Steel Pipe Processes
In the steel pipe production and manufacturing industry, different pipe manufacturing processes have a very obvious effect on the performance and quality of the pipe. Spiral Submerged Arc Welding are the four most commonly used tube manufacturing processes. By understanding the process of different steel pipe manufacturing processes, it will be a good reference for the purchase and use of steel pipe.
History of the evolution of the steel tube process
- In 1885, the Mannesmann brothers in Germany invented the inclined roll piercing technology, realizing the world’s first industrialized production of seamless steel pipe.
- 1920s high-frequency resistance welding (ERW) technology breakthroughs, welded steel pipe production costs by 60%.
- 1953 UOE molding technology (U.S.), to promote the revolution of large-diameter oil pipeline.
- 1967 Continuous pipe rolling (CPE) technology industrialized, production efficiency increased 3 times.
Dimensions of steel pipes of different processes
| Parameter | ERW (Electric Resistance Welding) | LSAW (Longitudinal Submerged Arc Welding) | SMLS (Seamless) | SSAW (Spiral Submerged Arc Welding) |
|---|---|---|---|---|
| Applicable Steel Grade | API 5L B | X60-X100 | 20#-45# | API 5L B |
| Standard Diameter | 20-630 mm | 219-1626 mm | 10-850 mm | 219-3000 mm |
| Wall Thickness Range | 3-25 mm | 6-100 mm | 2-120 mm | 5-25 mm |
| Production Speed | 30 m/min | 2 units/hour | 1 unit/2 hours | 15 m/min |
Below are the product descriptions as well as product differences about Steel Pipe Craft that have been selected for you to view directly. The steel pipes accepted in the article are produced by us, if you have any questions, you can contact us.
LSAW Pipe And SSAW Pipe Differences- Process/Performance
LSAW Pipe and SSAW pipe are the two most commonly used types of welded steel pipe in the infrastructure and
ERW Vs SMLS Pipe, What’s The Difference
According to the different production processes, steel pipes can be generally categorized into erw welded steel pipes and seamless steel
ssaw pipe
SSAW STEEL PIPE As your reliable partner, TUSPIPE can supply you with SSAW steel pipes that have obtained certifications from
lsaw pipe
LSAW STEEL PIPE Manufacturer TUSPIPE produces LSAW steel pipes (Longitudinally Submerged Arc Welded steel pipes) in strict compliance with standards
seamless pipe
Seamless pipe- China TUSPIPE smls pipe Manufacturer TUSPIPE manufactures seamless carbon steel pipes in strict compliance with international and regional
ERW Pipe- China ERW Welded Pipe Standards/ Process Manufacturer TUSPIPE
ERW Pipe- China ERW Welded Pipe Standards/ Process Manufacturer TUSPIPE TUSPIPE is a globally leading manufacturer of ERW steel pipes,
ERW Pipe Process
The full name of the ERW process is Electric Resistance Welding. The principle of this pipe manufacturing process is that an electric current is passed through the edges of the pipe to heat them, thereby fusing the edges together. Although the resistance welding process uses relatively simple equipment, it is extremely productive and is suitable for the manufacture of large diameter steel pipes.
In the production of ERW tubes, the raw steel plate is first uncoiling and levelling, and then end butt welding. After welding, the quality of the weld is ensured by online ultrasonic inspection. After that, the pipe is cooling, sizing, cutting, and end processing, and finally anti-corrosion and hydrostatic test are performed to ensure the quality and durability of the pipe.
LSAW Pipe Process
LSAW Process Basics
- Plate Pretreatment
Raw steel plates are first uncoiled, leveled and edge trimmed to ensure a flat surface and burr-free edges.
- Forming stage (core point of difference)
The difference in molding methods can be divided into two processes, JCOE and UOE:
- JCOE molding process: by multi-stage progressive pressure molding.
- UOE molding process: one-press molding using a die.
- Welding and post-processing
After forming the steel pipe are required to be submerged arc welding , and through the expanding, testing and other processes to complete the production.
JCOE Molding Process
- Applicable scenes: small and medium batch, multi-specification steel pipe production.
- Advantages of the process: low investment in equipment, high flexibility.
- Core process:
- Pre-Bending
Both ends of the steel plate through the hydraulic press pre-bending into a curved shape, to eliminate the subsequent molding of the edge of the stress.
- J-Forming
The middle of the steel plate by the hydraulic press into a “J” shape, the formation of the initial curvature. Process points: 3-5 passes gradually pressurized to avoid material damage.
- C-Forming
Reverse press the J-shaped steel plate into a “C” shape, to further reduce the radius of the arc.
- O-Forming
Through a number of molds will be C-shaped steel plate pressed into a round, at this time the weld gap should be controlled at 2-3mm. Equipment Description: 8000-12000 tons of hydraulic pressure machine.
- Expanding
The use of mechanical expander or hydraulic expander on the overall expansion of the steel pipe to eliminate residual stress and improve dimensional accuracy. Inspection focus: ellipticity ≤ 0.6% D, circumference deviation ± 0.2%.
UOE Molding Process Details
- Applicable scenario: high volume, large diameter steel pipe production.
- Process advantages: high molding efficiency, excellent dimensional accuracy.
- Core process:
- U-Pressing
Steel plate is pressed into U-shape by 10,000-ton press at one time, and the efficiency of single forming is increased by 60%. Technical parameters: Press tonnage ≥ 30,000 tons.
- O-Pressing
The U-shaped steel plate is fed into the round mold and pressed into O-shaped pipe blank, the forming time is only 2-3 minutes.
- Expanding
Segmented hydraulic expanding technology is used to bring the tube to standard size and improve the mechanical properties at the same time. Precision control: Diameter tolerance ± 0.5mm, wall thickness deviation ≤ 5%.
SMLS Steel Pipe Process
SMLS is fully known as Seamless process. Seamless process is one of the oldest processes in the history of steel pipe production. It makes a hollow steel pipe from a solid billet through the steps of piercing and rolling. The steel pipe produced by this process has the advantages of high strength and no welded seams, and is suitable for high pressure, high temperature and other harsh environments.
In the seamless steel pipe production process, the billet is heating and piercing to form the initial steel pipe. Subsequently, it is gradually shaped and sizing through multiple rolling processes, and finally cutting and end-processed (END PROCESSING). The finished pipe undergoes rigorous dimensional and weight measurements to ensure compliance.
SSAW Pipe Process
SSAW (Spiral Submerged Arc Welding) process, i.e. Spiral Submerged Arc Welding (SSAW) process, is a process in which steel plates are rolled into spiral shape and then submerged arc welded. This process has high production efficiency and is suitable for the production of large length steel pipes, which are widely used in oil and gas transportation and other fields.
SSAW process, the steel plate after uncoiling and leveling, through the molding machine rolled into a spiral forming. After forming, the pipe is submerged arc welded to ensure the quality of the weld seam. The welded pipe is then subjected to non-destructive testing and hydrostatic testing to ensure that it is free of defects. Finally, anti-corrosion and marking are applied to prepare the pipe for shipment.
Selection Of Application Scenarios
ERW high-frequency resistance welded pipe:
- City water supply pipe network (working pressure ≤ 4MPa) and construction scaffolding construction
- Manufacture of thin-walled pipes such as automobile exhaust pipes and furniture metal frames (wall thickness 3-6mm)
- Petroleum product oil transportation branch pipeline (temperature ≤ 80 ℃)
LSAW straight seam submerged arc welded pipe:
- Deep-sea oil and gas transmission pipeline (water depth ≥ 3000 meters)
- High-pressure natural gas trunk network (pressure level ≥ 10MPa)
- Nuclear power plant cooling water circulation system pipeline
SMLS seamless steel pipe:
- Chemical reactor high-pressure pipeline (pressure ≥ 100MPa)
- Thermal power generation boiler superheater pipe (temperature ≥ 540 ℃)
- Aerospace hydraulic system precision pipe fittings
SSAW spiral submerged arc welded pipe:
- Municipal drainage network (diameter ≥ 2000mm)
- Agricultural irrigation low-pressure water distribution system
- Harbor pile foundation support pipe (single length 30 meters)
Advantages Of The Process
ERW high-frequency resistance welded pipe:
- Continuous production of 30 meters per minute, cost 40% lower than seamless pipe
- Welded seam length is only 1.1 times the length of the pipe, reducing the risk of leakage
- Precision thin-walled tubes with diameters from 20 to 630mm (tolerance ±0.5mm) can be produced.
LSAW straight seam submerged arc welded pipe:
- 100mm ultra-thick wall production capacity, burst pressure up to 120MPa
- UOE molding process ensures ellipticity ≤ 0.2%, adapting to submarine high pressure.
- Weld seam after double-sided submerged arc welding + expansion treatment, impact toughness ≥ 200J
SMLS seamless steel pipe:
- Weldless structure completely eliminates the risk of welding defects.
- Hot rolling process realizes full coverage of wall thickness 2-120mm.
- 20#-45# medium carbon steel material, hardness up to HB220
SSAW spiral submerged arc welded pipe:
- Spiral welding seam avoids the main stress direction, bending strength increased by 15%.
- The same steel strip can produce a variety of pipe diameters, material utilization rate of 98%.
- Double-wire submerged arc welding speed of 1.5m/min, the cost is 20% lower than the straight seam pipe