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LINE PIPE PRODUCT CATALOGUE

Contents
Borusan Group At a Glance Borusan Mannesmann Production Flow Production Range Production Standards Advantages of Spirally Welded Pipes The Submerged Arc Welding Process Yield and Tensile Requirements for API - Grades for Sweet & Sour Services Protective OD & ID Coating Systems Pipe Joint Systems QEHS Management Integrated Logistics Experiences Operational Highlights References 1 3 5 7 9 10 11 13 15 22 23 28 29 35

Borusan Group At a Glance

Borusan
Steel
The Pipe Group The Flat Steel Group

Distributorship
The Earth Moving Equipments and Power Systems Group Borusan Makina ve Güç Sistemleri The Automotive Group

Borusan Mannesmann Borusan Paslanmaz Çelik Boru ve Profil (Stainless Steel Pipe and Profile Production) Borusan Mühendislik (Engineering) Borusan ‹stikbal Ticaret

Borçelik Kerim Çelik

Borusan Otomotiv& Borusan Oto

Supsan Manheim Turkey

Borusan Group has been among the pioneers of industrialization and corporate governance in Turkey throughout its 65 years of history. The group currently operates in four major business areas including steel, distributorship, logistics and energy. In 2006 Borusan Group signed the United Nations’ Global Compact Policy and it supports and adheres by the principles of “good corporate governance” and “sustainability” as a prerequisite of long-term and permanent components of success.

In 4 major business with

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Logistics
Borusan Lojistik Borusan Enerji

Energy

Contribution to Community: Borusan has adopted as one of its primary principles the concept of giving back to the community with which it does business. In order to better fulfill its social responsibility vision, the activities of the As›m Kocab›y›k Culture and Education Foundation, which was founded in 1992, and Borusan Culture and Arts, established in 1997, came together under one roof in 2008 to become the Borusan Kocab›y›k Foundation. With a deep social responsibility consciousness, the Borusan Group established the Borusan Center for Culture & Arts on October 15, 1997. The Borusan Center for Culture and Arts is a member of the International Society of Contemporary Music (ISCM) and the European Music Council (EMC) and organizes the annual Mediterranean Contemporary Music Days. It pursues its music activities through its prominent Borusan Istanbul Philharmonic Orchestra, the Borusan Chamber Orchestra, the Borusan String Quartet and the Borusan Children’s Choir, as well as its Music Library.

areas 5.000 employees...

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Borusan Mannesmann Celebrated 50th anniversary in 2008.S As the leader of Turkish steel pipe market. We have a track record which has a wide range in oil and gas pipeline applications both in Turkey and International markets with high grade API standards. U. The company has 77% shares of Borusan Mannesmann Boru San. CANADA UNITED STATES Corporate Structure: Borusan Group and one of Europe's leading steel and technology companies. we aim to meet customized expectations of our customers throughout the world. 77% 23% Borusan Mannesmann Boru Yat›r›m Holding 73% 16% Free Float 11% Others 3 . contract management. continuous development and customer oriented approach. production and integrated logistics services worldwide. reliability and commitment in its products and services.. Borusan Mannesmann has an established reputation in providing an extraordinary level of quality. ve Tic. Our SAWH line pipes (dia.fi. Borusan Mannesmann owes this outstanding position to its 50 years of corporate structure experience. A. oil and water transmission but also for piling applications. We produce our spiral welded (SAWH) and longitudinal welded (ERW) products using the latest production techniques.000 tons. “Borusan Mannesmann Boru Yat›r›m Holding” in 1998. Our Pipeline Projects Management Team.. merged their welded steel pipe investments in Turkey and named that partnership. specialized in providing total solutions to its customers in pipe supply contracts that includes manufacturing processes. Salzgitter Mannesmann GMBH. Especially in line pipe business. operates with five mills.14"-100") are not only used for gas. the flagship of Borusan Group. Giving priority to product quality and qualified work force in our growth strategies. Borusan Mannesmann. four in Turkey and one in Italy with a total annual production capacity of 925.

250 committed people.E OMAN YEMEN FRENCH GUIANA CAMEROON GABON CONGO TANZANIA ANGOLA REUNION SOUTH AFRICA Workforce of 1. LITH. BELGIUM GERMANY POLAND LAT... CUBA SENEGAL GAMBIA TUNISIA LEB. Location of Borusan Mannesmann Mills 4 .A....” Halkalı Plant Gebze Plant İzmit Plant Gemlik Plant Vobarno Plant QUEEN ELIZABETH ISLANDS ICELAND SWEDEN FINLAND NORWAY EST. DENMARK UNITED KINGDOM IRELAND NETH.“Our mission is to provide products and services that enhance the quality of life with our expertise in steel pipe industry and to promote the process of economic and social progress of our community. SLOVENIA ROMANIA CROATIA BOS. BELARUS FRANCE CZECH UKRAINE REP. ISRAEL JORDAN IRAQ IRAN PAKISTAN ALGERIA LIBYA EGYPT SAUDI ARABIA QATAR U.. SLOVAKIA AUSTRIA HUNGARY SWITZ. GREECE SICILY KAZAKHSTAN GEORGIA AZERBAIJAN UZBEKISTAN PORTUGAL SPAIN TURKEY CYPRUS SYRIA 50% of production going overseas.& SERBIA HERZ BULGARI ITALY ALB.

Helical Submerged Arc Welded Pipe Offline Ultrasonic Inspection X-Ray Inspection Hidrostatic Test Beveling of Pipe Ends Inside Welding Final Inspection and Marking Stockpiling Spiral Forming Outside Welding Ultrasonic Test Cutting to Length Edge Preparing Uncoiling Coil Identity and Analysis 5 .Production Flow SAWH Pipe Production .

ERW Pipe Production .Electric Resistance Welded Pipe Stockpiling Final Inspection and Marking Ultrasonic Test Hidrostatic Test Coil Identity and Analysis Uncoiling Edge Preparing Preforming Forming Welding Beat Cutting (inner/outer) Ultrasonic Test Sizing and Straightening Post-Annealer Quenching Cutting to Length Beveling of Pipe Ends 6 .

7 484.9 258.8 327.3 66.5 655.25 736.2 857.0 43.3 148.6 621.8 188.SAWH Line Pipes 1168 46 171.2 387.2 516.5 191.0 144.3 275.7 50.2 134.1 1550.6 559 22 54.9 130.2 295.4 704.47 649.4 489.7 256.0 514.0 134.1 1427.8 259.7 122.6 14 34.2 767.7 841.0 589.217 0.8 88.7 162.433 0.4 371.8 95.0 451.2 201.0 746.1 153.5 416.1 408.8 96.9 332.9 223.2 99.2 74.6 111.7 80.0 1372 54 235.2 491.4 759.0 534.3 510.7 732.5 200.6 269.9 759.0 208.0 515.3 641.8 595.3 240.2 38 130.0 238.7 666.6 354.9 1321 52 226.197 0.2 382.1 149.7 597.4 677.8 272.7 288.4 174.7 419.5 176.6 711.1 502.4 333.1 234.6 803.8 88.0 Production Range .9 546.6 285.9 354.8 591.1 81.4 16 39.0 314.5 5 5.6 406.2 170.8 486.4 207.1 647.0 252.0 68.3 330.4 104.9 614.7 1017.0 554.9 395.2 348.0 191.2 336.866 0.9 177.551 0.7 610 24 59.3 443.5 182.8 984.1 578.8 454.0 191.2 28 69.4 483.1 95.4 87.2 93.3 924.4 517.1 594.3 766.5 995.11 592.4 358.9 165.7 128.1 269.5 97.9 511.1 714.4 OD 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 mm 4 4.0 821.3 435.4 1237.1 1038.2 198.2 141.7 246.6 414.2 68.4 477.0 715.4 223.6 696.3 75.5 713.5 537.5 274.5 695.5 417.7 649.4 633.8 1016 40 137.9 313.4 800.8 122.2 323.1 258.2 468.9 282.5 716.5 160.0 436.3 374.4 198.6 49.6 457.7 146.5 445.8 423.6 633.4 558.8 260.7 55.2 992.2 235.8 914 36 112.5 1139.6 508 20 49.4 1090.7 451.4 443.5 370.8 78.4 148.8 948.5 851.0 89.6 725.6 1489.2 647.4 1146.8 691.2 257.5 741.3 925.5 381.1 185.6 1362.4 626.8 792.8 61.945 1.0 307.3 556.1 533.1 816.5 54.1 1168.8 121.9 535.3 389.0 397.3 462.4 705.5 6 7 8 mm inch 0.0 205.7 44.157 0.0 620.5 1366.1 1626 64 319.3 566.6 844.236 0.9 594.591 0.4 158.3 156.2 631.5 1007.1 142.5 119.3 1024.5 797.7 541.1 943.1 123.0 601.9 894.4 139.7 1119.9 363.7 568.3 321.2 937.4 438.0 916.1 671.2 327.276 0.7 217.1 883.3 86.787 0.8 161.9 1304.5 418.9 62.354 0.1 158.3 74.6 262.827 0.5 503.512 0.6 348.2 587.3 467.8 660 26 64.5 68.1 793.4 345.8 148.9 203.6 82.3 1041.4 228.2 591.7 72.1 366.9 870.8 32 99.5 370.6 254.9 200.3 1092.9 1067 42 157.7 126.7 762 30 93.1 313.3 397.2 276.5 51.0 131.9 221.4 354.3 108.3 291.5 493.906 0.9 222.0 977.9 237.4 402.4 126.7 324.7 175.8 375.3 342.5 582.3 312.3 909.3 116.1 118.2 447.1 861.2 214.9 167.4 369.2 1676 66 1727 68 X 42 X 52 1829 72 X 60 2032 80 2083 82 X 65 X 70 2235 88 X 80 2540 100 .5 248.2 373.0 189.0 520.3 663.5 1188.0 623.6 419.1 1422 56 279.6 109.4 673.9 78.5 231.6 465.9 1049.2 238.0 410.9 1118 44 164.1 451.3 707.1 398.6 1308.2 934.5 98.2 610.8 112.5 814.000 355.5 351.5 394.8 1219 48 209.8 612.4 1218.5 300.663 0.3 541.3 1112.9 657.4 507.4 334.0 391.6 712.8 240.7 434.6 286.7 539.7 514.2 47.7 328.6 138.3 102.4 272.1 987.6 482.2 68.9 776.5 573.8 736.1 291.3 386.3 244.8 206.8 827.6 492.5 1181.9 168.5 107.7 104.2 595.1 357.2 548.1 491.7 210.2 699.7 812.177 0.7 257.4 248.0 1524 60 299.3 313.7 61.3 121.8 810.1 617.3 980.5 778.8 293.9 376.6 178.1 312.3 310.3 848.2 562.7 866.6 1254.0 183.4 59.4 815.2 1242.9 116.8 77.7 410.3 1068.8 668.8 440.5 110.9 892.3 110.9 466.1 521.3 483.5 566.3 294.1 135.7 60.8 305.6 875.2 55.6 488.7 420.472 0.29 621.4 188.3 155.394 0.1 234.709 0.0 635.1 765.2 562.0 758.8 674.315 0.9 657.8 220.4 133.1 549.1 929.748 0.0 410.5 335.3 967.2 752.7 355.4 416.1 273.92 85.8 219.5 1067.3 340.5 936.0 426.4 352.4 563.1 440.5 1200.1 872.8 863.2 18 44.7 88.0 675.7 39.6 268.3 302.62 765.8 966.2 370.0 266.3 795.9 538.1 135.9 212.6 34 105.06 678.1 1017.3 831.4 178.8 67.7 965.4 194.2 461.9 398.2 285.5 474.6 1268.2 897.0 465.0 189.7 Wall Thickness (mm & inch) 9 76.8 1118.5 337.5 298.8 172.6 223.5 533.1 297.9 1057.2 568.4 887.630 0.9 147.

10 56.200 0.70 23.68 273 10 3/4 323.472 0.82 3.08 141.1 8.72 10.18 20.54 8.99 219.03 25.98 5.88 92.2 6 6.OD 3.7 4.84 28.76 3.9 3.35 66.10 6.54 2.432 0.318 0.09 12.9 3 1/2 6.3 1 1/2 3.69 4.87 3.21 21.69 9.77 21.32 1.277 0.27 5.25 48.74 42.45 20.91 54.15 7.5 mm inch 0.30 9.11 2.15 43.88 35.05 2.53 34.29 6.109 0.17 7.07 77.92 46.88 29.49 12.49 X 52 X 60 X 65 X 70 Wall Thickness (mm & inch) mm 2.6 7 7.73 13.113 0.93 4.91 24.147 0.80 33.02 17.53 18.1 5.02 15.3 1/2 1.ERW Line Pipes 88.36 45.02 21.3 4 1/2 7.08 65.5 5.7 1 2.15 73.9 1.81 56.97 9.04 51.64 48.60 2.72 1.51 3.53 48.52 18.73 2.81 18.133 0.4 8.09 10.3 5 9/16 11.44 40.04 10.00 33.53 28.54 10.65 8.60 8.27 3.18 17.18 13.86 5.60 1.1 8 5/8 19.61 27.65 20.09 40.8 2.85 5.4 1 1/4 2.87 72.18 23.73 71.21 15.9 12 3/4 We can meet all X 42 requirements in our production range.66 1.1 8.6 9.70 4.154 0.27 30.17 9.35 168.70 55. 8 .56 52.55 13.49 7.14 5.68 3.19 6.34 39.13 2.56 3.72 2.16 73 2 7/8 4.50 26.77 4.10 4.65 2.9 3/4 1.32 27.140 0.51 43.3 6 5/8 14.30 35.73 12.21 4.77 114.365 0.3 2 3/8 3.12 33.24 80.20 42.203 0.42 24.67 2.48 61.37 10.01 5.62 12.41 3.94 7.91 27.29 63.99 16.56 12.61 26.81 26.25 3.73 7.47 63.69 34.12 42.12 49.97 4.55 19.3 9.237 0.45 61.67 46.14 3.43 31.30 95.337 0.258 0.91 6.05 4.4 3.21 2.50 1.331 0.53 20.22 32.46 37.92 23.53 4.64 54.07 60.24 3.5 11 12 12.375 0.94 22.77 3.492 21.43 5.65 44.32 Production Range .42 6.07 60.01 26.27 7.87 36.65 84.179 0.87 47.61 37.94 15.07 4.56 1.59 36.145 0.20 2.84 6.280 0.14 30.28 1.97 2.13 17.12 33.

plain (beveled) or sleeve welded joints.40°C ASTM A139 : SAWH Piling & Construction Pipes ASTM A 252 : SAWH EN 10219 : SAWH & ERW EN 10210 : SAWH & ERW Pipe Lengths: any desired lengths between 6 . Service condition: max 400°C. Service condition: .Alloy. 2 and 3. EN 10217-1 : SAWH & ERW EN 10224 : SAWH & ERW AWWA C 200 : SAWH & ERW BS 534 : SAWH & ERW General Purpose Pipes EN 10217-3 : SAWH . min -50°C EN 10217-5 : SAWH .Production Standards Petroleum and Gas Line Pipes API 5L/ISO 3183 : Requirements of PSL 1 & PSL 2 Annex G : Resistance to ductile fracture propagation Annex H : For Sour Service EN 10208 : Requirements of Part 1 & Part 2 GOST 20295 : Requirements of Type 1.18 m These are our general production standards and specifications.Non-alloy. We can meet other production standards and specifications upon request. EN 10217-6 : SAWH . fine grain Service condition: max 400°C. 9 . Water Line Pipes With protective OD and/or ID coating.Alloy or non-alloy.

it is not necessary to take the weld seam position into account. . 10 . . Europe etc.) which have proven their high quality as high strength steel line pipes. Test results on fracture propagation prove this fact. . .Spirally welded pipes have more integrity structure wise.There is a favorable orientation of the weld seam and of the strip's direction of rolling relative to the direction of principal stress. Canada.Hot rolled coil is used as base material for the production of spirally welded pipes instead of plates. . the spirally welded pipe has a higher safety margin than cold expanded pipes.Advantages of Spirally Welded Pipes Spirally welded pipes have been used all over the world for high-pressure gas and oil pipeline projects (including USA. As a result the continuous process coming from HRC usage provides flexibility (diameter and length) of production.The mechanical properties are already present in the base material. Since any cold expansion reduces the material's ductility.When carrying out field cold-bending.

very impressive capabilities can be achieved for high rates of travel by using multiple electrodes in two-run technique. yet it can be applied to plate sections as thin as approximately 4 mm. generate considerable heat which leads to deep penetration of the base metal.The Submerged Arc Welding Process The principle of the spiral pipe production is simply bending the steel strip spirally into cylindrical pipe shape and ultimately welding edges together. The high currents. obtained by multiple electrodes. In Borusan Mannesmann. The submerged arc welding (SAWH) process is widely used for welding thick sections. Both of these factors have important effect on the chemical composition and metallurgical properties of the weld metal. The occurrence of weld seam step by step can be seen in the figure displayed on page 12. In spirally welded pipe production process. remarkable control is always exercised over the contour of the deposit and extent of the penetration into the base metal. 11 .

AC I DC AC I DC AC II 12 .

5 Elongation Correspondance to API Min 22 21 20 18 22 21 20 18 18 18 18 B X42 X52 X60 B X42 X52 X60 X65 X70 X75 Mpa Min 415 415 460 520 415 415 460 520 535 570 625 Max Max 0.Yield and Tensile Requirements for API-Grades for Sweet & Sour Services API 5L/ISO 3183 Yield Strength (Mpa) PSL 1 PSL 1 A25 A B X42 X46 X52 X56 X60 X65 X70 PSL 2 BN/S X42N/M/S X46N/M/S X52N/M/S X56N/M/S X60N/M/S X65M/S X70M/S X80M/S Min 175 210 245 290 320 360 390 415 450 485 Max PSL 2 Min 245 290 320 360 390 415 450 485 555 Max 450 495 525 530 545 565 600 635 705 Min 310 335 415 415 435 460 490 520 435 570 Tensile Strength (Mpa) PSL 1 Max PSL 2 Min 415 415 435 460 490 520 435 570 625 Max 760 760 760 760 760 760 760 760 825 EN 10208-1 L210GA L245GA L290GA L360GA EN 10208-2 Correspodence to L245NB L245MB L290NB L290MB L360NB L360MB L415NB L415MB L450NB L450MB L485NB L485MB L555NB L555MB EN 10208-1 Yield Strength Grade Min L210GA L235GA L245GA L290GA L360GA 210 235 245 290 360 Max Tensile Strength Rt /Rm Elongation 0.85 0.85 0.90 (%) Normalized or normalizing rolled 13 .5 Mpa Min 335 370 414 415 460 Max 475 510 555 555 620 Max - (%) Min 25 23 22 21 20 Correspondance to API A B X42 X52 EN 10208-2 Heat Treatment conditions Yield Strength Steel Class Grade Min L245NB Non-Alloy Special-Alloy Non-Alloy Thermo mechanically rolled L290NB L360NB L415NB L245MB L290MB L360 MB L415MB Alloy Special Steel L450MB L485MB L555MB 245 290 360 415 245 290 360 415 450 485 555 Max 440 440 510 565 440 440 510 565 570 605 675 Tensile Strength Rt /Rm 0.85 0.85 0.85 0.80 0.85 0.85 0.87 0.90 0.

Baku .194 Km Excellence in Sour Service 14 .Tbilisi .Ceyhan Oil Pipeline 42" .

Coal tar. OD (Outer Diameter): External Coating ID (Inner Diameter): Internal Coating General Application Area Type of Coating FBE Epoxy (liquid) Polyethylene (PE) Polypropylene (PP) Cement Mortar OD ID Gas & Oil Line Pipe Water Line Pipe Other OD&ID coating processes can also be designed for each specific application i.e. PU. The below table illustrates the type of coatings applied externally and internally according to standards and special customer requirements.Protective OD & ID Coating Systems Borusan Mannesmann offers wide range of anti-corrosive and protective OD & ID coatings in its fully integrated coating facilities. Maximum Operating Temperature of Coating PP SPECIAL PP NORMAL FBE DRY CONDITION FBE WET CONDITION HDPE MDPE LDPE 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Temperature (0C) 15 . which all above processes are within Borusan Mannesmann’s broad experience. Glass reinforced epoxy etc. Bitumen.

On demand regular cement mortar ID coating or synthetic dispersion added special cement mortar ID coating can be applied. TS 8590) 16 . (DIN 30670. NF A 49-711) Flow Efficiency ID Coating: For gas transmission lines. High mechanical strength and corrosion resistance are achieved by 3-layer coating method. High mechanical strength and corrosion resistance are achieved by 3-layer coating method. (AWWA C 205. (DIN 30678. Coating thickness is up to 1000 μm. TS 5139. UNI 9099) Polypropylene OD Coating: Excellent protection of buried line pipes. flow-coat ID epoxy coating is applied in order to reduce pipe wall roughness thus increasing throughput. BS 534. NACE RP 0394. AWWA C213) Polyethylene OD Coating: Excellent protection of buried line pipes. CSA Z 245-20.General Application Standards FBE (Fusion Bonded Epoxy) OD Coating: Fusion bonded powder epoxy coating provides high protection of gas and oil pipe lines. (API RP 5L2) Epoxy OD & ID Coating: Various epoxy coatings applied externally or internally are enabling hygienic inner surface for potable water transportation and outer surface to resist soil or sea water corrosion. (API 5L7. TS EN 10289) Cement Mortar ID Coating: Specifically for potable water pipe lines cement mortar ID coating provides hygienic and excellent corrosion resistance and protection. NF A 49-710. DIN 2614. (AWWA C 210.

Blasting (anchor pattern profile) .Protective OD & ID Coating Systems FBE (Fusion Bonded Epoxy) OD Coating for Gas and Oil Pipelines FBE OD coating consists of the following steps. NACE RP 0394.Solvent/detergent washing (if necessary) . • Surface preparation and cleaning . CSA Z 245-20. AWWA C213 Blast Cleaning Drying Acid Washing Induction and Induction Rinsing Heating Heating FBE Application Quenching Holiday Test 17 .Phosphoric acid washing and rinsing • Induction heating • Electrostatical application of powder epoxy • Quenching • Test and inspection Applied Standards: API 5L7.

1.Protective OD & ID Coating Systems Polyethylene / Polypropylene OD Coating For 3-layer PE/PP OD coating. 3 . Finally the pipe is cooled with water. epoxy primer is applied to the pipe surface. MDPE. Just after epoxy primer application. layer: Extruded adhesive wrapping 3. the extruded adhesive and PE/PP are coated to the pipe using wrapping method. Following preheating. HDPE). PP. layer: Electrostatical application of epoxy primer 2. TS 5139. layer: Extruded wrapping (PE. Applied Standards: DIN 30670. UNI 9099 Blast Cleaning Drying Induction Heating Epoxy Primer Quenching Pipe end Preparation Holiday Test Wrapping of Adhesive Wrapping of PE/PP 18 . NF A 49-710. at first pipe surface is cleaned by shot blasting in accordance with customer specs and then preheated to the desired temperature by using induction heating system. LDPE.layer PE/PP OD coating consists of.

Coating thickness is up to 1000 μm. TS EN 10289 Cement Mortar ID Coating for Water Line Pipes Cement mortar coating features permanent corrosion protection for handling potable water. Applied Standards: API RP 5L2 Solvent Free Epoxy Coating (ID) Various epoxy coatings applied internally are enabling hygienic inner surface for potable water transportation and outer surface to resist soil or sea water corrosion. Applied Standards: AWWA C 210. Applied Standards: AWWA C 205. • To reduce corrosion product deposits by considerable amounts. TS 8590 19 .Coat Epoxy) Pipes for gas and oil transmission pipe lines are internally coated with epoxy resin: • To reduce pipe ID roughness thus increasing throughput. BS 534. DIN 2614.Protective OD & ID Coating Systems Flow Efficiency ID Coating for Gas & Oil Line Pipes (Flow .

to standards SIS 55900 or ISO 8501-1 Max. 3 μgr/cm2 ISO 8502-3 max rating 2-2 Free from material surface defects Concentration: 5 . -3 V) Cross section porosity: ≤ Rating 5 (Rating 1-10) Flexibility: . -1.0 mm (660C. 7 days.300C.5V) Acc.OD Coating Main Application Parameters OD Processes Coating type Pre-preparation Tested / Inspected parameter Desired minimum Quality criteria PE PP FBE Contaminants Pipe surface temperature Ambient condition Surface profile Free from Oil and gress Metal surface temperature min 30C above atmospheric dew point Relative humidity less than 85% 50-100 μm Min. to customer requirements Peeling test: min. 48 hr.50 OD Hot water soak : Rating 1 (Rating 1-3) Adhesive thickness Total thickness of Coating Coating Performance Coating thickness Coating Performance FBE 20 . 2.0 mm (400C.20 % PH: 1-2 Recommendation of epoxy manufacturer Surface preparation PE PP FBE Surface cleaning degree Salt contamination Dust contamination Surface condition Phosphoric acid washing Heating for coating PE PP FBE Temperature Epoxy thickness PE PP Application of coating 80-150 μm 150-250 μm Acc.150 N/cm Cathodic disbonding: max 3. Sa 2 1/2 degree acc. to customer requirements (min 300 μm) CD: avg 2.

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6 mm ± 0. *Double Joint Operation 22 .Pipe Joint Systems Cylindrical end a a f PE S b Rubber Ring t Y D D1 Cement ZAP-LOK ® 26 29 24 20 21 30 25 27 22 28 31 32 * For water pipelines * For high pressure gas & oil pipelines up to 12” Spherical end fav S a S Butt Weld Joint Preparation 30˚ (+5˚/-0˚) do NW d1 a l NW do 1.8mm d2 * For water pipelines * For all types of applications Other types of joints may be available upon request.

Borusan Mannesmann. exemplary with its modern management approach as well as its investments.QEHS Management Borusan Group companies all share a common set of guiding principles. which is a first in steel pipe sector globally. Besides with the VOC process. and to continuously improve productivity. has been applying The Lean Six Sigma methodology since 2002 and Voice of Customer (VOC) process since 2003. controls each step of the process. Our Environmental Management System certificate (ISO 14001) proves our commitment to environment. we capture the requirements and feedback from our customers to provide the best product and service quality. 23 . profitability and customer satisfaction. Complaints Handling Management Systems Certificate (ISO 10002). Healthy performance is delivered through healthy people. In compliance with Occupational Health and Safety Management Standard (OHSAS 18001) Borusan Mannesmann endeavors to protect health and safety of its work force and service providers. Ongoing efforts to improve customer satisfaction brought Borusan Mannesmann. innovation and environmental responsibility. which help this vast enterprise to operate in complete harmony. From raw material to finished product. Borusan Mannesmann determines the impacts on environment and in order to reduce impacts. These principles are commitments to productivity. The Lean Six Sigma methodology is a highly disciplined business management strategy that seeks to remove the causes of defects in production and business processes.

Quality Almost every major Energy. Canada and Europe have approved our quality and listed us among their valuable supplier lists. highly qualified staff. Oil and Gas company along with some of the biggest EPC’s in USA. regularly trained to keep abreast of new production methods. (API Q1. ISO 29001) 24 . ensures that production conform to exacting quality standards. A dynamic. ISO 9001. Ongoing research and development activities are aimed at further improving product and service quality and increasing the product range through use of technology along with original and more cost effective marketing techniques.

Permissible lamination/separation Max. SENB Spectrometric chemical analysis Formula Weld Pipe body Toughness Properties Chemical Composition Weld Pipe body Free from defects Surface Inside & Outside pipe body Max. Permissible Inclusion Weld defects HAZ Ultrasonic testing Weld Ultrasonic testing X-ray testing (radiascopic method) Hydrostatic pressure testing 25 . Caliper. Ultrasonic measurement. Dye-penetrant testing Magnetic particle testing Ultrasonic testing Pipe body Homogeneity Max.Quality The feasibility and operational safety of a pipeline project are predominantly governed by the quality of the line pipe. Permissible surface defects Visual examination. These are the methods we are using to meet our clients most stringent requirements. The table given below contains the most important quality characteristics and examination determination methods. Ultrasonic testing. Quality Characteristics Pipe body Pipe Geometry Diameter Wall thickness Length Out of roundness Straightness Height Width Off-set Angle Penetration Misalignment Grain size Inclusions Structure Examination / Determination by Tape measurement circumference. Gauge Cord and range measurement Weld Macrographic examination Metallurgical Strructure Pipe body Macrographic examination Weld HAZ Pipe body Macrographic examination Strength Properties Yield strenght Tensile strenght Elongation Tensile strength Notch impact energy Fracture Properties Hardness Notch impact energy Hardness Fracture Properties Individual elements Carbon equivalent Tensile test Ring Expansion Test Tensile test Charpy impact test DWT-test HV-Hardness measurement Charpy impact test HV-Hardness test CTOD. Tape measurement Caliper.

hardness Indentation. V-notch. profilometer Comparison Surface Quality Free of material defects Visual inspection Dew point temperature Relative humidity Dew meter Thermometer FBE Coating material performance PE. Peeling speed by dead weight test Tensile test.Quality Quality Characteristics Dust contamination Salt contamination Surface profile Surface cleanliness Surface defects Environment condition Condition of coating plant Examination / Determination by Acceptable Dust degree With adhesive Tape Acceptable Salt degree Salt level measurement Profile depth & shape Near white surface Comparison gauge. flexibility test. FBE. OD Coating Resistance to disbonding from pipe surface Cathodic disbonding 26 . Cross cut Corrosion Curing Adhesion properties FBE OD Coating Application parameters DSC test Liquid Epoxy Solvent test PE. PP Coating Cement mortar PE & PP Coating Peeling resistance Cement mortar ID Coating FBE OD Coating Low temp. Melt flow index. bending Compressing strength. impact resistance. electrical resistivity % elongation Resistance to Heat & UV-ray ageing Sieve analysis Chemical analysis Visual inspection Cement mortar Homogeneity Surface Grain size Organic contaminants Free from defects OD & ID Coating Surface defects OD & ID Coating Discontinuity Thickness Holiday test Thickness meter Strength properties OD & ID Coating FBE OD Coating PE. PP. PP Thermal characteristics By DSC tester of epoxy Physical properties Elasticity Aging Density.. Carbon black. bending strength Peeling strength by load cell or dynamometer.

Just in time on-site delivery 27 .

leasing and management of stockyards. Borusan Mannesmann plants are located on the eastern coast of Marmara Sea in the vicinity of many piers that are expert in pipe loading equipped with mobile cranes. 28 . on-site delivery. We deliver • By railway • By barge transportation • By IACS class vessels (sous-palan unloading) • By truck and trailers • Even by containers In many of our projects we have been in charge of custom clearance. sous-palan operations. forklifts and other machinery necessary for international shipment. providing complete integrated logistics solutions to meet even the most stringent client delivery terms. together with Group’s integrated logistic company Borusan Logistics.Integrated Logistics Experiences The care devoted to proper storage and shipment of products is part of Borusan Mannesmann’s commitment to customer satisfaction. Borusan Mannesmann. is able to deliver with high versatility for every international project from Saharan desert to Rocky mountains.

Project: Elba Express Expansion Gas Pipeline / USA .2008 29 .

. Logistic Partners: Borusan Logistics (Transportation from Izmit/Turkey to USA) Borusan Logistics International (USA operations) On this prestigious project Borusan Mannesmann produced FBE coated 48" pipes according to the client’s requirements. double jointing. The logistics scope includes unloading. The pipes were double jointed to 80 ft (24 m) pipe length. . sand berms preparations and stacking. 80 ft pipes were transported with special trucks to 4 other designated pipe yards.On site double-joint operation .Management of 6 different stockyards. 30 .22 shipments via A class vessels.Operational Highlights Project Details: Size: Total Length: Standard: OD Coating: Client: 36"-42" 313 km API 5L PSL2 X70 FBE Southern Natural Gas Pipeline Group Scope of Logistics: DDP basis delivery to 5 pipe yards. girth weld coating.

Project: MOL Natural Gas Transmission Project / HUNGARY-2007 31 .

Operational Highlights Project Details: Size: Total Length: Standard: OD Coating: ID Coating: Client: End User: 40" 205 km EN 10208-2 L485 MB 3 Layer PE acc. to DIN 30670 Flow Coat Epoxy acc. stockpiling and safe guarding during entire delivery operation Logistic Partners: Borusan Logistics (Transportation from Izmit plant to Hungary) Borusan Logistics International (Hungary operations) The following transportation methods have been used simultaneously because of the tight delivery schedule 1. The logistics scope includes unloading.Transportation by train (55 % of the total quantity) Complete handover of the project to the Client was realized in 10 months time. 32 . to API RP5 L2 Salzgitter Mannesmann (GE) MOL-Hungary Scope of Logistics: DDP transportation to 14 different pipe yards along the pipeline route in Hungary.Transportation by vessel & barges (45 % of the total quantity) 2.

Ceyhan Crude Oil Pipeline / TURKEY.2005 33 .Project: Baku .Tbilisi .

Transportation by trucks (15 % of the total quantity) . The following transportation methods have been used simultaneously because of the tight delivery schedule: .PSL 2 X65 (HIC) 3 Layer PE acc. Erzincan. To DIN 30670 BTC Directorate BTC CO. This project was one of the most important pipeline projects of its time. Scope of Logistics: Delivery to the pipe yards located at 4 different locations (Kars.Operational Highlights Project Details: Size: Total Length: Standard: Outside Coating: Client: End User: 42" 194 km API 5L . Global energy conglomerates. including unloading and stockpiling of the pipes. along with the world’s top engineering groups took part in this major infrastructure investment. operational and HSE standards were applied. where highest technical. Ceyhan and Terminal). 34 .Transportation by train & trucks (85 % of the total quantity) The project has been completed within a period of 12 months.

ID EPOXY COATED 94 KM 2009 ALGERIA CAMEG GAS 717 KM 2009 USA TENNESSEE GAS PIPELINE GAS 212 KM 2008 HUNGARY SALZGITTER MANNESMANN SOUTHERN NATURAL GAS GAS 28" FGSZ PIPELINE PROJECT L450MB OD PE. ID EPOXY COATED QUANTITY YEAR ALGERIA SONATRACH GAS 305 KM 2009 HUNGARY SALZGITTER MANNESMANN GAS 209 KM 2009 TURKEY BOTAfi GAS 16" MUGLA NATURAL GAS DISTRIBUTION PR.42" ELBA EXPRESS PIPELINE PROJECT X70 OD FBE COATED 24" LZ2 HASSI R'MEL . ID EPOXY COATED 49 KM 2008 USA GAS 313 KM 2008 ALGERIA SNAMPROGETTI GAS 476 KM 2007 HUNGARY SALZGITTER MANNESMANN GAS 205 KM 2007 TURKEY ASK‹ WATER AUTHORITY WATER 185 KM 2007 35 .X70 OD PE. ID EPOXY COATED 36" . ID EPOXY COATED 30" 300 LINES PIPELINE PROJECT X70 OD FBE. ID EPOXY COATED 20" .56" KIZILIRMAK . ID EPOXY COATED 32" MOL CROATIAN TRANSIT PIPELINE L485MB OD PE.Major SAWH Reference List for the Last Five Years COUNTRY CLIENT USAGE PROJECT DESCRIPTION 48" GR4 PIPELINE PROJECT X70 OD PE. L485MB OD PE.KES‹KKÖPRÜ PIPELINE S355JR OD PE.28" GAS PIPELINE PROJECTS X60 .ARZEW PIPELINE X60 OD PE COATED 40" MOL NATURAL GAS TRANSMISSION PROJECT L485 OD PE. ID EPOXY COATED 64" .

GAS 30 KM 2006 IRAN PAYANDAN GAS 48" NIGC GAS PIPELINE PROJECT X65 NO OD & ID COATING 42" SHAHDENIZ PHASE 2 PIPELINE PROJECT X65 OD PE COATED 36" TURKEY GREECE PIPELINE X65 OD PE COATED 30" NK1 PIPELINE PROJECT X60 OD PE COATED 103 KM 2005 TURKEY BOTAfi GAS 115 KM 2005 TURKEY BOTAfi GAS 180 KM 2005 ALGERIA SONATRACH CRUDE OIL 665 KM 2005 IRAN NATIONAL IRANIAN GAS CO.42" BAKU .COUNTRY CLIENT USAGE PROJECT DESCRIPTION 32" MOL PIPELINE PROJECT L485MB OD PE. (NIGC) GAS 48" PIPELINE PROJECT X65 NO OD & ID COATING 226 KM 2005 TURKEY BOTAfi GAS 24" ÇANKIRI .KASTAMONU PIPELINE X52 OD PE COATED 34" .TBILISI . ID EPOXY COATED 40" GZ1 HASSI R'MEL . BTC Directorate CRUDE OIL 194 KM 2005 36 .TOSYA . ID EPOXY COATED 36" LOOP PROJECT X65 OD PE COATED QUANTITY YEAR HUNGARY OTF CONTRACTING COMPANY SONATRACH GAS 55 KM 2007 ALGERIA GAS 234 KM 2006 TURKEY AT‹LLA DO⁄AN CONTRACTING CO.MEDAREG PIPELINE X60 OD PE.CEYHAN PIPELINE X65 OD PE COATED 145 KM 2005 TURKEY BOTAfi.

ID EPOXY COATED 8" BP GAS TERMINALS CONNECTION LINE X42 OD PE COATED 8" ENFIDHA -SIDI ABDELHAMID PIPELINE X42 OD PE COATED 10" BISMIL GAS DISTRIBUTION LINES X46 OD PE COATED 8" PERENCO RDC MISCELLANEOUS PIPELINES GRB OD PE COATED 10" OZANGUE DIGA PIPELINE X42 OD PE COATED 1/2" .500 KM 2009 TURKEY BOTAS GAS 38 KM 2009 TURKEY AKSA GAS 293 KM 2009 EGYPT NATGAS GAS 3.8".3/4" GAS DISTRIBUTION PIPES GRA OD VARNISH COATING 10" BISMIL GAS DISTRIBUTION LINES X46 OD PE COATED 4" .8" . GAS 10 KM 2009 TUNISIA STEG GAS 20 KM 2009 TURKEY BOTAS GAS 76 KM 2009 CONGO SALZGITTER MANNESMANN GAS 63 KM 2009 GABON SALZGITTER MANNESMANN TOWNGAS GAS 35 KM 2009 EGYPT GAS 4.066 KM 2009 37 .10" .6" .12" GAS DISTRIBUTION PIPES GRB . GAS 8" PIPELINE PROJECTS X52 OD PE.10" PIPELINE PROJECT L290NB OD PE COATED QUANTITY YEAR AUSTRIA EVN GAS 15 KM 2009 EGYPT FAYUM GAS CO.Major ERW Reference List for the Last Five Years COUNTRY CLIENT USAGE PROJECT DESCRIPTION 6" .X52 OD PE COATED 1/2" .3/4" GAS DISTRIBUTION PIPES GRA OD VARNISH COATING 30KM 2009 AZERBAIJAN ETSUN CO.

6" . LINES X46 . GAS 10" OUM-CHIAH .12" PIPELINE PROJECTS X52 OD PE COATED 25KM 2008 EGYPT EGYPTGAS GAS 1/2" .800 KM 2008 GABON PERENCO S. ID EPOXY COATED 10" NAZILLI & ÇANKIRI DIST. GAS 115 KM 2007 TUNISIA PERENCO S. ID EPOXY COATED 2.A.8" .8" DJERBA ISLAND PROJECT X42 OD PE COATED 6" .8" .12" SOUTH LINE PROJECT GRB OD PE COATED 127 KM 2005 38 . LINES X42 OD PE COATED 75 KM 2006 BOTAS TURKEY BOTAS TURKEY SYRIAN GAS COMPANY GAS 114 KM 2006 GAS 162 KM 2006 GAS 40 KM 2005 SYRIA TURKEY BOTAS GAS 4" .GABES GAS PIPELINE X60 OD PE.X52 OD PE COATED 12" ÇANKIRI DIST. OIL 81 KM 2008 EGYPT TAQA GROUP GAS 6" . LINES X46 OD PE COATED 10" .A.3/4" GAS DISTRIBUTION PIPES GRA OD VARNISH COATING 8" LIBREVILLE GAS PIPE PROJECT X60 OD PE.12" ORDU DIST.10" OIL PIPELINE PROJECTS GRB OD PE COATED QUANTITY YEAR TUNISIA STEG GAS 45 KM 2008 TUNISIA STEG GAS 210 KM 2008 TURKEY TURKISH PETROLEUM CO.COUNTRY CLIENT USAGE PROJECT DESCRIPTION 8" GAZODUC KAIROUAN-TAG DE FERIANA X60 OD PE COATED 4" .10" .10" .

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fi. ve T‹C. Head Office: Meclisi Mebusan Caddesi 35.com +90 212 393 58 58 Borusan Mannesmann Call Center E-Mail: mannesmann@borusan.com June 2010 www. Sal›pazar› 34427 ‹stanbul / TURKEY Phone: +90 212 393 59 59 Fax: +90 262 323 18 03 ‹zmit Factory: Yeni Do¤an Mahallesi P.BORUSAN MANNESMANN BORU SAN.borusanmannesmann.K: 5 41001 ‹zmit / TURKEY Phone: +90 212 393 59 59 Fax: +90 262 323 18 03 E-Mail: mannesmann@borusan.com . A.