Steel Pipes for Automatic Fire Sprinkler Systems
from the pipe manufacturer’s point of view.
FG-sprinklerkonferansen 2015, Oslo
J. Ortner, 18.3.2015
Topics
1. Wuppermann. A short presentation of the company.
2. The variety of standards & approvals in regard to sprinkler pipes.
3. Sprinkler steel pipes on the test bench (e.g. FM, UL and LPCB).
4. Quality management & control in the production process.
5. The WGalweld pipe from Wuppermann compared to a traditional galvanized pipe.
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
2
The Wuppermann Group
Wuppermann AG (*)
Leverkusen / DE
Business Unit
Technical Products
Business Unit
Flat Products
Business Unit
Service & Consulting
(*) 100% family owned
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
3
Product Overview
Business Unit Flat Products
Commercial flats & specialities
•
•
•
•
•
•
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
Pickled hot-rolled flat products
Hot-dip galvanized strips
Zinc-magnesium coated strips
Polyolefin-film-coated galvanized strips
Pre-punched strip with zinc-coated edges
Cold re-rolled & edge-dressed strips
4
Product Overview (small excerpt)
Business Unit Technical Products
Steel tubes & Sheet Metal Components:
•
•
•
•
•
Black & pickled tubes and profiles
Stainless steel tubes & processing
Perforated tubes
Sheet metal assemblies
Galvanized tubes & profiles
• WGalweld, galvanized pipe with the fully
galvanized inner weld
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
5
Facts and Figures of Wuppermann Group
2014
Employees:
External Sales:
> 1,300
550 Mio. €
2015
Production plan:
Flat products
786,000 t
Perforated tubes
12,000 t
Unperforated tubes
102,000 t
Tube & sheet-metal components 103 Mio. €
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
6
Our Locations
Austria
Czech Republic
Germany
France
Hungary
Netherlands
Poland
Romania
Sweden
Switzerland
Turkey
Wuppermann Tube and Steel AB
Göteborg
Wuppermann Austria GmbH
Judenburg
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
7
Wuppermann Austria GmbH
Judenburg, Austria
Production
• since1989
Figures 2014
• Employees: 140
• Delivered: 111 kto
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
8
The pipe mill
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
9
The variety
of regulations
Illustrating its complexity
and Interplay
National Specifics
* VdS CEA (DE)
* SBF (SE)
* others
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
Approvals
* FM
* UL
* others
The challenge
for a pipe producer:
To meet all the requirements
in any country!
Continental Standards
* ASTM A795 (USA)
* EN 12845 (EU)
* others
10
Steel Pipes for Automatic Fire Sprinkler Systems
Black Steel Pipe
• Limited to wet pipe sprinkler systems only (i.e. FM, UL)
• Organic coated outside surface is mandatory (i.e. EN 12845, VdS)
Galvanized Steel Pipe
• Permitted in wet and dry pipe sprinkler system (i.e. UL)
• Recommended in dry systems (i.e. EN12845, VdS)
• Mandatory in dry systems (i.e. FM)
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
11
Steel Pipe Specifications
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
12
Wall Gauges
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
13
WD = Wall gauge
Minimal Wall Thickness
(FM)
Fitting
Pipe
WDX
Threaded Pipe:
WDX = Wall gauge under the 1st exposed thread.
WDX40 = 1,45 mm (NPS 50; Schedule 40; ASME)
Taper Pipe Thread
(ISO 7-1)
Roll Grooved Pipe:
WD = WDX = 1,65 mm (NPS 50; Schedule 5; ASME)
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
14
Downsizing of system components
105
6,05 x
P = --------------- x L x Q1,85
C1,85 x d4,87
Option 1:
• The larger the inner diameter,
• the lower the pressure loss,
• the cheaper the hydraulic system.
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
P = Pressure loss in bar
C = Pipe friction constant
Q = Flow rate inside the pipe
L = Length of the pipe net
d = Inner diameter of the pipe
Option 2:
• A given inside flow rate,
• implies smaller nominal pipe sizes,
• means cheaper pipe costs.
15
Data sheet
5
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
16
Data sheet
7
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
17
Approvals
7
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
5
18
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
19
Hydrostatic Strength (FM)
• Each NPS is tested under four times the rated working pressure.
• Test duration of 5 minutes without cracking, rupture or permanent distortion.
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
20
Bending Moment Resistance (FM)
• Each NPS is tested under rated hydrostatic working pressure of 12 bar.
• Leakage, fracture or coupling pull off must not happen!
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
21
Vibration Test (UL)
• After the vibration exposure, the assembly is to be subjected to the Leakage Test.
• Leakage Test: 1 Minute, two times the rated pressure, no leakage!
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
22
Quality standards at Wuppermann – taken for granted
 Certified according to ISO 9001:2008 and ÖNORM EN ISO 3834-3
 Pipe standards: EN 10.217-1 / ASTM A 795
 Galvanizing standards: EN 10.346 / ASTM A 53
 CE conformity according to EN 10.217-1
 Test report according to EN 10.204 - 3.1
 Certified welders according to ÖNORM EN ISO 14732:2013
 Certified NDT-personnel according to ÖNORM EN ISO 9712
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
23
Wuppermann
Production Process
Strict Process Control
Raw material
pickled hot rolled wide strip
* Entrance data
Slitting into thin strips
Continuous galvanising
of the slit strip
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
* Thickness (Isotope gauge; continuously)
* Width (inspection plan)
* Regulation of the zinc layer (air knife; continuously)
* Total thickness of the strip (Isotope gauge; cont.)
* Width of the galvanized strip (inspection plan)
* Zinc layer (magnetic inductive; inspection plan)
(stripping test; inspection plan)
* Zinc adhesion (ball-, folding test; inspection plan)
24
Wuppermann
Production Process
Strict Process Control
Roll forming & high frequent
welding of the galv. strip
to a round pipe
-------Thermal post galvanizing
of the weld seam
(inside & outside)
* Pipe geometry (diameter, lengths; insp. plan)
* Weld seam (Eddy current test; continuously)
(Thermographic test; continuously)
* Flattening test (inspection plan)
* Zinc layer weld seam outside (insp. plan)
inside (Cu-sulfate; insp. plan)
* Marking (inspection plan)
Pressure Test
* 85 bar (each pipe)
Roll-grooving
* A-Gauge (inspection plan)
* Groove diameter (Pipe tape; inspection plan)
* Tool measuring (each dimension change)
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
25
Conventional
Production Process
unpickled hot rolled wide strip…
slitted into thin strips…
roll formed & high frequent
welded to a round pipe…
batch galvanised.
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
26
Galvanizing Technologies by comparison
Pipes roll grooved
after the coating
Flaking of the
zinc coating
Batch Galvanized
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
7
27
Batch Galvanising Technology
Galvanizing
pipe
Rinsing
Degreasing
Drying
Rinsing
Pickling
Fluxing
Cooling
Galvanizing
ZnCl2 + NH4Cl
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
28
Continuous Galvanising Technology
Cooling System
Das kontinuierliche Bandverzinken
„Verfahren Wuppermann“
Kühl
ung
Induction furnace
Induktion
sofen
Air wiping
Scale breaker
Zunderbr
echer
Pickling
(Hydrochloride)
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
Rinsing
Sp
üle
Drying
Trock
ner
Galvanizing
Zink
bad
29
Galvanizing technologies by comparison
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
30
FeZn alloy versus pure zinc (Micrographs)
Pure zinc layer
Pure zinc layer
FeZn-layer
cracks
Steel pipe
FexAly < 0,5 µm
Steel pipe
Source: WE, R&D
Batch Galvanising:
The coating consists of approx. 30%
pure zinc on the surface, the rest below
of a FeZn-alloy. The cracks in the brittle,
iron-rich zone are typical of it.
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
Continuous Galvanising:
The coating is almost 100% pure zinc.
The very thin intermetallic layer FexAly
acts as a bonding agent and prevents the
forming of a FeZn-alloy.
31
Pipe
The customer’s benefits at a glance
 Thin wall gauges affect low weight of pipes.
 Light & straight pipes are easier to install.
 Larger pipe inner diameter make down-sized system components possible.
 A smooth coating surface ensures a safe seal seat of the coupling and the
sprinkler outlet fitting.
 The high quality of the outside surface makes a powder coating finish cheaper.
 A subsequent roll-grooving on site works without any loss of corrosion
resistance.
 All in all high grade WGalweld quality pipes are very cost-effective.
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
32
Thank you
for
your attention!
J. Ortner I Wuppermann Stahl GmbH I Gußstahlwerkstraße 23 | A-8750 Judenburg
33