Nippon Steel Pipe & Tube Nippon Steel Pipe & Tube

NIPPON STEEL PIPE & TUBE
Head Office Nippon Steel Corporation 6-1, Marunouchi 2-chome, Chiyoda-ku, Tokyo 100-8071, Japan Phone: 81-3-6867-4111 Fax: 81-3-6867-5607
Cat. No. PC316 2009.9 PDF

NIPPON STEEL CORPORATION 2007 All Rights Reserved. Printed in Japan

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
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 products:
Manufacturing Process Small-diameter Seamless
Oil Country Tubular Goods
Line Pipe
Structural Pipe & Tube
Boiler & HeatExchanger Tubes
Piping
Pipe Pile
Mechanical Tube
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
Notice: While every effort has been made to ensure the accuracy of the information contained within this publication, the use of the information is at the readers risk and no warranty is implied or expressed by Nippon Steel Corporation with respect to the use of information contained herein. The information in this publication is subject to change or modification without notice. Please contact the Nippon Steel office for the latest information.
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....degassing, 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.

Copyright 2007 NIPPON STEEL CORPORATION. All rights reserved.
(PC316)
Integrated Production of Pipe

Pipe can be manufactured in many ways. At Nippon Steel, pipe is made by the submerged 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, billets and blooms manufactured by the company. Nippon Steels technology is utilized for and close control is applied over, the manufacturing processes and product quality
Limestone Charging Oxygen scrap blow Iron ore Sintering plant
throughout the entire sequence of operations involved, from ironmaking and steelmaking 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 customers requirements to the letter.
Torpedo car Blast furnace Coal Coking plant Basic oxygen Charging furnace molten iron Vacuum degassing equipment Continuous casting
Blooming mill
Billet mill
Ultra sonic test
Magnaflux flaw detector
Billet grinder
Reheating furnace
Seamless Pipe Plug mill

Seamless Pipe, Seamless Stainless Steel Pipe
Rolling mill
Round billet
Hot extrusion
Continuous reheating furnace
Roughing mill
Hot rolling mill Reheating furnace Roughing mill Finishing mill Accelerated cooling Plate
UO pipe mill Largediameter Pipe Bending roll mill and Press bending mill Hot coil
(SAW Pipe)
Temper mill
Pickling line Spiral pipe mill Pickleol hot coil Continuous butt weld pipe mill CW Pipe
Cold rolling mill Aluminum-coating line
ALSHEET coil HF-ERW Pipe
Electrolytic cleaning line
Electrogalvanizing line
ZINKOTE, DURPAINT coil
High Frequency electric resistance weld pipe mill
Annealing furnace C.A.P.L.
Temper mill
Coil build-up line
Annealing furnace
Annealing and pickling line
Coil grinding line
Sendzimir mill
Annealing and pickling line
Skin-pass rolling mill
Coil polishing line
Stainless steel coil

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Pipe Making Facilities and Product Sizes

Mills Location of Mills Size: Outside diameter (inch) 1
1.315
Size Ranges
Seamless Pipe
16 20 56 200
inch
ERW & CW Pipe

Wall thickness Wall thickness
1.2 30 1.4 34 38 1.6 42
inch mm
6
6.625
10
12
14
0.2 6
0.4 10
0.6 14 18
0.8 22
1.0 26
0.1 2 4
0.2 6
0.3 8
0.4 10
0.5 12 14
0.6 16
0.7 18
0.8 20
mm 2
Hot finish Mannesmann-Plug Mill Stretch Reducer Cold finish Seamless Tokyo
Cold finished
0.236 6.000
1 4 2
inch Outside diameter
CW
Hot finish Ugine-Sejournet Hot Extrusion Cold finish Hikari

0.236
1.660
6.890
6.625
12
ERW
16
2 HF-ERW
0.850
2.559
Induction
Nagoya
Hot finished
6
4 HF-ERW
0.750
4.500
Induction
Kimitsu
7
20
4 HF-ERW HF-ERW 4 HF-ERW + Stretch Reducer
Induction
Nagoya (Subsidiary company) Hikari

0.543
1.492
4.500
8 24
Induction
2.382
Stainless Pipe (Hot extruded)

(Pipe In Coil)
SAW Pipe
Wall thickness
0.8 1.0 22 26 1.2 30
inch mm
Wall thickness
inch
0.2 2 6
0.4 10
0.6 14 18
4.500
16
0.5 10 20
1.0 30
1.5 40
2.0 50
2.5 60 70
3.0 80
3.5
4.0
16 HF-ERW
Thermatool
Nagoya
mm
90 100
Cold finished
8.625 24
Straight Seam Pipe (UO process)

20 40
24 HF-ERW
Thermatool
Hikari
CW
Kimitsu
Continuous Butt Weld
0.840
4.500
2 60 80 100 120 140
UO Process Longitudinal Weld Kimitsu
18
56
Spiral Seam Pipe Straight Seam Pipe (Bending roll process / Press bending process)
Hot finished
16
64
Spiral Weld SAW
Yawata
16
100
Spiral Weld Bending Roll Process / Press Bending Process Longitudinal Weld
6 160 7
Kimitsu
Related company
16
200
8 Notes: For sizes not listed in these figures, please contact Nippon Steel.
180 200

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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 compliance; 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.
BS (British Standards) 1387 3059 3600 3601 3602 3603 Steel Tubes and Tubulars
Standard
Seamless Pipe MM
Welded Pipe UO SP BR
HE ERW CW
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
DIN (Deutsche Normen) Standard API (American Petroleum Institute) 5L 5CT 5D 2B Line Pipe Casing and Tubing Drill Pipe Fabricated Structural Steel Pipe Seamless Pipe MM Welded Pipe UO SP BR 1626 1629 2440 2441 17172 17175 17177 17440 65 3183 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 HE ERW CW
AS (Australian Standard) 1836 Welded Steel Tubes for Pressure Purposes ASTM (American Society for Testing and Materials) A53 Black and Hot-Dipped Zinc-coated (galvanized) Welded Seamless Steel Pipe A106 Seamless Carbon Steel Pipe for High-Temperature Service A135 Electric Resistance Welded Steel Pipe A178 Electric-Resistance-Welded Carbon Steel and Carbon-Manganese Steel Boiler Tubes A213 Seamless Ferritic and Austenitic Alloy-Steels Boiler Superheater and HeatExchanger Tubes
ISO (International Organization for Standardization)
JIS (Japanese Industrial Standards) G 3441 Alloy Steel Tubes for Machine Purpose G 3442 Galvanized Steel Pipe for Water Service G 3443 Coating Steel Pipe for Water Service G 3445 Carbon Steel Tubes for Machine Structural Purpose G 3446 Stainless Steel Tubes for Machine and Structural Purpose G 3451 Deformed Pipe for Coating Steel Pipe for Water Service G 3452 Carbon Steel Pipes for Ordinary Piping G 3454 Carbon Steel Pipes for Pressure Service G 3455 Carbon Steel Pipes for High Pressure Service G 3457 Electric Arc-Welded Carbon Steel Pipe G 3458 Alloy Steel Pipes G 3459 Austenitic Stainless Steel Pipes G 3460 Steel Pipes for Low-Temperature Service G 3461 Carbon Steel Boiler and Heat-Exchanger Tubes G 3462 AIloy Steel Boiler and Heat-Exchanger Tubes G 3463 Stainless Steel Boiler and Heat-Exchanger Tubes G 3464 Steel Heat-Exchanger Tubes for Low Temperature Service G 3472 Electric Resistance Welded Carbon Steel Tubes for Automobile Structural Purposes G 3473 Carbon Steel Tubes for Cylinder Barrels LR (Lloyds Register of Shipping) Pressure Pipes Boiler and Superheater Tubes DNV (Det Norske Veritas) OS-F101 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
A214 Electric-Resistance-Welded Carbon Steel Heat-Exchanger and Condenser Tubes A250 Electric-Resistance-Welded Carbon-Molybdenum Alloy Steel Boiler and Superheater Tubes
A252 Welded and Seamless Steel Pipe Piles A268 Seamless and Welded Ferritic and Martensitic Stainless Steel Tubing for General Service
A269 Seamless and Welded Austenitic Stainless Steel Tubing for General Service A312 Seamless and Welded Austenitic Stainless Steel Pipes A333 Seamless and Welded Steel Pipe for Low-Temperature Service A334 Seamless and Welded Carbon and Alloy-Steel Tubes for Low-Temperature Service A335 Seamless Ferritic Alloy-Steel Pipe for High-Temperature Service A376 Seamless Austenitic Steel Pipe for High-Temperature Central-Station Service A423 Seamless and Electric-Welded Low-Alloy Steel Tubes A513 Electric-Resistance-Welded Carbon and Alloy Steel Mechanical Tubing AWWA (American Water Works Association) C200 Steel Water Pipe C203 Standard for Coal-Tar Enamel Protective Coating for Steel Water Pipe GOST (USSR Specifications) 10704 Electric-Welded Steel Tubes 10705 Specification for Delivery of Electric-Welded Steel Tubes of 8~530 mm in diameter

(PC316)
Applications
Oil Country Tubular Goods
Line Pipe
Casing string make up Submarine pipeline laying Pipeline under construction in Alaska
Submarine pipe laying by Kuroshio2 Drilling rig, casing string make up
Laying of HI-PL (Polyethylene-Coated) Pipe
Drilling rig
Casing arrived in Alaska
Pipeline in arctic area

(PC316)
Structural Pipe & Tube
Foundation work of bridge, inland sea
[Steel pipe sheet piles] driving for harbor construction
Production platform
Pipes for electric transmission tower
Pipe pile driving for seaberth construction
NS-PAC used as pier piles in japan
Roof trusses
SLP is available for reclaimed lands and areas with thick alluvial deposits
10

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11
Boiler and Heat-Exchanger Tubes
Pipes for Plants and Others
Stainless super-heater tubes in a power boiler
Piping in petrochemical plant
Piping for super tanker
Pipes for automobiles
Furnace wall tubes in a power plant
Large heat-exchangers in refinery
Piping in building
Pipes for hydraulic cylinder and piping
12

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13
Manufacturing Processes
Seamless Pipe Process
Hot Extrusion Process

Stainless and high alloy steel tubes which are difficult to produce by other methods, 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.
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.
Piercing
Rolling
Reeling
Sizing
Reheating
Stretch reducing
Hot extrusion mill
Billet heating furnance
Piercing mill
Rolling mill (plug mill)
Stretch reducing mill
Heat treatment furnace
Nondestructive inspection device
Heated billet during extrusion
14

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15
HF (High Frequency) ERW Process

A hot coil is first slit to a prescribed width, formed into a round shape by forming rolls then continuously electricresistance welded. Nippon Steels HF-ERW pipe is much different from that of conventional ERW. Nippon Steel-developed weld condition 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 following 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, heatexchanger 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 High frequency electric resistance welder
Ultrasonic tester
Hydrostatic tester
Forming rolls
Welding condition monitoring system
Seam normalizer
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17
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.
Reheating
Forming, Welding, Reducing
Heating furnace
Rotary hot saw
Hydrostatic tester
CW pipe mill
Zink coating line
18

(PC316)
19
UO Process
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 conditions. 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 specific customer requirements.
Edge miller
Crimping press
U-ing press
O-ing press
Longitudinal seam welding
U-ing press
Automatic marking equipment
O-ing press
Inside submerged arc welder
Outside submerged arc welder
20

(PC316)
21
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 products 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.
Skelp butt welding
Forming, inside and outside welding
Cutting off
General view of a spiral-weld pipe mill
Online cut-off machine
Outside welder
Ultrasonic tester
22

(PC316)
23
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 production 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 largediameter water mains, as well as other standards.
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.
Size range Outside diameter (mm) Length (mm)
Item Water pipe
Kind of 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 Coating (1) Two-component epoxy lining (2) Phenolic epoxy lining External coating (1) Polyethylene coating 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 3,600~12,000 5,500~6,300 ~100,000 ~100,000 5,000~34,500 5,000~18,300 11,000~18,600 (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 Fabrication Steel pipe sheet piles Conductor pipe vetco joint, etc. 89.1~1,420 34~508 9,000~12,800 5,000~12,200 21.7~1,524 89.1~2,250 5,000~18,300 5,000~18,600 89.1 or more 89.1 or more 21.7~114.3 21.7~355.6 4,000~12,200 4,000~12,200 5,500 5,500
MACRO structure of muIti-pass welding (WT: 90 mm) offshore structural pipes (see upper photo) are fabricated with sophiscated welding technique.
3-roll bender
Press bending
3-roll bender
24

(PC316)
25
Coating and Lining

On request, pipe is available with coatings and linings for corrosion protection, reduction of friction of the fluid, and other purposes.
Final inspection Water cooling
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 construction projects.
Polyethylene-coated pipe
(1) Longitudinal extrusion process
Holiday inspection
Polyethylene coating
Adhesive coating
Pre-heating Adhesive coating Primer Blasting
Polyethylene coating
Handling of extra-long pipe
Polyethylene coating Primer Holiday inspection
(2) Side-extrusion process
Pre-heating
Two-component epoxy lined pipe
Blasting
Line pipe performance testing apparatus
Fabrication yard
26

(PC316)
27
NS-PAC
With a view to developing corrosion resistant, maintenance-free and economical steel pipe pile and steel pipe sheet piles which will not require electrode replacement or repainting, Nippon Steel Corporation carried out extensive tests, and were aimed at technically assessing the performance of steel pipe pile under service conditions. These tests provided the basis for the development of Nippon Steelss NS-PAC polyethylene-coated anticorrosion steel pipe pile which since its marketing in April 1983 has earned an outstanding reputation among users. Now, carrying this technology a step further into the area of more complexly shaped products, the Company has developed a new line of urethane elastomer coated steel pipe sheet piles. These new products are the latest addition to the NS-PAC series.
Pipe Mills at Nippon Steel

Nippon Steel has 9 integrated steel works and operates different types of pipe mills, a fact that underscores the companys position as an experienced pipe manufacturer having a long history and a total capability.
Hikari pipe & tube division
Muroran Works
Kamaishi Works
NS-PAC polyethylene coated steel piles
Tokyo Works
Head Office : Pipe mill
Nagoya Works
Hirohata Works Sakai Works
Kimitsu Works
Hikari pipe & tube division Yawata Works

Oita Works
Kimitsu Works NS-PAC urethane elastomer coated steel pipe sheet piles
28

(PC316)
29
Research and Development
Research related to diversification
Research on steelmaking technologies
Integrated research activities
Basic research
Research on basic or peripheral technologies
Constant load stress corrosion cracking tester
Multiple creep rupture testing machine
Drop weight tear tester
Line pipe performance testing apparatus
Weld test in cold chamber
Solidifying cycle weld simulator
30

(PC316)
31
Production Control and Quality Assurance

Nippon Steels sophisticated equipment, expertise and technology make it possible to manufacture and supply pipe to your complete satisfaction. Throughout the processes and operations of Nippon Steels integrated steel production, exacting production control and quality assurance systems are in effect. Every pipe produced by the company must be certified as having met all the specified quality requirements before it is shipped from the mill. Examples of our pipe manufacturing methods include: (1) computer-aided production control and quality control of all operations, from raw materials handling to shipment of finished products; (2) employment of the latest advances in technology for the manufacture of pipe having the exact quality to suit specific needs and applications; and (3) inspection systems so designed as to meet particular purposes, as exemplified by the extensive and effective use of nondestructive testing equipment such as ultrasonic, eddy-current, X-ray and magnetic testers. AII incoming orders are processed at the companys Tokyo head-quarters. Orders are input into a computer, which specifies the quality of each product to suit the intended use, then dispatches this data to the computer at the steel mill which is best positioned to handle the manufacture of the products. Given the quality design, the mill performs the process design based on the materials best suited to meet the quality requirements of the order.
Legal Notice: While every effort has been made to ensure the accuracy of the information contained in this publication, the use of the information is at the readers risk and no warranty is implied or expressed by Nippon Steel Corporation with respect to the use of information contained herein.
32

(PC316)

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