Practical examples from pipeline construction
Selected examples demonstrate typical challenges from projects with high technical requirements. They provide insight into our manufacturing expertise, project management, and the implementation of customer-specific solutions.
Special tee with extended run ends
Initial situation: A plant project required a tee with a dimension of 406.4 mm, which fell outside standard dimensions. The run ends had to be extended by 250 mm on each side—while simultaneously meeting the tightest tolerance requirements.
Requirement:
- Special geometry outside standard norms
- Extended run ends (+250 mm per side) with a normal standard outlet
- Tight manufacturing tolerances: wall thickness (s-dimension) ±0.5 mm
- Precise integration into the existing plant design
Solution:
We modified existing dies and carried out the forming in our own production facility. This was followed by mechanical processing to the required finished dimensions—all from a single source, without outsourcing.
Result:
- Successful custom manufacturing within the required timeframe
- Compliance with all tolerances
- Precise integration into the plant
Elbow production within 5 working days
Initial situation: A customer urgently required five elbows in the dimension 219.1 × 40 mm made of P355N/NH—thick-walled and outside usual stock dimensions. Project delays had to be avoided at all costs.
Requirement:
- Delivery within one week
- Complete manufacturing including all processing steps
- Standard-compliant execution with documentation
Solution:
We completed the entire manufacturing process within 5 working days—including sawing, pressing, heat treatment, beveling, calibration, blasting, and coating. All steps were performed in our own plants in Unna, without external dependencies.
Result:
- On-time delivery within the required one-week deadline
- Project delay avoided
- Complete manufacturing documentation included
Regular delivery of ITNS components for the nuclear industry
Initial situation: A nuclear customer regularly requires pipe fittings as Items Important to Nuclear Safety (ITNS)—with the highest requirements for documentation, traceability, and inspection planning.
Requirement:
- Delivery on a fixed 4-week cycle
- Complete documentation according to nuclear requirements
- Project-specific ITPs with defined hold and witness points
- Seamless material traceability
Solution:
Coordination and processing via our own nuclear department—including full inspection planning, ITP creation, certificate management, and deadline coordination. The customer had a dedicated contact person for all deliveries.
Result:
- Stable, predictable supply chain on a 4-week cycle
- Complete documentation with every delivery
- Long-term cooperation—Europe-wide
Zirconium elbows—extreme material successfully formed
Initial situation: A customer required zirconium elbows in the dimension 60.3 mm—one of the rarest and most demanding materials in industrial piping construction. Zirconium is extremely expensive, difficult to procure, and places the highest demands on forming technology and tooling.
Requirement:
- Forming of an extreme material with very narrow processing windows
- No cracking or material defects during pressing
- Standard-compliant dimensional accuracy
- Full material traceability
Solution:
We realized the forming in our own production—with adapted process parameters and in-house quality control. The elbows were successfully pressed, tested, and delivered with full documentation.
Result:
- Successful first-time production in zirconium
- Dimensionally accurate elbows without material defects
- Complete documentation and traceability
Complete delivery of piping material—over 1,000 items, one delivery date
Initial situation: For a large-scale plant construction project, the complete provision of all piping components was required—over 1,000 items, different materials, dimensions, and standards, all for a fixed delivery date.
Requirement:
- Delivery of all items by the agreed date
- Combination of in-house production and commercial procurement
- Surface coating of all components
- Seaworthy packaging in wooden crates for international transport
- Complete documentation per item
Solution:
We took over the complete project coordination—in-house production for special parts, targeted procurement for standard items, central quality control, coating, and seaworthy packaging in Unna. One contact person, one delivery note, one deadline.
Result:
- On-time complete delivery of all items
- Seamless documentation for every item
- Packed ready for shipment for international transport
Tees with extended runs—25% more length upon customer request
Initial situation: A customer required tees with longer run ends than provided for in the standard—the standard leg dimensions were insufficient for the design.
Requirement:
- Extension of the run ends by 25% compared to the standard dimension
- Retention of all other standard parameters
- Tight tolerances for precise integration
- Series delivery in consistent quality
Solution:
At Nirotec, we realized the production with adapted tool parameters and subsequent mechanical processing to the required finished dimension. The solution was established as a series delivery.
Result:
- Dimensionally accurate tees with 25% extended runs
- Precise integration into the customer's design
- Stable series delivery
Special radius elbow according to customer specifications—new die developed in-house
Initial situation: A customer required elbows with a special radius that was not covered by any available standard die. Procurement on the market was not possible.
Requirement:
- Customer-specific bending radius outside all standard dimensions
- Dimensional accuracy according to customer specifications
- Production suitable for series for subsequent quantities
Solution:
For our customer, we developed and built a new die in our own special and mold construction department. After a successful initial sample, series production was started—entirely in Unna, without external dependencies.
Result:
- Successful initial sample production and approval by the customer
- Series-ready die for subsequent quantities
- Long-term delivery partnership established
Ultra-thick-walled tees in P91 – 323.9 × 50 mm
Initial situation: For a high-temperature application in a power plant, tees in the dimension 323.9 × 50 mm made of heat-resistant P91 steel (X10CrMoVNb9-1) were required—a combination of dimension and material that only a few manufacturers in Europe can still realize.
Requirement:
- Wall thickness 50 mm in P91—extreme forming effort
- Compliance with mechanical properties after heat treatment
- Standard-compliant execution according to EN 10253
- Complete documentation with 3.1 certificate
Solution:
We realized the production using our own hydraulic presses followed by heat treatment in the factory's own facility. Mechanical tests and full documentation were carried out within the framework of the QM system.
Result:
- Successful production of a dimension that is hardly available on the market
- All mechanical properties met after heat treatment
- On-time delivery with complete documentation
Regular deliveries for European nuclear power plants
Initial situation: Nuclear power plants in France, Great Britain, and Eastern Europe regularly require pipe fittings for maintenance, overhaul, and retrofitting—with the highest requirements for quality assurance, documentation, and traceability.
Requirement:
- Delivery according to nuclear regulations (KTA, RCC-M)
- Complete ITNS documentation
- Project-specific ITPs with hold and witness points
- Seamless material traceability from raw material to component
Solution:
Processing via our own nuclear department—with established processes for nuclear procurement, inspection planning, and documentation. Regular deliveries in a fixed rhythm, coordinated by a dedicated contact person.
Result:
- Long-standing delivery partnership for European nuclear power plants
- Reliable supply of ITNS-compliant components
- Complete documentation with every delivery
Let us solve your request together
At Nirotec, we support our customers in implementing project-specific requirements—from technical coordination to the finished component.
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At Nirotec, we offer solutions for industrial piping systems worldwide.
