LINE PIPE PRODUCT CATALOGUE

Contents

Borusan Group At a Glance 1

Borusan Mannesmann 3
Production Flow 5
Production Range 7
Production Standards 9
Advantages of Spirally Welded Pipes 10
The Submerged Arc Welding Process 11
Yield and Tensile Requirements for API - Grades for Sweet & Sour Services 13
Protective OD & ID Coating Systems 15
Pipe Joint Systems 22
QEHS Management 23
Integrated Logistics Experiences 28
Operational Highlights 29
References 35
 Borusan Group At a Glance

Borusan

Steel Distributorship

The Pipe The Flat Steel The Earth Moving The Automotive
Group Group Equipments and Group
Power Systems Group

Borusan Mannesmann Borçelik Borusan Makina ve Borusan Otomotiv&

Güç Sistemleri Borusan Oto
Borusan Paslanmaz Kerim Çelik
Çelik Boru ve Profil
(Stainless Steel Pipe
and Profile Production)
Supsan
Borusan Mühendislik
(Engineering) Manheim Turkey

Borusan ‹stikbal Ticaret

Borusan Group has been among the pioneers of industrialization and corporate governance in Turkey
throughout its 65 years of history. The group currently operates in four major business areas including
steel, distributorship, logistics and energy.

In 2006 Borusan Group signed the United Nations’ Global Compact Policy and it supports and adheres
by the principles of “good corporate governance” and “sustainability” as a prerequisite of long-term and
permanent components of success.

In 4 major business
with

1
 Logistics Energy

Borusan Lojistik Borusan Enerji

Contribution to Community:
Borusan has adopted as one of its primary principles the concept of giving back to the community with
which it does business. In order to better fulfill its social responsibility vision, the activities of the As›m
Kocab›y›k Culture and Education Foundation, which was founded in 1992, and Borusan Culture and Arts,
established in 1997, came together under one roof in 2008 to become the Borusan Kocab›y›k Foundation.
With a deep social responsibility consciousness, the Borusan Group established the Borusan Center for
Culture & Arts on October 15, 1997. The Borusan Center for Culture and Arts is a member of the
International Society of Contemporary Music (ISCM) and the European Music Council (EMC) and organizes
the annual Mediterranean Contemporary Music Days. It pursues its music activities through its prominent
Borusan Istanbul Philharmonic Orchestra, the Borusan Chamber Orchestra, the Borusan String Quartet
and the Borusan Children’s Choir, as well as its Music Library.

areas
5.000 employees...

2
 Borusan Mannesmann

Celebrated 50th anniversary in 2008...

Borusan Mannesmann; the flagship of Borusan Group, operates
with five mills, four in Turkey and one in Italy with a total annual
production capacity of 925.000 tons. We produce our spiral welded
(SAWH) and longitudinal welded (ERW) products using the latest
production techniques.
U.S

As the leader of Turkish steel pipe market, Borusan Mannesmann

owes this outstanding position to its 50 years of corporate structure CANADA
experience, continuous development and customer oriented
approach. Especially in line pipe business, Borusan Mannesmann
has an established reputation in providing an extraordinary level
of quality, reliability and commitment in its products and services.
We have a track record which has a wide range in oil and gas
pipeline applications both in Turkey and International markets with UNITED STATES
high grade API standards. Our SAWH line pipes (dia.14"-100") are
not only used for gas, oil and water transmission but also for piling
applications.

Giving priority to product quality and qualified work force in our

growth strategies, we aim to meet customized expectations of our
customers throughout the world. Our Pipeline Projects Management
Team, specialized in providing total solutions to its customers in
pipe supply contracts that includes manufacturing processes,
contract management, production and integrated logistics services
worldwide.

Corporate Structure:
Borusan Group and one of Europe's leading steel and technology
companies; Salzgitter Mannesmann GMBH, merged their welded
steel pipe investments in Turkey and named that partnership;
“Borusan Mannesmann Boru Yat›r›m Holding” in 1998. The company
has 77% shares of Borusan Mannesmann Boru San. ve Tic. A.fi.

77% 23%

Borusan Mannesmann Boru

Yat›r›m Holding
73%

16% Free Float

11% Others

3
 “Our mission is to provide products and services that
enhance the quality of life with our expertise in steel
pipe industry and to promote the process of economic
and social progress of our community...”

Halkalı Plant
Gebze Plant
Vobarno Plant İzmit Plant
Gemlik Plant

QUEEN ELIZABETH
ISLANDS

ICELAND
SWEDEN
FINLAND
NORWAY

EST.
LAT.
DENMARK
UNITED LITH.
KINGDOM
IRELAND BELARUS
NETH. POLAND
GERMANY
BELGIUM CZECH
REP. UKRAINE
SLOVAKIA
AUSTRIA KAZAKHSTAN
FRANCE SWITZ. HUNGARY
SLOVENIA
CROATIA ROMANIA
BOS.& SERBIA
HERZ
BULGARI UZBEKISTAN
ITALY GEORGIA
ALB.
PORTUGAL SPAIN AZERBAIJAN
GREECE TURKEY
SICILY
CYPRUS
SYRIA

50% of production
TUNISIA
LEB.
IRAQ IRAN
ISRAEL
JORDAN

going overseas... ALGERIA

LIBYA
EGYPT
SAUDI
QATAR
PAKISTAN

U.A.E
ARABIA
OMAN
CUBA

YEMEN
SENEGAL
GAMBIA

FRENCH
GUIANA
CAMEROON

GABON
CONGO

TANZANIA

ANGOLA

REUNION

SOUTH
AFRICA

Workforce of 1.250
committed people...

Location of Borusan Mannesmann Mills

4
 Production Flow

SAWH Pipe Production - Helical Submerged Arc Welded Pipe

Offline Ultrasonic
Inspection Final Inspection
Stockpiling
and Marking

X-Ray Inspection

Hidrostatic Test
Beveling of
Pipe Ends
Inside Welding

Spiral Forming
Edge Preparing
Outside Welding
Uncoiling
Coil Identity
Ultrasonic Test and Analysis

Cutting to Length

5
 ERW Pipe Production - Electric Resistance Welded Pipe
Stockpiling Final Inspection
and Marking

Ultrasonic Test

Hidrostatic Test

Coil Identity Beveling of

and Analysis Pipe Ends
Uncoiling
Edge Preparing
Preforming
Forming
Welding
Beat Cutting
(inner/outer)
Ultrasonic Test

Sizing and Straightening

Post-Annealer
Quenching
Cutting to Length
6
7
Wall Thickness (mm & inch)
OD
mm 4 4.5 5 5.5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
mm inch 0.157 0.177 0.197 0.217 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.663 0.709 0.748 0.787 0.827 0.866 0.906 0.945 1.000
355.6 14 34.7 39.0 43.2 47.5 51.7 60.2 68.6 76.92 85.2 93.5
406.4 16 39.7 44.6 49.5 54.4 59.2 68.9 78.6 88.2 97.8 107.3 116.7 126.1 135.5
457.2 18 44.7 50.2 55.8 61.3 66.8 77.7 88.6 99.5 110.3 121.0 131.7 142.4 153.0
508 20 49.7 55.9 62.0 68.3 74.3 86.5 98.6 110.7 122.8 134.8 146.8 158.7 170.5 182.4 194.1
559 22 54.7 61.5 68.3 75.1 81.8 95.3 108.7 122.1 135.4 148.7 161.9 175.0 188.2 201.2 214.2
610 24 59.8 67.2 74.6 82.0 89.4 104.1 118.8 133.4 148.0 162.5 177.0 191.4 205.8 220.1 234.4 248.6 262.8
660 26 64.7 72.7 80.8 88.8 96.8 112.7 128.6 144.5 160.3 176.0 191.8 207.4 223.0 238.6 254.1 269.6 285.0
711.2 28 69.8 78.4 87.1 95.7 104.3 121.6 138.7 155.8 172.9 189.9 206.9 223.8 240.7 257.5 274.3 291.0 307.7 324.3 340.9
762 30 93.3 102.6 111.9 130.3 148.7 167.1 185.4 203.7 221.9 240.1 258.2 276.3 294.3 312.3 330.2 348.1 366.0
812.8 32 99.6 109.5 119.4 139.1 158.8 178.4 198.0 217.5 237.0 256.4 275.8 295.1 314.4 333.6 352.8 371.9 391.0 410.0
863.6 34 105.9 116.4 126.9 147.9 168.8 189.7 210.5 231.3 252.0 272.7 293.3 313.9 334.4 354.9 375.3 395.7 416.1 436.3
914 36 112.1 123.2 134.3 156.6 178.7 200.9 222.9 244.9 266.9 288.8 310.7 332.5 354.3 376.0 397.7 419.3 440.9 462.4 483.9
965.2 38 130.2 141.9 165.4 188.8 212.2 235.6 258.8 282.1 305.3 328.4 351.5 374.5 397.5 420.4 443.3 466.2 489.0 511.7 534.4
1016 40 137.1 149.4 174.2 198.9 223.5 248.1 272.6 297.1 321.5 345.9 370.3 394.6 418.8 443.0 467.1 491.2 515.3 539.3 563.2 587.11
1067 42 157.0 183.0 208.9 234.8 260.7 286.5 312.2 337.9 363.5 389.1 414.7 440.2 465.6 491.0 516.4 541.7 566.9 592.1 617.29
1118 44 164.5 191.8 219.0 246.1 273.2 300.3 327.3 354.2 381.1 408.0 434.8 461.6 488.3 514.9 541.5 568.1 594.6 621.1 647.47
1168 46 171.9 200.4 228.8 257.2 285.6 313.8 342.1 370.3 398.4 426.5 454.5 482.5 510.5 538.4 566.2 594.0 621.7 649.4 677.06
Production Range - SAWH Line Pipes

1219 48 209.2 238.9 268.5 298.1 327.7 357.2 386.6 416.0 445.4 474.7 503.9 533.1 562.2 591.3 620.4 649.4 678.3 707.25
1321 52 226.8 259.0 291.2 323.3 355.4 387.4 419.3 451.2 483.1 514.9 546.7 578.4 610.0 641.7 673.2 704.7 736.2 767.62
1372 54 235.6 269.1 302.5 335.9 369.2 402.5 435.7 468.8 502.0 535.0 568.0 601.0 633.9 666.8 699.6 732.4 765.1 797.8
1422 56 279.0 313.6 348.2 382.7 417.2 451.7 486.1 520.4 554.8 589.0 623.2 657.4 691.5 725.5 759.5 793.5 827.4 861.3
1524 60 299.1 336.2 373.4 410.4 447.4 484.4 521.3 558.2 595.0 631.8 668.5 705.2 741.8 778.3 814.9 851.3 887.8 924.1
1626 64 319.2 358.9 398.5 438.1 477.6 517.1 556.5 595.9 635.2 674.5 713.8 752.9 792.1 831.2 870.2 909.2 948.1 987.0
1676 66 X 42 370.0 410.8 451.6 492.4 533.1 573.8 614.4 655.0 695.5 736.0 776.4 816.7 857.1 897.3 937.5 977.7 1017.8
1727 68 X 52 423.4 465.5 507.5 549.5 591.4 633.3 675.1 716.9 758.6 800.3 841.9 883.5 925.0 966.5 1007.9 1049.3
1829 72 X 60 493.2 537.7 582.2 626.6 671.0 715.3 759.6 803.9 848.1 892.2 936.3 980.3 1024.3 1068.3 1112.2
2032 80 X 65 548.2 597.8 647.3 696.7 746.1 795.4 844.7 894.0 943.2 992.3 1041.4 1090.5 1139.5 1188.4 1237.3
2083 82 X 70 562.1 612.9 663.6 714.3 765.0 815.6 866.1 916.6 967.1 1017.5 1067.8 1118.1 1168.4 1218.6 1268.8
2235 88 X 80 657.8 712.3 766.8 821.2 875.5 929.8 984.1 1038.3 1092.4 1146.5 1200.6 1254.6 1308.6 1362.5
2540 100 810.1 872.1 934.0 995.9 1057.7 1119.5 1181.2 1242.9 1304.5 1366.1 1427.6 1489.1 1550.5
 Wall Thickness (mm & inch)
OD
mm 2.8 2.9 3.4 3.56 3.68 3.7 3.9 4.5 5.1 5.2 6 6.6 7 7.1 8.1 8.4 8.6 9.3 9.5 11 12 12.5
mm inch 0.109 0.113 0.133 0.140 0.145 0.147 0.154 0.179 0.200 0.203 0.237 0.258 0.277 0.280 0.318 0.331 0.337 0.365 0.375 0.432 0.472 0.492
21.3 1/2 1.28 1.32 1.50 1.56 1.60 1.61 1.67
26.9 3/4 1.66 1.72 1.97 2.05 2.11 2.12 2.21 2.49
33.7 1 2.13 2.20 2.54 2.65 2.72 2.74 2.87 3.24 3.60 X 52
42.4 1 1/4 2.73 2.82 3.27 3.41 3.51 3.53 3.70 4.21 4.69 4.77 X 60
48.3 1 1/2 3.14 3.25 3.76 3.93 4.05 4.07 4.27 4.86 5.43 5.53 X 65
60.3 2 3/8 3.97 4.10 4.77 4.98 5.14 5.16 5.42 6.19 6.94 7.07 X 70
73 2 7/8 4.85 5.01 5.84 6.10 6.29 6.32 6.65 7.60 8.54 8.69 9.91
88.9 3 1/2 6.15 7.17 7.49 7.73 7.77 8.17 9.37 10.54 10.73 12.27
Production Range - ERW Line Pipes

114.3 4 1/2 7.97 9.30 9.72 10.04 10.09 10.62 12.18 13.73 13.99 16.02 17.53 18.52 18.77 21.21 21.94 22.42 24.08
141.3 5 9/16 11.56 12.09 12.49 12.55 13.21 15.18 17.13 17.45 20.02 21.92 23.18 23.50 26.61 27.53 28.14 30.27 30.88 35.35
168.3 6 5/8 14.94 15.02 15.81 18.18 20.53 20.91 24.01 26.32 27.84 28.22 32.00 33.12 33.87 36.46 37.20 42.67 46.25 48.03
219.1 8 5/8 19.55 19.65 20.70 23.81 26.91 27.43 31.53 34.59 36.61 37.12 42.15 43.65 44.64 48.12 49.10 56.45 61.29 63.68
273 10 3/4 25.88 29.80 33.69 34.34 39.51 43.36 45.92 46.56 52.91 54.81 56.07 60.48 61.73 71.07 77.24 80.30
323.9 12 3/4 35.44 40.09 40.87 47.04 51.64 54.70 55.47 63.08 65.35 66.87 72.15 73.65 84.88 92.30 95.99
We can meet all X 42 requirements in our production range.

8
 Production Standards

Petroleum and Gas Line Pipes

API 5L/ISO 3183 : Requirements of PSL 1 & PSL 2
Annex G : Resistance to ductile fracture propagation
Annex H : For Sour Service
EN 10208 : Requirements of Part 1 & Part 2
GOST 20295 : Requirements of Type 1, 2 and 3.

Water Line Pipes

With protective OD and/or ID coating, plain (beveled) or sleeve welded joints.
EN 10217-1 : SAWH & ERW
EN 10224 : SAWH & ERW
AWWA C 200 : SAWH & ERW
BS 534 : SAWH & ERW

General Purpose Pipes

EN 10217-3 : SAWH - Alloy, fine grain
Service condition: max 400°C, min -50°C
EN 10217-5 : SAWH - Alloy or non-alloy,
Service condition: max 400°C,
EN 10217-6 : SAWH - Non-alloy,
Service condition: - 40°C
ASTM A139 : SAWH

Piling & Construction Pipes

ASTM A 252 : SAWH
EN 10219 : SAWH & ERW
EN 10210 : SAWH & ERW

Pipe Lengths: any desired lengths between 6 - 18 m

These are our general production standards and specifications.

We can meet other production standards and specifications upon request.

9
Advantages of Spirally Welded Pipes

Spirally welded pipes have been used all over the world for high-pressure gas and oil pipeline
projects (including USA, Canada, Europe etc.) which have proven their high quality as high strength
steel line pipes.

- Hot rolled coil is used as base material for the production of spirally welded pipes instead of
plates. As a result the continuous process coming from HRC usage provides flexibility (diameter
and length) of production.

- The mechanical properties are already present in the base material. Since any cold expansion
reduces the material's ductility, the spirally welded pipe has a higher safety margin than cold
expanded pipes.

- Spirally welded pipes have more integrity structure wise. Test results on fracture propagation
prove this fact.

- When carrying out field cold-bending, it is not necessary to take the weld seam position into account.

- There is a favorable orientation of the weld seam and of the strip's direction of rolling relative
to the direction of principal stress.
10
 The Submerged Arc Welding Process

The principle of the spiral pipe production is simply bending the steel strip spirally into cylindrical
pipe shape and ultimately welding edges together. The occurrence of weld seam step by step
can be seen in the figure displayed on page 12.

The submerged arc welding (SAWH) process is widely used for welding thick sections, yet it can
be applied to plate sections as thin as approximately 4 mm.

In spirally welded pipe production process, very impressive capabilities can be achieved for high
rates of travel by using multiple electrodes in two-run technique. The high currents, obtained by
multiple electrodes, generate considerable heat which leads to deep penetration of the base metal.
In Borusan Mannesmann, remarkable control is always exercised over the contour of the deposit
and extent of the penetration into the base metal. Both of these factors have important effect
on the chemical composition and metallurgical properties of the weld metal.

11
 AC I
DC

AC I
AC II
DC

12
 Yield and Tensile Requirements for API-Grades for Sweet & Sour Services

API 5L/ISO 3183

Yield Strength (Mpa) Tensile Strength (Mpa)
Correspodence to
PSL 1 PSL 2 PSL 1 PSL 2
PSL 1 PSL 2 Min Max Min Max Min Max Min Max EN 10208-1 EN 10208-2
A25 - 175 - - - 310 - - - - - -
A - 210 - - - 335 - - - L210GA - -
B BN/S 245 - 245 450 415 - 415 760 L245GA L245NB L245MB
X42 X42N/M/S 290 - 290 495 415 - 415 760 L290GA L290NB L290MB
X46 X46N/M/S 320 - 320 525 435 - 435 760 - - -
X52 X52N/M/S 360 - 360 530 460 - 460 760 L360GA L360NB L360MB
X56 X56N/M/S 390 - 390 545 490 - 490 760 - - -
X60 X60N/M/S 415 - 415 565 520 - 520 760 - L415NB L415MB
X65 X65M/S 450 - 450 600 435 - 435 760 - L450NB L450MB
X70 X70M/S 485 - 485 635 570 - 570 760 - L485NB L485MB
X80M/S - - 555 705 - 625 825 - L555NB L555MB

EN 10208-1
Yield Strength Tensile Strength Rt /Rm Elongation
0.5

Grade Mpa (%) Correspondance

to API
Min Max Min Max Max Min
L210GA 210 - 335 475 - 25 A
L235GA 235 - 370 510 - 23 -
L245GA 245 - 414 555 - 22 B
L290GA 290 - 415 555 - 21 X42
L360GA 360 - 460 620 - 20 X52

EN 10208-2
Yield Strength Tensile Strength Rt /Rm
0.5 Elongation
Heat
Treatment Steel Correspondance
Class Grade Mpa (%)
conditions to API
Min Max Min Max Max Min
L245NB 245 440 415 - 0.80 22 B
Normalized
or Non-Alloy L290NB 290 440 415 - 0.85 21 X42
normalizing L360NB 360 510 460 - 0.85 20 X52
rolled
Special-Alloy L415NB 415 565 520 - 0.85 18 X60
L245MB 245 440 415 - 0.85 22 B
Non-Alloy L290MB 290 440 415 - 0.85 21 X42
Thermo - L360 MB 360 510 460 - 0.85 20 X52
mechanically
rolled L415MB 415 565 520 - 0.85 18 X60
Alloy L450MB 450 570 535 - 0.87 18 X65
Special
Steel L485MB 485 605 570 - 0.90 18 X70
L555MB 555 675 625 - 0.90 18 X75

13
Baku - Tbilisi - Ceyhan Oil Pipeline
42" - 194 Km
Excellence in Sour Service

14
 Protective OD & ID Coating Systems

Borusan Mannesmann offers wide range of anti-corrosive and protective OD & ID coatings in its
fully integrated coating facilities. The below table illustrates the type of coatings applied externally and
internally according to standards and special customer requirements.

OD (Outer Diameter): External Coating

ID (Inner Diameter): Internal Coating

General Application Area

Type of Coating OD ID
Gas & Oil Line Pipe Water Line Pipe

FBE
Epoxy (liquid)
Polyethylene (PE)
Polypropylene (PP)
Cement Mortar

Other OD&ID coating processes can also be designed for each specific application i.e. PU, Coal tar,
Bitumen, Glass reinforced epoxy etc. which all above processes are within Borusan Mannesmann’s
broad experience.

Maximum Operating Temperature of Coating

PP SPECIAL

PP NORMAL

FBE DRY CONDITION

FBE WET CONDITION

HDPE

MDPE

LDPE

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140

Temperature (0C)

15
General Application Standards

FBE (Fusion Bonded Epoxy) OD Coating: Fusion bonded powder epoxy coating provides high
protection of gas and oil pipe lines.
(API 5L7, CSA Z 245-20, NACE RP 0394, AWWA C213)

Polyethylene OD Coating: Excellent protection of buried line pipes. High mechanical strength and
corrosion resistance are achieved by 3-layer coating method.
(DIN 30670, TS 5139, NF A 49-710, UNI 9099)

Polypropylene OD Coating: Excellent protection of buried line pipes. High mechanical strength
and corrosion resistance are achieved by 3-layer coating method.
(DIN 30678, NF A 49-711)

Flow Efficiency ID Coating: For gas transmission lines, flow-coat ID epoxy coating is applied in
order to reduce pipe wall roughness thus increasing throughput.
(API RP 5L2)

Epoxy OD & ID Coating: Various epoxy coatings applied externally or internally are enabling
hygienic inner surface for potable water transportation and outer surface to resist soil or sea water
corrosion. Coating thickness is up to 1000 μm.
(AWWA C 210, TS EN 10289)

Cement Mortar ID Coating: Specifically for potable water pipe lines cement mortar ID coating
provides hygienic and excellent corrosion resistance and protection. On demand regular cement
mortar ID coating or synthetic dispersion added special cement mortar ID coating can be applied.
(AWWA C 205, DIN 2614, BS 534, TS 8590)

16
 Protective OD & ID Coating Systems

FBE (Fusion Bonded Epoxy) OD Coating for Gas and Oil Pipelines
FBE OD coating consists of the following steps;
• Surface preparation and cleaning
- Solvent/detergent washing (if necessary)
- Blasting (anchor pattern profile)
- Phosphoric acid washing and rinsing
• Induction heating
• Electrostatical application of powder epoxy
• Quenching
• Test and inspection

Applied Standards: API 5L7, CSA Z 245-20, NACE RP 0394, AWWA C213

Acid
Blast Cleaning Washing
and Induction FBE
Drying Induction Rinsing Heating Application
Heating
Holiday
Quenching
Test

17
Protective OD & ID Coating Systems

Polyethylene / Polypropylene OD Coating

For 3-layer PE/PP OD coating, at first pipe surface is cleaned by shot blasting in accordance with
customer specs and then preheated to the desired temperature by using induction heating system.
Following preheating, epoxy primer is applied to the pipe surface. Just after epoxy primer application,
the extruded adhesive and PE/PP are coated to the pipe using wrapping method. Finally the pipe
is cooled with water.

3 - layer PE/PP OD coating consists of;

1. layer: Electrostatical application of epoxy primer
2. layer: Extruded adhesive wrapping
3. layer: Extruded wrapping (PE, PP, LDPE, MDPE, HDPE).

Applied Standards: DIN 30670, TS 5139, NF A 49-710, UNI 9099

Blast Cleaning Pipe end

Drying Preparation
Induction Epoxy Primer
Heating
Holiday
Quenching
Test

Wrapping of
Adhesive Wrapping of
PE/PP

18
 Protective OD & ID Coating Systems

Flow Efficiency ID Coating for Gas & Oil Line Pipes

(Flow - Coat Epoxy)
Pipes for gas and oil transmission pipe lines are internally coated with epoxy resin:

• To reduce pipe ID roughness thus increasing throughput.

• To reduce corrosion product deposits by considerable amounts.

Applied Standards: API RP 5L2

Solvent Free Epoxy Coating (ID)

Various epoxy coatings applied internally are enabling hygienic inner surface for potable water
transportation and outer surface to resist soil or sea water corrosion. Coating thickness is up to
1000 μm.

Applied Standards: AWWA C 210, TS EN 10289

Cement Mortar ID Coating for Water Line Pipes

Cement mortar coating features permanent corrosion protection for handling potable water.

Applied Standards: AWWA C 205, DIN 2614, BS 534, TS 8590

19
 OD Coating Main Application Parameters

OD
Processes Coating Tested / Inspected parameter Desired minimum Quality criteria
type
Pre-preparation

PE Contaminants Free from Oil and gress

Metal surface temperature min
PP Pipe surface temperature 30C above atmospheric dew point

FBE Ambient condition Relative humidity less than 85%

Surface profile 50-100 μm

Surface cleaning degree Min. Sa 2 1/2 degree

PE
Surface preparation

acc. to standards SIS 55900

or ISO 8501-1
PP
Salt contamination Max. 3 μgr/cm2
FBE
Dust contamination ISO 8502-3 max rating 2-2

Surface condition Free from material surface defects

Phosphoric acid washing Concentration: 5 - 20 %

PH: 1-2
Heating for
coating

PE Temperature Recommendation of epoxy

PP manufacturer
FBE

Epoxy thickness 80-150 μm

Adhesive thickness 150-250 μm

PE
PP
Total thickness of Coating Acc. to customer requirements
Peeling test: min.150 N/cm
Application of coating

Coating Performance Cathodic disbonding: max 3,0 mm

(400C, 7 days, -1,5V)

Coating thickness Acc. to customer requirements

(min 300 μm)

Coating Performance CD: avg 2,0 mm

FBE (660C, 48 hr, -3 V)
Cross section porosity: ≤ Rating 5
(Rating 1-10)
Flexibility: - 300C, 2.50 OD
Hot water soak : Rating 1
(Rating 1-3)

20
21
 Pipe Joint Systems

®
Cylindrical end ZAP-LOK
26 29
30 25 24 21
a a 20
f
PE

27 28
S 22

b t
Rubber Ring Cement

Y
D D1
31 32

* For water pipelines * For high pressure gas & oil pipelines up to 12”

Butt Weld
Spherical end Joint Preparation
fav 30˚ (+5˚/-0˚)
S
S a

do d1 do

a 1,6 mm ± 0,8mm
d2
NW

NW

* For water pipelines * For all types of applications

Other types of joints may be available upon request.

*Double Joint Operation 22

 QEHS Management

Borusan Group companies all share a common set of guiding principles, which help this vast
enterprise to operate in complete harmony. These principles are commitments to productivity,
innovation and environmental responsibility.

From raw material to finished product, Borusan Mannesmann determines the impacts on environment
and in order to reduce impacts, controls each step of the process. Our Environmental Management
System certificate (ISO 14001) proves our commitment to environment.

Healthy performance is delivered through healthy people. In compliance with Occupational Health
and Safety Management Standard (OHSAS 18001) Borusan Mannesmann endeavors to protect
health and safety of its work force and service providers.

Borusan Mannesmann; exemplary with its modern management approach as well as its investments,
has been applying The Lean Six Sigma methodology since 2002 and Voice of Customer (VOC)
process since 2003.

The Lean Six Sigma methodology is a highly disciplined business management strategy that seeks
to remove the causes of defects in production and business processes, and to continuously
improve productivity, profitability and customer satisfaction. Besides with the VOC process, we
capture the requirements and feedback from our customers to provide the best product and
service quality.

Ongoing efforts to improve customer satisfaction brought Borusan Mannesmann, Complaints

Handling Management Systems Certificate (ISO 10002); which is a first in steel pipe sector globally.

23
Quality

Almost every major Energy, Oil and Gas company along with some of the biggest EPC’s in USA,
Canada and Europe have approved our quality and listed us among their valuable supplier lists.

Ongoing research and development activities are aimed at further improving product and service
quality and increasing the product range through use of technology along with original and more
cost effective marketing techniques. A dynamic, highly qualified staff, regularly trained to keep
abreast of new production methods, ensures that production conform to exacting quality standards.
(API Q1, ISO 9001, ISO 29001)

24
 Quality

The feasibility and operational safety of a pipeline project are predominantly governed by the quality of the
line pipe. The table given below contains the most important quality characteristics and examination
determination methods. These are the methods we are using to meet our clients most stringent requirements.

Quality Characteristics Examination / Determination by

Pipe body Diameter Tape measurement circumference,

Wall thickness Caliper, Ultrasonic measurement,
Length Tape measurement
Pipe Geometry

Out of roundness Caliper, Gauge

Straightness Cord and range measurement

Weld Height
Width
Off-set
Angle Macrographic examination
Penetration
Misalignment

Pipe body Grain size Macrographic examination

Strructure
Metallur-

Inclusions
gical

Weld Structure Macrographic examination

HAZ

Pipe body Yield strenght

Properties
Strength

Tensile strenght Tensile test

Elongation Ring Expansion Test

Weld Tensile strength Tensile test

Pipe body Notch impact energy Charpy impact test

Fracture Properties DWT-test
Toughness
Properties

Hardness HV-Hardness measurement

Weld Notch impact energy Charpy impact test

Hardness HV-Hardness test
Fracture Properties CTOD, SENB
Composition

Pipe body Individual elements Spectrometric chemical analysis

Chemical

Carbon equivalent Formula

Inside & Max. Permissible Visual examination,

Surface

Outside surface defects Ultrasonic testing,

pipe body Dye-penetrant testing
Magnetic particle testing
Free from defects

Pipe body Max. Permissible Ultrasonic testing

lamination/separation
Homogeneity

HAZ Max. Permissible Ultrasonic testing

Inclusion

Weld Weld defects Ultrasonic testing

X-ray testing (radiascopic method)
Hydrostatic pressure testing

25
 Quality

Quality Characteristics Examination / Determination by

Dust Acceptable Dust degree With adhesive Tape

contamination
Surface Quality

Salt Acceptable Salt degree Salt level measurement

contamination
Surface profile Profile depth & shape Comparison gauge, profilometer
Surface Near white surface Comparison
cleanliness
Surface defects Free of material defects Visual inspection
Environment

Condition of Dew point temperature Dew meter

condition

coating plant Relative humidity Thermometer

FBE Thermal characteristics By DSC tester

of epoxy
Coating material
performance

PE, PP Physical properties Density, Carbon black,

Melt flow index, electrical resistivity
Elasticity % elongation
Aging Resistance to Heat & UV-ray ageing
Cement mortar Grain size Sieve analysis
Organic contaminants Chemical analysis
Homogeneity Surface

OD & ID Coating Surface defects Visual inspection

Free from defects

OD & ID Coating Discontinuity Holiday test

Thickness Thickness meter

OD & ID Coating FBE OD Coating Low temp., flexibility test, hardness

properties
Strength

PE, PP Coating Indentation, impact resistance, bending

Cement mortar Compressing strength, bending strength

PE & PP Coating Peeling resistance Peeling strength by load cell

properties
Adhesion

or dynamometer,
Cement mortar Peeling speed by dead weight test
ID Coating Tensile test.
FBE OD Coating V-notch, Cross cut
Corrosion Curing

FBE OD Coating Application parameters DSC test

Liquid Epoxy Solvent test

PE, PP, FBE, Resistance to Cathodic disbonding

OD Coating disbonding from
pipe surface

26
 Just in time
on-site delivery

27
Integrated Logistics Experiences

The care devoted to proper storage and shipment of products is part of Borusan Mannesmann’s
commitment to customer satisfaction.

Borusan Mannesmann plants are located on the eastern coast of Marmara Sea in the vicinity of
many piers that are expert in pipe loading equipped with mobile cranes, forklifts and other machinery
necessary for international shipment.

Borusan Mannesmann, together with Group’s integrated logistic company Borusan Logistics, is
able to deliver with high versatility for every international project from Saharan desert to Rocky
mountains.

We deliver
• By railway
• By barge transportation
• By IACS class vessels (sous-palan unloading)
• By truck and trailers
• Even by containers

In many of our projects we have been in charge of custom clearance, sous-palan operations,
leasing and management of stockyards, on-site delivery; providing complete integrated logistics
solutions to meet even the most stringent client delivery terms.

28
 Project:
Elba Express Expansion Gas Pipeline
/ USA - 2008

29
Operational Highlights

Project Details:
Size: 36"-42"
Total Length: 313 km
Standard: API 5L PSL2 X70
OD Coating: FBE

Client: Southern Natural Gas Pipeline Group

Scope of Logistics: DDP basis delivery to 5 pipe yards. The logistics scope includes unloading,
double jointing, girth weld coating, sand berms preparations and stacking.

- 22 shipments via A class vessels.

- On site double-joint operation
- Management of 6 different stockyards.

Logistic Partners: Borusan Logistics (Transportation from Izmit/Turkey to USA)

Borusan Logistics International (USA operations)

On this prestigious project Borusan Mannesmann produced FBE coated 48" pipes according to
the client’s requirements. The pipes were double jointed to 80 ft (24 m) pipe length. 80 ft pipes
were transported with special trucks to 4 other designated pipe yards.

30
 Project:
MOL Natural Gas Transmission Project
/ HUNGARY-2007

31
Operational Highlights

Project Details:
Size: 40"
Total Length: 205 km
Standard: EN 10208-2 L485 MB
OD Coating: 3 Layer PE acc. to DIN 30670
ID Coating: Flow Coat Epoxy acc. to API RP5 L2

Client: Salzgitter Mannesmann (GE)

End User: MOL-Hungary

Scope of Logistics: DDP transportation to 14 different pipe yards along the pipeline route in
Hungary. The logistics scope includes unloading, stockpiling and safe guarding
during entire delivery operation

Logistic Partners: Borusan Logistics (Transportation from Izmit plant to Hungary)

Borusan Logistics International (Hungary operations)

The following transportation methods have been used simultaneously because of the tight delivery
schedule
1- Transportation by vessel & barges (45 % of the total quantity)
2- Transportation by train (55 % of the total quantity)

Complete handover of the project to the Client was realized in 10 months time.

32
 Project:
Baku - Tbilisi - Ceyhan
Crude Oil Pipeline / TURKEY- 2005

33
Operational Highlights

Project Details:
Size: 42"
Total Length: 194 km
Standard: API 5L - PSL 2 X65 (HIC)
Outside Coating: 3 Layer PE acc. To DIN 30670

Client: BTC Directorate

End User: BTC CO.

Scope of Logistics: Delivery to the pipe yards located at 4 different locations (Kars, Erzincan,
Ceyhan and Terminal), including unloading and stockpiling of the pipes.

The following transportation methods have been used simultaneously because of the tight delivery
schedule:

- Transportation by trucks (15 % of the total quantity)

- Transportation by train & trucks (85 % of the total quantity)

The project has been completed within a period of 12 months.

This project was one of the most important pipeline projects of its time. Global energy conglomerates,
along with the world’s top engineering groups took part in this major infrastructure investment,
where highest technical, operational and HSE standards were applied.

34
 Major SAWH Reference List for the Last Five Years

COUNTRY CLIENT USAGE PROJECT QUANTITY YEAR

DESCRIPTION

ALGERIA SONATRACH GAS 48" GR4 PIPELINE PROJECT 305 KM 2009

X70 OD PE, ID EPOXY COATED

HUNGARY SALZGITTER GAS 32" MOL CROATIAN TRANSIT PIPELINE 209 KM 2009
MANNESMANN L485MB OD PE, ID EPOXY COATED

TURKEY BOTAfi GAS 16" MUGLA NATURAL GAS 94 KM 2009

DISTRIBUTION PR.
L485MB OD PE, ID EPOXY COATED

ALGERIA CAMEG GAS 20" - 28" GAS PIPELINE PROJECTS 717 KM 2009
X60 - X70 OD PE, ID EPOXY COATED

USA TENNESSEE GAS GAS 30" 300 LINES PIPELINE PROJECT 212 KM 2008
PIPELINE X70 OD FBE, ID EPOXY COATED

HUNGARY SALZGITTER GAS 28" FGSZ PIPELINE PROJECT 49 KM 2008

MANNESMANN L450MB OD PE, ID EPOXY COATED

USA SOUTHERN GAS 36" - 42" ELBA EXPRESS PIPELINE 313 KM 2008
NATURAL GAS PROJECT
X70 OD FBE COATED

ALGERIA SNAMPROGETTI GAS 24" LZ2 HASSI R'MEL - ARZEW 476 KM 2007
PIPELINE
X60 OD PE COATED

HUNGARY SALZGITTER GAS 40" MOL NATURAL GAS 205 KM 2007

MANNESMANN TRANSMISSION PROJECT
L485 OD PE, ID EPOXY COATED

TURKEY ASK‹ WATER WATER 64" - 56" KIZILIRMAK - KES‹KKÖPRÜ 185 KM 2007
AUTHORITY PIPELINE
S355JR OD PE, ID EPOXY COATED

35
COUNTRY CLIENT USAGE PROJECT QUANTITY YEAR
DESCRIPTION

HUNGARY OTF CONTRACTING GAS 32" MOL PIPELINE PROJECT 55 KM 2007

COMPANY L485MB OD PE, ID EPOXY COATED

ALGERIA SONATRACH GAS 40" GZ1 HASSI R'MEL - MEDAREG 234 KM 2006
PIPELINE
X60 OD PE, ID EPOXY COATED

TURKEY AT‹LLA DO⁄AN GAS 36" LOOP PROJECT 30 KM 2006

CONTRACTING CO. X65 OD PE COATED

IRAN PAYANDAN GAS 48" NIGC GAS PIPELINE PROJECT 103 KM 2005
X65 NO OD & ID COATING

TURKEY BOTAfi GAS 42" SHAHDENIZ PHASE 2 PIPELINE 115 KM 2005

PROJECT
X65 OD PE COATED

TURKEY BOTAfi GAS 36" TURKEY GREECE PIPELINE 180 KM 2005

X65 OD PE COATED

ALGERIA SONATRACH CRUDE 30" NK1 PIPELINE PROJECT 665 KM 2005

OIL X60 OD PE COATED

IRAN NATIONAL IRANIAN GAS 48" PIPELINE PROJECT 226 KM 2005

GAS CO. (NIGC) X65 NO OD & ID COATING

TURKEY BOTAfi GAS 24" ÇANKIRI - TOSYA - KASTAMONU 145 KM 2005

PIPELINE
X52 OD PE COATED

TURKEY BOTAfi, BTC CRUDE 34" - 42" BAKU - TBILISI - CEYHAN 194 KM 2005
Directorate OIL PIPELINE
X65 OD PE COATED

36
 Major ERW Reference List for the Last Five Years

COUNTRY CLIENT USAGE PROJECT QUANTITY YEAR

DESCRIPTION

AUSTRIA EVN GAS 6" - 8" - 10" PIPELINE PROJECT 15 KM 2009

L290NB OD PE COATED

EGYPT FAYUM GAS CO. GAS 8" PIPELINE PROJECTS 30KM 2009
X52 OD PE, ID EPOXY COATED

AZERBAIJAN ETSUN CO. GAS 8" BP GAS TERMINALS CONNECTION 10 KM 2009

LINE
X42 OD PE COATED

TUNISIA STEG GAS 8" ENFIDHA -SIDI ABDELHAMID 20 KM 2009

PIPELINE
X42 OD PE COATED

TURKEY BOTAS GAS 10" BISMIL GAS DISTRIBUTION LINES 76 KM 2009

X46 OD PE COATED

CONGO SALZGITTER GAS 8" PERENCO RDC MISCELLANEOUS 63 KM 2009

MANNESMANN PIPELINES
GRB OD PE COATED

GABON SALZGITTER GAS 10" OZANGUE DIGA PIPELINE 35 KM 2009

MANNESMANN X42 OD PE COATED

EGYPT TOWNGAS GAS 1/2" - 3/4" GAS DISTRIBUTION PIPES 4,500 KM 2009
GRA OD VARNISH COATING

TURKEY BOTAS GAS 10" BISMIL GAS DISTRIBUTION LINES 38 KM 2009

X46 OD PE COATED

TURKEY AKSA GAS 4" - 6" - 8"- 10" - 12" GAS 293 KM 2009
DISTRIBUTION PIPES
GRB - X52 OD PE COATED

EGYPT NATGAS GAS 1/2" - 3/4" GAS DISTRIBUTION PIPES 3,066 KM 2009
GRA OD VARNISH COATING

37
COUNTRY CLIENT USAGE PROJECT QUANTITY YEAR
DESCRIPTION

TUNISIA STEG GAS 8" GAZODUC KAIROUAN-TAG DE 45 KM 2008

FERIANA
X60 OD PE COATED

TUNISIA STEG GAS 4" - 8" DJERBA ISLAND PROJECT 210 KM 2008
X42 OD PE COATED

TURKEY TURKISH OIL 6" - 10" OIL PIPELINE PROJECTS 81 KM 2008

PETROLEUM CO. GRB OD PE COATED

EGYPT TAQA GROUP GAS 6" - 8" - 10" - 12" PIPELINE PROJECTS 25KM 2008
X52 OD PE COATED

EGYPT EGYPTGAS GAS 1/2" - 3/4" GAS DISTRIBUTION PIPES 2,800 KM 2008
GRA OD VARNISH COATING

GABON PERENCO S.A. GAS 8" LIBREVILLE GAS PIPE PROJECT 115 KM 2007
X60 OD PE, ID EPOXY COATED

TUNISIA PERENCO S.A. GAS 10" OUM-CHIAH - GABES GAS PIPELINE 75 KM 2006
X60 OD PE, ID EPOXY COATED

BOTAS GAS 10" NAZILLI & ÇANKIRI DIST. LINES 114 KM 2006
TURKEY X46 OD PE COATED

BOTAS GAS 10" - 12" ORDU DIST. LINES 162 KM 2006

TURKEY X46 - X52 OD PE COATED

SYRIAN GAS GAS 12" ÇANKIRI DIST. LINES 40 KM 2005

SYRIA COMPANY X42 OD PE COATED

TURKEY BOTAS GAS 4" - 6" - 8" - 10" - 12" SOUTH LINE 127 KM 2005
PROJECT
GRB OD PE COATED

38
BORUSAN MANNESMANN
BORU SAN. ve T‹C. A.fi.
Head Office:
Meclisi Mebusan Caddesi 35,
Sal›pazar› 34427 ‹stanbul / TURKEY
Phone: +90 212 393 59 59
Fax: +90 262 323 18 03

‹zmit Factory:
June 2010

Yeni Do¤an Mahallesi P.K: 5 41001 ‹zmit / TURKEY

Phone: +90 212 393 59 59
Fax: +90 262 323 18 03
E-Mail: mannesmann@borusan.com

+90 212 393 58 58

Borusan Mannesmann Call Center E-Mail: mannesmann@borusan.com www.borusanmannesmann.com