Pipe Manufacturing Process – Seamless and Welded Pipe

Seamless Pipe Manufacturing Process

Seamless pipe is Strongest amongst all pipes type as it has a Homogeneous structure throughout
pipe length.

Seamless pipes are manufactured in a verity of size and schedule. However, there is a Restriction
on the manufacturing of large diameter pipe. Seamless pipes are widely used in the
manufacturing of pipe fittings such as bends, elbows, and tees.

Various Manufacturing process are explained in detail;

Mandrel Mill Process

In Mandrel Mill pipe manufacturing process, steel billet is heated to high temperature in the
rotary furnace. A cylindrical hollow, which is also known as mother hollow, is produced with the
help of a rotary piercer and set of roller arrangement that keeps the piercer at the center of the
billet. Outside diameter of piercer is approximately that of the inside diameter of the finished
pipe. With the help, secondary roller arrangement outside diameter and thickness are achieved.
Mannesmann Plug Mill Pipe Manufacturing Process

Mannesmann was German engineer who has invented this pipe manufacturing process. The only
difference between Plug mill process and Mandrel mill process is that in mandrel method inside
diameter is achieved in single pass whereas in Mannesmann multi-stage reduction is possible.
Forged Seamless Pipe Manufacturing Process

In a Forging pipe manufacturing process, a heated billet is placed in forging die that has a
diameter slightly larger than the finished pipe. A hydraulic press of forging hammer with
matching inside diameter is used to create cylindrical forging. Once this forging is done pipe is
machined to achieve final dimension. Forging pipe manufacturing process is used to
manufactured large diameter seamless pipe that cannot be manufactured using traditional
methods. Forged pipes are normally used for the steam header.
Extrusion Processes

In an extrusion pipe manufacturing a heated billet is placed inside the die. A hydraulic ram
pushes the billet against the piercing mandrel, material flows from the cylindrical cavity between
die and mandrel. This action produces the pipe from the billet. Sometimes pipe manufactured
produce pipe with a high thickness which is known as mother hollow. Many secondary pipes
manufactured used this mother hollow to produce pipe with different dimensions.
Welded Pipe Manufacturing Process

Welded Pipes are manufactured from Plate or continues Coil or strips. To manufacture welded
pipe, first plate or coil is rolled in the circular section with the help of plate bending machine or
by a roller in the case of continues process. Once the circular section is rolled from the plate, the
pipe can be welded with or without filler material. Welded pipe can be manufactured in large
size without any upper restriction. Welded pipe with filler material can be used in the
manufacturing of long radius bends and elbow. Welded pipes are cheaper with compared to the
seamless pipe and also Weak due to the weld

There are different welding methods used to weld the pipe.

ERW- Electric Resistance Welding

EFW- Electric Fusion Welding

HFW- High-frequency welding

SAW- Submerged Arc Welding (Long seam & Spiral Seam)

ERW Steel Pipe Manufacturing Process

In the ERW / EFW / HFW pipe process, first plate is formed in a cylindrical shape and the
longitudinal edges of the cylinder formed are welded by flash-welding, low-frequency
resistance-welding, high-frequency induction welding, or high-frequency resistance welding.

SAW Pipe Manufacturing Process

In SAW welding process, external filler metal (wire electrodes) are used to join the formed
plates. SAW pipes can have a single longitudinal seam of double longitudinal seam depend on
the size of the pipe. SAW pipe are also available in the spiral seam, which is continually rolled
from the single plate coil. The production rate of spiral SAW pipe is very high as compared to
Straight SAW pipe. However, Spiral SAW pipe are only used in low-pressure services such as
water, non-critical process services etc.