The production process of Submerged Arc Welded (SAW) or Helical Submerged Arc Welded (HSAW) steel pipes, commonly known as SSAW (Spiral Submerged Arc Welded) steel pipes, involves several key steps.

Typical Production Process of SSAW Steel Pipes

1. Raw Material Preparation:

The process begins with the procurement of raw materials, primarily steel coils. These coils are inspected for quality and then fed into the production line.

2. Uncoiling and Flattening:

The steel coils are uncoiled and flattened to form a flat strip. This strip will be shaped into the spiral pipe.

3. Forming:

The flat steel strip is gradually formed into a spiral shape using a series of forming rolls. The edges of the strip are welded together to create a continuous spiral seam.

4. Internal and External Welding:

The spiral seam is welded internally and externally using the submerged arc welding (SAW) process. This method ensures high-quality and strong welds along the length of the pipe.

5. Pre-Weld Inspection:

Before the welding is complete, the weld seam undergoes inspection to ensure it meets the required quality standards. Any defects are identified and rectified at this stage.

6. Post-Weld Heat Treatment:

The welded pipe undergoes a post-weld heat treatment process to relieve stress and improve the mechanical properties of the weld seam.

7. Pipe End Beveling:

The ends of the pipes are beveled to the required angle for welding, ensuring proper fit and alignment during installation.

8. Ultrasonic Testing:

Ultrasonic testing is conducted to detect any internal or surface defects in the welded seam. This non-destructive testing method ensures the integrity of the pipe.

9. Pipe End Hydrostatic Testing:

The pipes undergo hydrostatic testing to check for leaks or weaknesses in the welds. This test involves pressurizing the pipe with water to a specified level.

10. Pipe Coating:

Depending on the application, the pipes may undergo external coating processes for corrosion protection. Coating options include fusion bonded epoxy (FBE), three-layer polyethylene (3LPE), or other specialized coatings.

11. Pipe Marking and Packaging:

Each pipe is marked with essential information such as size, grade, and manufacturer details. The pipes are then bundled, packed, and prepared for transportation to the customer.

12. Quality Control and Documentation:

Throughout the production process, quality control measures are implemented to ensure that the pipes meet the required specifications and standards. Documentation of all testing and inspection results is maintained for traceability.

13. Non-Destructive Testing (NDT):

Non-destructive testing methods such as radiographic testing (RT), magnetic particle testing (MT), or dye penetrant testing (PT) may be employed to further inspect weld quality and detect any defects that could compromise the integrity of the pipe.

14. Dimensional Inspection:

Dimensional inspection ensures that the pipe's outer diameter, wall thickness, and length conform to the specified tolerances and requirements. Any deviations are identified and addressed to maintain consistency in the product.

15. Final Inspection and Approval:

Prior to shipment, a final inspection is conducted to verify that the pipes meet all quality standards and customer specifications. Approval for dispatch is granted only after the pipes pass this comprehensive assessment.

16. Documentation and Traceability:

Detailed documentation of the entire production process, including materials used, testing results, and inspection records, is compiled for each batch of pipes. This documentation enables traceability and quality control throughout the supply chain.

17. Loading and Shipment:

Once the pipes have been approved for dispatch, they are loaded onto trucks or containers for transportation to the customer's site or designated storage facility. Proper handling and securing of the pipes are essential to prevent damage during transit.

18. Installation Support:

Manufacturers may provide installation support services to assist customers in properly handling and installing the pipes at the intended location. This support ensures that the pipes are installed correctly and function as intended.

19. Customer Service and After-Sales Support:

Manufacturers offer ongoing customer service and after-sales support to address any queries, concerns, or issues that may arise post-installation. This assistance helps maintain a positive relationship with customers and ensures satisfaction with the product.

20. Continuous Improvement and Innovation:

Manufacturers engage in continuous improvement initiatives to enhance production processes, optimize product quality, and introduce innovative technologies that can improve the performance and durability of SSAW steel pipes.

The production process of SSAW steel pipes is a comprehensive and meticulous operation that involves a series of critical steps to ensure the quality, integrity, and reliability of the final product. By adhering to stringent quality control measures and incorporating best practices throughout the production cycle, manufacturers can deliver high-quality SSAW steel pipes that meet the diverse needs of customers in various industries.