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jfe technical report no 7 jan 2006 manufacturing processes and products of steel pipes and tubes in jfe steel 1 2 masamura katsumi nagahama yutaka abstract 2 distinctive features jfe ...

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                                                                                                                    JFE TECHNICAL REPORT 
                                                                                                                                No. 7 (Jan. 2006)
                Manufacturing Processes and Products 
                                                                                                     †
                of Steel Pipes and Tubes in JFE Steel
                                    *1                      *2
                MASAMURA Katsumi     NAGAHAMA Yutaka
                Abstract:                                                           2.  Distinctive Features 
                    JFE Steel operates manufacturing facilities for seam-              of Steel Pipes and Tubes at JFE Steel
                less pipes and various types of welded pipes in order to               2.1  Pipe and Tube Manufacturing System 
                respond to a wide range of customer requirements. Dis-
                tinctive  products  and  manufacturing processes include               JFE Steel operates manufacturing facilities for seam-
                large  diameter,  heavy  wall  electric  resistance  welded         less pipe and welded pipe at its East Japan Works, West 
                (ERW) pipe for linepipes, UOE pipe for high strength,               Japan Works, and Chita Works.
                high performance linepipes, and high performance, high                 An outline of the pipe and tube manufacturing pro-
                formability welded steel tubes used in automotive parts.            cess is shown in Fig. 1. Depending on the manufacturing 
                This paper presents an outline of the distinctive features          process, welded pipes can be divided into three classes 
                of  the  manufacturing processes at JFE Steel, together             by  welding  method,  i.e.,  arc  welding,  electric  resis-
                with representative steel pipe and tube products.                   tance  welding,  and  butt  welding.  Pipes  manufactured 
                                                                                    by the arc welding method can be further divided into 
                1.  Introduction                                                    UOE pipe, bending press pipe, and spiral welded pipe, 
                                                                                    depending on differences in the forming method. Among 
                    As a result  of  the  merger  of  the  former  Kawasaki         welded pipes, hot rolled steel sheet is used as the mate-
                Steel and former NKK in April 2003, the steel pipe and              rial  for  electric  resistance  welding  tube,  butt  welded 
                tube  manufacturing  system  at  the  newly-created  JFE            tube, and spiral tube, while steel plates are used as mate-
                Steel was expanded to include four districts, the Chiba             rial for UOE and bending press products.
                District and Keihin District of East Japan Works, Fuku-                JFE  Steel’s  pipe  and  tube  manufacturing  facilities 
                yama District  of West  Japan Works,  and  Chita Works              comprise one UOE line each at East Japan Works and 
                specialized  in  pipe  mills. With  a  product  line  encom-        West Japan Works, one ERW line at East Japan Works 
                passing seamless pipe and welded pipes, including butt              and four ERW lines at Chita Works, one spiral welded 
                welded  pipe,  electric  resistance  welded  (ERW)  pipe,           pipe line at West Japan Works, and two seamless pipe 
                UOE pipe, and spiral welded pipe, JFE Steel supplies                lines at Chita Works. Table 1 shows the manufacturing 
                all major types of steel pipe and tube products and has             facilities for pipe and tube production at JFE Steel.
                established a system which is capable of responding to a               The size range of the pipe and tube products in JFE 
                wide range of customer requirements.                                Steel is shown in Fig. 2. The available size range differs 
                    In fiscal year 2004, the company’s annual production            due to differences in materials and processing and form-
                of all types of steel pipes and tubes was approximately             ing methods. Appropriate use of each product type cor-
                1.85 million tons.                                                  responding to the application is important.
                † Originally published in JFE GIHO No. 9 (Aug 2005), p. 1–6
                           *1 Dr. Eng.,                                                        *2 General Manager, Tubular Products 
                             Staff General Manager,                                             Business Planning Dept.,
                             Tubular Products Business Planning Dept.,                          JFE Steel
                             JFE Steel
                                                                                                                                              1
                                                    Manufacturing Processes and Products of Steel Pipes and Tubes in JFE Steel
                                                    Fig. 1   Manufacturing procedure of pipes and tubes in JFE Steel
                                              Table 1  Manufacturing facilities for pipe and tubes production in JFE Steel
                                                                                                          Available size (mm)
                             Kind                    Works                  Line                                                                   Remarks
                                                                                                  OD         Wall thickness     Length
                                               Chita Works          Small diameter             25.4–   177.8    2.3–40.0        22 000      Mannesmann piercing/ 
                                                                    seamless pipe mill                                                      Mandrel mill
                         Seamless pipe
                                               Chita Works          Medium diameter          177.8–   426.0     5.1–65.0        13 500      Mannesmann piercing/ 
                                                                    seamless pipe mill                                                      Plug mill
                                               East Japan Works     Chiba UOE pipe mill      508.4–1 625.6      6.4–44.5        18 300
                                               (Chiba)
                                     UOE
                                               West Japan Works     Fukuyama UOE             406.4–1 422.4      6.0–50.8        18 300      External and internal 
                                               (Fukuyama)           pipe mill                                                               coating facility
                                    Spiral     West Japan Works     Spiral pipe              600.  –2 540.0     6.0–30.0        35 000
                                               (Fukuyama)
                                               Chita Works          Small diameter             28.6–     76.4   0.6–10.0        18 000
                                                                    ERW pipe mill (3”)
                                               Chita Works          Small diameter             60.5–   168.3    0.6–10.0        18 000
                   Welded pipe                                      ERW pipe mill (6”)
                                 Electric                           Small diameter 
                                 resistance    Chita Works          ERW pipe mill (4”)         21.3–   114.3    1.8–12.7        16 000
                                 welded pipe                        HISTORY
                                                                    Large diameter           318.5–   660.4     4.0–23.8        20 000
                                               Chita Works          ERW pipe mill (26”)
                                                                                             250.    250.0     6.0–25.0        18 000      For square pipes
                                               East Japan Works                              177.8–   609.6     3.2–19.1        18 500      External coating facility
                                               (Keihin)             24” ERW mill
                                                                                             200.    200.0     4.5–22.0        18 000      For square pipes
                                 Butt welded  East Japan Works      Butt weld mill             21.7–   114.3    2.8–  4.5         7 000     Plastic lining facility
                                 pipe          (Keihin)
                     The distinctive features of JFE Steel’s pipe and tube                      at  Chita Works, the small-diameter seamless pipe mill 
                 manufacturing technologies are outlined in the follow-                         using  the  Mannesmann  piercing/mandrel  mill  process 
                 ing.                                                                           and  the  medium-diameter  seamless  pipe  mill  using 
                     2.2  Seamless Pipes and Tubes                                              the Mannesmann piecing/plug mill process. The small-
                                                                                                diameter  mill  produces  pipes  and  tubes  with  outer 
                     JFE Steel has two seamless pipe manufacturing lines                        diameters  up  to  177.8 mm  (5”),  while  the  medium-
                 2                                                                                                 JFE TECHNICAL REPORT No. 7 (Jan. 2006)
                                                                       Manufacturing Processes and Products of Steel Pipes and Tubes in JFE Steel
                                                                (mm)(inch)
                                                                      2.5
                                                                      2.4
                                                                      2.3                            Bending
                                                                      2.2
                                                                      2.1
                                                                  50 2.0
                                                                      1.9
                                                                      1.8
                                                                      1.7
                                                                      1.6                            UOE
                                                                      1.5
                                                                      1.4
                                                                      1.3
                                                                      1.2
                                                             all thickness1.1
                                                             W    25 1.0
                                                                      0.9
                                                                      0.8                                                         Spiral
                                                                      0.7   SMLS
                                                                      0.6
                                                                      0.5      WFW
                                                                      0.4
                                                                      0.3
                                                                      0.2
                                                                      0.1
                                                                       0
                                                                        (inch)   10      20      30      40      50      60      70      80      90     100     110     120     130
                                                                        (mm)             500           1 000                                           2 500               3 200
                                                                                                                       Outside diameter
                                                                           Fig. 2   Size range of JFE Steel’s pipe and tubes for products
                         diameter  mill  produces  products  with  outer  diameters                                             and tubes by the optimum process corresponding to the 
                         from 177.8 mm (5”) to 426.0 mm (16”).                                                                  application.
                              Among materials for seamless pipes and tubes, carbon                                                        2.3.1 Large diameter, heavy wall ERW pipes
                         steel and low alloy steel are melted and rolled at West 
                         Japan Works (Kurashiki District) and supplied to Chita                                                           The 26” line at Chita Works produces ERW pipes 
                         Works. High alloy materials such as 13% Cr, etc. are                                                   having the largest outer diameter in the world. With the 
                         melted and cast into slabs at East Japan Works (Chiba                                                  manufacture of linepipe using this feature as one of its 
                         District); billet rolling is then performed at West Japan                                              strong points, JFE Steel has commercialized extra-heavy 
                         Works (Kurashiki District), and the materials are sup-                                                 wall ERW linepipes and conductor casings as substitutes 
                         plied to Chita in billet form.                                                                         for the conventional UOE products. To realize the same 
                              High  Cr  seamless  steel  pipes  used  in  oil  country                                          strength, toughness, and weldability as in UOE pipe, in 
                         tubular goods (OCTG) and boiler tubes are one of JFE                                                   these products, the composition design of the hot rolled 
                         Steel’s main product lines, and the company has a high                                                 steel sheet used in the ERW pipe was optimized and the 
                         level of know-how in rolling technology for these prod-                                                cooling capacity of the hot rolling line was strengthened.
                         ucts. In the past, seamless pipes and tubes of high Cr                                                       In parallel with this, Chita Works also strengthened 
                         alloy steel and stainless steel were generally produced                                                the pipe manufacturing capacity of the 26” ERW pipe 
                         by piercing using a hot extrusion process, followed by                                                 mill,  developed  an  oxide  control  technique  and  weld 
                         rolling. JFE Steel was the first steel maker in the world                                              seam heat treatment technology to improve the tough-
                         to succeed in obtaining stable product quality in these                                                ness of seam welds, and developed a weld seam quality 
                         products  in  manufacturing  by  the  Mannesmann  pierc-                                               assurance technology for heavy wall products.
                         ing process. These products were realized for the first                                                          2.3.2 HISTORY  tube
                         time as a result of improvement in the properties of the 
                         materials by heavy processing in the slab stage, in com-                                                         The 4” HISTORY pipe mill at Chita Works is a 
                         bination with the establishment of various pipe rolling                                                unique JFE Steel manufacturing process which produces 
                         technologies, including billet temperature control during                                              high strength, high ductility tubular products by apply-
                         pipe rolling, optimization of piercing conditions, optimi-                                             ing warm reduction after electric resistance welding.
                         zation of the pass schedule in mandrel rolling, etc1).                                                       As  a  steel  tube  for  machine  structural  use  which 
                              The seamless pipe mill also has processing equip-                                                 satisfies  both  high  strength  and  high  ductility  require-
                         ment for production of threaded joints for OCTG.                                                       ments, the HISTORY tube was developed for applica-
                              2.3  ERW Pipes and Tubes                                                                          tions which assume high formability, such as automobile 
                                                                                                                                suspension  parts2).  The  HISTORY  tube  manufacturing 
                              As manufacturing facilities for ERW pipes and tubes,                                              process is shown in Fig. 3.
                         JFE Steel has a four ERW lines at Chita Works and a one                                                      With this manufacturing process, strength and duc-
                         ERW line at East Japan Works (Keihin District).                                                        tility  are  improved  by  performing  warm  reducing,  in 
                              These facilities  each  have  distinctive  features,  giv-                                        which the tube is heated after normal electric resistance 
                         ing the company a system for manufacturing steel pipes                                                 welding; this results in texture formation simultaneously 
                         JFE TECHNICAL REPORT No. 7 (Jan. 2006)                                                                                                                                                           3
                                                     Manufacturing Processes and Products of Steel Pipes and Tubes in JFE Steel
                                                       Fig. 3   Schematic manufacturing procedure of HISTORY pipe
                 with refinement of the crystal grain size and refinement                         Works (Fukuyama District) and East Japan Works (Chiba 
                 of carbides. These improved properties enable a 20–30%                           District).  These  plants  mainly  produce  high  grade 
                 contribution  to  weight  reduction  in  automotive  parts.                      linepipes.
                 The problem of hardening of the weld seam is also elim-                              In manufacturing high quality linepipes, the proper-
                 inated by warm reducing.                                                         ties and quality of the plates used as material are impor-
                        2.3.3 Outside coated products                                             tant. The  majority  of  materials  for  UOE  pipes  at  JFE 
                                                                                                  Steel are supplied by Fukuyama District. The plate mill 
                        The 24” mill at East Japan Works (Keihin District)                        at Fukuyama District operates the state-of-the-art Super-
                 has  outside  coating  equipment,  making  it  possible  to                      OLAC (on-line accelerated cooling) thermo-mechanical 
                 manufacture pipes which require outside coatings.                                heat  treatment  equipment  and  HOP  (heat  treatment 
                     2.4  Butt Welded Steel Pipes and Tubes                                       on-line process), which is the world’s only on-line heat 
                                                                                                  treatment equipment for plates4). 
                     The butt welded pipe mill at East Japan Works (Keihin                            Utilizing these facilities, JFE manufactures as-rolled 
                 District) mainly produces SGP as specified in the Japa-                          high grade steel plates with high strength and excellent 
                 nese Industrial Standards (JIS)3). This plant produces Zn                        weldability as material for UOE pipe.
                 galvanized steel pipes used in city gas and water piping 
                 and resin-coated corrosion-resistant steel pipes.                                3.  Steel Pipe and Tube Products
                     2.5  UOE Pipe                                                                    Steel pipes and tubes are employed in a variety of 
                     JFE  Steel  has  one  UOE  mill  each  at  West  Japan                       applications,  from  linepipes  and  OCTG5)  used  in  the 
                                    Table 2  Major products of pipe and tubes and their manufacturing procedures in JFE Steel
                            Application             Manufacturing procedure                                           Description
                   General and building structure   UOE, SP, ERW                Marin structure, Pile, Square pipe
                   Piping                           ERW, BW                     Galvanized pipe, Inside lining pipe, Polyethelen coated pipe
                                                                                Tubing, Casing
                   Oil country tubular goods        SML, (ERW)
                                                                                Drill pipe
                   Line pipe                        SML, ERW, UOE               Transpotation of oil, gas, and water
                   Boiler and heat exchanger        SML, (ERW)                  Heat exchanger pipe for heat recovery boiler
                   Machine structure                SML, ERW, HIS               Parts for automobile, Gas cylinder
                  SML: Seamless pipe,   UOE: UOE pipe,   SP: Spiral pipe, 
                  ERW: Electric Resistance Welded Pipe,   BW: Butt Welded pipe,   HIS: HISTORY pipe
                 4                                                                                                    JFE TECHNICAL REPORT No. 7 (Jan. 2006)
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...Jfe technical report no jan manufacturing processes and products of steel pipes tubes in masamura katsumi nagahama yutaka abstract distinctive features operates facilities for seam at less various types welded order to pipe tube system respond a wide range customer requirements dis tinctive include large diameter heavy wall electric resistance its east japan works west erw linepipes uoe high strength chita performance an outline the pro formability used automotive parts cess is shown fig depending on this paper presents process can be divided into three classes together by welding method i e arc resis with representative tance butt manufactured further introduction bending press spiral differences forming among as result merger former kawasaki hot rolled sheet mate nkk april rial newly created while plates are was expanded four districts chiba district keihin fuku s yama comprise one line each specialized mills product encom passing seamless including lines two supplies table shows all...

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