Production of tubes and pipes

PRODUCTION OF TUBES AND PIPES

In a Nutshell

10/ME/134-140 MAHESH BANG

1 Outline of the Presentation

1. Background2.

Introduction 3. Procedure

Seamless Process

Welding Process

Plastic / PVC Pipes

4. Applications

5. Conclusion

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1.1 Look over the trends of production of tubes and pipes“ Before the facts of thing is realized, you need to know that

something is worth it.”

1. Background

The trends of ancient civilization

Fig.1 Bamboo tubes Fig.2 clay pipe In 1700’s England cast iron was used .

3 1. Background

Fig.3 Metal pipes found deep inside the mountain

Fig.4 Lead pipes used in Roman time

William Murdock invented a coal burning lamp system in 1815

Fig.5 William Murdock

1.1 Look over the trends of production of tubes and pipes …….. Contd.

4 1. Background

James Russell developed notable method in 1824 in which tubes were created by joining together opposite edges of a flat iron strips.

Next year , Comelius Whitehouse developed Butt-weld process for making the pipe.

Iron workers produce seamless tube of uneven thickness in 1840. The plant to produce seamless tube was built in 1895. In 1911, John Moon introduced the continuous process method for

producing the pipe.

Fig.6 Comelius Whitehouse Fig.7 Butt weld process

1.1 Look over the trends of production of tubes and pipes …….. Contd.

5 1. Background

1.1 Look over the trends of production of tubes and pipes …….. Contd.

6 1. Background

Steel is the primary raw materials. Other alloys may be included like aluminum, manganese, titanium, tungsten, vanadium and zirconium.

Thermo- plastic pipe Composite pipe (ASTMD 2680)

Steel Round billets , the primary source for manufacture. Helical Resistance coil (HR ) required to manufacture ERW pipes. For LASW pipes HR plates are required.

Fig.6 Steel round billets Fig.7 coil form

1.2 Raw Materials

7 1. Background

Composition of raw materials for seamless pipes

Elements C Si S P

Limit0.20% max0.10-0.35% max 0.01% max0.02% max

Limit0.20% max0.15%- 0.35%0.003 % max0.020 % max0.01 % max2-3 % max

Composition of raw materials for pipe line/ heat exchangers

Elements C Si S P N Ca/S

1.2 Raw Materials …. Contd.

1. Background

1.3 Tube verses pipe Tube is a structure while a pipe is a vessel.

Fig 8. frame Fig.9 structure

Pipes are normally seamless product while tubes are mostly seam welded.

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1. Background

1.4 Technology used for the production for tubes and pipes

CPE technology used for the production for seamless pipe

Fig.12 CPE process

Plug Mill technology used for higher dimension seamless tube.

High frequency Induction welding used for ERW pipes and tubes.

Fig.10 plug mill Fig.11 HFIW used for ERW pipe

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2. Introduction

• Steel Pipes may be : Seamless Pipes : Manufactured

thoroughly without joints, as a single piece via Rolling.

Seamed Pipes : Involve forming of flat sheets and then joining ends by various types of welding.

• Non Metallic i.e Plastic and PVC Pipes are increasingly being used these days as replacement of Metallic Pipes for various applications.

• Plastic / PVC Pipes are Seamless and generally manufactured by Extrusion

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3. Procedure

Tubes and Pipes

From Metal / Steel

From Non Metals i.e. Plastics

Seamless Pipes

Seamed / Welded Pipes

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3.1. Metallic Pipes

A. Seamless Pipes

• Pierce and Pilger process

• Plug rolling process

• Continuous mandrel rolling process

• Push bench process

• Pierce and Draw process

• Tube extrusion process

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3.1. Metallic Pipes / Seamless Pipes Contd.

PIERCE AND PILGER PROCESS

• Also known as manesmann process

• Cross roll piercing process

• For outside diameter of 60 to 660 mm.

• Length of pipe upto 18m.

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3.1. Metallic Pipes / Seamless Pipes Contd.

continuous mandrel process

• High performance production process

• Uses modern drive and control • Outer diameter of 60 to 178mm.

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3.1. Metallic Pipes / Seamless Pipes Contd.

PIERCE AND DRAW PROCESS

• For large diameter and large wall thickness tubes

• Not suitable for mass production

• Outer diameter 200 to 1450 mm.

• Wall thickness 20 to 270 mm.

• Power plant component, hydraulic actuators, high pressure cylinder and pressure vessels.

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3.1. Metallic Pipes / Seamless Pipes Contd.

TUBE EXTRUSION PROCESS

• Tubes up to 230mm can be produced

• First piercing and then stretch reducing mill.

• For high alloy tubes, starting material may be drilled, then bored and then extruded

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3.1. Metallic Pipes

B. Seamed / Welded Pipes

1. Forge welding(Fretz moon process).2. Electric welding3. Argon Arc welding4. Various shielded gas welding process

Features

• Large capacity and long distance pipes can be produced• Stainless steel and other non ferrous metal pipes can be

produced

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3.1. Metallic Pipes / Seamed Pipes Contd.

FORGE WELDING PROCESS

• Oldest method(150 years back)• Outer diameter range 6 to

2500mm• Wall thickness 0.5 to 40mm• Starting material-rolled flat

product

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3.1. Metallic Pipes / Seamed Pipes Contd.

ELECTRIC WELDING

SLIDING CONTACT (CONDUCTIVE TYPE)

INDUCTION COIL

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3.1. Metallic Pipes / Seamed Pipes Contd.

FUSION WELDING PROCESS

PROCESS• 3 roll bending process• C ing press process• U ing and O ing press

process• Spiral tube forming process

WELDING• Submerged Arc welding• Gas shield and submerged

arc welding• Spiral and longitudinal

welding(for stainless stell and non ferrous alloys)

SPIRAL PIPE PRODUCTION

• Helical seam pipe

• Pipe diameter upto 2500mm can be produced

• No plate width requied so from single strip/skelp various diameter pipe can be produced

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3.1. Metallic Pipes / Seamed Pipes Contd.

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3.2. Plastic Pipes Plastic Pipe Types :

1. Solid Wall Pipes 2. Structured Wall Pipes

3. Barrier Pipes

- General type, with homogenous material

- Designed for specific uses as per requirements

- Have specialized outer cover

- Has flexible metallic layer in between 2 plastic layers

- It provides additional protection for fluid inside

- Eg. Drinking Water Pipe, for preventing Chemicals / Pollution Contamination

Materials for Plastic Pipes : Thermoplastics• Polyvinyl Chloride – PVC• Polypropylene – PP• Polyethylene – PE

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Hopper

Heat + Pressure on Barrel of Extruder

Molten Plastic Shaping of Pipes by Die

Cooling / Hardening

Granules / Pellets / Flakes/Powder

Material

3.2. Plastic Pipes / Manufacturing Contd.

Very Long Lengths of pipes can be manufactured by this process

Very long lengths can be made even by coiling on a reel

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3.3. Desirable Coating Characteristics

Effective electrical insulator Effective moisture barrier Good adhesion to pipe surface Resistance to dis-bonding Ease of repair Non- toxic interaction with environment Good hardness/ abrasion resistance Good penetration resistance Some examples are COAL TAR ENAMEL, FUSION BONDED EPOXY, 3

LAYER POLYETHYLYNE

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4. Applications (Generalized )

1. Industrial Applications Hydro Carbon Processing Industries –

Refineries / Gas Processing / Petro Chemical Units

Any, Every other industries involving flow of normal/pressurized fluids

2. Transportation Applications – Pipelines Trans – Boundary Oil/Gas Pipelines Drinking Water Pipelines Sewage/Dirt Transportation

3. Power Plants Hydro Power Plants Thermal Power Plants : Gas / Coal

Fired Wind Tunnels / Geo Thermal

Plants

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4. Applications (Generalized ) Contd.

4. Construction Trusses and Supporting

structures of Roof, Bridges, Railings, Telecom Towers

5. Others Bicycle Frames Frame for high speed

Automotive Hydraulic operations as in

Automotive, Aircrafts etc.

5. Conclusion

The Present : Tubes and Pipes are Omnipresent and indispensable

The Future : Tubes and Pipes can be expected to have even broader and wider applications

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Areas of Research : Better Welding Techniques Better Tools for Manufacturing Anti – Rust Systems Improved Material Handling – Conveyors / Magnetic Lifting Better Systems for Bending / Bent Pipes Software Development for Automation Improved Heat Treatment Systems / Procedures

28 REFERENCES

1. The TPT Magazine – International Magazine in Tubes and Pipes Technology

2. Tenaris Corporation -- http://www.tenaris.com/en/default.aspx3. TEPPFA – The European Plastic Pipes and Fitting Association4. WERMAC -- http://www.wermac.org/5. Others – www.google.com

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