TRAINING REPORT

ON
“ERW TUBES AND PIPES”
A training report submitted for partial fulfilment of the requirement for the
degree of

Bachelor of Technology
in
Electrical Engineering
BY
Mohd Arman
(210202010044)
UNDER THE GUIDANCE OF
Dept. of EEE

Submitted to:

Mrs. Nisha Sharma

DEPARTMENT OF ELECTRICAL & ELECTRONICS

ENGINEERING
GURU JAMBHESHWAR UNIVERSITY OF SCIENCE AND
TECHNOLOGY, HISAR
2021
TRAINING CERTIFICATE

i
 DECLARATION

I hereby declare that this Training Report entitled “Industrial Training Report on
ERW Tubes and Pipes” is honestly prepared by me and data provided in this is authentic
to the best of my knowledge. I also declare that I have quoted some statements and texts from
various sources, and they are properly acknowledged in the text. The work presented here in
this training report has not been submitted by me for the award of any other degree of this or
any other Institute/University.

STUDENT: SUPERVISOR CHAIRPERSON

Mohd Arman
Roll no. 210202010044
Class: B. Tech (EE), 5th Sem
EEE Department

ii
 ACKNOWLEDGEMENT

Practical knowledge is very important to develop and apply engineering skills. It gives me great
pleasure to have an opportunity to acknowledge and to express gratitude to those who were
associated with me during my training at AVON TUBETECH PVT. LTD. I would also like to
thank the department of Electrical Engineering for encouraging me to do the summer training.
They have cleared my all doubts regarding the training procedure.

Special thanks to Mr. Chander Prakash for providing me this opportunity to undergo training
under their able guidance and offering me a very deep knowledge of practical aspects of
industrial work culture.

Mohd Arman
Roll no. 210202010044
Class: B. Tech (EE), 5th Sem
EEE Department

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 CONTENTS

TITLE PAGE NO.

CERTIFICATE i
DECLARATION ii
ACKNOWLEDGEMENT iii
LIST OF CONTENTS iv - v
1. INTRODUCTION: 7-8
1.1. INTODUCTION TO ATPL
1.2. SALIENT FEATURES OF ATPL
2.WORKSHOP: 9 - 13
2.1 INTRODUCTION
2.2 WORKSHOP PROCESSES
2.2.1. SURFACE TREATMENT PLANT
2.2.2. PICKLING LINE
2.2.3. SLITTING LINE
2.2.4. TUBE MILLS
2.2.5. PROCESS FLOW DIAGRAM
3. TYPES OF TUBES: 14 - 17
3.1. ELECTRIC RESISTANT WELDED TUBES
3.2. COLD DRAWN WELDED TUBES
3.3. COLD DRAWN SEAMLESS TUBES
3.4. STAINLESS STEEL TUBES

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4. NON – DESTRUCTIVE TESTING: 18 - 19
4.1. ULTRASONIC TESTING
4.2. RADIO GRAPHIC TESTING
4.3. PENETRATION TESTING
5. SPECIAL TESTING OF TUBES: 20 - 22

5.1. EDDY CURRENT TESTING

5.2. HYDROSTATIC TESTING

6. WELDING AND JOINING PROCESSES: 23- 24

6.1. HIGH FREQUENCY WELDING

6.2. TIG WELDING

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 CHAPTER – 1
INTRODUCTION:
1.1 INTRODUCTION TO ATPL:
Avon Tube tech made a humble beginning in 1997 and now it is one of India’s fastest growing
Company in tubes and pipes. For the past two decades, the company has been continuously
guided by its mission: To improve the quality of tubes (pipes) and the Vision: To be recognised
nationally &internationally both as best growing industry in tubes house.

Avon Tube tech has an impressive product line, manufactured in accordance with national and
international standard. The company has an integrated ERP (Enterprise Resource Planning)
system that controls the materials, production and inspection to ensure that deliveries are on
time. To get best quality of product it takes the raw material from world class steel mills.

The company is located just 40 Km from New Delhi in Faridabad, Haryana (India), a reputed
industrial hub. The set up includes three manufacturing plants equipped with latest state of the
art machinery, covering 400,000 sq. ft area produces steel tubes and about 500 skilled technical
human resources to meet the needful demand. The company is well connected from road and
rail for perfect delivery. The annual production capacity of the company includes 24000 MT
of ERW Tubes, 15000 MT of CDW Tubes, and 6000 MT of CDS Tubes.

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1.2 SALIENT FEATURES OF ATPL:

• Avon Tube tech Private Limited (ATPL) is a Private Limited Indian Non-Government
Company incorporated in India on 10 October 1997 and has a history of 26 years and
two months. Its registered office is in New Delhi, India.

• The Company is engaged in the business of manufacturing of electric resistance

welded, CDW, and cold-drawn seamless tubes for various applications such as cycles,
earthmovers, automobiles, and infrastructure.

• Avon Tube tech offers a wide range of products and services, including:
• Steel Pipes and Tubes
• Stainless Steel Pipes
• Welded Pipes
• The Company is currently in an Active status and has successfully submitted its Annual
Returns and Financial Statements until 31 March 2022. It operates as a company limited
by shares, with an authorized capital of Rs 6.00cr and a paid-up capital of Rs 2.05 cr.

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 CHAPTER – 2
WORKSHOP:
2.1. INTRODUCTION:
It provides the basic working knowledge of the production and properties of different
materials used in the industry. It further explains the utilization of diverse tools, equipment,
machinery, and methodologies in the manufacturing process, ultimately enabling the
transformation of these materials into a multitude of practical configurations. In general,
various mechanical workshops known by long training of how to use workshop tools, machine
tools and equipment, trained and skilled persons should be allowed to this type of mechanical
workshop and permitted to operate equipment.

2.2. WORKSHOP PROCESSES:

2.2.1. Surface treatment plant

2.2.2. Pickling Line

2.2.3. Slitting Line

2.2.4. Tube Mills

2.2.1 SURFACE TREATMENT PLANT:

Surface treatment is an additional process applied to the surface of material for the purpose of
adding functions such as rust and wear resistance or improving the decorative properties for
better appearance.

Corrosion is the biggest threat to industrial development, so the surface coating is that it
removes wonders for corrosion. By coating an inert metal on your substrate, we can minimize
its exposure to humidity and oxygen, which helps in slowing down the process of corrosion.

Surface treatments can be divided into three main categories: Mechanical, thermal and
chemical treatment.

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2.2.2. PICKLING LINE:
Pickling is a metal surface treatment process used to remove impurities, such as inorganic
contaminants, rust or scale from ferrous metals such as copper, precious metals and aluminium
alloys. A solution called pickle liquid which contains strong acids is used to remove the surface
impurities. It is commonly used to descale or clean steel in various steelmaking industries.

Once the coil leaves the hot mill, it goes through a series of various processing steps. The first
of which is pickling which involves unwinding the coil and running it through a series process
of hydrochloric acid tanks and rinse tanks.

The primary acid used is hydrochloric acid, although sulphuric acid was previously more
commonly used acid. Hydrochloric acid is more expensive than sulphuric acid, but the
hydrochloric acid pickles much faster and minimise base metal loss.

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2.2.3. SLITTING LINE:

Steel Slitting is a steel manufacturing process where a coil of steel is slit (cut) into the lengths
and widths specified by the end application. This process requires machinery lines equipped
with a de-coiler slitter, and a re-coiler to achieve the end product.

Slitting is a metal manufacturing process wherein a coil of material, such aluminium or steel,
is slit (cut) into the lengths and widths specified by the end application. As the material passes
through the machine, the steel rolls are guided across highly precise circular blades, resulting
in the formation of the cuts.

2.2.4. TUBE MILLS:

Tube mills produce pipe or tube by taking a continuous strip of material and rolling it
continuously until the edges of the strip meet together at a weld station. At this point, the
welding process melts and joins the edges of the tube together and the material is converted
into welded tube. Basic components include an un-coiler, straightener, forming section, welder,
cooling section, sizing section, cut off and runout table.
Each machine in the various sections is made up of an upper and lower shaft that contains roller
dies, which forms the steel strip gradually into a round shape or square according to the required
product
Tube or pipes formed can be used in different industries, such as gas, water and sewage piping,
structural, industrial and infrastructure applications.

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 TUBE MILLING MACHINE

2.2.5. PROCESS FLOW DIAGRAM:

Process flow diagram (PFD) are a graphical way of describing a process, constituent tasks, and
their sequence of operation. A PFD helps in the brainstorming and communication of the
process design. The flow diagram process needs a complete list of tasks that comprise the
process under analysis. Adding additional information requires additional time, however, it
decreases the chances of potential failure possibilities.

Tube manufacturing process is a series of tube mill process that builds longitudinal weld seam
pipe with steel strips of certain width. It starts by uncoil and flatten the slit steel coils into steel
strips. The flattened steel strips will be inserted into the forming machine and the rollers in the
machine will bend the strip to a round pipe shape. The rounded tube is then be sent into the
weld box where the pipe is welded by a high frequency, the tube manufacturing process be
formed to expected shape (round/ square/ rectangle etc) or size in a sizing machine. At the end
the pipe will be cut to length and bundled.

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PROCESS FLOW DIAGRAM:

Process flow diagram (PFD) are a graphical way of describing a process, constituent tasks, and
their sequence of operation. A PFD helps in the brainstorming and communication of the
process design. The flow diagram process needs a complete list of tasks that comprise the
process under analysis. Adding additional information requires additional time, however, it
decreases the chances of potential failure possibilities.

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 CHAPTER – 3

TYPES OF TUBES :-
3.1. ELECTRIC RESISTANT WELDED TUBES:

ERW pipes are produced through the cold forming of a steel coil, resulting in the creation of a
cylindrical shape pipe. In the initial times it was done by the low frequency A.C. current to heat
the edges but now the low frequency process changed to high frequency A.C. current to
produce a higher quality weld.

Avon manufactures Electric Resistant Welded (ERW) tubes which can be used for various
applications such as:

• Automobiles
• General Engineering
• Propeller Shafts
• Heat Exchanger Tubes
• Boiler & Air Heater Tubes
• Structural Tubes

Size Range:

• Carbon Steel:
• OD: 12.70 mm – 101.60 mm
• Thickness: 0.90 mm – 8.00 mm
•
• Stainless steel (400 series):
• OD: 19.00 mm – 90.00 mm
• Thickness: 0.90 mm – 2.50 mm

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3.2. COLD DRAWN WELDED TUBES:

Cold Drawn Tubes offers a high strength property that makes it suitable for safety critical
purposes. They have a uniform microstructure that makes it strong.

Cold drawn Tube Manufacturers also suggest these tubes be used in infrastructure, and general
fabrication and machining industries.

Avon produces Cold Drawn Welded (CDW) tubes that are available in Annealed, Bright
Annealed, As-Drawn condition, and H9 condition. These tubes are utilized to attain precise
tolerances in both Outer and Inner applications. These tubes have various applications like:

• Automobiles
• General Engineering
• Propeller Shafts
• Shock Absorber Tubes (SSID)
• Telescopic Front Fork Tubes
• Hydraulic Tubes

Size Range:
• OD: 8.00 mm – 90.00 mm
• Thickness: 0.90 mm – 7.50 mm

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3.3. COLD DRAWN SEAMLESS TUBES:

The process of producing Cold Drawn Seamless (CDS) seamless tube and pipe involves
piercing hot billets and then rolling them to decrease their diameter and increase their length.
This material is then passed through a die and a mandrel plug to achieve precise dimensions
and thickness, which is the fundamental aspect of the cold drawing process.

Unlike welded tubes, seamless tubes are made from billets and do not possess any vulnerable
points.

Cold Drawn Seamless Tuber offers enhanced machinability, uniform tolerance, and increased
strength.

Avon processes Cold Drawn Seamless (CDS) tubes which are also supplied in Annealed,
Bright Annealed and As-Drawn condition.

These tubes have various applications like:

• Automobiles
• General Engineering
• Boiler Tubes
• Fuel Injection Tubes
• Hydraulic Tubes
Size Range:
• OD: 8.00 mm – 90.00 mm
• Thickness: 0.80 mm – 10.00 mm

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3.4. STAINLESS STEEL TUBES:

Stainless steel pipes are predominantly utilized in piping systems for the transportation of fluids
or gases. Our company produces steel pipes made from a steel alloy that includes Nickel and
Chromium, imparting stainless steel with its corrosion-resistant characteristics.

A steel tube is made by roll forming stainless steel strips or sheets into a tube shape and then
longitudinally welding the seam. Welded tubing can be manufactured through the utilization
of either hot or cold forming methods. Cold forming produces smoother surfaces and tighter
tolerances than hot forming Each method, however, results in a long-lasting, strong steel tube
that is corrosion-resistant. The seam can be left beaded or worked further using cold rolling
and forging techniques.

Avon will be processing Stainless Steel tubes (400 Series) soon.

These are used for applications like:

• Injection Pipe
• Exhaust Pipe
• Airbag Cover Pipe
• Seat Belt Cover Pipe

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 CHAPTER – 4
NON - DESTRUCTIVE TESTING:
It is a method of detecting internal defects or performance status of an object through inspection
technology without damaging the object to be tested. Mostly used conventional non-
destructive testing methods are five basic testing methods that are widely used in the
engineering field, namely ultrasonic testing, radiographic testing, eddy current testing,
magnetic particle testing and penetrant testing. In this article we will discuss the three
conventional non-destructive testing methods for ERW pipes.

4.1. ULTRASONIC TESTING:

Ultrasonic testing uses the propagation of ultrasonic waves within the material to be tested to
detect defects or performance characteristics of the object. By emitting ultrasonic waves, the
internal structure and defects of the object being measured are observed based on the way of
difference in propagation speed of ultrasonic waves in different media and phenomenon such
as reflection, refraction, and scattering etc. Ultrasonic testing is widely used in defect detection
and structural analysis of metals, composite materials, ceramics, concrete and other materials.

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4.2. RADIO GRAPHIC TESTING:

Radio Graphic Testing uses rays (such as X-rays and Y-rays) to penetrate the material to be
tested, and to detect defects or performance status of the material through the absorption,
scattering and other phenomena of the rays. Radiographic testing is commonly used to detect
defects and quality checking of metals, welded parts, pipes, containers and other materials.
Radiographic testing has the characteristics of strong penetrating power and high sensitivity,
and can detect even the tiny defects. However, it also has radiation safety issues and requires
special protective measures.

4.3. PENETRATION TESTING:

Penetration testing uses the penetrating liquids to detect defects and performance status of
objects, by applying penetrant liquid on the surface of object to be tested, after it penetrates
into the defect, the remaining penetrant on the surface is removed, and a developer is applied
on the surface and the defects of the object being tested are detected by observing the colour
developer seeping out at the defect location. Penetrant testing is widely used in surface defect
detection and quality checking of metals, ceramics, plastics, pipes and other materials.

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 CHAPTER – 5
SPECIAL TESTING OF TUBES:
In this article we will discuss about the two most commonly use testing methods of ERW tubes,
namely Eddy current testing and Hydrostatic testing, which are stated as follows:

5.1. EDDY CURRENT TESTING:

Eddy current testing is a non-destructive test method that can be performed on conductive
material. A test coil that is energized with alternating current is placed close to the surface of
tube. This generates an alternating magnetic field that produces eddy currents in the test pipe.
Variations in eddy current flow produce a measurable change in the test coil. These changes
are shown on a screen and studied to identify defects.

Eddy current testing uses the principle of electromagnetic induction to detect flaws in
conductive materials. An excitation coil carrying current is placed in proximity to the
component to be inspected. The coil generates a changing magnetic field using an alternating
current, which interacts with the component generating eddy currents.

Here are the types of flaws that eddy current testing is generally used to find:

• Cracks
• Corrosion
• Wear (in tubes, often due to erosion)
• Freezing-related damage (in tubes)
• Lack of fusion
• Pitting
• Wall loss / thickness loss

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 EDDY CURRENT TESTING AT AVON TUBETECH PVT.LTD.

The product is passed through or adjacent to an electrical test coil, which has been excited by
an alternating current, this induces a flow of eddy currents around the test material.
The product moves longitudinally through the rotating test probes resulting in a helical search
pattern, as the probe passes over a defect, variations in the induced Eddy Current pattern are
detected.
Using eddy-current testing, inspectors can find very small defects that might not be visible to
the naked eyes. The raw data obtained from eddy current test probes must be processed using
software made for this purpose and then observed by trained inspectors, who know how to
identify defects in ETC results.

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5.2. HYDROSTATIC TESTING:
Hydrostatic testing is the final quality check before the pipe is placed in service, and any leak
indications require finding and repairing the leak, Which can be time consuming and costly.
To ensure that the pipeline can operated safely at its minimum acceptable operating pressure
the pipeline is tested at a higher internal pressure .

Hydrostatic testing may be defined as the process of subjecting a material to a controlled

pressure and observing how it reacts to that pressure. The test is used for many reasons:
determining if an object can withstand various loads or stresses, detecting leaks in hydraulic
systems or pipes, ensuring that equipment will functions properly before use, etc. Hydrostatic
testing is conducted by filling an object with water and pressurizing it to test for the strength
and leaks. The ability to detect leaks in an object is one of the most important reasons why this
type of testing is used mostly.

Hydrostatic testing provides many benefits for an industry by ensuring the quality of their
product. For example, this process can be used to ensure that the equipment is functioning
properly before use and also detect leaks in hydraulic systems or pipes.

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 CHAPTER – 6
WELDING AND JOINING PROCESSES:
6.1. High Frequency Welding:

High frequency welding (HFW) is generally used for ERW pipes. Through high-frequency
current welding resistance, the heat is generated at the contact objects, so the surface of objects
is heated to the melting state, then the metals joined together without the use of any other filling
material.

The high frequency current pass through the metal conductor, will produce two common effects
namely skin effect and proximity effect. The HFW process is use the skin effect to concentrate
the current on steel object surface, and use proximity effects to control the position and the
power of the high-frequency electric current flow path. Since the speed is very high, the
contacted plate edge could be heated and melted in short time, then joined together at the edges.
The productivity of HFW steel pipe is high, as the welding speed can reach 30m/min, and the
welding current frequency is equal to or greater than 70 KHZ. It is mainly used to make pipes
with welded longitudinal seams or spiral seams. The welded pipe is welded by high-frequency
welding technology and is mainly used for the transportation of pressurized fluids such as
water, oil, and natural gas.

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6.2. TIG Welding:
TIG welding, or Gas Tungsten Arc Welding (GTAW), is an exceptionally versatile and
productive welding technique. It is widely used for pipe applications, with its precise
control and ability to produce high-quality welds. TIG pipe welding offers several more
advantages over other welding processes. TIG welding has become the preferred method
for joining pipes in the industries, this is due to its precise control and ability to create
clean and high-quality welds.

TIG welding involves the use of a tungsten electrode and a shielding gas to protect the
weld site from oxidation. The tungsten electrode, which does not melt during the process
provides heat to the base metal. TIG welding is an excellent option for pipe applications
due to its ability to prevent oxidation and guarantee a clean weld through the use of
shielding gas. The perfect combination of heat control and shielding ensures optimal
results.

TIG welding also offers the advantage of being a manual and automated process. This
allows welders to have complete control over the welding parameters depending on the
application. This level of control is especially important in pipe applications, where
precision is needful to ensure leak-free joints and optimal performance. With TIG pipe
welding, welders can adjust the heat input, welding speed and electrode position helping
to achieve the desired results, resulting in strong and reliable welds.

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