The production process for spiral-welded pipes involves several critical steps to ensure high-quality output:
(1) The raw materials, including strip coils, welding wire, and flux, must undergo rigorous physical and chemical tests prior to use. This step is essential to guarantee the integrity and reliability of the materials.
(2) The ends of the strip steel are joined using either single-wire or double-wire submerged arc welding. Following the initial welding, the rolled steel pipe undergoes additional repair welding using automated submerged arc techniques to enhance durability and strength.
(3) Prior to forming, the strip steel is processed through leveling, trimming, planing, and surface cleaning to prepare it for optimal performance. Pre-bending is also conducted to facilitate proper shaping during the forming phase.
(4) An electric contact pressure gauge monitors and regulates the cylinder pressure on both sides of the conveyor belt, ensuring smooth and consistent movement of the strip steel throughout the process.
(5) The forming stage employs either external or internal control roll forming methods, depending on the specific requirements of the project.
(6) A specialized weld gap control mechanism ensures precise alignment of the welds, maintaining stringent control over the pipe's diameter, misalignment, and weld gap to meet industry standards.
(7) Both internal and external welding utilize advanced American Lincoln welding machines, employing single-wire or double-wire submerged arc welding to achieve reliable and consistent results.
(8) Post-welding, all seams are inspected using an online continuous ultrasonic automatic flaw detector. This ensures comprehensive non-destructive testing of the spiral welds. Any detected defects trigger an alarm and marking, allowing operators to promptly adjust parameters and rectify issues.
(9) Once formed, the steel pipe is cut into individual sections using an air plasma cutting machine.
(10) After segmentation, each batch of pipes undergoes a thorough initial inspection covering mechanical properties, chemical composition, weld fusion status, surface quality, and non-destructive testing. Only pipes passing these evaluations proceed to full-scale production.
(11) Sections marked by continuous sonic flaw detection undergo further review via manual ultrasonic and X-ray examination. Defective components are repaired and retested until confirmed free of flaws.
(12) Areas where the strip butt welds intersect with spiral welds are examined via X-ray television or film imaging to detect potential structural concerns.
(13) Hydrostatic pressure testing is performed on each pipe, with radial sealing and precise control over test pressures and durations achieved through a microcomputer-based detection system. Test data is automatically documented and recorded.
(14) The pipe ends are machined to ensure accurate control over perpendicularity, bevel angles, and edge thickness.
This meticulous process ensures that every spiral-welded pipe meets the highest standards of quality and safety, meeting diverse industrial needs across various sectors.
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