Prepared by: Gautam Wayse SHI India Piping dept.

Based

On Manufacturing Process Pipes classified as

Seamless Pipe Welded Pipe

EFW-Electric Fusion Welded Longitudinal SAW Pipe Spiral SAW Pipe ERW Electrical Resistance welded Pipe

 Mandrel

Mill

This process is used to make smaller sizes of seamless pipe, typically 1 to 6 inches (25 to 150 mm) diameter. The ingot of steel is heated to 2,370 F (1,300 C) and pierced. A mandrel is inserted into the tube and the assembly is passed through a rolling (mandrel) mill. Unlike the plug mill, the mandrel mill reduces wall thickness continuously with a series of pairs of curved rollers set at 90 angles to each other. After reheating, the pipe is passed through a multi stand stretch-reducing mill to reduce the diameter to the finished diameter. The pipe is then cut to length before heat treatment, final straightening, inspection, and hydrostatic testing.

 Plug

Mill

This process is used to make larger sizes of seamless pipe, typically 6 to 16 inches (150 to 400 mm) diameter. An ingot of steel weighing up to two tons is heated to 2,370 F (1,300 C) and pierced. The hole in the hollow shell is enlarged on a rotary elongator, resulting in a short thick-walled tube known as a bloom. An internal plug approximately the same diameter as the finished diameter of the pipe is then forced through the bloom. The bloom containing the plug is then passed between the rolls of the plug mill. Rotation of the rolls reduces the wall thickness

The tube is rotated through 90 for each pass through the plug mill to ensure roundness. The tube is then passed through a reeling mill and reducing mill to even out the wall thickness and produce the finished dimensions. The tube is then cut to length before heat treatment, final straightening, inspection, and hydrostatic testing.

Longitudinally Welded Pipe

Welded pipe (pipe manufactured with a weld) is a tubular product made out of flat plates, known as skelp, that are formed, bent and prepared for welding. The most popular process for large diameter pipe uses a longitudinal seam weld. the welds are made by heating with an electric arc between the bare metal electrode. Pressure is not used. Filler metal for the welds is obtained from the electrodes. For diameters above 36 inches, double seam welded pipe is specified as an alternative in API 5L. This has two longitudinal seams .

EFW PIPE MANUFACTURING PROCESS

Spiral welded pipe

As an alternative process, spiral weld construction allows large diameter pipe to be produced from narrower plates or skelp. The defects that occur in spiral welded pipe are mainly those associated with the SAW weld, An additional problem with early spiral welded pipe was poor dimensional accuracy, particularly out of roundness at the pipe ends. This led to problems of poor fit-up during field girth welding. Spiral line pipe gained a poor reputation in some companies as a result of these early experiences. Considered suitable only for low pressure applications such as water pipe.

Solid phase butt weld, was produced using resistance heating & high pressure to make the longitudinal weld (ERW), Nowadays Most pipe mills now use high frequency induction heating (HFI) for better control and consistency. However, the product is still often referred to as ERW pipe, even though the weld may have been produced by the HFI process. The defects that can occur in ERW/HFI pipe are those associated with strip production, such as laminations and defects at the narrow weld line.

Lack of fusion due to insufficient heat and pressure is the principal defect, although hook cracks can also form due to realignment of non metallic inclusions at the weld interface. Because the weld line is not visible after trimming, and the nature of the solid phase welding process, considerable lengths of weld with poor fusion can be produced if the welding parameters fall outside the set limits. In addition, early ERW pipe was subject to pressure reversals, a problem that results in failure in service at a lower stress than that seen in the pre-service pressure test. This problem is caused by crack growth during the pressure test hold period, which in the case of early ERW pipe was due to a combination of low weld line toughness and lack of fusion defects.

ERW PIPE MANUFACTURING PROCESS

 Single

random Length (6M) Double random length (12 M ) Some mill also producing the 18 m Pipe.

 ASME

B.36.10 Carbon steel Pipe ASME B.36.19 Stainless Steel pipe

 Forged

Fitting

(up to 4)(PE) ASME B.16.11- Dimensional standard for forged & threaded Pipe fittings

Wrought

Fitting (BW)

2 & above But welded end (Bevel end as per ASME B.16.25 ) ASME B16.9 -Wrought fitting

 Elbow

90 Deg. Long Radius (R=1.5D) Short Radius (R=1D)(ASME B.16.28) 45 Deg. Elbow Returns

Not used often

Non

standard Bend

5D bends

Used to avoid erosion in case of high velocity services , slurry & Pneumatic transport etc.

 Miter

bend

On site fabricated by welding of pipe Pieces Miter bend Calculations as per ASME 31. 3 Not preferred in high pressure services

 Equal

Tee

Reducing

Tee

 First

time introduced by Boney forge & Company In 1943. Self reinforce forge fitting meet the reinforcement requirement as per ASME B31.1, B31.3,B31.4 and B31.8 They also meet the 2001 edition of MSS-SP-97 Standard-Integrally Reinforced Forged Branch Outlet Fittings.

 Weldolet

But welded end

Thredolet

Threaded end

Sockolet

Socket Welded end

 Latrolet

45 deg. Connection Connection for Elbow

Elbolet

Sweepolet

Reinforment Requirement is High

 Nipolet

One piece fitting eliminate the requirement of nipple , Coupling & one weld.

For further details about Application , Installation & Welding etc. Please refer http://www.bonneyforge.com/products.php ?pg=branch

 Equal

Tee- SW & BW-

Header Size & Branch Size Same

Small bore SW Large bore BW

Reducing

Tee- SW & BW

Header size and up to Branch size=Header size /2 -1

WELDOLETS

Header size and Branch size=Header size /2 -2 & below .

Stub

in & stub on connection Reinforcement Calculations -Less Preferred

 Eccentric

Reducer

Concentric

Reducer

 Cap

Blind

flange

 Threaded

Connection

Threaded connection are avoided in oil & Gas SW- Small bore piping Shear stress But Weld Large bore Tensile stress

Welding

Flanged

Joints

Preferred in cases where often dismantle is required e.g. valves , Equipment Nozzles , Module interface , Inline instruments etc.

Slip on Flange

Weld Neck Flange

Socket weld Flange

Lap Joint Flanges

 Flat

Face (FF)
Face (RF)

The whole contact face of the flange is machined flat

Raised

The Raised Face is most common of all flange faces. The flange has a raised area machined on the flange face equal to the contact area of a gasket

Ring-type

Joint (RTJ)

This type has a higher raised portion on the face into which a ring groove is then machined. Mostly Preferred in high temperature services

Tongue and Groove (T&G)

This is also a form of flange face that in becoming obsolete. One flange face has a raised ring (Tongue) machined onto the flange face while the mating flange has a matching depression (Groove) machined into it's face. This is another form of flange face that is obsolete. One flange face has an area that extends beyond the normal flange face (Male). The companion flange or mating flange has a matching depression (Female) machined into it's face.

Male-and -Female (M&F)

Dissimilar flange faces such as the RTJ, T&G and the F&M shall never be bolted together.

Gaskets provide the tight seal that retains the pressure and keeps the gas or liquid leak Proof in the piping. Flange Face Finish: The part of a flange where the gasket touches is called the contact surface. This area is the most critical area to the prevention of leaks. Flange faces are machined with standard finishes.. The most common finish for the contact face of a flange is a concentric groove.

Based on service conditions such as pressure, temperature, and corrosiveness .

Non metallic Gaskets : are made of Rubber, PTFE and graphite. Metallic Gaskets : The Spiral Wound gasket has a graphite or Teflon material wound with a metal strip which is then held in shape by a flat metal ring. This metal retainer ring also acts as a centering tool to insure that the casket is not misaligned or blocks the product flow. Gaskets for Ring Type Joint flanges are simply a solid metal ring. There are two basic cross-sectional shapes for the RTJ gasket. These are "Oval" and "Hexagonal."

 Non-Metallic

Gaskets

ASME/ANSI B16.21 - 1992 - Nonmetallic Flat Gaskets for Pipe Flanges

This Standard covers types, sizes, materials, dimensions, tolerances, and markings for nonmetallic flat gaskets.

Metallic

Gaskets

ASME/ANSI B16.20 - 2007 Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-Wound, and Jacketed

This standard covers materials, dimensions, tolerances, and markings for metal ring-joint gaskets, spiral-wound gaskets, and metal-jacketed gaskets.

 Fasteners

such as nut & bolt is required to tight the piping Flanged Joints.

MECHANICAL JOINT MATERIAL 1. HUB & CLAMP( Hub, Blind Hub, Clamp, Seat ring) - Hub/Blind Hub : A105N/A350LF2, A182 F316, A182 F51 - Clamp : AISI 4140, - Seat Ring : A182 F55 - Service : High Pressure Mechanical Joint

HUB & CLAMP:

2. Hammer Lug Union ( ex: Weco Union )

- A105(N), A350 LF2. A694 F52/F65, AISI 4140

- Service: High pressure Hose Connector

3. GROOVED FLEXIBLE COUPLING (Victaulic Coupling) - Ductile Iron ( Style, Y, Delta, and Grooved fittings) - Service : Bulk ( Barrite, Bentonite, Cement ) Transfer Line

GROOVED FLEX.COUPLING