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EFW pipe

The EFW pipe divison consists of a JCO forming press, helical / spiral mill, inside and outside welding system, heat treatment furnace and testing facilities.

Please send your inquiry by   sales@sunnysteel.com

Description

The EFW pipe divison consists of a JCO forming press, helical / spiral mill, inside and outside welding system, heat treatment furnace and testing facilities. Welding process employed is gtaw for root-pass and saw/tig for final pass with suitable filler wires as prescribed by aws specifications and asme boiler and pressure vessel code, section-ix. These facilities are capable of manufacturing austenitic and various duplex grades.
efw pipe manufacturing process
Sunny Steel has been supplying EFW Electric Fusion Welded Pipe for many years.

We supply EFW electric fusion welded pipe to the folowing industries on a global scale:

  • Oil Industry
  • Gas Industry
  • Filtration Industry
  • Refrigeration Industry
  • Refining Industry
  • Petrochemical Industry
  • Offshore Industry

EFW pipe vs SSAW pipe,ERW pipe

ERW – Electric Resistance Welded

For pipes or tubes size 4 inch (10.2mm) OD and below, strip is fed into a set of forming rolls which consists of horizontal and vertical rollers so placed as to gradually from the flat strip in to a tube which is then allowed to pass the welding electrodes. The electrodes are copper disks connected to the secondary of a revolving transformer assembly.

The copper disk electrodes make contact on each side of the seam and temperature is raised to the welding point. Outside flash is removed by a cutting tool as the tube leaves the electrodes, inside flash is removed either by an air hammer or by passing a mandnel through the welded tube after the tube has been cooled.

This is termed as Electric Resistance welded or ERW tube/pipe. If this ERW is being drawn further to get desired size of tubes or pipes, in cold condition is called as Cold Drawn welded or CDW.

SAW – Submerged Arc Welded

This process is used for pipes from 24″ to 36″ i.e 610mm to 914mm OD. Flat plate is first pressed into U and later O shape.

The O shape is placed in an automatic welder and backed up on the inside by a water cooled copper shoe. Two electrodes in close proximity and used. The electrodes are not in actual contact with the pipe. The current passes from on electrode through a granular flux and across the gap in the pipe to the second electrode. The high temperature of the arc heats the edges of the plate, a welding rod placed just over the seam is thereby melted and metal is deposited in the groove.

After the outside weld has been made, the pipe is conveyed to an inside welder where a similar operation is carried on, except that no backup shoe is need.

Electric Resistance Welding (ERW steel pipe)

welding member combination is applying pressure through the electrodes, the use of current through the joint area of ​​the contact surface and the adjacent heat generating resistance welding process method, Also known as contact welding. It has excellent toughness and dynamic load strength, welding deformation.

Commonly used spot welding, seam welding and butt three.


Fusion welded method of new polyethylene pipe

In the field of fluid medium transmission, polyethylene (PE) pipe is wide attention in recent years and has been the rapid development of new pressure structure.

Compared with the traditional metal pipe, polyethylene piping systems for light weight, strength and specific rigidity, durability, corrosion resistance, insulation, composite capacity and resistance to fracture. Easy to manufacture and installation, and low cost, the typical service life of up to the metal several times and can save a lot of energy production and use. It is used in the field of urban water supply and drainage and gas transportation and distribution system, agricultural irrigation and drainage systems, factories, mines ventilation system and mud, ore pipeline transportation.

Polyethylene piping systems for manufacturing and laying pipe connection between the impact of an important part of its structural integrity and lasting strength. Since polyethylene molecular chain by a methylene group, and having a high degree of symmetry. Determines its polarity is low, so the connection of the polyethylene pipe can not be used solvent bonding method using only mechanical connection or welding. Practice shows that the welding is a high-quality, high-efficiency plastic pipe connection technology. More mature welding techniques include socket weld, butt welding, fusion welded.

Heating wire which are fused welding molten weld has been the development and promotion of the construction is simple, portable field devices, welding speed, and soon. The basic principle is the high resistance of the wire pre-embedded in the plastic casing wall. Plug, Walter current, electric heating wire to make it around the plastic Division Heating and melting into each other, to form a weld cooling. Its main disadvantage is: (1) when the plastic melts and a small amount of current, closely-spaced heating wire are overlapped with each other to cause a short circuit failure often makes welding; (2) the high cost, the heating wire embedded within the plastic injection molding process and mold complex, will inevitably lead to the high production costs of the welded joints; (3) Upon completion of the welding, electric wire remaining in the weld affect performance, on the one hand, on the other hand, cause unnecessary alloy material waste.

Prepared using the carbon felt polyethylene laminated composite conductive composites as fusion welded materials is feasible during power-up, the resistance of the composite rate of change is very small, can be heated to the melting temperature of polyethylene. Composite molding process parameters temperature of 160 ° C, time 10 min, pressure 10 MPa, the resistance of the composite control in a 100 W. Factors affect the weld strength of the fused heating power, heating time, they impact on the weld strength is mainly attributed to the influence of the temperature of the heating layer, when the temperature of the heating layer is controlled within the range of 140 220 ° C, to obtain satisfactory weld strength. Therefore, the type of input power, it is possible to select an appropriate heating time to achieve the desired welding effect. Electrofusion welding, the presence of a heat affected zone in the vicinity of the heating layer in the melted layer and the heat-affected zone, the degree of crystallinity of the polyethylene, the crystal size will be changed, so that the properties of the material affected.

Standard

Welded pipes specification and size

Product NameExecutive StandardDimension (mm)Steel Code / Steel Grade
Electric-Resistance-Welded Steel PipesASTM A13542.2-114.3 x 2.11-2.63A
Electric-Resistance-Welded Carbon Steel and Carbon-Manganese Steel Boiler and Superheater TubesASTM A17842.2-114.3 x 2.11-2.63A, C,D
ERW and Hot-dip Galvanized Steel PipesASTM A5321.3-273 x 2.11-12.7A, B
Pipes for Piling UsageASTM A252219.1-508 x 3.6-12.7Gr2, Gr3
Tubes for General Structural PurposeASTM A50021.3-273 x 2.11-12.7Carbon Steel
Square Pipes for General Structural PurposeASTM A50025 x 25-160 x 160 x 1.2-8.0Carbon Steel
Mechanical tubingASTM A51321.3-273 x 2.11-12.7carbon and alloy steel
Screwed and Socketed Steel TubesBS 138721.4-113.9 x 2-3.6Carbon Steel
Scaffolding PipesEN 3948.3 x 3.2-4Carbon Steel
Carbon Steel Tubes for General Structure PurposeJIS G344421.7-216.3 x 2.0-6.0Carbon Steel
Carbon Steel Tubes for Machine Structure PurposeJIS G3445 15-76 x 0.7-3.0STKM11A, STKM13A
Carbon Steel Pipes for Ordinary PipingJIS G345221.9-216.3 x 2.8-5.8Carbon Steel
Carbon Steel Pipes for Pressure ServiceJIS G345421.7-216.3 x 2.8-7.1Carbon Steel
Carbon Steel Rigid Steel ConduitsJIS G830521-113.4 x 1.2-3.5G16-G104, C19-C75, E19-E75
Carbon Steel Rectangular Pipes for General StructureJIS G346616 x 16-150 x 150 x 0.7-6Carbon Steel

Coating

Pipeline coating is the most consistent and successful solution for protecting ERW pipes from corrosion, from moisture, other harmful chemicals.

Anti-corrosion steel pipe is processed through the preservation process, which can effectively prevent or slow down the process in the transport and use of chemical or electrochemical corrosion reaction of steel pipe.

Therefore pipe anti-corrosion layer is an important barrier to prevent soil erosion. A well-known foreign scholar put forward” 3PE france protective layer”, so far, anti-corrosion methods is widely used.

Coated pipes offer high resistance to corrosion on pipes and provide many benefits such as:

1. Increased Flow Capacity – A coating on pipes helps provide a smoother surface thus improving gas and liquid flow within pipes.

2. Reduced Cost – The pipeline coating increases the pipes durability so they can be deployed with minimum maintenance cost even in the harshest environments.

3. Lower energy usage – Various studies have shown that pipelines that are internally coated use less energy for pumping and compression of products through pipes. This helps in increased saving over time.

4. Clean delivery of products – The inhibitors used for the protection products can also be minimized by the use of coated pipes for delivery of products.

Thus, coating of pipelines can help you in reducing your maintenance cost and at the same time providing a corrosion free reliable protection.

Basic functions of erw pipe coating

  1. making the surface of ERW steel pipes free from electrochemical corrosion of the soil medium, the basic physics of bacterial corrosion protection.
  2. resisting the move of the soil medium creep stress, static stress and abrasion force method and structure of the basic machinery protection.

The basic principles of urban gas pipeline coating selection:

  • good insulating and mechanical properties;
  • good resistance to cathodic disbondment performance;
  • good resistance to water, gas permeability;
  • good chemical resistance soaking performance and anti-aging properties;
  • resistance to low temperature and high temperature performance;
  • easy mending and mending;
  • at reasonable prices.

Types of coating:

Coating Specifications

2.1.External Coating

2.1.1 External Epoxy Coating

  • API RP 5L2 Recommended Practice for Internal Coating of Line Pipe for Non-Corrosive Gas Transmission Service.
  • CAN/CSA-Z245.20 Standard for External Fusion Bond Epoxy Coating for Steel Pipe
  • AS 3862 Standard Specification for External Fusion-Bonded Epoxy Coating for Steel Pipes
  • AWWA C210 Standard for Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
  • AWWA C213 Standard for Fusion Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines.
  • DEP 31.40.30.32-Gen TECHNICAL SPECIFICATION FOR EXTERNAL FUSION-BONDED EPOXY POWDER COATINGFOR LINE PIPE
  • NFA 49-710 Standard Specification for External FBE layered Coating
  • ISO 21809-2:2007, Petroleum and natural gas industries-External coatings for buried or submerged pipelines used in pipeline transportation systems-Part 2:
  • Fusion-bonded epoxy coatings
  • NACE RP0394 – National Association of Corrosion Engineers Standard Recommended Practice, Application, Performance, and Quality Control of Plant Applied, Fusion Bonded Epoxy External Pipe Coating.
  • NACPA 12-78 – National Association of Pipe Coating Applicators External Application Procedure for Plant Applied fusion Bonded Epoxy (FBE) to Steel Pipe.
  • SAES-H-002 Internal and External Coatings for Steel Pipelines and Piping
  • 09-SAMSS-089 Shop-Applied External FBE Coating
  • 09-SAMSS-091 Shop-Applied Internal FBE Coatings

2.1.2 Polyethylene Coating

  • CAN/CSA Z245.21 External Polyethylene Coating for Pipe
  • DIN 30670 Polyethylene Sheathing of Steel Tubes and of Steel Shaped Fittings
  • NFA 49-710 External Three-Layer Polyethylene Based Coating, Application by Extrusion
  • DNV-RP-F106 Factory Applied External Pipeline Coatings For Corrosion Control
  • AS/NZS 1518 External Extruded High-Density Polyethylene Coating System for Pipes
  • ISO 21809-1 Petroleum and natural gas industries — External coatings for buried or submerged pipelines used in pipeline transportation systems – Part 1: Polyolefin coatings (3- layer PE and 3- layer PP)
  • ISO 21809-4:2009, Petroleum and natural gas industries -External coatings for buried or submerged pipelines used in pipeline transportation systems-Part 4: Polyethylene Coatings (2-layer PE)
  • DEP 31.40.30.31-Gen. TECHNICAL SPECIFICATION FOR EXTERNAL POLYETHYLENE AND POLYPROPYLENE COATING FOR LINE PIPE
  • IPS-G-TP-335 Material and Construction Standard for Three Layer Polyethylene Coating System
  • NFA 49-710 External 3 layer Polyethylene Coating
  • PETROBRAS’ ET-200.03 Engineering Specification (“Piping Materials for Production and Process Facilities”) for using low density linear polyethylene in carbon steel piping, as to appendix 13 of such specification.
  • 09-SAMSS-113 External Renovation Coating for Buried Pipelines and Piping (APCS-113)
  • UNI 9099-DIN 30670 Polyethylene Coating Applied by Extrusion

2.1.3 Polypropylene Coating

  • DIN30678 Polypropylene Sheathing of Steel Tubes and of Steel Shaped Fittings
  • EN 10286 Steel tubes and fittings for onshore and offshore pipelines –External three layer extruded polypropylene based coatings.
  • NFA 49-711 External Three-Layer Polypropylene Based Coating, Application by Extrusion
  • 09-SAMSS-114 Shop-Applied Extruded, Three-Layer Polypropylene External Coatings for Line Pipe

2.1.4 Polyurethane Coating

  • AWWA C222-99: Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings
  • BS 5493- Polyurethane Coating
  • DIN 30677.2 polyurethane Insulation of the fittings
  • EN 10290- External Liquid Applied Polyurethane Coatings

2.1.5 Polyolefin Coating

  • AWWA C225-03: Fused Polyolefin Coating Systems for the Exterior of Steel Water Pipelines
  • AWWA C215-99: Extruded Polyolefin Coatings for the Exterior of Steel Water Pipelines
  • AWWA C216-00 Standard for Heat-Shrinkable Cross-Linked Polyolefin Coatings for the Exterior of Special Sections, Connections, and Fitting for the Steel Water Pipelines
  • AWWA C224 – 01: Two-layer Nylon-11 Based Polyamide Coating System for Interior and Exterior of Steel Water Pipe and Fittings
  • AWWA C225 – 03: Fused Polyolefin Coating Systems for the Exterior of Steel Water Pipelines

2.1.6 Tape Coating

  • ISO 21809-3:2008, Petroleum and natural gas industries-External coatings for buried or submerged pipelines used in pipeline transportation systems-Part 3: Field joint coatings
  • AWWA C209-00: Standard for Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines
  • AWWA C214-00 Standard for Tape Coating Systems for the Exterior of the Steel Water Pipelines
  • AWWA C217-99 Standard for Cold-Applied Petrolatum Tape and Petroleum Wax Tape Coatings for the Exterior for Special Sections, Connections, and Fittings for Buried/Submerged Steel Water Pipelines
  • AWWA C218-02 Standard for Coating the Exterior of Aboveground Steel Water Pipelines and Fittings
  • AWWA C224-01: Two-layer Nylon-11 Based Polyamide Coating System for Interior and Exterior of Steel Water Pipe and Fittings
  • EN 12068 – DIN 30672 STANDARD-POLYETHYLENE SELF ADHESIVE TAPES

2.1.7 Bitumen Coating

  • DIN 30673 Bitumen coatings and linings for steel pipes, fittings and vessels.
  • BS 534

2.1.8 Coal-Tar Enamel Coating

  • AWWA C-203 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines-Enamel and Tape-Hot-Applied
  • AWWA C205 Cement Mortar Protective Lining and Coating for Steel Water Pipe – 4 inch (100 mm) and Larger- Shop Applied
  • BS 534

2.1.9 Concrete Weighted Coating

  • DNV-OS-F101 Submarine Pipeline System
  • ASTM C171 Specification for Sheet Material for Coating Concrete
  • BS EN 12620 Aggregates for Concrete
  • ISO 21809-5:2009, Petroleum and natural gas industries -External coatings for buried or submerged pipelines used in pipeline transportation systems – Part

5:External concrete coating.

  • ASTM C42 Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete
  • ASTM C642 Standard Test Method for Specific Gravity, Absorption and Voids in Hardened Concrete
  • ASTM C87 Standard Test Method for Effect of Impurities in Fine Aggregate on Strength of Mortar BS 1881 Methods of Testing Concrete
  • BS 3148 Methods of Test for Water for Making Concrete
  • BS 4482 Hard Drawn Mild Steel Wire for the Reinforcement of Concrete
  • BS 4483 Specification for Steel Fabric for the Reinforcement of Concrete
  • BS 4449 Specification for Carbon Steel Bars for Reinforcement of Concrete
  • ISO 4012 Determination of Compressive Strength of Test Specimen

2.1.10 Marine Coating

  • EN ISO 12944:1998 – Paints & Varnishes – Corrosion Protection of Steel Structures by protective paint system (parts 1 – 8)
  • ISO 20340:2009 Paints and varnishes – Performance requirements for protective paint systems for offshore and related structures
  • ISO 15741 Paints and varnishes-Friction-reduction coatings for the interior of on- and offshore pipelines for non-corrosive gases

2.1.11 Other specification

  • British Gas BGC/PS/CM1,
  • BGC/PWS/CM2
  • GAZ de France R 09
  • NACE RP 0181
  • NF A 49-706
  • TS 5140
  • TS 5139

2.2. Lining

2.2.1 Epoxy Lining

  • AWWA C210: Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
  • API RP512 or NFA 49-709 Internal can be epoxy 80 microns
  • TS EN 10289
  • NFA 49708 Recommended Practice for Internal Coating of Line Pipe

2.2.2 Bitumen Lining

  • DIN 30673 Bitumen coatings and linings for steel pipes, fittings and vessels
  • UNI-ISO 5256/87 STANDARD-BITUMEN COATING
  • BS 534

2.2.3 Cement Mortar Lining

  • AS/NZS 1516 Cement Mortar Lining of Pipelines In Situ
  • AWWA C203-02: Coal-Tar Protective Coatings & Linings for Steel Water Pipelines, Enamel & Tape, Hot-pap. (Incl. add. C203a-99)
  • AWWA C205-00: Cement-Mortar Protective Lining and Coating for Steel Water Pipe- 4 In. (100 mm) and Larger-Shop application
  • AWWA C602 Standard for Cement-Mortar Lining of Water Pipelines – 4 inch (100 mm) and Larger – In Place
  • BS 534

2.2.4 Shop Cement Lined Piping

  • AWWA C205,C104,C602
  • DIN 2614
  • British Standard BS 534
  • British Petroleum GS 106-1
  • Shell DEP 30.48.30.31-Gen.
  • Saudi Aramco 01-SAMSS-005
  • KNPC ENG STD 87C1
  • API RP 10E

Pipe Coating Products

  • Fusion Bonded Epoxy – Fusion Bond Epoxy is a powder epoxy thermosetting coating applied for anticorrosion protection to steel pipelines. The pipe is first blast cleaned and heated. Then epoxy powder is spray applied by electrostatic guns to melt and form a uniform layer that hardens within a minute from application. Utilizing industry accepted materials supplied by manufacturers such as 3M, DuPont, and Valspar, the facility can apply FBE in a wide range of thickness to cost effectively meet any project specifications.
  • Fusion Bonded Epoxy with Abrasion Resistance Overcoating (FBE/ARO) – Utilizing two completely separate powder systems, the facility can produce FBE with an ARO at unprecedented processing speeds using industry accepted materials such as 3M 6352, DuPont 7-2610, and Lilly 2040.
  • Fusion Bonded Epoxy with High Temperature Resistant Overcoating – Utilizing two completely separate powder systems, the facility can produce FBE with a high operating temperature resistant overcoating such as DuPont’s Nap-Gard Gold and 3M’s 6258.
  • Fusion Bonded Epoxy with Zap-Wrap Overcoating – The facility is capable of processing line pipe with connections and of applying the Zap-Wrap abrasion resistance overcoating to the ends of each pipe.

Three Layer Polyethylene (3LPE)

To improve anticorrosion performance and adhesion, an additional layer of epoxy primer is sprayed onto pipe surfaces prior to the adhesive layer and Polyethylene top layer application. Three Layer Polyethylene is suitable for service temperatures from 60°C to 80°C (85°C peaks). Typical coating thickness is from 1-2 mm to 3-5 mm.

Three Layer Polypropylene (3LPP)

If a wider service temperature range and high stiffness is required, adhesive and top layers, applied over primer layer, are based on polypropylene instead of polyethylene. Three Layer Polypropylene is suitable for service temperatures up to 135 °C (140°C peaks). Typical coating thickness is from 1-2 mm to 3-5 mm.

Three Layer Polypropylene and Polyethylene

Three Layer applications involve a thermoplastic coating applied to steel pipelines as a form of anticorrosion protection. This mechanical resistance is appropriate when the risk of particularly severe coating damages exist. The Three Layer process involved several steps. First, the pipe surface is blast cleaned to remove any external residue from the mill or storage. It is then heated and sprayed with a Fusion Bond Epoxy (FBE) primer followed by the application of an adhesive copolymer and polyolefin polymers that are wrap extruded, one over the other.

Field applied products

  • 3M: SK 134, SK6233, SK6352 Toughkote, SK 314, SK 323, SK 206N, SK 226N, SK 6251 DualKote SK-6171, SK 206P, SK226P,
  • 3M Internal Coatings: Coupon EP2306HP
  • DuPont: 7-2500, 7-2501, 7-2502, 7-2508, 7-2514, 7-2803, 7-2504 Nap Gard Gold 7-2504, Nap Rock: 7-2610, 7-2617 FBE Powders
  • DuPont: Repair Kits; 7-1631, 7-1677, 7-1862, 7-1851
  • DuPont Internal Coatings: 7-0008, 7-0010, 7-0014, 7-0009SGR, 7-0009LGR, 7-2530, 7-2534, 7-2509
  • Akzo Nobel: FBE – Fusion Bond Epoxy
  • Internline 876 Seal Coat
  • Hampel: 85448,97840
  • Denso: 7200, 7900 High Service Temperature Coatings
  • Internal Liquid Epoxy: Powercrete Superflow

Delivery

FAQs

Advantage of ERW pipe

The alloy content of the coil is often lower than similar grades of steel plate, improving the weldability of the spiral welded pipe. Due to the rolling direction of spiral welded pipe coil is not perpendicular to the pipe axis direction, the crack resistance of the spiral welded pipe materials.

Inquiry

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Contact Form Demo

FAQ

Q: How long is your delivery time?
A: The delivery time of customized products is generally 25 35 days, and non customized products are generally shipped within 24 hours after payment.

Q: Do you provide samples? Is it free?
A: If the value of the sample is low, we will provide it for free, but the freight needs to be paid by the customer. But for some high value samples, we need to charge a fee.

Q: What are your payment terms?
A: T/T 30% as the deposit,The balance payment is paid in full before shipment

Q: What is the packaging and transportation form?
A: Non steaming wooden box and iron frame packaging. Special packaging is available according to customer needs. The transportation is mainly by sea.

Q: What is your minimum order quantity?
A: There is no minimum order quantity requirement. Customized products are tailor made according to the drawings provided by the customer.