NIRMAL OVERSEAS LIMITED.

N
> NIRMAL OVERSEAS was established in 1983. It was
the first company in INDIA who started the
manufacture wide range of HF/RF(high frequency/
radio frequency) Tube welder and Induction heaters.
> NIRMAL is the manufacture of TUBE MILL, PIPE MILL,
SLITTING MACHINE, SOLID STATE WELDER,BURR
FREE CUTTING CAR.
> NIRMAL Manufacture complete Trunkey projects for
Galvanized steel tube and pipes.

Now NIRMAL OVERSEAS is at the forth position

among the world in making HF/RF Tube Welders.
> NIRMAL executed several Projects on Turnkey basis
from INDIA to U.A.E, SYRIA, SUDAN, EGYPT ,
YEMAN
,
BANGLADESH,
CAMEROON,
RWANDA,SAUDI ARABIA, OMAN , UGANDA, DUBAI,
NIGERIA, NEPAL etc.
NIRMAL has been AWARDED AS A TOP TEN
EXPORTER in 1997 by honorable Prime Minister of
India.
NIRMAL has awarded President of India our
RAMASWAMY VENKATARAMAN for first company
tube mill of India.

NIRMAL has awarded our President of

India RAMASWAM VENKATARAMAN .

OUR RECENT ACHIEVMENTS

> Manufactured and Commissioned API Standard project from

1/2 to 14 line for GIAD PIPES CO. LTD.

> API Standard 8-20 line for ASIAN TUBES LTD, Ahmedabad
> 12 line equipment for JINDAL INDUSTRIES LTD, Hissar .

Erection and commissioning of 20 API line for RATNAMANI.

Erection and commissioning of 20 API line for JINDAL INDIA,Kolkata.
Manufactured and commissioning 16-50 mm turnkey project with
cold saw machine to STIL, Uganda.
Manufactured and commissioning Hydro Testing machine for 3000
as per API Standard.
Manufactured and commissioning Galvanizing Plant in Saudi Arabai,
Yeman , Egypt etc.
Manufactured and commissioning 2-8turnkey project to Mainawati
Steel, Nepal

Manufactured and commissioned Hot dip pipe galvanizing

plant from to 6 to Yemen.
Manufactured and commissioned Hot dip pipe galvanizing
plant from to 6 to Saudi Arabia.
Manufactured and commissioned -3 turnkey project
with Cold saw Machine to Nigeria.
Manufactured and commissioned -3 turnkey project
with cold saw machine to Oman.
Manufactured and commission -4 turnkey project with
cold saw machine to Bangladesh.
> Manufactured and commission Hot dip pipe galvanizing
plant from to 6 to Egypt.
Manufactured and commission Hot dip pipe galvanizing
plant from to 6 to Syria.
Manufactured and commission Hydro Testing Machine for
3000 PSI as per

NIRMAL USER NATWORK WITHIN INDIA

CUSTOMER NAME
DOMESTIC
INTERNATIONAL
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Mahalaxmi Profile pvt ltd.

Galglawa pipe Ltd.
Jindal saw Ltd.
Jindal India Ltd.
Sri sas steel tubes pvt Ltd.
inc.
Amkoya Engineering Contr.
R.S Ispat Ltd.
Veer roll forming industries.
Flnomax steel tube pvt Ltd.
Steel and Metal tubes Ltd.
Ltd.
Excel auto tube private Ltd.

> M/s Al Sultan Steel factory

> M/s Al- Nujoom metal factory
> M/s Shurooq Steel industries.
> M/s Joot Co. Ltd.
> Overseas distribution Service
> BJB Pipe industries Ltd.
> Assad Said co.
> Tanzania brush Products Ltd.
> Tiger steel industries LLC.
> Mainawati Steel industries Pvt
>

Giad pipe co Ltd.

TUBE MILL
TUBE MILL is a combination of equipment
installed in a line for the production of HIGH
FRENQUENCY INDUCTION WELDED carbon steel
tubes. The process involved is cold forming of
carbon steel strip in circular shape, longitudinal
welding, sizing, converting in to rectangular
square shape and cutting to pre-determined
length.

TYPES OF TUBE MILL

> TUBE MILL
> TUBE MILL
> TUBE MILL
PIPE.
> TUBE MILL
> TUBE MILL
drawn
welding.)

FOR PRECISION TUBE

FOR HOLLOW SECTION.
FOR CARBON STEEL
FOR API.
FOR CDW TUBE(Cold

TECHNICAL DESCRIPTION:
Machinery name : Tube mill (0.5 to 2 inch)
Coil weight : 3 to 5 ton one side
Material : HRC/CRC Carbon steel
Strip thickness tolerance : 0.05 mm
Coil material/Coil grade : HR
Coil Width : Maximum 185 mm
Tube Ovalty : 0.05 max
Pipe cutting length accuracy : 1mm max in cold saw
technology.
Welder : Solid state induction welder 250 kw
Gear box : Bevel type
Electricity supply : 420 volt
Cooling Water supply : Industrial water, max 32 C.
Humidity : 60 98 %

LIST OF EQUIPMENT
> PAY OFF REEL
SECTION
> PINTCH ROLL
> END SHEAR CUM BUTT WELDER
SOLID)
> ENTRY GUIDE
> CIRCULAR GUIDE
> PINTCH ROLL
> ACCUMULATOR
> HORIZONTAL GUIDE
> SIDE GUIDE
TABLE.
> LEVELLER
> STAMPING GUIDE
> PRESSURE PAID
> FORMING SECTION

> WELDING
1. SEAM GUIDE
2. WELDER( HF
3.
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TOOL POST
COOLING ZONE
SIZING SECTION
TRUCK HEAD
COLD SAW
RUN OUT

ENTRY SECTION
PAY OFF REEL: This is use for unwinding the coil. It
reduce the manpower as well the cost.
END SHEAR CUM BUTT WELDER: In this unit the strip
end of the preceding coil and leading end of the next
coil passing through the mill are trimmed parallel by
pneumatic shear then butt welded together using
TIG/MIG/SPOT welding.
ACCUMULATOR: This is mainly use to storage the strip .
Storage the strip as per the tube mill capacity.
Accumulator length : 10 mtr.
Height : 4.5 mtr.
Entry feeding sped : 150 m/min.
Exit line speed : 40 100 m/min.

FORMING SECTION:

Forming is a continuous
metal forming process. Forming section in
consists two types of stands
Horizontal stand( 4 stand)
Vertical stand (4 stand)
Both are used for forming the strip coming from
the entry guide in to tubular form.

> FIN PASS SECTION: In forming section

,after
the 4 stands (horizontal/vertical) there is
a fin pass mill section in the forming section. The
primary job of the fin section on any tube or pipe
mill is to prepare the edges of the strip parallel for
welding.
> SEAM GUIDE : This is mainly used to maintain
the proper gap b/w the edges of strip for welding.

WELDER: Welder are three typesERW

HIGH FREQUENCY VACUUM TUBE
HIGH STATE SOLID STATE.

VACUUM TUBE V/S SOLID STATE WELDER: In recent time,

solid state welder have become dominant choice for HF
welding and many old installation using vacuum tube
equipments have migrated to solid state equipments.
Solid state welder are available with power rating from
50 kW to 2000 kW and frequency range from 450 KHZ
to 800 KHZ. 1. 1. GREATER EFFICIENCY- Solid state
provide 80 to 85% energy efficiency versus 65 to 70% in
case of vacuum tube.
2. LESSER MAINTENANCE- Vacuum tube welder operate
at very high voltage (15000 volts) and Solid state
welder very low voltages(500v

VACUUM TUBE
WELDER

SOLID STATE
WELDER

COMPARE HF/RF INDUCTION WELDER AND ERW:

CHARACTERISTIC HF/RF WELDER
ERW
> Power
Efficiency

> Stitching
> Maintenance
Features

Size ranges

Up to 3 times as that
of ERW in terms of
welding rate /KW
input.
No effect .
Lowest .

Can weld very

thin wall.

Low due to higher

current penetration
and high amount of
metal heated.
Limits weld rate.
Periodic replacement
of costly rotary
transformer.
Cannot weld thin wall
due to contact

pressure.

Material

Cost

Can weld a wide

range of material.
Lower for a given
production footage.

Limited to low and

medium carbon steel.
Higher.

TOOL POST: Used for remove the burr on pipe. Used of

scarfing tool for remove the burr on pipe. These are two types
of bead scarfing.

OUTSIDE BEAD SCARFING: This arrangement employs

two independently adjustable scarfing tool holder blocks
moving on separate precision slides. The tool can be adjusted
in horizontal as well as vertical plane. V- shaped profile of tool
support the welded tube during de-burring operation. The tool
are supplied having 15 degree for aluminized and coated
material for 25 to 30 degree rake angle.

INSIDE BEAD SCARFING: Outside bead scarfing is easier

job because it is visible but inside bead scarfing is most
difficult .The internal tool radius can only have a radius less
than the radius of the inside of the tubes. Today various tool
have developed but the most common tool used is Tungsten
carbide ring. Normally angle of attack is 30 degree because
OD/ID of scarfing ring for different ranges of tubes diameters.

COOLING ZONE: In this unit welded pipe sprayed and

dipped in water for cooling. The cooling line serves to cool
the welded tube down to room temp. before it enters the
sizing machine.
SIZING SECTION: The outside diameter of tube that is
being finished in the welding stage at the welding roll
stand is still not completely accurate. It is than passed
through a sizing mill to bring it to required sizes and shape
This process uses a vertical and horizontal stand. Turks
head is provide to straighten the tube and set the size. In
this section stars are roll changing setup. According to
actual size and shapes change of roll setup in tube mill.
Number of sizing horizontal stand:4
Number of vertical slide:4
Number of 4 roll type Turk head:3

CUTTING SECTION: Three types of cutting section.

Friction saw

Rotary saw

Cold saw

COLD SAW: Continuously produced tubing is cut

to length by cold saw. Cold saw cut off unit are
designed and developed to make up to 18 cuts per
minute for cutting 6 meter long tube. Cold saw
technology produces almost burr free cutting and
any tubular shape can be cut in close tolerances.
It has two servo motor one is for the
reciprocating movement of trolley and another
is for the cutting blade.
It is necessary to keep both the motor in
synchronization else it create damage to blade or

SAW CARRIAGE MOTOR: AC MOTOR 15.71 Kw

Cutter motor : 15 kW
Tube clamping : Pneumatic
Cutting length accuracy : 1 mm
Pipe OD tolerance : 0.05 mm
Saw blade: HSS or TCT from 350 to 450 mm.

RUN OUT TABLE : The run out table takes the cuts
tubs from the cut off section out of the line. The
run out table will be driven type.
Conveyor motor : 3.75 5 nos.
TUBE MILL DESIGN: are two types> TOP LINE
> BOTTOM LINE
DIFFERENT BETWEEN TOP LINE AND BOTTOM
LINE : A Company bottom line can also be referred
to as net earning or net profit.
The top line refers to a company gross
salary or revenues .They are making reference to
an increase to an increase in gross sales or
revenues.

TUBE MILL FORMING METHOD: are three

types>
W forming ( Previously used)
>
State edges ( Then after)
>
Direct forming to square and rectangular.

INSPECTION AND TESTING OF TUBES:

Material can be inspected at our works prior to dispatch.
These types are> Visual Inspection
> Weld Decay test.
> Chemical Analysis.
> Hardness
> Dimension.
> Impact test
> Length Majoring
> Bend test
> Weight
> Tensile test.

AS PER INTERNATIONAL STANDARD:

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ASTM
API
GI
BS
IS.