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Production of tubes and pipes

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Production of tubes and pipes

  1. 1. PRODUCTION OF TUBES AND PIPESIn a Nutshell 10/ME/134-140 MAHESH BANG
  2. 2. 1 Outline of the Presentation 1. Background 2. Introduction 3. Procedure Seamless Process Welding Process Plastic / PVC Pipes 4. Applications5. Conclusion
  3. 3. 2 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 .
  4. 4. 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.
  5. 5. 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.
  6. 6. 5 1. Background 1.1 Look over the trends of production of tubes and pipes …….. Contd.
  7. 7. 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
  8. 8. 7 1. Background  Composition of raw materials for seamless pipes Elements C Si S P Limit 0.20% max 0.10-0.35% max 0.01% max 0.02% max Limit 0.20% max 0.15%- 0.35% 0.003 % max 0.020 % max 0.01 % max 2-3 % max  Composition of raw materials for pipe line/ heat exchangers Elements C Si S P N Ca/S 1.2 Raw Materials …. Contd.
  9. 9. 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. 8
  10. 10. 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 9
  11. 11. 10 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
  12. 12. 11 3. Procedure Tubes and Pipes From Metal / Steel From Non Metals i.e. Plastics Seamless Pipes Seamed / Welded Pipes
  13. 13. 12 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
  14. 14. 13 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.
  15. 15. 14 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.
  16. 16. 15 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.
  17. 17. 16 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
  18. 18. 17 3.1. Metallic Pipes B. Seamed / Welded Pipes 1. Forge welding(Fretz moon process). 2. Electric welding 3. Argon Arc welding 4. 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
  19. 19. 18 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
  20. 20. 19 3.1. Metallic Pipes / Seamed Pipes Contd. ELECTRIC WELDING SLIDING CONTACT (CONDUCTIVE TYPE) INDUCTION COIL
  21. 21. 20 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)
  22. 22. 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 21 3.1. Metallic Pipes / Seamed Pipes Contd.
  23. 23. 22 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
  24. 24. 23 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
  25. 25. 24 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
  26. 26. 25 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
  27. 27. 26 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.
  28. 28. 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 27 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
  29. 29. 28 REFERENCES 1. The TPT Magazine – International Magazine in Tubes and Pipes Technology 2. Tenaris Corporation -- http://www.tenaris.com/en/default.aspx 3. TEPPFA – The European Plastic Pipes and Fitting Association 4. WERMAC -- http://www.wermac.org/ 5. Others – www.google.com THANK YOU !

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