Detailed Project Report on ms pipe for spiral and erw

MS PIPE FOR SPIRAL AND ERW [3552]

Spiral submerged arc welded pipe, a type of spirally welded steel pipe produced by using the double-sided submerged arc welding method. Spiral welded pipes are formed using narrower plates or hot rolled coils, which lowers their production costs significantly. The spiral welding process permits the production of large-diameter pipes suitable for transporting large volumes of oil and gas. Traditional SSAW pipes were historically limited to low pressure applications; however, modern SSAW pipes have been used extensively in Russia, Canada and Asian countries in high pressure gas pipelines. Spiral Weld Pipe, as the name implies, is a steel pipe which has a seam running its entire length in a spiral form. In the past, due to the method of manufacture, Spiral Welded pipe was relegated to low pressure and structural applications. With the development of the Submerged Arc Welding process, the production of large hot rolled coils of sufficient width and the development of dependable non-destructive testing methods, it is now possible to produce Spiral Weld pipe for high pressure service. Spiral welded pipe is an alternative process, spiral weld construction allows large diameter pipe to be produced from narrower plates or skelp. The defects that occur in spiral welded pipe are mainly those associated with the SAW weld, and are similar in nature to those for longitudinally welded SAW pipe. 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 In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.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. (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                                                  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%


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 – 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)