Spiral Welded Pipes

All the machines for manufacturing of spiral Welded Pipes have been imported from Byard Malaysia and Germany, who are world class manufactures of Spiral Pipe Plant machinery.The plant is situated at a strategic location in close proximity to the ports at kandla(22km) and Mundra (35km) which have adequate facilities for handling heavy cargos.

NPS	Thickness	Capacity (MT Per annum)	Lenght	Specification	Pipes End
18"(457 mm) to 105" (2667 mm)	5 mm to 25 mm	200,000 (0.2 Million)	Upto 13000 mm	API 5L GR upto X80, ASTM A 252, ASTM A 139, IS 3598, IS 5504,	Plain / Bevelled

Manufacturing Process

HR Coils are loaded on the decoiler of the Spiral Pipe Mill. The strip is straightened and 100% coil is examined for any defects in the material by an automatic ultrasonic unit having of 36 probes & 144 channels. The edges are milled to desired joint geometry. The strip is guided into the forming station, where it is formed to produce a cylindrical hollow body at a predetermined forming angle, ensuring the proper welding gap between the abutting edges. Later, inside and outside welding is performed by an automatic submerged arc process.

After accomplishment of inside and outside welding, flux and slag from inside the pipes are cleaned. Pipes are cut to a predetermined length by an automatic plasma arc cutting device. The entire weld seam is scanned by Fluoroscopic Inspection / Real Time Radiography for analysis of the weld defects, if any. At the end facing machine, both ends of the pipes are machined simultaneously, to suit joint, to be used on the pipeline. Each pipe is hydrostatically tested to a given pressure as per API 5L specification or other desired specification.

100% weld length and HAZ of each pipe is examined by an automatic ultrasonic unit with the help of 16 probes and 16 channels for detecting the defects, if any. At the X-ray station, radiographs are taken of weld seam for each pipe end, to a distance of 4″. Every length of pipe is subjected to a rigorous check at the final stage before it is accepted by the Quality Control Department.

Modern Laboratory

To ensure product reliability through process control, SURYA has a fully equipped metallurgical laboratory with all the tools essential for comprehensive product quality testing and evaluation to withstand reactive processes. Destructive testing of pipes entails performance examination of the weld, as well as their tensile and compressive strength.

Testing and Quality Control Facilities

Besides the numerous quality assurance measures during the manufacturing process and at various inspection points, the following facilities are also utilized for ensuring stringent quality standards.

Universal Testing Machines(Digital)

For material testing(mechanical properties)

Eddy Current Testing Machine(NDT)

For ON-LINE flaw detection on welds

Ultrasonic Testing Machine(NDT)

For checking strip laminations and flow detection

Eddy Current Testing Machine(NDT)

For ON-LINE flaw detection on welds

(Parent Metal/ Welds)

on welds on pipes in auto mode

Metallurgical Microscope

For checking and evaluating the grain structure of material,heat affected and weld zones

Vickers Hrdness Tester(Digital)

For checking a micro & macro hardness on weld, heat affected zone and base metal

Digital Ultrasonic Thickness Gauge

For checking thickness of pipes

Mandrels and Fixtures

Reverse bend tst,GBT, Root bend test,Face bend test

Impact Test Machine (Charpy v notch)

For checking energy absorption test on base metal, weld and Heat Affected Zone.

Bending Machine

For pipe bend test

Drop weight tear test

For evaluating the % shear area of material

Spectroscope

For checking chemical composition of coil & pipe.

Apart from the above important testing machines,we have temperature recorders for seam normalizing, auto pressure recording for hydrostatic test pressure and many other sophisticated measuring instruments. The trained and committed work force ensures high quality of pipes made to various national and international standards, including the requirement of API specifications. The quality control system is audited time to time by the various certification bodies, including an API to verify the effectiveness of the system.