Spiral Welded Pipe Plant
As a part of Surya group's expansion plans in the steel sector and also to take advantage of the burgeoning demand for Spiral Welded Pipes for transportation of oil, gas and water as well as structural and industrial applications, Surya Roshni group has set up a modern, large manufacturing plant under the name Surya Global Steel Tubes Ltd. in Gujarat. This plant also has facilities for production of ERW pipes. The Spiral Welded Pipes are used mainly for transmission of oil, gas and water at various pressures and densities over long distances. Considering the challenging and varied applications, the pipes are produced to meet high standards of specifications, both national and international, including that of API (American Petroleum Institute).
The plant is situated in an area of about 100 acres and located on the National Highway at Bhuvad village (Anjar) in Kutch producing Spiral Welded Pipes in the range from 18" to 104" with maximum wall thickness of 1" (25.4mm) conforming to API/ASTM specifications upto API5L, Gr.X80. This plant has a capacity of 200,000 MT per annum.
All the machines for manufacturing of Spiral Welded Pipes are imported from Byard Malaysia and Germany, who are world class manufacturers of Spiral Pipe Plant machinery. It has a strategic locational advantage due to its close proximity to the ports at Kandla (22km) and Mundra (35km) that have facilities for handling heavy cargo.
HR Coils are loaded on the decoiler of the Spiral Pipe Mill. The strip is straightened and 100% coil is examined for any defects in the material by automatic ultrasonic unit having of 36 probes & 144 channels. The edges are milled to desired joint geometry. The strip is guided into the forming station, where it is formed to produce cylindrical hollow body at predetermined forming angle, ensuring the proper welding gap between the abutting edges. Later inside and outside welding is performed by an automatic submerged arc process.
After accomplishment of inside and outside welding, flux and slag from inside the pipes are cleaned. Pipes are cut to a predetermined length by an automatic plasma arc cutting device. The entire weld seam is scanned by Fluoroscopic Inspection / Real Time Radiography for analysis of the weld defects, if any.
At the end facing machine, both ends of pipes are machined simultaneously, to suit joint, to be used on the pipe line. Each pipe is hydrostatically tested to a given pressure as per API 5L specification or other desired specification.
100% weld length and HAZ of each pipe is examined by automatic ultrasonic unit with the help of 16 probes and 16 channels for detecting the defects, if any. At the X-ray station, radiographs are taken of weld seam for each pipe end, to a distance of 4". Every length of pipe is subjected to a rigorous check at the final stage before it is accepted by the Quality Control Department.
Customer satisfaction drives Surya Global in everything that it does. No wonder, its commitment to the high quality of its pipes commences right from the selection of raw material and continues at every stage of manufacturing process till the finished product. Steel strips are assessed for their mechanical strength and consistency. At every subsequent stage along the manufacturing line, our engineers employ sophisticated equipment and techniques to ensure not only defect free quality of pipes, but also their optimal performance under the most stringent conditions. The inspection procedures evaluate each pipe for surface finish, perfection of weld, correct diameter, wall thickness, length, weight etc.
To ensure product reliability through process control, Surya Global has a fully equipped metallurgical laboratory with all the tools essential for comprehensive product quality testing and evaluation to ensure that the products withstand reactive processes. Hydro testing of pipes is undertaken to detect leaks and fissures. Destructive testing of pipes entails performance examination of the weld, as well as their tensile and compressive strength.
Testing and Quality Control Facilities
Besides the numerous quality assurance measures during the manufacturing process and at various inspection points, the following facilities are also utilized for ensuring stringent quality standards.
Apart from the above important testing machines, we have temperature recorders for seam normalising, auto pressure recording for hydraulic test pressure and many other sophisticated measuring instruments. The trained and committed work force ensures high quality of pipes made to various national and international standards, including the requirement of API specifications. The quality control system is audited time to time by the various certification bodies including API to verify the effectiveness of the system.