You make delicious chocolates

we weld pipes at heights

You manufacture life-saving drugs

we wire complex control loops

You make incredible cars

we take on turnkey responsibility with erection and insulation

You design world-class breweries

we supply steam at the correct pressure every time

Industrial Process Piping & Insulation

Your brief: The Ideal Boiler House. We helped you build just that, with a central Boiler Monitoring System for all 5 boilers in the plant. And....while executing the project, we also saved an additional Rs. 100 Lakhs / year from Condensate Recovery!!

A high pressure boiler, HP steam piping, turbine outlet piping, a 100 -loop Boiler Control System, Pressure Reducing & De-superheating Stations, a bullet-proof Condensate Recovery System....

DYNAMIX DAIRY

FRESENIUS KABI
You called us for a simple job and we were suddenly opening up an entire machine, and rebuilding part of it, all because of a small heat balance equation...

Need we say more? ?

COCA-COLA

TATA-ACSI PRAJ
We worked tirelessly together, to augment your Steam System at your Pune plant. Obviously, you liked what we did, since you entrusted the turnkey Design, Erection and Comissioning of your new plant in Uttaranchal to us. Your brief: Utility piping for a world-class R&D facility. We helped your scientists get....... steam, cooling water, chilled water, compressed air, process water, etc. to their pilot plants and laboratories.

INTERVET
You wanted to quadruple production. Together, we re-designed your existing plant. Then, we installed and commissioned the entire steam system from the new Boiler, Chimney, FWT, DOT, Piping, PRSs, valves, flanges, down to the nuts & bolts....all in record time.

Engineering
ideas taking shape
Need evaluation. From turnkey Design Build solutions, Steam Products, Energy Audits and Piping and Insulation, SteamlineTM provides a full menu of services that you can count on. We first understand your project goals, budget, and schedule. We then combine new-generation estimating, scheduling and management systems, with qualified construction personnel ensuring that your project is well planned and executed in a manner that promotes trust and confidence. Engineering Standards. To steamline and standardize quality to a repeatable level, the adoption of proper Engineering Standards is critical. Standards also help to introduce and guarantee quality, reduce inventory, shorten project execution and provide a baseline for validation of installed equipment. Applicable Codes and Standards. Equipment and materials used in the entire project, including all systems, sub-systems, products, piping, etc. conform to one or more of the following Codes and Standards, or equivalent.
Code/ Standard IBR (1950) ASME Sec II ASTM SA516 BS 3059/320/360 IS 2002/2062 ASME Sec V ANSI B 31.1 &3 ASTM A 106 ANSI B 16.5 ANSI B 16.10 ANSI B 16.11 ASTM A 216 ASTM A 105 ASTM A 234 ASTM A 182 ASTM A 193/4 IS 1367 IS 2712 IS 6533 IS 14164 Description Indian Boiler Act (1923) and regulations and subsequent revisions Material specifications Material specifications for Steel Plate Material specifications for BQ ERW tubes Material specifications Standards for Non-Destructive Testing Piping Standards (American) Specifications for Carbon Steel Pipes Seamless and Welded Steel Pipe Flanges and Flanged Fittings Face-to-face and End-to-end dimensions of Ferrous valves Threaded Pipe Fittings Specifications for Cast Carbon Steel Valves and Fittings Specifications for Forged Steel Valves and Fittings Cast Steel Steel Pipe Fitting Forged Carbon Steel Pipe Fittings Fasteners for HP / MP Service Fasteners for LP Service Gaskets for Fluid Flow Piping Design Codes for Steel Stacks (Chimneys) Insulation of Process Piping

Sizing & Routing. No matter how well a pipe is fabricated, it will fail if it is not sized correctly. The selection of the correct size depends on flowrate, but also on velocity, allowable pressure drops and design life of the plant. Too small a pipe and you will get process starvation, high pressure drops, noisy operation and accelerated wear. Too big, and you lose energy as well as money. Steamline uses a variety of tools including the Moody charts, the Darcy-Weisbach method, Unwins formula and our own proprietary pipe-sizing software. Recommended Velocities For Piping Systems. SERVICE/ APPLICATION Raw or treated water Boiler feed pump suction Boiler feed pump discharge Saturated steam - HP Saturated steam - LP Superheated steam Flash steam Condensate VELOCITY (m/s) 1-5 1 - 1.5 2.5 - 3.5 25 - 40 15 - 30 30 - 50 5 - 15 0.5 - 1.5

Table 2: Recommended Velocities Documentation. Through the use of detailed engineering drawings, SteamlineTM provides customers with an accurate and permanent record of their project. Our design tools are used to combine ideas, specifications, and concepts into a blueprint for your piping process. Isometric drawings give craft personnel a single threedimensional reference document from which to build, spending more time in the building process and less in consulting reference drawings. They also give the customer the opportunity to see each step of the job, in detail, before fabrication begins. Revisions can be made and incorporated at any phase of a project with minimal delays in the work schedule. Specialized procedures can also be integrated into the drawings, including welding operations, NDE examinations, or torque operations. Each phase of a project, down to the smallest detail, is recorded, documented, and retained as an accurate reference for the customer's future use.

Table 1: Applicable Codes and Standards Materials. SteamlineTM maintains welding procedures covering carbon steel, low alloy, aluminum, Inconel, Hastelloy and others. Joining dissimilar materials is also in our repetoire. All pipe welding is performed by welders certified to ASME IX and each qualification is additionally certified by the Indian Boiler Regulations (IBR).

RELIABILITY
Top corporations nationwide rely on their infrastructure for day-to-day operations. In industry, stability and reliability are key. Equipment must function dependably, communication lines must remain open, workflow must be efficient. At SteamlineTM we understand the demands facing your company. We work to optimize your performance. We focus on completing projects that meet or exceed our clients expectations, while minimizing construction impacts and delivering the highest quality work. So, while you focus on growing and developing your business, we focus on making sure your infrastructure is ready to handle new challenges.

Process Piping & Utilities Projects

maintaining the arteries of the Process Industry
Responsibility. You are at the centre of all our business decisions. Established to streamline the traditional method of delivering construction performance, Steamline provides a single source of responsibility for total project execution. Whether your project demands a particular skill or a full range of disciplines, our services are tailored to the task at hand. Competence. Our workforce includes pipe-fitters, riggers, welders, and mechanics - each with a diverse background of practical experience. Experience has taught us that satisfied customers don't just return, but actively market our business by word-of-mouth. Tools of the trade. Our on-site team has been equipped with the best possible tools. Our German welding machines, for example, are packed with power and yet have extremely compact dimensions. In fact, they weigh only 6.0 kg !! These features make them the ideal companion for arduous outdoor work on building sites. Specialization in Steam. SteamlineTM has been in the business of steam for a decade. Steam Distribution systems pose certain special challenges. Sizing must be done keeping in mind the typical high turndowns of a steam load. The removal of moisture by correctly spaced pipe loops and automatic drain traps is critical. Installing a flow meter correctly makes the difference between accurate readings and money wasted. The expansion of pipes when steam passes through them presents special challenges for pipe supports. We have been doing exactly this for really long and it would be a wonderful opportunity to share this knowledge with you. Safety. As a leading piping and industrial contractor SteamlineTM is first in safety, quality and performance. Process Safety Management, Responsible Care, and OSHA-Compliance are terms that are heard on a daily basis at SteamlineTM jobsites. Safety is not a thread running through our operation, but the fabric from which it is woven. Whether it is entering a permit-required confined space, or climbing over the six-foot fall protection threshold, all our work is performed by employees with safety training under the direction of competent supervision. No work is performed without every employee being aware of the hazards of his workplace and having received the proper training to deal with those hazards. Typically, our site teams are fully equipped with boilersuits, safety shoes, protective eyewear, helmets, safety slings and harnesses, ear-muffs, etc. Projects. SteamlineTM takes pride in the ability to do precision machinery installation and equipment relocation. Whether it is the close-tolerance placement of manufacturing lines and conveyors or the setting of an entire tank farm,SteamlineTM can be called upon to do the job. We have years of experience serving a wide range of market sectors, including food and beverage manufacturing, healthcare, chemical and pharmaceuticals, paper and chemical, power generators, vegetable oils, and more.

SAVINGS
Savings come from competent implementation. One contact at one phone call puts you in touch with every facet of your project. The engineers, planners, designers, site managers and other experts at Steamline are talking to each other, making sure that your needs and concerns are always at the forefront.What does this mean for you? It means that your projects cure headaches instead of causing them. It also means that you save time.

QUALITY
Whether threaded, flanged or welded or brazed, from the ferrous to alloy, SteamlineTM can provide experienced piping fabricators and installers for every type of process piping system. Regardless of the material specification, the service classification, or the examination requirements, each system is installed in accordance with ANSI regulations. Material certifications are maintained, hydrostatic or pneumatic testing is documented, and the torquing of flanged connections is verified. Our stellar performance in the arena of process piping has established SteamlineTM as the contractor of choice when "close enough" really isn't.

Insulation
boosting plant Efficiency
Steamline'sTM in-house ability to provide painting, insulating and cladding services keeps "critical path" activities under the same roof. By reducing specialty contractors whenever possible, SteamlineTM maintains the forward momentum of its projects. Whether a red oxide primer or a three-part paint system, our coatings department can deliver. Surface blasting to maintain a specific profile and mill thickness testing are all services provided by our coatings personnel. Insulation can be attached concurrently with fabrication and assembly when it is applied by our insulators. Pipe spools can be insulated in the shop, eliminating time-consuming fieldwork. Vessels can have lagging installed prior to installation, eliminating elaborate scaffolding and consequent delays. We do all Insulation as per IS 14164. Thickness Charts. Table 3 to the right, gives recommended insulation thickness in mm required for different pipe sizes and different operating temperatures. Insulation material assumed is Mineral wool with a thermal conductivity of 0.035-0.04 kcal/m hr C and average density of about 100-200 kg/m. Payback. Given the rising cost and availibility of energy, an uninsulated hot or chilled line is a crime. The cost of insulation is recovered within 3-9 months, depending on the size and the temperature of the pipe. This is illustrated below in easy to read Rupee terms.
Pipe dia (NB) mm 25 40 50 80 100 150 200 250 300 Flat 90 25 25 25 25 25 40 40 40 40 40 Operating/ Fluid temp in deg C 150 200 260 315 40 40 40 40 50 50 50 65 65 65 65 65 65 65 75 75 75 90 90 90 65 65 65 65 75 75 75 90 90 90 75 75 75 75 100 100 100 100 100 100 375 90 90 90 90 100 115 115 125 125 125

A microscopic view of mineral fibres

Table 3: Recommended thickness

Rs Loss/yr for every 100 m of Pipe Length Fuel - FO Steam Pressure in kg/cm2 g NB 15 20 25 40 50 65 80 100 125 150 200 250 300 3 138872 173909 217864 273285 310870 487964 387314 570141 732583 1060653 1395731 1739089 2063337 5 166912 209023 261853 328464 373638 586489 465516 685258 880499 1274809 1677541 2090227 2479944 7 191555 239883 300513 376959 428802 673078 534245 786429 1010496 1463022 1925214 2398829 2846083 10 222949 279198 349765 438740 499079 783391 621804 915320 1176109 1702801 2240744 2791981 3312537 3 64501 80774 101190 126931 144388 226642 179893 264810 340259 492636 648267 807745 958346 Fuel - Coal Steam Pressure in kg/cm2 g 5 77525 97084 121621 152560 173541 272403 216215 318278 408960 592103 779158 970836 1151845 7 88970 111417 139577 175084 199163 312621 248138 365268 469339 679521 894193 1114170 1321904 10 103552 129678 162453 203779 231805 363857 288806 425133 546261 790890 1040745 1296775 1538555 3 49144 61542 77097 96710 110010 172680 137062 201760 259245 375341 493918 615425 730169 Fuel - Bagasse Steam Pressure in kg/cm2 g 5 59066 73968 92664 116236 132222 207545 164736 242497 311589 451126 593644 739685 877596 7 67787 84889 106345 133397 151743 238187 189057 278300 357592 517731 681290 848892 1007165 10 78897 98802 123774 155260 176613 277224 220042 323911 416199 602583 792949 988019 1172232

Table 4: Annual Loss in Rupees for uninsulated pipe

Head Office & Works Steamline, S. No. 32/3/14, Kondhwa Budruk, Pune Maharashtra, India 411 048. Phone: + 91 20 2693 2213 Fax: + 91 20 2693 2214 Email: info@steamline.com Web: www.steamline.com

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