Dee Development Engineers Limited

An Overview

February 2012

Pioneers of Pre-Fabricated Piping Systems

DDEL

Contents

Company Overview
Accreditions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
2

DDEL At a Glance

DDEL

Located in Indias Fastest Growing Industrial belt

STRATEGIC LOCATION : -

ICD, Tughlakabad
Airport, New Delhi
National Capital, New Delhi

- 40 Kms.
- 58 Kms.
- 31 Kms.

PLANTS :-

Plant 1 - North Pre Fabrication Plant ( 10000 MT/Year)

Plant 1 - South Pipe Fittings Plant ( 2400 MT/Year)
Plant 2 - Pre Fabrication Plant ( 12000 MT/Year)
4

DDEL

Dee Development Engineers Limited

One of the leading International engineering enterprises
offering a single window solution for all piping systems
MAJOR MILESTONES:

The Company is engaged

in Design & Engineering
Prefabrication of Piping
Systems

The Company has exclusive

manufacturing facility for Pipe
Fittings
Mainly caters to
Engineering, Procurement
and Construction (EPC)
contractors and multinational
organizations in power
generation, oil and gas,
chemical and food industries

Boast of Pre fabrication

capacity of 24000 MT and
Exclusive Fittings Capacity of
2400 MT per annum

1983

Incorporated as a Design Consultancy firm

1988

A humble start with half acre facility for Pre-Fabrication Piping

1994

Establish its own in-house Pipe Fitting Manufacturing facility

1996

Entered into the Power sector piping

1999

Started High value Product P91 Fabrication

2004

Shifted Fabrication base to New location at Tatarpur, Palwal ( 12 Acre Facility )

2004

Entered into the EPC space, commissioned first Biomass Power plant in Punjab

2007

Grabbed the major export order worth 6 million Euros

2009

EPC of another Biomass Based Power plant in Punjab

2010

Commissioned the state of the art Induction Bending Machine

2010

Expanded its facility base to cater sub/super critical technology

2011

Banyan Tree & Capvent infused in DDEL

2011

- BHEL awarded Best Performance Award in Piping System supplier category

2011

Largest Single order received from MHI Japan worth 11.40 Million USD
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DDEL

CMD
ED
CEO

A well organized

Fittings

Projects

Customer oriented

Quality

Welding

EHS

Bending

Engineering

Materials

Marketing

Strategy

HR

Finance

Structure in Place
6

DDEL

Management Profile

Mr. K.L. Bansal

Chairman cum Managing
Director

Mechanical Engineer
Total Experience - 30 years

Specialized in Design & Engineering of Steam piping,

Process Piping, Marketing, Project Management,
Finance Management etc.
Awarded as Business Leader of the Year FY 11 by
Faridabad Industries Association
Ex BHEL Piping Centre Executive Director

Mr. M Kannappan
Executive Director

Mechanical Engineer
Total Experience - 38 years

Specialized in welding technologies , Project

Management , Operations and Planning control etc.
Under his leadership the BHEL Piping Division saw
350% growth in Turnover in just three years, INR 7500
Mn in 2007-08 to INR 25000 Mn in 2010-11

Mr. Atul Bansal

Chief Executive Officer

Mechanical Engineer
Total Experience - 8 years

Operational Head ; particularly responsible for the

export operations
Also takes care of business development
7

DDEL

KEY PERSONNEL

Name

Department

Education

Total Experience

Mr. AK Goel

Head Projects

DME (Mechanical)

28

Mr. AK Jha

Head Finance & Accounts

C.A.

17

Mr. Gaurav Narang

Head Strategy

BE ( Mechanical ) + MBA

Ms. Haneet Kalra

Head HR

B.Com + MBA

Mr. Harsh Bhatia

Head Projects

BE (Mechanical)

16

Mr. S Jaya Kumar

Head Engineering Division

MTech ( Mechanical )

35

Mr. Pankaj Agarwal

Head Marketing & Projects

Bsc.Engg. (Mechanical)

17

Mr. Parimi Venu

Head Quality

BE (Mechanical)

19

Mr. Pawan Arora

Head Purchase

BE (Mechanical) + MBA

10

Mr. Piyush Bhatt

Head Projects

DME (Fabrication)

10

Mr. Ramesh Kumar

Head Projects

BSc. Engg (Mechanical)

21

Mr. Sanjay Jain

Head Welding

M. Tech. ( Mechanical )

15

Mr. SK Saini

Head Store & MR

DME (Mechanical)

23
8

DDEL

DDEL achieved excellent financial results with strong

Sales growth

DDEL

Business Strategy.The Road Ahead

10

DDEL

Diversified in terms of Products manufactured,

Target sectors & Sale locations
Product wise Turnover*
Domestic Vs Export Turnover

Sector wise Turnover*

* Based on last 3 years sales data

11

DDEL

Key Customers

Our clients list includes some of the most reputed

names in the domestic as well international markets

12

DDEL

Key Suppliers

Well entrenched supplier base comprising of domestic

& international manufacturers of seamless pipes

13

DDEL

Diversified high quality customer base

7%

29%

5%
11%

18%

14%
17%

% represent the share of exports in FY11

14

DDEL

Man Power at a Glance

Department

No. of Employees

Engineers & Managers

170

Skilled Manpower

310

Semiskilled Manpower

125

Helpers & Riggers

250

Supporting Departments

135

Total

990

Average years of experience of the engineering staff : 8 years

15

DDEL

Contents

Company Overview
Accreditions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
16

DDEL

The wide range of Accreditions and Approvals

showcase our Expertise and Experience

ISO 9001:2008

ISO 14001:2004

OHSAS 18001:2007

PED Certification
(Directive (97/23/EC)

17

DDEL

ASME 'PP' & 'S Stamp Certification

The company is one of the few test houses to be on the

list of NABL Accredited laboratories

NABL accredited Physical & Chemical Laboratory

18

DDEL

Contents

Company Overview
Accredit ions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
19

DDEL

Spread over 22 acres (90,000 sq. mt.)of land, our facility

is the cynosure of all eyes

Existing Plant Layout

Plant I

Plant II (1st Phase)

Work Area

13,750 sq. mt.

12,800 sq. mt.

Covered Area

15,270 sq. mt.

13,500 sq. mt.

Uncovered Area

17,392 sq. mt.

28,000 sq. mt.

6 Acres of land is available for

2nd phase capacity expansion
Implementation already initiated

Production Line Outlook

Spool Fabrication

4 Main Workshops having 11 Bays all equipped with EOT (upto 20

ton) cranes & latest technology welding equipments

Pipe Fittings & Rolled Welded Pipe

Spread over 1 workshop having 1 Bay for R&W pipe

manufacturing, 3 Bays for Pipe fittings manufacturing and one bay
exclusively meant for Inspection, Packing and Shipment
20

DDEL

Contents

Company Overview
Accredit ions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
21

DDEL

Pre Fabrication Facility at a glance

World class and Technologically advanced Fabrication Workshops

Equipped with 100+ stations to carry out manual as well as

mechanized welding via GTAW, Orbital GTAW, GMAW, SAW,
MCAW, FCAW, Orbital FCAW, SMAW processes

Orbital welding station for TIG welding

Post weld heat treatment by furnace and local heating
(Induction/Resistance)

New Plant Facility

Fully equipped NABL accredited testing laboratory

In house Non-destructive facilities like RT/MPT/UT/LPT
Separate fabrication bays for Stainless Steel material
Surface Treatment facilities Shot blasting, Chemical cleaning
and Painting

World class Induction pipe bending machine (PB 400 SPL) with
capacity of bending range 2 16 Diameter 5-65 mm thick
pipes

Induction Bending Machine

Range 2 64
22

DDEL

Product Portfolio : Pre Fabrication

Experience of more than 150000 MT of Pre Fabrication which
includes more than 5000 MT of P91 Fabrication
HRSG Piping

Gas Compressor Piping

Power Cycle Piping

Turbine Integral Piping

Process Plant Piping

Boiler Integral Piping

Balance of Plant Piping

Riser & Down comer Piping
Gas and Steam Turbine Piping
Cooling Water & Lube Oil Piping
Steam Distribution Headers

23

DDEL

Pre Fabrication Pipe spools

Process Flow Chart

Each process is followed by a Quality check

RECEIPT OF
BOMS &
SPOOLWISE
DRAWINGS

START JOB

RECEIPT OF RAW
MATERIAL (PIPES,
FITTINGS &
STRUCTURAL)

PRODUCTION
PLANNING

NOT OK

INCOMING
INSPECTION

REJECTED
BEND PIPES AS
PER DRAWING

FITUP AS PER
DRAWING

OK

EDGE
PREPARATION

CUT PIPES /
SECTIONS AS
PER MARKING

OK

DIMENSION
INSPECTION

NOT OK

DIMENSION &
ORIENTATION
INSPECTION

INTERNAL
STORAGE

NOT OK
REWORK
SHOT BLASTING
CS

OK

WELDING

MARK PIPE /
STRUCTURAL
FOR CUTTING &
BENDING

NDT
PROCESS

VISUAL &
DIMENSION
INSPECTION

VISUAL
(SURFACE)
INSPECTION

SPOOL

PAINTING

VISUAL / DFT
INSPECTION

SS
SPOOL

NOT OK

SOLVENT CLEANING
REPAIR

VISUAL
(SURFACE)
INSPECTION
FINAL
INSPECTION

JOB
COMPLETION

DISPATCH

PACKING

24

DDEL

Major Orders Executed by DDEL in recent times

Alstom Switzerland - GT 13 Piping

Lanco Kondapalli Stage II 1*370 MW Power Cycle Piping

Alstom India - 270 MW HRSG Piping Man Turbo AG - Process & Oil Piping
GE Tonnes of 7F/9F piping

2011

2009

2007
2008

MHI, Japan
Prefabricated plant
piping

2010

Alstom Switzerland - 870 MW Critical Piping Adani Power 7 X 660 MW Super Critical Piping
Doosan Babcock - 4*360 MW Pulverized fuel &
Alstom India - CCPP HRSG Piping
4*360 External Piping
Lanco Kondapalli Stage III 2*370 MW Power Cycle Piping
st
GE Energy - Their 1 IGCC Project
* DDEL caters to 95% and 75% of the total pipe spools requirement for ISGEC & Thermax respectively
* Executing Power Cycle Piping of 5x660 MW Super critical TPS for Adani Power Tiroda , 2*660 MW for Kawai.

25

DDEL

Contents

Company Overview
Accredit ions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
26

DDEL

Weld Less Technology at DDEL

Induction Bending Machine

27

DDEL

Induction Bending is a controlled means of Bending

Machine Specifications:
Make
COJAFEX BV, The Netherlands

Nominal Pipe Range

2 to 16

Thickness
Up to 65mm

Bend Radius
76mm to 2032mm

Bending Angle
0 to 180

Pipe Rotation
0 to 360 Degree

28

DDEL

Leading the technology curve with State of the Art M/cs

Induction Pipe Bending procedure

shall comply with the following
codes and standards:
ASME B31.1 Power Piping

ASME B31.3 Process Piping

CSA Z245.11-05 Steel Fittings

TPA-IBS-98 Recommended
Stds for Induction Bending of
Pipe and Tube

PFI ES 24 Pipe Bending

Methods
Indian Boiler Regulations
Customer specific / Drawing
requirements
29

DDEL

Benefits to the Customers

Faster delivery period
Reduction in fabrication and welding offers significant quality assurance
advantages over the use of fittings
Reduces Inspection of weld joints
Reduces number of field joints.
Induction Bending produces excellent results in terms of dimensional, physical &
chemical properties.
With Bending Technology, we can make single spool with multiple bend in 0 to
360 degree orientation,

Machine is capable of bending:Seamless, Spiral , ERW, L.SAW & H. SAW Types of pipes
Carbon Steel, Alloy Steel, Austenitic Steel, Stainless Steel, Incoloy material
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DDEL

Another Milestone: Bending Machine with 300 MT per month capacity

To be commissioned in beginning next financial year

Machine Specifications:
Make
AWS SCHAFER, Germany

Nominal Pipe Range

8 to 48

Thickness
Up to 120mm

Bend Radius
280mm to 6500mm

Bending Angle
0 to 182

Pipe Rotation
0 to 360 Degree

31

DDEL

Contents

Company Overview
Accredit ions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
32

Our Expertise in Pipe Fittings

DDEL

Major Operational Milestones

As an Initiative for Backward Integration for Piping, we installed Pipe

Fitting Manufacturing Facility
2010

17 Years of Huge
Experience
2009

Installed Induction
Mandrel, 3000 MT press
Capacity ~~ 200 MT pm

Installed Cold Forming Elbow making

machine Capacity ~~150 MT pm
2006

Installed another 1000 MT press

Capacity ~~ 125 MT pm
2003

Installed another 150 MT + 750 MT press

Capacity ~~ 75 MT pm
1994

Started with 350 MT press

Capacity ~~ 30 MT pm
34

DDEL

Pipe Fitting : Facility at a glance

One of the Best Fitting Workshops in Industry

Hot Pushing Mandrel Elbow Forming Automatic M/c having

Elbow Making Machine

capacity to form Elbows from 8-28 inch & thickness up to 50 mm

2 Cold Forming Machines of different sizes for Elbow production

complemented with 3 Edge Preparation machines

Various Hydraulic Presses ranging from 750 MT to 3000 MT for

manufacturing of Pipe Fittings

Hot Formed

Hot forming section equipped with 2 furnaces and 4 hydraulic

presses

Machining section having over 20 lathes and other related

machinery

3 Semi-automated Shot Blasting machines for fittings

Pipe Cutting Section having capability up to 52 with add on
capacity of up to 28 from automated machinery

Cold Formed
35

DDEL

Fittings : The Products we offer

90 Elbow

Concentric
Reducers

45 Elbow

Eccentric
Reducers

Half Socket Weld

Coupling

Full Socket Weld

Coupling

36

DDEL

Fittings : The Products we offer

Equal Tee

Unequal Tee

Weld olets

Long radius
Induction Bends

End Caps

U Bends

37

DDEL

Fittings* : The Process we follow

Each process is followed by a Quality check
Start

RECEIPT OF
BOM

BOM

RAW MATERIAL
IISUE FOR
PRODUCTION

END
CUTTING

INSPECTION

RAW
MATERIAL
CUTTING

INSPECTION

MACHINING

PRODUCTION
PLANNING

INSPECTION

RECEIPT OF
RAW MATERIAL

PLUGGING
&
DRAWING

HEAT
TREATMENT

INSPECTION

INSPECTION/
NDT

SHOT
BLASTING
&
PAINTING

INCOMING
INSPECTION

INSPECTION

PROFILING

INSPECTION

RAW MATERIAL
STORAGE

SAND
FILLING

INSPECTION

FINISHING

INSPECTION

FORMING

FINAL
INSPECTION

End
* Hot Forming Process

38

DDEL

Executed Tonnage ( Last 4 years Annual data )

1500 MT

2000 MT

2007

2009

2008

2010

1800 MT

2400 MT

We manufacture all type of Pipe Fittings i.e. Butt welding, Socket welding & Screwed in various grades of
Carbon Steel, Alloy Steel and Stainless Steel
Seamless up to 28

Welded up to 52
39

DDEL

Contents

Company Overview
Accredit ions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
40

DDEL

Engineering Division : Facility at a glance

Equipped with all latest software technology

The division is presently lead by a highly experienced professional with more than 35yrs of
experience in power equipment manufacturing industry and having worked in power piping
design department for more than 23yrs

11 Dedicated Engineers having varying hands on experience on the following Software's.

AUTOCAD
MODELLING IN PDMS
STRESS ANALYSIS WITH CAESAR II.
PIPE SIZING AND PRESSURE DROP CALCULATIONS USING PIPE FLOW

Access to following reference standards and codes.

ASME B16.5
ASME B16.9
ASME B16.3
ASME B16.11
ASME B16.25
ASME B31.1
ASME B31.3

Pipe flanges and flanged fittings

Butt weld and wrought fittings.
Valves-flanged, threaded & welding end.
Forged and SW fittings.
Butt welding ends.
Power piping.
Process piping
41

DDEL

Capabilities
We are capable to perform the following activities :

Pre - Bid Engineering

Basic Engineering

Detailed Engineering

Review Basic Enquiry

Drawings/ Documents.

Piping Design Criteria

Development.

Layout Engineering

Data Collection from

Client/ Site.

Pipe Sizing Calculations

Conceive proposed Pipe

Routing.
Estimate Bill of Quantities
for proposal Engineering

Materials Engineering
Stress Analysis
Pressure Drop
Calculations

Support Engineering

Piping Material Selection

IBR calculations

Specifications Preparation

42

DDEL

Capabilities ( Contd )

Layout Engineering

Piping General Arrangement Drawings (Plan & Sections)

Material Engineering

Piping Items Procurement Specifications.

Insulation Items Procurement Specifications.

Piping Isometrics
Painting Specifications,
Pipe Shop Fabrication Spools drawings

Piping Bill of Materials

Equipment Nozzle Orientation Plan

Preliminary BOM Issue (Based on P&ID and Plot Plan)

Intermediate (Based on Piping Layout)
Final (Based on Piping Isometrics).
- Pipe Supports Bill of Materials.
- Technical Bid Evaluation for procurement

Review of piping GADs with respect to P&IDs

Review of Vendor Drawings/ Documents

Stress Analysis

Capable to carry out stress analysis using Caeser-II

Pipe Support Engineering

Pipe Support Layouts, Pipe Support Detail

Drawings

Spring Hanger Data Sheets, specifications

Inserts & Loading Drawings (Input to Civil)

latest software package and suggest required changes

in the layout drawings and select proper and optimal
supports to bring the system with in permissible limits

of stresses and forces and moments at the terminals

43

DDEL

Key Highlights
Fabrication of more than 150,000 MT
Fabrication of P91 more than 5000 MT,
Fabrication of WB 36 more than 1500 MT
Bending Machine in operation since 2010 (2 years)
Induction Bends P91 (BHEL) more than 500 Nos.
Induction Bends other than P91 more than 200 ~400 MT
Induction Bends (P91) other than BHEL more than 100 MT
Another Bending Machine ( 8" to 48") being commissioned by July, 2012

44

DDEL

Contents

Company Overview
Accreditions and Approvals

Facilities at a glance
- Pre Fabrication Piping
- Induction Bending
- Pipe Fittings
Engineering Division at a glance

Exhibits
45

DDEL

DDEL in Pictures
Storage Facility

Facility Outlook

DDEL Fabrication Shop

46

DDEL

Men @ Job

Elbow Making Machine

Furnace Heat Treatment

Induction Mandrel
47

DDEL

DDEL Head Office

Client Visit at DDEL

DDEL at Event Boiler 2010

DDEL at ASSOCHAM Conference

48

DDEL

Thank You

Looking forward for a Long term relationship

For Further information please visit our Website

www.deedevelopment.com
49

DDEL

Alstom Power Switzerland

Project Details

Scope of Supply

Material Involved

Power Cycle Piping consisting of

Main Steam, Hot reheat, Cold
Reheat and Feed Water

SA 335 Grade P11, P22 and

P91 and SA106 Grade C

Balance of Plant Piping

CS and SS

870 MW CCPP
Langage Power Station at
Plymouth UK

Back to Projects Page

50

DDEL

Adani Power Limited - India

Project Details

Scope of Supply

Material Involved

5 * 660 MW Super Critical

Thermal Power Station at
Tiroda Maharashtra

Power Cycle Piping consisting of

Main Steam, Hot reheat, Cold
Reheat and Feed Water

SA 335 Grade P11, P22 and

P91 and WB36

2 * 660 MW Super Critical

Thermal Power Station at
Kawai Maharashtra

Power Cycle Piping consisting of

Main Steam, Hot reheat, Cold
Reheat and Feed Water

SA 335 Grade P11, P22 and

P91 and WB36

Back to Projects Page

51

DDEL

GE Energy - USA

Project Details

Scope of Supply

Material Involved

GEs
1st IGCC Project
Duke Energy Edwardsport

Riser and Downcomer large bore

Piping with ASME Stamp

SA 106 Grade B and SA 335

Grade P11

Back to Projects Page

52

DDEL

Lanco Infratech - India

Project Details

Scope of Supply

Material Involved

Lanco Kondapalli Stage II

1*370 MW Power Cycle
Piping

Power Cycle Piping consisting of

Main Steam, Hot reheat, Cold
Reheat and Feed Water

SA 335 Grade P11, P22 and

P91 and SA 106 Grade B/C

Power Cycle Piping consisting of

Lanco Kondapalli Stage III
Main Steam, Hot reheat, Cold
2*370 MW Power Cycle
Reheat and Feed Water
Piping

SA 335 Grade P11, P22 and

P91 and SA 106 Grade B/C

Back to Projects Page

53

DDEL

Mitsubishi Heavy Industries Ltd. - Takasago Japan

Project Details

Plant Piping for 2* 800 MW

Nong Saeng CCPP Project at
Thailand

Scope of Supply

Material Involved

Plant Piping

SA 106 Grade B/C, SA 335

Grade P11/P22/P91 and SA
312 Grade TP304
( Approximately 1750 MT )

Back to Projects Page

54