P.E.S.

COLLEGE OF ENGINEERING,
MANDYA - 571401
(An Autonomous Institution under Visvesvaraya
Technological University, Belagavi)

Internship Report
On
“STEEL PIPE MANUFACTURING”
Carried Out At

GEJJALAGERE, KIADB INDUSTRIAL AREA,

MANDYA, KARNATAKA - 571428

In partial fulfilment of the requirement for the award of the Degree

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Submitted by
MOHAMMED IMRAN N 4PS18ME417
Submitted to
Mr. SANTHOSH V. B.E, M.Tech
Assistant Professor,
Department of Mechanical Engineering,
P.E.S. College of Engineering, Mandya.
 P.E.S. COLLEGE OF ENGINEERING,
MANDYA - 571401
(An Autonomous Institution under VTU, BELAGAVI)

DEPARTMENT OF MECHANICAL
ENGINEERING
CERTIFICATE
This is to certify that MOHAMMED IMRAN N bearing the USN:
4PS18ME417 has successfully completed the INTERNSHIP PROGRAM
which is carried out at “WELSPUN CORP LTD” entitled “STEEL PIPE
MANUFACTURING”. Prescribed by the PESCE, Mandya for 8th semester
Bachelor of Engineering in Mechanical Engineering during the academic year
2021 - 2022. It is certified that all corrections and suggestions made during
Internship presentation are incorporated in the report deposited in the
departmental library. The Internship report has been approved as it satisfies the
academic requirement in respect of Internship work prescribed for the said
degree.

Signature of Guide Signature of HOD

Mr. Santhosh V Dr. Rudresh Addamani

Assistant Professor Professor and Head of Department
Department of Mechanical Engineering Department of Mechanical Engineering
P.E.S. College of Engineering, Mandya. P.E.S. College of Engineering, Mandya

Sl. Details of Internship viva examination held Date

No.
Examiner Signature
1
2
STEEL PIPE MANUFACTURING 2021-22

DECLARATION

I hereby declare that the Internship done on “STEEL PIPE

MANUFACTURING” in “WELSPUN CORP LTD” has been successfully
carried out under the guidance of Mr. SANTHOSH V assistant professor,
Department of Mechanical Engineering, P.E.S College of Engineering, Mandya
in the partial fulfilment of the requirement for the award of degree of Bachelor
of Engineering in Mechanical Engineering, P.E.S College of Engineering,
Mandya affiliated to Visvesvaraya Technological University, Belagavi, during
the academic year 2021-2022, the work conducted in this has not been submitted
in part or full to any other university or institute or professional body for the
award of any other degree or any fellowship.

PLACE: MANDYA

DATE:

MOHAMMED IMRAN N (4PS18ME417)

Department Of Mechanical Engineering, P.E.S.C.E, Mandya

STEEL PIPE MANUFACTURING 2021-22

ACKNOWLEDGMENT

I express my gratitude to our academic guide Mr. SANTHOSH V,

Assistant Professor, Department of Mechanical Engineering, P.E.S College of
Engineering, Mandya, who has been a guiding beacon of light, and with his
meticulous guidance, invaluable suggestions have profoundly assisted us in the
completion of our dissertation work.

I would like to express my gratitude to SHARATH A S (Associate

General Manager) and VARUN (HR General Manager) of WELSPUN CORP
LTD, GEJJALAGERE, KIADB INDUSTRIAL AREA, MANDYA,
KARNATAKA - 571428 for providing a grateful learning experience on
“STEEL PIPE MANUFACTURING”.

I express our profound gratitude to Dr. RUDRESH ADDAMANI, Professor

and Head of the Department of Mechanical Engineering, P.E.S College of
Engineering, Mandya, for providing permission and necessary facilities.

I take this opportunity to express our gratitude and indebtedness to Dr. R M

MAHALINGE GOWDA, Principle of P.E.S College of Engineering, Mandya,
for supporting us through the entire course of endeavour.

I would also like to extend our heartfelt gratitude to all my respected lecturers
and the staff members of the Mechanical Engineering Department, P.E.S
College of Engineering, Mandya.

I would like to express our sincere gratitude to our family who have been a
constant source of support and inspiration to me during the course of completion
of my dissertation work. I would also like to express thanks to all our friends,
for their support and encouragement in the successful completion of this
internship.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya

STEEL PIPE MANUFACTURING 2021-22

CONTENTS
Page No.
CHAPTER 1: INTRODUCTION 1
CHAPTER 2: SAFETY PRECAUTIONS 2
2.1 Safety Equipment’s 2
CHAPTER 3: ABOUT DEPARTMENTS 3
3.1 Business development and financial department 3
` 3.2 Stores and inventory status 3
3.2.1 Types of Stores 4
3.2.2 Types of Inventories 4
3.3Production department 4
3.3.1 Product Range 5
3.4 Welding department 5
3.4.1 Submerged Arc Welding 5
3.4.2 Longitudinal Submerged Arc Welding 6
3.4.3 Helical/Spiral Submerged Arc Welding 7
3.5 Testing and Quality control 8
3.5.1 Ultrasonic Testing Machine for Seam 8
3.5.2 Hydrostatic Testing Machine 9
3.6 Final inspection 9
3.6.1 Visual Inspection 9
3.6.2 X-Ray Inspection 10
3.7 Dispatch 10

CHAPTER 4: SEQUENCE OF OPERATIONS 11

4.1 De-coiling 11
4.2 First pinch roller 11
4.3 Edge milling machine (2 NOS) 11
4.4 Main pinch roller 12
4.5 Forming mill 12
4.6 Plasma cutting machine 12
4.7 Outer Diameter cross seam welding machine 13
4.8 Offline welding machine Inner Diameter (ID) - 3Lines 13

Department Of Mechanical Engineering, P.E.S.C.E, Mandya

STEEL PIPE MANUFACTURING 2021-22

4.9 Offline welding machine Outer Diameter (OD) - 3 Lines 13

4.10 End believing machine 14
4.11 Hydro testing machine 14
4.12 Manual ultrasonic testing machine for SEAM weld 15
4.13 Final inspection 15
4.14 Final Product 15

Department Of Mechanical Engineering, P.E.S.C.E, Mandya

STEEL PIPE MANUFACTURING 2021-22

CHAPTER 5: SUMMARY 16

LIST OF FIGURES

FIG NO. DESCRIPTION PAGE NUMBER

1 WELSPUN 1
2 Safety Equipment 2
3 Product 4
4 Submerged Arc Welding 6
5 Longitudinal Submerged Arc Welding (Lsaw) 7
6 Helical/Spiral Submerged Arc Welding (Hsaw/Ssaw) 8
7 Final Inspection 9
8 Plasma Cutting 13
9 Hydro-Testing 14
10 Final Product 15

Department Of Mechanical Engineering, P.E.S.C.E, Mandya

STEEL PIPE MANUFACTURING 2021-22

CHAPTER – 1
INTRODUCTION
Welspun Corp Limited is set up in 1995 as Welspun Gujarat Stahl Rohren Ltd the
flagship company of Welspun Group, which is among the Largest Welded Line Pipe
manufacturing companies in the world. It was ranked as the 2nd largest (largest diameter)
pipe producer by financial time UK and awarded "The emerging company of the year" by
economics times in 2008.
Welspun Corp Limited is a one-stop service provider of welded line pipes and a
preferred supplier to several Fortune 100 oil & gas companies which includes Chevron,
DOW, Elpaso, Enterprise, Exxon Mobil, GAIL, Hunt Oil, Kinder Morgan, PTTEP, Qatar
Petroleum, Reliance, Saudi Aramco, Shell, Statoil, TOTAL and TransCanada. With a strong
culture of engineering excellence, we are the forerunners in manufacturing a wide range of
welded line pipes, offering complete solutions and catering to sectors for oil and gas, and
water transmission industries using the steel sourced from world-class manufacturers.
Its facilities are in India, the Kingdom of Saudi Arabia, and the USA manufacturing
and delivering some of the most critical pipelines in executing complex and large on-shore
and off-shore projects. Being among the top 3 welded line pipe manufacturers globally, we
provide complete solutions and capabilities to manufacture a diverse variety of pipes.
The company has its credentials supplies to world's one of the deepest pipeline
project (Independence Trail in the Gulf of Mexico), one of the highest pipeline project (Peru
LNG), one of the longest pipeline (Canada to US) and the project involving supplies of one
of the heaviest pipe (56 inch X 1.34inch in Persian Gulf).

.
Fig 1: WELSPUN

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 1

STEEL PIPE MANUFACTURING 2021-22

CHAPTER – 2
SAFETY PRECAUTIONS IN WELSPUN INDUSTRY
The Welspun industry aim is ZERO ARMS. Industrial safety is primarily a
management activity which is concerned with

 Reducing Accidents.
 Controlling Accidents.
 Eliminating hazards form the ind+ustries.

2.1 SAFETY EQUIPMENTS:

 Half Mask Respirators

 Industrial Workwear
 Disposable Respirator
 Gauntlet Type Welding Gloves
 Safety Glasses Welding Cap
 Leather Welding Jacket
 High Top Leather Work Boots
 Leather Spats
 Leather Apron
 Welding Helmet

Fig 2: Safety Equipment

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 2

STEEL PIPE MANUFACTURING 2021-22

CHAPTER - 3
ABOUT THE DEPARTMENTS
Departments in WELSPUN,
 Business development and financial department
 Stores and inventory status
 Production department
 Welding department
 Testing and Quality control
 Final inspection
 Dispatch

3.1 BUSINESS DEVELOPMENT AND FINANCIAL DEPARTMENT:

Business development (BD) professionals help companies build strategic
partnerships with other companies and increase revenue. The goals of business development
managers may vary depending on the sector and employer. However, nearly all business
development managers lead initiatives that touch upon strategic planning, marketing and
sales. Some also work closely with engineers or provide technical knowledge during business
planning. Similar to sales professionals, business development managers generate leads,
manage customer and partner relationships and close deals.
The BD department is also responsible for dispatching the material to the
customer and handles all the financial aspects of the industry.

3.2 STORES AND INVENTORY STATUS:

Stores in organization are primarily intended to assist in the production of
goods or services. A storekeeper would have several duties and responsibilities, which he
may carry out himself or through his subordinates. These are,
 To receive incoming materials, including all work connected there with, like opening
of packages, counting and checking.
 To store materials in the right place and the best-suited prescribed manner.
 To ensure that materials are properly preserved and followed correct methods through
periodical inspection.
 To carry out all movements of materials including movement to storage from receipt
and storage to dispatch, packing and forwarding.
 To maintain complete, up-to-date and correct records both for physical storage and
financial accounts.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 3

STEEL PIPE MANUFACTURING 2021-22

3.2.1 TYPES OF STORES:

Stores fall into broadly two categories contingent on the following considerations,
 Functional: depending on the use to which the material is put into use, that is
chemical, tools, raw materials store etc.
 Physical: Depending on its size and location that is central stores, sub stores, site
stores, etc.

3.2.2 TYPES OF INVENTORIES:

 Stores inventory: Raw materials, Spares, Components, etc.
 Work in process: Semi-finished goods on the factory floor.
 Finished goods lying are the warehouse, prior to dispatch for sale.
 It is clear that stores and inventory management plays a major role in successful
completion of any infrastructure project and also accounts a major chunk of
profitability of the contractor.

3.3 PRODUCTION DEPARTMENT

The production department is responsible for converting raw materials and other
inputs into finished goods or services. In between the process of production, the department
works to improve the efficiency of the production or assembly line so that it can meet the
output targets set by company management and ensures finished products offers consumers
the best value and quality.

Fig 3: Product

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 4

STEEL PIPE MANUFACTURING 2021-22

3.3.1 PRODUCT RANGE:

Table 1: Product Specifications

MAX 3250 mm
OUTER DIAMETER
MIN 457 mm

MAX 25 mm
WIDTH
MIN 5 mm

MAX 12.5 m
LENGTH
MIN 6m

MAX 2200 mm
COIL
MIN 900 mm

COIL WEIGHT MAX 40 MT

The spiral pipe is made by ISI FE410. It is export from Jindal and Welspun. It can
produce large-diameter steel pipes with narrow strips. The spiral pipe has strong bearing
capacity and good plasticity, which is convenient for welding and processing. The spiral tube
has high production efficiency, low production cost and quick return.

3.4 WELDING DEPARTMENT

Welding is a process of by which two similar or dissimilar material or alloys

permanently joined together by the which induced by a combination of temperature, pressure
and metallurgy conditions.

3.4.1 SUBMERGED ARC WELDING

Submerged arc welding (SAW) is a common arc welding process. The first SAW
patent was taken out in 1935. The process requires a continuously fed consumable solid or
tubular (metal cored) electrode. The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under a blanket of granular fusible flux
consisting of lime, silica, manganese oxide, calcium fluoride, and other compounds. When
molten, the flux becomes conductive and provides a current path between the electrode and
the work. This thick layer of flux completely covers the molten metal thus preventing spatter
and sparks as well as suppressing the intense ultraviolet radiation and fumes that are a part of
the shielded metal arc welding (SMAW) process.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 5

STEEL PIPE MANUFACTURING 2021-22

SAW is normally operated in the automatic or mechanized mode, however, semi-

automatic (hand-held) SAW guns with pressurized or gravity flux feed delivery are available.
The process is normally limited to the flat or horizontal-fillet welding positions (although
horizontal groove position welds have been done with a special arrangement to support the
flux). Deposition rates approaching 45 kg/h (100 lb/h) have been reported — this compares to
~5 kg/h (10 lb/h) (max) for shielded metal arc welding. Although currents ranging from 300
to 2000 A are commonly utilized, currents of up to 5000 A have also been used (multiple
arcs).

Fig 4: Submerged Arc Welding

3.4.2 LONGITUDINAL SUBMERGED ARC WELDING (LSAW)

Longitudinal Submerged Arc Welding is a specific welding technique used in pipe
production where the finished product requires a particularly high wall thickness due to high
internal or external pressures. With this in mind the main applications of LSAW pipes
include oil, natural gas, gas, central heating, water supply, sewage treatment and other similar
uses. When operational conditions require high wall thickness due to high internal or external
pressures, LSAW (Longitudinal Submerged Arc Welding) pipes are commonly the most
economical solution.
The LSAW pipe diameter range is larger than ERW (Electric resistance welding),
normally from 16 inch (406 mm) to 60 inches (1500 mm). Good performances on high
pressure resistance, and low temperature corrosion resistance. In LSAW pipe mills,
processing is carried out by cold forming heavy carbon steel plates, the pipe pre-material on
which many of the pipe properties depend. The material of LSAW steel pipe is unit middle or
heavy thickness sheet, coiled in the molding or forming machine, welded by double
Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 6
STEEL PIPE MANUFACTURING 2021-22

submerged arc welding and expand the diameter. The specification scope is wide and has
good toughness, ductility, uniformity, compactness, etc.
Longitudinal submerged arc welded (LSAW) pipes manufacture process is bending
and welding wide steel plates to pipes from leveled hot rolled coils by both the JCOE and
UOE (the forming process in which the plate-like the letter "J", "C", "O" or "U" shape, then
expansion) forming processes.
The above-mentioned method of welding is used in Anjar, Dahej with a production
capacity of 3,50,000 MTPA in both the plant. Dimensions of line pipes manufactured.

 Length up to 18m.
 Wall thickness 6 mm to 65 mm.
 Outer Diameter 16 inches to 60 inches.

Fig 5: Longitudinal Submerged Arc Welding (LSAW)

3.4.3 HELICAL/SPIRAL SUBMERGED ARC WELDING (HSAW/SSAW)

LSAW and HSAW are variants of saw (submerged arc welding) pipes. The
difference between them is the way they are welded. In LSAW pipes, the welding is
longitudinal, which means that steel (hot rolled coil plate) is rolled into a pipe and the seam is
welded longitudinally. In the HSAW type, steel coils are welded spirally, like a helix, so that
the coil pipes are used mainly in oil and gas transportation.
Helical submerged are welding (spiral) steel pipe is the full name of HSAW pipe, to
the strip into the welded pipe unit, the multi-roll rolling, the strip gradually rolled up to form
a circular tube with an open gap, adjust the reduction of squeezing roller so that the weld gap
control in 1-3mm, and make both ends of the weld flush. Spital welded pipe is formed by
Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 7
STEEL PIPE MANUFACTURING 2021-22

forming the material strip spiral molding, through internal and external submerged are
welding, thus producing different specifications of the spiral welded pipe.
The above-mentioned method is used in Anjar. Dahej and MANDYA with plant
capacity of 5,00,000 MTPA, 50,000 MTPA and 1,50,000 MTPA respectively. Dimensions of
line pipes manufactured,

 Length up to 18m,
 Wall thickness 5mm-27mm,
 Outer diameter 18inch - 140inch.

Fig 6: Helical/Spiral Submerged Arc Welding (HSAW/SSAW)

3.5 TESTING AND QUALITY CONTROL

3.5.1 ULTRASONIC TESTING MACHINE FOR WELD SEAM

Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the
propagation of ultrasonic waves in the object or material tested. In most common UT
applications, very short ultrasonic pulse waves with center frequencies ranging from 0.1- 15
MHz, and occasionally up to 50 MHz, are transmitted into materials to detect internal flaws
or to characterize materials. A common example is ultrasonic thickness measurement, which
tests the thickness of the test object, for example, to monitor pipework corrosion.
In ultrasonic testing, an ultrasound transducer connected to a diagnostic machine is
passed over the object being inspected. The transducer is typically separated from the test
object by a couplant such as a gel, oil or water as in immersion testing. However, when
ultrasonic testing is conducted with an Electromagnetic Acoustic Transducer (EMAT) the use
of couplant is not required.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 8

STEEL PIPE MANUFACTURING 2021-22

3.5.2 HYDROSTATIC TESTING MACHINE

Hydro testing of pipes, pipelines and vessels is performed to expose defective
materials that have missed prior detection, ensure that any remaining defects are insignificant
enough to allow operation at design pressures, expose possible leaks and serve as a final
validation of the integrity of the constructed system.
This is the most common method employed for testing pipes and pressure vessels.
Using this test helps maintain safety standards and durability of a vessel over time. Newly
manufactured pieces are initially qualified using the hydrostatic test. They are then re-
qualified at regular intervals using the proof pressure test which is also called the modified
hydrostatic test. Testing of pressure vessels for transport and storage of gases is very
important because such containers can explode if they fail under pressure.

3.6 FINAL INSPECTION

3.6.1 VISUAL INSPECTION:

 Checks welding variables for complications with welding procedure.
 Checks for the quality or root pass.
 Check the quality of individual weld passes.
 Check inter-pass temperature.
 Check placement and sequencing of individual weld passes.
 Check background surface.
 Monitor in process NDT.

Fig 7: Final Inspection

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 9

STEEL PIPE MANUFACTURING 2021-22

3.6.2 X-RAY INSPECTION:

 X-ray inspection only at UT indications.
 Random inspection of a certain percentage of the welding line.
 Inspection of both ends of the welding line.
 Inspection of the complete welding line.

3.7 DISPATCH

Functions of Dispatching:
 To check the availability of input materials and ensure the movement of material from
store to first process and then from process to process.
 To ensure the availability of all production and inspection aids.
 To obtain the requisite drawings, specifications and material lists.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 10

STEEL PIPE MANUFACTURING 2021-22

CHAPTER - 4:
SEQUENCE OF OPERATION
4.1 DE-COILING

The De-coiling is a special equipment for metal sheet leveling. It can be used for
leveling steel sheet and uneven sheet. According to the relevant configuration, the production
line of uncoiling, levelling, shearing and other sheet products can be formed.

 Capacity: Weight 40mt (25mm thickness).

 Coil width range: 900mm to 2200mm.
 Use: Loading and De-coiling of coils with coil centering and alignment facility.
 Special feature: Equipped with heavy duty drivers and best cutting tools to ensure
minimized edges.

4.2 FIRST PINCH ROLLER:

Pinch roller comprises an entire family of non-reducing rolls that are used to redirect
the travel of a strip mill product and to provide strip tension for a downstream process.

 Capacity: Coil width 900 to 2200mm and 5 to 25mm thickness.

 Use: Pulling to strip from De-coiler and feeding to leavers.

4.3 EDGE MILLING MACHINE

An edge mill is a type of milling cutter, cutting tool used in industrial milling
applications. It is distinguished from the drill bit in its application, geometry, and
manufacture. While a drill bit can only cut in the axial direction, a milling bit can generally
cut in all directions, though some cannot cut axially.
Edge mills are used in milling applications such as profile milling, tracer milling,
face milling, and plunging.
 Capacity: Strip width 2200 mm max and 25 mm thickness max
 Milling Speed: 7.00 MTR /MIN MAX
 Use: To maintain the required width with 0.05mm tolerance Preparation of bevel
geometry on top and bottom of the strip edges as per weld joint design to ensure
proper welding.
 Special Features: Equipped heavy duty drives and best cutting tools.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 11

STEEL PIPE MANUFACTURING 2021-22

4.4 MAIN PINCH ROLLER

Pinch roller comprises an entire family of non-reducing rolls that are used to redirect
the travel of a strip mill product and to provide strip tension for a downstream process.
 Capacity: 90kw twin drive with roll diameter 650mm.
 Strip width 2200mm max and 25mm thickness max.
 Use: feeding for strip into spiral forming mill.

4.5 FORMING PROCESS

Metal forming processes are those in which force is applied to a piece of sheet metal
to modify its geometry rather than remove any material. The applied force stresses the metal
beyond its yield strength, causing the material to plastically deform. but not to fail. By doing
so, the sheet can be bent or stretched into a variety of complex shapes.
 Capacity: Pipe diameter 457 to 3250mm Outer Diameter (OD).
 Wall thickness: Up to 25mm max.
 Mill angle: 10-43degree.
 Pipe length: 12.5mt max.
 Mill speed=7.0mts/min.
We can also online welding.
 DC 1000AMPS-4NOS (OD & Inner Diameter (ID)).
 AC 1200AMPS-4NOS (OD & ID).

4.6 PLASMA CUTTING

Plasma cutting is a process that cuts through electrically conductive materials by

means of an accelerated jet of hot plasma. Typical materials cut with a plasma torch include
steel, stainless steel, aluminum, brass and copper, although other conductive metals may be
cut as well.
 Equipment: Cutting range-25mm max & Current 200 amps. Equipment is attached
with so to give proper cutting while pipe is moved ahead.
 Use: To cut the pipes online with forming and welding as per desired length.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 12

STEEL PIPE MANUFACTURING 2021-22

Fig 8: Plasma Cutting

4.7 OUTER DIAMETER CROSS SEAM WELDING MACHINE

 Equipment: cross-seam saw welder.

 Capacity: DC100AMP.
 Saw Welding Speed-: up to 3mt max.

4.8 OFFLINE WELDING MACHINE ID 3 LINES

 Capacity: DC 2000a (1000a,2nos).

 Speed: Up to 2.5/min.
 Special Features 2&3 wire (AC&DC).
 Purpose: To weld pipe from inside saw process.

4.9 OFF LINE WELDING MACHINE OD 3LINES

 Capacity: DC-2000a(1000a,2nos).
 Speed: Up to 3cm/min.
 Special Features:2 Wire (AC & DC).
 Purpose: To weld pipe from outside by saw process.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 13

STEEL PIPE MANUFACTURING 2021-22

4.10 END BEVELLING MACHINE

 Type of Machine: Equipped with controlled feeding drive system and human and
machine to indirect for parameter setting.
 Type of Beveling:
1. Square beveling.
2. Butt beveling.
3. Single beveling.
4. V-type beveling.

4.11 HYDRO TESTING

Having fully computerized controls, PRD Hydrostatic Pipe Testing Machines are
suitable for pipe applications to meet any internationally known standards, including those of
API and AWWA. Hydrostatic Pipe Testing Machines can be used with pipes produced by the
electric resistance welding (ERW) process as well as pipes produced by the submerged arc
welding (SAW) process.
 Equipment: Two High Pressure Pumps & Three Low Pressure Pumps.
 Capacity: Max Pipe Load 30mt up to 3250mm.
 Salient Features: The test is performed at a pressure that stress the pipe close to its
yield limit & is well above the pressure of pitch.
 Interlocking system for safe operation.
 Graph charts recording facility for each pipe which shows test pressure & holding
time.

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 14

STEEL PIPE MANUFACTURING 2021-22

Fig 9: Hydro-Testing

4.12 MANUAL ULTRASONIC TESTING MACHINE FOR WELD SEAM

 Equipment Range :0 to 5 m
 Scanning Speed: 6 inches per mm max
 Area coverage: Untested area by AUT & indication marked by AUT

4.13 FINAL INSPECTION

Purpose: To inspect the OD ID thickness at both ends & the body

 Ovality.
 Squareness.
 Bevel angle and root face.
 Straightness.
 Weld head height at OD & ID.
 Length.

4.14 FINAL PRODUCT

Fig 10: Final Product

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 15

STEEL PIPE MANUFACTURING 2021-22

CHAPTER – 5
SUMMARY
In this internship which was carried out at WELSPUN CORP LTD on STEEL PIPE
MANUFACTURING (for a period of two months), which was guided by a resourceful
person named Sharath A S (Associate General Manager) and Varun (HR General Manager)
of WELSPUN CORP LTD.

Here I was able to study and understand well about Steel Pipe manufacturing

 About Manufacturing Departments

 Sequence of Operations
 Machines Used for Production

During this, I would like to thank WELSPUN CORP LTD and Sharath and Varun Sir

Department Of Mechanical Engineering, P.E.S.C.E, Mandya Page 16