The SAW Steel Pipes Plant under construction in the Industrial City of Jubail, Kingdom of Saudi Arabia (KSA) shall be one of the most modern steel pipe mills in the region for producing high quality, large diameter, heavy wall, longitudinal seam submerged arc welded pipes (LSAW) using the ""UOE"" forming process and cold mechanical expansion.
The Plant will be producing pipes of 16 - 48" outside diameter with an average annual capacity of 180,000 ton per year.
The Product Pipes shall be ISO 9002 accredited and licensed to use the official API monogram under API SPEC Q1 for Quality Systems and Technical Specifications: 5L, 2B AND 5CT for Linepipe, Structural and Casing respectively. Other qualities like ASTM, DIN, JIS, DNV AWWA, .. etc, shall also be produced.
APC
Over the past decade, Arabian Pipes Co. has made significant achievements at its 6-20"" ERW (Electrical Resistance Welded Pipes) Facility in Riyadh and gained a prestigious track record with world-class clients in the Middle East, like Saudi Aramco, ADNOC, SHELL, ..etc.
In their perception, APC"s Shareholders believe that the new Project embodies their ambitious plans to diversify the existing Product range in the objective to meet the increasing demand on Linepipes.
The fixed capital investment budgeted for the UOE Plant is SR252 million (US$ 67 million).. Additional investment of SR84 million (US$ 22 million) is also foreseen for the HSAW Plant (First Expansion). Beside the promoters contribution and commercial loans, it"s anticipated to apply for SIDF loan to obtain supporting funds for this strategic industry.
Implementation & Technology Provider
A Project Site of 212,000 m2 has been allocated by the Royal Commission at Camp13 in Jubail Ind. City. The principal UOE Process Equipment has been received in July "03 and laid down at site. Additionally, advanced techniques and extra Equipment have been already considered and ordered from top European Vendors to challenge any stringent customers requirement & specs.
In collaboration with world-class Consultant (McLellan & Partners Ltd, UK), the Civil & Electro-Mechanical Eng. Designs have been accomplished, whereas the Civil Construction works has already commenced in March 04. McLellan is also now engaged in the Project Site Management and Supervision.
According to the Project Schedule, commissioning of the Plant is planned the second quarter 2005.
Virtually, the initiators of this Project have recognized the importance of adopting latest advanced technologies within the process.
APC has recognized the significance of involving the adequate Technology Partner in this Project in the objective to provide necessary backup to ensure its prosperity. The sought Technology Partner is expected to make available to APC its Technical Know-how, Intellectual Property (IP) and expertise relating to the Products and the Project, based on its extensive professional and technical experience, as highlighted in the following section.
Merits of UOE Process
Primarily, it was the Shareholders decision to choose the best technology and build a robust facility that can be distinguished from other competitors in the area. In terms of quality, the UOE Process is second to non as a reliable manufacturing process that guarantees best pipe straightness, roundness, dimensional uniformity and reproducibility.
HSAW Spiral Pipes & Potential Expansions
The Promoters are also ambitious to complement the production range of the current UOE Plant by adding another production line for the HSAW Pipes in the range of 16 - 100" diameter, targeting the Water Pipes attractive market.
This perception was based on and justified by the pressing demand for major trunk linepipes nationwide and in the region. The estimated budget for this First Expansion is SR22 million, while it"s estimated that putting up such second production line together with the UOE Plant on the same Site in Jubail shall enhance its profitability and turnover.
Also, was perceived is to install relevant Coating Facilities to have one-stop-shop for our clients, as the Second Expansion.
UOE Process
U Presses
U press has an automatic hydraulic system of plate positioners that permit to obtain an appropriate symmetric “U” Form.
O Presses
O press increase pipe quality as it permits to obtain uniformity in circumferential length, appropriate seam gap, low peaking and uniform curvature.
Washing
After forming, the pipe is washed and dried perfectly previously to tack welding.
Welding
Tabs are welded at both end of the pipe to ensure soundness in the weld at the pipe ends.
Inside Welding
The pipe is held in a fixed position while the welder moves along the inside of the pipe.
Outside Welding
The automatic submerged arc welding machine, fitted with three electrodes, performs the outside welding. The pipe is stationary while the welder moves on a platform. Only approved welding procedures are used and qualified personnel.
Visual Inspection
The pipe is submitted to a thorough visual inspection of external and internal surfaces. If the superficial defects are found, they are marked for grinding or weld repair.
Ultrasonic Inspection
The full length of the longitudinal weld is inspected for imperfections, such as porosity, slag inclusions, or cracks by automatic ultrasonic testing. This simultaneously detects and records the location of each flaw by activating a spray device.
X Ray Inspection
Marks indicated by ultrasonic testing are radiographed.
Washing
The inside of the pipe is cleaned with high pressure water.
Cold Mechanical Expansion
The expansion radio is up to 1.5 percent (maximum) of the original diameter. The pipe is mechanically expanded to remove off residual stress produced by thermal effects of submerged arc welding and removal of local strains generated during UO forming improving roundness, straightness and diameter. Recovery of mechanical strength lowered by the Bauschinger effect generated during “UO” Forming.
Pipe End Cutting
Pipes ends are cut as shown above.
Bevelling
The pipe ends are bevelled to 30°C - 35°C with a root face of 0.8-2.4 min. or 30° and lower using a high-speed machine.
Hydrostatic Testing
Each length of pipe is hydrostatically tested from 90% to 100 % SMYS up to 4000 PSI during 30 seconds maximum depending on the wall thickness and diameter of pipe and client requirements as well. Actually, the equipment it’s been improved to reach a pressure of 6000 PSI maximum.
Second Ultrasonic Inspection
After expansion and hydrostatic testing, another ultrasonic testing is performed in order to ensure the soundness of the weld bead.
Dimensions, Weight and Marking
Weight is measured and recorded as per API 5L, using a weighing machine with a capacity of 20,000 Kg, a minimum indication of 5 Kg and a tolerance of ±6 Kg. Visual and dimensional inspections are performed prior to customer’s inspection and marking at final station.
