Detailed Project Report on spiral welded pipe (hsaw pipe)
Detailed Project Report on spiral welded pipe (hsaw pipe)
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SPIRAL WELDED PIPE (HSAW PIPE)
[CODE NO.3813]
(A) SPIRAL WELDED PIPE
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.
COST ESTIMATION
Plant Capacity 200 MT/Day
Land & Building (8000 sq.mt.) Rs. 15 Cr
Plant & Machinery Rs. 4.06 Cr
Working Capital for 3 Months Rs. 71.69 Cr
Total Capital Investment Rs. 91.97 Cr
Rate of Return 68%
Break Even Point 22%
INTRODUCTION
(A) SPIRAL WELDED PIPE
PROPERTIES
OIL AND GAS PIPELINE
POWER PLANT
WATER & SEWERAGE
STRUCTURAL
OTHER INDUSTRIAL
PHYSICAL PROPERTIES OF PIPING MATERIALS
MALLEABILITY
DUCTILITY
BRITTLENESS
ELASTICITY
CONDUCTIVITY
CHEMICAL RESISTANCE/ RESISTANCE TO CORROSION
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
ULTRA-SONIC TESTING
X-RAY TEST AND FLUOROSCOPY
HYDRO TESTING
(8) FINAL INSPECTION, VISUAL CHECKING, WEIGHING AND MEASURING
(9) COATING OF PIPE
EXTERNAL COATING
INTERNAL COATING
(10) FINAL 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
GLOBAL MARKET OF STEEL PIPES
MARKET SEGMENTATION
BY MATERIAL
BY APPLICATION
BY END-USER
KEY MARKET PLAYERS
STEEL PIPE INDUSTRY AT A GLANCE
STRUCTURE AND APPLICATION OF STEEL PIPES AND TUBES INDUSTRY
EBITDA/TONNE AND LEVERAGE ACROSS PIPE SEGMENTS/PLAYERS
STEADY IMPROVEMENT IN CREDIT PROFILES OF BOTH SEGMENTS
DEMAND FOR STEEL PIPES TO LOG CAGR OF 7-8%
SAW AND SEAMLESS PIPES
PROFITABILITY TO REBOUND FOR ERW PLAYERS, STAY HEALTHY FOR
S&S PLAYERS
ERW PIPES
MOVEMENT IN OPERATING MARGINS VIS-À-VIS HR COIL PRICES
HR COIL PRICES HAVE CORRECTED SHARPLY DUE TO EXCESS GLOBAL SUPPLY, DRIVEN BY CHINA
SAW AND SEAMLESS
ORDER BOOK OF S&S PIPE PLAYERS SEEN SWELLING
CAPEX CYCLE DONE, UTILISATION UPTREND TO CONTINUE THIS FISCAL
SAW AND SEAMLESS PIPES
UTILISATION LEVELS HEADED NORTH
INDIAN SAW PIPE INDUSTRY
TABLE 1 – PRODUCT SUMMARY
INTERNATIONAL DEMAND DRIVERS
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%
REPLACEMENT DEMAND FROM THE US ALSO REMAINS STRONG
DEMAND SCENARIO IN THE WATER SEGMENT
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
ORDER BOOK POSITION LOOKS ROBUST
CAPACITY UTILIZATION RANGES BETWEEN 25–60%
HUGE INVESTMENTS IN THE SOUTH/EAST INDIA
STEEL PIPES MARKET OVERVIEW
MARKET SIZE & FORECAST
GROWTH DRIVERS & CHALLENGES
SUPPLIERS OF RAW MATERIALS
M.S STRIP COILS
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 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)
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