Embed Size (px)
Citation preview
LINE PIPE PRODUCT CATALOGUE
Borusan Group At a Glance
Borusan Mannesmann
Production Flow
Production Range
Production Standards
Advantages of Spirally Welded Pipes
The Submerged Arc Welding Process
Yield and Tensile Requirements for API - Grades for Sweet & Sour Services
Protective OD & ID Coating Systems
Pipe Joint Systems
QEHS Management
Integrated Logistics Experiences
Operational Highlights
References
1
3
5
7
9
10
11
13
15
22
23
28
29
35
Contents
1
Borusan Group At a Glance
In 4 major businesswith
Borusan
Borusan Group has been among the pioneers of industrialization and corporate governance in Turkeythroughout its 65 years of history. The group currently operates in four major business areas includingsteel, distributorship, logistics and energy.
In 2006 Borusan Group signed the United Nations’ Global Compact Policy and it supports and adheresby the principles of “good corporate governance” and “sustainability” as a prerequisite of long-term andpermanent components of success.
Steel
The PipeGroup
The Flat SteelGroup
Borusan Mannesmann
Borusan PaslanmazÇelik Boru ve Profil(Stainless Steel Pipeand Profile Production)
Borusan Mühendislik(Engineering)
Borusan ‹stikbal Ticaret
Borçelik
Kerim Çelik
Distributorship
The Earth MovingEquipments andPower Systems Group
The AutomotiveGroup
Borusan Makina veGüç Sistemleri
Borusan Otomotiv&Borusan Oto
Supsan
Manheim Turkey
Contribution to Community:Borusan has adopted as one of its primary principles the concept of giving back to the community withwhich it does business. In order to better fulfill its social responsibility vision, the activities of the As›mKocab›y›k Culture and Education Foundation, which was founded in 1992, and Borusan Culture and Arts,established in 1997, came together under one roof in 2008 to become the Borusan Kocab›y›k Foundation.With a deep social responsibility consciousness, the Borusan Group established the Borusan Center forCulture & Arts on October 15, 1997. The Borusan Center for Culture and Arts is a member of theInternational Society of Contemporary Music (ISCM) and the European Music Council (EMC) and organizesthe annual Mediterranean Contemporary Music Days. It pursues its music activities through its prominentBorusan Istanbul Philharmonic Orchestra, the Borusan Chamber Orchestra, the Borusan String Quartetand the Borusan Children’s Choir, as well as its Music Library.
Logistics
Borusan Lojistik
Energy
Borusan Enerji
areas5.000 employees...
2
Borusan Mannesmann
Borusan Mannesmann BoruYat›r›m Holding
77% 23%
73%
Free Float16%
Others11%
Borusan Mannesmann; the flagship of Borusan Group, operateswith five mills, four in Turkey and one in Italy with a total annualproduction capacity of 925.000 tons. We produce our spiral welded(SAWH) and longitudinal welded (ERW) products using the latestproduction techniques.
As the leader of Turkish steel pipe market, Borusan Mannesmannowes this outstanding position to its 50 years of corporate structureexperience, continuous development and customer orientedapproach. Especially in line pipe business, Borusan Mannesmannhas an established reputation in providing an extraordinary levelof quality, reliability and commitment in its products and services.We have a track record which has a wide range in oil and gaspipeline applications both in Turkey and International markets withhigh grade API standards. Our SAWH line pipes (dia.14"-100") arenot only used for gas, oil and water transmission but also for pilingapplications.
Giving priority to product quality and qualified work force in ourgrowth strategies, we aim to meet customized expectations of ourcustomers throughout the world. Our Pipeline Projects ManagementTeam, specialized in providing total solutions to its customers inpipe supply contracts that includes manufacturing processes,contract management, production and integrated logistics servicesworldwide.
Corporate Structure:
Borusan Group and one of Europe's leading steel and technologycompanies; Salzgitter Mannesmann GMBH, merged their weldedsteel pipe investments in Turkey and named that partnership;“Borusan Mannesmann Boru Yat›r›m Holding” in 1998. The companyhas 77% shares of Borusan Mannesmann Boru San. ve Tic. A.fi.
Celebrated 50th anniversary in 2008...
3
U.S
CANADA
UNITED STATES
4
“Our mission is to provide products and services thatenhance the quality of life with our expertise in steelpipe industry and to promote the process of economicand social progress of our community...”
Location of Borusan Mannesmann Mills
Halkalı PlantGebze Plantİzmit PlantGemlik Plant
Vobarno Plant
TURKEY
50% of productiongoing overseas...
Workforce of 1.250committed people...
ISRAEL
DENMARK
NETH.
BELGIUM
CYPRUS
CUBA
LEB.
PORTUGAL
SERBIA
SWITZ.
IRELAND
UNITEDKINGDOM
ITALY BULGARI
AZERBAIJAN
GEORGIA
TUNISIA
SLOVAKIA
CZECHREP.
AUSTRIA
GREECE
ALB.
BOS.&HERZ
SLOVENIACROATIA
EST.
LAT.
LITH.
REUNION
QUEEN ELIZABETHISLANDS
ICELAND
FINLANDSWEDEN
POLAND
GAMBIASENEGAL
SICILY
FRENCHGUIANA
ROMANIAFRANCE
SPAIN
ALGERIALIBYA
EGYPT
TANZANIA
ANGOLA
SOUTHAFRICA
CONGO
QATAR
GABON
CAMEROON
SAUDIARABIA
YEMEN
OMAN
IRANIRAQ
UZBEKISTAN
KAZAKHSTAN
SYRIA
JORDAN
GERMANY
NORWAY
UKRAINE
BELARUS
HUNGARY
PAKISTAN
U.A.E
5
Beveling ofPipe Ends
Hidrostatic Test
X-Ray Inspection
Offline UltrasonicInspection Final Inspection
and Marking Stockpiling
Inside Welding
Cutting to Length
Ultrasonic Test
Outside Welding
Spiral Forming
Edge Preparing
UncoilingCoil Identityand Analysis
Production Flow
SAWH Pipe Production - Helical Submerged Arc Welded Pipe
Beveling ofPipe Ends
Hidrostatic Test
Final Inspectionand Marking
Cutting to Length
Ultrasonic Test
Welding
Forming
Edge Preparing
Uncoiling
Coil Identityand Analysis
Ultrasonic Test
Quenching
Post-Annealer
Sizing and Straightening
Beat Cutting(inner/outer)
Preforming
6
ERW Pipe Production - Electric Resistance Welded Pipe
Stockpiling
7
Production Range - SAWH Line Pipes11
355.
6
406.
4
457.
2
508
559
610
660
711.
2
762
812.
8
863.
6
914
965.
2
1016
1067
1118
1168
1219
1321
1372
1422
1524
1626
1676
1727
1829
2032
2083
2235
2540
34.7
39.7
44.7
49.7
54.7
59.8
64.7
69.8
Wal
l Thi
ckne
ss (m
m &
inch
)
45
67
89
4.5
5.5
1012
1314
1517
1618
1920
2221
23
0.15
70.
197
0.23
60.
276
0.31
50.
354
0.39
40.
433
0.47
20.
512
0.55
10.
663
0.59
10.
630
0.70
90.
748
0.78
70.
827
0.86
60.
906
mm
mm
inch
OD
24
0.94
5
25
1.00
00.
177
0.21
739
.0
44.6
50.2
55.9
61.5
67.2
72.7
78.4
43.2
49.5
55.8
62.0
68.3
74.6
80.8
87.1
93.3
99.6
105.
9
112.
1
47.5
54.4
61.3
68.3
75.1
82.0
88.8
95.7
102.
6
109.
5
116.
4
123.
2
130.
2
137.
1
51.7
59.2
66.8
74.3
81.8
89.4
96.8
104.
3
111.
9
119.
4
126.
9
134.
3
141.
9
149.
4
157.
0
164.
5
171.
9
60.2
68.9
77.7
86.5
95.3
104.
1
112.
7
121.
6
130.
3
139.
1
147.
9
156.
6
165.
4
174.
2
183.
0
191.
8
200.
4
209.
2
226.
8
235.
6
68.6
78.6
88.6
98.6
108.
7
118.
8
128.
6
138.
7
148.
7
158.
8
168.
8
178.
7
188.
8
198.
9
208.
9
219.
0
228.
8
238.
9
259.
0
269.
1
279.
0
299.
1
319.
2
76.9
2
88.2
99.5
110.
7
122.
1
133.
4
144.
5
155.
8
167.
1
178.
4
189.
7
200.
9
212.
2
223.
5
234.
8
246.
1
257.
2
268.
5
291.
2
302.
5
313.
6
336.
2
358.
9
370.
0
85.2
97.8
110.
3
122.
8
135.
4
148.
0
160.
3
172.
9
185.
4
198.
0
210.
5
222.
9
235.
6
248.
1
260.
7
273.
2
285.
6
298.
1
323.
3
335.
9
348.
2
373.
4
398.
5
410.
8
423.
4
93.5
107.
3
121.
0
134.
8
148.
7
162.
5
176.
0
189.
9
203.
7
217.
5
231.
3
244.
9
258.
8
272.
6
286.
5
300.
3
313.
8
327.
7
355.
4
369.
2
382.
7
410.
4
438.
1
451.
6
465.
5
493.
2
548.
2
562.
1
116.
7
131.
7
146.
8
161.
9
177.
0
191.
8
206.
9
221.
9
237.
0
252.
0
266.
9
282.
1
297.
1
312.
2
327.
3
342.
1
357.
2
387.
4
402.
5
417.
2
447.
4
477.
6
492.
4
507.
5
537.
7
597.
8
612.
9
657.
8
126.
1
142.
4
158.
7
175.
0
191.
4
207.
4
223.
8
240.
1
256.
4
272.
7
288.
8
305.
3
321.
5
337.
9
354.
2
370.
3
386.
6
419.
3
435.
7
451.
7
484.
4
517.
1
533.
1
549.
5
582.
2
647.
3
663.
6
712.
3
810.
1
135.
5
153.
0
170.
5
188.
2
205.
8
223.
0
240.
7
258.
2
275.
8
293.
3
310.
7
328.
4
345.
9
363.
5
381.
1
398.
4
416.
0
451.
2
468.
8
486.
1
521.
3
556.
5
573.
8
591.
4
626.
6
696.
7
714.
3
766.
8
872.
1
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 52 54 56 60 64 66 68 72 80 82 88 100
182.
4
201.
2
220.
1
238.
6
257.
5
276.
3
295.
1
313.
9
332.
5
351.
5
370.
3
389.
1
408.
0
426.
5
445.
4
483.
1
502.
0
520.
4
558.
2
595.
9
614.
4
633.
3
671.
0
746.
1
765.
0
821.
2
934.
0
194.
1
214.
2
234.
4
254.
1
274.
3
294.
3
314.
4
334.
4
354.
3
374.
5
394.
6
414.
7
434.
8
454.
5
474.
7
514.
9
535.
0
554.
8
595.
0
635.
2
655.
0
675.
1
715.
3
795.
4
815.
6
875.
5
995.
9
248.
6
269.
6
291.
0
312.
3
333.
6
354.
9
376.
0
397.
5
418.
8
440.
2
461.
6
482.
5
503.
9
546.
7
568.
0
589.
0
631.
8
674.
5
695.
5
716.
9
759.
6
844.
7
866.
1
929.
8
1057
.7
262.
8
285.
0
307.
7
330.
2
352.
8
375.
3
397.
7
420.
4
443.
0
465.
6
488.
3
510.
5
533.
1
578.
4
601.
0
623.
2
668.
5
713.
8
736.
0
758.
6
803.
9
894.
0
916.
6
984.
1
1119
.5
324.
3
348.
1
371.
9
395.
7
419.
3
443.
3
467.
1
491.
0
514.
9
538.
4
562.
2
610.
0
633.
9
657.
4
705.
2
752.
9
776.
4
800.
3
848.
1
943.
2
967.
1
1038
.3
1181
.2
340.
9
366.
0
391.
0
416.
1
440.
9
466.
2
491.
2
516.
4
541.
5
566.
2
591.
3
641.
7
666.
8
691.
5
741.
8
792.
1
816.
7
841.
9
892.
2
992.
3
1017
.5
1092
.4
1242
.9
410.
0
436.
3
462.
4
489.
0
515.
3
541.
7
568.
1
594.
0
620.
4
673.
2
699.
6
725.
5
778.
3
831.
2
857.
1
883.
5
936.
3
1041
.4
1067
.8
1146
.5
1304
.5
483.
9
511.
7
539.
3
566.
9
594.
6
621.
7
649.
4
704.
7
732.
4
759.
5
814.
9
870.
2
897.
3
925.
0
980.
3
1090
.5
1118
.1
1200
.6
1366
.1
534.
4
563.
2
592.
1
621.
1
649.
4
678.
3
736.
2
765.
1
793.
5
851.
3
909.
2
937.
5
966.
5
1024
.3
1139
.5
1168
.4
1254
.6
1427
.6
587.
11
617.
29
647.
47
677.
06
707.
25
767.
62
797.
8
827.
4
887.
8
948.
1
977.
7
1007
.9
1068
.3
1188
.4
1218
.6
1308
.6
1489
.1
861.
3
924.
1
987.
0
1017
.8
1049
.3
1112
.2
1237
.3
1268
.8
1362
.5
1550
.5
X 42
X 52
X 60
X 65
X 70
X 80
8
Production Range - ERW Line Pipes
5.2
21.3
26.9
33.7
42.4
48.3
60.3
73 88.9
114.
3
141.
3
168.
3
219.
1
273
323.
9
2.8
3.4
3.68
3.7
3.9
4.5
2.9
3.56
5.1
66.
67
7.1
8.4
8.1
8.6
9.3
9.5
1211
0.10
90.
133
0.14
50.
147
0.15
40.
179
0.20
00.
203
0.23
70.
258
0.27
70.
331
0.28
00.
318
0.33
70.
365
0.37
50.
432
0.47
2m
m
mm
inch
OD
1/2
3/4
1 1 1
/4
1 1
/2
2 3
/8
2 7
/8
3 1
/2
4 1
/2
5 9
/16
6 5
/8
8 5
/8
10 3
/4
12 3
/4
0.11
30.
140
1.28
1.66
2.13
2.73
3.14
3.97
4.85
1.32
1.72
2.20
2.82
3.25
4.10
5.01
6.15
7.97
1.50
1.97
2.54
3.27
3.76
4.77
5.84
7.17
9.30
11.5
6
1.56
2.05
2.65
3.41
3.93
4.98
6.10
7.49
9.72
12.0
9
1.60
2.11
2.72
3.51
4.05
5.14
6.29
7.73
10.0
4
12.4
9
14.9
4
19.5
5
1.61
2.12
2.74
3.53
4.07
5.16
6.32
7.77
10.0
9
12.5
5
15.0
2
19.6
5
1.67
2.21
2.87
3.70
4.27
5.42
6.65
8.17
10.6
2
13.2
1
15.8
1
20.7
0
25.8
8
2.49
3.24
4.21
4.86
6.19
7.60
9.37
12.1
8
15.1
8
18.1
8
23.8
1
29.8
0
35.4
4
3.60
4.69
5.43
6.94
8.54
10.5
4
13.7
3
17.1
3
20.5
3
26.9
1
33.6
9
40.0
9
4.77
5.53
7.07
8.69
10.7
3
13.9
9
17.4
5
20.9
1
27.4
3
34.3
4
40.8
7
9.91
12.2
7
16.0
2
20.0
2
24.0
1
31.5
3
39.5
1
47.0
4
17.5
3
21.9
2
26.3
2
34.5
9
43.3
6
51.6
4
18.5
2
23.1
8
27.8
4
36.6
1
45.9
2
54.7
0
18.7
7
23.5
0
28.2
2
37.1
2
46.5
6
55.4
7
21.2
1
26.6
1
32.0
0
42.1
5
52.9
1
63.0
8
21.9
4
27.5
3
33.1
2
43.6
5
54.8
1
65.3
5
22.4
2
28.1
4
33.8
7
44.6
4
56.0
7
66.8
7
24.0
8
30.2
7
36.4
6
48.1
2
60.4
8
72.1
5
30.8
8
37.2
0
49.1
0
61.7
3
73.6
5
35.3
5
42.6
7
56.4
5
71.0
7
84.8
8
46.2
5
61.2
9
77.2
4
92.3
0
Wal
l Thi
ckne
ss (m
m &
inch
)
12.5
0.49
2
48.0
3
63.6
8
80.3
0
95.9
9
X 52
X 60
X 65
X 70
We
can
mee
t all
X 42
req
uire
men
ts in
our
pro
duct
ion
rang
e.
9
Petroleum and Gas Line PipesAPI 5L/ISO 3183 : Requirements of PSL 1 & PSL 2
Annex G : Resistance to ductile fracture propagationAnnex H : For Sour Service
EN 10208 : Requirements of Part 1 & Part 2GOST 20295 : Requirements of Type 1, 2 and 3.
Water Line PipesWith protective OD and/or ID coating, plain (beveled) or sleeve welded joints.EN 10217-1 : SAWH & ERWEN 10224 : SAWH & ERWAWWA C 200 : SAWH & ERWBS 534 : SAWH & ERW
General Purpose PipesEN 10217-3 : SAWH - Alloy, fine grain Service condition: max 400°C, min -50°CEN 10217-5 : SAWH - Alloy or non-alloy,
Service condition: max 400°C,EN 10217-6 : SAWH - Non-alloy,
Service condition: - 40°CASTM A139 : SAWH
Piling & Construction PipesASTM A 252 : SAWHEN 10219 : SAWH & ERWEN 10210 : SAWH & ERW
Pipe Lengths: any desired lengths between 6 - 18 m
These are our general production standards and specifications.We can meet other production standards and specifications upon request.
Production Standards
10
Advantages of Spirally Welded Pipes
Spirally welded pipes have been used all over the world for high-pressure gas and oil pipelineprojects (including USA, Canada, Europe etc.) which have proven their high quality as high strengthsteel line pipes.
- Hot rolled coil is used as base material for the production of spirally welded pipes instead ofplates. As a result the continuous process coming from HRC usage provides flexibility (diameterand length) of production.
- The mechanical properties are already present in the base material. Since any cold expansionreduces the material's ductility, the spirally welded pipe has a higher safety margin than coldexpanded pipes.
- Spirally welded pipes have more integrity structure wise. Test results on fracture propagationprove this fact.
- When carrying out field cold-bending, it is not necessary to take the weld seam position into account.
- There is a favorable orientation of the weld seam and of the strip's direction of rolling relativeto the direction of principal stress.
11
The Submerged Arc Welding Process
The principle of the spiral pipe production is simply bending the steel strip spirally into cylindricalpipe shape and ultimately welding edges together. The occurrence of weld seam step by stepcan be seen in the figure displayed on page 12.
The submerged arc welding (SAWH) process is widely used for welding thick sections, yet it canbe applied to plate sections as thin as approximately 4 mm.
In spirally welded pipe production process, very impressive capabilities can be achieved for highrates of travel by using multiple electrodes in two-run technique. The high currents, obtained bymultiple electrodes, generate considerable heat which leads to deep penetration of the base metal.In Borusan Mannesmann, remarkable control is always exercised over the contour of the depositand extent of the penetration into the base metal. Both of these factors have important effecton the chemical composition and metallurgical properties of the weld metal.
12
AC IDC
AC IIDCAC I
13
Yield and Tensile Requirements for API-Grades for Sweet & Sour Services
API 5L/ISO 3183
Yield Strength (Mpa) Tensile Strength (Mpa)
A25
A
B
X42
X46
X52
X56
X60
X65
X70
-
-
245
290
320
360
390
415
450
485
555
-
-
450
495
525
530
545
565
600
635
705
-
-
415
415
435
460
490
520
435
570
625
-
-
760
760
760
760
760
760
760
760
825
Correspodence to
-
-
L245NB
L290NB
-
L360NB
-
L415NB
L450NB
L485NB
L555NB
EN 10208-1
-
L210GA
L245GA
L290GA
-
L360GA
-
-
-
-
-
EN 10208-2
-
-
L245MB
L290MB
-
L360MB
-
L415MB
L450MB
L485MB
L555MB
Grade
Yield Strength Tensile Strength
Mpa (%) Correspondanceto API
Min Max Min Max Max Min
L210GA
L235GA
L245GA
L290GA
L360GA
210
235
245
290
360
-
-
-
-
-
335
370
414
415
460
475
510
555
555
620
-
-
-
-
-
25
23
22
21
20
A
-
B
X42
X52
Rt0.5/Rm Elongation
EN 10208-1
EN 10208-2
Grade
Yield Strength Tensile Strength
Mpa (%) Correspondanceto API
Min Max Min Max Max Min
L245NB
L290NB
L360NB
L415NB
L245MB
L290MB
L360 MB
L415MB
L450MB
L485MB
L555MB
245
290
360
415
245
290
360
415
450
485
555
440
440
510
565
440
440
510
565
570
605
675
415
415
460
520
415
415
460
520
535
570
625
-
-
-
-
-
-
-
-
-
-
-
0.80
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.87
0.90
0.90
22
21
20
18
22
21
20
18
18
18
18
B
X42
X52
X60
B
X42
X52
X60
X65
X70
X75
Rt0.5/Rm ElongationSteelClass
Non-Alloy
Special-Alloy
Non-Alloy
AlloySpecialSteel
Thermo -mechanically
rolled
Normalizedor
normalizingrolled
HeatTreatmentconditions
PSL 1 PSL 2
Min Max Min Max
PSL 1 PSL 2
Min Max
175
210
245
290
320
360
390
415
450
485
-
Min MaxPSL 1 PSL 2
-
-
BN/S
X42N/M/S
X46N/M/S
X52N/M/S
X56N/M/S
X60N/M/S
X65M/S
X70M/S
X80M/S
310
335
415
415
435
460
490
520
435
570
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
14
Baku - Tbilisi - Ceyhan Oil Pipeline42" - 194 KmExcellence in Sour Service
15
Protective OD & ID Coating Systems
Maximum Operating Temperature of Coating
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
HDPE
PP NORMAL
FBE DRY CONDITION
FBE WET CONDITION
PP SPECIAL
MDPE
LDPE
Temperature (0C)
Borusan Mannesmann offers wide range of anti-corrosive and protective OD & ID coatings in itsfully integrated coating facilities. The below table illustrates the type of coatings applied externally andinternally according to standards and special customer requirements.
OD (Outer Diameter): External CoatingID (Inner Diameter): Internal Coating
Type of Coating
FBE
Epoxy (liquid)
Polyethylene (PE)
Polypropylene (PP)
Cement Mortar
Gas & Oil Line Pipe
General Application AreaOD ID
Water Line Pipe
Other OD&ID coating processes can also be designed for each specific application i.e. PU, Coal tar,Bitumen, Glass reinforced epoxy etc. which all above processes are within Borusan Mannesmann’sbroad experience.
16
General Application Standards
FBE (Fusion Bonded Epoxy) OD Coating: Fusion bonded powder epoxy coating provides highprotection of gas and oil pipe lines.(API 5L7, CSA Z 245-20, NACE RP 0394, AWWA C213)
Polyethylene OD Coating: Excellent protection of buried line pipes. High mechanical strength andcorrosion resistance are achieved by 3-layer coating method.(DIN 30670, TS 5139, NF A 49-710, UNI 9099)
Polypropylene OD Coating: Excellent protection of buried line pipes. High mechanical strengthand corrosion resistance are achieved by 3-layer coating method.(DIN 30678, NF A 49-711)
Flow Efficiency ID Coating: For gas transmission lines, flow-coat ID epoxy coating is applied inorder to reduce pipe wall roughness thus increasing throughput.(API RP 5L2)
Epoxy OD & ID Coating: Various epoxy coatings applied externally or internally are enablinghygienic inner surface for potable water transportation and outer surface to resist soil or sea watercorrosion. Coating thickness is up to 1000 μm.(AWWA C 210, TS EN 10289)
Cement Mortar ID Coating: Specifically for potable water pipe lines cement mortar ID coatingprovides hygienic and excellent corrosion resistance and protection. On demand regular cementmortar ID coating or synthetic dispersion added special cement mortar ID coating can be applied.(AWWA C 205, DIN 2614, BS 534, TS 8590)
17
Protective OD & ID Coating Systems
FBE OD coating consists of the following steps;• Surface preparation and cleaning
- Solvent/detergent washing (if necessary)- Blasting (anchor pattern profile)- Phosphoric acid washing and rinsing
• Induction heating• Electrostatical application of powder epoxy• Quenching• Test and inspection
Applied Standards: API 5L7, CSA Z 245-20, NACE RP 0394, AWWA C213
Drying
Blast CleaningInductionHeating
FBEApplication
Quenching HolidayTest
InductionHeating
AcidWashing
andRinsing
FBE (Fusion Bonded Epoxy) OD Coating for Gas and Oil Pipelines
18
Protective OD & ID Coating Systems
Drying
Blast Cleaning
InductionHeating
Epoxy Primer
QuenchingHoliday
Test
Pipe endPreparation
Wrapping ofAdhesive Wrapping of
PE/PP
For 3-layer PE/PP OD coating, at first pipe surface is cleaned by shot blasting in accordance withcustomer specs and then preheated to the desired temperature by using induction heating system.Following preheating, epoxy primer is applied to the pipe surface. Just after epoxy primer application,the extruded adhesive and PE/PP are coated to the pipe using wrapping method. Finally the pipeis cooled with water.
3 - layer PE/PP OD coating consists of;1. layer: Electrostatical application of epoxy primer2. layer: Extruded adhesive wrapping3. layer: Extruded wrapping (PE, PP, LDPE, MDPE, HDPE).
Applied Standards: DIN 30670, TS 5139, NF A 49-710, UNI 9099
Polyethylene / Polypropylene OD Coating
19
Protective OD & ID Coating Systems
Pipes for gas and oil transmission pipe lines are internally coated with epoxy resin:
• To reduce pipe ID roughness thus increasing throughput.• To reduce corrosion product deposits by considerable amounts.
Applied Standards: API RP 5L2
Flow Efficiency ID Coating for Gas & Oil Line Pipes(Flow - Coat Epoxy)
Solvent Free Epoxy Coating (ID)
Various epoxy coatings applied internally are enabling hygienic inner surface for potable watertransportation and outer surface to resist soil or sea water corrosion. Coating thickness is up to1000 μm.
Applied Standards: AWWA C 210, TS EN 10289
Cement mortar coating features permanent corrosion protection for handling potable water.
Applied Standards: AWWA C 205, DIN 2614, BS 534, TS 8590
Cement Mortar ID Coating for Water Line Pipes
OD Coating Main Application Parameters
Contaminants
Pipe surface temperature
Ambient condition
Free from Oil and gress
Metal surface temperature min30C above atmospheric dew point
Relative humidity less than 85%Pre
-pre
par
atio
n
Tested / Inspected parameter Desired minimum Quality criteria
Sur
face
pre
par
atio
n
Processes
Surface profile
Surface cleaning degree
Salt contamination
Dust contamination
Surface condition
Phosphoric acid washing
50-100 μm
Min. Sa 2 1/2 degreeacc. to standards SIS 55900or ISO 8501-1
Max. 3 μgr/cm2
ISO 8502-3 max rating 2-2
Free from material surface defects
Concentration: 5 - 20 %PH: 1-2
Hea
ting
fo
rco
atin
g Temperature Recommendation of epoxymanufacturer
Ap
plic
atio
n o
f co
atin
g
Epoxy thickness
Adhesive thickness
Total thickness of Coating
Coating Performance
Coating thickness
Coating Performance
80-150 μm
150-250 μm
Acc. to customer requirementsPeeling test: min.150 N/cmCathodic disbonding: max 3,0 mm(400C, 7 days, -1,5V)
Acc. to customer requirements(min 300 μm)
CD: avg 2,0 mm (660C, 48 hr, -3 V)Cross section porosity: ≤ Rating 5 (Rating 1-10)Flexibility: - 300C, 2.50 ODHot water soak : Rating 1 (Rating 1-3)
ODCoating
type
PE
PP
FBE
PE
PP
FBE
PEPPFBE
FBE
PEPP
20
21
22
Pipe Joint Systems
f
NW
av
NW
do dod1
d2
a
a SS
l
Spherical endButt WeldJoint Preparation
30˚ (+5˚/-0˚)
1,6 mm ± 0,8mm
Cylindrical end
Rubber Ring
PE
S
b
D
Y
D1
Cement
f
a a
t
ZAP-LOK®
3020
2526
24 2129
2822
31 32
27
*Double Joint Operation
* For high pressure gas & oil pipelines up to 12”* For water pipelines
* For all types of applications* For water pipelines
Other types of joints may be available upon request.
23
QEHS Management
Borusan Group companies all share a common set of guiding principles, which help this vastenterprise to operate in complete harmony. These principles are commitments to productivity,innovation and environmental responsibility.
From raw material to finished product, Borusan Mannesmann determines the impacts on environmentand in order to reduce impacts, controls each step of the process. Our Environmental ManagementSystem certificate (ISO 14001) proves our commitment to environment.
Healthy performance is delivered through healthy people. In compliance with Occupational Healthand Safety Management Standard (OHSAS 18001) Borusan Mannesmann endeavors to protecthealth and safety of its work force and service providers.
Borusan Mannesmann; exemplary with its modern management approach as well as its investments,has been applying The Lean Six Sigma methodology since 2002 and Voice of Customer (VOC)process since 2003.
The Lean Six Sigma methodology is a highly disciplined business management strategy that seeksto remove the causes of defects in production and business processes, and to continuouslyimprove productivity, profitability and customer satisfaction. Besides with the VOC process, wecapture the requirements and feedback from our customers to provide the best product andservice quality.
Ongoing efforts to improve customer satisfaction brought Borusan Mannesmann, ComplaintsHandling Management Systems Certificate (ISO 10002); which is a first in steel pipe sector globally.
24
Quality
Almost every major Energy, Oil and Gas company along with some of the biggest EPC’s in USA,Canada and Europe have approved our quality and listed us among their valuable supplier lists.
Ongoing research and development activities are aimed at further improving product and servicequality and increasing the product range through use of technology along with original and morecost effective marketing techniques. A dynamic, highly qualified staff, regularly trained to keepabreast of new production methods, ensures that production conform to exacting quality standards.(API Q1, ISO 9001, ISO 29001)
25
Quality
The feasibility and operational safety of a pipeline project are predominantly governed by the quality of theline pipe. The table given below contains the most important quality characteristics and examinationdetermination methods. These are the methods we are using to meet our clients most stringent requirements.
DiameterWall thicknessLengthOut of roundnessStraightness
HeightWidthOff-setAnglePenetrationMisalignment
Grain sizeInclusions
Structure
Yield strenghtTensile strenghtElongation
Tensile strength
Notch impact energyFracture PropertiesHardness
Notch impact energyHardnessFracture Properties
Individual elementsCarbon equivalent
Max. Permissiblesurface defects
Max. Permissiblelamination/separation
Max. PermissibleInclusion
Weld defects
Tape measurement circumference,Caliper, Ultrasonic measurement,Tape measurementCaliper, GaugeCord and range measurement
Macrographic examination
Macrographic examination
Macrographic examination
Tensile testRing Expansion Test
Tensile test
Charpy impact testDWT-testHV-Hardness measurement
Charpy impact testHV-Hardness testCTOD, SENB
Spectrometric chemical analysisFormula
Visual examination,Ultrasonic testing,Dye-penetrant testingMagnetic particle testing
Ultrasonic testing
Ultrasonic testing
Ultrasonic testingX-ray testing (radiascopic method)Hydrostatic pressure testing
Pipe body
Weld
Pipe body
WeldHAZ
Pipe body
Weld
Pipe body
Weld
Pipe body
Inside &Outsidepipe body
Pipe body
HAZ
Weld
Pip
e G
eom
etry
Str
eng
thP
rop
ertie
sT
oug
hnes
sP
rop
ertie
sC
hem
ical
Co
mp
osi
tion
Fre
e fr
om
def
ects
Ho
mo
gen
eity
Sur
face
Quality Characteristics Examination / Determination by
Met
allu
r-g
ical
Str
ruct
ure
26
Quality
Quality Characteristics Examination / Determination by
Acceptable Dust degree
Acceptable Salt degree
Profile depth & shapeNear white surface
Free of material defects
Dustcontamination
Saltcontamination
Surface profileSurfacecleanliness
Surface defects
Sur
face
Qua
lity
Co
atin
g m
ater
ial
per
form
ance
Fre
e fr
om
def
ects
Ho
mo
gen
eity
Sur
face
Env
iro
nmen
t c
ond
itio
n Dew point temperatureRelative humidity
Condition ofcoating plant
Thermal characteristicsof epoxy
Physical properties
Elasticity
Aging
Grain sizeOrganic contaminants
FBE
PE, PP
Cement mortar
Surface defectsOD & ID Coating
FBE OD Coating
PE, PP Coating
Cement mortar
OD & ID Coating
DiscontinuityThickness
OD & ID Coating
Str
eng
thp
rop
ertie
s
Peeling resistancePE & PP Coating
Cement mortarID Coating
FBE OD Coating
Ad
hesi
on
pro
per
ties
Application parametersFBE OD CoatingLiquid Epoxy
Cur
ing
Resistance todisbonding frompipe surface
With adhesive Tape
Salt level measurement
Comparison gauge, profilometerComparison
Visual inspection
Dew meterThermometer
By DSC tester
Density, Carbon black,Melt flow index, electrical resistivity
% elongation
Resistance to Heat & UV-ray ageing
Sieve analysisChemical analysis
Visual inspection
Low temp., flexibility test, hardness
Indentation, impact resistance, bending
Compressing strength, bending strength
Holiday testThickness meter
Peeling strength by load cellor dynamometer,
Peeling speed by dead weight testTensile test.
V-notch, Cross cut
DSC testSolvent test
Cathodic disbondingPE, PP, FBE,OD Coating
Co
rro
sio
n
27
Just in timeon-site deliveryJust in timeon-site delivery
28
Integrated Logistics Experiences
The care devoted to proper storage and shipment of products is part of Borusan Mannesmann’scommitment to customer satisfaction.
Borusan Mannesmann plants are located on the eastern coast of Marmara Sea in the vicinity ofmany piers that are expert in pipe loading equipped with mobile cranes, forklifts and other machinerynecessary for international shipment.
Borusan Mannesmann, together with Group’s integrated logistic company Borusan Logistics, isable to deliver with high versatility for every international project from Saharan desert to Rockymountains.
We deliver• By railway• By barge transportation• By IACS class vessels (sous-palan unloading)• By truck and trailers• Even by containers
In many of our projects we have been in charge of custom clearance, sous-palan operations,leasing and management of stockyards, on-site delivery; providing complete integrated logisticssolutions to meet even the most stringent client delivery terms.
29
Project:Elba Express Expansion Gas Pipeline/ USA - 2008
30
Operational Highlights
Project Details:Size: 36"-42"Total Length: 313 kmStandard: API 5L PSL2 X70OD Coating: FBE
Client: Southern Natural Gas Pipeline Group
Scope of Logistics: DDP basis delivery to 5 pipe yards. The logistics scope includes unloading,double jointing, girth weld coating, sand berms preparations and stacking.
- 22 shipments via A class vessels.- On site double-joint operation- Management of 6 different stockyards.
Logistic Partners: Borusan Logistics (Transportation from Izmit/Turkey to USA) Borusan Logistics International (USA operations)
On this prestigious project Borusan Mannesmann produced FBE coated 48" pipes according tothe client’s requirements. The pipes were double jointed to 80 ft (24 m) pipe length. 80 ft pipeswere transported with special trucks to 4 other designated pipe yards.
31
Project:MOL Natural Gas Transmission Project/ HUNGARY-2007
32
Operational Highlights
Project Details:Size: 40"Total Length: 205 kmStandard: EN 10208-2 L485 MBOD Coating: 3 Layer PE acc. to DIN 30670ID Coating: Flow Coat Epoxy acc. to API RP5 L2
Client: Salzgitter Mannesmann (GE)End User: MOL-Hungary
Scope of Logistics: DDP transportation to 14 different pipe yards along the pipeline route in Hungary. The logistics scope includes unloading, stockpiling and safe guardingduring entire delivery operation
Logistic Partners: Borusan Logistics (Transportation from Izmit plant to Hungary) Borusan Logistics International (Hungary operations)
The following transportation methods have been used simultaneously because of the tight deliveryschedule1- Transportation by vessel & barges (45 % of the total quantity)2- Transportation by train (55 % of the total quantity)
Complete handover of the project to the Client was realized in 10 months time.
33
Project:Baku - Tbilisi - CeyhanCrude Oil Pipeline / TURKEY- 2005
34
Operational Highlights
Project Details:Size: 42"Total Length: 194 kmStandard: API 5L - PSL 2 X65 (HIC)Outside Coating: 3 Layer PE acc. To DIN 30670
Client: BTC DirectorateEnd User: BTC CO.
Scope of Logistics: Delivery to the pipe yards located at 4 different locations (Kars, Erzincan, Ceyhan and Terminal), including unloading and stockpiling of the pipes.
The following transportation methods have been used simultaneously because of the tight deliveryschedule:
- Transportation by trucks (15 % of the total quantity)- Transportation by train & trucks (85 % of the total quantity)
The project has been completed within a period of 12 months.This project was one of the most important pipeline projects of its time. Global energy conglomerates,along with the world’s top engineering groups took part in this major infrastructure investment,where highest technical, operational and HSE standards were applied.
COUNTRY CLIENT USAGE PROJECTDESCRIPTION
QUANTITY YEAR
ALGERIA
HUNGARY
TURKEY
ALGERIA
USA
HUNGARY
USA
ALGERIA
HUNGARY
TURKEY
GAS
GAS
GAS
GAS
GAS
GAS
GAS
GAS
GAS
WATER
48" GR4 PIPELINE PROJECTX70 OD PE, ID EPOXY COATED
32" MOL CROATIAN TRANSIT PIPELINEL485MB OD PE, ID EPOXY COATED
16" MUGLA NATURAL GASDISTRIBUTION PR.L485MB OD PE, ID EPOXY COATED
20" - 28" GAS PIPELINE PROJECTSX60 - X70 OD PE, ID EPOXY COATED
30" 300 LINES PIPELINE PROJECTX70 OD FBE, ID EPOXY COATED
28" FGSZ PIPELINE PROJECTL450MB OD PE, ID EPOXY COATED
36" - 42" ELBA EXPRESS PIPELINEPROJECTX70 OD FBE COATED
24" LZ2 HASSI R'MEL - ARZEWPIPELINEX60 OD PE COATED
40" MOL NATURAL GASTRANSMISSION PROJECTL485 OD PE, ID EPOXY COATED
64" - 56" KIZILIRMAK - KES‹KKÖPRÜPIPELINES355JR OD PE, ID EPOXY COATED
305 KM
209 KM
94 KM
717 KM
212 KM
49 KM
313 KM
476 KM
205 KM
185 KM
2009
2009
2009
2009
2008
2008
2008
2007
2007
2007
SONATRACH
SALZGITTERMANNESMANN
BOTAfi
CAMEG
TENNESSEE GASPIPELINE
SALZGITTERMANNESMANN
SOUTHERNNATURAL GAS
SNAMPROGETTI
SALZGITTERMANNESMANN
ASK‹ WATERAUTHORITY
Major SAWH Reference List for the Last Five Years
35
36
COUNTRY CLIENT USAGE PROJECTDESCRIPTION
QUANTITY YEAR
HUNGARY
ALGERIA
TURKEY
IRAN
TURKEY
TURKEY
ALGERIA
IRAN
TURKEY
TURKEY
GAS
GAS
GAS
GAS
GAS
GAS
CRUDEOIL
GAS
GAS
CRUDEOIL
32" MOL PIPELINE PROJECTL485MB OD PE, ID EPOXY COATED
40" GZ1 HASSI R'MEL - MEDAREGPIPELINEX60 OD PE, ID EPOXY COATED
36" LOOP PROJECTX65 OD PE COATED
48" NIGC GAS PIPELINE PROJECTX65 NO OD & ID COATING
42" SHAHDENIZ PHASE 2 PIPELINEPROJECTX65 OD PE COATED
36" TURKEY GREECE PIPELINEX65 OD PE COATED
30" NK1 PIPELINE PROJECTX60 OD PE COATED
48" PIPELINE PROJECTX65 NO OD & ID COATING
24" ÇANKIRI - TOSYA - KASTAMONUPIPELINEX52 OD PE COATED
34" - 42" BAKU - TBILISI - CEYHANPIPELINEX65 OD PE COATED
55 KM
234 KM
30 KM
103 KM
115 KM
180 KM
665 KM
226 KM
145 KM
194 KM
2007
2006
2006
2005
2005
2005
2005
2005
2005
2005
OTF CONTRACTINGCOMPANY
SONATRACH
AT‹LLA DO⁄ANCONTRACTING CO.
PAYANDAN
BOTAfi
BOTAfi
SONATRACH
NATIONAL IRANIANGAS CO. (NIGC)
BOTAfi
BOTAfi, BTCDirectorate
COUNTRY CLIENT USAGE PROJECTDESCRIPTION
QUANTITY YEAR
AUSTRIA
EGYPT
AZERBAIJAN
TUNISIA
TURKEY
CONGO
GABON
EGYPT
TURKEY
TURKEY
EGYPT
GAS
GAS
GAS
GAS
GAS
GAS
GAS
GAS
GAS
GAS
GAS
6" - 8" - 10" PIPELINE PROJECTL290NB OD PE COATED
8" PIPELINE PROJECTSX52 OD PE, ID EPOXY COATED
8" BP GAS TERMINALS CONNECTIONLINEX42 OD PE COATED
8" ENFIDHA -SIDI ABDELHAMIDPIPELINEX42 OD PE COATED
10" BISMIL GAS DISTRIBUTION LINESX46 OD PE COATED
8" PERENCO RDC MISCELLANEOUSPIPELINESGRB OD PE COATED
10" OZANGUE DIGA PIPELINEX42 OD PE COATED
1/2" - 3/4" GAS DISTRIBUTION PIPESGRA OD VARNISH COATING
10" BISMIL GAS DISTRIBUTION LINESX46 OD PE COATED
4" - 6" - 8"- 10" - 12" GASDISTRIBUTION PIPESGRB - X52 OD PE COATED
1/2" - 3/4" GAS DISTRIBUTION PIPESGRA OD VARNISH COATING
15 KM
30KM
10 KM
20 KM
76 KM
63 KM
35 KM
4,500 KM
38 KM
293 KM
3,066 KM
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
EVN
FAYUM GAS CO.
ETSUN CO.
STEG
BOTAS
SALZGITTERMANNESMANN
SALZGITTERMANNESMANN
TOWNGAS
BOTAS
AKSA
NATGAS
Major ERW Reference List for the Last Five Years
37
38
COUNTRY CLIENT USAGE PROJECTDESCRIPTION
QUANTITY YEAR
TUNISIA
TUNISIA
TURKEY
EGYPT
EGYPT
GABON
TUNISIA
TURKEY
TURKEY
SYRIA
TURKEY
GAS
GAS
OIL
GAS
GAS
GAS
GAS
GAS
GAS
GAS
GAS
8" GAZODUC KAIROUAN-TAG DEFERIANAX60 OD PE COATED
4" - 8" DJERBA ISLAND PROJECTX42 OD PE COATED
6" - 10" OIL PIPELINE PROJECTSGRB OD PE COATED
6" - 8" - 10" - 12" PIPELINE PROJECTSX52 OD PE COATED
1/2" - 3/4" GAS DISTRIBUTION PIPESGRA OD VARNISH COATING
8" LIBREVILLE GAS PIPE PROJECTX60 OD PE, ID EPOXY COATED
10" OUM-CHIAH - GABES GAS PIPELINEX60 OD PE, ID EPOXY COATED
10" NAZILLI & ÇANKIRI DIST. LINESX46 OD PE COATED
10" - 12" ORDU DIST. LINESX46 - X52 OD PE COATED
12" ÇANKIRI DIST. LINESX42 OD PE COATED
4" - 6" - 8" - 10" - 12" SOUTH LINEPROJECTGRB OD PE COATED
45 KM
210 KM
81 KM
25KM
2,800 KM
115 KM
75 KM
114 KM
162 KM
40 KM
127 KM
2008
2008
2008
2008
2008
2007
2006
2006
2006
2005
2005
STEG
STEG
TURKISHPETROLEUM CO.
TAQA GROUP
EGYPTGAS
PERENCO S.A.
PERENCO S.A.
BOTAS
BOTAS
SYRIAN GASCOMPANY
BOTAS
+90 212 393 58 58Borusan Mannesmann Call Center E-Mail: [email protected] www.borusanmannesmann.com
June
201
0BORUSAN MANNESMANNBORU SAN. ve T‹C. A.fi.
Head Office:Meclisi Mebusan Caddesi 35,Sal›pazar› 34427 ‹stanbul / TURKEYPhone: +90 212 393 59 59Fax: +90 262 323 18 03
‹zmit Factory:Yeni Do¤an Mahallesi P.K: 5 41001 ‹zmit / TURKEYPhone: +90 212 393 59 59Fax: +90 262 323 18 03E-Mail: [email protected]
