Essar Pipes

Delivering the difference

ESSAR
STEEL
LTD
OVERVIEW

Essar Steel is a global producer of

steel with a footprint covering India,
Canada, USA and Indonesia. With
an expanding capacity of 14 Million
Tons per annum (MTPA), it is fully
integrated from mining to retail.

Head Office:
Hazira Pipe Mill Limited

Registered Office:

6th Floor Essar Technopark

Hazira Pipe Mill Limited

LBS Marg, Kurla (W)

27th KM, Surat - Hazira Road

Mumbai 400070 India

Hazira

Tel: +91-22-67335000

Gujarat - 394270 India

Fax: +91-22-67082189

Tel: +91 261 6682400

For product related enquiries,

mail us at steel@essar.com

www.essarsteel.com

Its products find wide acceptance in

highly discerning consumer sectors,
such as automotive, white goods,
construction, engineering and
shipbuilding. Essar Steel produces
highly customized products catering
to a variety of product segments
and is Indias largest exporter of flat
products to the highly demanding
US and European markets, and to
the growing markets of South East
Asia and the Middle East.
It has strong downstream capability
with Steel Service Centres and a
global network of steel distribution
outlets branded Essar Hypermarts.
It has substantial investments in Pipe
and Plate mills and a leadership
position in value added segments of
Cold Rolled, Galvanized and
Pre-Painted steel.

Hazira Pipe Mill Limited (HPML) is part of the US$ 15 billion

Essar group. Its inception heralds Essars entry into the top
league of pipeline manufacturers. Strongly backed by Essar
Steel, which is geared up to become the first Indian steel
company to have domestic capacity of 10 mtpa at a single
location, HPML is poised to become one of the single

HAZIRA
PIPE MILL
LIMITED

largest pipe manufacturer in the world.

With the steel pipe industry being highly raw-material
intensive, HPML has a distinct advantage in terms of easy
access to raw material as the pipe mill is located within
Essar Steel complex. This in turn ensures a fast-delivery
mechanism leading to timely execution of orders.
The company is located at Hazira, Gujarat and has a

K. K. PUROHIT

combined

CEO

Submerged

Within months of starting operations, Hazira

Pipe Mill Ltd. (HPML), a part of Essar Steel,
achieved a significant milestone when the
company was awarded the American
Petroleum Institute (API) Certificate for pipe
production. This coveted certification paves
the way for HPML to establish a footprint in
niche market segments worldwide, especially
in the highly demanding oil and natural gas
industry.

Arc

of

600,000

Welded

(HSAW)

tonnes
and

of

Helical

Longitudinal

Submerged Arc Welded (LSAW) steel pipes along with

FOREWORD
Growing oil and gas demand in India and the
world and the zeal with which oil companies
are investing on adding pipeline infrastructure
promise a huge demand for pipes as it is the
most cost-effective way to transport oil & gas.
Moreover, factors like growing E&P budgets,
large scale creation of water and sewage
transportation, migration from traditional
modes to pipe transportation, huge gas
discoveries and large number of old oil & gas
pipelines that need to be replaced, has given
a fillip to this sector.

capacity

internal and external coating facilities of up to 2 mn square

meters annually.

Essar Steel is one of the few

manufacturers globally, who can make API
grade steel with low sulphur, which has
already been approved by various pipe
manufacturers in India and abroad and has
been used for critical oil and gas projects by
various end users.
HPML has embraced quality, innovation and
technology to produce high-grade steel
pipes. The company has adopted the
state-of-the-art
technology,
real-time
automated systems and processes, high
quality testing equipments to ensure high
degree of precision, consistency and quality.
An unflinching commitment to technical
excellence and quality, continuous innovation
and focused vision of the management, highly
motivated and trained manpower are factors
that enable HPML to cater to the growing
demand from international and domestic
markets and offer complete piping solutions

SALIENT FEATURE
OF HAZIRA
PIPE MILL LIMITED
1.

Being an integrated pipe mill, easy access to Raw Material enables speedy execution of orders.

2. State of the art technology, latest testing equipments ensures adherence to international
standards.
3. Automated systems and processes helps in real time tracking of pipe orders till despatch.
4. Minimal human interference that ensures high degree of precision and consistency.
5. High production to manpower ratio due to automation of processes.
6. Logistical advantage: Easy access to jetty and road ensures timely execution and delivery of
orders across the world.

SNAPSHOT OF CURRENT
CAPACITIES

APPLICATION
Oil & Gas

Combined capacity of HPML

600,000 TPA

HSAW

275,000 TPA

LSAW

325,000 TPA

Pipes for onshore

applications.

and

offshore

Cross country pipeline.

Project / Terminal Piping Water &

Sewage.

HPML has a production capacity to produce 275000

PIPES
SAW pipes are manufactured by welding the edges of steel plates or by spiral
welding of hot rolled coil (HR coil). The Saw Pipes manufactured from plates
are called Longitudinal Submerged Arc Welded (LSAW) and are mainly used
for transporting oil and gas (onshore/offshore). While, Helical Submerged Arc
Welded (HSAW) pipes are made from HR coil, where the coil is welded spirally
to give a shape of pipe and are mainly used for transporting oil and gas
(onshore) and water transport. Apart from these, both the category of pipes

Distribution and Transmission lines.

Irrigation systems and power plants.

Pipes for potable water.

tonnes of consistent quality HSAW pipes conforming

to international quality standards. One of the unique
features of the mirror-image HSAW mills (2 Nos) is that
it can manufacture pipes of the same size or two
different sizes simultaneously at a high speed, thereby
drastically reducing the delivery time. Moreover, state
of the art automated offline SAW welding and GMAW
(Tack) welding is deployed to enhance productivity with
consistent quality.

can be used for structural applications also.

HELICAL
SUBMERGED
ARC
WELDED
PIPES (HSAW)
The HSAW facility, which is an amalgamation
of best-in-class technologies, is capable of
manufacturing pipes in the range of 16 to 100 inch
diameter in 6.4mm to 25.4 mm thickness and grade
up to API 5L X - 80.

HPMLs LSAW facility, with an installed capacity of 325,000

TPA, produces high quality pipes adhering to international
standards. The manufacturing facilities incorporatfe the
hybrid JCO&E technology, which provides flexibility in
terms of thickness & grade, to produce pipes in a diameter
range of 16 to 64, 6 mm to 65 mm thickness and grade
up to API 5L X - 80. The facility also possesses latest
inspection and testing equipments to meet specific
requirements on execution, strength, tolerance, length etc.
The Mill has valid licenses to use API Monogram.

SALIENT FEATURES
OF HSAW MILL

SALIENT FEATURES OF LSAW FACILITY

The manufacturing process used for HSAW pipes consists of two steps:

1. Pipe forming combined with continuous tack welding.

2. Final internal and external submerged arc welding at separate welding stations.

Capacity to produce pipes with very close Diameter - Thickness ratio.

Ultrasonic Testing capable to scan 100% area of 5 meters wide plates to ensure internal

The two step technology offers both quality and economic benefits such as:

High pipe forming speed by continuous Tack Welding.

Emphasis on pipe geometry on pipe forming machine without hindrance by

SAW process, resulting in tightest tolerance even without cold expansion
with respect to.

Straightness.

Roundness.

Accuracy of diameter.

soundness prior to pipe forming.

LSAW Mill is equipped with 6000 MT JCO press, having capacity to form pipes of 65 mm WT.

Cold Expander (13 meters) to ensure tight and uniform control on pipe dimensions.

Fully automated size and data controlled cold expander to ensure tight and uniform control on
pipe dimensions.

Plant

High quality due to implementation of process automation technology.

HSAW forming mill has main drive feed motor with 500,000 Nm torque enabling
pipe formation of 1 inch wall thickness comfortably.
LSAW

Plant

H-SAW 1 & 2

LONGITUDINAL
SEAM
SUBMERGED
ARC WELDED PIPES

Configuration
Diameter

16" to 100"

Grade

API 5L - X 80

Thickness

6.0mm to 25.4mm

Pipe Length (max)

12.5 meter

Current Capacity

275000 TPA

Configuration
Diameter

16" to 64"

Grade

API 5L - x 80

Thickness

6.0mm to 65mm

Pipe Length (max)

12.5 meters

Current Capacity

325,000 TPA

Technology Support

JCO

COATING

Coating is an effective method to prevent corrosion, resist

To cater to the wide range of pipe products

toughness, macro and microstructure.

erosion and enhance operational life of line pipes. HPML

manufactured through various routes, Hazira Pipe

Our aim is to strive for excellence and manufacture

has imported technical know-how from Italy-based

Mill Limited (HPML) has full-fledged facilities for

the best-in-class pipes with respect to quality and

Socotherm, pioneers of coating. The facility deploys

inspection and testing to ensure production of high

cost by ensuring systemic efficiencies in terms of

external coating like Fusion Bonded Epoxy (FBE), Dual

quality

processes and training, continuous technological

layer FBE, 3 LPE, 3 LPP and Polyurethane - the latest

implementation of world-class quality standards,

methods to prevent corrosion having annual capacity of 2

quality control initiatives are undertaken by highly

million square metre and internal coating like Liquid Epoxy

experienced,

paint having annual capacity of 1 million square meter to

of HPML.

products. To further facilitate and ensure

qualified

and

trained

manpower

to all its customers and emerge as a leading

Quality checks start right from the receipt of raw

manufacturer and preferred supplier of steel pipes.

material till the final completion of the product. HPML

is equipped with sophisticated quality monitoring
systems like On-line Coil Ultrasonic Testing, Real
Time Radiography (Fluoroscopy), Fully Automatic
Weld Seam Ultrasonic testing and 100% Pipe-end
Radiography, to ensure that high quality standards

Deploys Buggy system, which facilitates smooth pipe movement and eliminates air entrapment.

are adhered to. The Mill also has a well equipped

Pipe curing system enables higher productivity.

laboratory for testing

The coating facility is designed to maintain dust - free atmosphere by separating shot blasting
and coating.

As a highly quality-conscious company, HPML

strives to deliver value- added products and services

improve product flow.

SALIENT FEATURES
OF COATING FACILITY

advancements and up-gradations.

pipes for its strength,

LEADING
THROUGH
QUALITY

HSAW PRODUCTION CAPABILITY

Plant Capability Matrix for HSAW
Thickness in mm

Pipe OD

CERTIFICATION & 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

Inch
Inch
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100

mm
mm
406
457
508
559
610
660
711
762
813
864
914
965
1016
1067
1118
1168
1219
1270
1321
1372
1422
1473
1524
1575
1626
1676
1727
1778
1829
1880
1930
1981
2032
2083
2134
2184
2235
2286
2337
2388
2438
2489
2540

6
6.4
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80

8
8.7
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80

10
10.3
X-70
X-70
X-70
X-70
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80

12
12.7
X-65
X-65
X-70
X-70
X-70
X-70
X-70
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80

14
14.3

16
15.9

18
19.1

20
20.6

22
22.2

24
23.8

25
25.4

X-65
X-65
X-65
X-65
X-70
X-70
X-70
X-70
X-70
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80

X-60
X-60
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80
X-80

X-65
X-65
X-65
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70

X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70
X-70

X-60
X-60
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65

X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65

X-60
X-60
X-60
X-60
X-60
X-60
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65
X-65

Our manufacturing process for spiral-welded pipes is not limited to diameter range mentioned above. Depending on the order quantity we suit the individual requirement beyond our design capacity.

LSAW PRODUCTION CAPABILITY

(GRADE:IS 2062, X - 42, X - 52, X - 56, X - 60, X - 65, X - 70 & X - 80)

Pipe Diameter
Inch
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60

mm
406.4
457.2
508.0
558.8
609.6
660.4
711.2
762.0
812.8
863.6
914.4
965.2
1016.0
1066.8
1117.6
1168.4
1219.2
1270.0
1320.8
1371.6
1422.4
1473.2
1524.0

Wall Thickness in mm
6.4 7.9 10.3 12.7 14.3 15.9 17.5 19.1 22.2 23.8 25.4 27 28.6 30.2 31.8 33.3 36.5 38.1 39.7 42

44

46

48

50

52

54

56

58

60

62

64 65

Essar Pipes

Delivering the difference

ESSAR
STEEL
LTD
OVERVIEW

Essar Steel is a global producer of

steel with a footprint covering India,
Canada, USA and Indonesia. With
an expanding capacity of 14 Million
Tons per annum (MTPA), it is fully
integrated from mining to retail.

Head Office:
Hazira Pipe Mill Limited

Registered Office:

6th Floor Essar Technopark

Hazira Pipe Mill Limited

LBS Marg, Kurla (W)

27th KM, Surat - Hazira Road

Mumbai 400070 India

Hazira

Tel: +91-22-67335000

Gujarat - 394270 India

Fax: +91-22-67082189

Tel: +91 261 6682400

For product related enquiries,

mail us at steel@essar.com

www.essarsteel.com

Its products find wide acceptance in

highly discerning consumer sectors,
such as automotive, white goods,
construction, engineering and
shipbuilding. Essar Steel produces
highly customized products catering
to a variety of product segments
and is Indias largest exporter of flat
products to the highly demanding
US and European markets, and to
the growing markets of South East
Asia and the Middle East.
It has strong downstream capability
with Steel Service Centres and a
global network of steel distribution
outlets branded Essar Hypermarts.
It has substantial investments in Pipe
and Plate mills and a leadership
position in value added segments of
Cold Rolled, Galvanized and
Pre-Painted steel.