.الCOﺤرYﺾTRﺋSالDUﺳالINمEﻐPﺋ IلL PﺧﻈAاNﺲOﺋTIالAمNﻌRاTEﺠﻐNرI
OUR CORE VALUES - Safety and the Environment - Professionalism - Accountability and Transparency - Collaboration - Community Development IرNﺠﻐTEاRﻌNمAالTIﺋOﺲNاAﺧﻈL P لIﺋPﻐEمINﺳالDUالSﺋTRﺾYﺤرCOال.
MISSION “We are Committed to Provide Steel Pipe and Steel Structures Solutions to Build Excellent Rapport with Existing And New Customers with Consistent Supply of Quality Products and Practices”.
VISION “To Survive, and Turnaround Achieving Sustainable Growth to be The Most Competitive and Diverse Pipe Solutions’ Provider in Africa”.
COMPANY PROFILE Authorized Capital 200 Million Usd Paid-up Capital 70 Million Usd IPIC was Incorporated and Registered in Egypt Since Jan. 2001 Under The Egyotian Private Free Zone Law No (8) for the Year 1997 for Providing Egyptian and International Oil and Gas Markets By Pipes and Bends for Oil and Gas Pipeline Projects.
SHAREHOLDERS KUWAIT PIPE INDUSTRIAL & OIL SERVICE CO (KPIOS) ENGINEERING FOR PETROLEUM AND PROCESS INDUSTRIES (ENPPI) EGYPTIAN NATURAL GAS CO (GASCO) THE PETROLEUM AND TECHNICAL CONSULTATION CO. (PETROJET) NATIONAL AUTHORITY FOR MILITARY PRODUCTION. 60% 11.42% 11.42% 11.42% 5.74% National Authority The Petroleum & Egyptian Natural Kuwait Pipe ENGINEERING For for Military Technical Gas Co. Industry&Oil Services Petroleum & Production Consultation Co. ( GASCO ) Co Process Industries (PETROJET) (KPIOS) (ENPPI)
LOCATION The Factory’s Location Was Selected To Be on the Main Road Between Two Egyptian Ports, Port-Said & Damiatta. This Location Provides IPIC with many Advantages to Export PiPes to European, African and Asian Countries in Less Time.
QUALIT API MONOGRAM CERTIFICATIONS IPIC Mills are Certified By Many International Authorities for The Pipe Product API MONOGRAM Which Guarantees That all Pipes Produced By IPIC Have to Comply With the API-5L as Minimum Requirements. And for the Total Quality Management System ISO 9001 : 2008 For Both Pipes and Bends Mills. Also API Q1 Which Guarantees That The Quality System in IPIC is in compliance with the API Requirements for Pipe Making. ISO 9001 : 2015 ISO 14001:2015 ISO 45001:2015 ISO 9001:2015 API Q1 API MONOGRAM ISO 9001:2015 API API Q1
QUALITY is Our Concern IN IPIC WE DO BELILEVE THAT QUALITY IS THE WAY TO SPREAD OUR BUSINESS, SO WE DESIGNED OUR PROCESS TO ACHIEVE THE MAXIMUM QUALITY AS: 60% Of the Pipe’s Making Eq are Inspection Equipme
60% quipments 100% 100% ents. Online Inspection Points Along Tracking of all Pipes Reporting Certifications The Whole Production Line. for Each Single Pipe.
INSPECTION POINTS
UT Lamination Plate Storage Visual Inspection Repair Vesual Area Random Check Plate Edge Milling UT I Inspection ٢ Plates Per Shift -٣Roll Bending Laboratory Post Bending Tack Welding Internal Welding External Welding Destructive Test Sample Out of Repair LimitPipe Sizing AreaX-Ray or Manual UTRepair Area Pipe Hydrostatic To Reject Pupe Yard Testing UI II Inspection X-Ray Real Time End Beveling Destructive Test Sample Magnatic Inspection Final Inspection To Pipe Yard Pipe Weighing, Length Measurement & Marking
OUR CUSTOMERS By Using Our Products in Your Worldwide Projects, Your Precious Trust Motivates Us to Achieve Keeping the Highest Quality for Your Satisfaction.
THANK YOU
PIPES PIPE LENGTH : 8 : 12 Meters RANGE OF PIPE DIAMETER : 16” : 42” (Capability to 60’’) THICHNESS : 8.7 : 27mm ANNUAL PRODUCTION : 150000 : 250000 TON DAILY PRODUCTION : 160 Pipes Per Day MATERIAL IN COMPLIANCE WITH API-5L : up to Grade X-80 or Equivalent. TECHNICAL HIGHLIGHTS
MANUDACTURING PROCESS LSAW PIPES
PLATE DESTACKING EDGE FORMING -٣ROLL FORMING POST BENDING CONTINOUS TACK INTERNAL WELDING EXTERNAL WELDING VISUAL INSPECTION WELDING PIPES X-RAY CONTROL OF ULTRASONIC TEST PRODUCTION CHART WELD REPAIR PIPE REPAIR (MANUAL) SHIPPING MARKING AND FINAL FINAL INSPECTION MAGNETIC PARTICLE PIPE ENDS BEVELING X-RAY REAL TIME HYDROSTATIC TEST FULL BODY EXPANDER RELEASE CUTTING TEST
PIPE DESIGN PIPE DESIGN DEPENDS MAINLY ON : - Proposed Palte Dimensions - Welding Parameters - Proposed Manufacturing Procedure - Proposed Quality Plan APPROVAL OF PIPE DESIGN Before Starting The Continuous Production, A First Day Production Should be Carried Out in Order to Assure the Proposed Pipe Design and Approve it According to the International Standards and Also Clients’ Requirements.
PLATE EDGES MILLING M/C Horizontal Feed Milling System Used to Prepare the Steel Plates Longitudinal Edges for Welding Prior to Forming of Pipe Body, he Machine is Equipped With CNC System. 3-ROLL BENDING M/C It is the Most Advanced Pipe Rolling M/C, Capable to Roll Pipe Size Starting ١٦” up to ٦٠” With Differnet Wall Thicknesses From ٦٫٤mm Up to ٣٠mm With Double Random Leegth of ١٢٫٢ Meters.
POST BENDING M/C As the 3-Roll Bending M/C Forming 80% From Full Roundness of the Pipe, The Post Bending M/C Crimps the Pipe Longitudinal Straight Edges to Achieve 100% Roundness. CONTINUOUS TACK WELDING First Welding Station, in this Station the Pipe Seam Edges are Joined Together by Continuous Weld. The Machine is Also Designed to Adjust Misalignment, H١/L٠ and Offset Between to Internal Welding.
INTERNAL WELDING M/C Automatic Submerged ARC Welding Process Using Three or Four Wires. Two Welding Machines are Working Parallel to Achieve Higher Productiviry. EXTERNAL WELDING M/C Final Welding Stage for the External Side of the Pipe Seam, Two Automatic Submerged ARC Welding Machines Using Four Wires.
VISUAL INSPECTION Frist Inspection Stage, Overall Visual Inspection Applied to the Pipe Internal and External Surfaces Including Weld Seams. AUTOMATIC ULTRASONIC M/C (STATION) After Visual Inspection, Automatic UT Inspection Applied to Assure Solidity of the Pipe Weld Seam Before Cold Expanding.
REPAIR STATION (X-RAY ROOM) In Case of Weld Repair, the Repaired Areas in the Pipe Seam Weld Subjected to X-Ray Inspection to Evaluate and Assure That the Defects Had Been Repaired, X-Ray Film Kept as Evidence. COLD EXPANDING M/C The Machine is Designedfor Adjusting Pipe Roundness And Straightness, This Process Also Recover The Base Metal Mechanical Properties.
HYDRO-STATIC TESTING M/C As Per API 5L Specifications, the Manufactured Pipe Should be Tested Hydrostaticaly to a Certain Pressure Indentified by the Spcification, Automatic Hydro-Testing M/C Capable to Perform the Test up to 320bar. AUTOMATIC ULTRASONIC (M/C (STATION II First Inspection Station After Cold Expanding and Hydro-Testing, Shear Angle Sound Beams (UT) Inspection to be Applied to Assure the Solidity of the Pipe Seam Weld Before Final Inspection
X-RAY REAL TIME X-Ray Real Time Station is for Inspection Of Seam Weld After (UT II). Full Scan of the Pipe Seam Weld Applied For Verification of any Comments From the Previous Station and Pipe Ends Radio-Graphed to Assure that Pipe Ends are Free of Defects. END BEVELING M/C For Pipe Ends Preparation to The Required Angle and Root Face According to The Project Specifications. The Station is Consists of Two End Beveling Machine Work Together at the Same Time.
MAGNETIC PARTICLE TESTING To Inspect Pipe BeveledEnds Surface for Deffects After End Beveling. FINAL INSPECTION : Visual and Dimensional Check Applied to The Final Product. This Inspection Product, This Inspection Stage Includes Pipe Length Measuring, Pipe Weighing, Pipe Straightness and Ovality Measurment in Addition to Overall Visual Inspection and External Surfaces.
PIPE TRACKING SYSTEM : IPIC Aprroved an Internal Computerized System for Tracking and Recording all The Pipes Production Data Starting From Steel Plates Recording up to FInal Products Dispatching Tracking and Recording all Pipe Making History is Parallel Process to Quality Control Process. Tracking System Could Be Usfeul in generating the following reports Automatically : - Daily, Weekly, Monthly and Annually Production Reports. - Pipe History Including all Stations Outputs. - Finished Products Reports. - Pipes Certifications of Quality.
PIPE PRODUCTION RANGE FOR 40FT. (12.2M) LOMG PIPES Available tooling up to size 42” only
BENDS BEND DIAMETER : From 6” : 48” From 8.7 : 38.1mm BEND THICKNESS : Any Degree up to 180˚ 3DR BENDING ANGLE : up to Grade X-80 or Equivalent. MINIMUM BEND RADIUS : MATERIAL IN COMPLIANCE WITH API 5L :
MANUDACTURING PROCESS INDUCTION BENDSS
CONTINOUS TACK HOT BENDING DIMENSIONS CHECK BEFORE HEAT TREATMENT DIMENSIONS CHECK WELDING MACHINE HEAT TREATMENT FURNACE AFTER HEAT TREATMENT PIPES UT ALONG PRODUCTION SEAM WELD CHART UT THICKNESS ON BENDED AREA DESTRUCTIVE TEST FINAL INSPECTION & MAGNETIC PARTICLE & EDGE BEVELING CUTTING ENDS HYDROSTATIC TEST MARKING UT FOR LAMINATION TO LENGTH
INDUCTION BENDING M/C The Machine Used The Induction Bending Theory to Convert Th Straight Pipe Into Bend. The Powerfull Design of the Machine Allows Producing of 3D Induction Bends and any Anglee up to 180 Degree. DIMENSIONS CHECK Visual and Dimensions Check Performed on Bend Before and After Heat Treatment in Order to Assure and Guarantee the Required Dimensions.
HEAT TREATMENT Depending on the Requested Machanical Properties, The Bend May be Heat Treated After Bending in Order to Achieve the Aimed Mechanical Properties. HYDROSTATIC TEST According to Client Requirement and The Bend Usage, Hydrostatic Test May be Carried Out on all Bends or Sample Bend For Qualification.
END BEVELING M/C For Bends Ends Preparation, to the Required Angle and Root Face According ro The Project Specifications. INSPECTION Visual and Dimensions Check Performed on Each Bend, The Ispection Stages Include But Not Limited to Bend Ovality Measurement, ut on Seam Weld and Bends, Ends Test For Lamination.
STEEL STRUCTURE The process of steel fabrication in IPIC involves grinding, FABRICATION & ERECTION welding, cutting, bending, drilling, punching, burning or melting and other general crafting methods using various high-quality tools and CNC equipment. The entire steel fabrication process is systematic and requires utmost planning, precision, and knowledge. Steel fabricators are well aware of all the crucial steps and measures that need to be considered in the fabrication process. Structural steel is usually fabricated to create structures like beams, trusses, hollow sections, angles and plates.
These steel members must be accurately fabricated before assembling them together. All component parts of these members are fitted-up temporarily with rivets, bolts, or small amounts of welds. Various fastening methods are employed to deliver different types of finishes. Finishing is generally performed by milling, sawing or other suitable methods. It’s important to understand how steel structures are designed before assembling them together. CONSTRUCTION NEEDS : First and foremost IPIC has a professional technical engineering specialists empowered with latest technologies and most efficient devices to provide all required engineering works such as design, workshop drawings, planning, monitoring and controlling of all production stages. It’s crucial to know the type of structure you want to construct. Commercial structures have a distinct designing process. Similarly, residential structures are totally dissimilar from industrial structures. Hence, all the structures demand different types of construction processes. Moreover, any type of construction process requires unique structures varying in sizes, dimensions, and designs. Each structure has to be specifically designed and fabricated before constructing and assembling them together. For any joint to be site welded, the members will have to be held securely in position such that the setup for welding is accurate and rigid.
STEEL ERECTION : There are four primary tasks that need to be considered before the steel erection process. - It is extremely important to establish the foundations and confirm if they are suitable and safe for erection to commence. - With the help of cranes or sometimes by jacking, lifting and placing components into position is essential. Additionally, to secure the components in place, bolted connections are made but they may not be fully tightened. Similarly, bracings may not be fully secured. - Aligning the structure is essential, principally by checking that column bases are lined and leveled and columns are plumb. To allow column plumb to be adjusted, packing in beam-to-column connections may need to be changed. - Last but the least, bolting-up is required, which means completing all the bolted connections to secure and impart rigidity. Steel fabrication and erecting steel structures are a lengthy process and they require immense skills, knowledge, and practice. Our steel fabricators at IPIC use the best steel fabrication tools and equipment to ensure that the fabrication and erection processes of steel structures are done with accuracy and perfection.
ERECTION TECHNIQUES : Mobile man boom lift (MMBL) and cranes are predominantly used in the erection of steel structures for buildings and bridges. However, there are other various techniques that are sometimes used for constructing steel bridges. Cranes are usually divided into two broad categories, mobile and non-mobile cranes. Truck mounted, crawler and all-terrain cranes are included in the first category, while tower cranes are included in the second category. The MMBLs can be used both on the ground or on the partly erected steel structure, in order to erect lighter steel elements. These MMBLs are used to access the steelwork during erection to bolt up the pieces lifted by the crane. Important measures need to be taken before using the MMBLs such as first checking if the steel structure can support the weight of the MMBL and then determining whether they should be used on the ground or on the erected structures.
PIPE The process of steel fabrication in IPIC involves grinding, welding, cutting, bending, drilling, punching, burning or melting and other general crafting ACCESSORIES methods using various high-quality tools and CNC equipment. The entire steel fabrication process is systematic and requires utmost planning, precision, and knowledge. Steel fabricators are well aware of all the crucial steps and measures that need to be considered in the fabrication process. Structural steel is usually fabricated to create structures like beams, trusses, hollow sections, angles and plates. These steel members must be accurately fabricated before assembling them together. All component parts of these members are fitted-up temporarily with rivets, bolts, or small amounts of welds. MITERED FITTINGS IPIC is specialized in fabrication and assemblyof Mitered fittings (Elbows, Tees and Reducers) according to AWWA C208 which are made from miter cut pieces of pipe. Tests which available to be performed on the mitered fittings include X-Ray, Ultrasonic testing, Magnetic Particle and other Non-Destructive Examinations, as well as Charpies, Yield and Tensile and Chemistry analyses are available as well. IPIC Mitered Fittings’ Fabrication Division can meet the needs of most Waterworks Projects & often supports the low pressure needs of other Major Fabrication Shops specializing in Heavy Power.
IPIC COMPREHENSIVE WORK INCLUDES : FABRICATION ASSEMBLY & INSTALLATION - Structural Steel and On-site Steel Fabrication. - Electrical & Instrumentation (Buildings, MCC’s, switchgear, remote / - On-site 110,000 sq. ft. / 30,000 MT per year. in-line instruments, cabinets with I/O, UPS,VFDs, Trays, JBs, RTDs, - Piping with all type of material. cables, connectors, lighting, HVAC etc.) - Expansion Loops, Cantilever, Pipe way. - Optimize weld locations / orientations. - Fire Proofing - Integrated Supplier Quality Surveillance (SQS), - Mechanical - expediting, logistics. - Hydro-testing - Equipment Modules. - Electrical Heat Tracing (EHT) / Glycol Heat Tracing (GHT) - Pump Modules. - Insulation - Valve Station. - Skids - Stair Modules. - Cladding - Heat Management - Non-Destruction Testing (NDT) - Painting - Digital control system (DCS) Support and Testing - Steel Erection - Mechanical / Rotating - Shipping Steel - Spool Installation - Scaffolding - Stair Modules - Heavy Haul Coordination - Rigging - Coordination of Overseas Fabrication
LABORATORY : In order to assure the independency of ipic quality, we designed an independent laboratory which is one of the most advanced and certified chemical & mechanical labs in egypt and middle east. This lab is equipped with most advanced and updated testing equipments to fulfill all the required testing equipments to fulfill all the required tests for both pipes and plates in compliance with international codes and standards. IPIC Lab Engineering Services: 1. Material Testing (Destructive & Non-Destructive Tests ) : - Ultrasonic Testing - Magnetic Particles Inspection - Liquid Penertrant Testing - Radiographic Testing - Destructive Testing Lab: * Material Conformance with client requirements * Qualification of Welding Procedures Operators * Capability of Performing: Tensile – Bending – Impact – DWTT Tests 2. Heat Treatment of Specific Products: Programmable LPG operated furnace equipped 12 thermocouple channels for stress relief & tempering processes.
SURFACE PROTECTION : Recntly, we have expanded our facilities extensively to improve efficiency and SAND-BLASTING productivity. IPIC is now ready for applying sand-blasting, wrapping and painting. IPIC offers a complete and diverse list of corrosion protection services and it has a state of the art mobile facility for internal abrasive pipe blasting and internal pipe painting. The same is used for pipe surface and steel structure. These services can conform to various standards including, but not limited to: NACE, SSPC, ISO, ASTM. The in-house sand blasting and painting with a several type of protection material using our own resources not only securing our commitment but also give us a completion advantage to cover our clients’ needs. As a reliable long-term partner, IPIC offers the most modern and effective testing solutions which are continuously being developed and maintained to help you to keep pace with the increasingly complex requirements of your systems.
Whether it is industrial corrosion protection, coating techniques or painting process – IPIC has professional experts and suitable facility to apply the most diverse processes in the area of surface technology. We ensure your pipes have long-lasting protection – reliably, safely and cost effectively. QUALITY FOR SURFACE PROTECTION One of the most critical areas in the Surface protection and involves testing the quality of the surface applications. A range of tests is needed to verify the coating formulation’s strength and wear resistance, and also allow engineers to develop viable solutions to produce tougher and more effective coatings in the pipe line industry, steel structure industry and more. Three steps for durable coating: 1- Analysis of media and environment where the steel structure or pipe or other is placed. 2- Specification of appropriate coating system, 3- Execution of coating application by trained and including quality of surface preparation and Skilled staff under supervision of experienced selection of suitable coating process to suit Coating inspectors for stringent QA/QC. specific project demands.
RESEARCHES AND DEVELOPMENT Industry is the Art of Invention and Development, the Life Time For Any Factories Can Improve and Develop Their Industries to Match Future Needs. R&D Activities in IPIC are Not Limited Only for Improving The Industry and Final Products But Also Creating New Ideas for the Whole Business. HUMAN RESOURCES DEVELOPMENT One of the Most Important Investment in Our Business is Human Resources. People are Making The Difference in any Field, So We Pay Special Attention in Training for Our Employess to the Highest Level of Knowledge.
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