3/26/2017 PipeManufacturingProcess

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PipeManufacturing
1Comment

Pipe

BasedonManufacturingProcessPipescanbeclassifiedasbelow

1.SeamlessPipe
2.WeldedPipe

a.EFWElectricFusionWelded

1.i.LongitudinalSAWPipe
2.ii.SpiralSAWPipe

b.ERWElectricalResistanceweldedPipe

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3/26/2017 PipeManufacturingProcess

1.SeamlessPipe

MandrelMill

>Thisprocessisusedtomakesmallersizesofseamlesspipe,typically1to6inches(25to150mm)diameter.

>Theingotofsteelisheatedto2,370F(1,300C)andpierced.

>Amandrelisinsertedintothetubeandtheassemblyispassedthrougharolling(mandrel)mill.

>Unliketheplugmill,themandrelmillreduceswallthicknesscontinuouslywithaseriesofpairsofcurved
rollerssetat90anglestoeachother.

>Afterreheating,thepipeispassedthroughamultistandstretchreducingmilltoreducethediametertothe
finisheddiameter.
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3/26/2017 PipeManufacturingProcess

>Thepipeisthencuttolengthbeforeheattreatment,finalstraightening,inspection,andhydrostatictesting.

PlugMill

>Thisprocessisusedtomakelargersizesofseamlesspipe,typically6to16inches(150to400mm)diameter.

>Aningotofsteelweighinguptotwotonsisheatedto2,370F(1,300C)andpierced.

>Theholeinthehollowshellisenlargedonarotaryelongator,resultinginashortthickwalledtubeknownasa
bloom.

>Aninternalplugapproximatelythesamediameterasthefinisheddiameterofthepipeisthenforcedthrough
thebloom.

>Thebloomcontainingtheplugisthenpassedbetweentherollsoftheplugmill.

>Rotationoftherollsreducesthewallthickness

>Thetubeisrotatedthrough90foreachpassthroughtheplugmilltoensureroundness.

>Thetubeisthenpassedthroughareelingmillandreducingmilltoevenoutthewallthicknessandproduce
thefinisheddimensions.

>Thetubeisthencuttolengthbeforeheattreatment,finalstraightening,inspection,andhydrostatictesting.

2.WeldedPipes

a.EFWPipe

i.LongitudinallyWeldedPipe

>Weldedpipe(pipemanufacturedwithaweld)isatubularproductmadeoutofflatplates,knownasskelp,that
areformed,bentandpreparedforwelding.Themostpopularprocessforlargediameterpipeusesalongitudinal
seamweld.Theweldsaremadebyheatingwithanelectricarcbetweenthebaremetalelectrodes.

>Pressureisnotused.Fillermetalfortheweldsisobtainedfromtheelectrodes.

>Fordiametersabove36inches,doubleseamweldedpipeisspecifiedasanalternativeinAPI5L.Thishastwo
longitudinalseams.
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3/26/2017 PipeManufacturingProcess

LongitudinallyWeldedPipe

EFWPipeManufacturingProcess

2.Spiralweldedpipe

>Asanalternativeprocess,spiralweldconstructionallowslargediameterpipetobeproducedfromnarrower
platesorskelp.

>ThedefectsthatoccurinspiralweldedpipearemainlythoseassociatedwiththeSAWweld,

>Anadditionalproblemwithearlyspiralweldedpipewaspoordimensionalaccuracy,particularlyoutof
roundnessatthepipeends.Thisledtoproblemsofpoorfitupduringfieldgirthwelding.Spirallinepipegained
apoorreputationinsomecompaniesasaresultoftheseearlyexperiences.

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3/26/2017 PipeManufacturingProcess

>Consideredsuitableonlyforlowpressureapplicationssuchaswaterpipe.
b.ElectricResistanceWelded(ERW)

>Solidphasebuttweld,wasproducedusingresistanceheating&highpressuretomakethelongitudinalweld
(ERW),

>NowadaysMostpipemillsnowusehighfrequencyinductionheating(HFI)forbettercontrolandconsistency.
However,theproductisstilloftenreferredtoasERWpipe,eventhoughtheweldmayhavebeenproducedby
theHFIprocess.

>ThedefectsthatcanoccurinERW/HFIpipearethoseassociatedwithstripproduction,suchaslaminations
anddefectsatthenarrowweldline.

>Lackoffusionduetoinsufficientheatandpressureistheprincipaldefect,althoughhookcrackscanalsoform
duetorealignmentofnonmetallicinclusionsattheweldinterface.Becausetheweldlineisnotvisibleafter
trimming,andthenatureofthesolidphaseweldingprocess,considerablelengthsofweldwithpoorfusioncan
beproducediftheweldingparametersfalloutsidethesetlimits.

>Inaddition,earlyERWpipewassubjecttopressurereversals,aproblemthatresultsinfailureinserviceata
lowerstressthanthatseeninthepreservicepressuretest.Thisproblemiscausedbycrackgrowthduringthe
pressuretestholdperiod,whichinthecaseofearlyERWpipewasduetoacombinationoflowweldline
toughnessandlackoffusiondefects.

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Onecomment

1.
Trisha
November7,2015at4:52pm

Thanksforsharingyourthoughts.IreallyappreciateyoureffortsandIwillbe
waitingforyournextwriteupsthanksonceagain.

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