I. ABSTRACT

The State Tube Institute (DTI-VMTJ), formerly (until 1992) named All-Union Scientific Research Tube Institute, is engaged in development of theories, processes and technologies for pipes, tubes, and pressure cylinders production in Ukraine and CIS countries. There are number of problems in tube manufacturing occurring at every stage of production cycle. DTI-VNITI solves all of these problems from obtaining billets to the finished product quality control and certification.

The institute's pilot tube plant specializes in manufacturing of precision and general-purpose tubes.

• offer to US enterprises a unique processes for manufacturing metal products (tubes, rods, wire, cylinders) used in nuclear engineering
• provide information on the pilot tube plant production and service potentials
• inform on development and manufacturing of products competitive at regional markets in CIS and Eastern Europe
• propose manufacturing a lower price products
• transfer technologies that can expand present American technologies
• offer a metal products and R&D services
• explain the feasibility of employment of Ukrainian industry potentials as a part of worldwide business activities

II. SHORT COMPANY DESCRIPTION

State Tube institute can be characterized as follows:

• it is the first in the world specialized institution in the field of pipe and tube production
• the multiplicity of R&D activities at all stages of pipe and tube production, from a starting billet to the finished product quality control, certification, standardization and economics
• 60-years of experience in developing new and improved processes of tube production used in nuclear engineering, aerospace, radio-electronics, shipbuilding, medical and other industries where the tubular products quality is of utmost importance.

DTI-VNITI scientific and research potential is formed of highly experienced experts in metallurgy, pipe and tube production, chemistry, metal physics, radiation metal study, diagnostic system, tube quality control, welding, economics, etc.

Production potential is formed of a pilot tube plant and experimental production department where the new technologies are tested and the tubular products are commercially manufactured.

Also, DTI-VNITI incorporates:

• interregional center for standardization and certification;
• scientific and engineering center for testing tubes, cylinders and other products and materials.

• production of titanium and titanium alloys tubes
• production of austenitic corrosion-resistant steels and alloys tubes for fuel elements cases used in nuclear reactors of various types (WCPR, FNR, etc.)
• production of seamless hexagonal tubes for fuel element cluster shells used in nuclear reactors of various types
• production of superthin-walled tubes and tubes intended for completing fuel element clusters (channeled tubes, guide tubes, distancing grids, etc.)
• production secondary contour line tubes of carbon, stainless and alloy steels in a wide size range
• condenser tubes of non-ferrous metals and stainless steel grades
• large diameter tubes inclusive centrifugal cast tubes

• novel technologies for making tubes by various methods
• tubes in a wide size range made of various steel grades and alloys
• carrying out R&D works
• development of new technologies, equipment and processes for tube manufacturing
• metal products certification and standardization
• metal products testing

DTI-VNITI is subordinate to the Ministry of Industrial Policy of Ukraine.

Address: State Tube Institute (DTI- VNITI),

III. PRODUCTS AND SERVICES

DTI-VNITI has developed and introduced technologies for tube production of more than 300 steel grades and alloys based on nickel, molybdenum, copper, aluminum, titanium, zirconium, and etc., and tubes with protective coatings, in all 8,000 sizes in 0.1 through 2,500 mm diameter and 0.04 through 130 mm wall thickness range.

DTI-VNITI is also responsible for the development of the technologies for production of shaped, finned, complex cross-section tubes and pressure cylinders to strict specification requirements.

DTI-VNITI has developed technologies for tubes production using methods of hot and cold rolling, drawing, welding and centrifugal casting. Bimetal and multilayer-wall tubes, pressure cylinders of diverse capacities and shapes are currently produced by DTI-VNITI methods.

DTI-VNITI services that are presently available:

• development of new technologies for manufacturing of tubular products and wires made out of various materials, and in different sizes and shapes
• evaluation of material plasticity, mechanical testing by tension, torsion, etc. for defining of s _B, s _O.2, d , y impact strength, cyclic fatigue and creep; ultrasonic diagnostics
• fine metal structure study with the use of electron and raster microscopy
• texture definition

DTI-VNITI pilot plant products are cold-deformed seamless tubes of various metals and alloys inclusive non-ferrous metals.

DTI-VNITI is the only enterprise of its kind in Ukraine and CIS countries.

Tube manufacturing plants in Ukraine and Russian Federation use technologies developed fully or partially by DTI-VNITI.

DTI-VNITI is the holder of a majority of the Specifications and technology patents for the production of different kinds of tubes.

DTI-VNITI pilot tube plant supplied Russian nuclear power industry with fuel element shall tubes of austenitic stainless steels and titanium alloys for FNR, WCPR and other types of nuclear reactors. At present production of such tubes has been organized in Russia.

Cooperation on a commercial basis is under way with Manncsmann-Demag AG, Germany, The Timken Co., USA, and Chori Co., Japan.

At present, DTI-VNITI takes an active part in creation of a national nuclear fuel cycle in the part of manufacture of rolled products for fuel element clusters to be used in WCPR-1000 type reactors:

• fuel element case tubes of zirconium alloys;
• fuel element cluster items (channelled tubes, guide tubes, rods for making plugs, etc.)

Currently under development are the technologies for production of titanium alloy tubes for nuclear power plant turbine condensers.

The technology for production of hafnium tubes and rods for protection and control system elements is under development as well.

DTI-VNITI offers for a joint benefit its R&D and engineering potentials in the field of new materials and improved quality tubes.

1. New economically efficient technology for making hot-deformed seamless tubes of corrosion-resistant steels of ASTM 321 type for structural elements of nuclear power plants (diameters: above 200 mm).

2. Production technology and hexagonal seamless tubes of ferritic and austenitic boron (about 2%B) steels for absorbing shells.

3. Technology and equipment for a superhigh-speed heat treatment of thin-walled tubes of corrosion-resistant steels and alloys ensuring obtaining nanocrystallite states enhancing radiation resistance of materials. This technology is applicable in making tubes of various steels and alloys for fuel elements and fuel element cluster shells.

4. Technology for making bimetal tubes in a variety of material combinations and in a wide size and shape range.

5. Use of economically alloyed Ni-Cr-Mn steel grades instead of 321 type steels in production of superheated tubes ensuring saving of nickel (80 to 100 kg/ton of tubes), higher corrosion and heat resistance.

6. Production of pressure cylinders to strict specification requirements.

7. Highly efficient process of microrolling wires.

1. Input tubes of zirconium and zirconium alloys

2. Tubes and wire of titanium.

3. Metal products of hafnium.

4. Products offered by pilot tube plant.

IV. MARKET REVIEW

Potential user of the products:

• companies producing nuclear fuel element clusters
• companies engaged in building storage for spent nuclear fuel (holding reservoirs, containers for nuclear fuel transportation)
• companies manufacturing pipeline elements for nuclear special-purpose structures
• power plants and special-purpose structures
• intermediary companies buying semi-finished materials to be used in third countries

Ukrainian nuclear power industry imports nuclear fuel (fuel element clusters made using of zirconium tubes) from Russia because of absence of required production facilities in Ukraine. At the same time, Ukraine possesses all prerequisites, such as production capacity and scientific and labor potentials for creation of a national nuclear fuel production cycle.

In organizing production of zirconium and zirconium products and securing their competitiveness at CIS markets, production and sales volume growth will be feasible with consideration of fuel needs at all WCPRs in Russia, Kazakhstan, Armenia and other CIS countries. Besides, feasibility of zirconium rolled product supplies for nuclear power plants in the countries of the former Soviet block and nuclear power stations planned for construction in other countries should be taken into consideration.

Zirconium products in a form of input tubes to be rolled into finished tubes can be introduced into the markets.

Marketing strategy will consist of supplying the products meeting requirements of international standards at price levels lower than the current world prices.

In the structures built for disposal of spent nuclear fuel, shaped (square, hexagonal) tubes of corrosion-resistant boron steel are used as absorbing shells. They are produced and used currently by a number of companies in Germany, Japan, Spain, Czech Republic, and Russian Federation.

In eighties, DTI-VNITI in cooperation with some of the leading enterprises in former Soviet Union (TsNIITMash, Izhora Works, etc.) took part in designing transportation containers and holding reservoirs for spent fuel element clusters of WCPR - 1000 type reactors, in the part of introduction of corrosion-resistant ferritic boron steel and development of a technology for production of seamless hexagonal seamless tubes for making shells.

Corrosion-resistant austentic steels of 304, 316, 321, 347, etc. types are used abroad for this purpose. Welded shells are used there instead of seamless ones. It is known that boron burns - out during welding.

In this Project, a technology of making seamless hexagonal shell tubes of corrosion-resistant austenitic steel is proposed. A necessary and sufficient scientific and production potential exists in Ukraine for creation of a complete cycle for production of such tubes (including steel melting and input tube producing facilities). Seamless hexagonal tube price will not be higher than the world price for currently produced tubes. Potential steel and tube consumers are nuclear power industry of Ukraine, Siemens-KWU (Germany), ZTS VVU (Slovakia), and etc.

Large diameter (219-325 mm) superthin-walled tubes of corrosion-resistant austenitic steel of AISI 321, 304, (Z6CND18.10, Z6CN18.09, 1.4541, 1.4301, 08X18H10T) type are indispensable in fabricating pipelines and equipment of nuclear power units. Such tubes should have a good technological effectiveness in fabrication of pipelines and equipment for nuclear power stations and keep stability of required set of operating properties. The major producers of such tubes are Sumitomo, Cobe Steel (Japan), Mannesmann Demag (Germany), Vallourec (France), Nikopol Pivdennotrubny Works (Ukraine).

The trends observed at modem markets of 219 to 325 mm diameter seamless tubes of stainless steels show that to be competitive, producers should:

• upgrade tube quality, reliability and longevity;
• reduce tubular product prices.

The existing production process patterns include a variety of deformation methods: forging, pressing, cross-rolling and longitudinal rolling, hot and cold drawing. For example, one of the existing processes consists of 12 main operations: obtaining a large size cast billet, its machining, pressing or forging, a number of hot deformations with preheating and thermal treatment. This is a costly process scheme with a number of disadvantages.

State Tube Institute has developed a technology consisting in obtaining a quality starting metal, billet piercing and subsequent tube rolling. This technology eliminates hot working of the billet (i.e. forging and pressing), reduces number of heating and deforming operations and consequently cuts, costs connected with working and chemical treatment and ensures obtaining high quality tubes due to a favorable choice of the process schedule and reduction rates.

Energy and metal consumption are reduced 2 and 1.5 times respectively. This enables production of large diameter seamless tubes at price levels considerably lower than those observed worldwide.

Seamless tubes in a diameter range of 219 to 325 mm with superthin walls (under 5 mm) can be produced by this technology.

Potential consumers of such tubes are nuclear power industries in Ukraine, Russia and other countries.

This steel is intended for making tubes used in high-pressure and supercritical pressure superheaters and high-power boiler units.

It can he used instead of 12X18H12T (of 32l type) steel.

Having strength characteristics equal to those of 12X18H12T steel, 10X1214H4M (~838) steel possesses a higher plasticity both in short time and long-time fracturing. This makes it possible to exclude thermal treatment of the bent tube sections used in fabrication of superheaters and ensures higher operating safety of superheaters.

Use of 10X1214H4M (~838) steel instead of 12X18H12T (321 type) steel will save 80 to 100 kg of nickel per 1 ton of tubes and ensure higher corrosion and heat resistance.

Table 1. Mechanical properties and performance of superheater tubes

Appendix. DTI-VNITI Managerial Staff

DTI-VNITI organizational scheme is appended.

Director: Victor V. Sergeyev, Dr.Sc.(Econ.)

Deputy Directors: Georgy I. Khaustov, Dr.Sc.(Tech.)

Vera S. Vakhrusheva, Cand.Sc.(Tech.)

Valentin A. Shevchenko

Director: Victor P. Sokurenko, Dr.Sc.(Tech.)

Director: Grigory P. Bloschinsky, Cand.Sc.(Tech.)

Subdivision (departments, laboratories) managerial staff consists of 30 persons.

Specialists graduated from higher education institutions in Ukraine and Russia and special courses in USA, Canada, Germany and UK are working in DTI-VNITI.

Staff completion and instruction system operates in DTI-VNITI:

• Post-graduate courses
• Personnel qualifications improvement
• Personnel skill appraisal and certification
• Employment of young specialists