PIPE PLANTS OF RSP

- AN OVER VIEW

By,

DT:
 PIPE PLANTS OF RSP

ELECTRICAL RESISTANCE SPIRAL WELDED

WELDED PIPE PLANT PIPE PLANT
(ERWPP) (SWPP)

PIPE COATING PLANT

What is a line pipe..???
A Line Pipe is a high strength carbon steel pipe used for
transporting crude oil, petroleum products, natural gas
and water. It is a pipeline which carries only one type of
fuel. Line pipes are manufactured in a wide range of
pipeline diameter size ranging from 2 inches to 48 inches.
DIFFERENT METHODS OF LINE PIPE MAKING

• Seam less pipes

• Butt- Welded pipes- Fretz Moon process
• SAW pipes- LSAW & HSAW (spiral) pipe
• HF Induction welded pipes
• HF contact welded pipes
ERW PIPES
• DI or Spun pipes
• U-O-E pipes
• TIG Welding
• Re-inforced plastic pipes
COMMON GRADES IN STEEL PIPES
IS 1239 – Mild steel tube
IS 1161 – MS for Structural purpose
IS 3601 – For mechanical & general use
IS 3589 – For water ,gas & Swege
IS 9295 – For Idlers for belt conveyors
IS 4270 – For water wells
IS 3074 – For automobile purpose
ASTM A 53 – Black pipe with hot dip coated
BS 3601 – for pressure purpose
BS 1387 – Screwed & socketed steel tube
 Established in 1960 in collaboration with
SMS-MEER , Germany.
 First Line pipe plant in India and Second in Asia
 1984- Installation of Normalizing unit & modified
profile to increase D/T ratio 50:1 to 80:1
 1991- Installation of HF Welder
 1997- Replacement of Eddy current m/c with Auto
UST m/c
 2005- Complete modernization with new entry section
New on line & off line UST m/c, HF welder
Normalizing unit, beveling m/c,Revamped hydrotester
with D/T ratio 100:1
 Installed capacity 75,000 ton/ year
 one of the highest NSR product of RSP
 Highest contributing product of RSP with
contribution above 11000 Rs/ ton
 Material yield consistently above 91%
 very less rejection %
 Established in 1976 in collaboration with
M/S HOESCH , WEST Germany
 Fully Automatic Welding Current, Voltage Controllers And
Weld Gap Control Equipment
 X-ray Testing, And An Automatic Ultrasonic On Line
Testing Machine Facilities Available
 Laser Seam Tracking Facility
 installed capacity 60,000 T/YEAR
 Grades

IS grade API grade

PSL 1
IS 3589 Fe-410
Fe-330 API5L grade A/B.
Fe-450 API5LX-42.
API5LX-46.
Other grades
IS 4270 API5LX-52.
(only ERW) ASTM A53 API5LX-56.
IS 5504 API5LX-60.
(only SW) CRLA
API5LX-65.
(COPPER)
API5LX-70.
 Length range 6.4 mtr to 12.4 mtrs
Outer Thickness (mm)
Diameter
219mm/ 4.5 5.2 5.6 6.0 6.4 7.1 7.9 8.7 9.5 10
85/8”
273mm/ 4.8 5.2 5.6 6.0 6.4 7.1 7.9 8.7 9.5 10
103/4”

323mm/ 4.8 5.2 5.6 6.0 6.4 7.1 7.9 8.7 9.5 10 11
123/4”

356mm/ 5.0 5.2 5.6 6.0 6.4 7.1 7.9 8.7 9.5 10 11
14”
406mm/ 5.0 5.2 5.6 6.0 6.4 7.1 7.9 8.7 9.5 10 11 12
16”
457mm/ 5.2 5.6 6.0 6.4 7.1 7.9 8.7 9.5 10 11 12
18”
THE STANDARD OUTER DIAMETERS OF SW PIPES ARE
20”, 22”, 24”,28”,30”, 32”, 34”, 36”, 38”, 40”, 42”,
44”, 46”, 48”, 52”, 56”, 60” & 64”
THE THICKNESS RANGE IS FROM 6.0 mm to 14.2 mm

Length range- in random length from 7.5 to 13 metres.

 3 Layer-Polyethylene PIPE COATING PLANT
(3LPE)

3- LAYERS OF EXTERNAL
COATING
• Epoxy Primary coating
• Adhesive layer
• Polyethylene top coat
3 LPE PIPE COATING
 ROURKELA STEEL PLANT 3 Layer Poly Ethylene / Poly Propylene Coating Flow Process

External Blast Pre-Heat

In-Coming
Rack
Reject / Hold (Hold
Point)

Inspection Rack * Transfer pipe identification

* Check for surface
(Hold Point) contamination
* Check surface condition
(i.e. damage free .. etc.)
Reject (Re-blast)/
Hold

Cut-Back Tapping

* Check for steel defects (i.e. slivers, lamination) * Check surface cleanliness
* Check for salt contamination * Check blasting profile Induction Heat
* Check pipe surface temperature •Monitor elapsed time between blasting and
* Check pipe wall thickness (if excessive grinding) coating (Weather Control: %RH & ADP)
Blow-out
Inspection Rack Extrusion of Adhesive
(Hold Point) Cutback Water Quenching Anti-Slip and Top Coat FBE Primer Application
SPP Coating Brushing
Plant

To
Internal
Plant
To PP / PE stock pipe
area
Holiday Testing

* Check coating thickness

* Check coating visual appearance
* Check for holiday In-house QC
* Pipe marking / colour coding Lab Temperature Control
* Check cut-back dimension and
taper (Hold Point)

File : SME Coating Flow Chart

 3LPE PIPE COATING PLANT
 MAKE: M/S SOCOTHERM S.p.A,ITALY

 PIPE RANGE - 8 5/8” O.D TO 42” (ERW,SAW)

 PIPE LENGTH CAPACITY – 8 M TO 13 M

 PIPE WALL THICKNESS : 4 - 12.7 MM

 SURFACE CLEANLINESS CAPACITY : SA 2 1/2

 TYPE OF COATING: 3 LAYER POLYETHYLENE

 3LPE PIPE COATING PLANT

 COATING THICKNESS : 3.7 MM MAX

 PIPE HEATING CAPACITY BY: 1000KW

INDUCTION OVEN
 POWDER APPLICATION: EPOXY (1.5 MM)
AT 300 SQ. MTR/HR
 ADHESIVE USED : LOW DENSITY PE
BASED CO POLYMER

 COATING MATERIAL: HD POLYETHYLENE

 3LPE COATING CAPACITY : 300 SQ.MTR./HOUR

 TESTING EQUIPMENT AT
3LPE COATING PLANT
 MITUTOYO SCANNING INST: PROFILE MEASUREMENT

 SWEDISH PICTORIAL STANDARD:CLEANLINESS

 WHIRLING HYGROMETER: REL.HUMIDITY

 TEMPIL-STICK: PIPE TEMP

 MELT FLOW INDEX TESTER: RAW MATERIAL TESTING

 DYNAMOMETER: TENSILE AND ELONGATION.

 IMPACT RESISTANCE TESTER: COATING ASSESSMENT

 PEELING TEST EQUIPMENT: COATING ASSESSMENT

 TESTING EQUIPMENT AT
3LPE COATING PLANT

 INDENTATION TEST EQUIPMENT: COATING ASSESSMENT

 CATHODIC DISBONDING TESTER: COATING ASSESSMENT

 SHORE D DUROMETE: RAW MATERIAL TESTING

 PORTABLE HOLIDAY DETECTOR 3-30KV: PE REPAIR

 PEELING TEST EQUIPMENT: COATING ASSESSMENT

 THICKNESS GAUGE: COATING THICKNESS

COMPLETELY FINISHED PRODUCT DISPATCHED DIRECTLY TO CUSTOMER

NOT IN BULK PRODUCT CATEGORY

LIMITED STOCKING FACILITY AVAILABLE ONLY AT THE PRODUCTION SITE

A PROJECT BASED ITEM USED MOSTLY IN POWER PLANT PROJECTS

VERY HIGH COMPETITION AS THE NUMBER OF SMALL MANUFACTURERS

IS HIGH

DIRECT CUSTOMER INSPECTIONS ON THE SITE IS APPLICABLE ON MOST OF

THE ORDERS
DAILY PRODUCTION CAPACITY IS LESS COMPARED TO OTHER BULK
PRODUCTS
Coil car & Strip end Edge Milling Strip UST
Uncoiler welder Machine (For API
PSL-2 only)

Internal HF Induction Universal

Bead Weld Throat Welder Cage
Trimmer

Outside Normalizing Cooling Flying cut-off

Bead # 1, 2 jacket Machine
Trimmer

Work Offline UST Hydro tester Beveling

inspection (For API 1&2 machines
only)
CO2
SCRAP BOX
SCRAP BOX
 BASIC PRINCIPLE OF
‘HIGH FREQUENCY
INDUCTION’
WELDING TECHNOLOGY
BASIC PRINCIPLE OF ‘HIGH FREQUENCY INDUCTION’ WELDING
TECHNOLOGY
BASIC PRINCIPLE OF ‘HIGH FREQUENCY INDUCTION’ WELDING
TECHNOLOGY
BASIC PRINCIPLE OF ‘HIGH FREQUENCY INDUCTION’ WELDING
TECHNOLOGY
 TECHNICAL SPECIFICATION OF H F WELDER

MAKE: EFD

POWER O/P : 1000 KW

FREQUENCY : 250 KHz

WELD THROAT OF ERWPP, RSP
STATE-OF-THE-ART SOLID STATE CONTROL.
PIPE IS MADE &
NUMBERED

BEVELLING
MACHINE
PIPE IS MADE &
NUMBERED

BEVELLING
MACHINE

HYDRO-TESTER
 PIPE IS MADE &
NUMBERED

BEVELLING
MACHINE

HYDRO-TESTER

FOR API-GRADE

FOR OFFLINE UST

IS-GRADE

WORKS INSPECTION

PIPE STACKING &

DESPATCH
 COIL INSIDE & PIPE
FORMING OUTSIDE CUTTING
PREPERATION CAGE
STAND WELDING UNIT
(SAW)

OUTSIDE VISUAL
X-RAY GRINDING WELDING INSPECTION
STATION STATION (SKELP JOINT) STATION

REPAIR UST
BEVELING HYDRO MACHINE
WELDING
MACHINE TESTING

ELECTRONIC FINAL WORKS END

WEIGH BRIDGE INSPECTION INSPECTION RADIOGRAPHY
ASH HANDLING IN POWER PLANTS:

 THESE ARE MOSTLY PROJECT BASED REQUIREMENTS

 ORDERS HAVE CERTAINTY IN NATURE AND SIZEABLE QUANTITY
 REQUIREMENT IS BOTH DIRECT AND INDIRECT i.e THROUGH
CONTRACTORS
 MOST ORDERS REQUIRE TO SUBMIT PAC AND OTHER CLEARANCE
 MOST OF THEM REQUIRE PRE- DESPATCH INSPECTION CLEARANCE
 HIGH LEAD TIME
 ORDERS IN MARKET MUCH BEFORE SUPPLY
 90% REQUIREMENT FROM NTPC & STATE POWER PROJECTS
 HCSD (HIGH CONCENTRATION SLURRY DISPOSAL)
EFFORTS AND RESEARCH IS GOING ON TO REPLACE THE
EXISTING ASH SLURRY DISPOSAL WITH HCSD METHOD IN SOME
PROJECTS OF NTPC. THIS WILL INCREASE THE PRESSURE REQUIREMENT
OF THE PIPES AND THERE BY REPLACING USE OF ERW PIPES WITH
SEAMLESS PIPES.

CHARACTERISTICS
• HIGH PRESSURE REQUIREMENT FOR PIPES
• SUPPOSEDLY ENVIRONMENT FRIENDLY
• SMOOTH INNER SURFACE OF PIPES REQD.
• HIGH COST COMPARED TO EXISTING MODEL
STATE WATER LINE PROJECTS-

 THROUGH CONTRACTORS OR TRADERS

 INTENSE COMPETITION
 SHORT NOTICE REQUIREMENT
 MODERATE QUANTITY AND MANY SPECIAL STIPULATIONS
 COMPETITION FROM DI PIPE SEGMENT
 VARIOUS SIZE REQUIREMENTS AND PREFERENCE TO PROCURE
FROM SINGLE SOURCE
RETAIL MARKET:

 VARIETY OF SIZES IN SMALL QUANTITY

 COMES WITH LENGTH STIPULATIONS
 ORDERS IN DIFFERENT SIZE BUT OFTEN REPEATING
 INTENSE COMPETITION
 ORDERS DIRECTLY BOOKED FROM AVAILABLE STOCK
 MANY ALTERNATE SOURCES OF PROCUREMENT.
NTPC L&T
BHEL MBL
 TATA PROJECTS  APGENCO
 MC.NALLY BHARAT  TSGENCO
 MEGHA  INDURE
 STATE JAL-NIGAMS  MPGCL
 RINL  NALCO
 SAIL SISTER PLANTS
 HITEK BINA COMMERCIAL
BGR BENGAL MILLS
DVC RELIANCE
BRIDGE & ROOF RAJKRISHNA
 MAHAGENCO MAHAVIR TUBES
DECCAN MECH
 JINDAL PIPE PLANTS
 MAHARASHTRA SEAMLESS
 SURYA ROSHINI
 SWASTIK PIPES
 BHUSHAN PIPES
 TATA PIPES
 WELSPUN
 RATNAMANI
MANN PIPES
IN HOUSE RAW MATERIAL (HSM)
 LESS LEAD TIME FOR SUPPLY
 STATE OF THE ART TECHNOLOGY
 ROBUST QUALITY ASSURANCE SYSTEM
 VERY LONG MARKET PRESENCE
 LEVEL II AUTOMATION
 MIS & REPORTS ARE PAPERLESS
 PSU CORPORATE CUSTOMERS
 AUTOMATED PLC CONTROLLED PROCESS
 200- 250 T PRODUCTION/DAY
 CUSTOMER’S SPECIAL
REQUIREMENTS THROUGH
TS/ENQUIRY
(TDC, QAP, DELIVERY REQ. ETC)

SUGGESTIONS / ACCEPTANCE
AMMENDMENTS
PPC/ PIPE PLANT

REVIEW BY PPC, PIPE PLANTS

& RCL
 PURCHASE ORDER FROM
CUSTOMER TO CMO

ANY
AMMENDMENTS/
MOVEMENT PLAN
ADDITIONAL INFO IN SAP DETAILS OF PAC
REQ REQUIREMENTS
TO BE SENT IN HARD
COPY AND ALSO TO
BE MAILED IN SOFT
ACCEPTED BY PPC FORMAT

PRODUCTION PLAN

SMS/HSM/PIPE A
PLANTS
 PIPES PRODUCED IN PP’S

NO YES
3RD
PARTY
INSP.
INSPECTION CALL
TO 3RD PARTY

PIPES READY FOR NOT CLEARED CLEARED

PIPE
DESPATCH INSPN.

PIPES READY FOR

PROD. PLANNING DESPATCH
 PIPES READY FOR DESPATCH

EXCISE EXCISE
APPLICABLE NOT -APPLICABLE
PUT UP FOR FINANCE
CLEARANCE WITH
A
REQ. DOCUMENTS
INDENT FOR
PIPE DESPATCH
NOT CLEARED CLEARED
FINANCE
CLEARANCE

INDENT
REQUEST FOR
CLARIFICATION DESPATCH
FROM C M O
 MINIMUM CAMPAIGN SIZE TO BE MAINTAINED
 SYSTEMATIC FLOW OF MARKET SURVEY DATA
 PRODUCT CATALOGUE IS NO LONGER THE BIBLE….
 COMMUNICATION OF MARKET NEEDS

 COMMUNICATION OF SPECIAL ORDER REQUIREMENTS

 COMMUNICATION OF PAC REQUIREMENTS FOR
EXCISE CLEARANCE
 DEVELOPMENT OF A NEW PRODUCT CATALOGUE

 ORGANIZING CUSTOMER MEETS TO UNDERSTAND NEEDS

 CUSTOMIZED PRODUCT DEVELOPMENT

SUPPLYING PIPE WITH VARIOUS OUTER SURFACE COATING REQUIREMENTS

 RUST PREVENTIVE VARNISH
 RED OXIDE
 ALLUMINIUM PAINT
 BLACK BITUMINOUS COATING
 ENAMEL PAINT
 LIQUID EPOXY
ANTI-CORROSIVE COAL TAR WRAPPING

* EXPLORING MEANS FOR

INTERNAL COATING OF PIPES FOR
FUTURE ORDERS

Black bituminous coated ERW pipes

 CUSTOMIZED PRODUCT DEVELOPMENT
DEVELOPMENT OF CORROSION RESISTANT LOW ALLOY (CRLA) GRADE PIPES,
IDEAL FOR THE PIPE LINE EXPOSED TO ATMOSHPHERE

1. Chemical Requirement

% C - 0.12 MAX
% P - 0.065 MAX
% S - 0.030 MAX
% Cu - 0.20 - 0.35
% Mn - 1.0 MAX
% Si - 0.35 MAX
% Al - 0.02 MAX

2. Mechanical properties in finished pipes

YS (MIN.) - 195 MPa

UTS (MIN) - 330 MPa
ELONGATION - 20 %

ENSURING REGULAR ORDER CAN LEAD TO “BRANDING” IN FUTURE

 CUSTOMIZED PRODUCT DEVELOPMENT
SUPPLYING PIPES WITH LENGTH 5.9 TO 6.2 MTRS WITH BOTH SIDE BEVELED

CATERING TO VARIOUS TYPES OF ORDERS WITH FIXED LENGTH CRITERIA

CATERING TO VARIOUS TYPES OF ORDERS WITH SPECIFIC THICKNESS BANDS

DEVELOPING PIPE LOADING AS PER CUSTOMER REQUIREMENTS

CASE STUDY: M/s Swastika Steel & Allied product Ltd
SUPPLY OF 6 mtr FIXED LENGTH PIPES FOR M/s SWASTIKA STEEL & ALLIED PRODUCT LTD.

M/s Swastika Steel & Allied product Ltd (a first time customer of RSP) had a
requirement of 6 mtr fixed length pipes to be used by their client ABB in a power grid
project at Sonitpur, Assam. When they approached SAIL CMO, initially it was said no as
it was not in our product range. However subsequent discussion direct with client
revealed that pipes were required for piling, hence suggested to take pipe one side gas
cut which was not an issue for client. Hence pipes were made to the fixed length in 12
mtr & thereafter cut in to two halves 6 mtr each. Accounting of pipes in ERP done
accordingly. Hence the order of 4.32 Km of pipes to be supplied in the fixed length of
6 metres each in the size 14 inch outer diameter and 6 mm thickness was executed
for the first time between 20th & 24th JULY’ 2015.
Next challenge was how to despatch economically through trailer. Trailer
was the modified to suit the loading in two lots in one trailer & then despatched.
This has given immense satisfaction to the customer and they have come
back with repeat orders.

BEFOR SAY “NO” TO ANY ORDER PLEASE DISCUSS WITH PLANT ONCE
CASE STUDY: M/s Swastika Steel & Allied product Ltd
SUPPLY OF 6 mtr FIXED LENGTH PIPES FOR M/s SWASTIKA STEEL & ALLIED PRODUCT LTD.

Appreciation letter
• High Dia-change time due to old mill set up

• Limitations in holding the pipe stock since stockyard

facility is not available.

• Rejection/arisings high in fixed length orders & very low

thickness pipes due to HR coil issues (old HSM)

• Limitation in supplying 6 mtrs length from stock.

• Limitation in witnessing the hydro testing of pipes from stock.

• All pipes are not rust preventive varnish coated, so surface

rusting prevails from stock.

• Coating facility is selectively available.

 STREN TRANSPOR RESALE
Type of pipe COST LIFE
GTH TATION Of scrap

Cost
ERW Limited Medium Medium Yes
effective

SEAM LESS High cost Limited High Medium Yes

D-I Costlier Longer High High Less

LSAW Costlier Limited High Higher Yes

Low
Cost
GRP High High compared No
effective
to MS pipes
 Mechanical Properties M.S Pipes D.I Pipes

Yield strength 235–300 MPa Not specified

Tensile strength 410-500 MPa 420 MPa

Impact strength 27 Joules 6 – 7 joules

Bending strength excellent

Flexibility Better than D.I

Safety against internal pressure

Higher than D.I
for same dia & thickness

Wall Thickness for same

Lower than D.I
pressure
Mechanical Properties M.S Pipes D.I Pipes

Joint Effectiveness Life at par with Gasket life 4- 5

the base years . Gasket
material. Joint failure needs
failure can be replacement
repaired without
shutdown
Joint flexibility & Same as base Poor due to diff
Joint ductility material material

Bends Any size bend Special bends

can be made are required
even at the site
 M.S Pipes D.I Pipes
Due to lower wt, Cost is Less Wt/ Mt is High, Thus Cost is
High

No chance of Damage Can get Damaged

Can be Handled Without Crane required

crane

No special storage Required Special Storage (A/C)

required for Gaskets etc

Can be stacked on uneven Ground preparation is

grounds required
 M.S Pipes D.I Pipes
Length more (12 mtrs) Length less (6 mtrs)
hence faster laying Hence slow
Laying cost lower Laying cost higher

Pipe cutting by Oxy- Needs special machines

acetylene
Bends and T’s can be Not possible on site
fabricated on site
It can take the shape of Difficult to lay on uneven
any terrian terrain
GLASS RE-ENFORCED PLASTIC PIPES (GRP)

•THREAT FOR BOTH THE PIPE SEGMENTS ERW & SW

• COST AT PAR WITH MS PIPES
• LIGHT AND EASY TO HANDLE
• VERY LONG LIFE COMPARED TO MS WELDED PIPES
PLUS POINTS OF MS PIPES OVER GRP
• Laying of pipes and maneuverability with respect to fabrication of bends is
much easier in MS pipes
• onsite repair & welding of pipes is much easier compared to GRP
• Stress bearing capability under ground for GRP is not yet established
• The change of pipe in ash handling projects is not due to life of pipe but
mostly due to jamming of inner deposited materials so high life of GRP nullifies
E R W PIPE PLANT
ROURKELA STEEL PLANT