SS TUBE MILL

[EIRI/EDPR/4038] J.C.: 2171XL

INTRODUCTION

Stainless steels are iron-based alloys usually containing at least 11.5% chromium.
Other elements, nickeI being the most Important, may be added in combination
with chromium to obtain special properties.

Stainless steels are highly resistant to corrosive attack and to oxidation at high
temperatures. in general, resistance to corrosion and oxidation increases
progressively, though not proportionately, with the increase in chromium content.

Stainless steel pipe and tubing are used for a variety of reasons: to resist corrosion
and oxidation, to resist high temperatures, for cleanliness and low maintenance
costs, and to maintain the purity of materials which come In contact with
stainless. The inherent characteristics of stainless steel permits the design of thin
wall piping systems without fear of early failure due to corrosion. The use of fusion
welding to join such piping eliminates the need for threading.

Type 304 stainless is the most widely used analysis for general corrosive resistant
tubing and pipe applications, it is used in chemical plants, refineries, paper mills,
and food processing industries. Type 304 has a maximum carbon content of .08%.
It is not recommended for use in the temperature range between 800° F and 1650°
F due to carbide precipitation at the grain boundaries which can result in inter-
granular corrosion and early failure under certain conditions.

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Type 304L. Is the same as 304 except that a .03% maximum carbon content is
maintained which precludes carbon precipitation and permits the use of this
analysis in welded assemblies under more severe corrosive conditions. Type 318 is
much more resistant to pitting than other chromium nickel alloys due to the
addition of 2% to 3% molybdenum. it is particularly valuable wherever acids,
brines, sulphur water, seawater or halogen salts are encountered. Type 316 is
widely used in the sulphite paper industry and for manufacturing chemical plant
apparatus, photographic equipment, and plastics.

Type 316L, like 304L, is held to a maximum carbon content of .03%. This permits
its use in welded assemblies without the need of final heat treatment. It is used
extensively for pipe assemblies with welded fitting.

Other fields where stainless steel pipe and tubing are used are: aviation,
electronics, automotive, cyrogenic, marine, air conditioning and heating, medical,
architectural and textiles.

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 SIZES OF PIPES

Sizes for Stainless Steel Tube

Stainless steel pipes, which were coming into more common use in the mid 20th
century, permitted the use of thinner pipe walls with much less risk of failure due
to corrosion. This led to the development of stainless steel tubing, which due to
it’s thinner wall it could not be threaded together according to the ASME code,
and therefore was fusion welded.

This led to the development of a range of hygienic stainless steel tube and fittings
which could be used in applications requiring a clean and sanitary flow of liquids
and where it is essential to avoid contamination of the products being carried.
These applications cover the food processing, beverage, biotech and
pharmaceutical industries including breweries and dairies.

The applications are low pressure with a maximum of 10 Bar

 The products are available in grades 304L and-316L.

 The size range is from ½”to 6 inch O/D.

The tube and fittings are of welded construction with the internal bead rolled and
polished to eliminate crevices, thus preventing interruptions to the flow and
eliminating the risk of contamination or bug traps as well as facilitate easy
cleaning.

Size range of stainless steel erw pipes 1/4" nb, 1/2" nb, 3/4" nb, 1" nb, 1-1/4"
nb, 1-1/2" nb, 2" nb, 2-1/2" nb, 3" nb, & 4" nb, 5" nb, 6" nb, 8" nb, 10" nb, 12"
nb, 14" nb, 16" nb, 18" nb, 20" nb, 22" nb & 24" nb in schedule 5, schedule 10,
schedule 20, schedule 40, schedule 80, schedule 160, schedule xxs and schedule
std.

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 CONTENTS

INTRODUCTION
SIZES OF PIPES
SIZES FOR STAINLESS STEEL TUBE
RAW MATERIAL
PHYSICAL PROPERTIES OF PIPING MATERIALS
MALLEABILITY
DUCTILITY
BRITTLENESS
ELASTICITY
CONDUCTIVITY
CHEMICAL RESISTANCE/ RESISTANCE TO CORROSION
USES AND APPLICATION
TYPICAL APPLICATIONS FOR STAINLESS STEEL PIPE:
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. STRAIGHTENING
12. END FACING AND BEVELLING
13. TESTING
ULTRASONIC TESTING
EDDY-CURRENT TESTING
HYDROSTATIC TESTING
MAGNETIC PARTICLE TESTING
RADIOGRAPHIC (X-RAY) TESTING
DYE-PENETRANT TEST
14. PICKLING
15. PASSIVATION
16. POLISHING
DIFFERENCE BETWEEN WET BRIGHT AND DRY BRIGHT:

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ADVANTAGES:
ELECTROPOLISHING SUPERIOR THAN MECHANICAL POLISHING:
ELECTROCHEMICAL POLISHING CHARACTERISTICS:
17. MARKING
NOMINAL PIPE SIZE (NOMINAL BORE)
QUALITY CONTROL
QUALITY ASSURANCE PLAN
A. INCOMING RAW MATERIAL
B. STAGE WISE INSPECTION
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:

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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
STEEL PIPE MARKET
EBITDA/TONE AND LEVERAGE ACROSS PIPE SEGMENTS/PLAYERS
STEADY IMPROVEMENT IN CREDIT PROFILES OF BOTH SEGMENTS
INTEREST COVER ON UPTREND
SO IS NET CASH ACCRUAL TO DEBT
MOVEMENT IN OPERATING MARGINS VIS-À-VIS HR COIL PRICES
EBITDA/TONNE FOR ERW
EBITDA/TONNE FOR S & S
UTILISATION LEVELS HEADED NORTH
PLANT LAYOUT
SUPPLIERS OF SS TUBES
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF CR SS STRIPS
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF RESSISTANCE WELDING ELECTRODE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF SS PIPE AND TUBE PLANT
CHINA SUPPLIER
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE

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SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF 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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 COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (10,000 sq.mt.) Rs. 7.58 Cr
Plant & Machinery Rs. 2.58 Cr
Working Capital for 2 Months Rs. 30.60 Cr
Total Capital Investment Rs. 41.86 Cr
Rate of Return 35%
Break Even Point 45%

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