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

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 companys 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.

576

The main products

Edited by
Nardi Jacopo

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 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 tackwelding 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

[ Danieli W+K ]

equipments: strip run-in part, CCF strip

accumulator (continuous coil feeder), cagetype 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.

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 inline, 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.

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):

Material tracking and Quality Assurance

System (QAS)

B
---------OD x p

sin a =

During the process, each pipe has its ID

number and quality-relevant process/ qualitycontrol data collected in the production
information system (by terminal/ recipe or on
line), and finally each individual pipe is
released by the QAS.

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).

Principle for the

manufacture of spiral
pipes.

B
OD

OD =

B
OD

sin

OD

B = constant
2

min
Max

= 15
=45-50
OD2
Fig.. 1b

sin

B
OD1

sin

B
OD2

Tubes

B
Fig.. 1a

OD1

VP
OD
VS
= constant

B1
sin 1

B2
sin 2

VP = VS sin

B1
Fig.. 1c

OD=

B2

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Danieli W+K

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
6.35 mm 25.4 mm
up to and incl. X80
8.0 m 24.5 m
acc. to API 5 L., ISO 3183 or
similar international specifications

Wall thickness:
Material grade:
Pipe length:
Pipe quality:

Production capacity
Material grade up to
incl. X80

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

578

,312

,344

,375

,406

,438

,469

,500

,531

,562

,600

,656

,688

,719

,750

,812

,875

,938

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

In the spiral pipe forming and tack-welding

machine, the pipes are formed with excellent
accuracy using a three-roll bending machine
with an outside roller cage.
During the forming process the spiral pipes
are continuously tack-welded at a very high
production speed (up to 10.0 m/min. strip
infeed speed) using the shielded-arc welding
process.

28,58 1,125

,281

7,92

Hot-rolled strips (coils) are used as the raw

material for the spiral pipe production.
The coils are prepared on a coil preparation
stand, where the coil tongues are cut off at a
right angle. Then, the coils are placed on the
coil reserve stand at the inlet of the spiral pipe
forming and tack-welding machine.

26,97 1,062

,250

7,14

Description of the main production flow

25,40 1,000

,219

914,0

38

6,35

864,0

36

,203

813,0

34

5,56

762,0

32

,188

711,0

30

5,16

660,0

28

,172

610,0

26

4,78

559,0

24

,156

508,0

22

4,37

457,0

20

3,96

18

mm

406,4

,125

mm

16

inch

inch

3,18

Wall thickness
Pipe
diameter

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 submergedarc 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

Diagrammatic
Representation
of the Two-Stage
Manufacturing Process
Process stage 1 pipe
forming and tackwelding
Process stage 2
submerged arc final
welding.

individual pipes, the machine stops and a new

coil is welded to the end of the preceding coil
in order to continue production. The coilchanging 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
(Inside)

Tack-Welding

Submerged-Arc Welding
(Inside and Outside)

4
2

Tubes

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

Process stage 2
1. Orthogonal Conveyor
2. Pipe Feed Unit
3. Three Welding Heads
for Inside Welding
4. Two Welding Heads
for Outside Welding

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Danieli W+K

Any pipe defect indicated by the x-ray

inspection 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.

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 welding
process.
Pipes with a cross-seam can be processed on
the cross seam re-welding stand, whereby
the outside of the cross seam will be finish
welded. Furthermore, on the cross-seam rewelding 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 customers 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.

Plant lay-out
1. Coil preparation stand
2. Spiral pipe-forming and
tack-welding machine
3. Visual inspection stands
4. Inside cleaning station
5. Welding tab installation
6. Final welding stands
7. Welding tabs removal
station
8. Inside cleaning station
9. Visual inspection station
10. Cross-seam re-welding
stand
11. Pipe ends cleaning
station
12. Hydrostatic test
machine
13. Ultrasonic weld-seam
inspection stand
14. Manual rotating
ultrasonic station
15. Pipe repairing station
16. X-ray photo stand
17. Pipe-cutting ring
18. Pipe-end beveling
machine
19. Pipe transport system
20. Pipe inspection station
21. Pipe weighing and
marking station
22. Customer acceptance
inspection station
Areas A - L show coil / pipe
storage areas, workshop
/ laboratory facilities, etc.

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 highperformance, spiral pipe mill, including the
most 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.
255000
200000

14000

30000

Pipe
buffer

Pipe
buffer

H
G

10

13

30000

10000

12

11

11

14

17

14

2
3

19
9

15
12000

21

18
16

22

120000

30000

20
6

A
K

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Danieli W+K 50 years of experience

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-andgas 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. Blent Demirciolu, 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

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 inhouse, with engineering provided by our
technical offices in Dortmund, Germany,
manufacturing and assembly at Danielis
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 Danielis outstanding
in-house capabilities to realize this
challenging project.

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