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Office:+381(0) 290320376REAKUTSTR. N.N. RR. REAKUTPN- 70000FERIZAJ KOSOVA/
Fax: +381(0) 290320172 [email protected]
NEWCOIMK PIPE FACTORY L.L.C.
THEFACTORY FORPRODUCTIONOF STEEL PIPESFABRIKAPR PRODHIMINE TUBAVETELIKUT
www.imk-ks.com
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NewCo IMK Pipes Factory L.L.C. The company for production of steel welded pipes and shapes of different profiles in Ferizaj, Kosova, is one of thebiggest companies in pipes industry in South-Eastern Europe.
Since its establishment in 1972, the company has produced over 12,000km (approx. 1,300,000 tons) of pipes for water, gas and oil supply systems in manycountries around the world.
Production of all types of steel welded pipes with dimensions from 114,3mm
2032mm enables presence of our products in the industry, in the region andworldwide. Quality of our products is in compliance with international standards for
production and controlling, such as: API, EN, DIN, ISO, ASTM, BS, NF, UNI, GOST,etc.
NewCo IMK Pipes Factory L.L.C. consists of three production units (the unit for
spiral welding, longitudinal welding and the coating-isolation unit), and has anadministrative building (with approx. 52,000m of covered surface) placed in a
surface of more than 28 hectares of land in Ferizaj, South-Eastern part of Kosova.
Spirally seamed pipes unit - consists of three production lines for production of
steel pipes.
Longitudinal seam unit - consists of a production line for production of steel weldedpipes, and the line for cutting steel sheet-Slitter.
Coating unit (insulation) consists of the line f or coating and protecting pipes from
corrosion (inner insulation with bitumen lacquer/ spray, epoxy raising, metallicbasic colour, etc., and external insulation with bitumen lacquer/ spraying, bitumen
quantity from 1 to 4 levels, metallic basic colour, etc.)
New Co IMK Pipes Factory L.L.C. also exercises supporting activities as follows:
Preparing and installing metallic constructions from steel pipes and other profiles (open and closed),
3 Production of reservoirs (horizontal and vertical with the volume of up to 100m ) for water, oil and other non-standard products.
The company has its train with wagons and railway infrastructure of 3.7km connected with the regional railway.
NewCo IMK Pipes Factory L.L.C
2
INTRODUCTION
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PLANT LAYOUT
Magjistralja Prishtine-Shkup
Hyrjaekonomike
Hyrjakryesore
Mainentrance
Restorani
Restaurant
AdministrataAdministration
GarderobaFitting room
Garazha
Garage
Rezervoariprmazut
Weigher
Depo e pjesve rezerv
Stacionii gazrave teknike
d e p o
e m a
t e r i a l i t
h a r g j u e s p
r r e p a r t i n
e i z
o l i m
i t
Rezervoariplinit
4
5
6
6
7
2
3
1
8 8
9
1
222
34
4
5
5
6
1
23
45
6
7
Hekurudha / Railway
Technical gas station
Gastank
Verticalmazuttank
Warehouse of spare parts
W a r e h
o u s e
o f s
p e n d i
n g m
a t e r i a l f
o r c o
a t i n
g p l a n t
Ngrohtorja
Centralheat
Main road Prishtine-Shkup
Porta
Entrance
Porta
Entrance
Peshorja
145.0
0
1
2
235.00
34.00
67.00
3
StacioniikompresorveCompressor station
KONSTRUKCIONEVE
NDERTIMORE(I-PROFILEVE)
REPARTIPER
PUNIMIN
EPROFILEVEDHE
3
1-Inside cleaning2-Outside cleaning3-Inner coating with bitulit4-Inner coating with bitumen5-Outer coating with bitulit6-Outer coating with bitumen
2
1-Slitter2-L-16 line3-Tuboscope4-Hydrotest5-Bevelling ends (lathe)6- Straightness
1
1-SP1 Pipe Mills2-SP3 Pipe Mills3-SP5 Pipe Mills4-Bevelling ends (lathe)5-Hydrotest6-X-ray control7-Mechanical laboratory8-Visuel control9-Final Control
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STEEL PIPES WITH SPIRAL WELDING
TUBAT E ELIKTA ME TEGEL SPIRAL
The Company also produces steel pipes with spiral welding, with diameters ranging from 219.1mm - 2032 mm, side width from 4 mm to 14 mm, and standard lengths from 11 m to 12 m or if
ordered, from 8 m to 16 m.
Apart from pipe profiles depicted in the table below taken as standardized products, we have thecapability of producing other non-standard profiles within the minimum and maximum ranges such
as ranges given on the table below with diameters 419, 426, etc.
Prodhimi i tubave t elikt me tegel spiral bhet me diametr prej 219.1 mm deri m 2032 mm,me trashsi t murit prej 4 mm deri m 14 mm.
Gjatsia standarde e tubave sht prej 11 m deri m 12 m ose sipas porosis prej 8 m deri m 16 m.
Prve profileve t tubave t dhna n tabel q merren si prodhime standarde, ka mundsi t
prodhimit t profileve tjera jostandarde brenda gams s diametrave minimal dhe maksimal (sip.sh. n tabel nuk jan prfshir diametrat 419 mm, 426 mm, etj.)
Outside diameterDiametri i jashtm
Wall thickness (mm)Trashsia e murit (mm)
mm
219,1244,5273298,5323,8355,6406.4457,2508558,8609,6660,4711,2762,8812,8863,6914.4965,2101610661117,61168,41219,212701320,81371,61422,415241625,61727,21828,81930,42032
inch
8910111214161820222426283032343638404244464850525457606468727680
min
4444444555556666777778889999910111111
max
1010101012.712.712.712.712.712.712.712.712.712.712.712.712.712.71414141414
14141414141414141414
SPIRAL WELDINGTEGEL SPIRAL
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TESTING - TESTIMI
TESTING OF WELDING FOR SPIRALLY WELDED PIPES
TESTIMI I SALDIMIT T TUBAVE ME SALDIM SPIRAL
During the production process, pipes pass through non-destructive testing and controlling(radiographic and ultra-sound), and destructive control (laboratory sample testing).
The equipments used for testing pipes with non-destructive testing are as follows:
Automatic ultrasonic inspection of welding
Visual inspection (inside and outside)
Radiographic inspection based on corresponding documentation
Hydro testing with maximum pressure up to 210 bar.
Gjat procesit t prodhimit, tubat kalojn npr kontroll testimi pa shkatrrim (ultratingulli dheradiografia) dhe kontroll me shkatrrim (provat laboratorike).
Pajisjet q prdoren pr testimin e tubave me metodn testuese pa shkatrrim jan:
Inspektimi automatik-ultrasonik i saldimit
Inspektimi vizuel (brenda dhe jasht)
Inspektimi radiografik me dokumentacionin korrespondues
Hidrotesti me presion maksimal deri n 210 bar.
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COATING - INSULATION
Protection of steel pipes from corrosion is done according to standards DIN 30673, AWW C210 andAWW C213.
Protection of pipes surface from corrosion is done using equipment for destruction under pressure
from inside and outside with steel spheres where the quality of cleaned surface reaches Sa2according to SIS 055900 criteria.
The internal insulation is done with lacquer/ spray - capitol BLC with thickness from 100 to 300,and epoxy raising with thickness from 100 to 300 (for drinking water).
The external insulation is done with bitumen and glass wool with a thickness from 3.5 mm to 8 mm
with electro testing rates 10, 15, 20, and 25 kV.
IMK will soon start the process of external insulation of pipes with 3-PE (Polyethylene) after the
contracted equipments are installed.
MBSHTJELLJA - IZOLIMI
Mbrojtja e tubave t elikta nga korrozioni bhet sipas standardeve DIN 30673, AWW C210 dhe
AWW C213.
Prgatitja e siprfaqes s tubit pr mbrojtje nga korrozioni realizohet nga ana e jashtme dhe e
brendshme me pajisje pr bombardim nn presion me sfera t elikta, me ka arrihet cilsia epastrimit t siprfaqes Sa2 sipas normave SIS 055900.
Izolimi i brendshm bhet me llak - kapitol BLC me trashsi prej 100 deri 300, me rrshira
epokside me trashsi 100deri 300 (pr uj t pijshm).
Izolimi i jashtm bhet me mas bitumi t armiruar me shirit t voal qelqit me trashsi 3.5 gjer 8 mm,me testim n elektrodeprtim 10, 15, 20, dhe 25 kV.
IMK s shpejti do t filloj t bj izolimin e jashtm t tubave me 3-PE (polietilen) pas instalimit tpajisjeve t kontraktuara.
COATING - INSULATIONMBSHTJELLJA - IZOLIMI
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MANUFACTURING PROCESS
Hot Steel sheet used for production of spirally seamed pipes (SAW) is obtained in the form of HotRolled Coil (HRC) with different dimensions.
The coil is then placed in the unpacking equipment on which the process continues to the
transverse cutter where the last transverse cutting is done for the end steel sheet and beginning ofthe new sheet.
The welding process starts with the engagement of welding equipment (joining of the two edges ofthe steel sheet), in which way we get t he continuation of the steel sheet for the production process.
After transverse welding, the steel sheet passes through the flattening equipment (the cylindersystem for flattening). Then, the steel sheet is put in the system of the main cylinders where the
entire process of production starts and passes through circular cylinders where the length cutting ofsteel sheet is done to prepare edges for welding. After cleaning the edges, steel sheet reaches the
system of cylinder rules with certain angles (alpha, beta and gamma), where through this systemand based on the t echnical preparation, the steel sheet takes the spiral shape (based on the system
of rules given in the calibrators) where the pipe of a certain profile is obtained.
First, the pipe is welded through the automatic welding machine with electric arc under protection ofpowder (SAW) for internal welding. The same process is then applied for external welding.
Furthermore, the produced pipe is controlled through ultra-sound throughout its length where thewelding was done.
The pipe cut is based on the length specified on the production order, and then the pipe undergoes
the process of quality verification and other technical testing to finalize the process.
The raw material used depends on the purchase order and designation of the pipes. Quality of steel
material used for production of pipes is specified in the international standards: API, DIN, EN etc.These standards include all specifications, such as chemical components and mechanical
specifications of materials used for production of pipes.
MANUFACTURING PROCESS
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PRODUCTION PROCESS PHASES
PRODUCTION PROCESS PHASES
START
P.K.P-1Placement of HRCin
the equipmentUltra sound control 100% P.K.P-11
P.K.P-2Unfolding and cutting of
HRC
Taking samples forlaboratory examinations P.A-1
P.K.P-3 Sides Welding of HRCCutting and noting the
pipes P.K.P-10
P.K.L-4 F la tt en in g o f t he HRC P ip es tr an sp or t P.K.P-13
P.K.L-5Main Cylinders pressing
HRCPipes cleaning P.K.P-14
P.K.L-6 Cutting of HRCsides V is ua l c on tr ol P.K .P -1 5
P.K.L-7 Preparation of HRCSides Radiographic control P.K.P-16
P.K.L-8 P ip e f or ma ti on P ro ce ss in g o f p ip e s id es P.K.P-17
P.K.L-9 Inside welding Hydrost atic test ing P.K.P-18
P.K.L-10 Outside welding Final control P.K.F
ENDOF PROCESS
P.K.P- Control point in the Process,P.K.F- Control point in the Final Control,
P.A- Examination point,HRC- Hot rolled coil
Pipe repairprocess HED
CROSSSECTION
MANUFACTURINGFEATURES
APPLICABLESTANDARDS
DIMENSIONS
APPLICATION
SPIRALLYWELDEDSTEEL
PIPES
Submergedarcwelding.
Protectivecoatingpo
ssible
D=355.6-2032mm
s=3.96-12.7mm
L=8-16m
APIStd.5Land5LS
DIN1626Sheet1-4
DIN17100and17172
GOST8696-62
JUSC.B5.240
ISO
Forconveyingwater,
steam,oil,crudeoil,gases,
etc.
LONGITUDINALYWE
LDED
STEELPIPES
Highfrequencywelding.
Weldareaanneal
ed.
Protectivecoatingpo
ssible.
APIStd.5Land5LS
DIN2458AND2461
DIN1626and17172
NFA49140,1,2,5
GOST10705
JUSC.B5.240
ISO
D=114.3-406.4mm
s=3.2-12.7mm
L=6-16m
Forconveyingwater,
steam,oil,crudeoil,gases,
etc.
Forsteelstructures.
STEELPIPESWIDENED
ATONE
END
"Tulipage"Proce
ss
Forconveyingliquids
(wateringsystems,water
linesetc.).
bxa=80x100through
245x405mm
s=3.2through11.91mm
Inconstruction,
shipbuilding,mechanical
engineering,electrical
engineeringetc.
Weldlocationinthem
iddleof
oneside.
Wldbeadremoved.
Formorecriticalstru
ctures
weldedshapesmeybeannealed.
Protectivepaintingpossible.
MANUFACTURER'S
INTERNALSTANDARDS
complyingtoDIN500,513
NFR03-150
axa=90x90through
325x325mm
s=3.2through11.91mm
PRODUCT
RECTANGULARSHAPES
PIPES
SQUARESHAPES
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NON-STANDARD PRODUCTSAND SERVICES
TRUSS type constructions
(production hall, storage)Konstruksione t tipit KAPRIAT(Repart prodhimi, Depo)
Billboard construction
Konstruksion i billbordve
Billboard construction
Konstruksion i billbordve
TRUSS type constructionsKonstruksione t tipit KAPRIAT
TRUSS type constructions (Gym)Konstruksione t tipit KAPRIAT (Sall sportive)
TRUSS type constructions (Gym)Konstruksione t tipit KAPRIAT (Sall sportive)
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NON-STANDARD PRODUCTSAND SERVICES
Construction of Gas station
Konstruksion i pomps s karburanteve
Construction of Gas station
Konstruksion i pomps s karburanteve
Covered up gas station
Mbulesa pr pompn e karburanteve
Covered up gas stationMbulesa pr pompn e karburanteve
Car garagesGarazha pr vetura
TRUSSKapriat
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NON-STANDARD PRODUCTSAND SERVICES
Slitter cutting line of the strip in plate
shapes and longitudinal shapesSliteri - linja e prerjes s shiritit n form tpllakave dhe form gjatsore
Ventilation profiles
Profile pr ventilim
Profile for construction
Profil pr konstruksion
Services for transportation of reservoirsShrbimi pr transportimin e rezervuarve
LatheTorno
Formation machine for shaped ringsMakina pr formimin e unazave me lakim
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