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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



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:


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)


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.


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.


TQM – our corporate philosophy

Control desk of the multi-test block

(automatic surface inspection and wall

thickness check)

Plug rolling process


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


Data acquisition


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


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


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


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


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


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)


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


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