BHUSHAN PRECISION TUBES ERW & CEW Future of Steel The BHUSHAN ISO: 9001 ISO: 14001 OHSAS: 18001 Future of Steel The BHUSHAN ISO: 9001 ISO: 14001 OHSAS: 18001 www.bhushansteel.com Works No. 104 / 3, SIPCOT Industrial Estate, Phase I, Zuzuvadi, Hosur - 635 126 (T.N.) Mob: 093451 29331 Hosur Sahibabad 28/4, Site IV, Sahibabad Industrial Area, Dist. Ghaziabad - 201 010 (U.P.) Tel: 0120 - 2770 601 - 08 Mob: 083769 00825 Khopoli Village: Nifan, Savroli, Kharpada Road, Tal.- Khalapur, Dist. Raigad - 410 203, (Mah) Tel: 02192 - 274 176 Mob: 099754 92604 Ahmedabad UL - 02, Wing ' B ', Samudra Complex, Nr. Klassic Gold Hotel, Off C. G. Road, Navrangpura, Ahmedabad - 380 009 (Guj) Tel: 098240 10767 Chennai No. 1, 3rd Floor, Mount Chambers, 190, (Old 758), Anna Salai, Chennai - 600 002 Tel: 044 - 2858 8154, 2858 8273 Mob: 098413 88154 Indore 213, Starlit Tower, 2nd Floor, 29, Y. N. Road, Indore (M.P) Mob: 098260 78902 608, Regent Chambers, Nariman Point, Mumbai - 400 021 (Mah) Mob: 097659 99551 Mumbai Branch Offices Hyderabad 305, Purni Plaza, Opp. Shadan College, Khairatabad, Hyderabad - 500 004 (A.P.) Mob: 098498 04006 Aurangabad Plot. No. 12-14, Gat No-378, Nagar - Aurangabad Road, Waluj, Aurangabad - 431 133 (Mah) Mob: 099754 92527 A - 3, SIDCO Industrial Estate, Phase I, SIPCOT, NH - 7, Hosur (T.N.) Mob: 098947 80369 Hosur Ludhiana D-37, Focal Point, Phase - V Ludhiana - 141 010 Mob: 099141 03070 Gurgaon (Manesar) Plot No. 26, Sector - 5, Imt Manesar, Gurgaon (Har) Mob: 098738 20924 Service Centers & Offices Pune Gat No.- 303, Village - Nanekarwadi - Chakan, Off. Pune Nashik Highway, Dist. Pune - 410 501 (Mah) Mob: 099754 92555 Photography & Design: Pankaj Mistry - 09967 888000
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B H U S H A N P R E C I S I O N T U B E SERW & CEW
Future ofSteel
The
BHUSHAN
ISO: 9001 ISO: 14001 OHSAS: 18001
Future ofSteel
The
BHUSHAN
ISO: 9001 ISO: 14001 OHSAS: 18001
www.bhushansteel.com
Works
No. 104 / 3,SIPCOT Industrial Estate,
Phase I, Zuzuvadi,Hosur - 635 126 (T.N.)Mob: 093451 29331
Off. Pune Nashik Highway, Dist. Pune - 410 501 (Mah)
Mob: 099754 92555
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& D
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Our mission is to grow our company by
providing innovative, strong and high
performance products and solutions to
meet our global customer needs
BHUSHAN STEEL LIMITED
ERW AND CEW PRECISION TUBES
Khopoli Adminstrative Building
Bhushan Steel Limited,
over 15,000 Crore ($3 billion), is a globally renowned and one of the leading players in steel industry - producing primary as well as secondary steel products. In the year 1987, the Company started its journey as a secondary steel producer with a unit at Sahibabad (Uttar Pradesh), and in the year 2003 set up its second unit at Khopoli (Maharashtra).
Bhushan Steel is Largest Producer of Precision Tubes
(ERW, Pre - Galvanized & CEW / CDW Steel Tubes) in
- Khopoli Tube Division started its commercial production in August - 2003. Bhushan Khopoli Plant produces low carbon, medium carbon, high tensile strength tubes for Automobile Industries, Cycle Industries, General Engineering, Textile Industries, Boiler Industries & other Engineering trade segments.
with a turnover of
Angul, Odisha
w Backed by own Raw Material (HR) source with various grades like low Carbon & High Strength.
w State-of-the-art technology with Modern facilities for Tube making process.
w 25 MW Captive Power DG sets for uninterrupted power supply.
w Bright Annealing Roller Hearth Furnaces Fully Automatic for Excellent Bright surface .
w State of art Surface Treatment Plant Fully Automatic PLC controlled.
w Capability to manufacture high strength tubes with close tolerance on OD & Thickness.
w Capability to offer wide Range of Tubes ( ERW , Pre-Galvanized & CEW Normal & Oil Draw Tubes ) in short Lead Time & small batches Flexibility.
w National distribution network through its Branch Offices & Capacious ware houses.
w Recognized as Self Certified Boiler & Pipe manufacturer by IBR
w Khopoli Tube plant is an ISO - 9001, ISO14001 & OHSAS - 18001 certified
Bhushan Steel is pioneer in adopting the most modern, state-of the-art technologies to produce a wide range of products for its customers with high-class facilities in tube making including CRCA, Tube making mills, Heat treatment furnaces and Cold draw facility.
ERW CEW tubes&
Strength of Bhushan Precision Tubes
Precision welded tubes are manufactured by the High Frequency Induction Welding Process which is commonly known as ERW process. After slitting the small slits/coil in desired sizes, slit coils are transferred to Steel Tubes Manufacturing Mills. Coils are loaded on Pay off Reel and passed through looping cage then to series of forming rolls which bend the strip in tubular form with abutting edges.
The abutting edges are then heated to the required Welding Temperature by means of High Frequency Induction The externally & internally Flash removed with the help of Scarfing Tools, then welded pipe passes through coolant tank and cooled.
The pipe passes through sizing section where the outer dia is maintained & pipe straightened with the help of Turk Head. The required length is cut on cut off carriage on line without stopping the mill. The cut length pipe is rolled out on conveyor & stopped by stopper at end of Conveyor and ejected to the pipe collecting pockets.
During entire tube processing change occurs in the steel structure & to remove the metallurgical difference between the weld zone & body of the tube effects of cold working caused in the forming & welding process, the tubes are subjected to heat treatment (normalizing). Normalizing process restore the grain structure thereby relieving the stresses It is essential where controlled mechanical properties are desired. The Normalizing process is carried out in a Bright Roller Hearth Furnace at temperature ranging between 750 ~900 degree.
The tubes are then straightened on 10 rolls straightening machine & tested (weld quality, mechanical properties , Eddy Current Testing, Hydro test – as per spec. requirement) oiled and packed as per customer requirement.
ERW CEW tubes&
mm (inch)
Outer Diameter Thickness
Fin Cut & Non Fin Cut
Beyond mill Capablity
0.30(0.010")
0.40(0.016")
0.50(0.020")
0.60(0.024")
0.65(0.026")
0.70(0.028")
0.80(0.031")
0.90(0.035")
1.00(0.039")
1.10(0.043")
1.20(0.047")
1.40(0.055")
1.50(0.059")
1.60(0.063")
1.80(0.071")
1.90(0.075")
2.00(0.079")
2.20(0.087")
2.30(0.091")
2.40(0.094")
2.50(0.098")
2.60(0.102")
2.80(0.110")
2.90(0.114")
3.00(0.118")
3.10(0.122")
3.20(0.126")
3.30(0.130")
3.40(0.134")
3.50(0.138")
3.60(0.142")
3.80(0.150")
3.90(0.154")
4.00(0.157")
4.20(0.165")
4.30(0.169")
4.50(0.177")
4.60(0.181")
5.00(0.197")
5.50(0.216")
6.00(0.236")
6.50(0.256")
12.70 (0.500")
15.88 (0.625")
17.25 (0.679")
18.25 (0.720")
19.05 (0.750")
21.40 (0.839")
21.90 (0.866")
22.23 (0.875")
23.42 (0.922")
25.40 (1.000")
28.58 (1.125")
30.00 ( 1.181")
31.75 (1.250")
33.70 (1.327")
34.93 (1.375")
38.10 (1.500")
40.00 (1.575")
41.28 (1.625")
42.70 (1.681")
44.45 (1.750")
48.30 (1.902")
50.80 (2.000")
55.56 (2.185")
57.15 (2.250")
60.30 (2.374")
63.50 (2.500")
65.00 (2.559")
69.85 (2.750")
76.20 (3.000")
81.20 (3.197")
88.90 (3.500")
93.50 (3.861")
101.60 (4.000")
108.00 (4.252")
9.53 (0.375")
114.30 (4.500")
Non Fin Cut
ERW Size Range Round Shape
ER
W
CE
W tu
be
s&
0.30(0.012")
0.35(0.014")
0.40(0.016")
0.45(0.018")
0.50(0.022")
0.60(0.024")
0.70(0.028")
0.80(0.031")
0.90(0.035")
1.00(0.039")
1.10(0.043")
1.20(0.047")
1.40(0.055")
1.50(0.059")
1.60(0.063")
1.80(0.071")
1.90(0.075")
2.00(0.079")
2.20(0.087")
2.30(0.091")
2.40(0.094")
2.50(0.098")
2.60(0.102")
2.80(0.110")
2.90(0.114")
3.00(0.118")
3.10(0.122")
3.20(0.126")
3.30(0.130")
3.40(0.134")
3.50(0.138")
3.60(0.142")
4.00(0.157")
Non Fin Cut
Fin Cut & Non Fin Cut
Beyond Mill Capablity
mm (inch)
Width Height Thickness
12.00(0.472")
12.70(0.50")
15.00(0.591")
18.00(0.709")
18.50(0.728")
19.05(0.750")
20.00(0.787")
21.00(0.827")
22.00(0.886")
24.00(0.945")
25.00(0.984")
25.40(1.000")
30.00(1.181")
31.75(1.250")
38.00(1.496")
40.00(1.575")
45.00(1.772")
50.00(1.969")
50.80(2.00")
60.00(2.362")
75.00(2.953")
12.00(0.472")
12.70(0.50")
15.00(0.591")
18.00(0.709")
18.50(0.728")
19.05(0.750")
20.00(0.787")
21.00(0.827")
22.00(0.886")
24.00(0.945")
25.00(0.984")
25.40(1.000")
30.00(1.181")
31.75(1.250")
38.00(1.496")
40.00(1.575")
45.00(1.772")
50.00(1.969")
50.80(2.00")
60.00(2.362")
75.00(2.953")
Sq
uar
e
ERW Size Range Square Shape
0.30(0.012")
0.35(0.014")
0.40(0.016")
0.45(0.018")
0.50(0.022")
0.60(0.024")
0.70(0.028")
0.80(0.031")
0.90(0.035")
1.00(0.039")
1.10(0.043")
1.20(0.047")
1.40(0.055")
1.50(0.059")
1.60(0.063")
1.80(0.071")
1.90(0.075")
2.00(0.079")
2.20(0.087")
2.30(0.091")
2.40(0.094")
2.50(0.098")
2.60(0.102")
2.80(0.110")
2.90(0.114")
3.00(0.118")
3.10(0.122")
3.20(0.126")
3.30(0.130")
3.40(0.134")
3.50(0.138")
3.60(0.142")
4.00(0.157")
Non Fin Cut
Fin Cut & Non Fin Cut
Beyond Mill Capablity
mm (inch)
Width Height Thickness
31.75(1.250")
27.00(1.063")
22.00(0.866")
30.00(1.181")
40.00(1.575")
40.00(1.575")
50.00(1.969")
50.80(2.00")
40.00(1.575")
50.00(1.969")
60.00(2.362")
60.00(2.362")
75.00(2.953")
80.00(3.150")
84.30(3.319")
85.00(3.346")
100.00(3.937")
115.00(4.528")
19.05(0.750")
20.00(0.787")
20.00(0.787")
20.00(0.787")
20.00(0.787")
25.00(0.984")
25.00(0.984")
25.40(1.00")
30.00(1.818")
30.00(1.181")
30.00(1.181")
40.00(1.575")
25.00(0.984")
40.00(1.575")
76.15(2.998")
44.00(1.732")
50.00(1.969")
60.00(2.362")
0.30(0.012")
0.35(0.014")
0.40(0.016")
0.45(0.018")
0.50(0.022")
0.60(0.024")
0.70(0.028")
0.80(0.031")
0.90(0.035")
1.00(0.039")
1.10(0.043")
1.20(0.047")
1.40(0.055")
1.50(0.059")
1.60(0.063")
1.80(0.071")
1.90(0.075")
2.00(0.079")
2.20(0.087")
2.30(0.091")
2.40(0.094")
2.50(0.098")
2.60(0.102")
2.80(0.110")
2.90(0.114")
3.00(0.118")
3.10(0.122")
3.20(0.126")
3.30(0.130")
3.40(0.134")
3.50(0.138")
3.60(0.142")
4.00(0.157") mm (inch)
Width Height Thickness
59.00(2.323")
30.00(1.181")
Ova
lR
ecta
ng
ula
r
ERW Size Range Rectangular ShapeE
RW
C
EW
tub
es
&
By Cold Drawing process we can make any non standard size for specific end use with close tolerances, better surface finish & superior close mechanical properties. In CEW process the welded tubes (ERW Tubes) are used as parent hollow. After Normalizing & Surface Treatment (Conventional & Oil route) the tubing is cold drawn through a Die and over a Mandrel to reduce diameter & wall thickness to required dimension. Bhushan has an Oil Draw facility to produce extremely smooth ID finish with close tube tolerance for Cylinder bore tubes where piston moves freely repeated under severe conditions. The tooling & process is well designed to achieve close ID tolerances with ID finish 0.40 Ra max. Such close tolerances & finish enable customer to use oil draw tube directly without additional operations. Bhushan is also manufacturing TFF tubes (Telescopic Front Fork) tubes as per customer specification, which is high tensile tubes (UTS - 88
kgmm2 min) with close dimensional tolerance.
Cold Drawing
ER
W
CE
W tu
be
s&
ERW CEW tubes&
Process Flow of CEW Tubes
Inspection & te
sting
Roller Hearth Furnace
Hot Air Dryer
Swaging
DrawingStraighteningEnd CuttingFinal InspectionR. P. Oiling / Coating
Bhushan steel use the finest quality steel for tube products which confirm the National & International standards. Bhushan Khopoli plant is fully equipped with an advanced and integrated Quality System to produce strips & tubes as per standards.
The Central Boiler Board has also recognized the Bhushan Khopoli, Tube Division as a “Well Known Tube & Pipe maker” under Regulation 4C (2) of the IBR Act 1950. Bhushan Tubes has also been awarded the ISO 9001/2008, IS:14001:2004 & OHSAS 18001:2007.
The Quality control systems is backed by Modern Laboratory and a test facility for Physical , Chemical & Metallurgical tests.
Tests Carried Out :-
The tubes are packed loose as well as in bundles in round, Hexagonal & square shape as per customer requirement.
w Loose
w Master Bundle with polythene
w Bundled with HDPE bagged at ends
w Bundles wrapped with polythene (HDPE )
ER
W
CE
W tu
be
s&
Testing & Quality Control
Packing
ERW CEW tubes&
Accreditation A
ccre
dit
ati
on
IS
O 9
00
1:20
08
ISO
14
00
1:20
04
ISO
18
00
1:20
07
Certificate of approval for wellknown Tube & Pipe Maker