environmental control, and utility equipment required for safe and continuous plant operation.
Steel pipe demand is influenced by infrastructure development, energy transportation, oil and gas activity, water and sanitation projects, industrial investment, and replacement requirements. The report specifically examines international and domestic demand drivers related to crude oil, natural gas, pipelines, water infrastructure, and the Indian energy sector. Pipeline project activity, natural gas demand, infrastructure investment, steel prices, capacity utilization, and the development of domestic manufacturing capabilities can all affect market conditions and the outlook for welded pipe producers.
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