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Report

On
Study on API Pipe Manufacturing Process at National Tubes Ltd
A practicum report prepared as a part of the requirements that are needed to fulfill to have the
degree of Bachelor of Science in Mechanical Engineering (BSME)

Prepared by
Md. Ashraful Sheikh
Program: BSME
ID: 12107103

Semester: Fall 2015

IUBATInternational University of Business Agriculture & Technology


15th December, 2015
REQUEST FOR GOING THROUGH MY REPORT
15th December, 2015

Coordinator
Department of Mechanical Engineering
IUBATInternational University of Business Agriculture and Technology
4 Embankment Drive Road, Uttara Model Town, Sector- 10,
Dhaka- 1230, Bangladesh
Subject: Request for going through my report.
Dear Sir,
With due respect and humble submission to state that, I would like to submit this report as a
partial fulfillment of the Bachelor of Science in Mechanical Engineering (BSME) program,
on the topic Study on API Pipe Manufacturing Process at National Tubes Ltd. It was a
great opportunity for me to study on this topic and get practical understanding. Now I am
looking forward to get your kind assessment on my works.
I should, therefore, pray and hope that you would be kind enough to take time to go through my report and

assess my performance.

Thanking You

Md. Ashraful Sheikh


Program: BSME
ID: 12107103
\

LETTER OF TRANSMITTAL

15th December, 2015


Coordinator
Department of Mechanical Engineering
IUBATInternational University of Business Agriculture and Technology
4 Embankment Drive Road, Uttara Model Town, Sector 10,
Dhaka-1230, Bangladesh

Subject: Submission of Practicum Report.


Dear Sir,
It is my pleasure to submit my practicum report on Study on API Pipe Manufacturing
Process at National Tubes Ltd. as a part of the requirements that are needed to fulfill to
have the degree of Bachelor of Science in Mechanical Engineering (BSME) from our reputed
university. This report is a must to the planned academic program, and I have felt honored
and lucky enough to work under supervision and guidance..
So, therefore, my humble request is to go through my works and feel much appreciated to
leave your valuable comments.

Thanking You

Md. Ashraful Sheikh


Program: BSME
ID: 12107103

To Whom It May Concern

Student Declaration

I, Md. Ashraful Sheikh, a student of the Department of Mechanical Engineering under the
College of Engineering and Technology (CEAT), would like to declare that this report on
Study on API Pipe Manufacturing Process at National Tubes Ltd is prepared . as a
part of the requirements that are needed to fulfill to have the degree of Bachelor of Science in
Mechanical Engineering (BSME) of the course Practicum (MEC-490). I have prepared this
report on the basis of the knowledge that I have gathered in my internship period in National
Tube Ltd.
I am assuring you that the report is only prepared to fulfill the academic requirement and not
for any other purposes.

Thanking You

Md. Ashraful Sheikh


Program: BSME
ID: 12107103

Acknowledgement
Internship is the period when one gains knowledge & wisdom. It is a gradual progression
where a Management student gets a glimpse of the industry and the corporate world. Such a
crucial period requires proper guidance; hence I would like to acknowledge the efforts of
individuals
who
have
guided
this
project
to
fruition.
I would like to express the deepest appreciation to the chair of my department, Prof. Engr.
AZA Saifullah. I want to express my sincere gratitude to Engr. Abdul Wadud, Coordinator
and faculty, for providing me with guidance of utter importance and a source of motivation &
inspiration .This project stands testimony for the knowledge and experience that I have
gained
under
their
competent
guidance.
I would like to thank Mr. Engr. Amminur Rahman, Head of Production Department, for
providing me with an amiable environment to work in this esteemed organization, National
Tubes Ltd, who has the attitude and the substance of a genius. He, along with Mr. Engr. Md.
Ferdous, PDI Department, and all the personnel continually and convincingly conveyed a
spirit of adventure in regard to the quality standards of the industry. Without their guidance
and persistent help this dissertation would not have been possible.
Again, I would like to thank my coordinators, Engr. Abdul Wadud whose faith in me and the
industry constantly motivated me to work in accordance with the modern technology thus,
transcending
academics
and
providing
a
quest
for
new
tasks.
In addition, I am really thankful to Human Resource (HR) Department and Production
Department team and all those people who have helped me a lot and have stayed by my side
through tough times and have never let me feel alone in the industry throughout my training
period.
In the end. I would like to extend my thanks to National Tubes Ltd and my university for
giving me an opportunity to be a part of a great culture of the great organization.
In fine, I must say I am thankful to all the faculties and all the employees of National Tube
Ltd. who helped me a lot to provide me with a platform to exchange ideas and information.

Executive Summary
National Tubes Limited was established in 1964 in the private sector. It was nationalized and
placed under Bangladesh Steel & Engineering Corporation (BSEC) in 1972. It is the only
Govt. owned steel pipe producer in Bangladesh. In 1989 the enterprise was transformed into a
public limited company by off-loading 49 percent shares to the general public. Now a
sovereign Board of Directors manages the company.
To contribute to the well being of the nation by producing high quality import-substitute
Gas/Oil line pipes according to the specifications (Spec. QI & 5L) of American Petroleum
Institute (API) and water line pipes (GI) according to British Standard (BS - 1387 & BS-729).
This is a unique enterprise reflecting utmost integrity, transparency and accountability at all
levels, thereby marketing products manufactured under uncompromising quality program. We
aspire to achieve continuous improvements for customers satisfaction with modern
technology, innovative vision and motivated workforce developed through strategic
management of human resource.
As a Trainee Engineer, during my internship period, my responsibilities were to supervise,
check and troubleshoot production line. National Tube Ltd produces high quality importsubstitute Gas/Oil line pipes according to the specifications (Spec. QI & 5L) of American
Petroleum Institute (API) and water line pipes (GI) according to British Standard (BS - 1387
& BS-729). National Tube Ltd is an API Licensee and an ISO 9001: 2000 Certified
Company. So it was a great opportunity for me to gain knowledge about tube manufacturing
process.
The company produces line pipe with API Spec 5L PSL 1 standard, water line pipe( GI) and
Mild Steel pipes, according to the British Standard BS-1387 and Bangladesh Standard BDS
-1031, Under this standard the every step of production is strictly maintained. The world class
lab facilities with lab expertise ensure the maximum quality product.
This report mainly deals with the fundamental process of abovementioned pipes
manufacturing and accessories used to run the whole process line. In the first month, the
concepts about working principles of different components and systems of the pipe
manufacturing system have been cleared. In the second and third months, the maintenance
and trouble-shooting were done on the basis of the knowledge of first month. Thus the report
has been accomplished on the basis of a nice combination of theoretical knowledge along
with practical knowledge. Especially my practicum has been conducted in production
department of National Tube Ltd. The full production line is consisted with mainly 14 steps:
Uncoiling, end Cutting or Treaming, Looping, Leveling, Forming, HF welding, Seam
Shaving, Water Cooling, Eddy Current Flaw Detector, Sizing, Cutting-Off, Facing &
Beveling, Annealing, Hydrostatic Test. During my practicum period I was directly involved
with tasks of these sections.

Contents
1. Preparatory Part:
A. Title Fly
B. Cover Page. I
C. Request for Report. II
D. Letter of Transmittal. III
E. To Whom May I Concern IV-V
F. Student Declaration
VI
G. AcknowledgementVII
H. Executive Summary
..VIII
I. Table of Contents........... IX-XI
J. List of Figures. XV-XVI
k. List of Table ..XVI
2. Experiential Part:

CHAPTER ONE (INTRODUCTION)

(01-03)

1.1Origin of the report


. 02
1.2 Objective
. 02
1.3 Scope
02
1.4 Background .
.. 02
1.5 Methodology
...............................02
1.6 Limitations
..03

CHAPTER TWO (COMPANY PROFILE & ACCEPTANCE):

(04-15)

2.1 Name of the Organization ...05


2.2 Plant Location..05
2.3 The Plant Brief History...05-06
2.4 The Plant....07
2.5 Company Feature ......07
2.6 Head Office 07
2.7 Web....07
2.8 Mission Statement...07
2.9 Vision......08
2.10 Organization Structure..08
2.11 Installed Production Capacity...09
2.12 Reduction Per Day.....09
2.13 Production Range......09
2.14 Production Process....09
2.15 Factory Area......09
2.16 Product Start Date.......09
2.17 Types of Produced09-10
2.18 Number of Department in Factory..11
2.19 Number of Shift.11
2.20 Number of sections for producing pipe.11
2.21 Utility section.12
2.22 Product Range of National Tubes Ltd...12
2.23 Different type of pipe in National Tubes Ltd....13
2.24 Acceptance of National Tubes Ltd.......14-15
CHAPTER THREE (PIPE MANUFACTURING PROCESS)
(16-42)

3.1Row materials .17-18


3.2 Various kind of equipment..18
3.3 Flow chart of API,MS,GI pipe process in National Tube Ltd.19

3.4 Manufacturing process.20


3.4.1 Steel sheet stilling machine...20
3.4.2 End cutting....20
3.4.3 Leveling.....21-22
3.4.3.1 Roll system..21
3.4.3.2 Drive....21
3.4.3.3 Operation.....22
3.4.3.4 Maintenance.....22
3.4.4 Forming............23-26
3.4.4.1 Various kinds of roller die.....24
3.4.4.2 Working diagram...25
3.4.4.3 Working procedure.......25-26
3.4.5Wielding machine..26
3.4.6 Length of pipe.27
3.4.7 Water cooling.28
3.4.8 Eddy Current Flow Detector29
3.4.9 Pipe cutting disk..29
3.4.10 End facing & Beveling machine............30
3.4.10.1 Description30
3.4.10.2 Application.30
3.4.10.3 Classification.30
3.4.11 Annealing...........31
3.4.12 Dimension weighing & Hydrostatic test...31-39
3.4.12.1 Low pressure water system.31-33
3.4.12.2 Test pressure....34-39
3.4.13 Ultrasonic test........40

3.4.14 Visual inspection...40-41


3.5 Marking system...........41
3.6 Saw equipment and Bundling.........42

CHAPTER FOUR (PIPE PODUCTION)

(43-49)

4.1 Man power utilization.44


4.2 Product type of National Tubes Ltd...44
4.3 Pipe Range.....44
4.4 The efficiency of process.......44
4.5 Monthly production of 2013 & 2014....45-46
4.6 Yearly production of 2002-2014...46-47
4.7 Statistical data of NTL...48-49

CHAPTER FIVE (QUALITY CONTROL FACILITIES)

(50-53)

5.1 Chemical analysis...51


5.2 Weld ductility test...51
5.3 Tensile test...51
5.4 Dimension check.52
5.5 Flow detection.52
5.6 Ultrasonic test..52
5.7 Metallographic test.52
5.8 Visual inspection..53
5.9 Hydrostatic test.53

CHAPTER SIX (PROBLEMS & REMEDIES)

(54-58)

6.1 Problems of mixing section.55


6.2 Problem faced in cutting section.56-57
6.3 Problem faced in sizing section58

CHAPTER SEVEN (GENERATOR)

(59-67)

7.1 Introduction...60
7.2 Main parts of Generator....60-62
7.2.1 Engine..60
7.2.2 Alternator.61
7.3 Thermal energy balance..63-64
7.4 Exhaust gas data....64
7.5 Combustion air data..64
7.6 General maintenance.........65
7.6.1 Pre maintenance65
7.6.2 Schedule maintenance..65

CHAPTER EIGHT (COMPRESSSOR)

(66-70)

8.1 Introduction...67
8.2 Mechanism of screw type of compressor..67
8.3 Main parts of compressor.68-70
8.3.1 Oil separator..68
8.3.2 Air filter.69
8.3.3 Dryer..69
8.3.4 Oil filter.69
8.4 Mechanical maintenance of compressor70
8.4.1 Leak screening techniques70

8.4.2 Advantage of maintenance...70

CHAPTER NINE ( MAINTENANCE)

(71-92)

9.1 Definition.72
9.2 Maintenance activities......72
9.3 Maintenance history.72-73
9.4 Maintenance objectives.73-74
9.5 Types of maintenance...74
9.6 Run of failure maintenance...75
9.6.1 Emergency maintenance..75
9.6.2 Break down maintenance.75
9.7 This types of maintenance is useful in the following situtation75
9.8 Preventive maintenance....76-77
9.9 Corrective maintenance77-79
9.10 Improvement maintenance..79
9.11 Predictive maintenance80
9.12 Mechanical maintenance of finishing system..80-81
9.13 Bush.82
9.14 Pulley & Belt.82
9.15 Maintenance schedule..82
9.16 Controlling...82
9.17 Cleaning and maintenance program83-88
9.18 Lubrication of machinery.88
9.18.1 Definition..88-89

9.17.2 Table of lubricants uses purpose in NTL...90-91


9.18 Remarks.....92

3. Supplementary Part:
CHAPTER TEN (CONCLUSION)

(93-97)

A. Recommendations..94
B. Conclusion...94
C. Bibliography...95-96
D. Abbreviations....9 7
List of Figures:

Fig.2.1: API Pipe.09


Fig.2.2: MS pipe..10
Fig.2.3: GI pipe...10
Fig.3.1: Hat rolled steel strips..17
Fig.3.2: pipe process diagram.....................19
Fig.3.3: Slitting machine...20
Fig.3.4: End cutting..20
Fig.3.5: Leveling machine....21
Fig.3.6: Forming machine23
Fig.3.7: Roller die...24
Fif.3.8: Working diagram25
Fig.3.9: Wielding machine..26

Fig.3.10: Pipe Measurement27


Fig.3.11: Water cooling28
Fig.3.12: Pipe cutting machine.29
Fig.3.13: End facing and beveling machine..30
Fig.3.14: Annealing..31
Fig.3.15: Hydrostatic Test..31
Fig.3.16: Diagram of Hydraulic..32
Fig.3.17: Pipe Testing machine..33
Fig.3.18: Ultrasonic test40
Fig.3.19: Visual inspection40
Fig.3.20: Pipe bundling.42
Fig.6.1: Time Setting..55
Fig.6.2: Bearing Corrosion56
Fig.6.3: Gear.....57
Fig.6.4: Shaft corrosion of Roller. .....58
Fig.7.1: Generator...59
Fig.7.2: Four stroke engine diagram..59
Fig.7.3: Alternator..60
Fig.8.1: Compressor...66
Fig.8.2: Screw type motors & diagram for compressor....66
Fig.8.3.1: Oil separator68
Fig.8.3.2: Air filter..69
Fig.8.3.3: Oil filter..69
Fig.8.3.4: Eco filter....70
Fig.8.3.5: Receiver tank....70
Fig.9.1: History of maintenance73

Fig.9.2: Types of maintenance..74

List of Tables:
Chart.4.1: Graphical view of per monthly production 46
Chart4.2: Graphical view of per yearly production..47
Table.7.3: Thermal energy balance63-64
Table 7.4: Exhaust gas data..64
Table7.5: Combustion air data.64
Table 8.3 Name of the compressor..68
Table19.17.1 Extruder (Model-92/28)...84-85
Table19.17.2 Extruder (Model-92/25)....85
Table19.17.3 Extruder (Model-K120).86
Table19.17.4 Extruder (Model-92/28,52/25)..86
Table19.17.5 Sizing machine (Model-k120)..87