P
Products
Pipes
IPIC is specialized in producing of large diameter Submerged Arc Welded Longitudinal Pipes (SAWL) from 16” to 60” outside diameter according to the international standard API 5L, all steel grades up to X-80 for Energy, Oil & Gas, Construction, Infrastructure and Water Transmission projects.
SPECIFICATIONS
| Length | 8 : 12.150 m |
|---|---|
| Diameter | 16” : 60” |
| Thickness | 7.9 : 27 mm |
| Annual Production | 150,000 : 250,000 Tons |
| Daily production | 160 Pipes per Day |
| Material | In compliance with API 5L up to grade X-80 or equivalent |
Manufacturing Process
Pipe Design
Pipe design depends mainly on:
- Proposed palte dimensions
- Welding parameters
- Proposed manufacturing procedure
- Proposed quality plan
Approval Of Pipe Design
- Before starting the continuous production, a first day production should be carried out in order to assure the proposed pipe design and approve it according to the international standards and also clients’ requirements.
Plate Edges Milling M/C
- Horizontal feed milling system used to prepare the steel plates longitudinal edges for welding prior to forming of pipe body, the machine is equipped with cnc system.
Roll Bending M/C
- It is the most advanced pipe rolling m/c, capable to roll pipe sizes starting 16” up to 60“ with differnet wall thicknesses from 6.4mm up to 30mm with double random length of 12.2 meters.
Post Bending M/C
- As the 3-roll bending m/c forming 80% from full roundness of the pipe, the post bending m/c crimps the pipe longitudinal straight edges to achieve 100% roundness.
Continuous Tack Welding
- First welding station, in this station the pipe seam edges are joined together by continuous weld. The machine is also designed to adjust misalignment, hi/lo and offset between the two edges prior to internal welding.
Internal Welding M/C
- Automatic submerged arc welding process using three or four wires.Two welding machines are working parallel to achieve higher productivity.
External Welding M/C
- Final welding stage for the external side of the pipe seam,two automatic submerged arc welding machines using four wires.
Visual Inspection
- First inspection stage, overall visual inspection applied to the pipe internal and external surfaces including weld seams.
Automatic Ultrasonic M/C (Station 1)
- After visual inspection, automatic ut inspection applied to assure solidity of the pipe weld seam before cold expanding.
Repair Station (X-Ray Room)
- In case of weld repair, the repaired areas in the pipe seam weld subjected to x-ray inspection to evaluate and assure that the defects had been repaired, x-ray film kept as evidence.
Cold Expanding M/C
- The machine is designed for adjsting pipe roundness and straightness, this process also recover the base metal mechanical properties.
Hydro-Static Testing M/C
- As per api 5l specifications, the manufactured pipe should be tested hydrostatically to a certain pressure indentified by the specification, automatic hydro-testing m/c capable to perform the test up to 320 bar.
Automatic Ultrasonic M/C (Station Ii)
- First inspection station after cold expanding and hydro-testing, shear angle sound beams (ut) inspection to be applied to assure the solidity of the pipe seam weld before final inspection.
X-Ray Real Time
- X-ray real time station is for inspection of seam weld after (ut ii)full scan of the pipe seam weld applied for verification of any comments from the previous satation and pipe ends radio-graphed to assure that pipe ends are free of defects.
End Beveling M/C
- For pipe ends preparation to the required angle and root face according to the project specifications.the station is consists of two end beveling machine work toether at the same time.
Final Inspection
- Visual and dimensional check applied to the final product, this inspection stage includes pipe length measuring, pipe weighing, pipe straightness and ovality measurment in addition to overall visual inspection of pipes’ internal and external surfaces, then pipes to be marked by API monogram and all project data.
Pipe Tracking System
- Ipic aprroved an internal computerized system for tracking and recording all the pipes production data starting from steel plates recording up to final products dispatching tracking and recording all pipe making history is a parallel process to quality control process.
tracking system could be useful in generating the following reports automatically:
• Daily, weekly, monthly and annually production reports.
• Pipe history including all stations outputs.
• Finished products reports.
• Pipes certifications of quality.
