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Technology in Action


thread machining reliability. For threading, quick-change Seco cartridges hold the threading inserts/chasers and allow Boru- san Mannesmann to easily switch from one thread form—API Buttress 5TPI and API Round 8TPI—to the next in a matter of seconds.


Single-Pass Threading Unlike traditional pipe threading that typically requires


two passes, the Seco tooling generates threads in fast single- pass operations. What makes this possible is a special custom Seco toolholder that holds four tools and allows two threading points (standard Seco carbide inserts) to cut simultaneously. As the machine’s turret moves forward, one tool rough threads while the other finish threads, essentially doubling the speed of the threading operation. Te Seco tooling provides threading cycle times of between


Unlike traditional pipe threading that typically requires two passes, the Seco tooling generates threads in fast single-pass operations.


connections. Te company produces three different common types of oil & gas industry connections—long thread type, short thread and a buttress type. Te buttress connection is an API Tread Form and features a larger-size thread pitch.


High Quality, Short Production Time According to Warren Williams, vice president of opera-


tions at Borusan Mannesmann, the cells produce the highest quality threads in the shortest amount of time possible. Tis capability stems from the fact that all individual cell compo- nents are interconnected and optimized, including the tooling used in the cell machines. For its cell tooling, the company worked with Seco


Tools LLC (Troy, MI) to provide special tooling that slashed pipe-threading cycle times by half while at the same time improving thread quality and extending tool life. But most importantly, the tooling helped boost machine output in both cells to levels that prompted Borusan Mannesmann to forego adding a planned third automated cell. “When it came to tooling up our cells, we were open for


new suggestions and were willing to venture outside the box,” explained Williams. “Seco helped us understand how much a one-pass threading technique would benefit our output, and we realized that was the type of innovative and forward think- ing we wanted. Tey partnered with us throughout the whole process and, in about a day or so, had our threading opera- tions up and running. And we can now honestly say that the tooling does exactly what they said it would.” Te Seco tooling used in the cells includes upper and lower


machine turret toolholders for facing and ID chamfering tools along with CP500 inserts. Te CP250T insert grade features a highly wear-resistant PVD coating that delivers strength and


42 Energy Manufacturing 2014


10 and 20 seconds. And overall machining cycle time—in- cluding pipe handling—per pipe end is only 30 seconds. Each of the two cells completes about 120 pipe ends per hour in an eight-hour shiſt. Prior to threading operations, Borusan Mannesmann must


first manufacture its pipes, and the first step is cold roll form- ing flat steel to the proper shape/diameter, then continuous electric resistance welding (ERW) the seams and cutting to customer-specific lengths. Te company can generate pipe with ODs from 4.5" (114.3 mm) to more than 13" (330 mm) made from ¼-gage to 5


/8-gage steel that can be harder than Rc 35. Welded and cut pipes then move to a flush-out process that


cleans them. Aſterwards, their ends are beveled, and they pro- ceed to hydro testing for weld line checking. From there, pipes undergo nondestructive testing (NDT). If they pass, they get marked to identify their size, gage, testing pressure and date manufactured—all of which is required to attain American Petroleum Institute (API) certification. Borusan Mannesmann then heat treats its pipes and subjects them to additional third-party testing.


In-House Capabilities Te company not only excels in producing high-quality


piping, but also differentiates itself from its competitors through its processing capabilities. Among these are in-house roll forming, heat treating (up to 35 tons [31.75 t]per hour), extensive inspection and, of course, automated high-produc- tion threading. Borusan Mannesmann uses three types of special propri-


etary steel. One is for transport line pipe; the other two are BMP for smaller pipe diameters and BMP-2 grades for large diameters. For the threading operations, the designated small-diameter machining cell handles pipe measuring from 4.5 to 7.625" (193.675 mm) in diameter, while the second large-diameter cell works on those from 4.5" up to 13.375" (339.725 mm) in diameter.


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