The Düsseldorf-Rath Worksen.vallourec.com.cn/Uploads/other/20150920/The Dusseldorf...6 VALLOUREC &...
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The Düsseldorf-RathWorks
VA LLO U R E C & M A N N E S M A N N T U B E S
2 VALLOUREC & MANNESMANN TUBES
A comprehensive performance package
• One of the world’s largest and most efficient pilger rolling mills
• One of the most modern high-performance plug mills
• A comprehensive range of materials, from carbon to high-alloy
stainless steels
• Production of quality tubes in diameters of 193.7 to 711.0 mm and
wall thicknesses of 6.3 to 110.0 mm (for special sizes up to150.0 mm)
• Full line of heat treatment facilities
• Oil tube production in diameters of 7� to 26�, with API and premium
thread connections (VAM® production line)
• State-of-the-art testing centre
• Wide range of machining and finishing services to specified
requirements
• Certification according to ISO 9001, ISO 14001, API Q1, AD-W0,
API 5CT and 5L licensee for many years
• More than 100 years’ expertise and experience in tube production
Plug mill
3The Düsseldorf-Rath Works
Dear business friends,
in 1899, the Mannesmann company started producing steel tube and pipe at the Düsseldorf-Rath works.
Today, over 100 years later, the Rath production site ranks among the most efficient tube mills in Europe.
Rath manufactures up to 500,000 tonnes of seamless steel tubes per year at its modern plug and pilger
rolling mills. The manufacturing programme covers tube diameters of 193.7 to 711.0 millimetre for a wide
range of applications.
Many years’ expertise, strategic investments in modern plant technologies, continuous process monitoring,
and a highly motivated and qualified workforce ensure that each steel tube produced at Rath is a top quality
product.
Meeting the demands and expectations of our customers is our prime objective. Needless to say, this also
includes related services, whether special heat treatment, customized machining or on-schedule delivery.
This not only means the very best quality, but also precisely reproducible parameters for every tube and each
service – at all times.
The Rath Works Management
VA LLO U R E C & M A N N E S M A N N T U B E S
4 VALLOUREC & MANNESMANN TUBES
Our products – ideal for your application
New Bangkok International Airport• Commercial tubes
• Quality tubes in C-steels
• Boiler tubes
• Structural tubing
• Tubes for the petrochemical
industry
• Cylinder and pressure vessel tubes
• MSH sections (circular, square and
rectangular)
• Mechanical tubing
• Oilfield tubes (casing and couplings)
• Line pipe
• Added value products (pre- and
finish-machined tubes and tubular
parts)
• Hollows for drawing mills
• Stainless steel tubes
Pipelaying operations; first the line pipe is coiled around a giant drum.
The production facilities at our
Rath works are extremely
flexible. No wonder our range of
products stretches far beyond
what is normally expected of a
tube mill:
5The Düsseldorf-Rath Works
Offshore structurals for jack up rigs
Our tube manufacturing pro-
gramme features an extensive
range of materials:
• unalloyed C-steels,
• micro-alloyed steels,
• medium-alloy steels,
• high-alloy steels,
• austenitic steels, and
• special steels up to 13 % Cr.
It’s a great advantage for V& M
TUBES – and for our customers –
that we have a closed production
chain. Our starting material
stems from our own steelworks or
from steelworks which have been
certified in line with our require-
ments. Whether continuously
cast rounds processed in the plug
mill, or conventionally cast
ingots processed in the pilger mill
– they both meet the same high
standards: the quality standards of
V& M TUBES.
Our ultramodern heat treatment
facilities allow us to produce
precisely the specified micro-
structure and properties in the
finished tube.
State-of-the-art testing using
conventional and/or nondestruc-
tive techniques goes without
saying.
MSH sections as an attractive structural element for the office building at the plug rolling mill in Düsseldorf-Rath
MSH sections in fine grain steel for cranes
Seamless tubes for power stations (Photo: HPE)
6 VALLOUREC & MANNESMANN TUBES
The quality management system
implemented at the Düsseldorf-
Rath works has been approved by
national and international stand-
ards and specifications (e.g. ISO
9001, ISO 14001, API Q1, AD-
W0-certification) for many years.
The works also holds API
licences according to API 5CT
and 5L.
In order to increase the company’s
efficiency and satisfy customer
expectations in an optimum
manner, V& M TUBES pursues
a total quality policy at all its
locations. The principles for the
TQM policy are published direct-
ly by the Vallourec Management
Board.
TQM – our corporate philosophy
Good cooperation with customers starts
as early as the planning phase.
The objective of this policy is not
limited to the formulation of
across-the-board quality assurance
principles alone. All employees
at every level are obliged to
realise these principles in their
own spheres of responsibility.
7The Düsseldorf-Rath Works
Multidisciplinary working groups and
continuous exchange of experience
Continuous improvement in the
finishing shop
Preparation of product release and
certification
Preproduction meeting
This gives all employees the
capacity to act under their own
responsibility, in line with their
qualifications, and in full aware-
ness of their obligation to con-
tribute towards the continuous
improvement of processes and
procedures. Interdisciplinary
working teams are instrumental
in achieving these objectives.
They meet at regular intervals in
order to identify and open up
hidden potential in all areas of
the company – with great com-
mitment and using the most
modern methods. The exchange
of ideas between corporate
locations and strategic bench-
marking outside the company
are an integral part of this work.
The visualization of decisive
indicators enables all employees
involved in the production pro-
cess to directly follow up all the
effects of ongoing improvement
measures.
8 VALLOUREC & MANNESMANN TUBES
TQM – our corporate philosophy
Control desk of the multi-test block
(automatic surface inspection and wall
thickness check)
Plug rolling process
9The Düsseldorf-Rath Works
Tube shipments and starting material supplies are both transported by rail.
In an efficient modern loading bay, tubesready for shipment are loaded onto trucks.
This exacting procedure is a
highly effective motivation factor.
All employees involved play a
role in the company’s continual
change; the working day
becomes a source of progress.
A major concern of V& M
TUBES is to encourage and
promote employees by recogniz-
ing and improving their personal
skills.
To support the objective of excel-
lent product quality, extensive
measurement and evaluation
systems have been installed at the
Rath works. They supply the
data base required for systematic
error analysis and optimum
process parameter setting.
Wherever a problem occurs,
expert teams work out a solution
together with the employees
involved.
These groups are, of course,
also concerned with the con-
tinuous improvement of our
services and the solution of
customer-specific problems.
Particularly important for us is
the further development of
our internal customer-supplier
relationship as an indispensable
prerequisite for the satisfaction
of our external customers.
Another essential factor is direct
customer contact in the form of
visits, preproduction meetings
and audits.
On these occasions we learn
what our customers require and
expect. At the same time, we
gain impulses for potential new
objectives.
The integration of our customers
into our activities and procedures
will remain our guiding principle
on our joint path into the future
with TQM.
Pilger rolling process
GlättwalzwerkeReeler
Billet storage
Plug mill
Reeling mill
Sizing mill
Weight
Preheating furnace
Length Wall thickness
Diameter
Rotary-hearth furnace
Cooling bed
Reheating furnace
Pierce rolling mill
Transfer to finishing line
The plug mill – plant layout and process
Temperature
10 VALLOUREC & MANNESMANN TUBES
Data acquisition
11The Düsseldorf-Rath Works
Transport
Tube straightenerReheating furnace
Billet storage
Sizing mill
Preheating furnace Rotary-hearth furnace
Pierce rolling mill Plug mill Reeling mill
Tube end testing and rotary milling Multi-test block Final inspection, dimensional check,
weighing
The continuously cast rounds are heated to
1,280˚C in the rotary-hearth furnace and then
rolled to hollows in the pierce-rolling mill.
The pierced hollows then undergo two passes
in the plug rolling mill to reduce their wall
thickness. During this process, an annular gap
is created between the rolls and the plug,
corresponding to the desired wall thickness.
After reeling, reheating and diameter reduc-
tion in the sizing mill, the tubes are allowed to
cool before being transferred to the finishing
lines.
VALLOUREC & MANNESMANN TUBES
Ingot storage
Piercing press I
Pierce rolling mill
Pilger rolling mill
Hot saw
Reheating furnaceCooling bed
Sizing mill
Cooling bed
Transfer to finishing line
Weight
Piercing press II
Rotary-hearth furnace
Length Wall thickness
Diameter
The pilger rolling mill – plant layout and process
Temperature
12
Data acquisition
13The Düsseldorf-Rath Works
Transport
Multi-test block Final inspection Dimensional check,
weighing
Pilger rolling mill Hot saw
Rotary-hearth furnace Piercing press
Reheating furnace
Ingot storage
Pierce rolling mill
Cold straightenerSizing mill
The starting material is conventionally cast
round ingots in unit weights of up to 7.5 tonnes.
They are heated in the rotary hearth furnace to
the temperature required for centre-piercing in
the downstream piercing press. The resulting
pierced bloom with integral bottom then passes
through the piercing mill, where the wall thick-
ness is reduced and the hollow is elongated.
In the pilger rolling mill, specially shaped rolls
finally elongate the hollow over an internal
tool, the so-called pilger mandrel, to the desired
tube dimensions.
After pilger rolling, the tube ends are cut off
and tube is either reheated and processed in the
sizing mill, or it is directly transferred to the
finishing line.
Standard Ø Wall thickness mmmm 6.3 7.1 8.0 8.8 10.0 11.0 12.5 14.2 16.0 17.5 20.0 22.2 25.0 28.0 30.0 32.0 36.0 38.0 40.0193.7196.9203.0206.4216.0219.1223.0229.0232.0241.0244.5254.0267.0273.0283.0298.5306.4318.0323.9327.0339.7346.1355.6368.3383.0406.4
circular
14 VALLOUREC & MANNESMANN TUBES
Plug mill manufacturing programme
Edge lengthWall thickness mmWidth x height
mm 6.3 7.1 8.0 8.8 10.0 11.0 12.5 14.2 16.0 17.5 20.0
150 x 150200 x 100160 x 160200 x 120220 x 120200 x 150250 x 100180 x 180260 x 110200 x 200250 x 150260 x 140300 x 100220 x 220260 x 180300 x 150250 x 250300 x 200260 x 260300 x 300
square/rectangular
15The Düsseldorf-Rath Works
Pilger mill manufacturing programme
circularStandard Ø Wall thickness mmmm 10.0 11.0 12.5 14.2 16.0 17.5 20.0 22.2 25.0 28.0 35.0 45.0 60.0 85.0 110.0241.0244.5254.0267.0273.0298.5318.0323.9330.2339.7346.1355.6368.0377.8393.7406.4419.1426.0444.5457.2473.1479.4495.3508.0521.0533.4546.1558.8571.5584.2609.6622.3635.0660.4711.0
16 VALLOUREC & MANNESMANN TUBES
and for internal and external
defect detection (longitudinal,
transverse, oblique); stray
flux testing; magnetic particle
inspection (MPI)
• Heat treatment facilities, e.g. for
quench-and-temper treatment
using either oil or water for
simultaneous internal and exter-
nal quenching; heat treatment in
air; tempering, stress relieving,
and solution annealing furnaces
Further processing departments
Quench-and-temper facility in the 16“ heat treatment shop
Production riser with gastight PRCintegral connection
Many of the tubes leaving the
rolling mills are immediately
processed further in various shops
adjoining the main production
area. For this purpose the follow-
ing equipment is available:
• Nondestructive testing facilities,
e.g. ultrasonic systems for
checking the wall thickness
Modern tube storage facility
17The Düsseldorf-Rath Works
Heat treatment takes place inhigh-performance furnaces under
precise temperature control.
Complex machining on a CNC lathe
Thick-walled line pipe withmachined ends, destined for a high-pressure piping system in Venezuela
Threading lathe for the production
of Big Omega casings
• Equipment for tube end upset-
ting and sizing equipment
(internal and external)
• Oilfield tube finishing lines
for the manufacture of API and
premium connections and
couplings for API and premium
connections
• Modern CNC chamfering
machines for tube end bevelling
in line with all applicable
standards and customer specifi-
cations (including heavy-wall
line pipe)
• Added value production (semi-
finished and finished tubes and
tube components)
• External machining facilities
(grinding, peeling, turning)
• Equipment for internal and
external shot blasting (up to
quality class SA 2 1/2)
18 VALLOUREC & MANNESMANN TUBES
How to find us Access to tube mill from Theodorstrasse:Gate 5, Am Röhrenwerk, 40472 Düsseldorf
V&
M 1
B00
04B
-8G
B
V& M DEUTSCHLAND GmbH
Düsseldorf-Rath Tube Works
Postfach 33 02 70
D-40435 Düsseldorf
Germany
Rather Kreuzweg 106
D-40472 Düsseldorf
Germany
e-mail: [email protected]
www.vmtubes.com
Vallourec Group
VA LLO U R E C & M A N N E S M A N N T U B E S