A brief guide to different types of carbon steel pipes

Classifications of Carbon Steel Pipes

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The material, diameter, wall thickness, and quality of a specific service determine the pipe manufacturing process. Carbon steel piping is classified according to the manufacturing methods as follows:

  • Seamless
  • Electric resistance weld (ERW)
  • Spiral-submerged arc weld (SAW)
  • Double submerged arc weld (DSAW)
  • Furnace weld, butt-welded, or continuous weld

Seamless Steel Pipe

Seamless pipe is formed by piercing a solid, near-molten steel rod, called a billet, with a mandrel to produce a pipe without seams or joints. The figure below depicts the manufacturing process of seamless pipe.

ERW Steel Pipe

ERW pipe is made from coils that are cupped longitudinally by forming rolls and a thin-pass section of rolls that brings the ends of the coil together to create a cylinder.

The ends pass through a high-frequency welder that heats the steel to 2600 °F and squeezes the ends together to form a fusion weld. The weld is then heat-treated to remove welding stresses, and the pipe is cooled, sized to the proper OD, and straightened.

ERW pipe is produced at individual or continuous lengths and then cut into individual lengths. It is supplied according to ASTM A53, A135, and API Specification 5L.

ERW is the most common manufacturing process due to its low initial investment for manufacturing equipment and its processability in welding different wall thicknesses.

The pipe is not fully normalized after welding, thus producing a heat-affected zone on each side of the weld that results in non-uniformity of hardness and grain structure, making the pipe more susceptible to corrosion.

Therefore, ERW pipe is less desirable than SMLS pipe for handling corrosive fluids. However, it is used in oil and gas production facilities and transmission lines for 26″ (660.4 mm) OD and more prominent lines after normalized or cold expansion.

SSAW Steel Pipe

Twisting metal strips form the spiral-welded pipe into a spiral shape, similar to a barber’s barber and welding, where the edges join one another to form a seam. Due to its thin walls, this type of pipe is restricted to piping systems using low pressures.

SAW or DSAW pipe?

SAW and DSAW pipes are produced from plate (skelp’s), skelp’sare either formed into a “U” and t “e” an “O” and t “e” welded along the straight seam (SS) or twisted into a helix and then welded along the spiral seam (SW). DSAW longitudinal butt joint uses two or more passes (one inside) shielded by granular fusible materials where pressure is not used.

DSAW is used for pipes greater than 406.4 mm nominal. SAW and DSAW are mechanically or hydraulically cold expanded and supplied according to ASTN Specifications A53 and A135 and API Specification 5L. They are supplied in sizes 16″ (406.4 mm) OD to 60″ (1524.0 mm) OD.

LSAW Steel Pipe

LSAW (LSAW) in leaflet plates is raw material, and the steel plate in the mold or molding machine pressures (volume) is usually double-sided submerged arc welding and flaring from production.

A wide range of finished product specifications, weld toughness, flexibility, uniformity, and density, with a large diameter, wall thickness, high-pressure resistance, low-temperature corrosion resistance, etc.. Steel pipe is required to construct high-strength, high toughness, high-quality long-distance oil and gas pipelines, mostly large diameter thick wall LSAW.

API standard provisions, in the large-scale oil and gas pipelines, when 1, Class 2 areas through the alpine zone, the bottom of the sea, the city densely populated area, LSAW only applied specifically casts.

The difference between hot rolled and cold rolled steel pipe

Hot-Rolled vs Cold-Rolled/Drawn Seamless Steel Pipe

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Introduction

In industries like oil and gas, petrochemicals, offshore engineering, and machinery manufacturing, the choice between hot-rolled seamless steel pipe and cold-rolled/drawn seamless steel pipe plays a critical role in determining the performance, durability, and cost-efficiency of equipment and projects. With demanding requirements for dimensional accuracy, mechanical properties, and durability, choosing the right pipe type that suits specific applications and environmental challenges is essential.

This guide will provide an in-depth comparison of hot-rolled seamless steel pipes and cold-rolled/drawn seamless steel pipes, highlighting the manufacturing processes, mechanical properties, and typical use cases for each. The goal is to help you make informed decisions that meet your project’s needs.

Understanding Seamless Steel Pipes

Before discussing the differences between hot-rolled and cold-rolled/drawn seamless steel pipes, it’s’ important to understand what seamless steel pipes are.

Seamless steel pipes are manufactured without welding, adding strength and uniformity. This makes them ideal for high-pressure applications like gas pipelines, oil wells, and hydraulic systems. Their seamless construction minimizes the risk of leakage and provides superior resistance to corrosion and mechanical stress.

Now, let’s examine the difference between hot-rolled and cold-rolled/-drawn processes and their impact on the final product.

Manufacturing Process: Hot-Rolled vs Cold-Rolled/Drawn Seamless Steel Pipe

Hot-Rolled Seamless Steel Pipes

Hot-rolling involves heating the steel billet above its recrystallization temperature (typically over 1,000°C). The billet is then pierced and rolled into the shape of a pipe through a set of rollers. After forming, the hot-rolled pipe is cooled at room temperature, which may lead to slight variations in shape and size.

The process is quicker and more efficient for producing large-diameter pipes, but the finished product typically requires further treatment if tighter tolerances and surface finishes are needed.

Cold-Rolled/Drawn Seamless Steel Pipes

Cold-rolling or cold-drawing starts with a hot-rolled pipe that undergoes additional processing at room temperature. During cold-rolling or cold drawing, the steel pipe is passed through a die or drawn over a mandrel, which reduces its diameter and thickness. This process results in a more refined surface finish and tighter dimensional tolerances.

The cold-rolling/drawing process increases the pipe’s strength through strain hardening, producing pipes with superior mechanical properties, such as higher tensile strength and better resistance to deformation.

Critical Differences: Hot-Rolled and Cold-Rolled/Drawn Seamless Steel Pipe

The two types of seamless pipes offer different advantages, depending on the application. Here’s a breakdown of the critical differences in properties:

1. Strength and Durability

  • Due to the high temperatures at which they are formed, hot-rolled seamless steel pipes have a relatively low yield strength and hardness. They are typically less intense but more ductile, making them suitable for applications where flexibility and resistance to shock loads are essential, such as structural components or low-pressure pipelines.
  • Due to the cold-working process, cold-rolled/drawn seamless steel pipes are more robust and more complex. Their higher tensile strength makes them suitable for high-pressure applications, such as hydraulic systems, heat exchangers, and precision engineering components where strength and tight tolerances are critical.

2. Surface Finish

  • Hot-rolled pipes usually have a rough, scaled surface finish, which may require further machining or treatment if a smooth surface is needed. The scale formation results from cooling at room temperature, which is acceptable in many structural applications but unsuitable for applications requiring a soft, aesthetic finish.
  • Cold-rolled/drawn pipes, on the other hand, have a much smoother surface finish due to the absence of high-temperature scaling. This makes them a preferred choice for components that require excellent surface quality, such as in machinery manufacturing and automotive industries.

3. Dimensional Accuracy

  • Due to the high-temperature manufacturing process, hot-rolled seamless steel pipes tend to have looser dimensional tolerances. While they can be used in applications where precision isn’t’ paramount, they are less suitable for projects that demand exact sizing.
  • Cold-rolled/drawn seamless steel pipes offer superior dimensional accuracy with much tighter tolerances. This is critical in applications such as hydraulic cylinders, precision machinery, and piping systems where fittings must be exact to avoid leaks or failures.

4. Mechanical Properties

  • Hot-rolled pipes are more malleable and easily welded, making them ideal for applications with flexibility over strength, such as construction or low-pressure gas transmission.
  • Cold-rolled/drawn pipes exhibit higher mechanical strength and toughness, making them better suited for high-pressure environments like power plants, chemical processing, and oil and gas refineries. They can withstand significant stress and pressure without deforming.

5. Cost Considerations

  • Hot-rolled seamless pipes are generally more economical to produce, especially for large-diameter applications. If cost efficiency is a primary concern and the project does not require tight tolerances or high surface quality, hot-rolled pipes may be the best option.
  • Cold-rolled/drawn seamless pipes are more expensive due to the additional processing required to achieve higher strength, accuracy, and finish. However, for high-precision projects or those involving high-pressure systems, the added cost is justified by the performance benefits.

Applications

Different industries have varying requirements for seamless steel pipes, and the choice between hot-rolled and cold-rolled/drawn depends on these specific demands.

Oil & Gas Industry

Hot-rolled seamless pipes are often used for low-pressure transmission pipelines in the oil and gas. In contrast, cold-rolled/-drawn pipes are preferred for high-pressure piping systems, such as those used in offshore drilling platforms or hydraulic fracturing equipment.

Petrochemicals

The petrochemical industry requires pipes with exceptional corrosion resistance and mechanical strength. In highly corrosive environments, cold-rolled/-drawn seamless pipes are commonly chosen for heat exchangers, pressure vessels, and piping systems.

Machinery Manufacturing

Cold-rolled/-drawn seamless steel pipes are favored in machinery manufacturing due to their high precision, strength, and smooth surface finish. They are often used in hydraulic cylinders, automotive components, and other critical machinery where tight tolerances and high strength are essential.

Offshore Engineering

Offshore engineering projects, including subsea installations, demand pipes that withstand harsh environmental conditions, including saltwater corrosion and extreme pressures. Cold-rolled/drawn pipes with enhanced mechanical properties and dimensional accuracy are typically preferred in these settings, especially in critical components like riser systems and flowlines.

Solving Common Challenges

Selecting suitable pipes for specific applications can address many common challenges in industries such as oil, gas, petrochemicals, and machinery manufacturing.

Challenge 1: Dimensional Accuracy

Cold-rolled/drawn seamless steel pipes are highly recommended in applications where precise measurements are vital, such as hydraulic systems or precision machinery. Their tight tolerances and refined surface finish minimize the risk of fitting errors and potential leaks.

Challenge 2: Surface Quality

Cold-rolled/drawn pipes often provide a smooth, polished surface without additional post-processing for applications requiring high-quality finishes, such as automotive parts or medical equipment.

Challenge 3: Strength Under Pressure

Cold-rolled/drawn seamless pipes are ideal for high-pressure environments. Their superior strength and resistance to deformation ensure that they can withstand the significant mechanical stresses encountered in applications like oil extraction or chemical processing.

Challenge 4: Cost Management

Suppose the project’s budget is a primary concern, and tight tolerances are not critical. In that case, hot-rolled seamless steel pipes offer a cost-effective solution, especially in large-scale structural or low-pressure applications.

Conclusion: Choosing the Right Seamless Steel Pipe

Hot-rolled seamless steel pipes and cold-rolled/drawn seamless steel pipes have their place in various industries, depending on the project’s specific requirements. Hot-rolled pipes are ideal for applications prioritizing cost-effectiveness and flexibility, while cold-rolled/drawn pipes offer enhanced strength, precision, and surface quality.

When choosing between the two, consider the key factors such as mechanical strength, dimensional accuracy, surface finish, and cost to ensure optimal performance and longevity in your application. Each type of seamless pipe serves a unique purpose, and the right choice can significantly improve the efficiency and reliability of your project.

Introduction of 3LPE Coated Line Pipe

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Introduction

The base materials of 3LPE Coated Line Pipe include seamless steel pipes, spiral welded steel pipes, and straight seam welded steel pipes. Three-layer polyethylene (3LPE) anti-corrosion coatings are widely used in the oil pipeline industry for their good corrosion resistance, water vapor permeability resistance, and mechanical properties. 3LPE anti-corrosion coatings are crucial to the service life of buried pipelines. Some pipelines of the same material are buried underground for decades without corrosion, while others leak in a few years. The reason is that they use different coatings.

Structure of 3LPE Coated Line Pipe

3PE anti-corrosion coatings generally consist of three layers: the first layer is epoxy powder (FBE) >100um, the second layer is adhesive (AD) 170~250um, and the third layer is high-density polyethylene (HDPE) 1.8-3.7mm. In actual operation, the three materials are mixed and fused, and processed to make them firmly bonded to the steel pipe to form an excellent anti-corrosion coating. The processing methods are generally divided into two types: winding type and ring die sleeve type.

3LPE anti-corrosion steel pipe coating (three-layer polyethylene anti-corrosion coating) is a new type of anti-corrosion steel pipe coating that cleverly combines the European 2PE anti-corrosion coating with the FBE coating widely used in North America. It has been recognized and used internationally for more than ten years.

The first layer of 3LPE anti-corrosion steel pipe is epoxy powder anti-corrosion coating, the middle layer is copolymer adhesive with branched functional groups, and the surface layer is high-density polyethylene anti-corrosion coating.

3LPE anti-corrosion coating combines the high impermeability and mechanical properties of epoxy resin and polyethylene. So far, it has been recognized as the best anti-corrosion coating with the best performance in the world and has been used in many projects.

Advantages of 3LPE Coated Line Pipe

Ordinary steel pipes will suffer severe corrosion in harsh use environments, thereby reducing the service life of steel pipes. The service life of anti-corrosion and thermal insulation steel pipes is also relatively long, generally about 30-50 years and correct installation and use can also reduce the maintenance cost of the pipeline network. Anti-corrosion and thermal insulation steel pipes can also be equipped with an alarm system to automatically detect pipeline network leakage faults, accurately grasp the fault location, and automatically alarm.

3LPE anti-corrosion and heat-insulating steel pipes have good heat preservation performance, and the heat loss is only 25% of that of traditional pipes. Long-term operation can save a lot of resources and significantly reduce energy costs. At the same time, it still has strong waterproof and corrosion resistance. It can be directly buried underground or in water without setting up a separate trench, and the construction is also simple, quick, and comprehensive. The cost is also relatively low, and it has good corrosion resistance and impact resistance under low-temperature conditions, and can also be directly buried in frozen soil.

Application of 3LPE Coated Line Pipe

For 3PE anti-corrosion steel pipes, many people only know one thing but not the other. Its role is really wide-ranging, suitable for underground water supply and drainage, underground spraying, positive and negative pressure ventilation, gas extraction, fire sprinkler,s, and other pipe networks. Waste slag and return water transportation pipelines for process water in thermal power plants. It has excellent applicability for water supply pipelines of anti-spraying and water spraying systems. Cable protection casings for power, communications, roads, etc. It is suitable for high-rise building water supply, thermal power pipe networks, water plants, gas transmission, buried water transmission, and other pipelines. Oil pipelines, chemical and pharmaceutical industries, printing and dyeing industries, sewage treatment discharge pipes, sewage pipes, and biological pool anti-corrosion projects. It can be said that 3LPE anti-corrosion steel pipes are indispensable in the current application and construction of agricultural irrigation pipes, deep well pipes, drainage pipes, and other pipe networks. I believe that through the extension of technology, more brilliant achievements will be made in the future.

If you need any kind of anticorrosion coating coated steel pipes such as 3LPE /FBE /3LPP/LE/International Brand Paints (AkzoNobel/Hempel/3M/Jotun) coated steel pipes, etc., please feel free to reach out to [email protected].