Welded pipes are widely used across industries such as oil and gas, construction, water treatment, and chemical processing due to their cost-effectiveness, high production efficiency, and ability to be manufactured in large diameters. Unlike seamless pipes, welded pipes are made by joining the edges of steel plates or coils through welding processes. Riyaarth Overseas offers premium welded pipes manufactured using advanced techniques to meet diverse industry requirements.
Key Features of Welded Pipes
Cost-Effective Production:
- Welded pipes are more economical to produce compared to seamless pipes, especially for larger diameters. This makes them ideal for projects where budget is a significant factor.
- The cost-effectiveness also allows for larger production volumes, making them suitable for extensive infrastructure projects.
Customizable Sizes:
- Welded pipes can be manufactured in a wide range of sizes and thicknesses, making them suitable for various applications. This flexibility caters to diverse industry needs, from small-scale plumbing to large-scale industrial piping.
- The ability to customize sizes ensures that welded pipes can meet specific requirements for different types of fluid transportation and structural systems.
High Dimensional Accuracy:
- Advanced welding and forming techniques ensure uniform wall thickness and consistent dimensions. This precision is crucial for maintaining structural integrity and performance in demanding applications.
- High-dimensional accuracy also facilitates easier installation and integration into existing systems, reducing downtime and increasing efficiency.
Versatile Applications:
- Welded pipes are suitable for fluid transportation, structural systems, and low- to medium-pressure environments. They are widely used in industries such as oil and gas, construction, and water treatment.
- Their versatility extends to handling different types of fluids, including water, gas, and chemicals, making them a reliable choice for diverse applications.
Manufacturing Processes for Welded Pipes
Welded pipe manufacturing involves several advanced processes to transform steel plates or coils into high-quality pipes. The most common methods include:
1. Electric Resistance Welding (ERW)
Overview: ERW is widely used for producing small- to medium-diameter pipes with high efficiency.
Steps:
- Steel strips or coils are uncoiled, leveled, and cut to the required width.
- The edges of the strip are heated using electric resistance and pressed together to form a weld.
- The weld flash is removed from the inner and outer surfaces using scarfing tools.
- Pipes undergo heat treatment to improve the weld zone’s mechanical properties.
2. High-Frequency Induction Welding (HFIW)
Overview: This process is similar to ERW but uses high-frequency currents for faster welding.
Steps:
- Steel strips are formed into a cylindrical shape using rollers.
- High-frequency induction heats the edges, which are then pressed together to form a weld.
- Pipes are cooled, cut to length, inspected, and finished.
3. Longitudinal Submerged Arc Welding (LSAW)
Overview: LSAW is used for producing large-diameter pipes suitable for high-pressure applications.
Steps:
- Steel plates are rolled into a cylindrical shape using a press or roll-bending machine.
- The edges of the plate are welded together using submerged arc welding (SAW) on both the interior and exterior surfaces.
- Pipes undergo heat treatment, straightening, inspection, and finishing.
4. Spiral Submerged Arc Welding (SSAW)
Overview: SSAW is ideal for manufacturing large-diameter pipes with continuous production capabilities.
Steps:
- Steel coils are fed at an angle into a forming machine that creates a spiral shape.
- The edges of the spiral are welded together using submerged arc welding.
- Pipes are cut to length, heat-treated, inspected, and finished.
Specifications of Welded Pipes
Welded pipes are available in various shapes, dimensions, and materials to suit diverse industrial applications.
Type | Outer Diameter Range | Wall Thickness Range | Applications |
Round Welded Pipe | 6mm – 2,500mm | 0.5mm – 40mm | Oil pipelines, gas transportation systems. |
Square Welded Pipe | 10×10mm – 400×400mm | 0.6mm – 20mm | Structural frameworks like bridges and buildings. |
Rectangular Welded Pipe | 20×10mm – 400×300mm | 0.6mm – 20mm | Industrial scaffolding systems; chemical reactors. |
Material Grades for Welded Pipes
Welded pipes are manufactured using a variety of steel grades to meet specific industry requirements. Below is a table summarizing commonly used material grades and their properties:
Material Grade | Standard/Specification | Properties | Applications |
Grade A & B | ASTM A135/A135M | Electric-resistance-welded steel; suitable for gas, vapor, and liquid transport. | Water pipelines, gas distribution lines. |
Grade C70 | ASTM A672 | High-pressure service; fabricated from pressure-vessel quality plate. | High-pressure pipelines, moderate temperatures. |
Grade 241 to 825 | CSA Z245.1 | Covers a wide range of grades for sour and non-sour service; notch-toughness properties. | Oil and gas pipeline systems. |
Grade EFW (Class 1–5) | ASTM A139/A139M | Electric-fusion-welded pipe with straight or helical seams; high mechanical strength. | Liquid, gas, or vapor transportation. |
Stainless Steel (304/316) | ASTM A312 | Excellent corrosion resistance; suitable for high-temperature and chemical environments. | Chemical processing, water treatment. |
Applications of Welded Pipes
Oil & Gas Industry:
- Widely used in pipelines for transporting oil, gas, and refined products over long distances. Welded pipes ensure cost-effective solutions for low- to medium-pressure applications.
- Large-diameter welded pipes are also utilized in offshore platforms and subsea pipelines due to their customizable sizes.
Water Treatment & Distribution:
- Used in water supply systems due to their corrosion resistance and ability to handle large volumes efficiently. Welded pipes ensure reliable operation in urban water networks.
- They are also used in sewage systems where they handle wastewater flow under low pressure effectively.
Construction & Structural Systems:
- Ideal for structural frameworks like bridges and buildings due to its load-bearing capacity and dimensional accuracy. Welded pipes provide stability in heavy-duty applications.
- They are also used in scaffolding systems and industrial structures where strength and customization are critical.
Chemical Processing:
- Suitable for handling non-corrosive fluids in reactors and transfer lines due to their uniform structure. Welded pipes offer cost-effective solutions for chemical plants.
- They facilitate the design of piping systems that can handle moderate temperatures and pressures efficiently.
Advantages of Welded Pipes
- Economical Production:
Manufacturing welded pipes is more cost-efficient compared to seamless pipes, especially for larger diameters. - Wide Range of Sizes:
Welded pipes can be produced in diameters ranging from small (1 inch) to very large (100 inches), catering to diverse industry needs. - High Efficiency:
Automated welding processes enable faster production rates while maintaining consistent quality.
Quality Assurance Processes
To ensure that welded pipes meet industry standards, rigorous quality checks are performed throughout the manufacturing process:
- Non-Destructive Testing (NDT): Techniques like ultrasonic testing detect internal flaws without damaging the product.
- Hydrostatic Testing: Pipes are subjected to high-pressure water tests to verify leak resistance.
- Dimensional Inspection: Radiometric gauges measure wall thickness and roundness over the pipe’s entire length.
- Surface Inspection: Visual checks ensure surface finish quality before delivery.
Environmental Considerations
Welded pipe manufacturing incorporates sustainable practices:
- Material Efficiency: Advanced forming techniques minimize waste during production.
- Energy Optimization: Modern welding technologies reduce energy consumption while maintaining precise control over the process.
Quality Assurance & Packaging
Riyaarth Overseas ensures strict adherence to international standards for welded pipes, ensuring reliability and safety in critical applications:
- Certifications: Compliant with relevant standards such as ASTM, ASME, EN, ISO specifications.
- Packaging: Welded pipes are securely packed with protective materials like wooden cases or bundles to prevent damage during transit.
Looking for reliable welded pipes? Contact Riyaarth Overseas today for customized piping solutions tailored to your industry needs! Fill out our inquiry form or call us now!
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