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007 02 PDF
007 02 PDF
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Originally published in JFE GIHO No. 9 (Aug 2005), p. 1–6
*1 *2
Dr. Eng., 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
Table 1 Manufacturing facilities for pipe and tubes production in JFE Steel
Available size (mm)
Kind Works Line Remarks
OD Wall thickness Length
Small diameter Mannesmann piercing/
Chita Works 25.4– 177.8 2.3–40.0 22 000
seamless pipe mill Mandrel mill
Seamless pipe
Medium diameter Mannesmann piercing/
Chita Works 177.8– 426.0 5.1–65.0 13 500
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 External and internal
406.4–1 422.4 6.0–50.8 18 300
(Fukuyama) pipe mill coating facility
West Japan Works
Spiral Spiral pipe 600. –2 540.0 6.0–30.0 35 000
(Fukuyama)
Small diameter
Chita Works 28.6– 76.4 0.6–10.0 18 000
ERW pipe mill (3”)
Small diameter
Chita Works 60.5– 168.3 0.6–10.0 18 000
ERW pipe mill (6”)
Welded pipe
Small diameter
Electric Chita Works ERW pipe mill (4”) 21.3– 114.3 1.8–12.7 16 000
resistance HISTORY
welded pipe
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
24” ERW mill
(Keihin) 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
the Mannesmann piecing/plug mill process. The small-
2.2 Seamless Pipes and Tubes
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-
(mm) (inch)
2.5
2.4
2.3 Bending
2.2
2.1
50 2.0
1.9
1.8
1.7
Wall thickness
1.6 UOE
1.5
1.4
1.3
1.2
1.1
25 1.0
0.9
0.8 Spiral
0.7 SMLS
0.6
0.5
0.4 WFW
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, etc 1). 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-
tions which assume high formability, such as automobile
2.3 ERW Pipes and Tubes
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
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-
tant. The majority of materials for UOE pipes at JFE
2.3.3 Outside coated products
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
on-line process), which is the world’s only on-line heat
2.4 Butt Welded Steel Pipes and Tubes
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
energy industry to steel tube columns and steel tube result, JFE Steel has now become the world’s top maker
piles for construction and tubes used as materials for of 13% Cr OCTG.
automobile parts. Table 2 shows the main steel pipe Table 4 shows the chemical composition of corrosion
and tube products at JFE Steel and their manufactur- resistant OCTG at JFE Steel6). In addition to 13% Cr,
ing processes by application. JFE Steel supplies various which is the standard product, JFE steel also produces
products for a wide range of applications by combining HP1 and HP2, which provide improved corrosion resis-
the optimum chemical composition and manufacturing tance in high temperature environments. Because the
process. Representative products are outlined in the fol- service limit of HP2 is 160°C, JFE Steel is developing
lowing. UP15Cr for higher temperature environments.
next-generation products. In particular, JFE was the first manufacture boiler tubes with a maximum length up to
in the world to produce X100 at the mass production 22 m.
level and conduct construction tests of this product in
3.4 Steel Tubes for Automotive Applications9)
linepipe.
One example of the application of JFE Steel’s out- Steel tubes are increasingly used in automobile sus-
standing steelmaking technology is linepipe for sour pension parts in order to reduce weight. In addition to
service, which requires advanced inclusion control. material and product development, JFE Steel has also
This is a technology for preventing the phenomenon of devoted much effort to cooperation with users in second-
hydrogen induced cracking (cracking due to hydrogen ary forming technologies and performance evaluation
penetration in steel) in environments which contain H2S, technologies for steel tubes. The company’s high form-
and thus is extremely important for securing the safety ability ERW tubes10) and HISTORY tubes are continuing
of linepipes7). to be adopted as materials for automobile suspension
parts.
3.2.2 Heavy wall, high strength, high toughness
linepipe (ERW pipe)
4. Conclusion
With the aim of substituting ERW pipe for small
diameter UOE pipe, which have the drawback of low JFE Steel possesses products and manufacturing
productivity, JFE Steel developed high strength, heavy facilities which are capable of responding to diverse cus-
wall ERW linepipe using the 26” ERW mill at Chita tomer requirements. The company is also energetically
Works, resulting in a large increase in orders. engaged in various technical development efforts. This
Special Issue of JFE Technical Reports introduces the
3.2.3 Martensitic stainless steel (MSS)
results of recent technical development.
12Cr high corrosion resistance
linepipe (SML)8)
The linepipe called a flow line which is used
between oil wells and the gas treatment facility is References
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