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Steel pipes are long, hollow tubes that are used for a variety of purposes. They are
produced by two distinct methods which result in either a welded or seamless pipe. In both
methods, raw steel is first cast into a more workable starting form. It is then made into a
pipe by stretching the steel out into a seamless tube or forcing the edges together and
sealing them with a weld. The first methods for producing steel pipe were introduced in the
early 1800s, and they have steadily evolved into the modern processes we use today.
Each year, millions of tons of steel pipe are produced. Its versatility makes it the most
often used product produced by the steel industry.
Steel pipes are found in a variety of places. Since they are strong, they are used
underground for transporting water and gas throughout cities and towns. They are also
employed in construction to protect electrical wires. While steel pipes are strong, they can
also be lightweight. This makes them perfect for use in bicycle frame manufacture. Other
places they find utility is in automobiles, refrigeration units, heating and plumbing systems,
flagpoles, street lamps, and medicine to name a few.
Materials:
The material with which a pipe is manufactured often forms as the basis for choosing any
pipe. Materials that are used for manufacturing pipes include:
Carbon steel
ASTM A252 Spec Grade 1, Grade 2, Grade 3 Steel Pile Pipe
Low temperature service carbon steel
Stainless steel
Nonferrous metals, e.g. cupro-nickel, tantalum lined, etc.
Alloy steel
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1. ASTM
2. ASME
3. UNI
4. GOST
5. European
6. DIN
7. JIS
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GOST 9941 Seamless stainless steel tubes, cold and hot finished
Seamless Steel Pipes for Steam Boilers and
TU 14-3-460
Pipelines
EUROPEAN-STANDARDS : STAINLESS STEELS
*Note: This European standard is replacing old national standards for pressure purpose
(DIN 17458 DIN 17459 NFA 49117 NFA 49217 NFA 49218 BS 3605 BS 3605-1 etc…
All European standards have their own national designation (example NF EN 10216-5
DIN EN 10216-5 BS EN XXXXX UNI EN XXXXX ..)
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History
People have used pipes for thousands of years. Perhaps the first use was by
ancient agriculturalists who diverted water from streams and rivers into their
fields.Archeological evidence suggests that the Chinese used reed pipe for transporting
water to desired locations as early as 2000 B.C. Clay tubes that were used by other
ancient civilizations have been discovered. During the first century A.D. , the first lead
pipes were constructed in Europe. In tropical countries, bamboo tubes were used to
transport water. Colonial Americans used wood for a similar purpose. In 1652, the first
waterworks was made in Boston using hollow logs.
Development of the modern day welded steel pipe can be traced back to the early 1800s.
In 1815, William Murdock invented a coal burning lamp system. To fit the entire city of
London with these lights, Murdock joined together the barrels from discarded muskets. He
used this continuous pipeline to transport the coal gas. When his lighting system proved
successful a greater demand was created for long metal tubes. To produce enough tubes
to meet this demand, a variety of inventors set to work on developing new pipe making
processes.
An early notable method for producing metal tubes quickly and inexpensively was
patented by James Russell in 1824. In his method, tubes were created by joining together
opposite edges of a flat iron strip. The metal was first heated until it was malleable. Using
a drop hammer, the edges folded together and welded. The pipe was finished by passing
it through a groove and rolling mill.
Russell’s method was not used long because in the next year, Comelius Whitehouse
developed a better method for making metal tubes. This process, called the butt-weld
process is the basis for our current pipe-making procedures. In his method, thin sheets of
iron were heated and drawn through a cone-shaped opening. As the metal went through
the opening, its edges curled up and created a pipe shape. The two ends were welded
together to finish the pipe. The first manufacturing plant to use
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Welded pipe is formed by rolling steel strips through a series of grooved rollers that mold
the material into a circular shape. Next, the unwelded pipe passes by welding electrodes.
These devices seal the two ends of the pipe together.
this process in the United States was opened in 1832 in Philadelphia.
Gradually, improvements were made in the Whitehouse method. One of the most
important innovations was introduced by John Moon in 1911. He suggested the
continuous process method in which a manufacturing plant could produce pipe in an
unending stream. He built machinery for this specific purpose and many pipe
manufacturing facilities adopted it.
While the welded tube processes were being developed, a need for seamless metal pipes
arouse. Seamless pipes are those which do not have a welded seam. They were first
made by drilling a hole through the center of a solid cylinder. This method was developed
during the late 1800s. These types of pipes were perfect for bicycle frames because they
have thin walls, are lightweight but are strong. In 1895, the first plant to produce seamless
tubes was built. As bicycle manufacturing gave way to auto manufacturing, seamless
tubes were still needed for gasoline and oil lines. This demand was made even greater as
larger oil deposits were found.
As early as 1840, ironworkers could already produce seamless tubes. In one method, a
hole was drilled through a solid metal, round billet. The billet was then heated and drawn
through a series of dies which elongated it to form a pipe. This method was inefficient
because it was difficult to drill the hole in the center. This resulted in an uneven pipe with
one side being thicker than the other. In 1888, an improved method was awarded a patent.
In this process the solid billed was cast around a fireproof brick core. When it was cooled,
the brick was removed leaving a hole in the middle. Since then new roller techniques have
replaced these methods.
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Steel pipes are made by two different processes. The overall production method for both
processes involves three steps. First, raw steel is converted into a more workable form.
Next, the pipe is formed on a continuous or semicontinuous production line. Finally, the
pipe is cut and modified to meet the customer’s needs.
Seamless pipe is manufactured using a process that heats and molds a solid billet into a
cylindrical shape and then rolls it until it is stretched and hollowed. Since the hollowed
center is irregularly shaped, a bullet-shaped piercer point is pushed through the middle of
the billet as it is being rolled.
INGOT PRODUCTION
1 Molten steel is made by melting iron ore and coke (a carbon-rich substance that
results when coal is heated in the absence of air) in a furnace, then removing most
of the carbon by blasting oxygen into the liquid. The molten steel is then poured
into large, thick-walled iron molds, where it cools into ingots.
2 In order to form flat products such as plates and sheets, or long products such
as bars and rods, ingots are shaped between large rollers under enormous
pressure.
3 To produce a bloom, the ingot is passed through a pair of grooved steel rollers
that are stacked. These types of rollers are called ―two-high mills.‖ In some cases,
three rollers are used. The rollers are mounted so that their grooves coincide, and
they move in opposite directions. This action causes the steel to be squeezed and
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stretched into thinner, longer pieces. When the rollers are reversed by the human
operator, the steel is pulled back through making it thinner and longer. This
process is repeated until the steel achieves the desired shape. During this
process, machines called manipulators flip the steel so that each side is
processed evenly.
4 Ingots may also be rolled into slabs in a process that is similar to the bloom
making process. The steel is passed through a pair of stacked rollers which
stretch it. However, there are also rollers mounted on the side to control the width
of the slabs. When the steel acquires the desired shape, the uneven ends are cut
off and the slabs or blooms are cut into shorter pieces.
FURTHER PROCESSING
5 Blooms are typically processed further before they are made into pipes. Blooms
are converted into billets by putting them through more rolling devices which make
them longer and more narrow. The billets are cut by devices known as flying
shears. These are a pair of synchronized shears that race along with the moving
billet and cut it. This allows efficient cuts without stopping the manufacturing
process. These billets are stacked and will eventually become seamless pipe.
6 Slabs are also reworked. To make them malleable, they are first heated to 2,200°
F (1,204°C). This causes an oxide coating to form on the surface of the slab. This
coating is broken off with a scale breaker and high pressure water spray. The
slabs are then sent through a series of rollers on a hot mill and made into thin
narrow strips of steel called skelp. This mill can be as long as a half mile. As the
slabs pass through the rollers, they become thinner and longer. In the course of
about three minutes a single slab can be converted from a 6 in (15.2 cm) thick
piece of steel to a thin steel ribbon that can be a quarter mile long.
7 After stretching, the steel is pickled. This process involves running it through a
series of tanks that contain sulfuric acid to clean the metal. To finish, it is rinsed
with cold and hot water, dried and then rolled up on large spools and packaged for
transport to a pipe making facility.
PIPE MAKING
8 Both skelp and billets are used to make pipes. Skelp is made into welded pipe. It
is first placed on an unwinding machine. As the spool of steel is unwound, it is
heated. The steel is then passed through a series of grooved rollers. As it passes
by, the rollers cause the edges of the skelp to curl together. This forms an
unwelded pipe.
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9 The steel next passes by welding electrodes. These devices seal the two ends
of the pipe together. The welded seam is then passed through a high pressure
roller which helps create a tight weld. The pipe is then cut to a desired length and
stacked for further processing. Welded steel pipe is a continuous process and
depending on the size of the pipe, it can be made as fast as 1,100 ft (335.3 m) per
minute.
10 When seamless pipe is needed, square billets are used for production. They
are heated and molded to form a cylinder shape, also called a round. The round is
then put in a furnace where it is heated white-hot. The heated round is then rolled
with great pressure. This high pressure rolling causes the billet to stretch out and
a hole to form in the center. Since this hole is irregularly shaped, a bullet shaped
piercer point is pushed through the middle of the billet as it is being rolled. After
the piercing stage, the pipe may still be of irregular thickness and shape. To
correct this it is passed through another series of rolling mills.
FINAL PROCESSING
11 After either type of pipe is made, they may be put through a straightening
machine. They may also be fitted with joints so two or more pieces of pipe can be
connected. The most common type of joint for pipes with smaller diameters is
threading—tight grooves that are cut into the end of the pipe. The pipes are also
sent through a measuring machine. This information along with other quality
control data is automatically stenciled on the pipe. The pipe is then sprayed with a
light coating of protective oil. Most pipe is typically treated to prevent it from
rusting. This is done by galvanizing it or giving it a coating of zinc. Depending on
the use of the pipe, other paints or coatings may be used.
Quality Control
A variety of measures are taken to ensure that the finished steel pipe meets specifications.
For example, x-ray gauges are used to regulate the thickness of the steel. The gauges
work by utilizing two x rays. One ray is directed at a steel of known thickness. The other is
directed at the passing steel on the production line. If there is any variance between the
two rays, the gauge will automatically trigger a resizing of the rollers to compensate.
Pipes are also inspected for defects at the end of the process. One method of testing a
pipe is by using a special machine. This machine fills the pipe with water and then
increases the pressure to see if it holds. Defective pipes are returned for scrap.
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Seamless steel pipe: seamless steel pipe is made from a single piece of metal on the
surface of steel pipe joints. Production methods can be divided into hot-rolled pipes, cold
rolled tubes, cold drawn tubes, extruded tube. Can be divided into two kinds of round and
shaped cross-sectional shape. The seamless pipe of the maximum diameter of 650 mm
(enlarged diameter tubes), a minimum diameter of 0.3 mm (capillary). According to
different thickness can be divided into thick-walled pipes and thin-walled tube. Seamless
pipe is mainly used for the petroleum exploration tube, petrochemical cracking tubes,
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boiler tubes, the bearing tube as well as the automotive, aerospace steel and other
high-precision structure.
Welded steel pipe: welded steel pipe refers to the bending deformation of the steel strip
or steel sheet as round, square and other shapes and then welded into the steel pipe, the
surface of the seam. According to the different welding methods can be divided into the
arc welded pipe, high or low frequency electric resistance welded pipe, gas pipe, stove
pipe, Bundy tube. Weld shape can be divided into Longitudinal and spiral welded pipe.
Welded steel pipe used for oil drilling and machinery manufacturing. The furnace can be
used as a water pipe and gas pipe, large diameter welded pipe used for high-pressure oil
and gas transmission; spiral welded pipe for oil and gas transmission pipe piles, piers.
The welded steel pipe is lower than the cost of seamless steel, high production efficiency.
Seamless steel pipe quality testing is a very important step, and for its detection
method is also very particular to now all three – ultrasonic testing, eddy current testing,
magnetic flux leakage testing, specific circumstances are as follows:
For steel quality inspection, ultrasonic testing, including for the purpose of detected
defects ultrasonic testing and ultrasound to measure the dimensions for the purpose of
measuring. Wider application of the former, automated testing, manually testing; latter
application, generally manual measurement.
NON-DESTRUCTIVE TESTING
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Non-destructive testing
The common inspection methods of NDT are visual testing (VT), ultrasonic testing (UT),
radiographic testing (RT), hydrostatic testing. Anson International co, ltd uses ultrasonic
testing (UT) and hydrostatic testing to inspect its line pipes.
In order to verify the mechanical properties of seamless steel pipe to meet the
requirements of the standard, the test sample of seamless steel pipe mechanical
performance should be prepared carefully. Mechanical property test includes tensile
strength, yield strength, elongation, impact energy and so on. Process performance test
includes flattening test, flaring test, hydrostatic testing, curling trials, cold bend test,
perforation test. These test items are based on different standards and different uses of
seamless steel tubes.
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suitable for the automatic inspection of large quantities of steel pipe. Therefore, under
normal circumstances, no special instructions, usually refers to the magnetic field of the
magnetic flux leakage testing of steel pipes assay.
Eddy current testing method is more wide range of applications in the industrial field
of non-destructive testing methods. It is based on the theory of electromagnetic induction,
without any coupling agent can 100% fast automatic detection of the specimen. it is even
more powerful tool for the rapid detection of bulk. Therefore, it is even not limited to the
large caliber thermal expansion seamless steel pipe, has become a necessary means of
various types of steel quality inspection. Automatic eddy current testing method is mainly
suitable for quality inspection of steel pipes a little probe testing method and
through-probe testing method two.
The former method of using the high-speed rotation of the point probe to detect
longitudinal defects in the steel pipe, the detection speed is determined by the quantity of
the probe and the speed of rotation, in general, is relatively slow, and the latter through
the probe to detect the steel pipe transverse defects, this method is simple, and the
testing speed (generally up to 60m/min), Further, since the eddy current flaw detection
method is particularly sensitive pair of through holes, the related standards of the main
method is to replace the pipe hydrostatic test.
Pipe connection
Pipe connection is varied, the commonly used have Butt weld, Flanged, Threaded, Socket
weld, Glued, Brazed and Grooved end.
You assign connection types in the Connector Properties dialog box as you build fittings
content using the Content Builder (see Adding Connectors to a Parametric Fitting).
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Assigned connection types are then displayed on the Connection Assignments tab of the
Pipe Layout Preferences dialog box.
Unthreaded Connections are not threaded, must be either welded or bolted together. The
following table shows the different orientations of pipe connection types:
Butt weld:
A butt weld is two pipes lined up with one another and welded along the contact edge to
create a seal.
A flange is a plate or ring that is attached to a pipe. Two flanged pipe then create a tight
seal by being bolted together.
The pipe is the male fitting and the socket is equivalent to a female fitting. To provide a
tight seal it is best to line the outside of the pipe and the inside of the socket with a
sealant.
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Fitting to pipe: Pipe segments typically have inherent male ends, and fittings are
typically female. The pipe inserts directly into the fitting.
Pipe to pipe: A female coupling is inserted between the pipe segments.
Fitting to fitting: Fittings connect directly to each other.
GROOVED END
A grooved end fitting has a groove or shoulder along the edge. This fittings groove allows
for a seal without the need for welding.
Fitting to pipe: Fittings and pipe segments are considered to have grooved ends
that are ready to accept a coupling. A coupling is added to connect the fitting and
pipe.
Pipe to pipe: A coupling is added to connect the pipe segments.
Fitting to fitting: A coupling is added to connect fittings.
NOTE:
The Piping domain includes a connection type called Same Connection. When Same
Connection is configured for a pipe object that is attached to a hub, connector 1 inherits
the connection type of the connection type on connector 2 of the attached hub.
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Thus ASTM standard allow the wall thickness difference of seamless pipes is bigger than
the welded pipes’. Slotted tube is made by precision cold-rolled plates (4-5 feet) per roll
width. These cold rolled sheet is usually the maximum wall thickness of 0.002 inches. The
steel sheet was cut to the width πd where d is the outer diameter of the pipe. Slit pipe wall
thickness tolerances are small, and the entire circumference of the wall thickness is very
uniform.
Welding performance: general tube and seamless pipe has certain differences on the
chemical composition. The production of seamless pipe steel composition is only the
basic requirements to meet ASTM. While the production of the chemical composition of
the steel slotted tube containing suitable for welding. For example, silicon, sulfur,
manganese, oxygen and the triangle of ferrite and other elements at a certain proportion
of mixed can be generated during the soldering process the solder melting and an easy
transfer of heat, so that the entire weld penetration. Lack of the above chemical
composition of the steel pipe, such as seamless tubes, in the welding process will produce
a variety of factors of instability, is not easy to weld and welding impervious.
Grain size: Typically, Metal grain size and heat treatment temperature and keep the
same temperature is related with the time. Therefore, the annealed the same seam pipe
and seamless pipe grain size. If there is a seam tube with a minimum of cold treatment,
the grain size of the weld seam is less than the grain size of the weld metal, otherwise, the
grain size is the same.
Strength: the strength of the pipeline depends on the alloy composition, and thus contain
the same alloy and the same heat treatment of seamless pipe and slotted tube essentially
are consistent strength. After tensile testing and three-dimensional vibration test, slotted
tube tear occur almost exclusively in a place away from the welding point or heated area.
This is because fewer impurities and a slightly higher nitrogen content of the weld, and
thus the strength of the weld at better than the other region. However, the ASME Boiler
and Pressure Vessel Association seam pipe can only bear 85% of the allowable pressure,
which is mainly due to the data collected as early as today has improved welding
equipment. ASME regulations 100% seam tube can withstand the allowable pressure by
ultrasonic testing. Similarly, Europe and Asia also provides seam pipe to ensure the
quality of its welding performance by means of eddy current testing, eddy current testing
require the approval of the legal procedures and licenses held by institutions. Trent eddy
current testing by the permission of the Swedish Ministry of Power. ASME small current
loss is based on the quality performance of the slotted tube.
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Source: China Steel Pipe Manufacturer – Yaang pipe fitting Industry Co., Limited
(www.steeljrv.com)
(Yaang Pipe Industry is a leading manufacturer and supplier of nickel alloy and stainless
steel products, including Super Duplex Stainless Steel Flanges, Stainless Steel Flanges,
Stainless Steel Pipe Fittings, Stainless Steel Pipe. Yaang products are widely used in
Shipbuilding, Nuclear power, Marine engineering, Petroleum, Chemical, Mining, Sewage
treatment, Natural gas and Pressure vessels and other industries.)
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References:
1. http://www.madehow.com/Volume-5/Steel-Pipe.html
2. https://en.wikipedia.org/wiki/Piping
3. https://www.yaang.com
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