Aplication Pipe and Tube - Nippon Steel
Aplication Pipe and Tube - Nippon Steel
Aplication Pipe and Tube - Nippon Steel
Contents
Introduction 1
Integrated Production of Pipe 2
Pipe Making Facilities and Product Sizes 4
Size Ranges 5
Available Grades 6
Applications 8
Manufacturing Processes 14
Secondary Processing of Pipe 25
Pipe Mills at Nippon Steel 29
Research and Development 30
Production Control and Quality Assurance 32
NIPPON STEEL PIPE & TUBE NIPPON STEEL PIPE & TUBE NIPPON STEEL PIPE & TUBE
1
Manufacture of high-quality pipe begins with the best materials, and that is why
Nippon Steel manufactures the materials that the companys pipe products are made
from. The companys extensive experience in all phases of steel production....degass-
ing, desulfurizing, rolling, etc....ensures that the finest billets, blooms, plates and sheets
available are produced to Nippon Steels own rigorous quality standards and for the
appropriate international standard to suit the intended application.
Piping
Pipe Pile
Line Pipe
Oil Country
Tubular
Goods
Boiler & Heat-
Exchanger
Tubes
Structural
Pipe & Tube
Mechanical
Tube
Manufacturing
Process
Small-diameter
Seamless
Hot Extrusion
Medium-diameter
HF-ERW
Small-diameter
HF-ERW
Continuous Butt
Weld
UO Process
Longitudinal Weld
Spiral Weld
Bending Roll Process /
Press Bending Process
Longitudinal Weld
Introduction
Nippon Steel, one of the worlds largest steelmakers was formed in 1970 through the
merger of Japans two leading and longest-established steel makers. The company
supplies a complete range of steel products worldwide, and one of its most important
products is pipe.
Nippon Steel has the total equipment capability necessary to serve your every
need and purpose. We produce nearly 1.5 million tons of pipe annually, and in doing
so employ stringent quality control systems so that every Nippon Steel pipe gives you
added assurance of quality. Our ongoing research efforts constitute a further
assurance of future improvements and innovations to meet new and increasingly
severe quality demands. Today, Nippon Steel pipe is serving on big jobs of all kinds
throughout the world.
Here are our pipe manufacturing methods and the main applications for pipe pro-
ducts:
3 2
Coal Coking plant
Blast furnace
Charging
molten iron
Torpedo car
Charging
scrap
Oxygen
blow
Basic oxygen
furnace
Vacuum
degassing
equipment
Continuous
casting
Hot rolling mill
Temper mill Pickling line
Roughing
mill
Continuous
reheating furnace
Cold rolling mill
Aluminum-coating line
Electrolytic
cleaning line
Annealing furnace
Annealing and pickling line Skin-pass rolling mill Coil polishing line Stainless steel coil Coil grinding line
Coil build-up line Annealing and pickling line
Sendzimir mill
Annealing furnace Temper mill
C.A.P.L.
Hot coil
Pickleol
hot coil
ALSHEET
coil
Reheating furnace Roughing mill Finishing mill Accelerated cooling Plate
Round billet Rolling mill
Reheating furnace Blooming mill Billet mill Ultra sonic test Magnaflux flaw detector Billet grinder
Limestone
Sintering plant Iron ore
ZINKOTE
,
DURPAINT
coil
Electrogalvanizing line
Integrated Production of Pipe
Pipe can be manufactured in many ways. At Nippon Steel, pipe is made by the sub-
merged arc weld (SAW), high frequency electric resistance weld (HF-ERW), continuous
butt weld (CW) and seamless processes.
As the flow chart, Nippon Steel pipe is made from plates, hot coils, cold coils, bil-
lets and blooms manufactured by the company. Nippon Steels technology is utilized
for and close control is applied over, the manufacturing processes and product quality
throughout the entire sequence of operations involved, from ironmaking and steelmak-
ing to the pipe-making materials and finished products. Also, Nippon Steels research
and development activities have the benefit of constant feedback from these individual
operations.
All the foregoing ensure that each pipe produced at Nippon Steel meets the cus-
tomers requirements to the letter.
UO pipe mill
Bending roll mill and Press bending mill
High Frequency electric resistance weld pipe mill
Spiral pipe mill
Continuous butt weld pipe mill
Hot extrusion
Seamless
Pipe
Seamless
Pipe,
Seamless
Stainless
Steel Pipe
Large-
diameter
Pipe
(SAWPipe)
CW Pipe
HF-ERW
Pipe
Plug mill
4
Pipe Making Facilities and Product Sizes
Mills
Mannesmann-Plug
Mill Stretch Reducer
Ugine-Sejournet
Hot Extrusion
2 HF-ERW
4 HF-ERW
4 HF-ERW
4 HF-ERW
+ Stretch Reducer
16 HF-ERW
24 HF-ERW
Continuous Butt Weld
UO Process
Longitudinal Weld
Spiral Weld
Spiral Weld
Bending Roll Process /
Press Bending Process
Longitudinal Weld
Hot finish
Cold finish
Hot finish
Cold finish
Induction
Induction
Induction
Induction
Thermatool
Thermatool
Location
of Mills
Tokyo
Hikari
Nagoya
Kimitsu
Nagoya
(Subsidiary
company)
Hikari
Nagoya
Hikari
Kimitsu
Kimitsu
Yawata
Kimitsu
Related
company
Seamless
HF-ERW
CW
SAW
Size: Outside diameter (inch)
10 12 14 16 20 56 200 8 6 4 2 1
18 56
16 64
16 100
16 200
0.850 2.559
0.750 4.500
1.492 4.500
0.840 4.500
1.315 6.625
0.236 6.625
1.660 6.890
0.236 6.000
16 4.500
8.625 24
0.543 2.382
(Pipe In Coil)
5
Size Ranges
10 20
200
180
160
140
120
100
80
60
40
20
30 40 60 50
Wall thickness
O
u
t
s
i
d
e
d
i
a
m
e
t
e
r
i
n
c
h
70 90 80 100
3.5 3.0 2.5 2.0 1.5 1.0 0.5 4.0
SAW Pipe
Seamless Pipe
ERW & CW Pipe
Stainless Pipe (Hot extruded)
mm
inch
2 4
24
20
16
12
8
4
6 8 12 10
Wall thickness
O
u
t
s
i
d
e
d
i
a
m
e
t
e
r
i
n
c
h
14 18 16 20
0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.8
mm
inch
2 6
8
7
6
5
4
3
2
1
10 14 22 18
Wall thickness
O
u
t
s
i
d
e
d
i
a
m
e
t
e
r
i
n
c
h
26 34 30 42
1.4 1.2 1.0 0.8 0.6 0.4 0.2 1.6
38
mm
inch
2 6 10
Wall thickness
O
u
t
s
i
d
e
d
i
a
m
e
t
e
r
i
n
c
h
14 30
0.8 1.0 0.6 0.4 0.2 1.2
22 26 18
mm
inch
8
7
6
5
4
3
2
1
Straight Seam Pipe
(Bending roll process /
Press bending process)
Spiral
Seam
Pipe
Straight Seam Pipe (UO process)
CW
ERW
Cold finished
Hot finished
Hot finished
Cold finished
Notes: For sizes not listed in these figures, please contact Nippon Steel.
6
Available Grades
Nippon Steel continues its development and improvement efforts so as to be able to
manufacture pipe to any designated standard to fulfill your specific requirements.
Some representative standards and specifications are tabulated below along with the
corresponding manufacturing processes employed at Nippon Steel to ensure com-
pliance; the company manufactures pipe to other international standards, too.
Also available are Nippon Steel standard for special use such as Weldable High
Tensile Strength Pipe, All-weather High Tensile Strength Pipe, Anti-abrasion High
Tensile Strength Pipe and Sea Water Resistant Pipe.
When you require quality and reliability, Nippon Steel has the pipe products you
need.
Seamless Pipe Welded Pipe
Standard
API (American Petroleum Institute)
5L
5CT
5D
2B
AS (Australian Standard)
1836
ASTM (American Society for Testing and Materials)
A53
A106
A135
A178
A213
A214
A250
A252
A268
A269
A312
A333
A334
A335
A376
A423
A513
AWWA (American Water Works Association)
C200
C203
GOST (USSR Specifications)
10704
10705
Line Pipe
Casing and Tubing
Drill Pipe
Fabricated Structural Steel Pipe
Welded Steel Tubes for Pressure Purposes
Black and Hot-Dipped Zinc-coated (galvanized) Welded Seamless Steel Pipe
Seamless Carbon Steel Pipe for High-Temperature Service
Electric Resistance Welded Steel Pipe
Electric-Resistance-Welded Carbon Steel and Carbon-Manganese Steel Boiler Tubes
Seamless Ferritic and Austenitic Alloy-Steels Boiler Superheater and Heat-
Exchanger Tubes
Electric-Resistance-Welded Carbon Steel Heat-Exchanger and Condenser Tubes
Electric-Resistance-Welded Carbon-Molybdenum Alloy Steel Boiler and
Superheater Tubes
Welded and Seamless Steel Pipe Piles
Seamless and Welded Ferritic and Martensitic Stainless Steel Tubing for
General Service
Seamless and Welded Austenitic Stainless Steel Tubing for General Service
Seamless and Welded Austenitic Stainless Steel Pipes
Seamless and Welded Steel Pipe for Low-Temperature Service
Seamless and Welded Carbon and Alloy-Steel Tubes for Low-Temperature Service
Seamless Ferritic Alloy-Steel Pipe for High-Temperature Service
Seamless Austenitic Steel Pipe for High-Temperature Central-Station Service
Seamless and Electric-Welded Low-Alloy Steel Tubes
Electric-Resistance-Welded Carbon and Alloy Steel Mechanical Tubing
Steel Water Pipe
Standard for Coal-Tar Enamel Protective Coating for Steel Water Pipe
Electric-Welded Steel Tubes
Specification for Delivery of Electric-Welded Steel Tubes of 8~530 mm in diameter
CW
ERW
MM
HE
BR
SP
UO
7
Seamless Pipe Welded Pipe
Standard
BS (British Standards)
1387
3059
3600
3601
3602
3603
DIN (Deutsche Normen)
1626
1629
2440
2441
17172
17175
17177
17440
ISO (International Organization for Standardization)
65
3183
JIS (Japanese Industrial Standards)
G 3441
G 3442
G 3443
G 3445
G 3446
G 3451
G 3452
G 3454
G 3455
G 3457
G 3458
G 3459
G 3460
G 3461
G 3462
G 3463
G 3464
G 3472
G 3473
LR (Lloyds Register of Shipping)
Pressure Pipes
Boiler and Superheater Tubes
DNV (Det Norske Veritas)
OS-F101
CW
ERW
MM
HE
BR
SP
UO
Steel Tubes and Tubulars
Steel Boiler and Superheater Tubes
Dimensions and Masses per Unit (Length) of Welded and Seamless Steel
Pipes and Tubes for Pressure Purposes; Metric Units
Steel Pipes and Tubes for Pressure Purposes; Carbon Steel with Specified
Room Temperature Properties
Steel Pipes and Tubes for Pressure Purposes; Carbon Steel: High Duties
Steel Pipes and Tubes for Pressure Purposes; Carbon and Alloy Steel:
Low Temperature Duties
Welded Steel Pipes in Unalloyed and Low Alloy Steels for Supply Purposes
Seamless Tubes in Unalloyed Steels
Steel Tubes Medium-Weight Suitable for Threading
Steel Tubes Heavy-Weight Suitable for Threading
Steel Pipes for Pipelines for the Transport of Combustible Fluids and Gases
Seamless Steel Tubes for Elevated Temperature
Electrically Resistance or Induction Welded Steel Tubes for Elevated Temperature
Stainless Steels
Steel tubes suitable for screwing in accordance with International Standard ISO 7
Steel pipe for pipelines for petroleum and natural gas
Alloy Steel Tubes for Machine Purpose
Galvanized Steel Pipe for Water Service
Coating Steel Pipe for Water Service
Carbon Steel Tubes for Machine Structural Purpose
Stainless Steel Tubes for Machine and Structural Purpose
Deformed Pipe for Coating Steel Pipe for Water Service
Carbon Steel Pipes for Ordinary Piping
Carbon Steel Pipes for Pressure Service
Carbon Steel Pipes for High Pressure Service
Electric Arc-Welded Carbon Steel Pipe
Alloy Steel Pipes
Austenitic Stainless Steel Pipes
Steel Pipes for Low-Temperature Service
Carbon Steel Boiler and Heat-Exchanger Tubes
AIloy Steel Boiler and Heat-Exchanger Tubes
Stainless Steel Boiler and Heat-Exchanger Tubes
Steel Heat-Exchanger Tubes for Low Temperature Service
Electric Resistance Welded Carbon Steel Tubes for Automobile Structural Purposes
Carbon Steel Tubes for Cylinder Barrels
Submarine Pipeline Systems
Notes: MM: Mannesmann Method Seamless HE: Hot Extrusion ERW: Electric Resistance Weld CW: Continuous Butt Weld UO: UO Process Longitudial Weld
SP: Spiral Weld BR: Bending Roll Process / Press Bending Process Longitudial Weld
8
Applications
Oil Country Tubular Goods
Casing string make up
Drilling rig
Drilling rig, casing string make up
Casing arrived in Alaska
9
Line Pipe
Pipeline in arctic area
Pipeline under construction in Alaska
Laying of HI-PL (Polyethylene-Coated) Pipe
Submarine pipeline laying
Submarine pipe laying by Kuroshio2
11 10
Foundation work of bridge, inland sea
Pipe pile driving for seaberth construction Roof trusses SLP is available for reclaimed lands and areas with thick alluvial deposits
Production platform Pipes for electric transmission tower
Structural Pipe & Tube
NS-PAC used as pier piles in japan
[Steel pipe sheet piles] driving for harbor construction
12
Stainless super-heater tubes in a power boiler
Furnace wall tubes in a power plant Large heat-exchangers in refinery
Boiler and Heat-Exchanger Tubes
13
Pipes for automobiles
Pipes for Plants and Others
Piping in building
Piping for super tanker
Pipes for hydraulic cylinder and piping
Piping in petrochemical plant
14
Manufacturing Processes
Seamless Pipe Process
We use billets that have undergone tapping, casting, blooming, and rolling in our
Kimitsu Works to produce seamless steel pipes and tubes by the Mannesmann
plug mill method. Tokyo Works produces high-quality hot seamless steel pipes
and tubes, using piercing mills, rolling mills, reeling mills, sizing mills, and stretch
reducers on billets heated to high temperatures. We also produce high-grade
cold products through cold processes using cold drawing equipment and a wide
range of heat treatment furnaces in order to satisfy the continuously rising
expectations of customers.
Stretch reducing mill Nondestructive inspection device Heat treatment furnace
Billet heating furnance Rolling mill (plug mill) Piercing mill
Reeling Rolling Piercing
Sizing Reheating Stretch reducing
15
Hot Extrusion Process
Stainless and high alloy steel tubes which are difficult to produce by other meth-
ods, are manufactured by the hot extrusion process at Hikari Works.
This process, put in service at Hikari in 1957 under a technical license from
CEFILAC, France, extrudes a heated billet.
Those grades which demand dimensional precision or attractive surface
appearances to suit specific purposes are additionally subjected to cold drawing
or cold Pilger-processing, then undergo NDT inspections to assure the quality of
the product.
Heated billet during extrusion
Hot extrusion mill
17 16
HF(High Frequency) ERW Process
High frequency electric resistance welder
Welding condition monitoring system
Ultrasonic tester Hydrostatic tester
Seam normalizer Forming rolls
A hot coil is first slit to a prescribed width, formed into a
round shape by forming rolls then continuously electric-
resistance welded.
Nippon Steels HF-ERW pipe is much different from that
of conventional ERW. Nippon Steel-developed weld condi-
tion monitoring and controlling equipment watches over
welding conditions at every second to prevent weld defects.
And not only the weld but also the base metal of pipe is
carefully inspected using UST and other equipment follow-
ing hydrostatic test.
A total of 8 HF-ERW pipe mills are operating at the
Hikari, Nagoya and Kimitsu Works. Thus, Nippon Steel can
fill orders for pipe for all applications..........line pipe, general
piping, structural pipe, pipe piling, boiler tubes, heat-
exchanger tubes, OCTG and others in the size range of
19.0 mm to 609.6 mm (24 inches) in outside diameter.
Nippon Steel can produce high-quality, high-grade pipe
with great efficiency. Some of the high-grade pipe include:
API X80 Iine pipe, and low-alloy steel boiler tubes.
Uncoiling Forming Electric resistance welding
19 18
CW Process
Nippon Steels continuous butt weld (CW) pipe mill is located at Kimitsu Works.
The CW process is suited to efficient and large-volume production of general
piping pipe of good quality. Available sizes range from 0.840 inch to 4.5 inches.
Zink coating line CW pipe mill
Hydrostatic tester
Rotary hot saw Heating furnace
Forming, Welding, Reducing Reheating
21 20
Nippon Steel makes UO double SAW straight seam pipe at
the Kimitsu Works; outside diameters range from 18 to 56
inches and wall thicknesses from 0.25 inch to 1.57 inches.
In UO pipe production, a plate is press-formed into a
U-shape and then an O-shape, after which the seam is
automatically submerged-arc welded on both the inside and
the outside, followed by mechanical expanding and, finally,
hydrostatic testing, NDT and other essential inspections.
The quality of Nippon Steel line pipe has been proven in
severe service environments around the world such as, for
example, in Alaska, Siberia and other frigid regions, and in
the North Sea, Black Sea and Mediterranean Sea where line
pipe must function in deep waters under punishing condi-
tions. In other words, Nippon Steel has supplied line pipe for
projects where the quality of these products is the key to the
success of the job.
The high-efficiency UO pipe mill at Kimitsu is capable of
producing annually about 1,000 miles of pipe, mainly line
pipe but also including pipe piling and water conduit line
pipe. The mill has auxiliary facilities for coating and lining
pipe with plastic, bitumen and other materials to meet specif-
ic customer requirements.
UO Process
O-ing press
U-ing press
Inside submerged arc welder Outside submerged arc welder
Edge miller
Automatic marking equipment
Longitudinal seam welding O-ing press U-ing press Crimping press
23 22
Spiral Weld Process
Nippon Steel has three spiral-weld pipe mills at Yawata and Kimitsu Works, both
of which manufacture large-diameter pipe from hot coils. These SAW pipe pro-
ducts range from 16 to 100 inches in outside diameter and from 1/4 to 1 inch in
wall thickness.
The spiral-weld pipe mill produces APl 5L line pipe, general piping, water
pipe, pipe piling, structural pipe and other types.
Ultrasonic tester Outside welder Online cut-off machine
General view of a spiral-weld pipe mill
Forming, inside and outside welding Cutting off
Skelp butt welding
24
Bending Roll Process / Press Bending Process
If you need extra large-diameter pipe or extra heavy-walled pipe beyond the size
range of the UO pipe mill, such as high-tensile strength grades for offshore pro-
duction platforms, Nippon Steel can supply straight-seam SAW pipe produced
by the bending roll process and press bending process in the size range of 16 to
200 inches in outside diameter, and 1/4 to 4 inches in wall thickness. Moreover,
these pipe products can be produced to API 2B specifications, AWWA (American
Water Works Association) and API 5L specification requirements for large-
diameter water mains, as well as other standards.
3-roll bender
MACRO structure of muIti-pass welding (WT:
90 mm) offshore structural pipes (see upper
photo) are fabricated with sophiscated weld-
ing technique.
3-roll bender Press bending
25
Secondary Processing of Pipe
A great variety of processing is needed depending on the intended application of the
pipe. Nippon Steel is fully equipped to perform the following processing.
Secondary Processing of Pipe
Water pipe
Internal coating
(1) Coal-tar epoxy lining
(2) Epoxy lining
(3) Polyethylene lining
(4) Vinyl chloride lining
External coating
(1) Polyethylene coating
(2) Coal-tar epoxy coating
Line pipe (oil, gas)
Internal coating
(1) Two-component epoxy lining
(2) Phenolic epoxy lining
External coating
(1) Polyethylene coating
(2) Polypropylene coating
External coating
(1) Polyethylene coating (NS-PAC)
(2) Urethane elastomer coating (NS-PAC)
(3) Special bitumen compound
(4) Coal-tar epoxy, zinc rich paint plus, etc.
Others
Galvanized pipe (internal/external)
Aluminized pipe (internal/external)
Pipe piling
Steel pipe sheet piles
Conductor pipe vetco joint, etc.
Outside diameter (mm)
89.1 or more
89.1 or more
21.7~114.3
21.7~355.6
21.7~1,524
89.1~2,250
89.1~1,420
34~508
21.7~1,524
216.3~1,524
168.3~1,524
406.4~1,800
168.3~2,250
168.3~4,064
21.7~1,800
21.7~508
168.3~2,800
406.4~2,800
~914.4
Length (mm)
4,000~12,200
4,000~12,200
5,500
5,500
5,000~18,300
5,000~18,600
9,000~12,800
5,000~12,200
5,000~18,300
11,000~18,600
5,000~34,500
3,600~12,000
5,500~6,300
~100,000
~100,000
Kind of pipe
Size range
Item
Coating
Fabrication
26
Polyethylene-coated pipe
Line pipe performance testing apparatus
On request, pipe is available with coat-
ings and linings for corrosion protec-
tion, reduction of friction of the fluid,
and other purposes.
Water
cooling
Holiday inspection
Final inspection
Polyethylene coating
Adhesive coating
Pre-heating
Blasting
Blasting
Primer
Primer
Adhesive
coating
Polyethylene coating
Polyethylene
coating
Holiday inspection
Pre-heating
(1) Longitudinal extrusion process
(2) Side-extrusion process
Two-component epoxy lined pipe
Coating and Lining
27
Fabrication yard
Handling of extra-long pipe
Fabrication of Pipe Piling
Pipe is manufactured in the size range
of 168.3 mm to 2,800 mm in diameter.
Nippon Steel manufactures extra-long
pipe piling up to 100 m in length by
means of arc welding.
Part of Nippon Steels sheet piling
series, steel pipe sheet piles are in wide
use in harbor construction and other
large-scale quay and embankment con-
struction projects.
28
NS-PAC urethane elastomer coated steel pipe sheet piles
NS-PAC polyethylene coated steel piles
NS-PAC