Stainless Steel 904L Large Diameter Pipe

What is Stainless Steel 904L, and what characteristics make it suitable for large-diameter pipes?

Stainless Steel 904L is a high-alloy austenitic stainless steel with low carbon content and high levels of chromium, nickel, and molybdenum. These unique alloying elements give Stainless Steel 904L exceptional properties, making it highly suitable for large-diameter pipes.

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One of the primary characteristics of Stainless Steel 904L is its remarkable corrosion resistance. It exhibits excellent resistance to various corrosive environments, including sulfuric acid, phosphoric acid, and chloride-containing media. This corrosion resistance is particularly crucial in industries such as chemical processing, petrochemicals, and oil and gas, where pipelines are exposed to aggressive substances and harsh conditions.

What are the advantages of using Stainless Steel 904L Large Diameter Pipes compared to other materials?

Using Stainless Steel 904L Large Diameter Pipes offers several advantages over other materials, making it a preferred choice in various applications. Its superior corrosion resistance stands out. Stainless Steel 904L exhibits exceptional resistance to corrosion in aggressive environments, including acids, chlorides, and high-temperature conditions. This corrosion resistance significantly reduces maintenance costs and extends the lifespan of the piping system.

The high strength and toughness of Stainless Steel 904L make it well-suited for large-diameter pipes. It can withstand high pressures and stresses without compromising its structural integrity. This robustness ensures reliable performance and minimizes the risk of leaks or failures, providing enhanced safety and operational efficiency.

Stainless Steel 904L's excellent weldability enables efficient fabrication and installation of large-diameter pipes. It can be easily welded using conventional methods, allowing for streamlined manufacturing processes and reducing project timelines. The ability to weld the material effectively also contributes to cost savings and facilitates on-site modifications or repairs.

Another advantage of Stainless Steel 904L is its versatility in different industries. It is widely utilized in chemical processing, petrochemicals, oil and gas, pharmaceuticals, and desalination plants. Its compatibility with diverse applications highlights its adaptability and reliability across various industrial settings.

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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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