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Spiral Pipes


Another method of pipe production is the spiral method, in which spiral steel pipes are manufactured from sheets of different thicknesses.The method of producing spiral pipes is very simple. The steel plate is dimensionally proportional to the diameter of the pipe aperture in the form of a roll from the opening of the rolling machine to the spiral state and is welded by two electrodes. Steel spiral tubes are generally high in size because of the need The pipe is manufactured in widths of more than 10 meters. Therefore, any size in the piping industry is required for any size. Using this method, a pipe can be produced and supplied. Therefore, in a spiral method, a pipe of different diameters can be Produced at a lower cost than direct seams.
 

Kalup company, using the latest technology in its production line machines, as well as equipping the production line with ultrasound testing machines, has been producing spiral steel pipes in sizes of 14 to 120 inches.

Standards:

AWWA-C200 , ASTM A53 , DIN

Features of the production line:

Line 1: Mini Spiral
Line Speed:1-1.7 m/min
Thickness:5-10mm
Output Diameter:16-32 inch
Length: 6-18 m

Line 2: Mini Spiral
Line Speed: 1-1.7 m/min
Thickness:5-10mm
Output Diameter:16-32 inch
Length:6-18 m

Line 3: Spiral
Line Speed: 0.4-4 m/min
Thickness:6-25mm
Output Diameter:16-64 inch
Length: 6-18 m

Line 4: Spiral
Line Speed:0.4-4 m/min
Thickness:7-14mm
Output Diameter:16-32 inch
Length: 6-18 m

Line 5: Spiral
Line Speed:0.5-3 m/min
Thickness:6-25mm
Output Diameter:16-120 inch
Length: 6-18 m

Linear Mass Table

Linear Mass(kg/m)
 OD (inch) OD (mm)  Thickness(mm)
4.5 5.5 6.3 7.9 9.5 11.1 12.7 14.3 16 17 19 21 22.2 23.8 25
16 406 45 54 62
18 457 50 61 70
20 508 56 68 78
22 558.8 61 75 86
24 609.6 67 82 94 117 141 164 187
26 660.4 73 89 102 127 152 178 202
28 711.2 78 96 109 137 164 197 219
30 762 84 103 117 147 176 205 235
32 812.6 90 109 125 157 188 219 250
34 863.8 95 116 133 167 200 233 266
36 914.4 101 123 141 177 212 247 282
39 990.6 109 134 153 191 230 268 306
40 1016 112 137 157 196 236 275 314
42 1066.8 118 144 165 206 248 289 330
45 1143 177 221 265 310 354 398 445 486 527
48 1219.2 188 236 283 331 378 425 475 519 562
51 1295.4 200 251 301 351 402 452 505 551 598
54 1371.6 212 266 319 372 426 479 535 584 634
57 1447.6 224 280 337 393 449 505 565 617 669
60 1524 236 295 355 414 473 532 595 650 705
63 1600.2 310 373 435 497 559 625 683 741 818 864 925 971.1
66 1676.4 325 390 456 521 586 655 716 777 857 906 970 1018
69 1752.6 340 408 477 545 613 685 749 812 897 947 1015 1065
72 1828.8 355 426 498 596 640 715 782 848 936 989 1059 1112
75 1905 370 444 518 593 667 745 815 884 976 1031 1104 1159
78 1981.2 384 462 539 616 694 775 847 919 1015 1073 1149 1206
81 2057.4 399 480 560 640 720 805 880 955 1055 1114 1194 1253
84 2133.6 414 498 581 664 747 835 913 991 1094 1156 1238 1300
87 2209.8 429 515 602 688 774 866 946 1027 1134 1198 1283 1347
90 2286 444 533 623 712 801 898 979 1062 1173 1239 1328 1394
96 2438.4 473 569 664 760 855 956 1045 1134 1252 1325 1417 1488
102 2590.8 503 605 706 807 909 1016 1111 1205 1331 1406 1507 1582
108 2743.2 533 640 748 855 962 1076 1176 1276 1410 1490 1596 1676
114 2895.6 563 676 790 903 1016 1136 1242 1348 1489 1573 1686 1771
120 3048 592 712 831 951 1070 1196 1308 1419 1568 1657 1775 1864

Advantages of Spiral Pipe

The advantages of high pressure Spiral pipe compared to traditional rectangular duct are numerous and compelling:

Attractive appearance

  • Exposed spiral duct is attractive and is frequently specified by architects because of its superior aesthetic appeal.
  • Paintable Spiral duct can be finished to blend in with, or stand out from, the indoor environment.

Economical to install

The unique attributes of Spiral duct can reduce installation costs:

  • Easier to install through and around structural framing
  • Longer spans reduces installation operations and the number of connections and hangers required
  • Connections are made quickly and easily, and are easier to seal.

Lower cost of ownership

Spiral duct reduces upfront and operating costs:
  • ​Low air leakage, optimal airflow characteristics, and less pressure drop allow smaller and more efficient air moving equipment
  • Inherently stronger, allowing the use of lighter gauge, less costly metals
  • Efficiently manufactured from strip steel to any diameter
  • Spiral duct’s smooth interior traps less dust and is easier to clean

Many options and accessories

Spiral pipe provides a solution to almost any system design requirement:
Manifold ducts efficiently handle complex distribution requirements and reduce installation time and cost
Standard components for every application, such as gored and die formed elbows, tees, laterals, pant wyes, reducers, rectangular to round transitions, pick-up hoods, blast gates, cleanouts, access doors, diverters, and many more
Custom components can be engineered for any purpose or specific application

Production Process:

1. Coil entry Section:
At the beginning of production line this section leads the sheet toward the production line which includes:

  • • Bringing coil to the machine
  • • Coil holder
  • • Sheet trimmer

2. Section dedicated to cutting and welding the beginning and end of coil:
Cutting and preparing the end of produced coil and beginning of new coil and welding these two edges together by the use of submerged-arc welding (SAW).
3. Flattener:
The beginning and end of coil is flattened by the use of flattening rollers
4. Cutting the edge and collecting the waste:
The edge of sheet is cut by the use of spinning discs at the edge cutting section and the waste are collected.
Navigating side pipes:
Holding and adjusting sheet at the center of spiral line
5. Angle maker of edge of sheet:
Angle making is applied to both sides of the sheet for modifying and reaching the required conditions of the sheet according to the required angle.
6. Forming:
When the coil pass through different rollers, they take the form of pipes. These rollers are adjustable for different sizes.
 

7. Internal and external welding section:
After taking the form of pipes, the edges are welded by the use of SAW method, and firstly their inside and then their outside are welded.

8. Ultrasonic Testing Section:
This machine is able to detect the possible flaws in seam welding area and HAZ immediately after welding; thus it is able to immediately remove the defective pipe out of the production line.

9. Cutting the pipe:
Pipes are cut by the use of plasma cutting in different lengths according to the customer’s demand.

10. Pipe numbering:
In order to increase the ability to follow the produced pipe and to have access to accurate production history of each of pipes the number of pipe is written at the end of the pipe.
Through this it is possible to determine the exact date of production and the number of mother coil.
Numbering includes the following descriptions:

  • Manufacturer
  • Size
  • Steel thickness and grade
  • Pipe number
  • Year/week/day of production

11. chamfering both ends of pipe:
At this section, two ends of all produced pipes are chamfered.
12. Hydrostatic testing section:
This machine tests all produced pipes with maximum pressure of 5000PSI in hydrostatic mode. At this section, due to high liquid pressure inside the pipe, in case of any defect on the welding section or the sheet the defects apear as water leakage and pipe will be reviewed by the quality control group of the factory. This device is able to test the pipes up to 200Bar of pressure.
 

13. Dimension Control and Visual inspection of the Welding:
At this stage all pipes are checked by the quality control group of the factory and additionally two ends of the pipes are controlled regarding the angle and diameter and in case of no problem the QC lable is put on them.