Industry Overview
Spiral submerged arc welded (SSAW) pipe is a steel pipe manufactured by forming narrower plates or hot-rolled coils into a spiral shape and joining the seam using the double-sided submerged arc welding process. This method enables the economical production of large-diameter pipes for transporting substantial volumes of oil, gas and other fluids. Advances in submerged arc welding, hot-rolled coil production and non-destructive testing have enabled spiral welded pipes to be used for higher-pressure service in addition to traditional structural and low-pressure applications.
ERW steel pipes and tubes are manufactured by cold-forming steel into a cylindrical shape and joining the edges through electric resistance or induction heating. Low-frequency ERW was used from the 1920s until 1970, after which high-frequency welding became the preferred process because it offered better weld quality and control. ERW pipes are widely used in water, oil and gas distribution, infrastructure, engineering, agriculture, power, fencing, scaffolding and other applications. Available products vary in diameter, wall thickness and quality according to end-user requirements.
The report covers spiral welded and ERW pipe manufacturing processes, material properties, testing methods, plant and machinery, industry trends, demand drivers, market structure, plant layout and supplier categories. It also examines applications in oil and gas, water and sewerage, power plants, structural uses and other industrial sectors.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- INTRODUCTION
- SPIRAL WELDED PIPE
- PROPERTIES
- USES AND APPLICATION
- OIL AND GAS PIPELINE
- POWER PLANT
- WATER & SEWERAGE
- STRUCTURAL
- OTHER INDUSTRIAL
- ERW PIPE
- TYPES OF ERW PIPE
- LOW-FREQUENCY-WELDED ERW (LF-ERW) PIPE
- HIGH-FREQUENCY-WELDED ERW (HF-ERW) PIPE
- 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
- FOR SPIRAL WELDED PIPE
- PROCESS FLOW CHART FOR SPIRAL WELDED PIPE
- MANUFACTURING PROCESS OF SPIRAL WELDED PIPE
- STEPS ARE GIVEN BELOW
- PRODUCTION METHODOLOGY
- GEOMETRIC MONITORING
- END SHEARING, BUTT WELDING AND SIDE GUIDE ROLLERS
- THE MAKING OF SPIRAL WELD PIPES
- WELDING OF PIPE
- CUTTING OF PIPE
- TESTING OF PIPE
- FINAL INSPECTION, VISUAL CHECKING, WEIGHING AND MEASURING
- COATING OF PIPE
- FINAL MARKING
- FOR ERW PIPE
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- UNCOILED, LAVELED AND WELDING OF STRIP
- STRIPPING
- LOOPING
- EDGE TRIMMING
- FORMING
- WELDING
- BEAD TRIMMING
- SIZING
- CUTTING
- NORMALISING
- END FACING AND BEVELLING
- TESTING
- ULTRASONIC TESTING
- EDDY-CURRENT TESTING
- HYDROSTATIC TESTING
- MAGNETIC PARTICLE TESTING
- RADIOGRAPHIC (X-RAY) TESTING
- DYE-PENETRANT TEST
- MARKING
- PLANT AND MACHINERY
- UNCOILER
- LAVELER
- SHEAR AND WELDER
- HIGH QUALITY WELDING SEAM.
- SWITCHGEAR RECTIFYING CABINET
- INVERTER OUTPUT CABINET
- CONNECTING OPTICAL FIBER
- CIRCULATION SOFT WATER COOLING SYSTEM
- CENTRAL OPERATION CONSOLE
- MECHANICAL ADJUSTMENT DEVICE
- ACCUMULATOR
- THE HORIZONTAL SPIRAL ACCUMULATOR FOR WELDED PIPE LINE
- 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
- HF SOLID STATE WELDER
- ANNEALING FURNACE
- FLYING SAW
- MAIN SPECIFICATION:
- FLYING SAW ALL DIGITAL CONTROL SYSTEM
- FACING AND BEVELING MACHINE
- STRAIGHTNER MACHINE
- THREADING MACHINE
- THREADING MACHINE FEATURES:
- 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 submerged arc welded pipe is a steel pipe manufactured by forming steel plate or hot-rolled coil into a spiral shape and joining the seam using submerged arc welding. The spiral manufacturing method allows large-diameter pipes to be produced from relatively narrower raw material. Such pipes can be used in applications including oil and gas pipelines, water transmission, sewerage, structural work and other industrial services, subject to the required specifications, material grade, testing and operating conditions.
Spiral welded steel pipes are commonly used for large-volume fluid transportation and structural applications. The report identifies oil and gas pipelines, power plants, water and sewerage systems, structural applications and other industrial uses as important areas. Their suitability for a particular service depends on factors such as pipe diameter, wall thickness, steel grade, welding quality, pressure requirements, corrosion conditions and applicable standards. Appropriate inspection and testing are therefore essential before pipes are placed into service.
SSAW and ERW pipes differ mainly in their forming and welding methods. SSAW pipes are formed spirally from steel plate or coil and joined along a helical seam using submerged arc welding. ERW pipes are formed from steel strip into a cylindrical shape and the edges are joined using electrical resistance or induction heating. These manufacturing differences affect available dimensions, production methods and typical applications. Selection should be based on design requirements, applicable specifications, service conditions and the quality requirements of the end user.
The report covers three principal ERW pipe categories: low-frequency-welded ERW (LF-ERW), high-frequency-welded ERW (HF-ERW) and direct-current-welded ERW (DC-ERW). LF-ERW was historically used from the 1920s until 1970 but was superseded by high-frequency welding because of concerns associated with weld performance. HF-ERW provides improved control and weld characteristics and continues to be used in pipe manufacturing. DC-ERW represents another historical method in which individual pipe sections were welded using direct current.
Welded steel pipes can be subjected to several non-destructive and performance tests depending on their specification and intended service. The report identifies ultrasonic testing, eddy-current testing, hydrostatic testing, magnetic particle testing, radiographic or X-ray testing and dye-penetrant testing. These methods help identify weld or material discontinuities and verify pipe integrity. Visual inspection, dimensional checks, weighing, measuring and final inspection are also important parts of quality control before the finished pipe is marked and dispatched.
An ERW pipe plant generally requires equipment for coil handling, leveling, strip preparation, forming, welding, sizing, cutting and finishing. The report includes 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, threading machine and hydraulic testing machine. Supporting electrical, cooling, material-handling and testing systems are also important for reliable plant operation and product quality.
High-frequency ERW technology is important because it provides controlled electrical heating and efficient joining of the steel strip edges. According to the report, manufacturers moved from low-frequency welding toward high-frequency welding around the 1960s and 1970s because the newer process was easier to control and maintain and produced weld zones with better resistance to brittle fracture. Modern ERW manufacturing combines high-frequency welding with forming, sizing, heat treatment where required, inspection and testing to produce pipes for a broad range of industrial applications.
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