Corporate Office: Regd.Office & Works. Website: JPL CAT-01, Issue No. 03, Rev. No.2; Date

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1 Corporate Office: Website: Regd.Office & Works Mumbai Kolkata JPL CAT01, Issue No. 03, Rev. No.2; Date Chennai

2 About us:

3

4 MANUFACTURING AND TESTING FLOW DIAGRAM ELECTRIC RESISTANCE WELDED BLACK IDENTITY AND ANALYSIS CHECK DECOILER SLITTING ULTRASONIC TESTING OF STRIP SIZING EDDY CURRENT TESTING IDENTIFICATION CUTTING TO LENGTH DIMENSIONAL CHECKS END SHEAR BUTT WELD WELD SEAM TEST PIPE END BEVELLING/ FACING STRIP ACCUMULATOR LOOP PIT HYDROSTATIC TESTING OF HIGH FREQUENCY INDUCTION WELDED / AND GALVANIZED PIPES/ TUBES STRIP EDGE PREPARATION (MILLING) ULTRASONIC TEST OF WELD SEAM PREFORMING ULTRASONIC TEST OF PIPE END FORMING FINAL INSPECTION PILOT LINE MARKING HFI WELDING AUTOMATIC TEMPERATURE CONTROL MARKING AND STAMPING REMOVAL OF INTERNAL AND EXTERNAL WELD BEAD ACCEPTANCE AND RELEASE FOR DESPATCH INDUCTION ANNEALING OF WELD SEAM BUNDLING NORMAL WATER COOLING STACKING FOR BOILER TUBES FULL BODY NORMALIZING STRAIGHTENING HYDROSTATIC TESTING DRYING FURNACE HOT DIP ZINC COATING FULL BODY EDDY CURRENT FOR GALVANIZED TUBES PICKLING & FLUXING STEAM BLOWING PASSIVATION (DICHROMATING) VISUAL INSPECTION THREADING METALLOGRAPHIC EXAMINATION SHIPPING

5 SERIES BLACK & GALVANIZED ERW STEEL TUBES CONFORMING TO IS:1239(PtI) EQUIVALENT TO BS:1387 & STRUCTURAL TUBES CONFORMING TO IS:1161 LIGHT MEDIUM NOMINAL BORE O.D. OUTSIDE DIA. W.T. WEIGHT OUTSIDE DIA. W.T. WEIGHT OUTSIDE DIA. INCH mm mm MIN. MAX. mm P/E Kg/m Kg/m S/S MIN. MAX. mm P/E Kg/m Kg/m S/S MIN. MAX. mm P/E Kg/m S/S Kg/m 1/ / / / / H H H H H H H H H H H H H H H H H NOTE: (l) IS:1239 & BS:1387 cover sizes upto 100 mm NB all series and 125 & 150 mm NB medium & heavy series, plain end and screwed & socketed ends. (ll) IS:1161 covers all sizes Plain End only. (lll) IS:1161 O.D. Tolerance will be as per dimension tolerance clause.above table min./max. O.D. applicable for IS:1239 only. (lv) Hydro test Pressure 5 MPa (IS:1161 Hydro Test not required.) NB SIZE OD NOTE: (I) IS:4270 covers Pipe size 100 mm to 350 mm NB & IS:3589 covers Pipe size mm O.D. to mm O.D. (II) IS:4270 covers Wall Thickness upto 10 mm. (III) Other thickness may be supplied as per agreement. (IV) Max. Hydro Test Pressure IS: MPa, IS: MPa. HEAVY ERW PIPES FOR WATER & SEWAGE CONFORMING TO IS:3589 & WATER WELL CASING CONFORMING TO IS:4270 CONVENTIONAL MASS PER UNIT LENGTH (Kg/m) WALL THICKNESS mm mm W.T. WEIGHT ERW Line Pipes conforming to API 5L, IS/ISO : 3183 & ASTM A 53 Dimensions, Weights and Test Pressures for Sizes 3 1/2" through 14" (SI Units) Size Specified Outside Specified Wall Thickness Plainend Weight per Unit Length Calculated Inside Minimum Test Pressure (kpa x 100) D t Wpe d Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade (Kg/m) A25 A B X42 X46 X52 X56 X60 X65 X70 3 1/2" " /2" /16" /8" /8"

6 ERW Line Pipes conforming to API 5L, IS/ISO : 3183 & ASTM A 53 Dimensions, Weights and Test Pressures for Sizes 31/2" through 14" (SI Units) API CASING Size Specified Outside Specified Wall Thickness Plainend Weight per Unit Length Calculated Inside Minimum Test Pressure (kpa x 100) D t Wpe d Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade (Kg/m) A25 A B X42 X46 X52 X56 X60 X65 X /4" /4" " API TUBING

7 ERW Boiler, Super Heater, Heat Exchanger, Condenser & Air Heater Tubes & Pipes Out side Conforming to BS 3059(Ptl & ll), BS 6323 (PtV), ASTM, A178, A214, A333, A334, IS 2416 (PtIV). Conventional Mass per Unit length in kg/m for a Tube Thickness in mm of: / / NOTE: (i) Leak Test Hydro Test / NDT test as per specification requirements TOLERANCE ON OUTSIDE DIAMETER, WALL THICKNESS, WEIGHT AND LENGTH OF PIPE SPEC ASTM A178 & A214 ASTM A333 & A334 API 5CT PIPE BODY <1 (25.4mm): ± 0.10mm 1 (25.4mm) to 11/2 (38.1mm) Incl.: ± 0.15mm > 11/2 (38.1mm) to 2 (50.8mm) excl.: ± 0.20mm 2 (50.8mm) to 2 1/2 (63.5mm) excl.: ± 0.25mm 21/2 (63.5mm) to 3 (76.2mm) excl.: ± 0.30mm 3 (76.2mm) to 4 (101.6mm) Incl.: ± 0.38mm > 4 (101.6mm) to 71/2 (190.5mm) Incl.: mm, 0.64mm > 71/2 (190.5mm)to 9 (228.6mm) Incl.: +0.38mm, 1.14mm 1/8 to 11/2 Incl.: mm, 0.80mm over 11/2 to 4 Incl.: ± 0.80mm over 4 to 8 Incl.: mm, 0.80mm over 8 to 18 Incl.: mm, 0.80mm < 41/2 (114.3mm) O.D.: ± (0.79mm) > 41/2 (114.3mm) O.D.: +1% D, 0.5% D OUT SIDE DIAMETER PIPE END WALL THICKNESS WEIGHT LENGTH NORMAL Avg. (MIN) MINIMUM MAXIMUM ft mtr ft mtr ft mtr ft mtr + 18%, %, 0 < 2 (50.8mm) O.D. : +3mm, 0 > 2 (50.8mm) O.D. : +5mm, 0 At any point: 12.5% (max) + not limited 12.50% Single pipe NPS 12 & under: +10%, 3.5% Single pipe over NPS 12: +10%, 5% Single Length: +6.5%, 3.5% Carload > 40,000 Ibs (18,144 kgs): 1.75% Carload < 40,000 Ibs (18,144 kgs): 3.5% Specified length: + 6mm, 0 Range 1 Range 2 Range 3 Casing ft mtrs. ( ) ( ) ( ) ft Tubing mtrs. ( ) ( ) ( ) Pup joints 2,3,4,6,8,10 & 12 ft. tolerance : ± 3 SPEC API 5L & IS/ISO:3183 IS:1239 & BS:1387 PIPE BODY <23/8 (60.3mm) OD = mm, 0.80mm > 23/8 (60.3mm) OD = ± D As per table OUT SIDE DIAMETER PIPE END < 2 3/8 (60.8mm): + 0.4mm, 0.8mm > 2 3/8 (60.8mm) to < 6 5/8 (168.3mm) mm, 0.40mm > 6 5/8 (168.3mm) ± D (but max.of ±1.6mm) WALL THICKNESS < 5.0mm WT ± 0.5mm > 5.0mm WT to < 15.0mm WT ± 0.1t > 15.0mm WT ± 1.5mm WEIGHT Single length of pipe + 10%, 3.5% Car loades 40,000 lb (18,144 Kg.) or more 1.75%, less 3.5% LENGTH NORMAL Avg. (MIN) MINIMUM MAXIMUM ft mtr ft mtr ft mtr ft mtr Light 8% + not limited Medium & Heavy 10%, Carload 10 MT Light +7.5%, 5%, M & H ± 7.5% not limited Single Tube Light 8% + 10% Med & Heavy ± 10% Tolarance Exact length + 6, 0mm Approximate length ± 150mm IBR ± 0.75% (But min 0.30mm) RDSO ETI/OHE/ mm OD + 0.8, 1.0mm 38.0mm OD , 0.2mm 49.0mm OD , 0.2mm for grade WC1: < 3.2mm: ± 10% > 3.2mm : ± 7.5% for grade WC2 & WC3: ± 10% tolerance Upto & incl. 6 mm, 0 and above 6 mtrs.: 1.5mm will incesase for every 3 mtr increase of length. ( 12mm max.) 28.4 (Std. ID) & (Min. ID) 29.9 (Std. ID) & (Min. ID) 40.9 (Std. ID) & (Min. ID) 0.31mm, + not limited 0.35mm, + not limited 0.35mm, + not limited Tolarance As agreed IS:3589 Upto 508mm OD = % ± 10% Carload 10MT and above ± 7.5% Tolerance For exect length + 10, 0mm IS:4270 ± 1.0% Upto 406.4mm OD + 10% 8% = +15% 12.5% IS:4923 ± 1.0% N.A ± 10% ( ±0.5mm min.) Excluding Weld Area Carload 10MT : ±7.5% Single Tube +10%, 8% Tolarance Exect Length : ±6mm IS:1161 Upto 48.3mm OD 10%, + not limited + 0.4mm, 0.8mm Over 48.3mm ± 1.0% Carload 10 MT Light ± 5%, M & H ± 7.5% Single Tube Light 8% + 10% Med & Heavy ± 10% Tolarance Exact length as agreed Random Length 4 to 7 mtr. IS:9295 ± 0.8% ±10% Single Length : ±10% Carload per 10 tonnes : ±7.5% IS:1914 PtIV IS:2416 PtIV IS:11714 PtIII Tolarance Exact length : +6mm, 0 + 0, 1% + 10%, 5% Tolarance Upto 9 mtr +3, 0mm Above 9 mtr +6, 0mm ± 0.75% (± 0.30mm min.) + 10%, 5% Tolarance Upto 9 mtr +3, 0mm Above 9 mtr +6, 0mm As per table + 18%, %, 0 Tolarance Below 50mm + 3.2, 0mm 50mm & above + 4.8, 0mm BS:3059 PtI BS:3059 PtII ± 0.75% (± 0.30mm min.) Upto 3.25mm ± 10% Over 3.25mm ± 7.5% Tolarance Upto 6 mtr +6, 0mm Above 6 mtr 1.5mm will increase for every 3 mtr increase of length. (12mm max.) ± 0.75% (± 0.30mm min.) ± 10% (excluding weld area) BS:6323 PtV As per table Less than 3mm + 10% 3mm & above + 8% ASTM A53 11/2 NPS & under = ± 0.4mm At any point 12.5% (max.) ±10% 2 NPS and over = ±1.0% 3 12 Tolarance Upto 0.5 mtr +2, 0mm 0.5 to 2 mtr +3, 0mm ; 2 to 5 mtr +5, 0mm ; 5 to 7 mtr + 10, 0mm ; Above 7 mtr as agreed

8 CHEMICAL COMPOSITION & MECHANICAL PROPERTIES CHEMICAL COMPOSITION & MECHANICAL PROPERTIES Specification Grade C Mn P S Si C.E. Yield Strength Tensile Strength PCM IIW Min Max Min Max PSI MPa PSI MPa PSI MPa PSI MPa API 5L PSL 1 & IS/ISO:3183 PSL 1 API 5L PSL 2 & IS/ISO:3183 PSL 2 Chemical Composition (%) Max. Mechanical Properties L210 or A , , L245 or B , , L290 or X , , L320 or X , , L360 or X , , L390 or X , , L415 or X , , L450 or X , , L485 or X , , L245M or BM , , , , L290M or X42M , , , , L320M or X46M , , , L360M or X52M , , , , L390M or X56M , , , , L415M or X60M , , , , L450M or X65M , , , , L485M or X70M , , , , UPTO 25 mm NB 20 ABOVE 25 mm Fe Fe Fe YST YST YST Fe Fe YST YST YST YST YST YST % Elongation e (min) U.S Customary Unit e = 625,000 A 0.2 / U 0.9 S.I Unit e = 1940 A 0.2 / U 0.9 Legend : e = Specified min. elongation A= Tensile test piece cross sectional area. U= Specified min. tensile strength GL= 5.65 Area GL= 5.65 Area upto 25.4 above GL= 5.65 Area GL= 5.65 Area Impact Energy J (Ft.lb) (min.) Distance between plates Forweld75%, 85%, 85% For parent 60%, 75%, 75% Hardness= 230 HV max Drift test = minimum increase in OD after expansion shall be 2.5% Flattering distance between plates for weld = 75% and for parent = 60% Specification Type Grade e CHEMICAL COMPOSITION YIELD STRENGTH MECHANICAL PROPERTIES TENSILE STRENGTH C Mn P S Sl Min Max Min Max Min Max Min Max Max Max Min Max PSI MPa PSI MPa PSI MPa PSI MPa IS:2416 ERW PtIV IS:11714 ERW PtIII IS:1914 ERW PtIV BS:1387 ERW BS:3059 ERW PartI BS:3059 ERW PartII BS:6323 ERW ERW PartV ERW ERW ASTM A53 ERW A Cu, Ni, 30, , Cr = 0.40 max. B Mo= 0.15 max., 35, , V= 0.08 max. ASTM ERW A , , A178 C , , ASTM ERW A214 ASTM ERW , , A333 & , , A334 IBR ERW W C W C , W C % Elongation (min) (100 RM / 9.81) /C C=2.20 RM = Measured T.S. (100 RM / 9.81) /C C=2.20 RM = Measured T.S. 12 UPTO 25 mm NB 20 ABOVE 25 mm 77 HRB (Max) D/a <20 10 D/a >20/ e= 625,000 A 0.2 /U 0.9 at GL 50.8 mm Remarks Impact / Hardness 72 HRB (Max) 14 J 85 HRB (Max) 18 J 90 HRB (Max) RDSO ERW YST Exp7.5% fo ID (ETI/ OHE /11) API ERW J CT N Type1 N TypeQ e= A 0.2 U 0.9 e = Min. elongation A = tensile test piece cross sectional area U = Specified minimum tensile strength(mpa) NOTE: Refer current editions of Relevant Specification for Dimension and Properties data. Specifications are subject to change without any prior notice. A= Speciman crosssectional area U= Specified Min. T.S.

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