Knowledge sharing Session on

Boiler Segment

13th April 2020

Kolkata / Jamshedpur (Through Microsoft Teams)

Controlled document: Strictly confidential

 Tata Steel Slide 2

Agenda

▪ Boilers and Key Applications

▪ Air Preheater

▪ Tube Manufacturing Process at a Glance

▪ Boiler Tube manufacturing Process, Specs etc

▪ Key Competitors

▪ Case study on Boiler Tubes Quality

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 Tata Steel Slide 3

What is a Boiler?

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 Tata Steel Slide 4

What is a Boiler?
▪ Boiler is a closed vessel in which water or other liquid is heated , steam or vapor is
generated for use external to itself, by the direct application of energy from the
combustion of fuels
▪ Typically capacity measured in terms of Steam raising Capacity in TPH
Category Type
Position of water and Hot gases Fire Tube and Water Tube
Axis of Shell Horizontal and Vertical
Position of Boiler External and Internal
Pressure Low and High
Circulation Natural and Forced
Mobility Stationary and Mobile
No of Drums Single and Multi Solid: Wood, Coal,
Briquette, pet Coke, Rice
Drought Forced and Natural
Husk
Furnace Single and Dual Liquid: LDO, Furnace Oil
Fuel Solid, Liquid, Gaseous Gaseous: LPG,LNG,PNG
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 Tata Steel Slide 5

Broad classification of Boilers

Fire Tube Water Tube

Water drum

• Combustion gases pass thru Tube
• Compact and inexpensive
• Easy to replace tubes
• Suitable for space heating & Industrial
process applications
• Fluid inside the tubes and combustion
gases pass around the outside tubes
• Suitable for Large steam users such as
Chemical and Fertilizer plants, Power
plants

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 Tata Steel Slide 6

Package Boiler
▪ A package boiler is a modern type of boiler. They are factory-made to a range of standard
designs, according to the size and evaporative capacity required
▪ They are available off-the shelf without lengthy design step and easier to install
▪ Typically a packaged boiler is one or two pass fire tube boiler with an internal furnace
▪ These are fuel supplied burners with built in electric fans to provide draught

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 Tata Steel Slide 7

Key Applications of Steam

Sector Typical Applications

Power To run turbine and generate power
Textiles Spindle running, yarn/fabric washing, Polymer treatment
Plywood / Fiberboard, To dry the moisture content in the wood
particle board
Sugar To heat the sugar juice and convert it in to syrup, Power
generation
Paper mills Steam used to evaporate pulp and dry paper
Rice mills Steam used for heating the water for soaking and drying
steamed paddy. Thermal energy is used in Parboiler rice
mills only
FMCG (mineral oil / synthetic oil heater, Molten salt heater

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 Tata Steel Slide 8

Typical Process flow of a Sugar Mills

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 Tata Steel Slide 9

What IBR and Non IBR Boiler?

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 Tata Steel Slide 10

Agenda

▪ Boilers and Key Applications

▪ Air Preheater

▪ Tube Manufacturing Process at a Glance

▪ Boiler Tube manufacturing Process, Specs etc

▪ Key Competitors

▪ Case study on Boiler Tubes Quality

Tubes Marketing & Sales

 Tata Steel Slide 11

What is a Air Pre Heater?

▪ Air Pre Heater is a device designed to heat air before another process (for example
combustion in a boiler) with primary objective of increasing the thermal efficiency of
the process

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 Tata Steel Slide 12

Types of Air Pre Heaters

Tubular Type Regenerative Type

• Need more space and • Suitable for large size boilers

structural support • Very compact and help to save
• Due to abrasive flue gases, space
tubes wear fast
• Useful for small and medium
size boilers

With usage of better grades of steel (Corten),many Fluidized Bed Combustion type boilers
incorporating Tubular Air heaters which are smaller in size
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 Tata Steel Slide 13

Agenda

▪ Boilers and Key Applications

▪ Air Preheater

▪ Tube Manufacturing Process at a Glance

▪ Boiler Tube manufacturing Process, Specs etc

▪ Key Competitors

▪ Case study on Boiler Tubes Quality

Tubes Marketing & Sales

 Tata Steel Slide 14

Tube Manufacturing Processes at a Glance

TSL’s Boiler
Tubes use
HFIW
Process

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 Tata Steel Slide 15

Key Applications of Various types of Tubes and Pipes

Application Mfg Process Description
General & Building Structure UOE,SP, ERW Marine Structures, Pile, Structural
Piping ERW, BW Galvanized pipe, lining pipe,
Polyethylene coated pipe
Oil Country Tubular goods SML,ERW Tubing, Casing, Drill pipe
Line Pipe SML,ERW, UOE Transportation of oil, gas, and water
Boiler and Heat Exchanger SML, ERW Heat exchanger pipe for heat recovery
boiler
Machine Structure SML,ERW Parts for automobile, Gas cylinder

SML: Seamless pipe, UOE: UOE pipe, SP: Spiral pipe, ERW: Electric Resistance Welded Pipe, BW: Butt Welded pipe,

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 Tata Steel Slide 16

Agenda

▪ Boilers and Key Applications

▪ Air Preheater

▪ Tube Manufacturing Process at a Glance

▪ Boiler Tube manufacturing Process, Specs etc

▪ Key Competitors

▪ Case study on Boiler Tubes Quality

Tubes Marketing & Sales

 Tata Steel Slide 17

Manufacturing Process Flow of Boiler /Air Heater Tubes

Slit Coil Storage PT4 Rolling at PT4 Mill

Mill PT Finishing

Heat Treatment

Storage in Warehouse / DESPATCH

in 6 Ton Fce. End cutting

OILING / PACKING
Hydraulic Testing

in Gallium/KR100
Straightening
Cutting to
Customized Length

Inspection

Heat Treatment Stenciling

Rolling at PT3 Mill in 3 Ton Fce & IBR mark stamping

Slit Coil Storage PT3 Note 1:Corten and Coil Type routed through PT4 (HRPO as Input)
Note 2: Stenciling is optional for AHT
Note 3: IBR mark only for Boiler Spec Tubes

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 Tata Steel Slide 18

Specifications of Boiler/ AHT segment

Eq Std ---- - British Japanese German DIN American

Application
Boiler BS 3059 JIS G 3461 EN 10217 Pt-1 ASTM A53 Gr B
Pt-1 and Pt- and Pt-2 ASTM A178 Gr A
2
Air Heater BS 6323 -5 JIS G 3461 DIN 17177 ASTM A214
BS 6323-6 EN 10305 2&3
EN 10217 1&2
Corten - - - ASTM A423 Gr 1

General Specifications and Tolerances

Length: Up to 12m max customized length

Straightness : 1 in 600
End Finish: Plain end, With End Caps

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 Tata Steel Slide 19

Key Differences between Boiler and Air Heater Tubes

Boiler Air Heater Corten
Process Route Same Same Same
Spec BS 3059 BS 6323 A 423 Gr 1
A 178 Gr A
ASTM A53 Gr B
Test Certificate IBR Self certified TC Works TC Works TC
Stenciling Yes Optional Yes
Size range As per IBR A per Mill Capability
Hydraulic Test Mandatory. Specific TSL follows mandatory Hydraulic Testing
cases can be replaced
by NDT on customer’s
consent
Normalizing Yes Yes. TSL Follows 100% Normalizing
OD (mm) Min Thickness (mm)
Up to & including 32mm 2.03
IBR’ recommended size Over 32mm & Up to & including 51mm 2.34
Over 51mm & up to & including 76mm 2.64
range
Over 76mm & up to & including 89mm 3.25
Over 89mm & up to & including 114mm 3.66
Steel Marketing & Sales
 Tata Steel Slide 20

Key Features of Tata Boiler Tubes

▪ Central Boiler Board recognized “Well known Tube/Pipe maker”
▪ Made of fully killed steel from sate of the art steel works that can be used up to 454oC
▪ Online eddy current testing with auto sorting technology and 100% Hydraulic Testing
ensures best in class weld quality
▪ Laser stenciling for permanent identification
▪ Thick walled ERW pipes can be supplied as per ASTM A53 Gr B as substitute for
Seamless tubes for temperatures up to 454oC.

Corten Steel Tubes – Salient Features

▪ High acidic dew point corrosion resistance property
▪ Rate of corrosion is very slow and uniform
▪ No significant pitting corrosion
▪ Economical and easily available compared to Stainless steel

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 Tata Steel Slide 21

Discussion Document : IBR TC and Way Forward

✓ IBR TC in “Form-III B” is issued with digital signature (Green Colour √ ). Original TC with colour
print required by the customer. [Ref. Gazette Notification by Ministry of Commerce & Industry
(Dept. of Industrial of Policy & Promotion) (Central Boilers Board) Notification, New Delhi, the
26th August, 2015)], copy attached.

✓ Mother as well as Child IBR TC can be issued as per the requirement of the customer.

✓ Mother IBR TC can be issued for total invoiced qty against each line item.

✓ Child TC can be issued for the smaller qty. e.g., in multiple 10 or 15 or 20….as per the
requirement of the customer. Generally this requirement comes from Channel
Partners/Distributors.

Note: Boiler Inspector will accept only colour printout of original IBR TC (√).

Going forward we propose to move to IT enabled system (Block Chain Technology)

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 Tata Steel Slide 22

Content of Stencil
IBR TC certify that boiler tubes supplied to the customer are as per the specification BS 3059 Pt
1 ERW320 or BS 3059 Pt 2 ERW360. Heat No, Lot no mentioned in TC shall match with the
stenciling marked on tubes. And boiler inspector will certify for use of tube after matching TC
with tubes.

Heat No & Lot No & Dimension mentioned on tubes and TC for traceability.

Example: Heat No : V28148

Lot No : 6519C43
Dimension : 63.50 x 3.66 x 4.500

Lot No : 6 5 19 C 4 3

Year Month Date Shift Mill code Sl. no

22
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 Tata Steel Slide 23

Block chain Technology: A new way of working(1/2)

As Is
2nd Leg Sale BUSINESS SCENARIO
Invoicing

 Boiler Industry is highly

regulated & safety is of
paramount importance.
Distributor
 Boiler Tubes are rendered
2nd Leg Sale useful only with IBR Test
certificates.
 Tata Tubes is an IBR self
certified Manufacturer
TATA STEEL
Parent TC*
 TATA Steel issues child TC
to the distributor

 The distributor in turn

issues the child
Direct Sale Distributor TC(photostated copies) to
to Customer the secondary/tertiary buyer
Parent TC* customer
.

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 Tata Steel Slide 24

Block chain Technology: A new way of working(2/2)

Distributor TC (Parent TC) Dealer/ End User/Small Reseller (TC) End User

3 7
1

4 8 10
TSL SAP
5 Boiler
Name Segment Lot No Name Segment Lot No 9
6 Inspecto
Address Phone Qty Address Phone Qty r
2
11

ID Status
SMART CONTRACT
Lot No

Purchase Request to Small

1 Purchase Request to Tata/SAP 3 Purchase Request to Distributor 7
Reseller
11 Boiler Inspector
SAP populates the purchase 4 Distributor populates customer 8 Small Reseller populates customer confirms quality
2 details in blockchain via mobile app
details in blockchain details in blockchain via mobile app check
5 Challenge response (OTP) for 9 Challenge response (OTP) for
liveness and authenticity liveness and authenticity
6 Auto generated certificates are issued 10 Auto generated certificates are issued
to dealer’s email id and sent to buyer’s email id

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What information is needed to prior to log the order

Information to be submitted by the Purchaser

▪ Specification (Say BS 3059 Part1 or Part 2)
▪ Method of Manufacture (ERW/CEW/ Seamless (Hot Finished / Cold Finished)
▪ Tube OD and Thickness
▪ Tube length
▪ Qty in mtrs or no of lenths In case of Part 1
For Seamless, steel has to be
Optional
fully killed where as for ERW, it
▪ Steel making process used to be reported can be killed, semi killed and
▪ Final supply Condition rimmed steel)
▪ Random lengths allowed
where as for Part2, for all
▪ Method of leak tightness test (Hydraulic or Eddi Current Test) methods, it has to be fully
▪ If Hydraulic Test, pressure and duration killed steel

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Importance of Going through Purchase Order and sharing the same with
QA/Plant

The following Order attributes need to be understood by entire chain to ensure proper
servicing of the orders :
❖ Specification (3059 Pt 1/2/ 6323 / ASTM Spec)
❖3rd Party / Customer Inspection criteria / Delivery based clearance of Provisional TC
❖ Sampling Inspection Criteria (Each customer specifies their own sampling mechanism).
❖ End Caps required or not required
❖ Packaging Criteria (For eg Customers like Isgec want Export type packaging)
❖ Surface Finish Criteria

Steel Marketing & Sales

 Tata Steel Slide 27

Agenda

▪ Boilers and Key Applications

▪ Air Preheater

▪ Tube Manufacturing Process at a Glance

▪ Boiler Tube manufacturing Process, Specs etc

▪ Key Competitors

▪ Case study on Boiler Tubes Quality

Steel Marketing & Sales

 Tata Steel Slide 28

Key Competitors

Competitor Process Products

TI ERW Boiler
Good Luck ERW Boiler, AHT and Corten
Pennar ERW Boiler, Air Heater(KM)
MSL Seamless Boiler
Jindal ERW Air Heater (KM)
ISMT Seamless Boiler

BS 6323 Delivery Condition (Circular) BS 6323 Delivery Condition (Non Circular)

Only in KM
KM: As welded
GKM : Annealed
NKM: Normalised
ZGF: Annealed (Incl Descaling) Tata Steel offers only
NZF: Normalised (Incl Descaling) normalized Air heater Tubes

Steel Marketing & Sales

 Tata Steel Slide 29

Agenda

▪ Boilers and Key Applications

▪ Air Preheater

▪ Tube Manufacturing Process at a Glance

▪ Boiler Tube manufacturing Process, Specs etc

▪ Key Competitors

▪ Case study on Boiler Tubes Quality

Tubes Marketing & Sales

30
Tata Steel Slide 30

Problem Statement: Flattening of Boiler Tubes during bending operations (1/3)

Boiler Investigation Report

Customer:Isotex Corporation, Naroda, Ahmedabad

One competitor sample of Boiler Tube: 76.2 mm (OD) X 3.66 mm (Thickness) X 400 mm (Length) was sent
to us for testing and comparison with our tubes.

Batch No./ Tube Flattening

Specification/ during bending
Customer Complaint Size (mm) Source of Test required operation
Grade
supply
M/s Isotex Corp Tube
76.2 mm X N/A Visual, tensile, weld
(Through Pankaj flattening on BS 3059 Part 1,
bend 3.66 mm X (Market macro, grain size,
Trading Competition) ERW 320
400 mm chemical analysis
Corporation)

Representational image

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Tata Steel Slide 31

Problem Statement: Flattening of Boiler Tubes during bending operations (2/3)

Boiler Investigation Report

3) Chemical Analysis: Competitor sample is having richer chemistry in context of C (%) than our TPT grade of steel (C (%) – 0.04/0.06).
Sample ID C (%) Mn (%) S (%) P (%) Si (%) Al (%) Nb (%) Cu (%)
Actual (Competitor) 0.10 0.41 0.007 0.019 0.009 0.066 0.001 0.0042
Min - 0.30 - - - - - -
Specified as per BS 3059 Part 1 ERW 320
Max 0.16 0.70 0.04 0.04 0.35 - - -
Min - 0.40 - - 0.10
Specified as per BS 3059 Part 2 ERW 360
Max 0.17 0.80 0.035 0.035 0.35
TSBSL – Khapoli supply for
0.101 0.485 0.004 0.014 0.012 - - -
BS 3059 Part 1 ERW 320

4) Mechanical Test Results

4.1) Hardness Test Results 4.2) Tensile Test Results
Sample ID Hardness (VHN) Sample ID YS (MPa) UTS (MPa) Elongation (%)
Actual 128 Actual 318 404 42
Specified as per BS: Specified as per BS: 3059
NA 195 Min 320 - 480 25 Min
3059 Part 1 ERW 320 Part 1 ERW 320

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Tata Steel Slide 32

Problem Statement: Flattening of Boiler Tubes during bending operations (3/3)

Boiler Investigation Report

7) Conclusion:
➢ Chemical analysis of the sample conforms to the specification BS: 3059 Part 1 ERW 320; and it’s not Si- killed.
➢ Chemical analysis also reveals that competitor sample is having richer chemistry in context of C (%) but it is richer than our
TPT. grade (C – 0.04-0.06), which is used for part 1 ERW320 for our product offerings in the market.
➢ Dimensions of the sample conforms to the specification BS: 3059 Part 1 ERW 320.
➢ Mechanical properties of the sample conforms to the specification BS: 3059 Part 1 ERW 320; but having range of properties
Part2 ERW 360; means it’s higher side of the requirements which is enabling resistance for Flattening during bending
operation.
Chemical properties are confirming to SAE1010 Grade. The steel grade is widely produced at TSK and TSJ and supplied to all our
competitors (M/s TPI, M/s Goodluck, M/s Swatik Pipes, M/s Hansa Tubes, M/s Surya Roshini, M/s Vishal Precision Tubes
Limited)
8) Way Forward:
➢ We can use RM TDC – SC85 Steel grade SAE1010 from LD#2-TSJ >> HSM-TSJ route. In contingency,
we can also use K4 steel (RM TDC - TU24); used for BS 3059 Part 2 ERW360.

➢ PAG accompanied with QA/Operations team need to witness the customer processing's during
trial supply.

© rights reserved with Tata Steel Limited

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 Tata Steel Slide 33

End of Document

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