JAMUNA RIVER CROSSING PORTION OF BOGURA KALIAKAIR 400KV DOUBLE CIRCUIT TRANSMISSION LINE OF TURNKEY BASIS

[Audio] The purpose of this presentation is to outline the methodology for fabricating steel piles at the workshop. This process involves several stages, including visual and dimensional inspections of the raw materials, correlation with manufacturer material test certificates, and ultrasonic testing. We will also examine the importance of quality control and assurance in guaranteeing the reliability and safety of the final product..

[Audio] The technical specifications aim to establish a comprehensive set of guidelines for the production, quality control, and quality assurance procedures involved in the fabrication process of steel pipes. This includes adhering to various industry-standard specifications and standards, such as API 2B, ASTM A 6–99, and others, to ensure the highest level of quality and reliability in the final product.

[Audio] The specification outlines the requirements for fabricating structural steel pipes with longitudinal and circumferential butt-welded seams, typically in sizes 14 inches outside diameter and larger, with wall thicknesses ranging from 3/8 inch to greater than 40 feet in length. These pipes are designed for use in constructing welded offshore structures, particularly in piling and main structural members, such as tubular truss/stiffener connections. Manufacturers seeking to apply the API Monogram to these products must demonstrate their personnel's competence in welding, inspection, non-destructive examination, and testing, as specified by this standard. The pipes will serve as permanent pile casings for installing steel piles, subjected to dynamic and cyclic loading, and exposed to environmental corrosion..

[Audio] The pipe spools produced in the workshop will be further joined together to form approximately 90 meters in length at the Jamuna River Project site in Bangladesh. These permanent steel casing piles will be driven into the riverbed using high-energy hydraulic impact hammers. During their installation, the piles will experience dynamic impact loading and then be subject to cyclic loading over their 100-year service life, including exposure to environmental corrosion. The material used for these pipes has a thickness delivery condition of less than or equal to 70 millimeters, with a killed and normalized condition. All plates will undergo 100% testing according to EN 10160 S0/E0 standards. The designation of this material is S355 Grade J0, with a method of deoxidization specified. The chemical composition of this material includes carbon, silicon, manganese, sulfur, phosphorus, nitrogen, and copper, all within specific limits. The mechanical properties of this material include minimum yield strength, tensile strength, percentage of elongation, and impact energy, all of which meet specific requirements..

[Audio] We inspect the steel plates visually and dimensionally to ensure they meet our quality requirements. We verify the information provided by the manufacturer through their material test certificates. Additionally, we conduct ultrasonic testing on each and every plate to detect any defects or anomalies. This thorough examination helps us identify any potential issues early on, allowing us to take corrective action if necessary. By doing so, we can guarantee the highest level of quality in our steel pipes..

[Audio] Establishing the welding procedure specification, we follow a systematic approach. First, we identify the new material, specifically EN 10025-2, S355-J0. This material has specific properties and characteristics that need to be taken into account when developing the welding procedure. Next, we conduct destructive testing, also known as DT, to evaluate the mechanical properties of the material. This includes tensile tests and impact tests. We also perform non-destructive testing, or NDT, to assess the material's integrity and detect any defects. These tests help us establish the welding procedure specification, ensuring that our welds meet the required standards. By following this rigorous process, we can guarantee the quality of our welds and ensure the reliability of our final product..

[Audio] We ensure that all necessary equipment and tools are available and ready for use. We verify that the welding process meets the required standards and specifications. This involves checking the metal bars on the table, ensuring they are properly aligned and positioned for welding. Furthermore, we inspect the area where the welding will take place, making sure there are no obstacles or hazards that could interfere with the process. Only then can we proceed with the welding operation..

[Audio] After setting up the welding procedure specification, we proceed to the welder qualification test. This stage is vital as it guarantees that our welders possess the essential skills and expertise to generate high-quality welds. We carry out this test to confirm that our welders are capable of meeting the mandatory standards and specifications..

[Audio] The once-completed plate marking and cutting process is followed by the edge preparation stage. Here, the edge milling machine meticulously trims and shapes the edges of the steel plate to achieve a precise fit upon welding. This meticulous attention to detail is vital in maintaining the structural integrity of the final product, thereby ensuring a high-quality finish that adheres to the necessary specifications..

[Audio] After the plate has been rolled into its desired shape, we proceed to the next stage of our process. Here, we prepare the long seam for welding by ensuring that all edges are properly aligned and fitted together, ready for the welding process to begin. This crucial step demands meticulous attention to detail and precision to guarantee that the finished product satisfies the necessary standards..

[Audio] Before preheating the long seam, it's essential to ensure that the metal is at the optimal temperature for welding. The preheating process is crucial as it prepares the metal for the welding process. Once the preheating is complete, the root run of the long seam welding begins using GMAW from the inside of the pipe. This initial pass lays the foundation for the rest of the welding process. Finally, the remaining welding is completed using SAW from the inside of the pipe..

[Audio] The manufacturing process for steel pipes involves several stages. Long seam butt welding is performed from the outside of the pipe, ensuring a strong and reliable joint. The rest of the welding process is then completed using a submerged arc welding method from the outside of the pipe. Finally, the welding process is finished by completing it from both sides for smaller spools of 3 meters or 3.5 meters in length. This rigorous process guarantees high-quality steel pipes for our clients..

[Audio] The manufacturing stages for steel pipe include circular seam fit-up, where all components are properly aligned and ready for welding. Next, preheating is applied to the area before starting the welding process, which prevents defects or irregularities in the weld. The welding process itself begins with GMAW, with the root run starting from the inside of the pipe. This is a crucial step in ensuring the integrity of our welds..

[Audio] The manufacturing process proceeds with rest welding being carried out from the inside of the pipe utilizing a submerged arc welding technique. This step guarantees the integrity of the pipe's internal surface. Afterward, circular seam welding is accomplished from the exterior of the pipe subsequent to back gauging having been applied. This procedure is reiterated until a comprehensive spool measuring 10 to 12 meters in length is produced..

[Audio] The methodology for steel pile fabrication at the shop includes production, quality control, and quality assurance procedures. To ensure the highest quality, various important steps are involved, including ultrasonic testing. The 100% long seam ultrasonic testing detects potential defects or flaws in the long seam of the steel pile. The 100% circular seam and "T" ultrasonic testing checks the circular and "T" seams, ensuring they meet high standards. Additionally, the 10% PAUT provides random data to further enhance the quality of the steel piles. By following these procedures, the steel piles are ensured to be of the highest quality and ready for construction..

[Audio] We use various tools to inspect steel pipes visually and dimensionally in this stage. These tools include calipers, micrometers, and other precision instruments. Additionally, we employ specialized software to analyze the data gathered during the inspection process. This enables us to detect any defects or irregularities promptly, allowing us to take corrective measures before proceeding with the fabrication process..

[Audio] We use various tools to inspect steel pipes visually and dimensionally in this stage. These tools include calipers, micrometers, and other precision instruments. We also utilize specialized software to analyze the data collected during the inspection process. This ensures that any defects or irregularities are detected early on, allowing us to take corrective action before proceeding with further processing..

[Audio] We use various tools to inspect steel pipes visually and dimensionally in this stage. Calipers, micrometers, and other precision instruments are employed to ensure that the dimensions meet the required specifications. Additionally, we check for any defects, such as cracks, dents, or corrosion, that could impact the integrity of the pipe. Our team of experienced inspectors verifies that the pipes meet our high standards for quality by utilizing these tools..

25) Visual Inspection for 100% surface, Bevel Edge, Weld Seam from Inside and Outside.

[Audio] Dimensional inspection is a crucial step in the manufacturing process of steel pipes. Here, we measure the circumference of the pipe's outer diameter using a pi meter. This ensures that the pipe meets the required specifications and dimensions. The measurement is taken carefully to ensure accuracy, and any deviations from the standard dimensions are noted and addressed accordingly. By performing this dimensional inspection, we can guarantee the quality of our steel pipes and ensure they meet the requirements of the EHV transmission line project..

[Audio] Dimensional inspection is a vital stage in the production process of steel pipes. Here, we assess the thickness of the pipe to verify that it satisfies the necessary specifications. Additionally, we examine the bevel edge angle and root face measurement from the outer diameter of the pipe. This guarantees that the pipe is manufactured to the precise dimensions, which is crucial for its intended application in the construction of EHV transmission lines. By conducting these measurements accurately, we can assure the quality of our products and fulfill the demands of our clients..

[Audio] Dimensional inspection is a crucial step in the manufacturing process of steel pipes. At this stage, we measure the length of the pipes to ensure they meet the required specifications. This measurement is critical because it affects the overall performance and functionality of the final product. Our team uses specialized equipment and techniques to take precise measurements, ensuring accuracy and reliability. By doing so, we can guarantee that our steel pipes meet the highest standards of quality and safety..

[Audio] In this stage, we measure the straightness of the steel pipe using specialized equipment called Line-Dori. This measurement is crucial because any deviation from the straight line can affect the overall performance of the structure. We take precise measurements to guarantee that the pipe remains straight throughout its length. This process is essential to maintain the integrity of the structure and prevent any potential issues during installation..

[Audio] Dimensional inspection is a crucial step in the steel pile fabrication process. We measure the radial offset of the longitudinal welded seam and circumferential welded seam to ensure that they meet the required specifications. This measurement helps us identify any deviations from the expected dimensions, allowing us to take corrective action if necessary. By performing this inspection, we can guarantee the quality of our fabricated steel piles, ensuring they meet the requirements for the construction of the EHV transmission line for Jamuna River crossing project in Bangladesh..

[Audio] The dimensional inspection involves measuring the weld bead height from the outside diameter to ensure that the weld meets the required specifications and dimensions. Our team takes great care to measure the weld bead height accurately, guaranteeing that it falls within the acceptable range. This critical step is essential in maintaining the high quality of our fabricated steel piles..

[Audio] In this final stage of the manufacturing process, we measure the out-of-roundness of the steel pipe from its inside diameter. We ensure that the pipe meets the required specifications and standards before shipping it out for use in the construction of the EHV transmission line for the Jamuna River crossing project in Bangladesh..

[Audio] As we move forward in the fabrication process, we now reach the final stage where we conduct a thorough inspection of our steel pipes. This includes checking for any signs of out-of-roundness after the spider tack welding process has been completed. We also verify the marking details, including the API monogram, dimensions, pipe number, plate heat number, weight, and ITD pile type and serial number. This ensures that our finished product meets the required standards and specifications..

[Audio] The American Petroleum Institute has granted Ratnamani Metals and Tubes Ltd. a certificate of authority to use their official monogram, with a license number of 2B-0217. According to the terms of this certification, the company can manufacture steel pipes in accordance with the conditions specified in the API 2B publications. The scope of work covered by this agreement includes the production, quality control, and quality assurance procedures for the casing spool joining in 1G position at the workshop. The effective date of this certification is June 22, 2024, and it will expire on June 22, 2027..

[Audio] As we progress through the manufacturing stages for steel pipe, it is vital to guarantee the quality of the final product. During this phase, we implement a protective measure to the beveled edge of the steel pipe. This is critical to prevent any damage or corrosion during transportation and installation. We utilize metal end protectors to safeguard the edges, ensuring they remain intact and prepared for utilization. Upon completing this step, we capture a final image of the product, documenting its quality and readiness for deployment. This signifies the culmination of our manufacturing process, where we have ensured the highest standards of quality and reliability..

an. (D Cem Commitment. Reliability & Ouality. “Improve quality, you automatically improve productivity”- W. Edward Deming.