SAWPIPE Pipelines - Industrial Overview

rohangajjar

New member
INDUSTRIAL OVERVEIW
Pipelines in one form or another have been used since the early days of
civilization for transportation of liquid elements. This is mainly because of its
economical mode of transportation compared to any other modes of
transportation, especially for liquid and gaseous elements. Transportation
through steel pipes is a one time high investment cost which serves the
civilization for long years with regular maintenance. Today pipes have been
used for transportation of various liquid and gaseous elements like
water/sewerage, Oil and Gas over long distances. With rising domestic and
global demand for transportation of petroleum products through pipelines,
we expect the golden era for the pipe industry to be at the onset.
Types of Pipes:
Pipes in the industry are classified according to the production process used
for manufacturing the same. The pipes are accordingly classified as HSaw
(Helically submerged arc welded) and LSaw (Longitudinally submerged arc
welded) pipes. However, both these pipes have their own processing and
application limitations.
Growth Segments

Water segment:
Increased government spending on setting up infrastructure facilities such
as water transportation, irrigation etc has been on a rise. Major projects like
the Tripura water supply and sewerage project – I in January 2003,
Baherika Naka Project - Dist. Rajasthan in June 2003 and the Godavari
Lift irrigation Scheme project in March 2004 represent the government
initiatives in the implementation of such huge projects. We expect similar
such projects to be implemented by other state governments in the coming
years, which in turn would pull the demand for steel pipes in India.
Oil and Gas:
Demand for pipes has cropped up over the last few months as
transportation of oil and gas through pipes is considered the most
economical way. Currently only one third of India’s petroleum products are
moved through pipe lines. The recent gas finds and increased thrust on LNG
imports has resulted in growing demand for gas transportation. Over the
next 5 years ONGC, GAIL, Reliance, GSPL and even Unocal, which is
endorsing the India – Bangladesh natural gas pipeline are all expected to
lay pipelines of approx 21,090 Km, an annual average addition of 4,218 km.
Gail India alone has the biggest capex plan for setting up 7900 Km of new
trunk lines over the next 5 years.
Company Pipe Kms
ONGC 1,000
GAIL 7,900
GSPL 1,200
Reliance 2,250
Unocal 1,740
Others 7,000
Total over next 5 years 21,090
Annual average demand 4,218

We feel that even if some of the projects are delayed by 2 -3 years and
some are shelved; demand is expected to be in excess of 3000 Km per
annum which would be more or less in line with the total domestic capacity
(post expansion).
Export Market:
Countries in the Middle East followed by Russia and India are the major
demand areas. The recent upsurge in crude prices to levels above $ 50 per
barrel has led to an improvement in refining margins. This in turn led to an
overall improvement in cash flow position of global refiners and oil majors
(especially in the middle east) prompting them to make investments in
infrastructure i.e. setting up their own pipelines, an economical way to
transport oil and gas. Further, India’s close proximity to international
demand zone i.e Middle East and benefits of low labour cost has helped
domestic manufacturers make inroads into international market giving them
a competitive edge against their global counter parts. Hence, exports could
be a major contributor considering the demand from countries like Oman,
Qatar, Iraq, Libya and Saudi Arabia in Middle East which do not have any
domestic manufacturers.

Entry Barriers within the Industry

􀂾 Since oil and gas transportation, under high pressure, is hazardous,
oil companies approve vendors only after stringent quality assessment
and audit procedures which can take 2-3 years and most approvals
are plant specific.
􀂾 Some approvals require performance track record and major projects
are not initiated till requisite quantity of pipes are supplied leading to a
high working capital requirements.
Hence a new player within the industry may have to work at lower capacity
utilization in the initial years till it is able to prove its quality and standards
in the international market.

Risks/Concerns for the industry

The major raw material used in manufacture of pipes is steel which has
been highly volatile and thereby any upward movement in prices of steel
could affect the margins of the company. This would even impact the
project profitability in the absence of escalation clause. Further, the
company needs to have much better financial liquidity and a credit standing
as huge project size involves higher borrowings. Since large projects require
higher working capital, in the absence of financial liquidity execution of large
projects per schedule becomes difficult task.






ABOUT COMPANY

WELSPUN GROUP

Welspun, currently a U.S $1.5 billion group is one of the fastest growing business conglomerates that truly represent an amalgamation of expertise resources, opportunities and engineering excellence. Welspun has a presence in 50 countries with a small textile unit, it has grown magnanimously, diversifying into various other business industries and region. Today it consist of six companies, each being a separate entity with distinct board structures and over18,000 employees contributing to its growth.


Global Leadership of Welspun
• Largest saw pipe company in Asia excluding Japan.
• Largest Terry Towel producer in Asia.
• Among top three Terry Towel producer in the world.
• 80-90% of the products are exported.
• Supplied pipes for the “deepest off shore pipeline project” in the gulf of mexico.
• Accreditations from over 40 oil & gas major’s globally.
• Largest speciality Retailer of home furnishing in India.












AWARD /ACCOLADES -2007

• “Fastest growing Steel Product Company” by Construction World NIMCAR
• Amongst the 20 companies to watch out for 2008 by Business Today.
• Amongst the top three Saw pipes companies in the world by CLSA Asia Pacific Markets.
• The “fastest growing company” by Business Today.
• Ranked among india’s top 100 corporates 2007 Standard and poor’s and CRISIL.
• “Outstanding Textile Exporter” at International trade Award by bCNBC TV 18.
• “Sustainability awards” by Wal- Mart Stores Inc., the world’s largest retailer and no.2 company as per “Fortune” 2006 list.



ABOUT ASSOCIATES



WELSPUN INDIA LIMITED (W.I.L)

Welspun India Limited, eastablished in 1985 is one of the oldest companies under the Welspun Umbrella.Over the years it emerged as the largest integrated manufacturer of the Terry Towel in asia and is currently among the top three companies globally. With the capacity nearly 40,000 metric tonnes per annum and manufacturing facilities at Vapi and Anjar, Gujarat W.I.L, also manufactures bedsheet sets. In June 2007, Welspun decided to put up a decorative bedding facility in Mexico with capacity to produce 1.04 million bed-sets per annum.

In July 2006, Welspun acquired 85% interest in CHT Holding company of UK’s leading towel branding Christy. Christy is world’s oldest towel manufacturer% sole supplier to the renowed Wimbeldon Tennis Champion Ships.

Currently Product Manufactured by W.I.L are:-
• Terry Towels
• Bed Sheet sets
• Decorative Bedding.



Welspun Retail Limited (WRL)

Welspun Retail Limited was established in 2006. WRL anticipated the boom in the retail segment and launched two brands – “SPACE” and “Welhome” to capture the Home textile market in India.

SPACE has carved a niche market with its fashion driven model in the country’s major metro’s, while Welhome targets a larger audience with its value for money model.

SPACE
Products can be classified as under
• Bed
• Bath
• Living & Dining

Welhome
Product can be classified as under
• Bed
• Bath
• Kitchen
• Living
• Dining
• Kids’ collection.



Welspun Syntax Limited

Established in 1982 Welspun Syntax Ltd (WSL).It is amongst the largest manufacturers and exporters of Polyester Texturised filament Yarn from India. It has capacity of 31400 metric tonnes in Polyester Yarns and 7200 metric tonnes plant for dyeing located at Silvasa and Thanne.

Products being manufactured are:-
• Polyester Texturised Filament Yarn



Welspun Power and Steel limited
Welspun Power and Steel was established in 2004, recognizing the enormous potential in the construction and infrastructure industry. With plant at Anjar, WPSL is well equipped to manufacture ingots, billet and ribbed Thermo Mechanically Treated (TMT) rebars which have the prestigious ISI Certification. It has also set up an 18 megawatt Power plant that utilizes waste heat from the steel furnaces.

Welspun Gujarat Stahl Rohren Limited (WGSRL)
WGSRL, established in 1995 is capable of manufacturing saw pipes from ½ an inch diameter to 100 inches of diameter, in varying qualities and grades, as high as X80. Today has its manufacturing facilities at Bharuch and Anjar in the state of Gujarat with a capacity of one million metric tonnes, it is well equipped with resources, expertise, equipment and technology leading to engineering excellence.

More recently, WGSRL has set up U.S $100 million facility to produce 300,000 net tonnes of pipe annually in the city of Little Rock, Arkansas, USA at a 740 acre site adjustment to the little Rock Port. In addition to the capacity of LSAW Pipes is being increased by 300,000 tons at the SEZ, Gujarat, India by March 2009.

CERTIFICATIONS
• ISO 9001 - By APIQR
• API 5L (Line Pipes)
• API 5CT (Casing)
• API 2B (Tubular)
• ISO/TS 29001
• ISI by Bureau of Indian Standards
• ISO 14001 by LRQA
• OHSAS 18001 by LRQA
• Six Sigma certificate.

W.G.S.R.L has taken up capacity expansion and de bottlenecking of H SAW (spiral) pipes at existing facility at Anjar, resulting in a capacity increase of 150,000 tons.
On completion of these projects, Welspun shall have an annual capacity of 1.75 million tons making Welspun one of the largest line pipe companies in the world.
At Anjar W.G.S.R.L established in





LOCATION:
WGSRL chose this place as location because of the following reasons
• Availability of labour:-
Here in kutch labour is available due to more population having lck of employement(during set up).because of less industries in this area. So unskilled labour was available also at lower rates.

• Tax free zone ;- It is one of the most important reasons to coose this location, because the tax saving makes the financial statement healthier.

• location allowing export and import to near and far countries;-
as kandla port nearer to this location it makes easy and cheaper for the
export of finished goods and import of raw material.
• Large domestic market allowing economies of scale:-
• Indegeneous availability of raw material.
• Nearer to supplier.
• Nearer to parent company facility.


DIFFERENT PRODUCTS - WGSRL:-
• LSAW
• HSAW
• ERW
• Coating









CUSTOMERS:-
Most international oil and gas companies recognize WGSRL as preferred supplies because of it stringent quality control process.
It is the only Indian company with approved to bid for pipeline contract floated by global majors such as chevron, british petroleum and transcanada.


Its Indian customers are:-
• GSPL
• GGCL
• Lone star (Bangladesh)
• Reliance
• GAIAL
• IOC
• Jay Somnath

MAJOR SUPPLIER:-
It is most important raw material is hot rolled coil
So major supplier for WGSRL are:-
• ESSAR Steel
• ISPAT Steel
• POSCO


COMPITITORS:-
Some of the competitor of WGSRL are.
• Jindal Steels
• MAN Industries
• PSL
• Ratnamani Metals and TubesROD



PRODUCTION STRATEGY:-
Strategy of production differs from company to company according to their competitive priorities and product.
Usually there are three strategies:-
• Make to stock strategies.
• Assemble to order strategies.
• Make to order strategies.

Here WGSRL uses make to order strategy. There is no standard product this strategy provide high degree of customization and typically uses project and job process.
Its product are produced according to customer specification. The process is complex, with high degree divergence.

As products are custom made its manufacturing facility is flexible to accommodate variety and different quality.















WGSRL Organization Structure (Anjar)
President















PRODUCTION PROCESS:
Production process broadly consists of four steps:
 Forming
 Welding
 Testing
 Coating


 FORMING:

1) Decoiling: It is the process in which the parent raw material – hot rolled coil is decoiled with the help of an electrical driver. The driver holds one end of the coil and pulls it outward, and then it pushes the coil forward or the rollers.
2) End cutting: After decoiling during its end are cut which is also known as end shearing process by shearing machine.
3) Coil joining: As forming of pipe is an continuous process.When the decoiling of our coil is over,then another is introduced for decoiling.So, the last end of previous coil and first end of the new coil are joined by welding. To make this welding proper end cutting is done in the above step.
4) Edge milling: The plates are the milled on longitudinal edges to get the required width and u shape for welding.also even coil width.
5) Pipe forming:
• JCO forming: The plate is often to a forming plate is formed into pipe. The first half of the plate is pressed fincet and tarcting from the end and then other half is pressed. So, an fincet ….
• Three roller bending: it occurs parallel to JCO press. In this plate is passed between three rollers to get the required pipe diameter.


• Continuous Tack Welding: The edges are tacked continuously by MIG comprising of filler wire and shielding of Ar-Co2 mixture. These tack welding is used to keep the coil in the pipe form or the pipe to not to open up. Later it is fully welded.
1) Plasma cutting: As pipes are continuously produced, pipe of desired length are cut by plasma cutting machine.

 WELDING:

a).Tab joining: Tabs are joined at the end of pipe ends to avoid welding defects at the ends.

b).There are two types of welding:
IDW:- Inner diameter Welding.
ODW:- Outer Diameter Welding.
For this German machine are used.
o IDW (Inner Diameter Welding): The pipe is welded by submerged arc welding process, comprising of filler, wire & flux. The welding is tracked and monitored on the TV screen at the control room.
o ODW (Outside Diameter Welding): The pipe is welded from outside by same process as in IDW. The welding is tracked by laser system which controls the alignment of the welding in a straight line.
Flux is used in welding because it:
 Maintains voltage.
 Maintains wire feed speed.
 Maintains welding travel speed.




c).Tab cutting: After welding the tab which was joined in the beginning is being cut.
d).Mechanical expansion: The pipes are subjected to cold expansion. To get desired diameter, out of roundness, straighten etc. This process also determines the strength of material as the pipe is expanded beyond its yield strength.
o End Beveling: The ends of the pipes are beveled to the required angle and root face. There is a set of tool of set holder which makes the bevel angle tool face and maintain square ness.
 TESTING AND INSPECTION:
Broadly there are three types of inspection:
• Visual inspection
• Mechanical test
• Non destructive testing
Though these process are carried out during the processes.after the production final testing is done.
• Visual inspection: 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 bike is weighted on a weighing machine.
• Mechanical Testing: Under this test only one test is carried out which is hydro testing. In this the whole pipe is allowed to float amidst the very high specified pressure of water for a specific time and this is recorded in the form of chart.
• Non destructive testing:
1) Final ultrasonic testing:-
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.



2) X-ray testing:
Each pipe is X-rayed 30 cms from both the ends to ensure that
weld is free from defects. X-ray are developed on films and used to
view weld quality, also to keep records.


3) Magnetic Particle Inspection:-
The bevel end of the pipe is magnetic particles inspected for
any lamination, cracks, etc on the surface of the pipe.


• COATING



































Reasons for Coating

1. To prevent it from rusting.
2. To protect it from heat.


External Coating

• After the pipe has been produced it goes to the coating plant as per the customer requirement for coating.
• First, the blow out session is conducted to remove dust particles from the blower. The dust is collected from dust collector.
• Quality check of micro dust or salt is done. If the content of it is more then 10-15micron then it is rejected.
• Aerometer is used for moisture check, if moisture is more then 80°C then it is heated.
• Sulfuric acid test is carried out.
• There after the pipe is washed with high pressure water. The pipe is then soaked with high pressure air.

• The blasting process is done by throwing small iron particles at high speed on pipe to make the pipe surface rough, so that the coating stuck on pipe easily and lasts for a longer period of time.

• The pipe is then heated at 230°C before coating in induction oven where the temperature is 1200kw.

• The coating of Epoxy powder is done on the outer surface of pipe by heating at 200°C so that it sticks on the pipe. The coating is about 120micron.

• Then the thermo plastic adhesive is stick on pipe to make one side polar and other non polar bond.

• Then the coating of Polypropylene is coated, which is 3 layer coating as per the customer requirements. The pipe temperature is 230°C, and then it is cooled by water and brought to 20°C.
• After coating the brushing of pipe from both sides is done so that it can be easily welded to make two pipes joint.

• The last step is quality check of checking any air pockets in the coating process; any metal particles are there it can be removed. Polypropylene melting test, condition test for 30 days test, pin hole test, bonding test, acid test for epoxy check.



Internal Coating
• Internal coating is done if it is demanded by customer.
• It is done by gun spray.













THIRD PARTY INSPECTION:-

Until now inspection process was done by W.G.S.R.L. only now again testing are done by third party, third party is the people who are inspecting are neither Welspun nor customer.
Mechanical and chemical testing
1. Tensile strength
2. Guided bend test
3. Hardness test
4. Drop weight tear test





flying








LAYOUTS:-
There are four types of layouts:-
• FLEXIBLE FLOW LAYOUTS
• LINE FLOW LAYOUTS
• HYBRID LAYOUTS
• FIXED POSITION LAYOUTS

In W.G.S.R.L. the layout is line flow layout i.e. A layout in which work stations are arranged in liver batch.
In these the product moves along in a smooth, continuous flow.
This layout is often called as production line.




Production planning and control

First marketing department confirm order from the costomer then specification from customer passed to ppc dept.. PPC Dept. follows different steps to complete the task.
























After getting approved from QA, PPC Dept. allow to operation dept. for sampling. If samples fulfill requirement of customers specifications (like physical dimensions and quality parameters)then go bulk production. If sample is not ok than go for revision.


Preparation of monthly production plan:
Before going for production HOD of operation check raw materials and PPC check the available order in hand. Than PPC Dept. priority is given to the customer as specified by marketing dept. and also keep in mind expected order provided by marketing Dept.
PPC Dept. then go for
Raw material planning
Machine planning
Shipment planning

Raw material planning:-
1) R.M dispatch schedule from central process department.
2) Confirmation ofdispatch.
3) Coils from port
4) Receipt of coils at plant from store

Machine planning:-
1) Keeping in mind of the capacity of machine planned accordingly.
2) Strategic planning of machine with production Dept.

Shipment planning:-
1) Requirement of container date wise
2) Planning of loading at plant and unloading at port.





Procurement process:
In procurement process first step is supplier assessment. In this first list of approved vendors are prepared on past records performance and if and
new vendors are selected on the approval of HODs (Purchase and Marketing).
After assessment of capabilities a trial order is placed. If company get satisfied with the trial order they place order with them other wise reject the supplier.
In this initial thing is placement of purchase order.









INVENTORY
Type of inventory is
1) Cycle inventory
2) Safety inventory
3) Anticipation inventory
4) Pipe line inventory

Though these inventories are difficult to recognize but in these has been classified because this helps in finding where inventory is more and to maintain inventory in such a way that it can minimize inventory cost.
INVENTORY CONTROL SYSTEM
Inventory control system employed by W.G.S.R.L is periodic review system i.e. fixed interval recorder system. Here review period for the W.G.S.R.L is 30 days.
For example. For the month of May company review the inventory and places order in April. After placing order it is received in three parts i.e. first on 10th May, second on 20th May while last will be received 30th May. Every time order received is 1/3rd of the order placed. Also order is placed in amount – required raw material + 2% of required material.
This is done for safety from any lose of raw material in any form.

REASONS FOR ADOPTING ‘P’ SYSTEM:
1) No constrain on lot size as order are all ready booked.
2) There is no uncertainty in demand.




MAINTAINANCE
Broadly classifying, two maintenance techniques are used:
a). Break down maintenance
b). Preventive maintenance




In Preventive maintenance technique again there are two techniques used:
1). Periodic Maintenance
2). Predictive Maintenance

a).Break down Maintenance:-
When any machine stops working or creates problem than break down maintenance is done to restart the machine or to make it in proper working condition.

b). Preventive Maintenance:-

1). Periodic Maintenance:-
To prevent break down which cause a lot of losses( stop production, loss of time and many).An periodic maintenance occurs which is done after every 15 days.

2). Predictive Maintenance:-
It is based on the experience of the people on the shop floor. Usually when machine is about to break down or improper functioning it starts giving some signals like change in sound and so on, which are easily detected by there experienced people.





QC & QA:
All quality control and quality assurance procedures are followed at the
W.G.S.R.L.

QUALITY PROCEDURE:
1) Handling of H.R Coils: All incoming Raw material coils are handled by ‘C’ hook for handling and storing. From storage to mill the coils are lifted by 30 Ton crane.
2) Handling of pipe inside the plant:- Handling inside the plant is carried out by combination of following methods
o Rolling of the pipes on the level beds and racks.
o V- roller conveyers with rubberized surface to prevent scratch.
o By cranes.
3) As per the specifications of the customer testing are done at the
different places.
4) The pipes are stored in rust and dust free to protect deterioration.
5) Finished goods are stacked in stand for storage.
 

rosemarry2

MP Guru
Re: sawpipe

INDUSTRIAL OVERVEIW
Pipelines in one form or another have been used since the early days of
civilization for transportation of liquid elements. This is mainly because of its
economical mode of transportation compared to any other modes of
transportation, especially for liquid and gaseous elements. Transportation
through steel pipes is a one time high investment cost which serves the
civilization for long years with regular maintenance. Today pipes have been
used for transportation of various liquid and gaseous elements like
water/sewerage, Oil and Gas over long distances. With rising domestic and
global demand for transportation of petroleum products through pipelines,
we expect the golden era for the pipe industry to be at the onset.
Types of Pipes:
Pipes in the industry are classified according to the production process used
for manufacturing the same. The pipes are accordingly classified as HSaw
(Helically submerged arc welded) and LSaw (Longitudinally submerged arc
welded) pipes. However, both these pipes have their own processing and
application limitations.
Growth Segments

Water segment:
Increased government spending on setting up infrastructure facilities such
as water transportation, irrigation etc has been on a rise. Major projects like
the Tripura water supply and sewerage project – I in January 2003,
Baherika Naka Project - Dist. Rajasthan in June 2003 and the Godavari
Lift irrigation Scheme project in March 2004 represent the government
initiatives in the implementation of such huge projects. We expect similar
such projects to be implemented by other state governments in the coming
years, which in turn would pull the demand for steel pipes in India.
Oil and Gas:
Demand for pipes has cropped up over the last few months as
transportation of oil and gas through pipes is considered the most
economical way. Currently only one third of India’s petroleum products are
moved through pipe lines. The recent gas finds and increased thrust on LNG
imports has resulted in growing demand for gas transportation. Over the
next 5 years ONGC, GAIL, Reliance, GSPL and even Unocal, which is
endorsing the India – Bangladesh natural gas pipeline are all expected to
lay pipelines of approx 21,090 Km, an annual average addition of 4,218 km.
Gail India alone has the biggest capex plan for setting up 7900 Km of new
trunk lines over the next 5 years.
Company Pipe Kms
ONGC 1,000
GAIL 7,900
GSPL 1,200
Reliance 2,250
Unocal 1,740
Others 7,000
Total over next 5 years 21,090
Annual average demand 4,218

We feel that even if some of the projects are delayed by 2 -3 years and
some are shelved; demand is expected to be in excess of 3000 Km per
annum which would be more or less in line with the total domestic capacity
(post expansion).
Export Market:
Countries in the Middle East followed by Russia and India are the major
demand areas. The recent upsurge in crude prices to levels above $ 50 per
barrel has led to an improvement in refining margins. This in turn led to an
overall improvement in cash flow position of global refiners and oil majors
(especially in the middle east) prompting them to make investments in
infrastructure i.e. setting up their own pipelines, an economical way to
transport oil and gas. Further, India’s close proximity to international
demand zone i.e Middle East and benefits of low labour cost has helped
domestic manufacturers make inroads into international market giving them
a competitive edge against their global counter parts. Hence, exports could
be a major contributor considering the demand from countries like Oman,
Qatar, Iraq, Libya and Saudi Arabia in Middle East which do not have any
domestic manufacturers.

Entry Barriers within the Industry

􀂾 Since oil and gas transportation, under high pressure, is hazardous,
oil companies approve vendors only after stringent quality assessment
and audit procedures which can take 2-3 years and most approvals
are plant specific.
􀂾 Some approvals require performance track record and major projects
are not initiated till requisite quantity of pipes are supplied leading to a
high working capital requirements.
Hence a new player within the industry may have to work at lower capacity
utilization in the initial years till it is able to prove its quality and standards
in the international market.

Risks/Concerns for the industry

The major raw material used in manufacture of pipes is steel which has
been highly volatile and thereby any upward movement in prices of steel
could affect the margins of the company. This would even impact the
project profitability in the absence of escalation clause. Further, the
company needs to have much better financial liquidity and a credit standing
as huge project size involves higher borrowings. Since large projects require
higher working capital, in the absence of financial liquidity execution of large
projects per schedule becomes difficult task.






ABOUT COMPANY

WELSPUN GROUP

Welspun, currently a U.S $1.5 billion group is one of the fastest growing business conglomerates that truly represent an amalgamation of expertise resources, opportunities and engineering excellence. Welspun has a presence in 50 countries with a small textile unit, it has grown magnanimously, diversifying into various other business industries and region. Today it consist of six companies, each being a separate entity with distinct board structures and over18,000 employees contributing to its growth.


Global Leadership of Welspun
• Largest saw pipe company in Asia excluding Japan.
• Largest Terry Towel producer in Asia.
• Among top three Terry Towel producer in the world.
• 80-90% of the products are exported.
• Supplied pipes for the “deepest off shore pipeline project” in the gulf of mexico.
• Accreditations from over 40 oil & gas major’s globally.
• Largest speciality Retailer of home furnishing in India.












AWARD /ACCOLADES -2007

• “Fastest growing Steel Product Company” by Construction World NIMCAR
• Amongst the 20 companies to watch out for 2008 by Business Today.
• Amongst the top three Saw pipes companies in the world by CLSA Asia Pacific Markets.
• The “fastest growing company” by Business Today.
• Ranked among india’s top 100 corporates 2007 Standard and poor’s and CRISIL.
• “Outstanding Textile Exporter” at International trade Award by bCNBC TV 18.
• “Sustainability awards” by Wal- Mart Stores Inc., the world’s largest retailer and no.2 company as per “Fortune” 2006 list.



ABOUT ASSOCIATES



WELSPUN INDIA LIMITED (W.I.L)

Welspun India Limited, eastablished in 1985 is one of the oldest companies under the Welspun Umbrella.Over the years it emerged as the largest integrated manufacturer of the Terry Towel in asia and is currently among the top three companies globally. With the capacity nearly 40,000 metric tonnes per annum and manufacturing facilities at Vapi and Anjar, Gujarat W.I.L, also manufactures bedsheet sets. In June 2007, Welspun decided to put up a decorative bedding facility in Mexico with capacity to produce 1.04 million bed-sets per annum.

In July 2006, Welspun acquired 85% interest in CHT Holding company of UK’s leading towel branding Christy. Christy is world’s oldest towel manufacturer% sole supplier to the renowed Wimbeldon Tennis Champion Ships.

Currently Product Manufactured by W.I.L are:-
• Terry Towels
• Bed Sheet sets
• Decorative Bedding.



Welspun Retail Limited (WRL)

Welspun Retail Limited was established in 2006. WRL anticipated the boom in the retail segment and launched two brands – “SPACE” and “Welhome” to capture the Home textile market in India.

SPACE has carved a niche market with its fashion driven model in the country’s major metro’s, while Welhome targets a larger audience with its value for money model.

SPACE
Products can be classified as under
• Bed
• Bath
• Living & Dining

Welhome
Product can be classified as under
• Bed
• Bath
• Kitchen
• Living
• Dining
• Kids’ collection.



Welspun Syntax Limited

Established in 1982 Welspun Syntax Ltd (WSL).It is amongst the largest manufacturers and exporters of Polyester Texturised filament Yarn from India. It has capacity of 31400 metric tonnes in Polyester Yarns and 7200 metric tonnes plant for dyeing located at Silvasa and Thanne.

Products being manufactured are:-
• Polyester Texturised Filament Yarn



Welspun Power and Steel limited
Welspun Power and Steel was established in 2004, recognizing the enormous potential in the construction and infrastructure industry. With plant at Anjar, WPSL is well equipped to manufacture ingots, billet and ribbed Thermo Mechanically Treated (TMT) rebars which have the prestigious ISI Certification. It has also set up an 18 megawatt Power plant that utilizes waste heat from the steel furnaces.

Welspun Gujarat Stahl Rohren Limited (WGSRL)
WGSRL, established in 1995 is capable of manufacturing saw pipes from ½ an inch diameter to 100 inches of diameter, in varying qualities and grades, as high as X80. Today has its manufacturing facilities at Bharuch and Anjar in the state of Gujarat with a capacity of one million metric tonnes, it is well equipped with resources, expertise, equipment and technology leading to engineering excellence.

More recently, WGSRL has set up U.S $100 million facility to produce 300,000 net tonnes of pipe annually in the city of Little Rock, Arkansas, USA at a 740 acre site adjustment to the little Rock Port. In addition to the capacity of LSAW Pipes is being increased by 300,000 tons at the SEZ, Gujarat, India by March 2009.

CERTIFICATIONS
• ISO 9001 - By APIQR
• API 5L (Line Pipes)
• API 5CT (Casing)
• API 2B (Tubular)
• ISO/TS 29001
• ISI by Bureau of Indian Standards
• ISO 14001 by LRQA
• OHSAS 18001 by LRQA
• Six Sigma certificate.

W.G.S.R.L has taken up capacity expansion and de bottlenecking of H SAW (spiral) pipes at existing facility at Anjar, resulting in a capacity increase of 150,000 tons.
On completion of these projects, Welspun shall have an annual capacity of 1.75 million tons making Welspun one of the largest line pipe companies in the world.
At Anjar W.G.S.R.L established in





LOCATION:
WGSRL chose this place as location because of the following reasons
• Availability of labour:-
Here in kutch labour is available due to more population having lck of employement(during set up).because of less industries in this area. So unskilled labour was available also at lower rates.

• Tax free zone ;- It is one of the most important reasons to coose this location, because the tax saving makes the financial statement healthier.

• location allowing export and import to near and far countries;-
as kandla port nearer to this location it makes easy and cheaper for the
export of finished goods and import of raw material.
• Large domestic market allowing economies of scale:-
• Indegeneous availability of raw material.
• Nearer to supplier.
• Nearer to parent company facility.


DIFFERENT PRODUCTS - WGSRL:-
• LSAW
• HSAW
• ERW
• Coating









CUSTOMERS:-
Most international oil and gas companies recognize WGSRL as preferred supplies because of it stringent quality control process.
It is the only Indian company with approved to bid for pipeline contract floated by global majors such as chevron, british petroleum and transcanada.


Its Indian customers are:-
• GSPL
• GGCL
• Lone star (Bangladesh)
• Reliance
• GAIAL
• IOC
• Jay Somnath

MAJOR SUPPLIER:-
It is most important raw material is hot rolled coil
So major supplier for WGSRL are:-
• ESSAR Steel
• ISPAT Steel
• POSCO


COMPITITORS:-
Some of the competitor of WGSRL are.
• Jindal Steels
• MAN Industries
• PSL
• Ratnamani Metals and TubesROD



PRODUCTION STRATEGY:-
Strategy of production differs from company to company according to their competitive priorities and product.
Usually there are three strategies:-
• Make to stock strategies.
• Assemble to order strategies.
• Make to order strategies.

Here WGSRL uses make to order strategy. There is no standard product this strategy provide high degree of customization and typically uses project and job process.
Its product are produced according to customer specification. The process is complex, with high degree divergence.

As products are custom made its manufacturing facility is flexible to accommodate variety and different quality.















WGSRL Organization Structure (Anjar)
President















PRODUCTION PROCESS:
Production process broadly consists of four steps:
 Forming
 Welding
 Testing
 Coating


 FORMING:

1) Decoiling: It is the process in which the parent raw material – hot rolled coil is decoiled with the help of an electrical driver. The driver holds one end of the coil and pulls it outward, and then it pushes the coil forward or the rollers.
2) End cutting: After decoiling during its end are cut which is also known as end shearing process by shearing machine.
3) Coil joining: As forming of pipe is an continuous process.When the decoiling of our coil is over,then another is introduced for decoiling.So, the last end of previous coil and first end of the new coil are joined by welding. To make this welding proper end cutting is done in the above step.
4) Edge milling: The plates are the milled on longitudinal edges to get the required width and u shape for welding.also even coil width.
5) Pipe forming:
• JCO forming: The plate is often to a forming plate is formed into pipe. The first half of the plate is pressed fincet and tarcting from the end and then other half is pressed. So, an fincet ….
• Three roller bending: it occurs parallel to JCO press. In this plate is passed between three rollers to get the required pipe diameter.


• Continuous Tack Welding: The edges are tacked continuously by MIG comprising of filler wire and shielding of Ar-Co2 mixture. These tack welding is used to keep the coil in the pipe form or the pipe to not to open up. Later it is fully welded.
1) Plasma cutting: As pipes are continuously produced, pipe of desired length are cut by plasma cutting machine.

 WELDING:

a).Tab joining: Tabs are joined at the end of pipe ends to avoid welding defects at the ends.

b).There are two types of welding:
IDW:- Inner diameter Welding.
ODW:- Outer Diameter Welding.
For this German machine are used.
o IDW (Inner Diameter Welding): The pipe is welded by submerged arc welding process, comprising of filler, wire & flux. The welding is tracked and monitored on the TV screen at the control room.
o ODW (Outside Diameter Welding): The pipe is welded from outside by same process as in IDW. The welding is tracked by laser system which controls the alignment of the welding in a straight line.
Flux is used in welding because it:
 Maintains voltage.
 Maintains wire feed speed.
 Maintains welding travel speed.




c).Tab cutting: After welding the tab which was joined in the beginning is being cut.
d).Mechanical expansion: The pipes are subjected to cold expansion. To get desired diameter, out of roundness, straighten etc. This process also determines the strength of material as the pipe is expanded beyond its yield strength.
o End Beveling: The ends of the pipes are beveled to the required angle and root face. There is a set of tool of set holder which makes the bevel angle tool face and maintain square ness.
 TESTING AND INSPECTION:
Broadly there are three types of inspection:
• Visual inspection
• Mechanical test
• Non destructive testing
Though these process are carried out during the processes.after the production final testing is done.
• Visual inspection: 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 bike is weighted on a weighing machine.
• Mechanical Testing: Under this test only one test is carried out which is hydro testing. In this the whole pipe is allowed to float amidst the very high specified pressure of water for a specific time and this is recorded in the form of chart.
• Non destructive testing:
1) Final ultrasonic testing:-
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.



2) X-ray testing:
Each pipe is X-rayed 30 cms from both the ends to ensure that
weld is free from defects. X-ray are developed on films and used to
view weld quality, also to keep records.


3) Magnetic Particle Inspection:-
The bevel end of the pipe is magnetic particles inspected for
any lamination, cracks, etc on the surface of the pipe.


• COATING



































Reasons for Coating

1. To prevent it from rusting.
2. To protect it from heat.


External Coating

• After the pipe has been produced it goes to the coating plant as per the customer requirement for coating.
• First, the blow out session is conducted to remove dust particles from the blower. The dust is collected from dust collector.
• Quality check of micro dust or salt is done. If the content of it is more then 10-15micron then it is rejected.
• Aerometer is used for moisture check, if moisture is more then 80°C then it is heated.
• Sulfuric acid test is carried out.
• There after the pipe is washed with high pressure water. The pipe is then soaked with high pressure air.

• The blasting process is done by throwing small iron particles at high speed on pipe to make the pipe surface rough, so that the coating stuck on pipe easily and lasts for a longer period of time.

• The pipe is then heated at 230°C before coating in induction oven where the temperature is 1200kw.

• The coating of Epoxy powder is done on the outer surface of pipe by heating at 200°C so that it sticks on the pipe. The coating is about 120micron.

• Then the thermo plastic adhesive is stick on pipe to make one side polar and other non polar bond.

• Then the coating of Polypropylene is coated, which is 3 layer coating as per the customer requirements. The pipe temperature is 230°C, and then it is cooled by water and brought to 20°C.
• After coating the brushing of pipe from both sides is done so that it can be easily welded to make two pipes joint.

• The last step is quality check of checking any air pockets in the coating process; any metal particles are there it can be removed. Polypropylene melting test, condition test for 30 days test, pin hole test, bonding test, acid test for epoxy check.



Internal Coating
• Internal coating is done if it is demanded by customer.
• It is done by gun spray.













THIRD PARTY INSPECTION:-

Until now inspection process was done by W.G.S.R.L. only now again testing are done by third party, third party is the people who are inspecting are neither Welspun nor customer.
Mechanical and chemical testing
1. Tensile strength
2. Guided bend test
3. Hardness test
4. Drop weight tear test





flying








LAYOUTS:-
There are four types of layouts:-
• FLEXIBLE FLOW LAYOUTS
• LINE FLOW LAYOUTS
• HYBRID LAYOUTS
• FIXED POSITION LAYOUTS

In W.G.S.R.L. the layout is line flow layout i.e. A layout in which work stations are arranged in liver batch.
In these the product moves along in a smooth, continuous flow.
This layout is often called as production line.




Production planning and control

First marketing department confirm order from the costomer then specification from customer passed to ppc dept.. PPC Dept. follows different steps to complete the task.
























After getting approved from QA, PPC Dept. allow to operation dept. for sampling. If samples fulfill requirement of customers specifications (like physical dimensions and quality parameters)then go bulk production. If sample is not ok than go for revision.


Preparation of monthly production plan:
Before going for production HOD of operation check raw materials and PPC check the available order in hand. Than PPC Dept. priority is given to the customer as specified by marketing dept. and also keep in mind expected order provided by marketing Dept.
PPC Dept. then go for
Raw material planning
Machine planning
Shipment planning

Raw material planning:-
1) R.M dispatch schedule from central process department.
2) Confirmation ofdispatch.
3) Coils from port
4) Receipt of coils at plant from store

Machine planning:-
1) Keeping in mind of the capacity of machine planned accordingly.
2) Strategic planning of machine with production Dept.

Shipment planning:-
1) Requirement of container date wise
2) Planning of loading at plant and unloading at port.





Procurement process:
In procurement process first step is supplier assessment. In this first list of approved vendors are prepared on past records performance and if and
new vendors are selected on the approval of HODs (Purchase and Marketing).
After assessment of capabilities a trial order is placed. If company get satisfied with the trial order they place order with them other wise reject the supplier.
In this initial thing is placement of purchase order.









INVENTORY
Type of inventory is
1) Cycle inventory
2) Safety inventory
3) Anticipation inventory
4) Pipe line inventory

Though these inventories are difficult to recognize but in these has been classified because this helps in finding where inventory is more and to maintain inventory in such a way that it can minimize inventory cost.
INVENTORY CONTROL SYSTEM
Inventory control system employed by W.G.S.R.L is periodic review system i.e. fixed interval recorder system. Here review period for the W.G.S.R.L is 30 days.
For example. For the month of May company review the inventory and places order in April. After placing order it is received in three parts i.e. first on 10th May, second on 20th May while last will be received 30th May. Every time order received is 1/3rd of the order placed. Also order is placed in amount – required raw material + 2% of required material.
This is done for safety from any lose of raw material in any form.

REASONS FOR ADOPTING ‘P’ SYSTEM:
1) No constrain on lot size as order are all ready booked.
2) There is no uncertainty in demand.




MAINTAINANCE
Broadly classifying, two maintenance techniques are used:
a). Break down maintenance
b). Preventive maintenance




In Preventive maintenance technique again there are two techniques used:
1). Periodic Maintenance
2). Predictive Maintenance

a).Break down Maintenance:-
When any machine stops working or creates problem than break down maintenance is done to restart the machine or to make it in proper working condition.

b). Preventive Maintenance:-

1). Periodic Maintenance:-
To prevent break down which cause a lot of losses( stop production, loss of time and many).An periodic maintenance occurs which is done after every 15 days.

2). Predictive Maintenance:-
It is based on the experience of the people on the shop floor. Usually when machine is about to break down or improper functioning it starts giving some signals like change in sound and so on, which are easily detected by there experienced people.





QC & QA:
All quality control and quality assurance procedures are followed at the
W.G.S.R.L.

QUALITY PROCEDURE:
1) Handling of H.R Coils: All incoming Raw material coils are handled by ‘C’ hook for handling and storing. From storage to mill the coils are lifted by 30 Ton crane.
2) Handling of pipe inside the plant:- Handling inside the plant is carried out by combination of following methods
o Rolling of the pipes on the level beds and racks.
o V- roller conveyers with rubberized surface to prevent scratch.
o By cranes.
3) As per the specifications of the customer testing are done at the
different places.
4) The pipes are stored in rust and dust free to protect deterioration.
5) Finished goods are stacked in stand for storage.

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