Manufacturing of pipes and elbows , Description of the processes and sequence , How pipe is deformed , welded and tested to make sure that it has now defect by using visual inspection , x-rays , ultrasonic and hydrostatic pressure test

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Steps sequence of deformation of
pipes and elbows
By : Basel Raafat Radwan Saleh Selim
Production and mechanical design department

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ndexI
1 -Introduction
2 –Information aboutproduced pipes and bends
3-Grinding the surfaceand preparation for welding
4-Edgemilling
5- 3 roll bending machine
6- post bending
7- tack weld
8-internal weld
9- external weld
10- visualinspection
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 bendsproducedInformation about-2
Pipe length Min. 8 m - Max. 12.15 m
61”-24( ”capability to 60)"Range of Pipe Diameter
1.2Range 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
3DRMINIMUM BEND RADIUS
Material According to API-5L Up to Grade X80 OR
EQUIVALENT

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the surface and preparationfor weldingrindingG-3
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 makethe weld
process easier and to reduce welding defects.
dge millingE-4
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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oll bending machine3 R–5
The metal sheet it transformed to pipe circular shapeby roll bending
machine by two fixed roller and one rotating roller which also apply
pressure

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ost bendingP-6
Postbending is the second process of deformation , 3 roller bending
machine produces a pear shaped incomplete pipe so that post bending
machine makes pipe shapemore rounded and makes the two ends

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ready to be welded.
ack weldingT–7
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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nternal weldI-8
By using submerged arc welding the pipe is welded fromthe inside.

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xternal weldE–9
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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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.
anual arc weldingM–11
If it was a defect or a crack an operator with manual arc welding may fix
this defect .
ray inspection-X-12
Itis non-destructivetest which defines if there is a defect or a crack or
not

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Ultrasonic inspection–31
Takes place after x-ray test to detect the defect in the weld line
testydrostatic pressureH–14
Itis a test which uses flow of water under high pressureto make sure
that the pipe will endure the desired pressureor not.

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15 – Expander
A machine to ensurethat the pipe has a fully rounded shapealong its
section.

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inal inspection on the pipeF–16
Itis considered as the final step in which the operator inspect the pipe
using magnetic method or visually
lbow bending machineE–17
Itis 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)
Firstwe blow up air to ensurethat water doesn’tget in the heated part
then the temperature of the metal is increased by the coil , Quenching
treatment takes place to keep the bent in the pipe , Finally heat

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treatment is occurred to take the stress away and the elbow is measured
on a measuring floor .
References :-81
www.ipic-eg.com