Pipes and elbows

Steps sequence of deformation of pipes and elbows

By : Basel Raafat Radwan Saleh Selim

Production and mechanical design department

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Pipes and elbows

Index

1- Introduction

2– Information about produced pipes and bends

3-Grinding the surface and preparation for welding

4-Edge milling

5 -3 roll bending machine

6 -post bending

7 -tack weld

8-internal weld

9 -external weld

10 -visual inspection

11 -manual arc weld

12 -X-ray inspection

13 -ultrasonic inspection

14 -hydrostatic inspection

15 -expander

16 -final inspection for pipe

17 -elbow bending machine

18-references

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Pipes and elbows

2- Information about produced pipes and bends

Pipe length Min. 8 m - Max. 12.15 m

16- ”42( ”capability to 60 )"Range of Pipe Diameter

6.4 Range of Plate Thickness mm -27 mm

Ton annual production )250,00-150,000( tons

Daily production 160 pipe / day

Material According to API- 5L Up to Grade X80 OR EQUIVALENT

Bends:

BEND DIAMETER Min. 6 " - Max. 48 "

BEND Thickness From 8.7 to 38.1 mm

BENDING ANGLE Any degree up to 180º

3DR MINIMUM BEND RADIUS

Material According to API- 5L Up to Grade X80 OR EQUIVALENT

3 - Grinding the surface and preparation for welding

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Pipes and elbows

After storing the sheet of metals , A layer of oxide is formed on its surface , So that it's needed to be removed by grinding to make the weld process easier and to reduce welding defects.

4 - Edge milling

Milling process happens on the edge of the sheet to get the edges chamfered to weld the two edges ( The pictures below defines the cutting tool and the milling machine)

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Pipes and elbows

5 – 3 Roll bending machine

The metal sheet it transformed to pipe circular shape by roll bending machine by two fixed roller and one rotating roller which also apply pressure

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Pipes and elbows

6 - Post bending

Post bending is the second process of deformation , 3 roller bending machine produces a pear shaped incomplete pipe so that post bending machine makes pipe shape more rounded and makes the two ends

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Pipes and elbows

ready to be welded.

7 – Tack welding

In this method of welding shielding Gas is used (Co2)then the arc welding takes place to bring the line of the pipe closer or to weld the line

of the pipe .

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Pipes and elbows

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Pipes and elbows

8 - Internal weld

By using submerged arc welding the pipe is welded from the inside.

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Pipes and elbows

9 – External weld

The external welding happens by submerged arc welding with powder flux and electrode rolls are fed and placed on the top of the machine.

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Pipes and elbows

10- Visual inspection

The first step of inspection which cameras are used or the naked eye by which the operator will determine if there is a defect or not .

11 – Manual arc welding

If it was a defect or a crack an operator with manual arc welding may fix this defect.

12 - X-ray inspection

It is non-destructive test which defines if there is a defect or a crack or not

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Pipes and elbows

13 – Ultrasonic inspection

Takes place after x-ray test to detect the defect in the weld line

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Pipes and elbows

14 – Hydrostatic pressure test

It is a test which uses flow of water under high pressure to make sure that the pipe will endure the desired pressure or not.

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Pipes and elbows

15 – Expander

A machine to ensure that the pipe has a fully rounded shape along its section.

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Pipes and elbows

16 – Final inspection on the pipe

It is considered as the final step in which the operator inspect the pipe using magnetic method or visually

17 – Elbow bending machine

It is a machine that bends pipes to make elbow with different measurements , the center of the radius of the elbow is made like the

compass makes circles .

(The measurements of the elbows is mentioned at the first of this report)

First we blow up air to ensure that water doesn’t get in the heated part then the temperature of the metal is increased by the coil , Quenching

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Pipes and elbows

treatment takes place to keep the bent in the pipe , Finally heat treatment is occurred to take the stress away and the elbow is measured

on a measuring floor .

18- References :

www.ipic-eg.com

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