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The document discusses various aspects of pipe manufacture and coating. It describes the manufacturing process for seamless and welded pipes, including the different types of welding used. It also discusses pipe grades, chemical and physical properties, marking, coating and its properties. Concrete coating is used for offshore pipelines to provide negative buoyancy and keep the pipeline sunk on the seabed. Different application techniques are used for concrete coating like forming, guniting and extrusion.
The document discusses various aspects of pipe manufacture and coating. It describes the manufacturing process for seamless and welded pipes, including the different types of welding used. It also discusses pipe grades, chemical and physical properties, marking, coating and its properties. Concrete coating is used for offshore pipelines to provide negative buoyancy and keep the pipeline sunk on the seabed. Different application techniques are used for concrete coating like forming, guniting and extrusion.
The document discusses various aspects of pipe manufacture and coating. It describes the manufacturing process for seamless and welded pipes, including the different types of welding used. It also discusses pipe grades, chemical and physical properties, marking, coating and its properties. Concrete coating is used for offshore pipelines to provide negative buoyancy and keep the pipeline sunk on the seabed. Different application techniques are used for concrete coating like forming, guniting and extrusion.
according to the specifications of American Petroleum Institute (API). Qualified manufacturer are permitted to use API monogram on pipe they sell. Grade Distribution in Pipe Manufacturing
Grade Minimum Yield Strength
Grade A 30,000 psi
Grade B 35,000 psi
Grade X42 42,000 psi
Grade X60 60,000 psi
Manufacturing Process Two general types of line pipes are manufactured : 1)Seamless 2)Welded Seamless steel pipe is made without longitudinal weld by hot working lengths of steel to produce pipe of the desired size and properties. Welded pipes have several manufacturing process . They differ both in number of longitudinal weld seams in the pipe and the type of welding equipment used. Types Of Welding There are three types of welding: 1)Electric flash welding: Flash welding is a type of resistance welding that does not use any filler metal. 2)Electric resistance welding: Electric Resistance welding refers to a group of welding process such as spot and seam welding that produce junction faying(Tendency of cracking) surfaces where heat to form the weld generated by electrical resistance of material. 3)Electric induction welding: Is a process the uses electromagnetic induction to heat the work piece.
Flash welding is mainly used in Pipe Line.
Types Of Welded Pipes There are different types of welded pipes: 1) Submerged-arc welded pipe: This type of pipe has one longitudinal seam formed by automatic submerged arc welding. At least pass must be made on the inside and at least one pass at the outside. 2) Gas metal arc welded pipe: Pipe has one longitudinal welding formed by continuous gas metal arc welding. At least one pass must be made on inside and at least one pipe on the outside of the pipe . Continuing types of welded pipe
3) Double seam welded pipe:
Specified in API 5L as applicable to Grades A through X80 in sizes larger than 36 in. outside diameter (OD), has two longitudinal seams formed by the submerged arc welding process or the gas metal arc welding process. The seams are located about 180˚ apart. 4) Spiral Weld Pipe : This type of pipe has a spiral seam along its length formed by either the electric welding process or the automatic submerged arc process. At least one welding pass is made on the inside and at least one welding pass is made on the outside. Figure: Seamless and Welded pipe
Seamless pipe Welded pipe
Chemical properties:
Carbon is the key component in all steels.
The amount of carbon affects the strength, ductility, and other physical properties of steel. Maximum carbon content ranges from 0.21%- 0.31%,depending on the grade of steel used and the method of pipe manufacture. Manganese , phosphorous, sulfur, columbium , vanadium and titanium are also used in different quantity according to steel grades. The amount of manganese required in line pipe steel increases as the grade (strength) increases. Physical properties Some tests are done to know physical properties of pipe. Such as : 1)Tensile test, 2)Fracture roughness test, 3) Bending test, 4) Ductility test, 5) Hydrostatic test, 6)Other tests depending on specification. Pipe Ends Pipe is manufactured with either plain end or threaded end. Bell and spigot ends are also furnished in a few of the lighter pipe weight. On pipe furnished with a threaded end , the coupling is screwed onto one end of the pipe and a thread protector is installed on the other end. Threads on the pipe and threads on the coupling must meet specification requirements and tolerance. Plain end pipe is used for a pipeline in which the individual joints will be welded together. Marking Pipe manufactured under API specifications must be properly marked so pertinent information can be obtained at a glance. Markings include the following : 1) Manufacturer’s name or mark, 2) Spec 5L, 3) Size of the pipe in inches, 4) Weight of the pipe in pounds per foot, 5) The pipe grade ( A= Grade A; B= Grade B; X52= Grade X52; etc. ) 6) The process used to manufacture the pipe (S=seamless; E=welded pipe; except continuous welded; F= continuous- welded pipe ) Continued 7) Heat treatment performed (HN=normalized; or normalized and tempered; HS=subcritical stress relieved; HA=subcritical age-hardened; HQ= quenched and tempered ) 8) Test pressure , if higher than the pressure tabulated in the appropriate specifications . 9) Any other requirements.
As an example, the stencil marking for 14 in pipe size,
weight 54.57 lb/ft , Grade B, seamless (S) ,regular weight plain end pipe is : ABCO Spec. 5L 14.00 54.57 B S What’s Used Where Pipe manufactured by each of the different process is used in a variety of applications. In general seamless pipe is manufactured in the smaller sizes because the process is not practical for very large diameter pipe. Welded pipe is manufactured in a wide range of sizes. The use of spiral welded pipe for a large- diameter pipeline is growing in part because of advantages of spiral welding offers in the manufacturing process. The size pipe (diameter) used in any pipeline depends primarily on the volume to be handled. Continued The size selected for a given throughput represents the most economical combination of pumping or compression horse power and working pressure. A given volume of gas could be transported through a relatively small-diameter pipeline by operating the pipeline at a high pressure and using large amount of compression horse power . A larger pipeline could handle the desired volume at lower operating pressure using less compression horsepower. A significantly lower pressure would require a lighter pipe and would eliminate the need for high pressure valves and other special equipment. Larger diameter pipe is more costly, but added cost could easily be offset by its advantages. Pipe Coating Coating and wrapping pipelines has provided to be an economical way to extend pipeline life. To be effective, a coating must resist corrosion, and it must resist damage that would uncover areas of pipe where corrosion could occur. The purpose of the wrap on the outside of the coating is to provide protection to the corrosion- inhibiting coating. After the coating is applied tape is wrapped around the pipe in a spiral. Wrapping tape protects coating from damage. Other Types Of Pipes Gathering systems for oil and gas and long distance pipelines are virtually made of steel and individual lines of pipe are normally joined by welding. Pipe made of materials other than steel are used in special application such as: -Fiberglass pipe -Pipe made of various plastics -Cement asbestos pipe Steel pipe with internal lining with cement or other materials has also been used. This special pipe materials are typically used in relatively low pressure applications and in corrosive service. Continued Saltwater disposal pipelines are of these special types as it needs high corrosion resistance. Installation of fiber glass or plastic pipe is not done by welding. Individual lengths are joined by a bell and spigot joint, an adhesive bonded joint, a coupling that uses an O-ring to steal the joint , or other special joining methods Properties Of Coating An effective pipeline corrosion coating needs several properties: 1) Ease of application, 2) Good adhesion to pipe, 3) Good resistance to impact, 4) Flexibility, 5) Resistance to soil stress, 6) Resistance to flow (of the coating), 7) Water resistance, 8) Electrical resistance, 9) Chemical and physical stability. 10) Resistance to soil bacteria , marine organisms and cathodic disbondment. Fusion Bonded Epoxy Coating Plant Concrete coating Offshore pipeline are coated with concrete in addition to the corrosion to provide negative buoyancy ( a weight greater than the buoyant force of the water ) to the pipeline . This added weight is necessary to cause the pipeline to sink to the ocean floor and remain in position on the seabed. Application of the concrete coating
1) Forming: It a system more suitable for small quantities of
weight coating of water crossing of short length. It is a slow process. 2) Guniting: It is a process in which concrete is sprayed onto the pipe under pressure. 3) Extrusion: It is a process in which the concrete is rolled onto the pipe beneath an outer wrap. A heavy paper wrap has been used, as a polyethylene tape. Wire reinforcement is used in this process : one layer of wire in thinner coatings and two layers of reinforcing wire in thicker coating . Continued 4) Impingement: It is used to meet requirements for a high strength, high-impact-resistance coating. This application technique required better reinforcing . Wire mesh reinforcing is replaced with performed cages of hard drawn wire. The cage-type reinforcing is fitted to the corrosion coated pipe by plastic spares. Pipe Coating Concrete weight Coating Reference:
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