Pre Fabrication Piping - Imimg

February 2012
Dee Development Engineers Limited
An Overview
Pioneers of Pre-Fabricated Piping Systems

DDEL
Contents
Company Overview
Accreditions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
2

DDEL – At a Glance

DDEL
Located in India’s Fastest Growing Industrial belt
STRATEGIC LOCATION : -
ICD, Tughlakabad - 40 Kms.
Airport, New Delhi - 58 Kms.
National Capital, New Delhi - 31 Kms.
PLANTS :-
Plant 1 - North Pre Fabrication Plant ( 10000 MT/Year)
Plant 1 - South Pipe Fittings Plant ( 2400 MT/Year)
Plant 2 - Pre Fabrication Plant ( 12000 MT/Year)
4

DDEL
The Company is engaged
in Design & Engineering
Prefabrication of Piping
Systems
The Company has exclusive
manufacturing facility for Pipe
Fittings
Mainly caters to
Engineering, Procurement
and Construction (EPC)
contractors and multinational
organizations in power
generation, oil and gas,
chemical and food industries
Boast of Pre fabrication
capacity of 24000 MT and
Exclusive Fittings Capacity of
2400 MT per annum
Dee Development Engineers Limited
One of the leading International engineering enterprises
offering a single window solution for all piping systems
MAJOR MILESTONES:
1983 – Incorporated as a Design Consultancy firm
1988 – A humble start with half acre facility for Pre-Fabrication Piping
1994 – Establish its own in-house Pipe Fitting Manufacturing facility
1996 – Entered into the Power sector piping
1999 – Started High value Product P91 Fabrication
2004 – Shifted Fabrication base to New location at Tatarpur, Palwal ( 12 Acre Facility )
2004 – Entered into the EPC space, commissioned first Biomass Power plant in Punjab
2007 – Grabbed the major export order worth 6 million Euros
2009 – EPC of another Biomass Based Power plant in Punjab
2010 – Commissioned the state of the art Induction Bending Machine
2010 – Expanded its facility base to cater sub/super critical technology
2011 – Banyan Tree & Capvent infused in DDEL
2011 - BHEL awarded “Best Performance Award” in Piping System supplier category
2011 - Largest Single order received from MHI Japan worth 11.40 Million USD
5

DDEL
CMD
A well organized Customer oriented
Fittings
Bending
Marketing
Projects
ED
CEO
Quality
Engineering Materials
Welding
EHS
Strategy HR
Finance
Structure in Place
6

DDEL
Mr. K.L. Bansal
Chairman cum Managing
Director
Mr. M Kannappan
Executive Director
Mr. Atul Bansal
Chief Executive Officer
Management Profile
Mechanical Engineer
Total Experience - 30 years
Mechanical Engineer
Total Experience - 38 years
Mechanical Engineer
Total Experience - 8 years
Specialized in Design & Engineering of Steam piping,
Process Piping, Marketing, Project Management,
Finance Management etc.
Awarded as “ Business Leader of the Year ” FY 11 by
Faridabad Industries Association
Ex – BHEL Piping Centre Executive Director
Specialized in welding technologies , Project
Management , Operations and Planning control etc.
Under his leadership the BHEL Piping Division saw
350% growth in Turnover in just three years, INR 7500
Mn in 2007-08 to INR 25000 Mn in 2010-11
Operational Head ; particularly responsible for the
export operations
Also takes care of business development
7

DDEL
KEY PERSONNEL
Name Department Education Total Experience
Mr. AK Goel Head Projects DME (Mechanical) 28
Mr. AK Jha Head Finance & Accounts C.A. 17
Mr. Gaurav Narang Head Strategy BE ( Mechanical ) + MBA 7
Ms. Haneet Kalra Head HR B.Com + MBA 7
Mr. Harsh Bhatia Head Projects BE (Mechanical) 16
Mr. S Jaya Kumar Head – Engineering Division MTech ( Mechanical ) 35
Mr. Pankaj Agarwal Head Marketing & Projects Bsc.Engg. (Mechanical) 17
Mr. Parimi Venu Head Quality BE (Mechanical) 19
Mr. Pawan Arora Head Purchase BE (Mechanical) + MBA 10
Mr. Piyush Bhatt Head Projects DME (Fabrication) 10
Mr. Ramesh Kumar Head Projects BSc. Engg (Mechanical) 21
Mr. Sanjay Jain Head Welding M. Tech. ( Mechanical ) 15
Mr. SK Saini Head Store & MR DME (Mechanical) 23
8

DDEL
DDEL achieved excellent financial results with strong
Sales growth
9

DDEL
Business Strategy………….The Road Ahead
10

DDEL
Product wise Turnover*
Sector wise Turnover*
* Based on last 3 years sales data
Diversified in terms of Products manufactured,
Target sectors & Sale locations
Domestic Vs Export Turnover
11

DDEL
Key Customers
Our clients list includes some of the most reputed
names in the domestic as well international markets
12

DDEL
Key Suppliers
Well entrenched supplier base comprising of domestic
& international manufacturers of seamless pipes
13

DDEL
7%
Diversified high quality customer base
14%
29%
11% 18%
5%
17%
% represent the share of exports in FY11
14

DDEL
Man Power at a Glance
Department No. of Employees
Engineers & Managers 170
Skilled Manpower 310
Semiskilled Manpower 125
Helpers & Riggers 250
Supporting Departments 135
Total 990
Average years of experience of the engineering staff : 8 years
15

DDEL
Contents
Company Overview
Accreditions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
16

DDEL
The wide range of Accreditions and Approvals
showcase our Expertise and Experience
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
PED Certification
(Directive (97/23/EC)
17

DDEL
ASME 'PP' & 'S’ Stamp Certification
The company is one of the few test houses to be on the
list of NABL Accredited laboratories
NABL accredited Physical & Chemical Laboratory
18

DDEL
Contents
Company Overview
Accredit ions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
19

DDEL
Spread over 22 acres (90,000 sq. mt.)of land, our facility
is the cynosure of all eyes…
Existing Plant Layout
Plant I Plant II (1 st Phase)
Work Area 13,750 sq. mt. 12,800 sq. mt.
Covered Area 15,270 sq. mt. 13,500 sq. mt.
Uncovered Area 17,392 sq. mt. 28,000 sq. mt.
Spool Fabrication
Pipe Fittings & Rolled Welded Pipe
Production Line Outlook
6 Acres of land is available for
2 nd phase capacity expansion –
Implementation already initiated
4 Main Workshops having 11 Bays all equipped with EOT (upto 20
ton) cranes & latest technology welding equipments
Spread over 1 workshop having 1 Bay for R&W pipe
manufacturing, 3 Bays for Pipe fittings manufacturing and one bay
exclusively meant for Inspection, Packing and Shipment
20

DDEL
Contents
Company Overview
Accredit ions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
21

DDEL
New Plant Facility
Induction Bending Machine
Pre Fabrication Facility at a glance
World class and Technologically advanced Fabrication Workshops
Equipped with 100+ stations to carry out manual as well as
mechanized welding via GTAW, Orbital GTAW, GMAW, SAW,
MCAW, FCAW, Orbital FCAW, SMAW processes
Orbital welding station for TIG welding
Post weld heat treatment by furnace and local heating
(Induction/Resistance)
Fully equipped NABL accredited testing laboratory
In house Non-destructive facilities like RT/MPT/UT/LPT
Separate fabrication bays for Stainless Steel material
Surface Treatment facilities – Shot blasting, Chemical cleaning
and Painting
World class Induction pipe bending machine (PB 400 SPL) with
capacity of bending range 2” – 16” Diameter 5-65 mm thick
pipes
Range – 2” – 64 “
22

DDEL
Experience of more than 150000 MT of Pre Fabrication which
includes more than 5000 MT of P91 Fabrication
HRSG Piping
Power Cycle Piping
Process Plant Piping
Balance of Plant Piping
Riser & Down comer Piping
Gas and Steam Turbine Piping
Cooling Water & Lube Oil Piping
Steam Distribution Headers
Product Portfolio : Pre Fabrication
Gas Compressor Piping
Turbine Integral Piping
Boiler Integral Piping
23

DDEL
Process Flow Chart
START JOB
BEND PIPES AS
PER DRAWING
FITUP AS PER
DRAWING
DIMENSION &
ORIENTATION
INSPECTION
WELDING
OK
RECEIPT OF
BOMS &
SPOOLWISE
DRAWINGS
EDGE
PREPARATION
NOT OK
Pre Fabrication Pipe spools
Each process is followed by a Quality check
REWORK
NDT
PROCESS
REPAIR
NOT OK
CUT PIPES /
SECTIONS AS
PER MARKING
PRODUCTION
PLANNING
VISUAL &
DIMENSION
INSPECTION
OK
JOB
COMPLETION
DIMENSION
INSPECTION
CS
RECEIPT OF RAW
MATERIAL (PIPES,
FITTINGS &
STRUCTURAL)
SHOT BLASTING
SPOOL
SS
SPOOL
NOT OK
SOLVENT CLEANING
DISPATCH
MARK PIPE /
STRUCTURAL
FOR CUTTING &
BENDING
VISUAL
(SURFACE)
INSPECTION
VISUAL
(SURFACE)
INSPECTION
PACKING
INCOMING
INSPECTION
OK
INTERNAL
STORAGE
PAINTING
NOT OK
REJECTED
VISUAL / DFT
INSPECTION
FINAL
INSPECTION
24

DDEL
Alstom Switzerland - GT 13 Piping
Alstom India - 270 MW HRSG Piping
GE – Tonnes of 7F/9F piping
2007
Major Orders Executed by DDEL in recent times
2008
Alstom Switzerland - 870 MW Critical Piping
Alstom India - CCPP HRSG Piping
GE Energy - Their 1 st IGCC Project
Lanco Kondapalli Stage II 1*370 MW– Power Cycle Piping
Man Turbo AG - Process & Oil Piping
2009
2010
Adani Power – 7 X 660 MW Super Critical Piping
Doosan Babcock - 4*360 MW Pulverized fuel &
4*360 External Piping
Lanco Kondapalli Stage III 2*370 MW– Power Cycle Piping
* DDEL caters to 95% and 75% of the total pipe spools requirement for ISGEC & Thermax respectively
* Executing Power Cycle Piping of 5x660 MW Super critical TPS for Adani Power Tiroda , 2*660 MW for Kawai.
MHI, Japan –
Prefabricated plant
piping
2011
25

DDEL
Contents
Company Overview
Accredit ions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
26

DDEL
Weld Less Technology at DDEL
Induction Bending Machine
27

DDEL
Machine Specifications:
Make
COJAFEX BV, The Netherlands
Nominal Pipe Range
2” to 16”
Thickness
Up to 65mm
Bend Radius
76mm to 2032mm
Bending Angle
0’ to 180’
Pipe Rotation
0’ to 360’ Degree
Induction Bending is a controlled means of Bending
28

DDEL
Induction Pipe Bending procedure
shall comply with the following
codes and standards:
ASME B31.1 – Power Piping
ASME B31.3 – Process Piping
CSA Z245.11-05 – Steel Fittings
TPA-IBS-98 – Recommended
Std’s for Induction Bending of
Pipe and Tube
PFI ES – 24 – Pipe Bending
Methods
Indian Boiler Regulations
Customer specific / Drawing
requirements
Leading the technology curve with State of the Art M/c’s
29

DDEL
Faster delivery period
Benefits to the Customers
Reduction in fabrication and welding offers significant quality assurance
advantages over the use of fittings
Reduces Inspection of weld joints
Reduces number of field joints.
Induction Bending produces excellent results in terms of dimensional, physical &
chemical properties.
With Bending Technology, we can make single spool with multiple bend in 0 to
360 degree orientation,
Machine is capable of bending:-
Seamless, Spiral , ERW, L.SAW & H. SAW Types of pipes
Carbon Steel, Alloy Steel, Austenitic Steel, Stainless Steel, Incoloy material
30

DDEL Another Milestone: Bending Machine with 300 MT per month capacity
Machine Specifications:
Make
AWS SCHAFER, Germany
Nominal Pipe Range
8” to 48”
Thickness
Up to 120mm
Bend Radius
280mm to 6500mm
Bending Angle
0’ to 182’
Pipe Rotation
0’ to 360’ Degree
To be commissioned in beginning next financial year
31

DDEL
Contents
Company Overview
Accredit ions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
32

Our Expertise in Pipe Fittings

DDEL
As an Initiative for Backward Integration for Piping, we installed Pipe
Fitting Manufacturing Facility
1994
17 Years of Huge
Experience
2003
Started with 350 MT press
Capacity ~~ 30 MT pm
Major Operational Milestones
2006
Installed another 150 MT + 750 MT press
Capacity ~~ 75 MT pm
2009
Installed another 1000 MT press
Capacity ~~ 125 MT pm
2010
Installed Induction
Mandrel, 3000 MT press
Capacity ~~ 200 MT pm
Installed Cold Forming Elbow making
machine …Capacity ~~150 MT pm
34

Elbow Making Machine
DDEL
Hot Formed
Cold Formed
Pipe Fitting : Facility at a glance
One of the Best Fitting Workshops in Industry
Hot Pushing Mandrel Elbow Forming Automatic M/c having
capacity to form Elbows from 8-28 inch & thickness up to 50 mm
2 Cold Forming Machines of different sizes for Elbow production
complemented with 3 Edge Preparation machines
Various Hydraulic Presses ranging from 750 MT to 3000 MT for
manufacturing of Pipe Fittings
Hot forming section equipped with 2 furnaces and 4 hydraulic
presses
Machining section having over 20 lathes and other related
machinery
3 Semi-automated Shot Blasting machines for fittings
Pipe Cutting Section having capability up to 52” with add on
capacity of up to 28” from automated machinery
35

DDEL
Fittings : The Products we offer
90 ° Elbow
45 ° Elbow
Half Socket Weld
Coupling
Concentric
Reducers
Eccentric
Reducers
Full Socket Weld
Coupling
36

DDEL
Fittings : The Products we offer
Equal Tee
Weld olets
End Caps
Unequal Tee
Long radius
Induction Bends
U Bends
37

DDEL
Start
BOM
RAW MATERIAL
IISUE FOR
PRODUCTION
END
CUTTING
INSPECTION
* Hot Forming Process
RECEIPT OF
BOM
RAW
MATERIAL
CUTTING
INSPECTION
MACHINING
Fittings* : The Process we follow
Each process is followed by a Quality check
PRODUCTION
PLANNING
RECEIPT OF
RAW MATERIAL
INSPECTION
PLUGGING
&
DRAWING
INSPECTION
HEAT
TREATMENT
INSPECTION/
NDT
INSPECTION
SHOT
BLASTING
&
PAINTING
INCOMING
INSPECTION
SAND
FILLING
RAW MATERIAL
STORAGE
INSPECTION
PROFILING INSPECTION FORMING
INSPECTION FINISHING
FINAL
INSPECTION
End
38

DDEL
1500 MT
2007
Executed Tonnage ( Last 4 years Annual data )
2008
1800 MT
2000 MT
2009
2010
2400 MT
We manufacture all type of Pipe Fittings i.e. Butt welding, Socket welding & Screwed in various grades of
Carbon Steel, Alloy Steel and Stainless Steel
Seamless – up to 28” Welded – up to 52”
39

DDEL
Contents
Company Overview
Accredit ions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
40

DDEL
Engineering Division : Facility at a glance
Equipped with all latest software technology
The division is presently lead by a highly experienced professional with more than 35yrs of
experience in power equipment manufacturing industry and having worked in power piping
design department for more than 23yrs
11 Dedicated Engineers having varying hands on experience on the following Software's.
AUTOCAD
MODELLING IN PDMS
STRESS ANALYSIS WITH CAESAR II.
PIPE SIZING AND PRESSURE DROP CALCULATIONS USING PIPE FLOW
Access to following reference standards and codes.
ASME B16.5 – Pipe flanges and flanged fittings
ASME B16.9 – Butt weld and wrought fittings.
ASME B16.3 – Valves-flanged, threaded & welding end.
ASME B16.11 – Forged and SW fittings.
ASME B16.25 – Butt welding ends.
ASME B31.1 – Power piping.
ASME B31.3 – Process piping
41

DDEL
Pre - Bid Engineering
Review Basic Enquiry
Drawings/ Documents.
Data Collection from
Client/ Site.
Conceive proposed Pipe
Routing.
Estimate Bill of Quantities
for proposal Engineering
Capabilities
We are capable to perform the following activities :
Basic Engineering
Piping Design Criteria
Development.
Pipe Sizing Calculations
Pressure Drop
Calculations
Piping Material Selection
Specifications Preparation
Detailed Engineering
Layout Engineering
Materials Engineering
Stress Analysis
Support Engineering
IBR calculations
42

DDEL
Layout Engineering
Piping General Arrangement Drawings (Plan & Sections)
Piping Isometrics
Capabilities ( Contd… )
Pipe Shop Fabrication Spools drawings
Equipment Nozzle Orientation Plan
Review of piping GAD’s with respect to P&IDs
Review of Vendor Drawings/ Documents
Stress Analysis
Capable to carry out stress analysis using Caeser-II
latest software package and suggest required changes
in the layout drawings and select proper and optimal
supports to bring the system with in permissible limits
of stresses and forces and moments at the terminals
Material Engineering
Piping Items Procurement Specifications.
Insulation Items Procurement Specifications.
Painting Specifications,
Piping Bill of Materials
Preliminary BOM Issue (Based on P&ID and Plot Plan)
Intermediate (Based on Piping Layout)
Final (Based on Piping Isometrics).
- Pipe Supports Bill of Materials.
- Technical Bid Evaluation for procurement
Pipe Support Engineering
Pipe Support Layouts, Pipe Support Detail
Drawings
Spring Hanger Data Sheets, specifications
Inserts & Loading Drawings (Input to Civil)
43

DDEL
Key Highlights
Fabrication of more than 150,000 MT
Fabrication of P91 more than 5000 MT,
Fabrication of WB 36 more than 1500 MT
Bending Machine in operation since 2010 (2 years)
Induction Bends P91 (BHEL) more than 500 Nos.
Induction Bends other than P91 more than 200 ~400 MT
Induction Bends (P91) other than BHEL more than 100 MT
Another Bending Machine ( 8" to 48") being commissioned by July, 2012
44

DDEL
Contents
Company Overview
Accreditions and Approvals
Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance
Exhibits
45

DDEL
DDEL in Pictures
Facility Outlook Storage Facility
DDEL Fabrication Shop
46

DDEL
Men @ Job
Furnace Heat Treatment
Elbow Making Machine
Induction Mandrel
47

DDEL
DDEL Head Office
Client Visit at DDEL
DDEL at Event “Boiler 2010”
DDEL at ASSOCHAM Conference
48

DDEL
Thank You
Looking forward for a Long term relationship
For Further information please visit our Website
www.deedevelopment.com
49

DDEL
Alstom Power Switzerland
Project Details Scope of Supply Material Involved
870 MW CCPP
Langage Power Station at
Plymouth – UK
Power Cycle Piping consisting of
Main Steam, Hot reheat, Cold
Reheat and Feed Water
Balance of Plant Piping CS and SS
SA 335 Grade P11, P22 and
P91 and SA106 Grade C
Back to Projects Page
50

DDEL
Adani Power Limited - India
Project Details Scope of Supply Material Involved
5 * 660 MW Super Critical
Thermal Power Station at
Tiroda Maharashtra
2 * 660 MW Super Critical
Thermal Power Station at
Kawai Maharashtra
Power Cycle Piping consisting of
Main Steam, Hot reheat, Cold
Reheat and Feed Water
Power Cycle Piping consisting of
Main Steam, Hot reheat, Cold
Reheat and Feed Water
SA 335 Grade P11, P22 and
P91 and WB36
SA 335 Grade P11, P22 and
P91 and WB36
Back to Projects Page
51

DDEL
GE Energy - USA
Project Details Scope of Supply Material Involved
GE’s
1 st IGCC Project
Duke Energy – Edwardsport
Riser and Downcomer large bore
Piping with ASME Stamp
SA 106 Grade B and SA 335
Grade P11
Back to Projects Page
52

DDEL
Lanco Infratech - India
Project Details Scope of Supply Material Involved
Lanco Kondapalli Stage II
1*370 MW– Power Cycle
Piping
Lanco Kondapalli Stage III
2*370 MW– Power Cycle
Piping
Power Cycle Piping consisting of
Main Steam, Hot reheat, Cold
Reheat and Feed Water
Power Cycle Piping consisting of
Main Steam, Hot reheat, Cold
Reheat and Feed Water
SA 335 Grade P11, P22 and
P91 and SA 106 Grade B/C
SA 335 Grade P11, P22 and
P91 and SA 106 Grade B/C
Back to Projects Page
53

DDEL
Mitsubishi Heavy Industries Ltd. - Takasago Japan
Project Details Scope of Supply Material Involved
Plant Piping for 2* 800 MW
Nong Saeng CCPP Project at
Thailand
Plant Piping
SA 106 Grade B/C, SA 335
Grade P11/P22/P91 and SA
312 Grade TP304
( Approximately 1750 MT )
Back to Projects Page
54