Essar Steel Pipes Brochure

From the finest steel to the finest pipes7Pipes5Essar Steel11Helical Submerged Arc Welded (HSAW) pipesContents13Longitudinal Submerged Arc Welded (LSAW) pipes17Coating Facility14Essar Pipe Mill18Testing Equipment20Certifications andApprovals21Marking and OrderingEssar SteelEssar Steel is a global integrated steel producer with an annual capacity of 14 million tonnes with a strong presence in intensive steel consuming markets of Asia and North America. It has operations in four countries• A 10 MTPA integrated facilities in India• A 4 MTPA steel plant in Canada• A 7 MTPA Taconite plant under execution in USA• A 0.4 MTPA downstream complex in IndonesiaEssar Steel India is an integrated steel producer with an annual production capacity of 10 million tonnes. Essar Steel’s manufacturing facility comprises ore beneficiation, pellet making, iron making, steel making, and downstream facilities including cold rolling mill, galvanising, pre-coated facility, steel processing facility, extra wide plate mill and a pipe mill. The steel plant located at Hazira has modern infrastructure like a power plant and a port that can handle 30 million tonne cargo annually.With a focus on value added products, it produces over 300 grades of steel conforming to quality standards of international certification agencies like API, ABS, NACE, Lloyd’s Register to name a few. Essar Steel uses information technology extensively for its operations thereby ensuring consistent quality of its products. Essar Steel has set up a 1.5 MTPA plate mill and a 0.6 MTPA pipe mill at Hazira to add further value to its product portfolio. With one of India’s largest steel processing and distribution network with a capacity of 4 MTPA located at several industrial hubs, Essar Steel manufactures customised products catering to a variety of industry segments.Sustainability has been given due importance in design and operations and the company has become a zero waste company. It has received many accolades and recognitions from reputed institutions like Centre for Science and Environment, Water Digest, World Steel Association, Golden peacock, Green Tech foundation, CII, CII-ITC Sustainable Development Center, Carbon Disclosure Project to name a few.Essar Steel PipesFrom the finest steel to the finest pipesThe growing demand for oil and gas across the world and in India have created a huge demand for pipes. Reasons being increasing E&P budgets, huge gas discoveries and a large number of old oil and gas pipelines that need to be replaced.Recognising the potential of the pipe market in India and the world, Essar Steel started operations of a state-of-the-art pipe mill at Hazira. The 0.6 MTPA pipe mill includes top-line Helical Submerged Arc Welded (HSAW) and Longitudinal Submerged Arc Welded (LSAW) mills, and internal and external coating units with a capacity of up to 2 million square metres annually; that manufacture world-class pipes.Being a fully-integrated steel manufacturer with quick access to raw material gives Essar Steel a direct advantage. The pipes are manufactured using heavy plates produced in one of the world’s widest plate mills, and hot rolled coils, both of whose manufacturing facilities are located within the Hazira complex itself. Their proximity ensures a steady supply of raw material, and the port location of the plant provides Essar Steel with a logistical advantage ensuring timely execution and delivery of orders across the world.Essar Steel is one of the few manufacturers globally, capable of producing API (American Petroleum Institute) grade steel, with a supply track record of over 3.2 million tonnes. The Essar Steel pipe mill is API certified to make pipes of low sulphur that finds wide acceptance and approval from international oil and gas majors. Supported by the best technology and the latest testing equipment including plate ultrasonic testing, real time radiography (fluoroscopy), hydrostatic testing and final ultrasonic testing (automatic weld cut), Essar Steel pipes ensure adherence to international standards and a high degree of precision, consistency and quality. Water LineWelding) which ensures quality with high productivity and is pipe line segment, Essar has provided services to various EPC contractors and Government bodies such as -• Karnataka Urban Water Supply & Drainage Board• Gujarat Water board(Narmada Canal ,Dhanki –Navda & Navda-Bhudel project)• Surat Municipal Corporation• Mysore Water Supply board, Irrigation Department,• JMC projects India Ltd.,• Karnataka Nirvari Nigam Limited,• GVPR Engineering Ltd., • Mahan Power plant, • MIDC Chindwada project, • Subhash Projects and Marketing Limited.• Tight tolerance in straightness, roundness and accuracy of diameter even without cold expansion. DimensionSalient FeaturesDiameter 16 Inch – 110 InchThickness 6.4 mm – 25.4 mmLength 12.50 Meter MaximumGrade Up to API 5L X80External Coating 4 Inch – 100 Inch DiameterInternal Coating 8 Inch – 100 Inch Diameter • High Pipe forming speed by continuous tack welding. • Implementation of process automation technology for high quality.• IS 10748, IS 2062, API GR-B - API X80Steel Used for Pipe production• External and Internal Lining (Food Grade Epoxy) to endure corrosion.Coating Process Flow Bare Pipe Entry Preliminary Heating Shot Blasting Visual InspectionCoating Inspection withHigh Voltage Flaw DetectorFinal VisualInspection and MarkingBare Pipe Entry Pre-heating andShot BlastingInternal EpoxyCoatingStock Yard or Dispatch Oil & Gas• Tight and uniform control on pipe dimension throughout the pipe length suitable for critical services like offshore applications.• • External Coating and Internal Lining to endure corrosion.• High quality weld, resistant to cracking and restriction to repair.• Flexibility of thickness and grade, capacity to form pipes upto 65 mm thickness with close diameter-thickness ratio.• application etc.• Process automation technology for high qualityGeneral Requirements• API 5L Gr B to API 5L X80 in sweet services and upto X65 in sour services (specially offshore applications)ASTM, BS and other international standards applicable for Oil & Gas pipesSteel Used for Pipe productionDimensionDiameter 16 Inch – 60 InchThickness 6.4 mm – 65 mmLength 12.5 Meter MaximumGrade Up to API 5L X80External Coating 4 Inch – 100 Inch DiameterInternal Coating 8 Inch – 100 Inch DiameterEssar Steel Pipe mill has State-of-the-art HSAW & LSAW technology and the latest testing equipment which ensures highquality and adherence to international standards. Having been audited by Technip, Dubai Petroleum, Occidental Petroleum,EIL, GAIL, IOCL, SHELL, SAIPEM, ENI, SOCAR, and CHEVRON, the audit results and approvals with well-known End Users, EPC contractors and Third Party Inspection Agencies showcases our proven capabilities in Pipe manufacturing. With vast experience in the API segment. Essar Steel has provided its services to many well known agencies such as -• Essar offshore Subsea Ltd.• Mundra port SEZ India• Gas Authority of India Limited (GAIL),• Dubai Petroleum Establishment• Occidental petroleum Corporation Qatar• Storytransgaz - Russia• West African Ventures Nigeria• Chevron• Technip - Abu Dhabi• Sour and Non Sour (Sweet)• Offshore and OnshoreService Condition Phosphate and Chromate TreatmentPipe Heating FBE ApplicationAdhesive and Polyethylene /Propylene ApplicationWater QuenchingRemoval of Coatingfrom Ends (Cut Back)Curing Final Visual Inspectionand MarkingCoil Opening Coil End Welding Ultrasonic Testing of Coilscovering Full WidthHydrotesterMagnetic ParticleInspection of EndsUltrasonic Testing ofWeld, HAZ and EndsRadiography of Ends Final Visual Dimensional Inspection,Weighing and MarkingHSAW Process Flow 10Helical Submerged Arc Welded (HSAW) PipesThe Essar Steel HSAW mill has a capacity of 275,000 TPA producing consistent-quality HSAW pipes conforming to international quality standards. The pipes are manufactured using a two-step process that involves continuous tack welding as well as internal and external submerged arc welding at separate welding stations.One of the unique features of the HSAW mill is that it is a mirror-image mill which can manufacture pipes of the same size or two different sizes simultaneously at high speed, thereby reducing delivery time.Salient Features of the HSAW Mill• High forming speed by continuous tack welding, laser seam • Tight tolerance even without cold expansion with respect to straightness, roundness and accuracy of diameter• Main drive feed motor with 500,000 Nm torque enabling pipe formation of 25.4 mm wall thickness• Excellent mechanical properties (high strength and • due to forming processEquipment SupplierTube mill 1 Byard, MalaysiaTube mill 2 Phamitech, ChinaID/OD forming line – 3 sets each mill Uhrhan & Schwill, GermanyFinal ultrasonic testing machine GE, GermanyX-ray machine YXlone, GermanyCoil ultrasonic machine, intermediate UT machineRD-Tech, CanadaCapacity 275,000 TPADiameter 406 – 2,540 mmThickness 6 – 25.40 mmGrade Up to API 5L- X-80, PSL-2Pipe length (max) 12,500 mmCoil width range 900 – 2,000 mmCoil weight 30 MT (max)Forming speed 4 – 8 m / minPipe Forming and Continuous Mig WeldingInside and Outside SAW Welding: 3 LineReal Time Radiography ofWeld and Visual Inspectionof Weld and Pipe BodyEnd Bevelling of Pipes11State-of-the-art Technology, World-renowned SuppliersCapabilityApplications• Onshore and offshore oil and gas pipelines• • Project / Terminal piping water and sewage distribution and transmission lines• Irrigation systems• Power plants• Pipes for potable water Plate Ultrasonic TestingReal Time RadiographyRadiography TestingUltrasonic TestingMechanical ExpanderEnd BevellingHydrotesterPlate Edge Milling Plate Edge CrimpingLSAW Process Flow 12Plate Ultrasonic TestingReal Time RadiographyRadiography TestingUltrasonic TestingMechanical ExpanderEnd BevellingHydrotesterPlate Edge Milling Plate Edge CrimpingLSAW Process Flow 13Longitudinal Submerged Arc Welded (LSAW) PipesThe Essar Steel LSAW mill, with an installed capacity of 325,000 TPA, produces high-quality pipes by incorporating the to the manufacturing process in terms of thickness and grade. The mill possesses the latest inspection and testing equipment Salient Features of the LSAW Mill• Pipe production with very close diameter-thickness ratio• Ultrasonic testing capable of scanning 100% area of up to 5 metres to check internal soundness prior to pipe forming• 5,600 MT JCO press having a capacity to form pipes of 65 mm WT• Fully-automated size and data-controlled cold expander (13 m)State-of-the-art Technology, World-renowned SuppliersApplications• Onshore and offshore oil and gas pipelines• Pipes for potable water• • Power plants• Structural pipes for offshore structures and pilesEquipment SupplierJCO forming machine and pre-bender, tack welderYSD, ChinaEnd bevelling Linsinger, GermanyID/OD and cross seam welding machine Uhrhan & Schwill,GermanyPlate UT, Final ultrasonic testing machineGE, GermanyHydrotester, expander, edge milling Iprolam, RomaniaCapacity 325,000 TPADiameter 406 – 1,524 mmThickness 6 – 65 mmGrade Up to API 5L – X-80Pipe length (max) 12,500 mmCapabilityOutside Welding (SAW)Intermediate Ultrasonic TestingVisual, Dimensional Inspection,Weighing and MarkingMagnetic Particle TestingInside Welding (SAW)Continuous Tack WeldingJCO Forming PressOutside Welding (SAW)Intermediate Ultrasonic TestingVisual, Dimensional Inspection,Weighing and MarkingMagnetic Particle TestingInside Welding (SAW)Continuous Tack WeldingJCO Forming Press Coil Opening Coil End Welding Ultrasonic Testing of Coilscovering Full WidthHydrotesterMagnetic ParticleInspection of EndsUltrasonic Testing ofWeld, HAZ and EndsRadiography of Ends Final Visual Dimensional Inspection,Weighing and MarkingHSAW Process Flow Essar Steel Pipe MillInside Welding and Outside Welding The pipe is welded from inside and outside by automatic SAW World-class Processes, Ultra-modern FacilitiesSalient Features• Aut heating, feeding and recycling system to • Precise measurement of curves of the welding process with the true-RMS (root-mean-square) converters for each arc• • Data record and long-time storing mechanism for referencing actual welding parameters of each pipe• Automatic Laser Seam Tracking and stick-out control system for accurate tracking in the horizontal and vertical directionWire arrangement 5 wire tandem welding system (1 DC & 4 AC)Thickness 6 mm – 65 mmDiameter 406 – 2,540 mmGrade Up to API 5L – X-80Welding speed 0.5 to 2.5 m / minCurrent 2,000 Amp DC, 1,500 Amp AC and 1500 Amp ACOutside Diameter WeldingSalient Features• Pipe forming and continuous tack welding by gas metal arc welding (GMAW)• Laser seam tracking system to keep the wire always in the centre of the weld grove even at higher welding speeds of up to 6 m / minContinuous Tack WeldingPower source 1,500 ampsGas Argon and CO2 / O2 mixture or CO2 gasInside Diameter WeldingPipe Forming and Continuous Mig WeldingInside and Outside SAW Welding: 3 LineReal Time Radiography ofWeld and Visual Inspectionof Weld and Pipe BodyEnd Bevelling of Pipes Salient Features• High speed PLC enabling excellent controls of operation• Automatic seam detection and positioning• 13 m single boom expander to achieve uniform dimensional tolerance throughout the lengthSalient Features• PLC control with a digital data recording system.• Auto Centering of pipe.• Chart recorder to record the test pressure and holding time.• Automatic shield barrier to ensure safety.ExpanderThe expander is a fully-automatic CNC machine that minimises residual stresses and improves mechanical properties. It is used to achieve roundness, straightness and accuracy of diameter.Hydrostatic Testerto aid in leak detection, and pressurization of the vessel to the Force 1,200 TExpanding value Up to 1.5% of outer diameterHSAW LSAWDiameter 406 – 2540 mm 406 – 1524 mmThickness 6 – 25.4 mm 6 – 65 mmTest Pressure 300 Bar Maximum 350 Bar MaximumPipe ExpanderEnd bevellingEnd BevellingAt end bevelling, the pipes ends are machined and prepared for Salient Features• Fully-automatic CNC machine to control parameters such as bevel angle and root face with customer requirements• Automatic pipe length measurement after chamfering of the edgesHSAW LSAWDiameter 406 – 2,540 mm 406 – 1,524 mmThickness 6 – 25.4 mm 6 – 65 mmCutting speed 70 rpm 110 rpmNumber of tool holder2 tool post / head 2 tool post / headCoating Process Flow Bare Pipe Entry Preliminary Heating Shot Blasting Visual InspectionCoating Inspection withHigh Voltage Flaw DetectorFinal VisualInspection and MarkingBare Pipe Entry Pre-heating andShot BlastingInternal EpoxyCoatingStock Yard or Dispatch16 17Coating FacilityOil and gas exploration and production companies face requirements as lines are installed at larger lengths and at greater sea-bed depths. Onshore oil and gas transportation pipelines require adequate protection against corrosion to ensure reliable service over a long period of time.The Essar Steel pipe mill coating unit has an annual external coating capacity of 2 million square metres and an annual internal coating capacity of 1 million square metres. It deploys external coating like Fusion Bonded Epoxy (FBE), dual layer FBE, 3 LPE, 3 LPP and Polyurethane to prevent corrosion, and liquid epoxy solvent base and Salient Features of the Coating Facility• and eliminates air entrapment• Pipe curing system for higher productivity• Dust-free atmosphere by separating shot-blasting and coatingCapabilityEquipment SupplierFBE coating system, adhesive and PE coating extruders, fume exhaust systemSocotherm, ItalyBlasting system, induction heaters, internal coating plant Nanjing, ChinaExternal CoatingCapacity 2 mill sq m / annum 3LPEDiameter 101.6 – 2,540 mmType of coating FBE, 3LPE, 3LPP, DFBEInternal coatingCapacity 1 mill sq m / annum liquid epoxyDiameter 203.2 – 2,540 mmType of coating Liquid epoxy solvent base and solvent freeState-of-the-art Technology, World-renowned SuppliersPhosphate and Chromate TreatmentPipe Heating FBE ApplicationAdhesive and Polyethylene /Propylene ApplicationWater QuenchingRemoval of Coatingfrom Ends (Cut Back)Curing Final Visual Inspectionand MarkingTesting Equipmentand testing to ensure production of high-quality pipes through the implementation of best practices and quality control initiatives. technological advancements and upgradations.Quality checks start right from the receipt of raw material till monitoring systems like plate ultrasonic testing, real time ultrasonic testing (automatic weld cut) ensure adherence to international standards. The mill also has a well-equipped laboratory for testing pipes for its strength, toughness, macro and microstructure.State-of-the-art Technology, World-renowned SuppliersEquipment SupplierPlate ultrasonic testing GE Inspection Technology, GermanyReal time radiography YXlone, GermanyHydrotester Iprolem, RomaniaFinal ultrasonic testing (automatic weld cut)GE Inspection Technology, GermanyPlate Ultrasonic TestingThe equipment used in the testing of LSAW pipes uses probes easily. An audio-visual alarm and automatic spray marker will This process is used to inspect the pipe weld seam continuously for any welding defect with the help of an industrial x-ray.HydrotesterThe hydrotester is PLC controlled and equipped with a digital data recording system and requires minimal operator intervention. It is capable to test the pipe up to 350 bar with an automatic shield barrier and can auto centre the pipe. Final Ultrasonic Testing (automatic weld cut)This process is used to inspect the pipe weld seam continuously for any welding defect. The system consists of an automatic device for lifting and lowering of individual each guiding block for correction of the probe symmetry with weld deviations.18 NACE LaboratoryThe plant is equipped with latest generation NACE testing facility to evaluate corrosion resistance in pipes. Corrosion resistance is evaluated using testing for Stress Corrosion Cracking, Chloride Corrosion, Hydrogen Induced Cracking, Pitting corrosion & Crevice customer standards namely NACE TM-0284, NACE TM-0177 etc. The testing facility maintains a very high level of safety. The facility is quarantined and equipped with advance safety features including the gas sensing device with visual & audio alarm, safety gadgets and emergency exit.Hydrogen Induced Cracking Test Sulphide Stress Corrosion Cracking Test – Method A (Tensile Method) 2 • • Health, Safety and Environment• Tracking of emissions and discharges through online monitors• Robust oil consumption and recovery tracking system• Installation of two Online Ambient Air Quality Monitoring stations and 15 online stack analysersEssar Steel is marching towards a green drive, richer bio-diversity and zero discharge as an assurance to the ever-growing and sustained efforts towards environmental the World Steel Association for actively participating in COemission data collection – testimony to the fact that Essar Steel is the best-in-class and sets industry benchmarks.Essar Steel has always remained committed to achieving excellence in health, safety and environment by providing and maintaining safe and healthy working conditions and following operating practices that protect the environment.Environmental Awareness and TrainingA continuous environmental awareness drive and environmental training is being implemented through in-house and external training sessions that is a mandate for all employees including senior management. All Essar employees are covered under the Environmental Awareness Programme. The training network is comprehensive and aims and trains each individual at a particular site.Development ProjectsEco-restoration by greenbelt development, mangrove plantation, creation of eco-life and marine lifeImplementation of a vigorous Environment Management System1920• API 5L, API 2B by American Petroleum Institute • ISO / TS 29001 by API • ISO 9001: 2008 by DNV • BIS Certificate• OHSAS 18001:2007 • ISO 14001:2004Marking and OrderingMarking• Pipe number, heat number and ASL number• type of pipe• Hydro test pressure• API monogram • Month and year of manufacture• Length and weight of pipeOrdering • Outer diameter• Wall thickness• Grade• • Quantity• Type of pipe22HSAW & LSAW Dimensions X-60 X-65 X-70 X-80Grade: API 5LPipe diameterWall thicknessmm 6.4 8.7 10.3 12.7 14.3 15.9 19.1 20.6 22.2 23.8 25.44064575085596106607117628138649149651,0161,0671,1181,1681,2191,2701,3211,3721,4221,4731,5241,5751,6261,6761,7271,7781,8291,8801,9301,9812,0322,0832,1342,1842,2352,2862,3372,3882,4382,4892,540HSAW23Wall thicknessmm 6 8 10 12 14 16 18 20 22 24 25 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 654064575085596106607117628138649149651,0161,0671,1181,1681,2191,2701,3211,3721,4221,4731,524LSAWPipe diameterGrade: API 5LX-80Contact us Corporate OfficeEssar House,11 K.K.Marg,Mahalaxmi - 400034,India.Tel: +912266601100Fax: +91 22 2353 2695 www.essarsteel.comGive your business a competitive edge. Mail us at steel@essar.comIndia Offices: Marketing OfficesAhmedabadEssar House, EllisbridgeAhmedabad - 380 006Tel: +91 79 6608 6666Kolkata2nd Floor, Block: EP, Plot Y16,Sector V, Saltlake City,Kolkata - 700 091Tel: +91 33 6612 6608 BengaluruNo. 2, 2nd Floor, RR Chambers,11th Main, Vasanth Nagar,Bengaluru - 560 052Tel: +91 80 2220 2131 NCRA-5, Sector-3,Noida - 201 301Tel: +91 120 6626 666 ChennaiChennai House,5th Floor, No. 7, Esplanade,Chennai - 600 108Tel: +91 44 2535 1271 / 73 MumbaiEssar Technopark,# 2, L.B.S. Marg, Kurla (West),Mumbai - 400 034Tel: +91 22 6733 5000 Hyderabad301, Sidhu Shree Vaishnavi Arcade,Road No. 1, Banjara Hills,Hyderabad - 500 034Tel: +91 40 2337 0125 / 6677 0980Pune408, City Tower,17, Boat Club Road,Pune - 411 001Tel: +91 20 6620 9901 / 2 Indore409, City Centre,570 M.G. Road,Indore - 452 001Tel: +91 731 2538 825 / 2537 974 GurgaonEssar Steel India Ltd. 1st Floor, AEGIS Bldg, 247 Udyog Vihar, Phase-IV,Gurgaon-122 016 Haryana, India Tel: +91 124 6796666 FaridabadEssar Steel India Ltd. 33-A, Industrial Area, NIT, Faridabad-201301 Haryana, India Tel: +91 129 4163915 International OfficesUAE Essar Steel Middle East FZE, (Middle-East Asia Regional Office) S 40402, JAFZA South,Dubai, UAE - 261754Tel: +971 48998500China Essar Steel Limited Essar - Beijing Representative Office Unit 1509, China World Tower 1China World Trade CentreNo 1 Jian Guo Men Wai AvenueBeijing 100004. PR CHINA Tel: +86 (10) 5866 9923Fax: +86 (10) 5866 9924SpainEssar Steel Processing and Distribution Iberia, S.L. Poligono Industrial Ingruinsa, C/Jeronimo Roure, 43Puerto de Sagunto - 46520 Valencia, SpainTel: 34 672053570 IndonesiaPT Essar IndonesiaBFI Estate, Inds 3 Kav B1,Cibitung, Bekasi 17520,West Java , IndonesiaTel: +62 21 8980 152ItalyEssar Steel Processing & Distribution Italia S.R.L.Via G. Boccaccio 4, 20123Milano, ItalyTel: 39 02 4980402 Fax: 39 02 4986434 CanadaEssar Steel Algoma Inc.105 West StreetSault Ste. MarieON Canada P6A 7B4Tel: 1 905 331 3400 United KingdomEssar Steel Processing & Distribution UK Ltd Pensnett Road, DudleyWest Midlands, England - DY12HAUnited KingdomTel: 44 7538 092676Corporate OfficesMumbai Essar Steel Limited Essar House11, Keshavrao Khadye MargMahalaxmi, Mumbai - 400 034Phone: +91 (22) 2495 0606 / 6660 1100 Fax: +91 (22) 2492 8896 Registered OfficesHazira (Registered Office)Essar Steel India Ltd27th KM, Surat Hazira RoadDistrict - SuratHazira - 394 270. Gujarat, IndiaTelephone: (+91 261) 2872400 Fax: (+91 261) 2872796