From the finest steel to the finest pipes

Contents

5
Essar Steel

15
Coating Facility

3
Essar Group

9
Helical Submerged Arc Welded (HSAW) pipes

11
Longitudinal Submerged Arc Welded (LSAW) pipes

17
Health, Safety and Environment

7
Pipes

16
Testing Equipment

19
Marking and Ordering

12
Essar Pipe Mill

Essar Group
The Essar group is a multinational conglomerate and a leading global player in the sectors of steel, energy, power, communications, BPO, shipping, ports & logistics, construction and mining & minerals. With operations in more than 20 countries across five continents, and over 60,000 employees, the groups annual revenues are over USD 15 billion. Essar began as a construction company in 1969 and has now diversified into manufacturing, services and retail. Over the last decade, it has captured new markets and discovered new sources for raw materials either through strategic global acquisitions and partnerships or through greenfield and brownfield development projects. Today, the group continues to expand its global footprint by focussing on the Asian, American, African and European markets. Essar invests significantly in forward and backward integration of its businesses, and on leveraging synergies between businesses. It also focusses on in-house research, innovation and on embracing the latest technology to remain a low-cost manufacturer with high-quality products and innovative customer offerings. Along with its ambitious business pursuits, Essar has ensured that it also delivers on its social responsibility. The group runs community outreach initiatives in all its plant locations with a focus on education, healthcare, environment, agricultural development and self-employment. The Essar group is widely regarded as a responsible and conscientious global employer. It has experience in managing businesses in different geographies with a culturally-diverse workforce. This is why its people practices are sensitive to cross-cultural nuances. The groups people strategy is focussed on promoting a learning culture that continually enhances the professional skills of its employees.

Essar Steel
Essar Steel is a global steel producer with a strong presence in intensive steel consuming markets like Asia and North America. Its goal is to reach a global production capacity of 20 25 million tonnes per annum (MTPA) by augmenting its current capacity of 14 MTPA. Essar Steel is a fully-integrated operation from mining to retail, with strong downstream capability and a worldwide network of processing and distribution facilities. Global Operations Essar Steel Algoma in Canada has a current capacity of 4 MTPA. Essar Steel Minnesota USA (with iron ore reserves of over 1.4 billion tonnes) is developing a 8 MTPA pellet plant, an ore concentration plant and a direct reduced iron plant. In Indonesia, Essar Steel is the largest private steel processor and operates a 0.4 MTPA cold rolling complex with a galvanising line of 0.15 MTPA. Essar Steel is the largest steel producer in western India, with a capacity of 10 MTPA at Hazira, Gujarat. The steel plant is backed by an iron ore beneficiation and a pellet unit that ensures supply of quality raw material. It operates the world's second largest slurry pipeline of 267 km from Bailadila to Vishakapatnam and a 253 km slurry pipeline from Dabuna to Paradip in India. The Essar Steel complex at Hazira has a complete infrastructure setup including a captive port; power, lime and oxygen plants; and a township. It has set up a 1.5 MTPA plate mill and a 0.6 MTPA pipe mill at Hazira to make further value-additions to its product portfolio. Essar Steel has India's largest steel processing and distribution capacity of 3.7 MTPA at its seven facilities, located at key automotive and industrial hubs. It also has the distinction of being one of the country's biggest galvanisers and producers of cold rolled and colour coated products. Additionally, it is setting up 12 MTPA iron ore beneficiation and pellet plants in Orissa, India. Products and Services Essar Steel manufactures customised products catering to a variety of industry segments. It is one of Indias largest exporter of flat products to the highly-demanding US and European, and to the growing markets of South East Asia and the Middle East. It invests in world-class research and development and has technology collaborations with global steel majors to develop enhanced value-added products and grades that find wide acceptance in sectors like automotive, white goods, construction, engineering and shipbuilding. With investments in downstream capabilities, Essar Steel has evolved from being a product-based company to a valueadded service provider with an extensive product portfolio.

Pipes
From the finest steel to the finest pipes
The growing demand for oil and gas across the world and in India have created a huge demand for pipes. Reasons being increasing E&P budgets, huge gas discoveries and a large number of old oil and gas pipelines that need to be replaced. Recognising the potential of the pipe market in India and the world, Essar Steel started operations of a state-of-the-art pipe mill at Hazira. The 0.6 MTPA pipe mill includes top-line Helical Submerged Arc Welded (HSAW) and Longitudinal Submerged Arc Welded (LSAW) mills, and internal and external coating units with a capacity of up to 2 million square metres annually; that manufacture world-class pipes. Being a fully-integrated steel manufacturer with quick access to raw material gives Essar Steel a direct advantage. The pipes are manufactured using heavy plates produced in one of the worlds widest plate mills, and hot rolled coils, both of whose manufacturing facilities are located within the Hazira complex itself. Their proximity ensures a steady supply of raw material, and the port location of the plant provides Essar Steel with a logistical advantage ensuring timely execution and delivery of orders across the world. Essar Steel is one of the few manufacturers globally, capable of producing API (American Petroleum Institute) grade steel, with a supply track record of over 3 million tonnes. The Essar Steel pipe mill is API certified to make pipes of low sulphur that finds wide acceptance and approval from international oil and gas majors. Supported by the best technology and the latest testing equipment including plate ultrasonic testing, real time radiography (fluoroscopy), hydrostatic testing and final ultrasonic testing (automatic weld cut), Essar Steel pipes ensure adherence to international standards and a high degree of precision, consistency and quality.

Helical Submerged Arc Welded (HSAW) Pipes

The Essar Steel HSAW mill has a capacity of 275,000 TPA producing consistent-quality HSAW pipes conforming to international quality standards. The pipes are manufactured using a two-step process that involves continuous tack welding and internal and external submerged arc welding at separate welding stations. One of the unique features of the HSAW mill is that it is a mirrorimage mill which can manufacture pipes of the same size or two different sizes simultaneously at high speed, thereby reducing delivery time. Salient Features of the HSAW Mill High pipe forming speed by continuous tack welding Tight tolerance even without cold expansion with respect to straightness, roundness and accuracy of diameter Main drive feed motor with 500,000 Nm torque enabling pipe formation of 25.4 mm wall thickness Excellent mechanical properties (high strength and toughness) attained through fine microstructure State-of-the-art Technology, World-renowned Suppliers Equipment Tube mill 1 Tube mill 2 ID/OD welding machine 3 sets Final ultrasonic testing machine X-ray machine Coil ultrasonic machine, intermediate UT machine Supplier Byard, Malaysia Phamitech, China Urhan & Schull, Germany GE, Germany YXlone, Germany RD-Tech, Canada Capability Capacity Diameter Thickness Grade Pipe length (max) Coil width range Coil weight Forming speed Applications Onshore and offshore oil and gas pipelines Refineries Project / Terminal piping water and sewage distribution and transmission lines Irrigation systems Power plants Pipes for potable water 275,000 TPA 406 2,540 mm 6 25.4 mm Up to API 5L X-80 12,500 mm 900 2,000 mm 30 MT (max) 4 8 m / min

Coil Opening

Coil End Welding

Ultrasonic Testing of Coils covering Full Width

Pipe Forming and Continuous Mig Welding

HSAW Process Flow

Ultrasonic Testing of Weld, HAZ and Ends

Magnetic Particle Inspection of Ends

Hydrotester

End Bevelling of Pipes

Real Time Radiography of Weld and Visual Inspection of Weld and Pipe Body

Inside and Outside SAW Welding: 3 Line

Radiography of Ends

Final Visual Dimensional Inspection, Weighing and Marking

Longitudinal Submerged Arc Welded (LSAW) Pipes

The Essar Steel LSAW mill, with an installed capacity of 325,000 TPA, produces high-quality pipes by incorporating the world-renowned hybrid JCO technology, which gives flexibility to the manufacturing process in terms of thickness and grade. The mill possesses the latest inspection and testing equipment to meet specific requirements. Salient Features of the LSAW Mill Pipe production with very close diameter-thickness ratio Ultrasonic testing capable of scanning 100% area of up to 5 metres to check internal soundness prior to pipe forming 6,000 MT JCO press having a capacity to form pipes of 65 mm WT Fully-automated size and data-controlled cold expander (13 m) State-of-the-art Technology, World-renowned Suppliers Equipment JCO forming machine and pre-bender, tack welder End bevelling ID/OD and cross seam welding machine Plate UT, Final ultrasonic testing machine Hydrotester, expander, edge milling Supplier YSD, China Linsinger, Germany Urhan & Schull, Germany GE, Germany Iprolam, Romania Capability Capacity Diameter Thickness Grade Pipe length (max) Applications Onshore and offshore oil and gas pipelines Pipes for potable water Refineries Power plants Structural pipes for offshore structures and piles 325,000 TPA 406 1,524 mm 6 65 mm Up to API 5L X-80 12,500 mm

Plate Ultrasonic Testing

Plate edge milling

Plate Edge Crimping

JCO Forming Press

Continuous Tack Welding

LSAW Process Flow

End Bevelling

Mechanical Expander

Real Time Radiography

Intermediate Ultrasonic Testing

Outside Welding (SAW)

Inside Welding (SAW)

Hydrotester

Ultrasonic Testing

Radiography Testing

Magnetic Particle Testing

Visual, Dimensional Inspection, Weighing and Marking

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11

Essar Steel Pipe Mill

Inside Welding and Outside Welding

World-class Processes, Ultra-modern Facilities

Expander The expander is a fully-automatic CNC machine that minimises residual stresses and improves mechanical properties. It is used to achieve roundness, straightness and accuracy of diameter. Force Expanding value Salient Features High speed PLC enabling excellent controls of operation Automatic seam detection and positioning Salient Features Automatic flux heating, feeding and recycling system to avoid contamination of flux Precise measurement of curves of the welding process with the true-RMS (root-mean-square) converters for each arc Pre-programmed welding, crater fill and burn back procedure Data record and long-time storing mechanism referencing actual welding parameters of each pipe for 12 m single boom expander to achieve uniform dimensional tolerance throughout the length 1,200 T Up to 1.5% of outer diameter Continuous Tack Welding Power source Gas Salient Features Pipe forming and continuous tack welding by gas metal arc welding (GMAW) Laser seam tracking system to keep the wire always in the centre of the weld grove even at higher welding speeds of up to 6 m / min 1,500 amps Argon and CO2 / O2 mixture or CO2 gas HSAW Diameter Thickness Cutting speed Number of tool holder Salient Features CNC controlled fully-automatic machine to control parameters such as bevel angle and root face with customer requirements Automatic pipe length measurement after chamfering of the edges 406 2,540 mm 6 25.4 mm 70 rpm 2 tool post / head LSAW 406 1,524 mm 6 65 mm 110 rpm 2 tool post / head End Bevelling At end bevelling, the pipes ends are machined and prepared for field welding.

The pipe is welded from inside and outside by automatic SAW as per ASME Sec. IX or other customer specification. Wire arrangement Thickness Diameter Grade Welding speed Current 3 wire tandem welding system (1 DC & 2 AC) 6 mm 65 mm 406 2,540 mm Up to API 5L X-80 0.5 to 2.5 m / min 2,000 Amp DC, 1,500 Amp AC and 1500 Amp AC

Automatic Laser Seam Tracking and stick-out control system for accurate tracking in the horizontal and vertical direction

Pipe expander

End bevelling

12

Coating Facility
Oil and gas exploration and production companies face significant technical challenges protecting carbon steel pipelines from corrosion and addressing significant insulation requirements as lines are installed at larger lengths and at greater sea-bed depths. Onshore oil and gas transportation pipelines require adequate protection against corrosion to ensure reliable service over a long period of time. The Essar Steel pipe mill coating unit has an annual external coating capacity of 2 million square metres and an annual internal coating capacity of 1 million square metres. It deploys external coating like Fusion Bonded Epoxy (FBE), dual layer FBE, 3 LPE, 3 LPP and Polyurethane to prevent corrosion, and liquid epoxy solvent base and solvent-free internal coating to improve product flow. Salient Features of the Coating Facility Deploys buggy system which facilitates pipe specification and eliminates air entrapment Pipe curing system for higher productivity Dust-free atmosphere by separating shot-blasting and coating State-of-the-art Technology, World-renowned Suppliers Equipment FBE coating system, adhesive and PE coating extruders, fume exhaust system Blasting system, induction heaters, internal coating plant Supplier Socotherm, Italy

Nanjing, China

Capability External Coating Capacity Diameter Type of coating Internal coating Capacity Diameter Type of coating 1 mill sq m / annum liquid epoxy 203.2 1,524 mm Liquid epoxy solvent base and solvent free 2 mill sq m / annum 3LPE 101.6 1,524 mm FBE, 3LPE, 3LPP, DFBE

Bare Pipe Entry

Preliminary Heating

Shot Blasting

Visual Inspection

Phosphate and Chromate Treatment

Pipe Heating

FBE Application

Coating Process Flow

Stock Yard or Dispatch

Final Visual Inspection and Marking

Coating Inspection with High Voltage Flaw Detector

Removal of Coating from Ends (Cut Back)

Water Quenching

Adhesive and Polyethylene / Propylene Application

Bare Pipe Entry

Pre-heating and Shot Blasting

Internal Epoxy Coating

Curing

Final Visual Inspection and Marking

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15

Health, Safety and Environment

Essar Steel has always remained committed to achieving excellence in health, safety and environment by providing and maintaining safe and healthy working conditions and following operating practices that protect the environment. Environmental Awareness and Training A continuous environmental awareness drive and environmental training is being implemented through in-house and external training sessions that is a mandate for all employees including senior management. All Essar employees are covered under the Environmental Awareness Programme. The training network is comprehensive and aims and trains each individual at a particular site. Development Projects Eco-restoration by greenbelt development, mangrove plantation, creation of eco-life and marine life Implementation of a vigorous Environment Management System Tracking of emissions and discharges through online monitors Robust oil consumption and recovery tracking system Installation of two Online Ambient Air Quality Monitoring stations and 15 online stack analysers Essar Steel is marching towards a green drive, richer biodiversity and zero discharge as an assurance to the evergrowing and sustained efforts towards environmental protection. The company is the first Indian steel company to receive ISO-14001 certification. Essar Steel is recognised by the World Steel Association for actively participating in CO2 emission data collection testimony to the fact that Essar Steel is the best-in-class and sets industry benchmarks.

Testing Equipment
The Essar Steel pipe mill has full-fledged facilities for inspection and testing to ensure production of high-quality pipes through the implementation of best practices and quality control initiatives. A highly experienced, qualified and trained manpower maintains efficiencies in terms of processes and training, continuous technological advancements and upgradations. Quality checks start right from the receipt of raw material till the final completion of the product. Sophisticated quality monitoring systems like plate ultrasonic testing, real time radiography (fluoroscopy), hydrostatic testing and final ultrasonic testing (automatic weld cut) ensure adherence to international standards. The mill also has a well-equipped laboratory for testing pipes for its strength, toughness, macro and microstructure. State-of-the-art Technology, World-renowned Suppliers Equipment Plate ultrasonic testing Real time radiography (fluoroscopy) Hydrotester Final ultrasonic testing (automatic weld cut) Supplier GE Inspection Technology, Germany YXlone, Germany Iprolem, Romania GE Inspection Technology, Germany Plate Ultrasonic Testing The equipment used in the testing of LSAW pipes uses probes and provides online A-scan and C-scan presentation of flaws associated. The system is very flexible the number of probes and the location of each probe along the plate can be modified easily. An audio-visual alarm and automatic spray marker will be operated whenever a flaw is detected. Real time radiography (fluoroscopy) This process is used to inspect the pipe weld seam continuously for any welding defect with the help of an industrial x-ray. Hydrotester The hydrotester is PLC controlled and equipped with a digital data recording system and requires minimal operator intervention. It is capable to test the pipe up to 350 bar with an automatic shield barrier and can auto centre the pipe. Final Ultrasonic Testing (automatic weld cut) This process is used to inspect the pipe weld seam continuously for any welding defect. The system consists of an automatic device for lifting and lowering of individual test levels. It is a self-sufficient transverse shift device for each guiding block for correction of the probe symmetry with weld deviations.

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Certifications and Approvals

API 5L, API 2B by American Petroleum Institute API Specification Q1 by American Petroleum Institute ISO 9001: 2008 by APIQR ISO / TS 29001 by API ISO 9001: 2008 by DNV BIS certificate

Marking and Ordering

Marking Pipe number, heat number and ASL number Pipe size, steel grade, product specification level, type of pipe Hydro test pressure API monogram Month and year of manufacture Length and weight of pipe Ordering Outer diameter Wall thickness Grade Product specification level Quantity Type of pipe

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35

HSAW & LSAW Dimensions

Unmatched Properties, Infinite Possibilities HSAW
Pipe diameter mm 406 457 508 559 610 660 711 762 813 864 914 965 1,016 1,067 1,118 1,168 1,219 1,270 1,321 1,372 1,422 1,473 1,524 1,575 1,626 1,676 1,727 1,778 1,829 1,880 1,930 1,981 2,032 2,083 2,134 2,184 2,235 2,286 2,337 2,388 2,438 2,489 2,540 Grade: API 5L X-60
20

LSAW
Wall thickness 6.4 8.7 10.3 12.7 14.3 15.9 19.1 20.6 22.2 23.8 25.4 Pipe Wall thickness diameter mm 406 457 508 559 610 660 711 762 813 864 914 965 1,016 1,067 1,118 1,168 1,219 1,270 1,321 1,372 1,422 1,473 1,524 Grade: API 5L X-80 6 8 10 12 14 16 18 20 22 24 25 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 65

X-65

X-70

X-80
21

Contact us
India Offices Ahmedabad Essar House, Ellisbridge, Ahmedabad - 380 006 Tel: +91 79 6608 6666 Bengaluru No. 2, 2nd Floor, RR Chambers, 11th Main, Vasanth Nagar, Bengaluru - 560 052 Tel: +91 80 2220 2131 Chennai Chennai House, 5th Floor, No. 7, Esplanade, Chennai - 600 108 Tel: +91 44 2535 1271 / 73 Hyderabad 301, Sidhu Shree Vaishnavi Arcade, Road No. 1, Banjara Hills, Hyderabad - 500 034 Tel: +91 40 2337 0125 / 6677 0980 Indore 409, City Centre, 570 M.G. Road, Indore - 452 001 Tel: +91 731 2538 825 / 2537 974 Kolkata 2nd Floor, Block: EP, Plot Y16, Sector V, Saltlake City, Kolkata - 700 091 Tel: +91 33 6612 6608 NCR A-5, Sector-3, Noida - 201 301 Tel: +91 120 6626 666 Mumbai Essar Technopark, # 2, L.B.S. Marg, Kurla (West), Mumbai - 400 034 Tel: +91 22 6733 5000 Pune 408, City Tower, 17, Boat Club Road, Pune - 411 001 Tel: +91 20 6620 9901 / 2 International Offices Canada Essar Steel Algoma Inc. 5515 North Service Road, Burlington, Ontario, L7L 6G4 , Canada Tel: +1 905 331 3400 Dubai, U.A.E. Essar Steel Middle East FZE Emaar Business Park, # 4, Sheikh Zayed Road, P.O. Box 61078, Dubai, U.A.E. Tel: + 97150 658 1757 / 651 4263 Egypt Suite # 63, 17 Port Said Street, Maadi Serayat, Cairo 11431, Egypt Tel: +20 2 2378 1551 / 120 700 199 Indonesia PT Essar Indonesia BFI Estate, Inds 3 Kav B1, Cibitung, Bekasi 17520, West Java , Indonesia Tel: +62 21 8980 152 Kenya ZEP-Re Palace, Longonot Road, Upper Hill, PO Box 45742-00100 Nairobi, Kenya Tel: +254 736 714 575 Qatar Qasco Building, Al Hilal Doha State of Qatar PO Box 24086 Tel: +974 467 4343 / 465 7036 United Kingdom Essar Steel Processing and Distribution Pensnett Road, Dudley, West Midlands DY1 2HA, United Kingdom Tel: +44 1384 471 371 United States of America 36th Floor, 145, E, 48th Street, New York 10017, U.S.A. Tel: +1 212 758 5520 / 5860 Registered Office 27th KM, Surat Hazira Road, Hazira - 394 270, India Tel: +91 26 1668 2400 Corporate Office Essar House, 11, K. K. Marg, Mahalaxmi, Mumbai - 400 034, India Tel: +91 22 6660 1100

Essar House, 11 K. K. Marg, Mahalaxmi, Mumbai - 400 034. India Tel: +91 22 6660 1100 Fax: +91 22 2353 2695

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