The production process of spiral welded pipes involves a series of precise and controlled steps to ensure the quality and reliability of the final product. First, raw materials such as steel strip coils, welding wires, and flux must undergo rigorous physical and chemical testing before they are used in the manufacturing process.
Next, the ends of the steel strip are joined using single or double wire submerged arc welding. After the strip is rolled into a pipe shape, any imperfections are repaired using automatic submerged arc welding to maintain structural integrity.
Before forming the pipe, the steel strip is leveled, trimmed, planed, cleaned, and pre-bent. This ensures that the material is properly prepared for the next stage of the process.
An electric contact pressure gauge is employed to regulate the pressure on both sides of the conveyor, ensuring smooth and consistent movement of the steel strip throughout the production line.
The strip is then formed using either external or internal control roll forming methods, depending on the specific requirements of the pipe being produced.
A weld gap control device is used to maintain proper alignment during welding, ensuring that the weld gap meets the required specifications. The diameter, misalignment, and weld gap are all closely monitored to guarantee quality.
Both internal and external welds are performed using American Lincoln welding machines, which allow for single or double wire submerged arc welding. This method ensures a stable and high-quality weld.
After welding, all seams are inspected using an online continuous ultrasonic automatic flaw detector. This system provides full coverage of the spiral welds and automatically alerts operators if any defects are detected. It also marks the defective areas, allowing workers to adjust parameters in real time and eliminate issues promptly.
Once the pipe is fully welded, it is cut into individual sections using an air plasma cutting machine. Each batch of pipes undergoes a strict first inspection, checking mechanical properties, chemical composition, weld fusion, surface quality, and non-destructive testing to confirm that the production meets all necessary standards before mass production begins.
Pipes with markings from ultrasonic flaw detection are manually re-examined using ultrasonic waves and X-ray imaging. If defects are confirmed, the affected areas are repaired and retested until all flaws are resolved.
Pipes where the butt weld seam intersects with the spiral weld seam are inspected using X-ray television or film to ensure there are no hidden defects.
Each pipe is subjected to a hydrostatic pressure test, during which it is sealed radially. The test pressure and duration are precisely controlled by a microcomputer-based water pressure detection system, and the results are automatically printed and recorded for documentation.
Finally, the pipe ends are machined to ensure accurate verticality of the end face, proper bevel angle, and correct edge preparation, meeting the required dimensional specifications for installation and use.
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