Carbon Steel Large Diameter Pipes

What is carbon steel large diameter pipe, and what are its main applications?

Carbon Steel Large Diameter Pipe refers to pipes made from carbon steel with a relatively large diameter, typically exceeding 24 inches. Carbon steel contains primarily carbon as the main alloying element, with trace amounts of other elements such as manganese, silicon, and copper. These pipes are known for their robustness, durability, and high tensile strength, making them suitable for various demanding applications.

The main applications of carbon steel large diameter pipe are found in industries such as oil and gas, petrochemicals, water and wastewater treatment, construction, and infrastructure development. These pipes transport crude oil, natural gas, and other fluids over long distances in the oil and gas sector. They are also utilized in refineries and chemical plants to transport various liquids and gases. Carbon steel large-diameter pipes convey water, sewage, and industrial effluents in water and wastewater treatment facilities.

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What are the advantages of using large carbon steel pipes over other materials?

Using carbon steel large diameter pipes offers several advantages over other materials. Carbon steel exhibits exceptional strength and durability, making it highly suitable for applications requiring full pipes. The inherent strength of carbon steel allows these pipes to withstand high-pressure environments, heavy loads, and harsh operating conditions, ensuring reliable performance over an extended lifespan.

Carbon steel pipes have excellent corrosion resistance. They can withstand exposure to various corrosive elements such as water, chemicals, and gases without undergoing significant deterioration. This corrosion resistance minimizes the risk of leaks, contamination, and structural damage, making carbon steel pipes a reliable choice for critical applications.

Another advantage is the cost-effectiveness of carbon steel large-diameter pipes. Carbon steel is a widely available and relatively affordable material compared to alternatives like stainless steel or exotic alloys. That makes carbon steel pipes a cost-effective option for various industries, particularly large-scale projects requiring extensive piping networks.

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Forming

According to the name, the plate is bent into a "U" and then a "O" in succession. The lowering of the die starts the process of forming in the U-ing press. The side rollers move the crimped plate in the direction of the die. The O-ing press is then used to mould the U-shaped plate into a slit pipe. Working at up to 60,000 tonnes of pressure, this is precision work.

Two lower rolls and one higher roll bend the plate to the appropriate radius during the three-roll bending procedure. Different top roll diameters are employed, depending on the steel grade and necessary pipe diameter. Afterward, the crimping machine rounds the created edges.

Tack welding of the slit pipe

The open edges of the slit pipe are tacking welded together in shielding gas prior to submerged-arc welding. Frames (roller cages) are used for this, which precisely position the edges and prevent misalignment. Additionally, the continuous tack weld keeps the weld pool in place for subsequent submerged arc welding.

Pipe identification

material tracking throughout the entire production process. For identification each pipe is marked with a pipe production number. Additionally a line, marking the centre of the pipe, is the reference for late non-destructive testing of the weld seam.

Inside and outside welding

Two passes are used to attach the longitudinal edges. At the pipe ends, run-on and run-off tabs are positioned to stabilise the electric arc at the start and end of the welding process.

Outside welding is done after the inside welding has been completed. The tack weld pass has fused entirely. Up to five welding wires can be positioned in a line behind one another during submerged-arc multi-wire welding. Welding wire and flux, amperage, voltage, welding speed, wire spacing, wire diameter, the angle of the wires in relation to one another and the weld groove, as well as flux height and width, all affect how consistently good a weld is. A welding data monitoring system enables online manufacturing process monitoring.

X-ray weld inspection / Filmless radiography

Each seam is first visually inspected from the inside out. In addition to X-ray and manual ultrasonic testing, our internal quality checks also involve ultrasonic inspection of the whole seam.

When compared to traditional film-based approaches, the use of automatic picture evaluation software and image processing capabilities considerably increases the reliability of inspection and detection. Any ultrasonic signals are automatically and precisely verified. We take pride in being the only manufacturer of large-diameter pipes to use digital technology for all radiography examinations. We streamline the inspection procedure, record the findings, and keep track of any deviations for later follow-up.

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