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Spiral Welded Pipes

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Spiral Welded Pipes

Spiral welded pipes are produced from coils of steel that are unwound and flattened. The flattened strip is formed by angled rollers into a cylinder of the desired diameter. At the end of the coil, a new coil is butt-welded to the trailing edge of the pipe, forming a cross seam.

Spiral Welded Steel Pipes

A G Universal Limited is a supplier and manufacturer of high quality Spiral Welded Steel Pipes in India. We manufacture Spiral Welded Pipes in different sizes, grades and specification as per international guidelines as we also export our products in many countries. Spiral welded pipes are manufactured from coils of steel which are unwound and flattened. The flattened strip is formed by angled rollers into a cylinder of the desired diameter. Spiral welded pipes are available in sizes from 24 inches to 144 inches.

Spiral welded pipes are also known as helical welded pipes. They are mainly used for water distribution service. They are used in many types of industries such as tap water engineering, chemical industry, electric power industry, petrochemical industry, agricultural irrigation and construction.

Like ERW pipe, spiral welded pipe is also manufactured from steel coil but the only difference is that the coil is wound at an angle, so the weld runs around the outside of the pipe in the shape of a helix. Spiral welded pipes are also known as helical welded pipes. The manufacturing process of spiral welded pipe is one of the most cost-effective ways to produce steel pipes. It typically utilises a helical Double Submerged Arc Weld (DSAW), which is protected against outside contaminants in the air, thus keeping the welded steel purified. Our mill produces a wide range of pipe diameters and wall thicknesses.

Various steps in manufacturing process of a spiral welded pipe are:

  1. First of all upon receipt of a coil, it is placed on a horizontal Un-coiler Mandrel and fed into the Straightener.
  2. Then, the steel strip of coil is introduced into the flattener through a roll stand and the coil set is removed.
  3. During movement through the straightener, the leading and trailing edges of the strip are trimmed in preparation for butt welding.
  4. The edges of the coil are trimmed with carbide teeth to prepare for welding.
  5. Then, the strip of coil enters the three roll apparatus composed of lead, buttress and mandrel roll sets. Now, the coil starts to form the spiral shape that will then become pipe.
  6. Using a submerged arc welding process, the welding system welds the pipe, first along the inside diameter and then along the outside diameter.
  7. Once the welding is complete, the finished pipe is visually inspected by Quality Control (QC)
  8. Once the pipe reaches the desired length, the cut-off machine is engaged.

There are many advantages of spiral welded pipes as described below:

  • The equipment used in manufacturing is light in weight.
  • The cost of production has a lower initial investment.
  • The welded tubes can be directly presented at the installation site where the pipeline is to be set.
  • Spiral welded pipe puts less stress on the seam than its straight seam counterpart, thus allowing it to withstand more pressure.
  • It is more flexible and customizable, thus allowing for larger diameters and longer lengths with varying levels.

Modern Laboratory

HR Coils are loaded on the decoiler of the Spiral Pipe Mill. The strip is straightened and the 100% coil is examined for any defects in the material by an automatic ultrasonic unit having 36 probes and 144 channels. The edges are refined to desired joint geometry. The strip is guided into the forming station, where it is formed to produce a cylindrical hollow body at a predetermined forming angle, ensuring the proper welding gap between the adjoining edges. Later, inside and outside welding is performed by an automatic submerged arc process.

Testing and Quality Control Facilities

After accomplishment of inside and outside welding, flux and slag from inside the pipes are cleaned. Pipes are cut to a predetermined length by an automatic plasma arc cutting device. The entire weld seam is scanned by Fluoroscopic Inspection/Real Time Radiography for analysis of the weld defects, if any. At the end facing machine, both ends of the pipes are machined simultaneously, to suit joint, to be used on the pipeline. Each pipe is hydrostatically tested to a given pressure as per API 5L specification or other desired specification.

Automatic Ultrasonic

An 100% weld length and HAZ of each pipe is examined by an automatic ultrasonic unit with the help of 16 probes and 16 channels for detecting the defects, if any. At the X-ray station, radiographs are taken from the weld seam of each pipe end up to a distance of 4″. Every length of pipe is subjected to a rigorous check at the final stage before it is accepted by the Quality Control Department.

  • Universal Testing Machines (Digital) for material testing (mechanical properties)
  • Eddy Current Testing Machine (NDT) for ON-LINE flaw detection on welds
  • Ultrasonic Testing Machine (NDT) for checking strip laminations and flow detection
  • Eddy Current Testing Machine (NDT) for ON-LINE flaw detection on welds (Parent Metal/Welds) and on pipes in auto mode
  • Metallurgical Microscope for checking and evaluating the grain/heat affected/weld zone structure of material

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