Akcakoca Plant

Ümran Cad. 17 Akcakoca -

Düzce / Türkiye T: +90 380
618 72 65
F: +90 380 618 72 60

Head Office
Meclisi Mebusan Cad. 19/5
Salipazari - Istanbul / Türkiye
T: +90 212 252 52 80
F: +90 212 249 43 49
e-mail: export@umran.com
FOREWORD
Umran is a well known and well established linepipe manufacturer that serves its customers
globally. It is specialized in project supply that demands the highest commitment in terms of
quality, experience, logistics, financial strength and know-how.

Umran has a very wide range of products that caters the linepipe industry.
These are:

• Longitudinally double submerged arc welded linepipes.

• Spirally double submerged arc welded linepipes
• High frequency induction welded linepipes
• SRM pipes

Through years of experience, and focus for bringing value to its customers, Umran has
outgrown the typical supplier role of a pipe manufacturer, but is more acting as a project
partner.

On-site coating facilities are able to apply most required coating types, saving handling and
logistics costs of projects. Three layer polyethylene coating and epoxy lining are a few examples.

Logistics play a very important role in successful implementation of any project. Having
recognized this fact, through its subsidiaries Umran operates a fleet of vessels and trucks
that specialize in logistics of linepipe, thus can deliver its pipes to anywhere in the world.

Last but not least, it should be kept in mind that Umran has an extensive stock of raw
materials. Fast-track projects and last minute requirements can be supplied in a much faster pace
with Umran.

Umraniye Pipe Production Complex is situated on 200,000 sq. meters of land with a covered area
of 50,000 sq. meters. Production of SAW Spirally welded pipes takes place in this complex
having 200.000 Ton annual production capacity totally in 5 production lines with a maximum
diameter of 120”.

Akcakoca Pipe Production Complex is built on 500,000 sq. meters of land with a covered area
of 110,000 sq. meters. Akcakoca complex, having 750.000 Ton annual production capacity
totally in 7 production lines, manufactures SRM (Stretch Reduced Mill), HFW high frequency
welded pipes, LSAW (U.O.E.) and SAW Spiral welded pipes with a maximum diameter of 3
1/2”, 16”, 42” and 140” respectively.
PLANT LAYOUTS
 SAW Longitudinal (UOE)

O-FORMING

LONGITUDINAL SUBMERGED ARC WELDED PIPES

UOE is a method used for production of longitudinally welded large diameter pipes. Longitudinal edges of steel
plates are first beveled using carbide milling equipment. Beveled plates are then formed into a U shape using a U-
press and subsequently into an O shape using an O-press. Longitudinal edges of the plates are then tack welded
followed by internal and external welds.

Pipes manufactured by this process are subjected to expanding operation in order to relieve internal stresses and
obtain a perfect dimensional tolerance. After the pipes are conveyed to cold expansion, hydrostatic testing and
NDT inspection, the pipes will be subject to final inspection for the compliance to customer requirements.

Starting from incoming control up to the final inspection stage; entire process is monitored and supported by
computerized system. Traceability is achieved by input controls and barcodes through entire production lines.
 SAW Longitudinal (UOE)
PIPE MANUFACTURING FLOWCHART

Plate entry Plate Plate Plate Edge U forming

UT inspection identification edge milling preforming

Tab welding End squaring Tack weld Tack welding Pipe washing O forming
inspection and drying

Inside welding Outside welding Pipe Pipe Pipe Expansion

Visual inspection UT inspection X-ray inspection

Final Pipe end Final X-ray Final UT Laboratory Hydraulic

inspection beveling inspection inspection testing testing

Certificates

O-Forming O-Forming
 SAW Longitudinal (UOE)

PLATE UT INSPECTION PLATE MILLING

TACK WELDING HYDROSTATIC TEST

SAWL
MANUFACTURING RANGE

42 1067

40 1016

36 914

34 864

32 813

30 762

28 711

26 660

24 610

22 559

20 508

inch mm 6,4 7,1 7,9 8,7 9,5 10,3 11,1 11,9 12,7 14,3 15,9 17,5 19,1 20,6 22,2 23,8 25,4

PIPE O. D . (0,250) (0,281) (0,312) (0,344) (0,375) (0,406) (0,438) (0,469) (0,500) (0,562) (0,625) (0,688) (0,750) (0,812) (0,875) (0,938) (1,000)

NOMINAL WALL THICKNE SS (inch) / mm

 SAW Helical

SPIRAL SUBMERGED ARC WELDED PIPES

Spiral welded pipe production by submerged arc method is based on using tandem welding technique for joining
inside and outside coil edges, which have been trimmed and beveled by carbide milling for high quality weld
structure. Welding of hot rolled steel coils takes spiral form after passing through preforming and forming rolls.
Excellent exterior weld quality at high production speeds is provided by double submerged arc welding process.
Manufactured pipes are cut to the desired lengths at the exit of the pipe machine. Pipe ends are beveled by
means of carbide machining for accurate on-site welding.

After the pipe is conveyed to hydrostatic testing and off-line ultrasonic testing and/or real time X-ray
inspection, the pipe will be subject to final inspection for the compliance to customer requirements.

Starting from incoming control up to the final inspection stage; entire process is monitored and supported by
computerized system. Traceability is achieved by input controls and barcodes through entire production lines.
 SAW Helical
PIPE MANUFACTURING FLOWCHART

Coil entry Uncoiling Pre-leveling Skelp Skelp Leveling

end cutting end welding

UT weld Outside welding Inside welding Forming Edge Edge milling

inspection preforming

UT pipe body Length cutting Pipe Pipe Pipe ende Hydrostatic

inspection identification Visual inspection beveling testing

Certificates Final Final X-ray Off-line UT

SAWH inspection inspection inspection

MANUFACTURING RANGE
148 3,370
140 3.566
120 3.048
100 2.540
88 2.235
80 2.032
76 1.930
72 1.829
68 1.727
64 1.626
60 1.524
56 1.422
52 1.321
48 1.219
46 1.168
44 1.118
42 1.067
40 1.016
38 965
36 914
34 864
32 813
30 762
28 711
26 660
24 610
22 559
20 508
18 457
16 406,4
14 355,6
12 323,9
10 273,1
8 219,1

inch mm 4,0 4,4 4,8 5,2 5,6 6,4 7,1 7,9 8,7 9,5 10,3 11,1 11,9 12,7 14,3 15,9 17,5 19,1 20,6 22,2 23,8 25,4

(0,156) (0,172) (0,188) (0,203) (0,219) (0,250) (0,281) (0,312) (0,344) (0,375) (0,406) (0,438) (0,469) (0,500) (0,562) (0,625) (0,688) (0,750) (0,812) (0,875) (0,938) (1,000)

NOMINAL WALL THICKNE SS (inch) / mm

 HFW High Frequency Welding

HIGH FREQUENCY WELDED PIPES

In HFW pipe production, hot rolled steel coils are fed with a high capacity accumulator in order to achieve
continuous welding. Coil edges are milled using carbide cutters in order to assure a high quality weld. Coils are then
formed by cold forming method using a set of cage rolls and fin passes, and then joined using high frequency
currents using induction or alternatively conduction methods.

The coil edges, which reach welding temperature through the resistance shown by steel to the applied electrical
current, are butted together and welded without using filler material. As a result of applied controlled normalization
process, the weld area achieves a fine grain structure with required ductility.

The pipe string is brought to the exact required and precise outside diameter and straightness by passing through
a set of sizing rolls. Following beveling, hydrostatic testing, non-destructive testing, the pipes are subject to final
inspection for the compliance to customer requirements.

Starting from incoming control up to the final inspection stage; entire process is monitored and supported by
computerized system. Traceability is achieved by input controls and barcodes through entire production
 HFW High Frequency Welding
PIPE MANUFACTURING FLOWCHART

Coil entry Uncoiling Leveling Shear Shear Spiral coil

end cutting end welding accumulating

HF induction Forming Edge Preforming Plate UT Edge milling

welding preforming inspection

Inside and outside Trimming Weld seam Cooling Sizing Length cutting
trimming UT inspection annealing

Final UT Hydrostatic Pipe Cleaning Pipe end Straightening Pipe

inspection testing beveling identification

Final Certificates
HFW
inspection
MANUFACTURING RANGE

16 406,4

14 355,6

12 323,9

10 273,1

8 219,1

6,5 168,3

6,5 165,1

6 159,0

5,5 141,3

5 139,7

4 114,3

3,5 101,6

3 88,9

2,5 78,1

2 60,3

inch mm 2,1 2,8 3,2 3,6 4,0 4,4 4,8 5,5 6,4 7,1 7,9 8,7 9,5 10,3 11,1 11,9 12,7

PIPE O. D . (0,083) (0,109) (0,125) (0,141) (0,156) (0,172) (0,188) (0,216) (0,250) (0,281) (0,312) (0,344) (0,375) (0,406) (0,438) (0,469) (0,500)

NOMINAL WALL THICKNE SS (inch) / mm

 SRM Stretch Reduction Mill

STRETCH AND REDUCED STEEL PIPES

SRM stands for Stretch and Reduction Mill. This is a sizing method used in conjunction with high frequency welding
technology. HFW pipes are first heated to normalizing temperatures and then rolled thru a number of rolling stands in order
to reduce the diameter of the pipe and adjust the wall thickness.

As a result of normalization process applied during production, the weld area of SRM pipes becomes uniform and the
material structure doesn’t show any variations. Applied normalization process relieves the stresses on the weld area and
provides a ductile fine grain structure.

The internal pipe surface is burr free because of the HFW welding process, despite the small diameter of the pipe
resulting from SRM process. Compared to standard piping, SRM pipes are preferred due to their properties such as
malleability and high resistance to corrosion, as well as machineability.

SRM MANUFACTURING RANGE

2 60,3

1 1/2 48,3

1 1/4 42,4

1 33,7

3/4 26,9

1/2 21,3

inch mm 2,4 2,6 2,8 3,0 3,2 3,4 3,6 3,8 4,0 4,2 4,4 4,6 5,0 5,2 5,4 5,6 5,8 6,0

PIPE O. D. (0,095) (0,102) (0,109) (0,119) (0,126) (0,133) (0,140) (0,150) (0,156) (0,165) (0,173) (0,181) (0,197) (0,203) (0,213) (0,220) (0,228) (0,237)

NOMINAL WALL THICKNE SS (inch) / mm

Steel Grade & Standards

Steel Grade
Pipe and steel material specified by API 5L standard published by American Petroleum Institute are globally used for oil
and gas pipelines. API 5L standard identifies the delivery condition of product specification level & service (i.e. on-
shore, off-shore, sour service) and the steel grade such as Normalized, Quenched or Thermo mechanical Rolled and etc.

Depending on project requirements and application areas; unalloyed, micro alloyed or specially designed steels are
used for pipe production. A project specific specification is drawn for each project which forms the basis for the
material to be allocated for the production. The aim is to obtain uniform fine microstructure that is suitable for forming,
welding and bending, yet tough and ductile.

The new European Directive calls for designers to consider even trace amounts of H2S when designing pipelines. This is a
result of recent experiences accumulated in the oil & gas industry. This has lead to an increasing number of projects
requiring corrosion resistant steels. Umran has successfully developed special procedures for welding of corrosion resistant
material and applied successfully for a number of important projects.

Production Standards
API 5L, EN, GOST, AFNOR, AWWA, BS, UNI, DIN, ASTM, TS EN, ISO and all other major international standards and
specific project requirements for the purpose of meeting all requests according to application areas.

Pipe Connections
Depending on application areas and customer requirements:

• Welded joint
• Cylindrical welded joint (Slip-joint)
• Flanged connection.
 COATINGS

Internal & External Protective Coating

The corrosion protection systems for pipelines are applied exclusively for specific projects by assuring high quality, long-term
technical performance and management of Umran’s proficient and trained staff in modern facilities.

Surface Preparation
For the purpose of achieving effective performance in internal or external surfaces where the corrosion protection systems
will be applied, satisfactory surface roughness and cleanliness is obtained by using appropriate abrasives for the system.

Polyethylene & Polypropylene Coating

3 layer PE and PP coating systems are the most preferred external protective coating systems available in the market
today. While the FBE layer provides for excellent resistance to cathodic disbondment, the outer hard layer of PE
or PP provides for excellent mechanical protection, assuring integrity of the coating system.

Adhesive
Adhesive PE/PP Extrusion PE/PP
Extrusion Extrusion Adhesive Extrusion
Spray
Cross Head Die
Flat Film Die

Induction Holiday Induction Holiday

Pressure Roll Inspection
Heating Heating Inspection
Surface Cleaning Spraying of Surface Cleaning Spraying of
Epoxy Powder Epoxy Powder

PE / PP Coating Process for SAW pipes PE / PP Coating Process for HFW pipes
 EPOXY LINING CEMENT LINING

Liquid Epoxy Coating

Epoxy coating system is preferred for lining pipe internal surfaces for potable water pipelines in order to protect steel
surface from corrosion. Equally, thru the use of alimentary grade epoxies, the properties of water is maintained safe and healthy
for the use in household.

A special grade of liquid epoxy is also applied for gas pipes in order to reduce the backpressure created by roughness of the
internal pipe surface. Application of this type of epoxy reduces energy costs related with transportation of natural gas.
Cement Lining
Cement lining is preferred type of corrosion protection system for internal pipe surfaces widely used in water lines due to its
hygienic compatibility and high corrosion resistance strength.
Fusion Bonded Epoxy
FBE is an economical external coating system widely used in areas where mechanical protection of pipe’s external surface is
not critical. Excellent cathodic disbondment
resistance of the FBE provides for long lasting protection for
pipelines.

Polyurethane Coating
Specially preferred in seawater environment due to its high
corrosion resistance and long service life under such conditions.
Concrete Coating
Concrete coating provides superior mechanical protection for
pipelines in road and river crossings.

CONCRETE COATING FBE FUSION BONDED EPOXY

QUALITY
Quality Management System
Umran’s Quality System has been certified by API QR and TÜV in line with ISO 9001:2008 Quality Management
System. These activities are managed by Umran’s proficient and trained specialists assuring high quality products.

Quality Control Activities

Quality control and performance tests in accordance with project and client’s requirements are conducted under
laboratory conditions using sophisticated equipments, destructive and non-destructive testing systems.

• Non-destructive Tests
• Spectrometric chemical analysis
• H yd ro s t at i c Te s t s
• D e s t r u c t i ve Te s t s
• Vi s u a l inspection
• Measurement and laboratory tests

CHEMICAL ANALYSIS

RADIOSCOPIC INSPECTION MANUAL UT INSPECTION

Health & Safety
HEALTH & SAFETY AND ENVIRONMENTAL MANAGEMENT
In accordance with international regulations, Umran’s Health and Safety, and Environmental, Management Systems are
certified with ISO 14001 and OHSAS 18001 Management System certificates. As such, Umran’s products are not only
reliable and of high quality, but also have been manufactured responsibly with respect to Health and Safety in addition to
the Environment.
Umran’s Health & Safety and Environmental Management Systems are certified to conform;

• ISO 14001 Environmental, Management System issued by TUV RH

• OHSAS 18001 Health and Safety Management System issued by TUV RH
APPLICATIONS

Baku - Ceyhan crude oil pipeline

Istanbul water supply project Istanbul / Halic Bay subsea crossing

 LOGISTICS

UMRAN GROUP OF COMPANIES

Logistics play a very important role in successful implementation of any project. Having recognized this fact,
through its subsidiaries Umran owns and operates a fleet of vessels and trucks that specialize in logistics of linepipe,
thus can deliver its pipes to anywhere in the world.

UMRAN TRANSPORT AND TRADING INC.

Specialized in “Project Cargo”, UMRAN TRANSPORT owns and operates a fleet of 50 trucks for transportation of steel
products, steel pipes, hot rolled coils & plates.