TPI March 2022

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The trade magazine for tube and pipe products

March 2022

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Business & market news

Severstal increases supplies to export markets and announces new opportunities for 2022

Severstal has shared its energy market outlook for 2022 and provided an overview of key achievements in 2021 at an on online media briefing. Dmitry Goroshkov, director of sales and business development, energy led the briefing, which highlighted that Izhora Pipe Mill’s share of exports in the order book increased by 11pp in 2021 compared to 2020, with large diameter pipes (LSAW) remaining a key product for the energy segment. Volumes supplied to export markets more than doubled in 2021 compared to 2020. Mr Goroshkov said: “2021 has been a very productive year for Severstal in the energy market. We more than doubled our export volumes and significantly expanded our sales geography. “Next year, we will continue to further build on this, focusing on offshore and sour service projects while expanding our wind energy and hydrogen trans- portation market presence.” Last year, the company significantly expanded its sales geography with shipments to a number of new regions, including South America (Brazil & Peru) and Canada. Severstal continues to

Last year, the company significantly expanded its sales geography with shipments to a number of new regions

Large diameter pipes (LSAW) remained a key product for the energy segment in 2021

up with several market leaders with the goal of developing the best design and material solution for hydrogen pipelines as early as 2022. Severstal has also expanded its presence in the wind energy sector, aiming to support the continued development of the renewable energy sector in Russia to provide companies with more opportunity to reduce their environmental impact. WindarSeverstal, a join venture between Severstal and Renovables SL, has produced over 340 steel towers for wind turbines. Severstal www.severstal.com FEM plugs are available with pressure eliminator resulting in the possibility to connect couplings in the presence of accumulated or residual pressure without any problems. A miniature valve automatically relieves the pressure in the connecting phase. The new FEM series is resistant to vibrations and other mechanical stresses. Whether being used in mobile hydraulics, transport or construction industry, the process of connection and disconnection is designed to be fast and safe, with the locking sleeve as standard to avoid accidental disconnection.

develop mutually beneficial partnerships with customers in Europe, MENA, South and North America. In Canada, the company strengthened its co-operation with local distributors. Severstal also reported a significant number of new product qualifications. It is now qualified to supply to 38 new companies, including EGPC, GASCO, ADNOC, McDermott and ILF, bringing its total number of qualifications to 66 at the end of 2021. The company has continued to explore newopportunities, including in hydrogen transportation, and has partnered with the DNV GL Design and Operation of Hydrogen Pipelines initiative, teaming Motion and control technologies company Parker Hannifin has launched the new optimised FEM Quick Coupling Series, which offers an increased working pressure up to 350 bar and a decreased pressure drop for better flow properties. The revised and updated FEM and FEC series have profiles corresponding to ISO 16028 and exceed the technical requirements in the ISO 16028 specifications. They are compatible with other series complying with the same standard. The couplings offer a spillage-free disconnection, minimal oil loss during uncoupling and are also easy to clean as they have flat face valves/ bodies. The new valve design means that the couplings are cost effective and have a minimum pressure drop.

Parker High Pressure Connectors Europe launches new optimised FEM quick coupling series

The new FEM Quick Coupling Series offers an increased working pressure up to 350 bar

Parker Hannifin www.parker.com

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Business & market news

SFL creates the world’s first stainless steel coolant distribution unit for high performance cooling

brass or copper. Another advantage is lower maintenance costs as the coolant fluid does not need to be filtered or changed as frequently. A further benefit is that stainless steel is resistant to both corrosion and leaks. After the unit was unveiled at the exhibition, orders flowed in from around the world and SFL was asked to manufacture 50 kits, destined for end customers located in Australia, Japan and the US. Andrew Sharp, manufacturing manager at SFL, and part of the team that worked on the CDU project, said: “As well as becoming part of our client’s design engineering team, working on the design concepts, we also helped with the ongoing manufacture and assembly of the pipework units. We even became part of their purchasing department, buying the various components we needed in order to build our stainless- steel kits. This puts us in a strong position to help other manufacturers of large data centre cooling systems who are looking to benefit from the advantages of stainless-steel pipework in their units.” Stainless Fittings Limited www.sfluk.co.uk in – aerospace, medical, oil & gas, and nuclear – are all very exciting to me, and offer significant future potential.” Prior to joining Fine Tubes, Mr Brear held various positions of responsibility at a number of manufacturing companies in the UK and US. He has a bachelor of science degree in Business Economics as well as an extensive background in metals manufacture and engineering. Tom Matway, vice-president and general manager at AMETEK engineered materials, interconnects and packaging, added: “We are very pleased towelcome Martin to the Fine Tubes and AMETEK SMP team. His extensive experience in specialty metals, international business, and commercial leadership will help grow our Fine Tubes business around

approach, the team successfully arrived at the first version of the CDU pipework that fitted perfectly into the same footprint. SFL’s next task was to manufacture the set of pipework for the prototype unit, ensuring the kit was manufactured to the highest possible standard. SFL then assisted in the assembly and successful fitting of the pipework into the initial unit. The unit was then shipped off to a major trade exhibition in the US to demonstrate the first stainless steel CDU for high performance computing and enterprise data centres. Following the initial blueprint of the prototype design, SFL helped its client fix a number of bugs and resolve a few issues in order to create the optimum design. Once everyone was happy with the final result, the team was then in a position to embark on full-scale manufacture. Switching from brass to stainless steel offers a marked increase in quality and purity that had never been available in this market before. For example, stainless steel pipework in CDUs means improved performance, as the coolant fluid flows more efficiently through stainless steel pipes, compared to

A manufacturer of data centre cooling units had received a request from one of its customers to supply its coolant distribution units (CDUs) with stainless steel pipework instead of the traditional brass or copper. Realising this was a gap in the market that needed filling, the manufacturer turned to Stainless Fittings Limited (SFL) to see if it could help. Given SFL’s extensive manufacturing knowledge of, and experience in, stainless steel pipework, it was in an excellent position to advise and guide the CDU manufacturer. So began a four-year journey during which SFL assisted its client in the design, manufacture and assembly of the world’s first stainless steel coolant distribution unit. SFL’s initial input into the project was to help in the design of the stainless-steel pipework that would be installed in the CDU. Working as an extension of its client’s engineering team, SFL helped create a series of 2D CAD drawings and 3D models. One of the challenges SFL faced was how to fit the new pipework into the existing space, given that stainless steel is not as malleable as brass or copper. Through its meticulous and methodical Mr Brear joined the business in November 2021 and now oversees the commercial strategy development and deployment, as well as growing customer relationships and accounts. He also has the remit of profitably growing business revenue for Fine Tubes in 2022 and beyond. Mr Brear said: “I am delighted to join Fine Tubes and believe I can make a real difference in my new role. Fine Tubes is an exciting business with plenty of growth opportunities. Being part of the wider AMETEK Specialty Metal Products Division (SMP) gives us the right blend of security and financial backing from a larger organisation, combined with the agility that comes with operating as a smaller entity within it.

Fine Tubes appoints new commercial director Precision metal tubing manufacturer Fine Tubes has appointed Martin Brear to the key role of commercial director. “On a personal level, I love everything that goes with working with metal, and the sectors that Fine Tubes operates

the world.” Fine Tubes www.finetubes.co.uk

Mr Brear oversees the commercial strategy development and deployment

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March 2022 TUBE PRODUCTS INTERNATIONAL

Business & market news

Strohm and Siemens Gamesa collaborate for offshore pipe infrastructure

exciting collaboration, working with Siemens Gamesa to understand how TCP can be the missing link in an offshore wind farm, generating green hydrogen. The key attributes of TCP – flexibility, no corrosion or maintenance requirements – allow for the most cost- effective infrastructure on a given wind farm. Our proven track record with TCP offshore is a pre-requisite to be considered a solution in future green hydrogen.” Produced at Strohm’s plant in The Netherlands, the TCP is a corrosion- resistant technology that does not fatigue or suffer from issues associated with using steel pipe for hydrogen, such as embrittlement. Manufactured in long spoolable lengths and flexible in nature, the pipe can be pulled directly into the wind turbine generator, quickly and cost effectively building an offshore wind farm infrastructure. TCP does not require any maintenance and is suitable for over 30 years in operation, lowering the levelised cost of electricity (LCOE) to a minimum and enabling the decentralised concept solution. Siemens Gamesa has already taken steps in shaping the industry and developing the basis for a decentralised offshore solution that fully integrates an electrolyser into an offshore wind turbine, with clear benefits and value- add potential such as capex reduction, increase of system efficiency, and increase of wind farm uptime. Finn Daugaard Madsen, innovation manager – Power to X at Siemens Gamesa, added: “At Siemens Gamesa, we believe in the potential of green hydrogen and have been working on the decentralised concept for some years. Strohm has supported us through several case studies, identifying the solutions that can be readily used, which complement our own systems. “This partnership will assist us to innovate together in an open format, accelerating the availability of green hydrogen.” Strohm www.strohm.eu Siemens Gamesa www.siemensgamesa.com

hydrogen concept, whereby green hydrogen is generated in each wind turbine generator and transported to shore by a subsea pipe infrastructure. In this concept power cables are replaced by a pipe infrastructure, storing and transferring hydrogen. Siemens Gamesa has a technical advisory role. Martin van Onna, chief commercial officer at Strohm, said: “This is a truly

Strohm, a manufacturer of fully bonded, Thermoplastic Composite Pipe (TCP), has signed a memorandum of understanding with Siemens Gamesa Renewable Energy, a specialist in the development and expansion of onshore wind. The collaboration will focus on developing hydrogen transfer solutions that improve the decentralised green

Strohm and Siemens Gamesa collaborate on offshore green hydrogen solutions

Corinth Pipeworks awarded contract from GAZ-SYSTEM SA Poland

evaluated and ranked first amongst other international and Polish manufacturers, as being the most advantageous. Its value amounts up to €47mn including quantity and transportation tolerance. The aim of the project is to build a high- pressure gas pipeline from Gustorzyn to Wronow, which will enable the transmission of increased volumes of gas to Warsaw and Lodz agglomerations, Radom and its surroundings, and to the south-eastern regions of Poland. Pipes manufacturing and coating will take place at Corinth Pipeworks’ facilities in Greece. Deliveries are planned to start in Poland at the beginning of April 2022 and conclude by August 2022. Corinth Pipeworks www.cpw.gr GAZ-SYSTEM SA www.en.gaz-system.pl

Pipe manufacturer Corinth Pipeworks has won the contract to supply steel pipes for the Gustorzyn – Wronow gas pipeline. The linepipe contract from the gas transmission operator of Poland GAZ- SYSTEM SA forms part of Gustorzyn – Wronow gas pipeline in Poland and comprises of 80km of 40" coated steel pipes. Corinth Pipeworks’ proposal was

The aim of the project is to build a high-pressure gas pipeline from Gustorzyn to Wronow

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The S. F. E. Group will be exhibiting at MACH 2022 from 4 - 8 April 2022 at the NEC Birmingham, UK Come and visit us at: Stand 6-580

Introduction to S.F.E. Group S.F.E. Group was founded in 2019 after the merger of three world leading OEM’s in the field of pipe fabrication tooling and machinery: B&B Pipe and Industrial Tools LLC (USA), Mathey Dearman Inc. (USA) and TAG Pipe Equipment Specialists (UK). Most recently the S.F.E Group has completed the acquisition of the Axxair Group (France).

Business & market news

ICR Integrity plays critical role in Cruden Bay terminal’s regeneration ICR Integrity (ICR), a provider of integrated maintenance, repair and production solutions for the offshore oil & gas, power, defence, nuclear, utilities and renewables industries, has completed a scope of work for Doosan Babcock on the Forties Pipeline System (FPS) shutdown project at the Cruden Bay Booster Station, in North-east Scotland. The use of ICR’s team meant time and cost savings for the three-week shut- down. The project is intended to ensure reliability to 2040, and supported the removal and reinstatement of the main valves and piping from the sealine receiver from the Forties field through to the new, above ground, piping sys- tem and pig launcher at the land line during the planned FPS outage scope. Shane Gregory, business development manager, ICR, said: “This has been a great project to be part of – our client Doosan Babcock made us an integral

The project is intended to ensure reliability to 2040

to embedding a team for the outage at site. The ICR team were responsible for bolt tensioning, torquing and flange management work for the above ground large bore piping and valves, which led to a 14-person multi-skilled team working 12-hour shifts day and night, back-to-back, during the shutdown to complete the critical path works. The team also completed pre outage hot bolting, outage bolting operations, pipe cutting for removal of the redun- dant piping and land-line launcher, line boring on critical path spool work and the reinstating of all large bore spools and valves. Colin Macdonald, construction manager at Doosan Babcock, added: “There was a good collaborative approach to this scope of work involving all parties. “ICR supported and integrated well into the team, to ensure a safe and quality deliverable for the project.” ICR Integrity www.icr-world.com

part of their planning for the tight turnaround window a shutdown brings, and our teams have really delivered. “The final completion of the leak testing package gave the site a 100 per cent pass rate, meaning the sealine could be de-isolated to enable offshore to start pumping again.” The regeneration works at Cruden Bay is a critical part in the shutdown of the FPS, requiring close planning with the Doosan Babcock site construction team for several months during the construction phase of the project, prior

TechnipFMC and DOF Subsea awarded long-term contracts by Petrobras

Ltda, a 50/50 joint venture between TechnipFMC and DOF Subsea. Each contract is for three years, with an option to extend. Operations are expected to begin by February 2022. Skandi Niteroi will operate mostly in shallow water, while Skandi Vitória will work in shallow and deep water. Both vessels will perform decommis- sioning and subsea installation work. TechnipFMC www.technipfmc.com DOF Subsea www.dofsubsea.com

TechnipFMC and its joint venture partner DOF Subsea have been awarded a long- term charter and services contracts by Petrobras for the pipelay support vessels Skandi Vitória and Skandi Niteroi. Jonathan Landes, president, Subsea at TechnipFMC, said: “Our vessels serve as an important component of the strong flexible pipe ecosystem we have in Brazil. We are proud to extend our multi-decade relationship with Petrobras through these long-term contracts, which are built on close collaboration and our client’s trust in our ability to safely and efficiently deliver quality.” The Brazilian-built and flagged vessels are owned by DOFCON Navegação

The Forties Pipeline System (FPS) shutdown project at the Cruden Bay Booster Station, in North-east Scotland

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TMK and IRE-POLUS to use laser technology in pipe manufacturing Producer of tubular products for the oil & gas industry TMK, and IRE-POLUS, the founder of research and development (R&D) group IPG Photonics Corporation, have signed a programme for joint development and adoption of laser technology in pipe manufacturing at TMK sites. The document was signed at Metal-Expo’2021, the 27 th International Industrial Exhibition. The programme is designed to improve the efficiency of manufacturing processes for tubular products and parts through laser technology as well as to explore new applications for these technologies. The parties intend to implement several projects across a range of areas by 2023, including new high-tech products with improved performance; improvements to manufacturing and repair technology to maximise cost efficiency; R&D- intensive solutions; and equipment upgrades. Sergey Chikalov, first deputy CEO for operations and development at TMK, said: “TMK is constantly improving its R&D capabilities and continuously driving innovation across its operations. Laser technology is currently cutting edge, and we are the leader among pipe and steel companies in adopting this technology: our Chelyabinsk Pipe Plant was the world’s first manufacturer to develop and operationalise laser welding of longitudinal seams in large diameter pipe. “The cooperation programme signed today with IRE-POLUS, the global leader in fibre lasers, will boost TMK’s efforts in this area to bring a new level of technology. The programme will unlock even broader opportunities for TMK to apply these technology solutions across its operations.” The partners plan to use laser welding solutions for tubular products and parts to design a “next-generation pipeline” model of high-strength steel. The programme also aims to harness laser welding technology for casing and stainless steel pipes. Another collaboration will include the use of laser cladding and hardening to restore the operability of tools, parts and accessories used in pipe manufacturing. The technology will extend equipment service life and improve product performance, such as resistance to corrosion, high temperatures, impact and abrasion. The two companies will also investigate using manual laser welding for repairing pipe weld seams and body and for upgrading the existing laboratory laser installations at TMK facilities to create a new laser technology platform. Nikolay Evtikhiev, CEO of IRE-POLUS, said: “Rolling out our fibre lasers and driving innovative new use cases for this technology in real industrial settings to maximise manufacturing efficiency is IPG’s priority. By partnering with TMK, a clear industry leader, we will definitely achieve impactful and tangible results and once again demonstrate that our technology solutions can make all the difference.” TMK www.tmk-group.com

20–24June 2022

SAVE THE NEW DATE

join the best: Düsseldorf Germany www.tube.de

join the best — welcome to the world’s leading trade fair for the tube industry! Anyone who wants to gain comprehensive information on innovation and pioneering trends in the industry, or on machines and systems, pipe fittings and the tubing industry, will not want to miss out on the most important showcase in the world: This is the international meeting point for trade professionals, for specialists and world market leaders. Discover new paths to sustainability by following the ecoTrails to the exhibitors that have dedicated themselves to providing truly sustainable technology and process chains. Find out more at tube.de/ecometals_en.

A constant in your calendar — visit Tube 2022 in Düsseldorf!

International Tube and Pipe Trade Fair Internationale Rohr-Fachmesse

Plants and Equipment

Pipe and Tube Processing Technology

Bending and Forming Technology

Tube Manu- facturing and Distribution

Tube Accessories

Profiles

Plastic Tubes

Messe Düsseldorf GmbH P.O. Box 10 10 06 – 40001 Düsseldorf – Germany Tel. +49 211 4560 01 – Fax +49 211 4560 668 www.messe-duesseldorf.de

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March 2022 TUBE PRODUCTS INTERNATIONAL

Business & market news

WITT-Gasetechnik expands its ULTRA model range WITT-Gasetechnik has introduced new, larger ULTRA 30 and ULTRA 40 models to its range of ULTRA non-return valves. The ULTRA 30 and ULTRA 40 extend the model range to now include four models with type-dependent connections from ½" to 2½".

The ULTRA series is the latest generation of non-return valves from the gas safety technology company and offers performance features such as high, optimised flow rates despite its small size and an opening pressure of around 4 mbar, making them ideal for low pressure applications. “We are pleased to further expand our range of high-performance models with the ULTRA 30 and 40,” said sales manager Andrew Smart. “This will enable us to provide our customers with further competitive advantages.” The ULTRA is small in size, has a low weight, high flow, low pressure drop, and low-noise operation.

The valves can also be configured to meet specific requirements. Brass, stainless steel or aluminium housings can be combined with sealing materials such as FPM, EPDM or FFKM. The ULTRA series is suitable for towns/ natural gas, as well as for LPG, propane and hydrogen. The non-return valves can be installed in any position and are available with G or NPT threads. They are cleaned for use with oxygen in accordance with the EIGA and CGA standards.

The ULTRA 30 and ULTRA 40 extend the model range to now include four models with type-dependent connections

Design engineers can also reduce the system size and increase efficiency at the same time as well as reduce costs in pipework, thanks to smaller nominal diameters, for example in low pressure natural gas lines.

WITT-Gasetechnik www.wittgas.com

Decom Engineering celebrates three contract wins and a strong performance in 2021

Decom’s cutting technology engaged in a 1,000-cut programme to remove seabed pipeline infrastructure located in water depths of 70 to 100m and includes concrete-coated pipelines ranging in diameter from 5 to 18". Prior to the Asia Pacific mobilisation, Decom completed the cutting of a production spool in 160m of water from one of the UK North Sea’s most northerly platforms, which followed on from supporting a well-abandonment workscope located in the Kinsale gas field in the Celtic Sea, off the south coast of Ireland. In addition to the triple contract, Decom has invested £200,000 to establish a new operational base near Aberdeen, Scotland, and will mark its opening in the coming weeks with a series of technology showcase demonstrations for UKCS-based clients. “With the imminent opening of our new facility in Aberdeen, located on the doorstep of a strategically important North Sea client base, and further investment planned for extending our equipment fleet, we are very much looking forward to taking the business to new levels of activity in the year ahead.” Decom Engineering www.decomengineering.co.uk

half of 2021 with lots of strong interest in both our cutting tools and our Pipeline Coating Removal technologies. This has been sealed with landing our largest-value cutting project to date, and if all goes to plan in the Gulf of Thailand, we expect this will create more opportunities. “We are in the process of tendering for a number of other significant contracts, which if successful would propel the business forward and ensure we start 2022 in a very strong position.”

Decom Engineering Limited (Decom) has announced three international contract wins valued at more than £400,000. solutions company has deployed two of its pipeline cutting saws to the Asia Pacific region to start a six-month campaign on behalf of a global oil & gas operator, following on from two other projects in the North Sea and Celtic Sea. Decom Engineering chief executive officer, Sean Conway, said: “We had an extremely busy and successful final The decommissioning

The Gulf of Thailand project will see

The decommissioning solutions company has deployed two of its pipeline cutting saws to the Asia Pacific region to start a six month campaign

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Business & market news

New technology for production of green hydrogen will support future energy needs

The aim of the project is to develop a new generation of electrolysers that contain new design concepts for com- ponents, all in order to have the pos- sibility to scale production depending on the needs. This has resulted in the project being conducted as a research and develop- ment project, where the challenges are handled in an interdisciplinary manner with significant analysis, experiments, and input from various experts. Magnus Thomassen, CPO and co-founder of Hystar, added: “We are very happy to be able to work with Semcon. They have specialist expertise in many areas that complement what we have internally, and they can contribute with exactly the right person when the need arises.” Hystar’s aim is for its products to be used in many different industries as well as for fuel in all forms of transportation. Semcon Hystar www.semcon.com www.hystar.com

Product development company, Semcon is collaborating with Norwegian company Hystar to develop new technology for hydrogen gas production. The project aims to increase the amount of hydrogen gas that can be produced through electrolysis by over 150 per cent compared to current electrolyser technology – without using more energy. To produce renewable green hydrogen gas is identified as a priority by the EU and crucial to achieving the European Green Deal. Tommy Ekman, technical lead and project manager at Semcon, said: “The electrolyser technology we’re developing together will allow Hystar to produce highly energy efficient electrolyser stacks, with the potential to reduce the capital cost of electrolysis by up to 60 per cent. This is something that the world really needs.” Traditional production processes, in which hydrogen gas is produced from natural gas, emit large amounts of CO 2 . A more eco-friendly alternative is

water electrolysis, in which electricity is used to split water molecules into hydrogen and oxygen. When electricity from renewable sources is used for this process, the result is classified as green hydrogen. “Green hydrogen is key for the energy transition and provides a possibility to fully utilise renewable energy sources in the decarbonisation of various sectors,” added Mr Ekman. Hydrogen can be used not only as a fuel in fuel cells to decarbonise the transport sector – in particular, heavy transport segments such as trucks, boats, and machinery – but it can also be used to decarbonise industry. A good example is the steel production industry, where hydrogen can be used for heating or directly as a reducing agent. The recently published EU strategy for hydrogen gas identifies renewable, green hydrogen gas as crucial to achieving the European Green Deal – one of the European Commission’s six priorities for the years 2019 to 2024.

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Reducing scale-related problems during the process of making steel for tube production By Daniel Vila-Flor, Dipl.-Ing, DMK Oy

Yield loss is not the only problem associated with scale. Other major problems that affect quality are rolled in scale defects. Scale by its nature is harder than the hot piece of steel being formed. If it is left on the surface of the steel when the billet/ shell/slab/etc is rolled, the scale is rolled into the surface causing pits, scratch, cracks, or other-shaped defects, in the surface. As the billet/shell/slab/etc is then elongated, the size of these defects are multiplied by the elongation and can stretch up to the entire length of the final product. The result is significantly poor surface quality with potentially the whole piece needing to be recycled. In addition to the surface of the product being damaged by scale, the scale may also stick to and damage the surface of the rolls being used to shape the billet/shell/slab/etc. When this happens, the rolls stamp markings onto the billet/shell/ slab/etc causing repetitive surface damage. Depending on the process, this damage may worsen the surface quality and can also cause the end product to be recycled. The surface of the rolls are also damaged by the scale, something that degrades the tool life of the rolls and increases tooling costs. The industry standard solution is descaling. Descaling is the process where a hot billet/shell/slab/etc comes out of the furnace and the surfaces are blasted with high pressure water to remove the scale. This solution works but is not without its limitations. The first problem is efficiency. It has been reported that descaling by water is not effective with the more specialty steels. As a result higher pressure more expensive descalers have been installed in an attempt to overcome this obstacle. The second, perhaps more significant problem, is heat loss. Because the surface of the steel is blasted with water, this cools the surface down; with a lower temperature it becomes harder to roll multiple pass with the billet/shell/slab/etc. Because of this billet/shell/slab/etc are typically descaled only once, because otherwise the temperature drops so low that the steel becomes extremely difficult to roll. This is problematic because during each rolling pass, the surface is elongated, allowing for additional new scale to form. While not all steel-forming processes require it, some processes sandblast or pickle the end piece during finishing to remove scale and other surface defects. This process, depending on the level of surface quality, entails an additional cost, which, in some cases, can be significant. Depending on the pickling technology being used, the cost can vary between €12-15/ ton. With a mill producing 1.3million tons annually, the annual pickling cost may vary between €15.6 to €19.5mn. The solution to all of these problems is ScaleFree technology. ScaleFree technology consists of two components: equipment and a coating product.

The formation of scale begins when the surface of a steel billet/shell/slab/bar/etc, is heated to high temperatures and exposed to oxygen. High temperature is required to enable the reaction of oxygen to the steel, thus forming scale (or oxides). Depending on the process and material conditions, scale formation, and resulting yield losses, have been typically reported to be between 2-4 per cent but, in some cases, actual losses may be much greater than that. The cost to the producer of steel can be easily calculated: The problems that scale causes occur immediately after formation and may compound during the following rolling and forming processes. Although there have been signifi- cant studies conducted by various steel mills, and at the EU level, no proper technology by these parties has been developed that would solve the problems associated with scale. ScaleFree technology, as the name suggests, is a technology developed, tested and proven to work to reduce scale-related problems extending from casting to finishing. Within the process of making steel, regardless of shape, size or material, the process creates scale. Scale (also known as oxide) forms when the surface of the steel is heated to temperatures exceeding 600 o C while being exposed to oxygen.

1,3 million tons/year * 3%

*

500eu/ton = €19,500,000

Annual production

scale formation

cost of

cost of

losses

steel

scale loss

As demonstrated above, the cost of yield losses due to the formation of scale is significant. However, as the formation of scale is inherent to the process of making steel, steel producers have grown accustomed to accepting these needless losses. ScaleFree technology has been proven to reduce scale formation from up to around 45 per cent and, in some cases, up to 90 per cent.

Effect of ScaleFree technology

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TUBE PRODUCTS INTERNATIONAL March 2022

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Improvements for seamless tube The seamless tube industry has gone through certain revolutions process improvements. PQF/FQM mills which replace previous MPM, FMM and Plug mills have been installed across the globe thanks to the successes of their respective manufacturers. However, even with these new mill types, the basics of seamless tube remain the same, and what remains as two critical areas that have been neglected are deoxidation and mandrel bar lubrication. A case for deoxidation improvement Deoxidation remains a critical process within the seamless-tube manufacturing process. When a round billet is pierced, scale formation starts immediately inside the newly formed shell. This scale, if not handled correctly, will cause serious problems throughout the rest of the process. Typically, immediately after piercing, the loose scale is blasted out through the shell via a method referred to as Scale Blowout. Immediately after that, deoxidation powder is blown through. This powder interacts with the scale and turns it into a lubricating liquid. The shell is then transferred to the next process where a graphite-coated mandrel is inserted into the shell and together they are rolled in the rolling process. The amount of powder that is blown has drastic consequences for the final pipe quality: too little powder and the scale is not melted, while the operator risks having significant wall thickness variation and rolled-in scale defects. If too much powder is added, the added mass can cause serious cold bits to form on the mandrel, stopping the process altogether. Therefore, it is critical that the deoxidation powder is properly applied. Design Management Konsulting Oy (DMK) has just delivered the most modern deoxidation system currently known. The system allows for the handling and injection of powder to be located further away from the powder nozzle than ever before. The spray has been optimised using high-level 3D printing techniques. But the most important feature is the dosing accuracy. Where current and previous systems boast an accuracy of ±10 to 20 per cent, the DMK system boasts an accuracy ±6 per cent, which can be further improved, if process conditions allow, to ±1.5 per cent. This improvement not only saves the mill money in deoxidation powder consumption, but permits having a tighter control of the amount of powder being dosed. Having better control of the deoxidant powder allows for the operator to have a tighter control of the entire process and therefore allows the operator to improve product quality, consistency, overall efficiency and savings due to improved prime yield. A case for mandrel-bar lubrication improvement The other significant, and often under-engineered, process in many seamless-tube mills is the Mandrel-Bar Lubrication (MBL) system. After piercing, the shell is transferred to the front of the rolling mill where a coated mandrel is inserted. The mandrel is coated with a graphite lubricant by the MBL

These are applied in the following way: the ScaleFree equipment is installed in a location where scale formation is at its lowest, typically right after casting or descaling. The ScaleFree equipment then sprays the ScaleFree coating onto the hot billet/shell/slab/etc forming a 5-80µm protective layer on the surface. The ScaleFree layer then inhibits the formation of scale by significantly reducing the interaction of oxygen with the steel surface. The ScaleFree coating further reacts only with the existing surface scale to turn it into a lubricating paste. This results in a protective layer being formed on top of the steel so that: • The billet/shell/slab/etc can be reheated with only a limited amount of new scale being formed • Rolling loads are reduced, which then improves tool life • Scale pickup on the rolls is reduced, further improving tool life • Rolled-in scale defects are also minimised, thus improving surface quality • Pickling costs shrink since the method improves pickling efficiency • Sandblast costs are reduced due to improved surface quality The benefits of ScaleFree technology are significant. With a yield improvement of 33 per cent the customer’s plant could save almost €6.5mn annually. With increased pickling efficiency of 25 per cent the customer could save an additional €4.4mn annually. With the average operating cost being €1-4/ton the impact for the customer, not only in direct financial savings but also improved quality, increased efficiency and value-added prime yield, is clear. Investing in ScaleFree technology is both financially and technically sound. ScaleFree technology has been tested with major companies within the steel industry and is currently being implemented in locations around the globe. Design Management Konsulting Oy (DMK), is looking for new locations and interested partners to further implement ScaleFree technology.

Deoxidation system with overhead crane loading and climate control cabinets

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March 2022 TUBE PRODUCTS INTERNATIONAL

Standard system – loose, porous application

DMK system – clean, tight, dry film

the flow rate. If the operator increases the flow, the operator risks flooding the mandrel bar with too much graphite. Another key issue with many MBL systems is the manner in which they are pumped. Some systems use air-driven diaphragm pumps, or piston pumps. Diaphragm pumps do not give a good even flow while piston pumps wear out, due to the diamond like hardness of graphite. Strong pulsation and uneven flow cause even further problems with the application of lubricant through airless nozzles. The DMK MBL consists of air-assisted nozzles driven by positive displacement-metering pumps with “pulse free” linear flow. Air-assisted nozzles allow the DMK MBL system to both atomise and adjust the fan width for each mandrel size without replacing nozzles and at different flow rates. This allows for exceptional lubricant adhesion and reduces drying time significantly, thus providing excellent lubrication and thermal properties. In addition, the positive displacement pump that DMK uses allows the operator to adjust the flow on the fly with high accuracy output. These key features place the DMK MBL system a large step ahead of current systems, in my opinion, and provides the customer with the reliability, control and high quality production required in today’s highly competitive markets.

system. This coated mandrel serves as a mould, allowing for the rolling mill to elongate the shell along the length of the mandrel setting the shell ID and forming a pipe. As the graphite lubricant layer is situated between the mandrel and shell ID, its role as a lubricating layer and insulation layer are critical. If there is significant variation in the graphite layer, risks arise. The graphite layer works as a form of insulation for the mandrel to reduce thermal cycling. Thermal cycling is the repetitive cycle of heating and cooling of a work piece, in this case the mandrel. If the surface of the mandrel suffers from significant thermal cycling, the mandrel will wear out faster, significantly increasing tooling costs for production. Furthermore, significant variation in the coating will result in variation of the elongation of the shell and the resulting wall thickness, thereby affecting pipe quality. Moreover, if there is not enough graphite on the mandrel, the risk is high that the shell will stick to the mandrel, causing production to stop. Additional risks include damage to the rolls, the rolling mill and to the mandrel itself. It is therefore critical that the graphite lubricant be properly applied to the mandrel with a proper MBL system. With many of the presently used MBL systems, the graphite is pumped through airless nozzles. The problem with airless nozzles is two things: first, the spray fan is fixed, and, second, atomisation is dependent on the flow rate. Neither of these options allow for good control of the spraying of the lubricant on the mandrel. With a fixed spray fan, the operator has no ability to optimise the spray pattern for different-size mandrels, or allowing for over or under application of the lubricant. With too small a spray fan, portions of the mandrel risk being left exposed and uncoated. With too large a spray fan, lubricant is lost as it is sprayed past the mandrel, creating variation in the lubricant layers. In both cases, the spray fan will not coat the mandrel properly. The second problem, and probably the more significant one, is the atomisation of the lubricant droplets. Atomisation of the lubricant is the transformation of the liquid graphite into a fine spray of tiny droplets or even a very fine mist. With airless nozzles the atomisation is controlled by the flow of lubricant through the nozzle. Therefore, if the operator wants to increase the atomisation, the operator needs to increase

DMK Oy – Finland sales@dmkoy.com www.dmkoy.fi

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TUBE PRODUCTS INTERNATIONAL March 2022

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