Workshop design of large diameter LSAW steel pipe

In 1940, the United States first utilized the UOE method to produce large diameter LSAW steel pipes. By the early 1950s, a LIOE pipe workshop was established in the U.S., producing pipes with diameters ranging from 607 to 915 mm. Between 1955 and 1967, UOE welded pipe workshops were built in Europe, the U.S., and Japan, with pipe diameters ranging from 406 to 1067 mm and lengths up to 12 meters. From 1967 to 1976, advancements in Germany and Japan allowed for welded steel pipes with diameters up to 1626 mm, wall thicknesses of 40 mm, and lengths of 18 meters, incorporating continuous pre-welding, automatic nondestructive testing, and automatic control.

1. Layout and Space Allocation

Receiving Area: Designate a receiving area for raw materials, equipped with storage racks and cranes for handling heavy steel plates.

Milling and Pre-bending Area: Allocate space for milling machines and pre-bending equipment, ensuring enough room for maneuvering large plates.

Forming Section: Include JCO forming machines with sufficient space around them for the sequential forming process from "J" to "C" to "O" shapes.

Welding Zones: Separate zones for pre-welding, inside welding, and outside welding to ensure a smooth workflow and minimize contamination between processes.

2. Equipment Placement

Ultrasonic Testing Station: Place ultrasonic testing equipment near the forming section to promptly inspect and identify defects before further processing.

X-ray Inspection Area: Situate X-ray inspection facilities in an isolated area to protect workers from radiation exposure, ensuring safety protocols are followed.

Expansion Machines: Install expansion machines close to the welding zones to streamline the transition between welding and expansion processes.

Hydraulic Testing Station: Position hydraulic testing equipment near the expansion machines for efficiency and to facilitate immediate testing after expansion.

3. Workflow Optimization

Sequential Processing: Arrange equipment in a linear sequence to ensure a smooth and logical flow of materials from one stage to the next.

Conveyor Systems: Utilize conveyor systems or automated guided vehicles (AGVs) to transport pipes between stages, reducing manual handling and increasing efficiency.

Quality Control Checkpoints: Establish quality control checkpoints at each stage of the production process to ensure continuous monitoring and immediate rectification of any issues.

4. Safety and Ergonomics

Safety Barriers and Signage: Install safety barriers around hazardous equipment and clearly mark safety zones and pathways with appropriate signage.

Ventilation and Dust Control: Ensure adequate ventilation and dust extraction systems are in place, especially in welding and milling areas, to maintain air quality.

Ergonomic Workstations: Design workstations with ergonomic considerations to reduce worker fatigue and improve productivity.

5. Supporting Facilities

Storage and Handling: Designate storage areas for both raw materials and finished products, equipped with cranes and forklifts for efficient handling.

Maintenance Area: Include a maintenance workshop equipped with tools and spare parts for routine equipment maintenance and repairs.

Employee Amenities: Provide amenities such as break rooms, restrooms, and changing rooms to support worker well-being and productivity.

6. Quality Control and Testing Laboratories

NDT Laboratory: Equip a dedicated laboratory for non-destructive testing (NDT) including ultrasonic, magnetic particle, and radiographic testing.

Mechanical Testing Lab: Include facilities for mechanical property testing, such as tensile and hardness tests, to ensure compliance with standards.

7. Digital Integration and Monitoring

Automated Systems: Integrate automated control systems for monitoring and managing production processes in real-time.

Data Collection and Analysis: Implement systems for data collection and analysis to continuously monitor production efficiency and quality control metrics.

8. Environmental Considerations

Waste Management: Establish protocols for the proper disposal of waste materials and recycling where possible.

Energy Efficiency: Incorporate energy-efficient machinery and processes to minimize the environmental footprint of the production facility.

9. Compliance and Certification

Adherence to Standards: Ensure the workshop design and processes comply with relevant industry standards, such as API, ASTM, and ISO.

Certification and Audits: Regularly conduct audits and maintain certifications to demonstrate compliance with safety, quality, and environmental standards.