Detailed Project Report on m.s. erw pipe
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M.S. ERW PIPE
[CODE NO.4340]
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 In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.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.
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
(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 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%
- 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 – 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)
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