Surya MFR
ERW Tube Mill Manufacturer
ERW Tube Mill
Lucknow, Uttar Pradesh, Bharat
Project & Engineering Partner with Surya MFR Tube Mills Pvt Ltd
Sonipat, Haryana, Bharat
Since: 03 January 2024
Proposal No.: MX-ERW-PROJECT-2025
Validity: 30 Days from Date of Issue
1. Executive Summary
Project Objective
To ensure safe, efficient, and rapid commissioning of your ERW tube mill with stable production quality, minimal startup issues, and maximum operational efficiency.
Scope of Services
Erection Services
Complete mechanical, electrical, and process supervision with precision alignment and quality control throughout erection phase.
Commissioning Services
Structured dry → wet → trial → stabilization commissioning ensuring stable mill performance and product quality validation.
Training & Handover
Comprehensive operator and maintenance staff training with SOP documentation and troubleshooting guides.
Annual Maintenance Support
Long-term AMC covering periodic health audits, preventive maintenance, and breakdown support for sustained operational excellence.
Key Deliverables
- Detailed erection plan with daily progress reports
- Certified alignment and installation verification reports
- Complete commissioning protocols and SOPs
- Trial production report with quality metrics
- Performance acceptance certificate
- Operator & maintenance training modules
- Annual health audit reports under AMC
- Continuous process optimization recommendations
Why MetaTechX?
Proven Expertise
20+ years of steel industry experience with 30+ tube mill commissionings successfully executed
Fast Commissioning
Structured methodology achieves 30-40% faster commissioning than industry average
Quality Assured
SOP-driven operation ensures 85%+ quality specifications met in first month
2. Detailed Scope – Erection Services
MetaTechX Engineers will provide complete supervision and technical support for all erection activities of your ERW tube mill.
2.1 Pre-Erection Phase
Drawing Study & Planning
- Detailed review of mechanical, electrical, and process drawings
- Identification of critical erection sequences and dependencies
- Review of equipment technical specifications and receiving inspection checklist
- Preparation of erection master plan with detailed methodology
Site Readiness Assessment
- Civil foundation verification (levels, squareness, load-bearing capacity)
- Utility infrastructure audit (electrical supply, water, compressed air)
- Safety compliance and work environment preparation
- Identification of storage areas and crane/lifting requirements
2.5 Quality Checkpoints
| Checkpoint | Equipment/System | Acceptance Criteria |
|---|---|---|
| Foundation Leveling | All stands and baseframes | ±2 mm deviation tolerance |
| Roll Alignment | Forming & sizing mill rolls | ±1 mm parallelism |
| Spindle Runout | Forming mill spindles | < 0.1 mm TIR |
| Drive Synchronization | Motor + gearbox + transmission | Smooth, vibration-free operation |
| Electrical Safety | All electrical connections | Megger > 10 MΩ resistance |
3. Detailed Scope – Commissioning Services
Our commissioning follows a proven 4-phase methodology: Dry Run → Wet Commissioning → Trial Production → Performance Stabilization.
Phase 1: Dry Run Commissioning (Days 1-5)
Mechanical Verification
- All mechanical systems checked for proper movement without load
- Gearbox oil circulation and cooling system operation
- Bearing temperature and vibration monitoring
Electrical Control Testing
- PLC/DCS power-up and initial programming verification
- Sensor functionality testing (pressure, temperature, speed)
- Control logic dry run (no load movement)
Phase 4: Performance Stabilization (Days 21-25)
Final Optimization & Handover Preparation
- Fine-tuning of weld parameters for consistent quality
- Speed optimization for maximum TPH with quality assurance
- SOP validation based on actual operating experience
- Signing of commissioning completion certificate
4. Our Commissioning Expertise
Our team brings hands-on experience in commissioning high-speed ERW tube mills across various configurations and capacities. Below are representative images from similar tube mill commissioning projects:
Commissioning Capabilities
- Round Tubes: up to 20″ OD (Automotive, general engineering, furniture applications)
- Square/Rectangular: Various sections (Structural, construction, infrastructure use)
- Production Rates: Up to 25 TPH (High-speed and heavy-duty mills)
- Material Range: Mild steel, HSLA, stainless steel (Per IS1239 and customer specifications)
- Quality Standards: ISO 9001 certification, stringent QA/QC processes
5. Training & Knowledge Transfer
Successful mill operation depends on skilled operators and maintenance personnel. We provide comprehensive, hands-on training programs tailored to your team’s requirements.
5.1 Operator Training Program
Duration & Schedule
5-7 days of intensive on-the-job training during commissioning phase.
Training Modules
- Mill Operation Fundamentals: How each system works, interrelationships, safety protocols
- Control System Operation: PLC/DCS basics, panel operation, emergency procedures
- Standard Operating Procedures (SOPs): Step-by-step normal operation, parameter adjustment
- Quality Monitoring: How to measure OD, wall thickness, ovality acceptance criteria
5.3 Training Materials Provided
- Operator Training Manual (20-30 pages with diagrams and photos)
- Maintenance Training Manual (15-20 pages with maintenance schedules)
- Standard Operating Procedures (SOP) Documents
- Breakdown Diagnostic Flowcharts
- Safety & Emergency Response Guide
- Video recordings of key procedures for ongoing reference
6. Annual Maintenance Contract (AMC)
Long-term partnership with MetaTechX ensures your tube mill operates at peak efficiency with minimal unplanned downtime and sustained productivity growth.
6.2 Annual AMC Timeline & Activities
| Quarter | Focus Area | Key Activities | Deliverables |
|---|---|---|---|
| Q1 (Jan-Mar) | Post-Winter Performance | Health audit, lubrication system check, bearing inspection, motor efficiency | Q1 Health Report |
| Q2 (Apr-Jun) | Mid-Year Optimization | Alignment verification, drive analysis, roll wear study, parameter review | Q2 Optimization Report |
| Q3 (Jul-Sep) | Peak Season Support | Preventive maintenance, cooling system verification, production ramp support | Q3 Performance Report |
| Q4 (Oct-Dec) | Annual Assessment & Planning | Comprehensive audit, year-end KPI review, planning for next year | Annual Review + Next Year Plan |
7. Commercial Terms & Pricing
7.2 Cost Breakdown (Fixed-Price Model)
| Cost Head | Description | Estimated Value (₹) | Final Quoted Value (₹) |
|---|---|---|---|
| Engineering Services – Erection | Supervision, planning, alignment, daily reports (30-45 days on-site) | 5,50,000 | 5,00,000 |
| Engineering Services – Commissioning | Dry run, wet commissioning, trial production, parameter optimization (20-25 days) | 2,00,000 | 1,50,000 |
| Training & Documentation | Operator & maintenance training, SOP preparation, training materials (5 days) | 1,00,000 | 50,000 |
| Travel & Accommodation | Travel, lodging, local transport (40 days × approx rate) | 1,00,000 | 75,000 |
| Documentation & Reporting | Engineering reports, certificates, video documentation | 50,000 | 25,000 |
| TOTAL (Before Taxes) | 10,00,000 | 8,00,000 | |
7.3 Annual Maintenance Contract Pricing
| AMC Model | Annual Fee (₹) | On-Site Days/Year | Emergency Support |
|---|---|---|---|
| Basic Care (Model A) | 6,00,000 | 12 days (3/quarter) | Remote only |
| Comprehensive (Model B) | 9,00,000 | 36 days (9/quarter) | 24-hour response |
| Excellence (Model C) | 18,00,000 | 120 days (30/quarter avg) | Dedicated engineer |
7.4 Payment Schedule
| Milestone | Payment % | Timing / Condition |
|---|---|---|
| Advance Payment | 60% | Upon agreement signature and PO from customer |
| Progress Payment | 35% | Upon completion of erection phase (before commissioning starts) |
| Final Payment | 5% | Upon commissioning completion and performance acceptance by customer |
| AMC Payment | 100% | After commissioning of project and AMC acceptance by customer |
All payments to be made by cheque/bank transfer to MetaTechX Engineers LLP account. Invoice will be issued with GST as applicable.
8. Terms & Conditions
8.1 General Conditions
Proposal Validity
This proposal is valid for 30 days from the date of issue. After 30 days, costs and team availability may change. Please confirm acceptance within this timeframe.
8.2 Confidentiality & Data Protection
MetaTechX Engineers LLP commits to maintaining strict confidentiality of:
- Engineering designs, drawings, and technical specifications
- Production parameters, process data, and performance metrics
- Quality procedures, SOPs, and operational know-how
- Commercial information and contractual details
All proprietary information is for project delivery purposes only and will not be shared with third parties without explicit written consent.
8.5 Force Majeure
MetaTechX is not liable for delays or failures caused by circumstances beyond our control, including natural disasters, pandemics, political instability, strikes, or customer-caused delays (incomplete site readiness, missing utilities, poor equipment condition).
9. Project Implementation Steps
How We Proceed After Your Approval
You review this proposal and raise any questions or customization requests. We schedule a discussion call to finalize scope, timeline, and pricing.
Based on discussion, we prepare a detailed SOW specifying scope, deliverables, timeline, and cost breakup. Both parties sign the SOW.
You issue PO for agreed amount. We invoice 50% advance upon PO receipt. Payment processed, project mobilization begins.
Mechanical erection, electrical installation, alignment verification. Daily progress reports. First payment milestone (40%) due at erection completion.
Commissioning completion certificate signed. Final 10% payment due. Transition to AMC support initiation.
Next Immediate Actions
- Review this proposal – Ensure scope aligns with your project needs
- Send feedback/clarifications – Any technical questions or customization requests
- Schedule discussion call – Let’s finalize details with your project team
- Issue Purchase Order – Once approved, PO initiation begins the engagement
Contact & Commitment
Get In Touch – Let’s Make It Happen
Kolkata, West Bengal
India
+91 9676849859
WhatsApp: +91 7323000303
LinkedIn: metatechx-engineers
Our Commitment to You
“We don’t just commission tube mills. We build lasting partnerships that drive your success.”
Why Partner with MetaTechX?
- Proven Track Record: 30+ successful tube mill commissionings
- Expert Team: Hands-on metallurgical and engineering expertise
- Quality Focus: Structured methodology ensuring stable production
- Long-term Support: AMC services for sustained operational excellence
Ready to transform your ERW Tube Mill project?
Contact us today to discuss your requirements and explore how MetaTechX can be your trusted partner.
📧 Email us or call – Let’s get started!
MetaTechX Engineers LLP
Engineering Excellence Since 2016
In Technical Partnership with Surya MFR ERW Tube Mill
© 2025 MetaTechX Engineers LLP. All Rights Reserved. | Confidential & Proprietary
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