Prepared By: Jayraj Bhuptani (08067) Leena Kanjani (08080) Sulabh Maheta (08084) Anita Paryani (08096) Amin

Pattani (08100) Mehul Rakholiya (08101)

Introduction
Till a few years ago, manufacturing pipes was not a very exciting line of business. Logging 67% compounded annual growth rate over the past 3 years. The size of pipes industry has risen sharply. 2006 -7000 crore 2007 -1000 crore
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Introduction of PSL
PSL has production capacity in excess of the 1 million ton mark. PSL is Indias largest producer/manufacturer of HSAW pipes - the line-pipe industry's preferred pipe There selling is not only in domestic market but also selling in international market.
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 There selling is not only in domestic market but also selling in international market. PSL Supply product on time and very competitive prices. PSL manufactures and supplies SPIRAL WELD PIPES conforming to API (American Petroleum Institute) standards. PSL-NA is a Joint Venture (JV) controlled by PSL Limited, an Indian company based in Mumbai, with Indian and American partners.
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MISSION
A continued Development. investment in Research & Building and nurturing engineering talent. Developing a culture that fosters teamwork and enhances leadership abilities. The highest standards of corporate conduct and ethics. Ensuring the highest levels of customer satisfaction for every customer across geography and scale.
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VISION
"Being the global supplier of choice for the energy infrastructure sector industry by 2020"

COMPETITIVE PRIORITIES
Flexible Customization Time Top Quality Product

MAINTENANCE
Engineers carry out preventive maintenance. There has never been a major breakdown. The hours of breakdown they have face till now is not more than two hours. They have to maintain documents as per ISO 4000.
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 One of the preventive measures they take is that work instructions are provided on all machines. Daily and weekly check is conducted. Production worker intimate the maintenance department about the break down. Details of machines are formatted in soft copy.
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COATING SPECIFICATION
1. Coal Tar Enamel Coating. 2. Concrete Weight Coating. 3. Polyethylene Coating.

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1. Coal Tar Enamel Coating

Steel pipe external surface shot blasting. Inspection. Dope enamel and wrapping. Coating. Inspection. Whitewash.
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2. Concrete Weight Coating

Raw materials: Cement. Aggregate. Iron ore. Welded steel wire mesh. Steps for concrete weight coating: Inspection of coated pipe. Concrete Coating application with impingement method with reinforcement. Inspection Weighing. Curing.
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3. Polyethylene Coating
External cleaning. Shot blasting. Gas induction. Epoxy application Adhesive application Brushing and End cleaning. Painting.
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H-SAW PIPE MANUFACTURING

Large diameter API / IS Grade pipes with a diameter ranges from 406 mm to 3175 mm, wall thickness up to 25 mm, length up to 12.5 meter Annual mill capacity is around 75000 MT per mill. H-SAW (Helical-Submerged Arc Welded) Pipes 10 Pipe Mills
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Step 1:- Raw Material Receiving & Inspection Hard rolled (HR) coils are received from the steel suppliers. They are sent to the stores department after chemical analysis and mechanical testing of each coil is done, thereafter, each coil is given an unique identification numbers and bent them to give the form of pipe and after that submerged arch welding is done simultaneously inside and outside the pipe. Step 2:- Coil Slitting & Loading HR coil is then loaded on the spiral welding pipe, where it is de-coiled.
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Step 3:- Leveling & End-shearing By using that leveler or straighter unit, the coil to make it plane and smooth. By pinch roller unit, It acts as a scissor, which cuts the edges of the coil and make them regular. shearing End unit is used to join the next coil with the present one. Step 4:- Edge Preparation At this stage, with the help of Edge Pre-bending unit the edges of the spitted coil is milled on the longitudinal edges to get the desired width and V groove for welding.
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Step 5:-Pre Bending and Forming H.R coil is bent at Helix angle. Here at Bending and welding station coil is bended in the U shape through feed roll. Now, the U rolled coil is rolled into a complete O shape. Step 6:-High frequency Welding (pending) Two types of welds are used at this stage: Induction Welding: The coil is heated through high temperature, high voltage current at 1400 degree centigrade and feretories are used to transfer the heat to the edges. It weld Internal in diameter and External Diameter and gives better weld quality, but uses 25 to 35% more power compared to contract welding. Piercing the Pipe with the help of Plasma cutting machine Contract Welding: The open edges are welded in the given portion internally and externally and the pipe is prepared.
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Step 7:- Weld Seam Annealing At this stage, the rough portion created on the edges due to weld, are smoothed through the grinding. Now welding portion and heat-affected zone is put to normalizing to regularize the mechanical and chemical properties by applying heat unto 900 degree Celsius. Step 8:-Cooling Zone Air & water Quenching The brittleness of the pipes increases if temperature is more than 300 degree Celsius. So, in order to reduce this temperature, it is passes through the cooling zone where it is cooled by water.
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Step 9:-Pipe Sizing & Cutting The pipe is then resized and cutted as per the customer requirements Step 10:-Dimension & Visual Check Each pipe is visually inspected from both inside and outside to measure dimensions like outside diameter, wall thickness, length, out of roundness, bevel angle, root face, straightness etc are measured and recorded and also each pipe is weighted on a weighing machine.
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Step 11 :- Weld Seam Test The weld seam is scanned by automatic Ultrasonic testing for any weld defects. The defective pipe is sent for repairs and after repairing the repaired area is again scanned. Step 12:-End beveling and sample cutting Each pipe is beveled at both ends to form welding to the customers specification.

field

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Step 13:- Washing After welding pipe is washed from inside to remove all the dirt, slug. Etc. Then the FIRST INSPECTION DONE,IN THAT pipe is visually inspected from inside and outside for any welding or base metal irregularities. Step 14:- Hydro Testing Each pipe is subjected to Hydro Test in which a specified pressure is applied to the pipe for a specified holding time and the same is recorded on a chart recorder.
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Step 15:- Weld UT The Weld seam is scanned through automatic ultrasonic testing for any weld defect. The defective pipe is sent for repairs and the repaired area is again scanned. Step 16:- Body UT After scanning of weld defect by the weld UT, the body (parent material) defect shall be detected by UT.
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Step 17:- MPI The bevel ends of the pipes are inspected through magnetic particle inspection for any lamination, cracks, etc. HERE 2ND INPECTION. Step 18:- Manual UT Pipes are subjected to ultrasonic rays for any defect in the welding. In this when ultrasonic rays passes through the welding part, time is recorded of its return from the surface which is recorded in the form of charts. If there is change in the time or rays do not return it shows the presence of defects.
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Step 19 :-Weighing Before final inspection each & every pipes weighing shall be done by weighing machine. Step 20:- Marking & Final inspection After this final inspection of pipes is done. Visual & Dimensional inspection is done as per specification & customer requirement. After making a inspection reports marking shall be done by stenciling. As per QA plan (QAP) inspection review will be done either by Manufacturer or TPIA (third party inspection agency). After stenciling the pipes as per requirement it is send to the stock yard for dispatch. After getting the final inspection clearance from QA & dispatch advice from marketing, pipes shall be dispatched 26 to the respective customer

Step 21:- Stock yard All finished and rejected pipes are stored over there. Step 22:- Dispatch After the goods are prepared, they are dispatched to the customer. Non-destructive test is conducted that includes: X-ray test Hydro-static testAir exhaustion Water pressure at speed of 146kg/cm2. Ultrasonic test with the help of cathode ray tubes. Radio-graphic test. Destructive test involves testing that includes bent 27 test, all-well test and impact test.

PRODUCTION PLANNING

As per costumer order pre-qualification test and 3rd party inspectors (TPI) green signal to start production. Quality Control (QC) department and TPI carry out stage inspections. Non-destructive test that includes If any defects are found in any of the pipes during the testing stage those defective pipes are sent for manual repair. If any defects are found in any of the pipes during the testing stage those defective pipes are sent for manual repair. 28

TYPES OF WASTAGE IN PRODUCTION PROCESS

As per costumer order pre-qualification test and Green signal to start production. Quality Control (QC) department and TPI carry out stage inspections. If any defects are found in any of the pipes during the testing stage those defective pipes are sent for manual repair.
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HELICAL TWO STEP TECHNOLOGY PIPE MANUFACTURING

API Grade pipes with a diameter range of 457 mm to 1524 mm, wall thickness up to 25 mm, length up to 18 meter Annual plant capacity is around 3,00,000 MT depending upon order mix. HTS SAW (Helical Two Step Submerged Arc Welded) Pipes (1 Tack Welding Mill + 3 SAW Stations) 1 Pipe Mill
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TWOTWO-STEP METHOD
In this method spiral formation is done first and
then pipes are send for welding.

Three lines welding is done after the Hard rolled

coil has been bent in a helix angle to give it a form of pipe, verification is possible as welding is done ata later stage.

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THERE AFTER THIS FOLLOWING PROCESS:PROCESS:1. First Hydro check is done on pipes. 2. Checking is done through ultrasonic rays. 3. Then Radiography test is conducted. 4. This is followed by cleaning of pipes.

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STEP - 2 RO water acid that they are using for washing with acid.

STEP - 3 Chromate application.

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STEP 4 Layer external coating of chemicals STEP - 5 Water is sprayed for cooling the pipes STEP - 6 Brushed at the speed of 150mm per pipe. STEP 7 Internal and external coating is done and pipes are cleaned from within and outside
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STEP 8 Pipe is painted from inside. STEP 9 Weighing. STEP - 10 Marking & Final Inspection. STEP 11 Stockyard
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STEP - 12

Dispatch
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RECENT PROJECT
Larsen & Toubro Ltd. Essar Constructions Ltd. Pratibha Industries Ltd. Gail DNP Ltd. FUSION PROVIDA LIMITED
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LOCATION
INDIA

UAE Sharjaha

Nani Charai Varsana Kandla New delhi Jaipur A bad Daman Mumbau Channai Kakinada Vishakha Patnam

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LOCATION LOATION BENEFITS

Port facility Good road and rail connectivity Abundance of suppliers

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TYPES OF WASTAGE IN PRODUCTION PROCESS

1. In process wastage. 2. Coils End is cut. 3. Milling and surface preparation. 10% of thickness is to be trimmed on either sides.

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PURCHASER INSPECTION
Inspection Notice Plant Access Compliance Rejection

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STORES DEPARTMENT
PSL is having two yards at Kandla unit Manufactured pipes are kept on Sand rows at PSL. Raw material from local as well as international markets Not maintain stock of HR Coil
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PROCEDURE FOR PURCHASE OF MATERIALS.

Material purchase requisition stock checking purchase order and release MPR/P.O. reference Gate Inward of Material Verification Visual Inspection
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Supplier Selection:Selection:Price Quality Delivery

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The types of gate pass are

1. Chargeable. 2. Unchangeable. 3. Stock Transfer. 4. Returnable challan. 5. Material Return. 6. Pay rejection Challan.
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QA/QC Department
Quality control
Raw material inspection.

Quality Assurance

In process inspection Finished goods inspection

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POM Concepts Related to PSL

Process Management 1. Project Process 2. Job Process 3. Batch Process 4. Line Process 5. Continuous Process
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Project Process Job Process Batch Process Line Process

Mass Customization

Continuous Process

The process in PSL is job process

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Total Quality Management

A philosophy that stresses three principles 1. customer satisfaction 2. employee involvement 3. continuous improvement in quality

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Statistical Process Control

p-chart C-chart R-chart X-chart

PSL use SPC like different type of Pie Charts for controlling there process and thus maintains quality of there product.
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Layout Planning
Fixed Position Layout PSL follows an arrangement in which the manufacturing site is fixed in place and employees along with their equipment, come to the site to do their work.

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Maintenance Management
Breakdown Maintenance Preventive Maintenance

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