Danieli W+K

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 activities
discontinued there have been continued at W+K IndustrieTechnik.

Comprehensive experience from the fields of The main products Edited by

engineering, construction and commissioning
of machinery and equipment, indispensable
production know-how, highly qualified
employees as well as a number of patents,
are qualities that W+K IndustrieTechnik
makes widely available to its customers.
Since April 2007 W+K IndustrieTechnik has
joined Danieli and the new division of
Danieli W+K was born.
The integration into the group strengthened
the company’s market position. The synergy
with the proven Danieli network/system and
facilities reflects greater flexibility and
suitable leanness to maintain its
competitiveness in a market that becomes
more demanding and challenging every day.
Nardi Jacopo
Here follows the main products provided by [ Danieli W+K ]
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 the
production 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 main
International standards, such as API 5L, API 5
CT o EN 10208. Outside diameter range:
1,660", 24" (42.16 mm, 610.0 mm). Main

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 equipments: strip run-in part, CCF strip
accumulator (continuous coil feeder), cage-
type pipe forming section with quick-change
and rapid-adjustment systems, (cage forming
system), conventional forming stands with
quick-change and rapid-adjustment systems,
final pass stands and final sizing stands (with
quick-change and rapid-adjustment systems),
flying cutting shear, complete finishing lines
according to the final pipe destination.
Spiral pipe forming process principle
The principle for the manufacture of spiral
pipes has been applied in industrial
production for more than 100 years. A steel
strip with a constant width is formed at a
specified angle into a cylindrical body (pipe).
The geometrical ratio is described by the
formula (Fig. 1 a):
B System (QAS)
sin a = ----------
OD x p
It follows from this basic formula that any pipe
diameter (OD) can be produced with a
constant strip width (B) by altering the run-in
angle (a) (Fig. 1 b).
However, Fig. 1 c also shows that a specified
pipe diameter can be manufactured with a
variable strip width (B1, B2). Here lies the
flexibility of the process.
Spiral pipe production process principle:
in-line or off-line SAW welding
Once the pipe is formed, it can be finished in-
line, the conventional system, or off-line, the
two-stage system.
The first one of these, completed by in-line
Submerged- Arc Welding and UT testing, is
recommendable for lower annual output; the
second, completed by a number of off-line
Submerged- Arc Welding (SAW) stations and
relevant UT testing equipment, is preferable
for higher productivities.
Material tracking and Quality Assurance
During the process, each pipe has its ID
number and quality-relevant process/ quality-
control data collected in the production
information system (by terminal/ recipe or on
line), and finally each individual pipe is
released by the QAS.

Principle for the

sin B
manufacture of spiral OD 1 = B = constant
pipes. OD
B
OD =
2 1

OD

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sin B
Fig.. 1a min = 15° 1 =
Max =45°-50° OD1
OD2 B
sin 2 =
OD2
OD1
Fig.. 1b

VP

OD B1 B2
VS OD= =
sin 1 sin 2
= constant
VP = VS sin
1

B2
B1

Fig.. 1c 2

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Two-stage system spiral pipe mill in Turkey

Technical data – final pipe

Outside diameter: OD 20" – OD 64"

508.0 mm – 1,626.0 mm
Wall thickness: 6.35 mm – 25.4 mm
Material grade: up to and incl. X80
Pipe length: 8.0 m – 24.5 m
Pipe quality: acc. to API 5 L., ISO 3183 or
similar international specifications

Production capacity

Material grade up to
Wall thickness
incl. X80
Pipe
mm
,125
,156
,172
,188
,203
,219
,250
,281
,312
,344
,375
,406
,438
,469
,500
,531
,562
,600
,656
,688
,719
,750
,812
,875
,938
25,40 1,000
26,97 1,062
28,58 1,125
diameter
inch
3,18
3,96
4,37
4,78
5,16
5,56
6,35
7,14
7,92
8,74
9,52
10,31
11,13
11,91
12,70
13,49
14,27
15,00
16,66
17,48
18,26
19,05
20,62
22,23
23,83
inch mm
16 406,4
18 457,0
20 508,0
22 559,0
24 610,0
26 660,0
28 711,0
30 762,0
32 813,0
34 864,0
36 914,0
38 965,0
40 1016,0
42 1067,0
44 1118,0
46 1168,0
48 1219,0
50 1270,0
52 1321,0
56 1422,0
60 1524,0
64 1626,0
66 1727,0

Description of the main production flow In the spiral pipe forming and tack-welding
machine, the pipes are formed with excellent
Hot-rolled strips (coils) are used as the raw accuracy using a three-roll bending machine
material for the spiral pipe production. with an outside roller cage.
The coils are prepared on a coil preparation During the forming process the spiral pipes
stand, where the coil tongues are cut off at a are continuously tack-welded at a very high
right angle. Then, the coils are placed on the production speed (up to 10.0 m/min. strip
coil reserve stand at the inlet of the spiral pipe infeed speed) using the shielded-arc welding
forming and tack-welding machine. process.

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 Danieli W+K 50 years of experience

The spiral pipe forming and tack-welding
machine 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 manufacturing
process 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 coil
in 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 is
completely re-melted.

Submerged-Arc Welding Submerged-Arc Welding

Diagrammatic Tack-Welding (Inside and Outside)
(Inside)
Representation
of the Two-Stage
Manufacturing Process
Process stage 1 – pipe
forming and tack-
welding
Process stage 2 –
submerged arc final
welding.

4
2
3

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4 3
1

2
1
5

Process stage 1
1. Incoming Strip Process stage 2
2. Three-Roll Bending 1. Orthogonal Conveyor
System 2. Pipe Feed Unit
3. Outside Pipe Guide Cage 3. Three Welding Heads
4. Welding Head for CO2 for Inside Welding
Tack-Welding 4. Two Welding Heads
5. Weld-Pool Support Roller for Outside Welding

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Danieli W+K

Welding tabs are removed and the inside of Any pipe defect indicated by the x-ray
the pipes is cleaned again in order to remove inspection can be repaired on the weld seam
the slag, scale, and residual flux resulting repair stand.
from the submerged arc final welding Finally, internal inspection, weighing and
process. marking stations and customer acceptance Plant lay-out
Pipes with a cross-seam can be processed on inspection take place. 1. Coil preparation stand
2. Spiral pipe-forming and
the cross seam re-welding stand, whereby Then, the pipes are transported out of the tack-welding machine
the outside of the cross seam will be finish building to the storage area. 3. Visual inspection stands
4. Inside cleaning station
welded. Furthermore, on the cross-seam re- 5. Welding tab installation
welding stand ,the inside and outside welding 6. Final welding stands
can be repaired. Conclusion 7. Welding tabs removal
station
The inside and outside of both pipe ends shall 8. Inside cleaning station
be ground flushed with the parent metal. This Danieli W+K IndustrieTechnik has recently 9. Visual inspection station
10. Cross-seam re-welding
is carried out on the grinding stations. received a large-scale order from Borusan stand
Before entering the hydrotester the pipes will Mannesmann Boru (BMB) for the design, 11. Pipe ends cleaning
be processed on the beveling machine, manufacturing, delivery and supervision of station
12. Hydrostatic test
where the pipe ends are machined. installation and commissioning for a high- machine
In the hydrotester each pipe is tested in performance, spiral pipe mill, including the 13. Ultrasonic weld-seam
inspection stand
accordance to the customer’s requirements. most advanced two-stage welding technology. 14. Manual rotating
The test result will be recorded in a time / BMB is the largest pipe producer in Turkey ultrasonic station
pressure diagram for each pipe, and also and one of the leading European producers 15. Pipe repairing station
16. X-ray photo stand
recorded electronically. of welded pipe, with a wide-ranging portfolio. 17. Pipe-cutting ring
After the hydrotester, the welding seam area BMB already operates several ERW lines for 18. Pipe-end beveling
machine
is checked by means of ultrasonic testing the smaller-diameter pipe range, and three 19. Pipe transport system
(UST) device. UT indication are re-checked spiral pipe mills for the larger-diamter pipe 20. Pipe inspection station
and repaired. range, plus coating lines. The new line will 21. Pipe weighing and
marking station
After the UST the pipes are transported to the enable BMB to produce high-quality linepipes 22. Customer acceptance
X-ray stations for the relevant test. with reduced cost, and guarantee a leading inspection station
Areas A - L show coil / pipe
For the internal production control, a x-ray edge over the global competition in spiral storage areas, workshop
photo and image intensifier stand is installed. welded pipe. / laboratory facilities, etc.

255000
14000 200000 30000 10000

Pipe Pipe
buffer buffer
H J J B

G 10
13 9 C
17
30000

12 2
11 14
14 11 3
19

9 4
5 1 D
20
30000

15 7
120000
18 21 22 6
12000

16 A
8
K L E

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The investment has been designed to be a
state-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 the
investment 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 an
investment 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
Danieli W+K 50 years of experience
more competitive among the national and
international peers. The investment
decision, in a time of global crisis, shows
our trust and commitment to the promise
of the company, as well as the country
of Turkey.”
Danieli W+K IndustrieTechnik was awarded
a contract for the implementation of this
important 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’s
workshops 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.
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