Project Background
The Kazakhstan Soda Ash Plant, located in the Zhambyl Region, is a landmark industrial project within the framework of regional capacity cooperation, significantly boosting local chemical manufacturing and economic development. The engineering, procurement, and construction (EPC) are managed by the renowned international giant CAMCE.
To connect the plant with external water, gas, and process fluid systems, a robust and highly dependable utility pipeline infrastructure was required. For this critical external pipeline network, Allland Steel was entrusted to manufacture and deliver 2,300 tons of high-grade, multi-layer coated ERW steel pipes compliant with international energy standards.
Client Challenge
- Harsh Continental Climate: The Zhambyl Region experiences severe seasonal temperature drops and complex soil geology. The external pipelines require superior external corrosion protection—specifically a 2.2mm 3PE (Three-Layer Polyethylene) coating combined with a 300μm FBE layer—to withstand thermal expansion, mechanical impact, and soil stress.
- Heavy Wall Thickness for Medium Diameter: Manufacturing an ERW pipe with an outer diameter of 323.9mm and a heavy wall thickness of 12.7mm requires exact forming capabilities. Maintaining uniform weld seam strength and eliminating residual stress during the high-frequency welding process is essential for high-pressure safety.
- Strict EPC Logistics Schedule: As an international EPC project managed by CAMCE, material delivery had to synchronize perfectly with the field piping layout schedule. Any delays in manufacturing or overland cross-border transport to Kazakhstan would stall the overall plant commissioning.
Our Solution and Results
- Precision ERW Manufacturing and Advanced Coating: Allland Steel utilized its fully automated ERW production lines to process high-strength X52M hot-rolled coils. The weld seams underwent online heat treatment (seam annealing) to match the base metal’s toughness. Our coating facility then applied the dual-layer system (FBE + 3PE), ensuring a seamless, pinhole-free barrier against environmental degradation.
- Comprehensive Quality Verification: To meet CAMCE’s strict quality standards, the 2,300 tons of pipes underwent full-body non-destructive testing (NDT), including ultrasonic and electromagnetic inspections of the weld area. Hydrostatic testing was conducted on every pipe to verify pressure rating integrity, alongside rigorous adhesion and thickness checks on the 3PE layer.
- Efficient Cross-Border Logistics: We coordinated a seamless land-freight logistics plan from our facility directly to the project site in Kazakhstan. The pipes were systematically loaded and secured to protect the external 3PE coating and pipe bevels during long-distance shipping, achieving a successful and timely delivery milestone.
Project Outcomes
The successful delivery of the API 5L X52M ERW steel pipes provided a durable and secure foundation for the external pipeline networks of the Kazakhstan Soda Ash Plant. CAMCE highly commended Allland Steel for our technical compliance, rigorous factory testing, and professional supply chain execution. This successful collaboration strengthens Allland’s position as a premium piping supplier for large-scale industrial projects across Central Asia and the Belt and Road initiative.
