Line Pipe for

Flammable Liquids and Gases

 With gas, quality counts

M ANNESMANN FUCHS ROHR has a long tradition in the

production of longitudinally HFI-welded steel pipe and a
wealth of experience in the correct coordination of all the de-
Our customers find seven core competencies that they can
depend on. They converge in the one objective: perfect pipe
for every application.
cisive quality dimensions.

Flexibility Wide product range

Quality Expertise and

advice experience
Delivering
Perfection

Customer Quality
proximity deliveriers

Quality products

Wide product range Quality products

A comprehensive manufacturing programme for gas, oil, water, The entire production chain in our own hands, strictest quality
construction, heat transport, and mechanical engineering – and management at all stages of manufacture, from the hot wide
all of it in steel grades to German and worldwide international strip to shipment of the finished products, all embedded in a
standards, with various different joining techniques. Rounded off state-of-the-art inspection and testing regime.
with a broad range of accessories.
Customer proximity
Expertise and experience A worldwide marketing network, a can-do approach to special
Modern manufacturing processes based on a century of experi- application requirements, and an ongoing exchange of insights
ence in pipe production, valuable investments in research and and experience with customers around the globe.
development, close cooperation with research institutes and
professional bodies, national and international projects. Quality advice
Specialists for pipeline planning, pipe specification, transport,
Quality deliveries storage and laying, experience gained in numerous challenging
Short delivery times through optimised production programmes, projects, from planning through to implementation.
extensive stock on hand for all kinds of replacement pipes and
small orders, schedule reliability for optimum project time per- Flexibility
formance. Two locations for the parallel production of orders of all sizes
and degrees of specialisation, production control geared to
customer needs.
2
 Line pipe for flammable liquids and gases

Contents
Securing energy for the future
Securing energy for the future
Page 3

P ipelines are the safest and most cost-effective way of trans-

porting mineral oil, natural gas and refinery products over
long distances. Transport means and route in one, pipelines will
Product overview
Page 4
become even more important in the future, given that the re-
sources indispensable for human survival are found in increas-
Coatings
ingly remote regions, far away from the centres of consumption.
Page 5
Ever greater volumes of industrial raw materials and fuels for the
energy industry, heating systems and vehicles are being trans-
Perfect all around ...
ported to the world's conurbations faster and at ever higher
Page 6
pressures.
... inside and out
Pipe networks and long-distance transmission lines are the ar-
Page 7
teries of our modern industrial society, criss-crossing vast re-
gions of our planet.
Quality management
As a leading specialist in HFI pipe, MANNESMANN FUCHS
Page 8
ROHR is on site around the globe, wherever new pipelines have
to be laid.
Testing methods
Page 9
That's why we compare ourselves and our work to Nature and
the processes in an eco-system. Just like Nature, we produce
Transport and storage
within a system, where the one process leads smoothly and
Page 10
precisely into the next. This approach brings us closest to our
ideal: pipes our customers can rely on, absolutely.
From A to Z
Page 11
Unlike Nature, though, we tolerate no nonconformities in our
products. From the base material, steel, through to the finished
pipe, everything at MANNESMANN FUCHS ROHR must adhere
to our fixed ”genetic code“, which ensures that each individual
pipe is a model of perfection.

This brochure will tell you more about the line pipe we produce
for flammable liquids and gases. For all their diversity, there is
one decisive feature that the products in our range have in com-
mon: top quality.

3
 Product overview

Standardized diversity Fibrous cement mortar (FCM)

MAPEC® plastic coating
Adhesive agent

M ANNESMANN FUCHS ROHR is your worldwide partner for

longitudinally HFI (high frequency induction) welded steel
line pipe. Our expertise and experience takes advantage of our
Epoxy resin
Steel pipe

close links to the ultra-modern steelworks and rolling mills with-

in our Group. With a weld efficiency factor of v = 1.0, our pro-
ducts meet the highest requirements of international standards
such as DIN EN, API, ISO, GOST, and DNV Rules, in conjunc-
tion with project specific demands from our customers in the
international oil and gas industry.

We offer you a one-stop service, complete with a wide range of

coatings and linings for all application profiles in both onshore
and offshore projects.
Our MAPEC® 3-layer polyethylene or polypropylene coating is
made of proven and approved materials and applied using the
blown film extrusion process. Its quality and efficiency satisfy all
Standards Materials the relevant national and international standards (e.g. DIN, NFA,
DIN EN 10208 T 1 L 235GA–L360GA CAN-CSA) and customer specifications.
DIN EN 10208 T 2 L 245NB–L485MB
DVGW Worksheet G 463 Supplement to DIN EN 10208 T 2
MAPEC® can be supplemented with a fibrous cement mortar
AD Regelwerk 2000 Supplement to DIN EN 10217 Part 1-4
(FCM) coating according to DVGW GW 340. To suit specific soil
EU Directive 97/23/EC
ISO 3183 Part 1 L245–L485 conditions, FCM coating is available in different varieties, inclu-
ISO 3183 Part 2 L245NB–L485MB ding FCM-N, FCM-S with T-profile, or even on our new rough
ISO 3183 Part 3 L245NC–L485MC plastic coating, the most recent addition to the range.
API 5L (latest edition) Grade A–X80 PSL 1/2
API 5 CT (latest edition) H 40, J55, K55, HC80, N80, M65 The frictionless flow of media through the pipe is ensured by our
DIN EN 10210 Parts 1 and 2 S235JRH–S460NLH epoxy resin linings, e.g. according to API RP 5L2, which round
DIN EN 10217 Part 1 P195TR1–P265TR2
off our product portfolio.
DIN EN 10217 Part 2 P195GH–P265GH, 16Mo3
DIN EN 10217 Part 3 P275 NL1–P460 NL 2
DIN EN 10217 Part 4 P215 NL, P265 NL
DIN EN 10219 Parts 1 and 2 S235JRH–S460NLH
DIN EN 10224 L235–L355

Customer specifications

Line pipe for flammable liquids and gases

Outside diameter Outside diameter Nominal width Wall thickness Length
in mm in inches DN in mm in m
88.9 3 80 2.9-6.3 12-16
114.3 4 1/2 100 2.9-6.3 12-16
168.3 6 5/8 150 2.9-10.0 12-16
219.1 8 5/8 200 3.2-12.7 12-18
273.0 10 3/4 250 3.6-16.1 12-18
323.9 12 3/4 300 4.0-20.6 12-18
355.6 14 350 4.0-20.6 12-18
406.4 16 400 5.0-20.6 12-18
457.2 18 450 5.6-20.6 12-18
508.0 20 500 5.6-20.6 12-18
610.0* 24 600 6.3-20.6 12-18

* Pipe outside diameter 610.0 mm will probably be available from 2007/2008

4
 Coatings

1 Type MAPEC® polyethylene (PE) coating

N (LD-PE), maximum operating temperature Tmax 60 ° C,
S (MD-PE) for Tmax 80 ° C or S (HD-PE) for Tmax 85 ° C
Description 3-layer coating to DIN 30670: epoxy resin primer, adhesive and polyethylene

Properties Standard corrosion protection for line pipe

Application example Pipelines buried in rock-free soils

2 Type MAPEC® ribbed polyethylene coating

Description As under item 1, polyethylene, but increased thickness

with integrated longitudinal ribbing
Properties Pipe coating with increased impact resistance

Application example Buried pipelines and relining (protection against abrasion)

3 Type MAPEC® polyethylene coating with rough coat (RC) surface

Description As under item 1, polyethylene, but with rough surface layer

Properties Pipe coating with high friction resistance

Application example Applications requiring high friction resistance, e.g. offshore pipe-laying

4 Type MAPEC® polypropylene (PP) coating (combined with epoxy resin lining)
Tmax 110 ° C
Description 3-layer coating to DIN 30678: epoxy resin primer, adhesive, polypropylene

Properties Corrosion protection coating for operating temperatures up to 110°C, coatings for
higher temperatures on request. Also available in combination with flow coat lining
(epoxy) for significantly reduced friction resistance
Application example Increased thermal loads on the pipe coating
(external or internal)

5 Type MAPEC® polyethylene coating with FCM-N fibrous cement mortar top coat

Description As under item 1, but with additional FCM coating (standard type)
to DVGW Worksheet GW 340
Properties Increased mechanical protection for pipe and PE coating

Application example Pipe-laying in rocky terrain

Greater thicknesses as heavy coat against buoyancy

6 Type MAPEC® polyethylene coating with FCM-S fibrous cement mortar top coat
Description As under item 5, but with additional adhesive layer between the PE coating and the
FCM coat or with interlocking (T-rib) profile

Properties The bond between the PE coating and the FCM coat withstands high shear forces
on the pipe
Application example The combination of mechanical protection and shear force transmission makes this
coating type specially suited to trenchless pipe-laying

5
 Perfect all around ...

MAPEC® coating – efficient protection for your pipe

M APEC® is the registered trade mark for a 3-layer plastic

coating which offers maximum protective efficiency. There
are various types of MAPEC® coating available to suit all types
of terrain and service conditions up to operating temperatures
of 85°C.

MAPEC® coating (LDPE / MDPE / HDPE) Fibrous cement mortar coating –

For a long service life under high thermal, mechanical, or chemi- top-level mechanical protection for your pipe
cal loads; suitable for severely aggressive soils.
MAPEC® coating with additional FCM top coat –
MAPEC® coating (PP) standard system (FCM-N)
For applications beyond the loadability of polyethylene and
increased requirements on thermal and mechanical stability. Especially for pipe-laying in rocky soils with extremely high
mechanical loads and in subsidence regions.
MAPEC® coating with integrated ribbing
For special protection requirements, e.g. trenchless pipeline re- Additional benefits through major savings potential, e.g.:
vamps using the pulling technique. The ribbing protects the pipe • no sand cushioning required
against damage and provides for a uniform space between the • spoil can be used as backfill
outer pipe and the new liner. • no sand transports
• no dumping charges for spoil
MAPEC® RC – special rough coating (PP)
For special requirements on the surface roughness of plastic Coating thicknesses for special applications such as offshore
coating: pipe-laying are available on request.

• Onshore pipe-laying: MAPEC® coating with interlocking (T-rib) profile and

anti-skid property when pipelines or pipe racks have to additional FCM coat, special system (FCM-S)
be walked on
A further developed variety of the standard MAPEC® coating
• Offshore pipe-laying: with FCM-N top coat. The interlocking T-rib profile ensures a
a) increased pipe-laying safety due to higher sliding friction firm bond between the PE coating and the FCM coat.
b) heavy coat: higher interlocking effect between concrete and Additional benefits:
pipe surface • no excessive stresses between the PE and cement mortar
coatings
• no spalling of FCM over large areas

6
 ... inside and out

The right protection in all conditions

Plastic coating thickness

DIN 30670 / DIN 30678 specify the following minimum values
for the coating layer thicknesses:

Pipe size Normal coating (n) Increased coating(v) Special coating

Minimum thickness Minimum thickness thickness
in mm in mm in mm
subject to spezial
= DN 100 1.8 2.5 agreement
> DN 100 subject to spezial
= DN 250 2.0 2.7 agreement
> DN 250 subject to spezial
< DN 500 2.2 2.9 agreement
= DN 500 subject to spezial
< DN 800 2.5 3.2 agreement

For higher mechanical loads the minimum coating thickness can All the required tests and inspections are carried out in our own
be increased by 0.7 mm (reinforced (in German: verstärkte) works laboratories. Depending on the customer's wishes, we
variety, type "v"). Depending on the pipe diameter, wall thick- issue a 3.1 or a 3.2 acceptance certificate for the coating.
ness and coasting type, the coating increases the pipe weight
by between 1% and 8%.
Epoxy resin linings
For special project requirements, the coating thickness can be
increased beyond the standardized values. Our plastic coatings Steel pipes can be lined to reduce the friction resistance on
are manufactured to a wide range of international standards and their inside surface. Epoxy resin flow-coat linings have estab-
customer specifications. lished themselves as standard practice in this application.
These linings meet all the applicable requirements, including
Each pipe is subjected to coating holiday detection at 25 kV API RP 5L2 and DIN EN 10311.
over the entire surface. The marking is applied in accordance
with the applicable standard. If required by the customer, we Other linings, coatings or metallic claddings can also be sup-
can also include additional information, e.g. related to the order, plied on request.
or use a customer-specific colour code. The finish-coated pipes
can be given a temporary corrosion protection.

7
 Quality management

Why you always get the quality you expect from us

T he energy industry needs a partner who has been constantly

out in front, for decades now, when it comes to innovation,
production and service.

Uncompromising quality in every aspect of our work

The first precondition for pipe longevity is continuous high qual-
ity in the manufacture, right through to the point of application.
That's why the quality philosophy at MANNESMANN FUCHS
ROHR covers the entire process – from the production of the
hot wide strip as the starting material for our pipes through all
the various stages of production right up to the technical sup-
port we provide in the completion of pipeline projects.

Technology leader
We are experts in all the technologies used in steel pipe pro-
duction. Back in the 1950s we introduced plastic coating for
steel pipe. And we know that ongoing improvement of the ma-
terials and processes we use is essential if we are to maintain Tested safety
and expand our leading position in the industry. Such start-to-finish monitoring guarantees to our customers
that each individual pipe complies with the applicable specifica-
tions and maintains its outstanding properties for a long service
Comprehensive quality management life. Each pipe is marked with its unique Q ID-number as a
Each pipe is manufactured with the same care and passes ”quality seal“ both on the outside and inside surface and on the
through the same quality management from the starting material pipe's barcode label. This means the entire manufacturing pro-
to the final inspection. Our quality assurance is an integral part cess can be traced back, right through to the steel mill. With the
of all aspects of the process flow, governing our daily work to pipe Q ID, the digitally stored test data can be called up for
an extent far beyond the requirements laid down in the applica- each pipe and the precise status before and after each produc-
ble standards. tion step can be ascertained. Just in case any doubts should
ever arise.

We spend millions on getting everything right

Our ultra-efficient pipe mills in Siegen and Hamm leave nothing
to chance. Meticulous inspection of the incoming starting mate-
rial and of the entire pipe production process ensures that only
products of perfect quality reach our customers.

8
 Testing methods

Monitoring fosters confidence

T ests and checks at MANNESMANN FUCHS ROHR are not

restricted to those prescribed by the various standards. We
carry out a large number of additional internal in-process
checks and tests in order to ensure that the finished products
more than meet the customers' specifications. We inspect and
check just about everything that's checkable.

Heat analysis
The steel we work with is extremely homogeneous and is made with the utmost
exactness to meet particular requirements. Each heat is subjected to analysis
ISO/DIS 14284 to check whether its chemical composition is in keeping with the
applicable tolerances. This is re-checked at our mill in the form of one product
analysis per heat.

Peel resistance of plastics Both our locations are fully equipped with state-of-the-art mea-
Plastic coatings have to protect the steel body in particular against corrosion, so suring and testing facilities. It's almost like in a modern diagno-
they must be very tough in their resistance to external influences (pressure, im- sis clinic, the way the pipes are subjected to a thorough-going
pact, etc.). They must adhere firmly to the steel structure and not peel off or come ”check-up“: they're measured, weighed, and have to pass ultra-
loose at all. This is verified by testing according to DIN 30670/DIN 30678. sonic testing and visual inspection, followed by microscopic
In addition, all the coatings must be approved for the given application by external and macroscopic evaluation of the results. They also undergo
laboratories. destructive testing, so nothing at all is left to chance.

In very complex diagnosis cases, we have the full backing of

In-process checks our Group's own research institute with its specialists in every
At every stage of the production process, checks are performed to verify a pipe's sphere of pipe science and technology.
compliance ”in all its essential characteristics“ with the applicable specifications.
This includes dimensional checks (length, diameter, wall thickness), mechanical-
technological tests, hydrostatic testing for leaks, and measuring the layer thick-
nesses both of the PE coating and the cement mortar lining. Statistic evaluation of
the results forms the basis for any necessary preventive measures to ensure the
continuous high quality of the processes.

9
 Transport and storage

The safe way to the site

O
too.
ur work doesn't stop once the pipe passes its final works
inspection. Storage and logistics are part of our service,

The pipes are shipped, stored and stacked according to strict

regulations. Safe transport, without damage to the valuable car-
go, is also a quality feature of MANNESMANN FUCHS ROHR.

We regularly stock several thousand tonnes of gas line pipes for

high- and low-pressure applications. This stock is designed for
quick delivery in emergencies as well as for medium-sized con-
struction projects. So we can ease the load on your own stor-
age capacities while you continue to maintain and expand your
supply system safely and flexibly.

Our logistics experts can take over all your inventory manage-
ment and the subsequent on-time delivery of the pipes to the
construction site. Our service package is rounded off by ex-
press and emergency deliveries, overhead unloading, trucks –
even for long lengths, stacking, transferring to storage, routing
and aggregated shipments.

Ship, rail or truck – we find the best form of transport for you
so you can rely on having your pipes delivered safely and punc-
tually, to the furthest corner of the world.

10
 From A to Z

Questions are best discussed directly with us

O utstanding and specialist advice is part of our supply pro-

gramme. It is also a central element of our quality philoso-
phy. And we're happy to share our knowledge and experience
with our partners.

Consulting and advice

The quality of our advice is based on a broad foundation:
• our own pool of competencies
• close cooperation with R & D scientists and engineers
• hundreds of projects at all levels of difficulty
• an ongoing exchange of ideas and experience
with our customers

We can advise you in every aspect, from the definition of the

pipe you need and joining techniques through detailed project
planning and right on to the pipe-laying operations and startup
of the pipeline.

Partnering the oil & gas industry

We have proved our all-round competence for infrastructure
projects of every size in countless projects in the energy sector.
With MANNESMANN FUCHS ROHR, you have a pipe producer
by your side whose role is a partnering one. Our aim is to do
everything in our power to ensure the success of your underta-
king.

We look forward to contact with you

You can best turn our competencies and experience to account
if you contact us at the early stages of projects. If you wish,
we'll be happy to let you have detailed particulars of our techni-
cal capabilities, our quality assurance and our references.

You'll find your contact for oil & gas line pipe in the Internet
at www.mannesmann-fuchs.com

11
MANNESMANN FUCHS ROHR GmbH

Head Office
Siegen Works
In der Steinwiese 31
57074 Siegen
Germany
Phone: +49 (0) 271 691-0
Fax: +49 (0) 271 691-299

Postal address:
Postfach 12 01 52
57022 Siegen
Germany

Hamm Works
Kissinger Weg
59067 Hamm
Germany
Phone: +49 (0) 2381 420-701
Fax: +49 (0) 2381 420-719

Postal address:
Postfach 17 13
59061 Hamm
Germany

info@mannesmann-fuchs.com
www.mannesmann-fuchs.com

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