8/16/2019 50years[1]

http://slidepdf.com/reader/full/50years1 1/6

576

Danieli W+K IndustrieTechnik:50 years of experience in welded pipe technology

W+K IndustrieTechnik has taken over the operating units for pipe mill technology,building component technology and customer service from the ThyssenKrupp Group

(formerly Hoesch Maschinenfabrik Deutschland AG). The business activitiesdiscontinued there have been continued at W+K IndustrieTechnik.

Edited by Nardi Jacopo[ Danieli W+K ]

Danieli W+K

Comprehensive experience from the fields ofengineering, construction and commissioningof machinery and equipment, indispensableproduction know-how, highly qualifiedemployees as well as a number of patents,are qualities that W+K IndustrieTechnikmakes widely available to its customers.Since April 2007 W+K IndustrieTechnik hasjoined Danieli and the new division ofDanieli W+K was born.The integration into the group strengthenedthe company’s market position. The synergywith the proven Danieli network/system andfacilities reflects greater flexibility andsuitable leanness to maintain itscompetitiveness in a market that becomesmore demanding and challenging every day.

The main products

Here follows the main products provided by

Danieli W+K:> Longitudinal Submerged Arc Welded (LSAW)

pipe mill up to 64”, devoted to the production

of steel pipes for linepipe applications (ducts

for combustion fluids, oil-and-gas transfer)

according to all the main International

standards, such as API 5L, EN 10208 o

AWWA. Outside diameter range: 24", 64"

(610.0 mm, 1,626.0 mm). Main equipments:

plate edge milling machines, plate edge

prebending installations, 3-roll bending

machines, pipe forming presses, continuous

pipe tack-welding stands, SAW stands for final

inside and outside submerged-arc welding,

pipe straightening and calibration presses, and

complete finishing lines according to the final

pipe destination.> Spiral pipe mill up to 100”, devoted to theproduction of steel pipes for linepipe (ducts for

combustion fluids, oil, gas and water transfer)

according to all the main International

standards, such as API 5L, EN 10208, ISO

3183 o AWWA. Outside diameter range: 16",

100" (406.9 mm, 2,540.0 mm). Main

equipments: spiral pipe welding machines –

conventional, spiral pipe forming and tack-

welding machines – two-step production

process, SAW stands for final submerged arc

welding – 2-step production process, complete

finishing lines according to the final destination

of the pipe products.

> Electric Resistance Welding (ERW) pipe mill

up to 24”, devoted to the production of steel

pipes for linepipe (ducts for combustion fluids,

oil-and-gas transfer) according to all the mainInternational standards, such as API 5L, API 5

CT o EN 10208. Outside diameter range:

1,660", 24" (42.16 mm, 610.0 mm). Main

8/16/2019 50years[1]

http://slidepdf.com/reader/full/50years1 2/6

8/16/2019 50years[1]

http://slidepdf.com/reader/full/50years1 3/6

8/16/2019 50years[1]

http://slidepdf.com/reader/full/50years1 4/6

57

The spiral pipe forming and tack-weldingmachine is equipped in the strip run-in part

with an ultrasonic testing installation (optional

item) in order to test the base material.

The spiral-pipe manufacturing process used

in this project is a two-stage process that

separates the pipe0forming and submerged-

arc pipe welding operations.The main advantage in finishing welding

(SAW) of tack-welded pipes is that there is no

movement between the strip edges during the

SAW welding process, which results in

excellent pipe geometry and pipe quality.

Other advantages are easier setting and

adjusting of the welding heads to ensure

constant weld quality and lower investment costs.

On the enclosed drawings the diagrammatic

representation of the two-stage manufacturingprocess is shown.

When a whole coil has been processed into

individual pipes, the machine stops and a new

coil is welded to the end of the preceding coilin order to continue production. The coil-

changing process takes approx. 15 – 20

minutes, depending on the strip dimensions.

The strip-connection seam is welded on the

inner side only, using the submerged-arc

welding process.After pipe forming and tack-welding the

endless pipe strand is cut into single pipes

by a plasma cutting unit.

Then, the pipes are subjected to an inside

cleaning station, followed by visual inspection

stands and welding tab installation, where the

welding tabs are welded on to the pipe ends.

On the three submerged-arc-welding stations

the inside and outside final welding is carried

out simultaneously using the submerged-arc

welding process. The tack-weld here iscompletely re-melted.

Danieli W+K 50 years of experienc

DiagrammaticRepresentationof the Two-StageManufacturing Process

Process stage 1 – pipeforming and tack-welding

Process stage 2 –submerged arc finalwelding.

Process stage 11. Incoming Strip2. Three-Roll Bending

System3. Outside Pipe Guide Cage4. Welding Head for CO

2

Tack-Welding5. Weld-Pool Support Roller

1

2

5

3

4

1

2

3

4

Tack-WeldingSubmerged-Arc Welding

(Inside)

Submerged-Arc Welding(Inside and Outside)

Process stage 21. Orthogonal Conveyor2. Pipe Feed Unit3. Three Welding Heads

for Inside Welding4. Two Welding Heads

for Outside Welding

8/16/2019 50years[1]

http://slidepdf.com/reader/full/50years1 5/6

580

Any pipe defect indicated by the x-rayinspection can be repaired on the weld seam

repair stand.

Finally, internal inspection, weighing and

marking stations and customer acceptance

inspection take place.

Then, the pipes are transported out of the

building to the storage area.

Conclusion

Danieli W+K IndustrieTechnik has recently

received a large-scale order from Borusan

Mannesmann Boru (BMB) for the design,

manufacturing, delivery and supervision of 

installation and commissioning for a high-

performance, spiral pipe mill, including themost advanced two-stage welding technology.

BMB is the largest pipe producer in Turkey

and one of the leading European producers

of welded pipe, with a wide-ranging portfolio.

BMB already operates several ERW lines for

the smaller-diameter pipe range, and three

spiral pipe mills for the larger-diamter pipe

range, plus coating lines. The new line will

enable BMB to produce high-quality linepipes

with reduced cost, and guarantee a leading

edge over the global competition in spiral

welded pipe.

Welding tabs are removed and the inside of 

the pipes is cleaned again in order to remove

the slag, scale, and residual flux resulting

from the submerged arc final weldingprocess.

Pipes with a cross-seam can be processed on

the cross seam re-welding stand, whereby

the outside of the cross seam will be finishwelded. Furthermore, on the cross-seam re-

welding stand ,the inside and outside welding

can be repaired.

The inside and outside of both pipe ends shall

be ground flushed with the parent metal. This

is carried out on the grinding stations.

Before entering the hydrotester the pipes will

be processed on the beveling machine,

where the pipe ends are machined.

In the hydrotester each pipe is tested in

accordance to the customer’s requirements.

The test result will be recorded in a time / pressure diagram for each pipe, and also

recorded electronically.

After the hydrotester, the welding seam area

is checked by means of ultrasonic testing

(UST) device. UT indication are re-checked

and repaired.

After the UST the pipes are transported to the

X-ray stations for the relevant test.

For the internal production control, a x-ray

photo and image intensifier stand is installed.

Danieli W+K

Plant lay-out1. Coil preparation 2. Spiral pipe-form

tack-welding ma

3. Visual inspection4. Inside cleaning s5. Welding tab inst6. Final welding sta7. Welding tabs rem

station8. Inside cleaning s9. Visual inspection10. Cross-seam re-

stand11. Pipe ends clea

station12. Hydrostatic tes

machine13. Ultrasonic weld

inspection stand14. Manual rotating

ultrasonic statio15. Pipe repairing s

16. X-ray photo sta17. Pipe-cutting rin18. Pipe-end bevel

machine19. Pipe transport 20. Pipe inspection21. Pipe weighing a

marking station22. Customer acce

inspection statioAreas A - L show c

storage areas, w / laboratory facil

Pipebuffer

Pipebuffer

        1        2        0        0        0

30000

        3        0        0        0        0

        3        0        0        0        0

255000

20000014000

8

9

9

1

A

A

B

F

G

H   J J

K L

3

2

45

7

6

10

16

15

14

14

13

1211

11

2221

20

19

18

17

8/16/2019 50years[1]

http://slidepdf.com/reader/full/50years1 6/6

58

The investment has been designed to be astate-of-the-art production facility with

respect to production technology, capability,

flexibility, plant lay-out.

The potentially strong demand for oil-and-

gas distribution in target markets combined

with the strong brand recognition and

market positioning of BMB has led to theinvestment decision.

Commenting on the new investment,

Mr. Bülent Demircioğlu, BMB Chairman

of the Board said:

“One of the strategic targets of Borusan

Mannesmann Boru is to invest in high-end

product segments, thus increasing value

creation for our stakeholders. In order to

take advantage current and future market

opportunities, we have decided to make aninvestment in the linepipe market. In our

target markets (Turkey, Europe, North Africa,

Middle East and the Americas), many

important projects are on the agenda and in

scope of BMB. The Nabucco and Southern

Stream projects are the biggest ones on our

targeted projects list. BMB has reinforced its

position in this sector by being a reliable

pipe supplier to many important projects,

such as Baku-Tbilisi-Ceyhan, Shahdeniz,

Blue Stream. As a result of this investment

decision BMB will become stronger and

more competitive among the national and

international peers. The investment

decision, in a time of global crisis, shows

our trust and commitment to the promiseof the company, as well as the country

of Turkey.”

Danieli W+K IndustrieTechnik was awarded

a contract for the implementation of thisimportant project by Borusan Mannesmann

Boru and will execute it with emphasis and

highest priority. Danieli W+K

IndustrieTechnik has been part of the

Danieli Group since 2007 and will prove

Danieli`s reputation as the reliable and

innovative supplier to the steel industry even

in the field of welded pipes.

The entire project will be performed in-

house, with engineering provided by our

technical offices in Dortmund, Germany,

manufacturing and assembly at Danieli’sworkshops in Buttrjo, Italy, and supervision

of installation and commissioning provided

again from the German offices.

Handling the project in this way ensures

high quality and on-time execution.

Because of the short timeframe for

completion, BMB as an experienced

pipemaker entrusted Danieli’s outstanding

in-house capabilities to realize this

challenging project.

Danieli W+K 50 years of experienc