Industry Overview
Electric resistance welded (ERW) pipe is manufactured by cold-forming steel sheet into a cylindrical shape and using electric resistance or induction heating to bring the edges together and form a bond without welding filler material. Historically, low-frequency alternating current was used from the 1920s until 1970, after which high-frequency ERW technology became established because it provided higher-quality welds. Low-frequency ERW pipe was subsequently associated with selective seam corrosion, hook cracks, and inadequate seam bonding.
ERW steel pipes and tubes are widely used in engineering, water, oil and gas distribution, line pipes, fencing, scaffolding, agriculture, drinking-water supply, thermal power, deep-boring hand pumps, and telecom cable protection. Products are available in different wall thicknesses, diameters, and qualities, including line precision pipes, tubular poles, electric poles, and lightweight galvanised pipes for sprinkler irrigation. High-performance ERW products offer strength, toughness, and corrosion resistance. Improved welding technology has also expanded ERW applications in the oil and gas sector, while demand from oil and gas, infrastructure, and automobile industries has supported increased production.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 100 MT/Day |
| Land & Building | On Rented |
| Plant & Machinery | Rs. 12.23 Cr |
| Working Capital for 2 Months | Rs. 30.25 Cr |
| Total Capital Investment | Rs. 43.12 Cr |
| Rate of Return | 54% |
| Break Even Point | 32% |
Content Index
- INTRODUCTION
- 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
- 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
- MARKET POSITION
- CHAINA SUPPLIERS OF STEEL PIPE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF MS STRIP COIL BY CHINA
- SUPPLIERS OF RESISTANCE WELDING ELECTRODE BY CHINA
- SUPPLIERS OF PLANT AND MACHINERY
- CHINA SUPPLIERS OF PIPE PLANT
- ETP BY CHINA
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
ERW pipe is steel pipe manufactured by forming steel strip into a cylindrical shape and electrically welding its edges.
The process brings the prepared edges together and uses electric resistance or induction to generate the heat needed for bonding, without welding filler material. A typical production line can include uncoiling, leveling, strip preparation, looping, edge trimming, forming, high-frequency welding, bead trimming, sizing, cutting, normalizing, end facing and beveling, followed by testing and marking. The specific equipment configuration depends on the required pipe dimensions, quality, and production requirements.
The report identifies three main types of ERW pipe: low-frequency-welded, high-frequency-welded, and direct-current-welded ERW pipe.
Low-Frequency-Welded ERW (LF-ERW) pipe historically used low-frequency alternating current and was used extensively before being superseded by higher-frequency technology. High-Frequency-Welded ERW (HF-ERW) pipe uses a higher-frequency welding process that provides better process control and weld-zone characteristics. Direct-Current-Welded ERW (DC-ERW) pipe represents another historical approach in which direct current was used for welding separately formed pipe units.
High-frequency ERW technology is preferred because it provides better weld quality and improved process control than the older low-frequency method.
The report notes that low-frequency ERW welds were found to be susceptible to selective seam corrosion, hook cracks, and inadequate seam bonding. High-frequency welding became established as an alternative because the process was easier to control and its equipment was easier to maintain. It also produced weld zones with better resistance to brittle fracture than the low-frequency process. These characteristics contributed to the continued use of high-frequency ERW technology for modern pipe manufacturing and pipeline applications.
ERW steel pipes are used across engineering, infrastructure, utility, agricultural, and industrial applications.
The report identifies uses including water distribution, oil and gas distribution, line pipes, fencing, scaffolding, agricultural systems, drinking-water supply, thermal power applications, deep-boring hand pumps, and telecom cable protection. ERW products are also manufactured in forms such as line precision pipes, tubular poles, electric poles, and lightweight galvanised pipes for sprinkler irrigation. Their range of available diameters, wall thicknesses, and qualities allows manufacturers to supply products for different end-user requirements.
An ERW pipe manufacturing plant requires a forming and welding line supported by material handling, finishing, testing, and control equipment.
The report lists 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. The HF welding system also includes electrical and control components such as switchgear, an inverter output cabinet, optical-fiber connections, a soft-water cooling system, a central operation console, and mechanical adjustment equipment.
ERW pipe quality can be evaluated through several non-destructive and pressure-testing methods.
The report includes ultrasonic testing, eddy-current testing, hydrostatic testing, magnetic particle testing, radiographic (X-ray) testing, and dye-penetrant testing. These methods can be used to assess weld integrity, identify surface or subsurface discontinuities, and verify pressure performance as applicable to the product and specified requirements. The manufacturing sequence also includes dimensional and finishing operations such as sizing, cutting, normalizing, end facing, beveling, and marking, which support conformity with the applicable product specifications.
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