Pipe

Pipe Manufacturing and

Fabrication

© Copyright 2010, William G.

Beazley, All Rights Reserved

http://nla.gov.au/nla.pic-an24914320

4 Types of UOE mill: U-ing and O-ing Forming

Pipe (Sumitomo Metal Industries, Ltd. )
Forming
(Source: Don
Griser
Fluor)

1. Fabricated
(Rolled &
Welded)
2. Spiral
3. Seamless
http://www.sumitomometals.co.jp/e/news/news2006-09-14.html

Fabricated Pipe Fabricated Pipe

(Roscoe Moss Company) (Roscoe Moss Company)
• Large diameter pipe for special end uses
• Non-continuous and multi-staged process
– Flat sheets or plates squared and sheared
– Longitudinal edges preformed to pipe curvature
– Steel driven between rolls, bending it into
cylinder
– Seam welding is performed by SAW process
– Longer lengths made by welding cylinders
A Guide To Water Well Casing and Screen Selection

http://www.roscoemoss.com/tech_manuals/gwwc/p7.html http://www.roscoemoss.com/tech_manuals/gwwc/p7.html

1
 Pipe Rolling Mill Rolled Pipe
(MMHE) (MMHE)

Pipe on Positioning Rollers Pipe Welder

(MMHE) (MMHE)

Large Diameter Fabricated Pipe Butt Welded Pipe Mill Line

(Kawasaki Steel 21st Century Foundation)

http://www.jfe-21st-cf.or.jp/chapter_3/3e_1.html

2
Current Paths of Forged Weld of ERW Pipe
High-Frequency (Gerald Weimer and Ray Cagganello)
(HF) ERW Pipe
(Robert K. Nichols,
PE
Thermatool Corp.)

• Most HF welds are “forge welds” in

that they neither use a filler metal nor
melt the edges together as do more
conventional welding methods.
• The forge weld is accomplished first
by applying the HF current to the
edges, either by direct contact or
induction coil.
• Next the edges are brought together
under pressure forcing the liquid
metal to ejected from the bond plane.
• Lastly, the hot, unoxidized metal
beneath the liquid metal on each
edge metallurgically bonds to form
the weld.
http://www.thermatool.com/technical_papers.htm http://www.thefabricator.com/ResistanceWelding/ResistanceWelding_Article.cfm?ID=89

ERW Mill Line Manufacture of

(Kawasaki Steel 21st Century Foundation) Spiral Pipe
(Schlüter Consulting)
• Skelp is flattened and formed into
a cylindrical spiral tube
• Seam is welded at the first point
of strip contact
• Most spiral tubes welded both
inside and outside, assuring full
weld penetration
• Continuous operation: individual
lengths cut downstream

http://www.jfe-21st-cf.or.jp/chapter_3/3e_1.html http://www.schlueter-sc.de/en/manufacturing.html

Advantages of Spiral Pipe

Spiral Pipe in Wastewater Service
(Roscoe Moss Company)
• Skelp adheres to very close tolerances=> more
uniform and accurate in wall thickness
• Flexibility on grades of steel, non-ferrous weldable
metals and non-scheduled diameters and thicknesses
• High product roundness and straightness
• Greater strength of submerged arc electric welded
seams.
• High strength, heavy wall, large diameter pipes
currently required in petroleum and gas industries
http://www.roscoemoss.com/tech_manuals/gwwc/p7.html

3
 Spiral Pipe Seam Spread Stress Seamless Pipe Process
(Roscoe Moss Company) (Wyman Gordon)
• Weld Reinforcement • Billet of Steel Is
Heated to a
• Hoop stresses in a Plastic State
spiral seam tube less • Pierced by a
than straight seam Spear or Lance
• Hollow Billet
tube ("bandage" Elongated,
effect) Shaped Over
Mandrils
• Sized by Rollers
http://www.roscoemoss.com/tech_manuals/gwwc/p7.html http://omni.bus.ed.ac.uk/opsman/virtual/wyman/wgab.htm

Extruded Seemless Pipe Process Rotary Tube Piercing Process

(Kawasaki Steel 21st Century Foundation) (E. Ceretti, et al)

http://www.jfe-21st-cf.or.jp/chapter_3/3e_1.html http://www.tubenet.org.uk/technical/piercing.html

Seamless Piercer Pipe Mill Line

(Kawasaki Steel 21st Century Foundation) Pipe
Straightening
(Turner Machine
Company)

• High Pressure Tubing and Drill Pipe

– Thicknesses and Chemistries Difficult to Weld
– Diameters up to 20 Inches
• Higher Cost, Less Consistent Wall thickness

http://www.tubenet.org.uk/technical/turner_m.html
http://www.jfe-21st-cf.or.jp/chapter_3/3e_1.html

4
 NPS - "Nominal Pipe Size" and DN
- "Diametre Nominel”
• Inch pound names for pipe products called
NPS or “Nominal Pipe Size“
• Metric equivalents called DN or “Diametre
Nominel".
• Metric designations conform to International
Standards Organization (ISO) usage and
apply to all plumbing, natural gas, heating
Pipe Manufacturing Processes oil, and miscellaneous piping used in
(JFE Steel) buildings.
http://www.jfe-steel.co.jp/en/research/report/007/02.html

Common NPS and DN Sizes Weights of Pipe

Diameter Nominal Diameter Nominal Diameter Nominal
Nominal
- DN -
Pipe Size
- NPS -
Nominal
- DN -
Pipe Size
- NPS -
Nominal
- DN -
Pipe Size
- NPS -
• Three long standing traditional designations:
(mm) (inches) (mm) (inches) (mm) (inches)
6 1/8 300 12 1200 48
– Standard wall (Std)
8 ¼ 350 14 1400 54
10 3/8 400 16 1500 60
– Extra strong wall (XS) or extra heavy wall (XH)
15 ½ 450 18 1600 64
20 ¾ 500 20 1800 72
– Double extra strong wall (XXS) or double extra
25 1 550 22
32 1¼ 600 24
2000
2200
80
88
heavy wall (XXH).
40 1½ 650 26
50 2 700 28 • OD is Same for All Weights
65 2½ 750 30
80 3 800 32 – Valves & Fittings Dimensions Stay Constant
100 4 900 36
150 6 1000 40
200 8 1100 42
250 10 1200 48
Source: http://www.piping-toolbox.com/nps-nominal-pipe-sizes-16_45.html Source: http://www.piping-toolbox.com/pipes-schedules-16_620qframed.html

ANSI B36.10 Pipe Schedules Weights vs Schedules

• Std. and S.40 are the same in sizes thru 10-inch;
• To broaden range of wall thicknesses, schedule
numbers adopted for steel pipe • In sizes above 10-inch:
– Schedule 10 (S.10) thru schedule 160 (S.160). – Std has a wall of 3/8-inch.
– Schedule numbers indicate approximate values for 1000 – XS has a wall thickness of 1/2-inch.
times pressure-stress ratios (Always check stresses) • XXS has no corresponding schedule number, but in
• Later, stainless steel schedule numbers published in sizes thru 6-inch, XXS has a wall thickness twice as
ANSI B36.19 thick as XS.
– Schedule 5S thru schedule 80S • Stainless steel schedules 40S and 80S are identical
– For sizes thru 12-inch with carbon steel designations Std and XS,
– Letter "S" after the schedule number respectively, thru 12-inch.
Source: http://www.durovac.com/industrial-vacuum/tubing-fittings/stuff-about-pipe.htm Source: http://www.durovac.com/industrial-vacuum/tubing-fittings/stuff-about-pipe.htm

5
 Pipe Wall Thickness Steel Pipe Weight/Length)
• Unless otherwise designated, references to
pipe wall thickness always mean the • W = 10.68 t (D -t) (1)
nominal, or average, wall thickness • where
• Most ASTM tolerances on regular pipe –W = weight (lb/ft)
products specify that wall thickness of pipe at
any point is to be no more than 12 1/2%
–t = wall thickness (in)
under the nominal wall thickness specified. –D = outside diameter (in)
• A minimum wall of 0.875 times the nominal • Note: 1 lb/ft = 1.49 kg/m
wall could apply for regular mill rolled steel
Source: http://www.durovac.com/industrial-vacuum/tubing-fittings/stuff-about-pipe.htm

• Generally Supplied in
21 ft lengths (6.4 m +-
1/2” (12.7 mm)
Pipe Lengths Pipe End
• Other lengths: 20’,
Preparation for
24’, 40’ Joining
• Random lengths ( (Source: Don
Damaged ends are cut
away during the
Griser
finishing operations) Fluor)
– RL - 16 ft to 22 ft
(4.88 m to 6.71 m) and
– Double RL - 22ft (6.71
m) min with min
average length per
order of 35 ft (10.67
m)
• Note: US standard
flatcar is 40 ft long
http://adm.ky.gov/doneeslisting.htm

Victaulic
Taper Pipe
Thread Coupler
Engagement Installation
(ASME
B1.20.1-
1983)

http://www.victaulic.com/Docs/lit/I-100.pdf

6
 Stock End Finishes
• Plain end,
• Bevelled -30 deg
with 1/16” (1.6
mm) land,
Sanitary
• Threaded (with end
Connections protector),
• Threaded and
coupled (one end),
• Shouldered,
• Roll or cut grooved
(for mechanical
couplings).
http://www.cfsan.fda.gov/~ear/nss2-43a.html

Pipe Identification and Marking ASTM Marking

• Numerous manufacturing classifications,
grades, weights, schedule numbers, sizes, and
lengths.
• Steel pipe identified by paint stencil, or
stamped markings on pipe itself or by a tag
attached to smaller sized bundles of pipe.
• Marking requirements can differ:
– ASTM Marking
– API Marking
• Pipe made to their specifications labeled with:
– Manufacturer's Name (trademark or brand may be used).
– Pipe manufacturing method:
• F = Furnace butt welded, continuous welded
• E = Electric resistance welded
• S = Seamless
– Weight of Pipe: Std., XS., or XXS.Specification Number; ASTM
specification number.
– Length: units pipe was ordered in.
Source: American Society for Testing and Materials (ASTM)

API Marking
Added ASTM Pipe markings (Source: American Petroleum Association)
• Certain ASTM pipe classifications may
require pipe to be marked with:
– Grade of pipe
• Pipe made to their specifications labeled with:
– Hydrostatic Test Pressure or: NH when
– Manufacturer's Name or Mark
not tested
– API's Specification Number
– Schedule Number – Diameter: either the nominal or outside diameter in
– S for supplementary requirements inches
– Grade: API's grades use numbers following letters to
– Pipe size indicate minimum yield strength

7
 API Marking API Marking
• Process of Manufacture: • Heat Treatment:
–S = Seamless – HN-Normalized or normalized/ tempered
–E = Welded, except butt-welded
– HS-Subcritical stress relieved
–F = Butt-welded
– HA-Subcritical age hardened
– SW = Spiral welded
• Type of Steel: – HQ-Quench and tempered
– E-Electric-furnace steel • Test Pressure: if pressure is higher than in
– R-Rephosphorized steel (class 11) no marking tables
required for open hearth or basic-oxygen steel
Source: American Petroleum Association (API) Source: American Petroleum Association (API)

Pipe Marking Steel Pipe Finishing Processes

(Tenaris)
• Standard finish for steel pipe is lacquer
coating to prevent corrosion in transit.
This pipe is usually referred to as black
iron pipe.
• Other common surface finishes include:
– Bare Metal
– Pickled and oiled
– Pickled only
http://www.tenaris.com/comunes/view.asp?idarticulo=281&category=55 – Galvanizing

Galvanizing Galvanizing Line

(Superior Technologies, Inc.)
• Zinc is a corrosion protective coating for steel
• Galvanized pipe is carbon steel pipe coated with
zinc both inside and outside
• Zinc usually applied by a hot-dipping process (pipe
submerged in molten bath of zinc)
• Standard weight of zinc applied is a minimum
average of 1.8 oz of zinc per square ft. of pipe (.55
kg per square m).

http://www.superior-tech.net/galdescr.html

8
 Structure of PE Pipe Coating
(Schlüter Consulting)
Steel Pipe Epoxy
Coating and PE
Wrapping
(Schlüter Consulting)

http://www.schlueter-sc.de/en/manufacturing.html http://www.schlueter-sc.de/en/manufacturing.html

Threaded Pipe
Fittings
(Smith Fastener Company)

Pipe Fittings/Components

http://www.smithfast.com/black.htm

Butt Welded Pipe Fittings Selected Flange Types

(Alibaba.com Corporation) (Franklin Flange Div., SUNN Industries)

Slip-on Weld Lap Joint

Weld Neck Flanges Flanges
Flanges

Socket Weld Threaded

http://www.alibaba.com/catalog/10846325/Butt_Welded_Pipe_Fittings.html Flanges Flanges
http://www.franklinflange.com/

9
 Contact Faces for Flanges ANSI Flange Face Types
(MSS SP-6) (API RP 14E)
• 1/16” raised face normally supplied on 150 and 300# classes (1/4”
supplied by special order)
• Raised Face (RF) - Increased ease of maintenance
• Male/Female refer to screw-on flanges and equipment replacement over RTJ.
• Large Male/Female not used on 150# class because of dimensional • Ring-Type Joint (RTJ)
conflicts
– Commonly used in:
• Higher pressure service of ANSI 900 and above
• May also be used for ANSI 600 in piping systems subject to
vibrating service.
• Considered for services with special temperature or hazard
problems.
– Piping should allow component removal since additional
flexibility required to remove the ring gasket.

ANSI Flange Materials API Flange Materials

(API RP 14E) (API RP 14E)
• Normally manufactured in accordance with • API flange Materials specified in API Spec 6A.
ASTM A-105. – Some API material types require special welding procedures.
– 2000, 3000, 5000, 10,000, 15,000and 20,000 psi pressure
• Flanges manufactured in accordance with ASTM ratings, applicable for temperatures between -20°F and 250'F.
A-181 may be suitable for certain noncritical • API Type 6B
services, e.g., water or atmospheric drains. – Rated 2000, 3000 and 5000
– Have a relieved-face contour
– Require Type R or RX gaskets
• API Type 6BX
– Rated 10,000, 16,000, and 20,000 psi
– Have a full-face contour.
– Require BX ring gaskets.

Welding neck flanges Slip-On Flanges

(Seyu Flange Co.)
• Referred to as "high hump" flange.
• Best design choice: Transfers stresses to
pipe, reducing high stress concentrations
at base of flange
• Expensive.
• API: Preferred for piping 2 inch and larger
• ANSI type flanges (ANSI B16.5) are used
in most applications.
• API type flanges (API Spec 6A) are used
primarily near the wellhead.
http://www.allproducts.com/korea/seyu/p01.html
(Seyu Flange Co.)
• Has a low hub because the pipe slips into
the flange prior to welding
• Welded both inside and out to provide
sufficient strength and prevent leakage
• All bored slightly larger than the O.D. of
the matching pipe
• Preferred over welding neck flanges due
to their lower initial cost but final
installation cost is probably not much less
because of the additional welding
involved.
http://www.allproducts.com/korea/seyu/p01.html

10
 Socket welding flanges Gap-A-Let® Rings Hold 1/16" Socket Weld Gap
(G.A.L. Gage)
(Seyu Flange Co.)
• Similar to a slip-on flange except it • ASME B31.3 Fig.
has a bore and a counter bore 328.5.2B: 1/16"
minimum gap inside
dimension
socket welds
• Smaller bore is shoulder for the pipe • Rings assure constant,
to rest on. Most codes require 1/16" proper gap whether in
gap between pipe & shoulder field run or fab shop
• Little restriction in flow when using a assembly.
socket-welding flange.
• Typical: Minimum engagement of 2t
(pipe) using 2 passes

http://www.allproducts.com/korea/seyu/p01.html
http://www.galgage.com/socketweld.html

Reducing Tees, Elbow, Threaded (screwed flanges)

Slip-on/Socket Flange in (Seyu Flange Co.)
Distribution Manifold • Similar to the slip-on flange,
but the bore is threaded.
• Reduction to Brach Sizes
• Chief merit: It can be
• Cheap Slip-on or Socket assembled without welding:
Flanges at Butterfly Valves – low-pressure services at ordinary
atmospheric temperatures
– highly explosive areas where
welding create a hazard.

http://www.allproducts.com/korea/seyu/p01.html

http://dhflange.en.ec21.com/Threaded_Screwed_Flanges--2526531_2545301.html

Lap joint flanges Lap Joint Flanges at Module Interface

(Seyu Flange Co.) (NSnet.com)
• Practically identical to a slip-on flange
except it has a radius at the intersection of
the bore and flange face to accommodate a
lap joint stub end.
• Normally, a lap joint flange and a lap joint
stub end are mated together
• Also know as a “Van Stone” flange
• Used on expensive pipe; e.g. stainless steel
– “Stub end” same material as pipe run
– Flange can be carbon steel instead of stainless.
DON’T confuse STUB END with STUB IN…
TWO TOTALLY DIFFERENT THINGS!!!!
http://www.allproducts.com/korea/seyu/p01.html

11
 Blind flanges Assorted Pipe Fittings
(Seyu Flange Co.) (MMHE)
• A flange without a bore
• Used to close off the ends
of a piping system and/or
pressure vessel opening.
• Permits easy access to the
interior of a line or vessel
nonce it has been sealed
and must be reopened
http://www.allproducts.com/korea/seyu/p01.html

Assorted Pipe Fittings Flange Gasket

(MMHE) (Prof Ken Fitzpatrick, Sacramento City College)

http://www.scc.losrios.edu/~tech/edt/332/332index.html

Victaulic Grooving Machine Victaulic Pipe Groove

(Prof Ken Fitzpatrick, Sacramento City College) (Prof Ken Fitzpatrick, Sacramento City College)

http://www.scc.losrios.edu/~tech/edt/332/332index.html http://www.scc.losrios.edu/~tech/edt/332/332index.html

12
 Victaulic Pipe Grooves
(Prof Ken Fitzpatrick, Sacramento City College)

Pipe Fabrication

http://www.scc.losrios.edu/~tech/edt/332/332index.html

Pipe Spools
• Prefabrication of a Particular Piping Section
– Includes Fittings and Flanges
– “Connection” to “Connection”
• Physical size and dimensions limited by:
– Transportation From the Fabrication Location
to Job Site
– Ability to Handle on Site
Spool Drawings
(Shop Fabrication Drawings)
• Made up from:
– Piping Layout
– Detailed Isometric Drawings (Fabrication ISOs)
• Incorporate all dimensions, material
specifications and information needed for
fabrication of spool
• Can be done in:
– orthographic (single or double line)
– isometric projection (single line)

Spools Double Line Orthographic Spool Drawing

http://www.johnson-williamson.com/seeproducts2.html
http://www.cimtaspipe.com/WhatsNew/fabrication2004.htm

13
 Single Line Isometric Spool Drawing

Single Line Orthographic

Spool Drawing

Spool Bill of Materials Spool Fittings Await Fit-up and Welding

(NSnet.com)

• Each box contains fittings for one spool

• Each spool has own BOM

Shop vs Field Fabrication

(W. M. Huitt)
Size (in.) Material Joint Shop or Field
Hard to
transport ≤1½ Pipe 1,2,3,6 Field
buttwelded
pipe spools ≤1½ Pipe 4&5 Shop
NPS 1 1/2
≥2 Pipe 3&6 Field
in. and less.
≥2 Pipe 4&5 Shop
Pipe Bending
≤1 Tubing 5 Field
≤1 Tubing 5 Shop (a, b)
Joint type:
≥1½ Tubing 5 Shop
1 = Socketweld
2 = Threaded
3 = Grooved - Fully (Grooved fittings and pipe ends). Notes: -
4 = Grooved - Partially (Shop-welded spools with grooved ends.) a. Hygienic tubing
5 = Buttweld b, Special cribbing and support for transport
6 = Flanged -Lined or unlined Pipe
http://www.wmhuittco.com/images/Article_5_Piping_Design_Part_5_Installation_and_Cleaning.pdf

14
 Bending Pipes using Sand Filling Hot Bending a Double 90° Bend,
Using a Template Wire
(Deutscher Entwicklungsdienst – DED)
(Deutscher Entwicklungsdienst – DED)

http://www.crystal-netbook.info/e158795/e171023/e171117 http://www.crystal-netbook.info/e158795/e171023/e171117

Hot Bending a Double 90° Bend, Furnace Bending • Pipe is firmly packed with sand
• Heated to about 2000 degrees F
Using a Template Wire (Pipe Fabrication Institute • One end retained in holding device
(Deutscher Entwicklungsdienst – DED) ES-24) • Bending moment is applied
• Radius controlled by dies, stops or
templates.
• For long radius bends and/or heavy wall
pipe, sand filling may not be necessary.

http://www.crystal-netbook.info/e158795/e171023/e171117

Furnace Bending of High Temperature Steam Pipe Cross-Sectional Deformation

(Photo: ZNIITMASCH)
(Deutscher Entwicklungsdienst – DED)
• Bending machine at BELENERGOMASCH plant in Belgorod for the thick-walled bend of
X10CrMoVNb9-1. On the right in the background is the preheating furnace in which the pipe
is heated to hot forming temperature before bending.

http://www.vmtubes.com/jsp/epctrl.jsp?con=vmtubes000058&cat=vmtubes000183&mod=vmtubes000061&pri=vmtubes&lng=1 http://www.crystal-netbook.info/e158795/e171023/e171117

15
 Place Welding Seam at Neutral Axis Pipe Defects from Bending
During Bending (Deutscher Entwicklungsdienst – DED)
(Deutscher Entwicklungsdienst – DED) • The bigger the bending radius, the smaller
the possibility for cracks or wrinkles to
occur.
• For all pipes, there is a minimum-bending
radius.
• Depends on the material, pipe diameter, wall
thickness and heating temperature.

http://www.crystal-netbook.info/e158795/e171023 http://www.crystal-netbook.info/e158795/e171023

• Pipe clamped in anchor box • Pipe is Placed In Bed

•
•
Front tangent is connected to hydraulic cylinder
Heating device heats a narrow circumferential band on
Incremental Bending •
•
Front Tangent Is Clamped To Radial Arm
Induction Heating System Heats Narrow Circumferential
Induction Bending
the arc to the proper bending temperature (Pipe Fabrication Institute Band to Appropriate Bending Temperature (Pipe Fabrication Institute
• Force bends small increment a predetermined amount ES-24) • Pipe is Continuously Moved through Heating Coil while ES-24)
• Heating device then moved to successive segments & Bending Moment is Applied.
repeat until the required arc is attained. • Pipe Forced Or Naturally Cooled As Required
• After bending heated area is cooled as required

• Pipe is Secured to Bending Die By Clamping

Induction Pipe Bending Die. Rotary Draw
(BendTec Inc.) • As Bending Die Rotates, It Draws Pipe Bending
Against Pressure Die and, if Necessary to (Pipe Fabrication
Prevent Wall Collapse, over Internal Mandrel Institute ES-24)
• Pressure Die May Remain Fixed or Move
With Pipe

http://www.bendtec.com/induct.html

16
 Cold Pipe Bending Cold Pipe Bending
(BendTec Inc.) (BendTec Inc.)

http://www.bendtec.com/induct.html http://www.bendtec.com/induct.html

• Pipe is Held by Two Supporting Dies

• Force Applied by Hydraulic Ram to Ram Bending
Forming Shoe at Center Of Workpiece (Pipe Fabrication
• Supporting Dies Rotate on Mounting Institute ES-24)
Pins to Follow Pipe and Maintain
External Support
Small Pipe
Cold Bender
(gavnor.com )

http://www.gavnor.com/item236.htm

• Three Forming Rolls of

Hydraulic Ram Bender Approximately Same Diameter
Roll Bending
(Deutscher Entwicklungsdienst – DED) (Pipe Fabrication Arranged in a Pyramid are Used.
Institute ES-24) • Two Fixed Rolls Oppose One
Adjustable Center Roll
• Pipe Is Passed through Rolls with
Position of Adjustable Roll
Controlling Bend Radius.

Roll Bending Video

17
 Minimum • Minimum Straight Tangents are
Tangents (TM) Required nOn Both Ends of the Arc
for Holding and/or Pulling Purposes
for Bending
(Pipe Fabrication • Differs for Each Method of Bending
Institute ES-24) • Differs for End and Between Bends

Bendable Shapes
(Cal Pipe Mftg., Inc.)
http://www.webendtubing.com/

Specialized Pipe Bending

(Central Fabricators Inc.)

Spiral Helical (Spring) Serpentine

Mitered Pipe on Precondenser

http://www.centralfabricators.com/
http://www.graham-mfg.com/ (Graham Corporation)

De-Scaling? Pipe Wheel Brush

(Prof Ken Fitzpatrick, Sacramento City College)

Source: SPED http://groups.msn.com/SocietyofPipingEngineersandDesigners/pipingdesign.msnw?action=ShowPhoto&PhotoID=14

http://www.scc.losrios.edu/~tech/edt/332/332index.html

18
 Pipe Cutting Jig Rigid Pipe Cutting Machine
(Prof Ken Fitzpatrick, Sacramento City College) (Prof Ken Fitzpatrick, Sacramento City College)

http://www.scc.losrios.edu/~tech/edt/332/332index.html http://www.scc.losrios.edu/~tech/edt/332/332index.html

Pipe Brazing
(US Navy)

Pipe Welding

http://www.defenselink.mil/photos/newsphoto.aspx?newsphotoid=6904

Welded Reducer & Flange Welded Pipe Reducer

(Prof Ken Fitzpatrick, Sacramento City College) (Prof Ken Fitzpatrick, Sacramento City College)

http://www.scc.losrios.edu/~tech/edt/332/332index.html http://www.scc.losrios.edu/~tech/edt/332/332index.html

19
 Pipe Mill Shop Welding of Pipe
(Ultimate Technology & Services Co., Ltd.)
(PHALCO,
INC.)

• 14" and up.

• Cut up to
five-inch
wall.
• Cut and
bevel at the
same time

http://www.phalco.com/pipeTools.htm http://www.rbwelding.com/Media/RVT_Video_engl001b001.mov http://www.uts-steel-construction.com/steel_construction_thailand/company.htm

End Preparation for Butt Welding Welding Ells Prepped 01

(Prof Ken Fitzpatrick, Sacramento City College)
• Required for Pressure Pipe, Matching Fitting
Ends
• V-beveling ends to angle of 37 1/2 degrees
– For wall thickness greater than 7/8 in. (22.2
mm), a compound or double angle bevel is used
– Land or root face is approximately 1/16 to 1/8
inch (1.6 to 3.2 mm)
• Lands help prevent sharp edges of bevel
burning off
http://www.scc.losrios.edu/~tech/edt/332/332index.html

Welding Ells Prepped 02

(Prof Ken Fitzpatrick, Sacramento City College)
End Preparation for Butt Welding

Source: Robert A. Lee, IPT’s Pipe Trades Handbook

http://www.scc.losrios.edu/~tech/edt/332/332index.html

20
 End Preparation for Butt Welding Butt Welding of Differing Wall
Thicknesses and Diameters

Required for Pressure Pipe, Matching Fitting Ends

V-beveling ends to angle of 37 1/2 degrees
For wall thickness greater than 7/8 in. (22.2 mm), a compound or
double angle bevel is used
Land or root face is approximately 1/16 to 1/8 inch (1.6 to 3.2
mm)
Source: Robert A. Lee, IPT’s Pipe Trades Handbook
Lands help prevent sharp edges of bevel burning off Source: Robert A. Lee, IPT’s Pipe Trades Handbook

Welding Flanges Prepped Fit Up of Pipe

(Prof Ken Fitzpatrick, Sacramento City College) 3" Compressor Inlet Suction Line
(Evaporative Systems, Inc.)

http://www.remote-site.com/laplata_mtns.html
http://www.scc.losrios.edu/~tech/edt/332/332index.html

Spacing Pipe for Pipe Alignment for Butt Welding

Butt Welding

Source: Robert A. Lee, IPT’s Pipe Trades Handbook Source: Robert A. Lee, IPT’s Pipe Trades Handbook

21
 Pipe
Alignment
for Butt
Welding

Clamping Pipe
for Butt
Welding
Source: Robert A. Lee, IPT’s Pipe Trades Handbook

Clamping Pipe for Tack Welding

Butt Welding Pipe on
(Rigid) Opposite Ends
Elbow Pipe Welding Vise

Flange Welding Vise Flange Welding Vise Straight Welding Vise Source: Robert A. Lee, IPT’s Pipe Trades Handbook
http://www.ridgid.com/Tools/Pipe-Welding-Vises

Pipe to Flange
Fitup
Pipe to Tee
Fitup

Source: Robert A. Lee, IPT’s Pipe Trades Handbook

Source: Robert A. Lee, IPT’s Pipe Trades Handbook

22
 Pipe Welding Clamps
(North State Group)
Angle Weld Vise

Pipe to 45º
Elbow Fitup

Source: Robert A. Lee, IPT’s Pipe Trades Handbook http://www.northstate.com/ridgid/en-us/dept_16.html

http://www.rbwelding.com/Media/walhonde01b.mov

Aligning Pipe with Clamps Welding Between Clamps

(Shell) (source: weldreality.com)

http://www.weldreality.com/flux_cored_pipe_welding.htm

Pipe Welding Stands Using Stands

(North State Group)

V-HEAD HIGH
PROFILE STAND

Adjustable Roller High V-head High Conveyor High

Pipe Support Profile Stand Profile Stand Profile Stand

http://www.northstate.com/ridgid/en-us/dept_16.html
• A pipe fitter is preparing to weld this section of cooling
water piping on the elbow in the bottom of the picture.

23
 Welding a 3" Gas Line Turning Pipe for Optimum Weld
(Source: Bill Pellegrino) (Team Industries)

http://www.ua322.org/atlantic.htm http://www.teamind.com/capabilities.html

Pipe Support Wheels 03 Pipe Support Fixture

(Prof Ken Fitzpatrick, Sacramento City College) (Prof Ken Fitzpatrick, Sacramento City College)

http://www.scc.losrios.edu/~tech/edt/332/332index.html http://www.scc.losrios.edu/~tech/edt/332/332index.html

Pipe Support Wheels 01 Pipe Support Wheels 02

(Prof Ken Fitzpatrick, Sacramento City College) (Prof Ken Fitzpatrick, Sacramento City College)

http://www.scc.losrios.edu/~tech/edt/332/332index.html http://www.scc.losrios.edu/~tech/edt/332/332index.html

24
 Pipe Welding Gripper /
Positioner Weld
(Team Industries)
Certification

http://www.teamind.com/capabilities.html

Branch Outlet Connections

• Fittings - Cast or forged fittings, saddle Branching by Fitting
connectors or weld-o-lets depending on the (Source T-DRILL Industries Inc.)
application
• Holes - Produced in the tube or pipe.
– Mating branch tube is inserted and brazed or welded
– Sometimes the mating tube utilizes a flange or saddle
shape to obtain more braze area
• Extruded Outlets - A flare, flange or collar is
formed on the main tube. The branch tube is
either inserted for a lap joint or butt welded to a
faced collar http://www.tubenet.org.uk/technical/bill1_m.html

Branching by Hole Branching by

(Source T-DRILL Industries Inc.) Extrusion
(Source T-DRILL
Industries Inc.)
Punch Forming

http://www.tubenet.org.uk/technical/bill1_m.html External Spin Forming

http://www.tubenet.org.uk/technical/bill1_m.html

25
 External Spin Forming Weldolets – Reinforcement
(Source T-DRILL Industries Inc Area & Tapered Entrance
(Bonny Forge)

http://www.tubenet.org.uk/technical/bill1_m.html http://www.bonneyforge.com/

Weldolets Weldolets – Higher Inspectability

(Bonny Forge) (Bonny Forge)
• Neither Stab-in or Stab-on
• Less Obstruction

http://www.bonneyforge.com/ http://www.bonneyforge.com/

Other “-olets” Bleed Rings

(Bonny Forge) (Piping-Designer.com/Mack Iron Works)

LATROLET®
NIPOLET®
ELBOLET®

THREDOLET® INSERT
http://www.bonneyforge.com/ SWEEPOLET® WELDOLET® http://www.mackiron.com/products/blinds/brinfo.htm

http://piping-designer.com/Bleed_Ring

26
 Drain with 8in Hot Tap Through 2.25in Thick Blind Flange
(Source: Speer Taps Inc )
Coupling,
Nipple, Ball
Valve and Plug

http://www.speertaps.com/ht.htm

Heat Treating Induction Heating of Pipe

(BendTec Inc.) (Miller Electric Mfg Co.)
• Types of heat treatment:
– stress relieving
– normalizing
– annealing (soften steel for machining, remove
rolling or hammering strains)
– quenching and tempering
• Equipment
– induction heating utilizing scanners
– batch furnaces
http://www.bendtec.com/induct.html
http://www.millerwelds.com/education/articles/story39.html

Local Heat Treatment of Pipe Induction Heating for Welding

(BendTec Inc.) (Miller Electric Mfg Co.)
• After wrapping induction coils around a P91 pipe,
pipefitter Charlie Yadon connects a thermocouple to
the induction heating power system

http://www.bendtec.com/induct.html
http://www.millerwelds.com/education/articles/story39.html

27
 Furnace Heat Treatment of Pipe Pipe Transport
(BendTec Inc.) (Pipe Fabrication Institute)
• Truck Bed, Rail Car or Barge can Limit Spool
Length

http://www.bendtec.com/induct.html
Photo: Tim Monday

Truck Bed Standard Dimensions Pipe Transport

(World Trade Press) (Pipe Fabrication Institute)

OVERALL WEIGHT
TYPE TARE
Length Width CAPACITY
Platform 26' 96" 6,100 lbs. 50,000 - 55,000 lbs.
Platform 40' 96" 10,800 lbs. 50,000 - 55,000 lbs.
Platform 42' 96" 11,050 lbs. 50,000 - 55,000 lbs.
Platform 45' 96" 12,420 lbs. 50,000 - 55,000 lbs.
Platform 45' 102" 12,870 lbs. 50,000 - 55,000 lbs.
Platform 48' 102" 13,430 lbs. 50,000 - 55,000 lbs.
Platform 48' triaxle 102" 15,460 lbs. 50,000 - 55,000 lbs.
http://www.worldtraderef.com/WTR_site/Truck_Trailers/Guide_to_Truck_Trailers.asp Photo: Tim Mahoney

Trailer Transport of Pipe Lengths Pipe by Railcar

(Phillips Mine and Mill) (Traingeek.ca)

http://www.irwincar.com/phillips/phillips-transfer.asp http://www.traingeek.ca/blog/2008_03_01_archive.html

28
Greenbrier Heavy Duty Flatcar Dimensions Pipe Spools in
(World Trade Reference)
Shipping
Container
(We On Engineering
Sdn Bhd )

Dimensions Weight/Capacity Stainless Steel Pipe Spools

Light weight 60,000 lbs 27,216 kg
Length, over end sill 85' 21/2" 25.97 m Gross rail load 286,000 lbs 129,727 kg
for Turbine drainage
Length, over couplers 90' 61/4" 27.59 m Load limit 226,000 lbs 102,512 kg fabricated by We On
Length, between truck centers 66' 0" 20.12 m
Height, rail to pedestal support 3' 11" 1.2 m
Engineering Sdn Bhd for
Curve Negotiability Radius
Width, extreme 9' 101/4" 3 m
Uncoupled 180' 54.86 m
Bakun Hydroelectric Project.
Width, over side sills 9' 1" 2.77 m Coupled to like car 214' 65.23 m
Coupled to 40' base car 350' 106.68 m
http://flickr.com/photos/49554810@N00/

Ocean Container Dimensions Shipping and Handling

(Foreign Trade On-Line) Limitations for Offshore
STANDARD 20' Piping
INSIDE LENGTH 19'4"
INSIDE WIDTH 7'8"
5.89 m
2.33 m
(Expro-Aberdeen
INSIDE HEIGHT 7'10" 2.38 m Construction Department)
DOOR WIDTH 7'8" 2.33 m
DOOR HEIGHT 7'6" 2.28 m
CAPACITY 1,172 ft³ 33.18 m³
TARE WEIGHT 4,916 lb 2,229 kg
MAX. CARGO 47,999 lb 21,727 kg

STANDARD 40' HIGH CUBE 40'

INSIDE LENGTH 39'5" 12.01 m 39'5" 12.01 m
INSIDE WIDTH 7'8" 2.33 m 7'8" 2.33 m
INSIDE HEIGHT 7'10" 2.38 m 8'10' 2.69 m
DOOR WIDTH 7'8" 2.33 m 7'8" 2.33 m
DOOR HEIGHT 7'6" 2.28 m 8'5" 2.56 m
CAPACITY 2,390 ft³ 67.67 m³ 2,694 ft³ 76.28 m³
TARE WEIGHT 8,160 lb 3,701 kg 8,750 lb 3,968 kg
MAX. CARGO 59,040 lb 26,780 kg 58,450 lb 26,512 kg

http://www.foreign-trade.com/reference/ocean.cfm

Weight of Spool Example

Working with Pipe Weight and

Dimensions:
Finding the Weight of a Spool

29
 Adding Up the Pieces Fittings Lookup, Pipe=Length*lbs/Foot
88

1007.2
162
739.2 18"
88
678.9
97.5"
122 10‘=120"
435.5 97.5"/12*53.60 lbs/ft=435.5 lbs
4.5"
88

Adding Up the Pieces Spool ISO for Assignment #1

88
88.0
435.5
1007.2 122.0
678.9
162
162.0
739.2
1007.2
88
88.0
678.9 739.2
122 88.0
435.5

88
3408.9 lbs

For the Spool of Assignment #1

• Find the total weight
• Given a stack of raw pipe and box of fittings and a
rail car waiting outside:
– List all the steps in fabricating the Spool, including:
• materials and tools needed for each step Questions
• Skills (Welding, Crane Lifting, Checking, etc.)
• Allow for setup, tacking and pipe rotation for better welding
– Estimate the time for each task (Use your best guess)
– Draw a CPM (Critical Path Method) Diagram of these
tasks.
– Extra credit: Get Reasonable Shortest and Longest task
Duration's and Find the Critical Path

30
 Hot Piercing Seamless Pipe
(Wyman Gordon)

Pipe Manufacturing
http://omni.bus.ed.ac.uk/opsman/virtual/wyman/wgab.htm
(Metals International Ltd)
http://www.klsteel.com/sdp/229183/4/cp-1029278.html

Taper Pipe Thread Engagement

(ASME B1.20.1-1983)

31