Benefits and Drawbacks of ERW Steel Pipes:

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Electric Resistance Welded (ERW) Steel Pipe is used in a wide variety of industries including oil and gas, construction and water supply. ERW steel pipe is made by the electric resistance welding process, which involves passing an electric current through a strip of metal to create a weld between two pieces of metal. In recent years, the use of ERW steel pipe has increased due to its many advantages, including cost-effectiveness, ease of use, and availability. However, like any other product, ERW steel pipe has its drawbacks. In this article, we will explore the advantages and disadvantages of ERW steel pipes and examine their overall effectiveness as a product.

Benefits of ERW Steel Pipes:

1. Cost-effectiveness
One of the most significant benefits of ERW steel pipes is their cost-effectiveness. ERW steel pipes are less expensive than seamless pipes, which are produced through a more complicated process. ERW steel pipes are also more cost-effective than welded pipes made using other methods. The lower production cost of ERW steel pipes makes them an attractive option for industries looking to reduce costs.

2. Availability

ERW steel pipes are readily available, making them an attractive option for industries that require a constant supply of pipes. ERW steel pipes are produced in large quantities, making them widely available from a range of manufacturers. The availability of ERW steel pipes reduces the risk of production delays and ensures a steady supply of pipes for industries that rely on them.

3. Ease of use
ERW steel pipes are easy to use, making them a popular choice for industries that require quick and efficient installation. ERW steel pipes can be easily cut and welded together, which reduces the need for specialized tools and equipment. ERW steel pipes also come in a variety of lengths and diameters, making them adaptable to a wide range of applications.

4. Strength and Durability
ERW steel pipes are strong and durable, making them suitable for use in a wide range of applications. ERW steel pipes are made from high-quality steel and are designed to withstand the rigors of use in harsh environments. ERW steel pipes are also resistant to corrosion, making them a reliable option for use in industries that require corrosion-resistant pipes.

5. Versatility
ERW pipes are versatile, making them suitable for use in a wide range of industries. ERW pipes are used in the construction industry for the construction of buildings and bridges, in the oil and gas industry for the transportation of oil and gas, and in the water supply industry for the transportation of water.

Drawbacks of ERW Steel Pipes:

1. Welding Defects
One of the drawbacks of ERW steel pipes is the potential for welding defects. The welding process used to create ERW steel pipes can create defects such as porosity, lack of fusion, and cracks. These defects can reduce the strength and durability of the pipes and can lead to leaks and failures.

2. Limited Size Range

ERW pipes have a limited size range, which can be a drawback in some industries. ERW steel pipes are typically available in smaller diameters than seamless steel pipes, which can limit their use in industries that require larger pipes.

3. Quality Control Issues
Another drawback of ERW steel pipes is the potential for quality control issues. ERW pipes are produced in large quantities, and it can be challenging to ensure that each pipe meets the required quality standards. Quality control issues can lead to defects in the pipes, reducing their strength and durability and increasing the risk of failure.

4. Susceptible to Corrosion
Although ERW steel pipes are resistant to corrosion, they are still susceptible to corrosion in certain environments. ERW steel pipes that are exposed to corrosive materials or environments may corrode over time, reducing their strength and durability and increasing the risk of failure.

5. Reduced Load Capacity
ERW steel pipes have a reduced load capacity compared to seamless pipes. The welding process used in ERW steel pipes creates a welded seam along the length of the pipe, which can be a weak point. This welded seam reduces the load-carrying capacity of the pipe compared to seamless pipes, which have a continuous structure without any welded seams. In applications where high pressure or heavy loads are involved, seamless pipes may be a more suitable choice.

Conclusion:

ERW steel pipes offer several benefits, including cost-effectiveness, ease of use, availability, strength, durability, and versatility. These advantages make ERW steel pipes a popular choice in various industries. However, it is essential to consider the drawbacks associated with ERW pipes, such as welding defects, quality control issues, limited size range, susceptibility to corrosion, and reduced load capacity.

To mitigate these drawbacks, proper quality control measures should be implemented during the manufacturing process of ERW steel pipes. Regular inspections and testing can help identify and address welding defects and ensure that the pipes meet the required quality standards. Additionally, proper maintenance and protection against corrosion can extend the lifespan of ERW steel pipes in corrosive environments.

In conclusion, while ERW steel pipes have their drawbacks, their benefits and overall effectiveness make them a viable option for many applications. It is crucial to consider the specific requirements and conditions of each project when selecting the type of pipe to use. Proper installation, maintenance, and quality control practices can maximize the benefits of ERW steel pipes and minimize the potential drawbacks, leading to successful and efficient pipe systems in various industries.

The Difference Between ERW and EFW Pipe

Two of the most common methods to produce pipe are Electric Resistance Welding (ERW), and Electric Fusion Welding (EFW). Both processes involve a coil of steel being continuously fed through a series of rollers/dies which shape the flat steel into the desired shape of the pipe. 

How the edges of the steel plate are joined together are what makes the ERW and EFW processes different. 

Over the course of this Blog, we will discuss both processes, the benefits each have, and why you would use ERW or EFW pipe.

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ERW vs EFW Pipe Forming Process

As stated above, once the flat steel plate has been formed into the pipe shape the two edges need to be joined together.

In an ERW process, a high frequency electrical current is used to heat the edges of the steel plate just before the final shaping rollers/dies join them together to create the circular pipe shape. 

A high frequency Is prevalent in modern piping because the low frequency current had several deformities including: seam corrosion, hook cracks and the seam bonding was inadequate.  

ERW pipe has a weld seam that runs along the length of the pipe. ERW pipe will either clean/trim the weld seam, or just use a roller/die to smooth out the seam to match the outside diameter; leaving a visible weld seam on the inside diameter.

For EFW (also known as electron beam welding), an electron beam (laser) is used to heat the edges prior to the rollers/dies joining them together. 

EFW pipe also has a weld seam that runs along the length of the pipe. This seam is cleaned/trimmed on the outside, and inside, diameter for EFW pipe.

EFW pipe is a cost effective solution for environments that require high pressure and are corrosive. This type of pipe has better strength and durability. This pipe is stronger, denser and more uniform as compared to ERW because of its fusion method.

Finally, the pipe continues to go through another few sets of rollers/dies to ensure its final shape before each section of pipe is cut to length.

Benefits of ERW

The ERW manufacturing process is highly efficient and cost-effective. Machinery required for ERW pipe is very common, and with proper care and maintenance can run for decades. As a result, it is the predominant method for producing pipe in the PVF industry. 

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Benefits of EFW

The fusion process in EFW manufacturing produces a much narrower “heat affected zone” in the pipe than the ERW process. This translates to a better uniformity of the metal in the pipe, and a higher pressure rating than ERW. 

Combining the higher pressure, with a still cost-effective end product (the initial tooling investment is greater for EFW pipe), means that EFW pipe can be looked at as a substitute for seamless pipe in certain applications.

What is ERW Pipe Used For?

Just as ERW is the predominant pipe manufacturing process, ERW pipe can be found in just about every industry where fluid/media needs to be moved from one location to another. 

Common industries where you would find ERW pipe include: plumbing, HVAC, fire suppression, commercial, aviation, aerospace, automotive, rail, electronics, energy, oil & gas, and industrial.

What is EFW Pipe Used For?

Being viewed as a cost-effective alternative to seamless pipe means that EFW can be used in higher pressure, more corrosive applications where ERW could not be considered. Industries such as petrochemical, textile, food & processing and chemical processing can utilize EFW in areas of their pipelines.

ERW Pipe Specifications

• ERW pipe sizes range from ½” – 48”
• Manufactured in several schedulesranging from schedule 5 to schedule 160 as well as schedule XXS and XS. The schedule used is dependent upon the application and pressure of the piping system.  
• The most common alloys ERW pipe is manufactured from are stainless steel and carbon steel.  
• Ends: plain, bevelled, threaded
• Industry Standards & Specifications:
• ASTM A178: Standard Specification for Electric-Resistance-Welded Carbon Steel and Carbon-Manganese Steel Boiler and Superheater Tubes

EFW Pipe Specifications

• EFW pipe sizes range from 1/8” through 100”.   The availability of these diameters depends on the ASTM specification.  
• Manufactured in several schedules including schedule 10, schedule 40 and schedule 80, etc. These schedules are used in different applications based on the pressure requirements of the system they will be used in.  
• Available in several alloys such as stainless steel, high nickel alloy and carbon steel. This gives flexibility to those installing piping systems. 
• Surface finishes: HF pickled, matt polish, sandblast
• Ends: plain, bevelled, threaded
• Industry Standards & Specifications:
• ASTM A672: Standard Specification for Electric-Fusion-Welded Steel Pipe for High-Pressure Service at Moderate Temperatures
• ASTM A691: Standard Specification for Carbon and Alloy Steel Pipe, Electric-Fusion-Welded for High-Pressure Service at High Temperatures

Other pipe standards, such as ASTM A53, ASTM A252, and ASTM A312 would apply to both ERW and EFW pipe.

It is important to understand the differences between ERW and EFW pipe to ensure that you are using the correct pipe for your system’s application. Pressure, corrosive environment and budget are just some of the considerations when determining which type of pipe to use. 

Always consult your project and engineering firm prior to installing any pipe into your system to ensure a safe and proper installation. 

STILL HAVE QUESTIONS?

Author:  Kimberly Wallingford, Director of Marketing - Merit Brass and Marcus Estrella, Director of Product Line Management - Merit Brass

Sources:

https://www.nucorskyline.com/globalnav/products/pipe/erw#:~:text=Electric%20resistance%20welded%20(ERW)%20pipe,are%20limited%20to%%20inches.

SAW vs ERW and EFW Welded Steel Pipe (hu-steel.com)

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https://www.husteel.com/news355_146.html#:~:text=EFW%20steel%20pipe%20(Electric%20Fusion,the%20formation%20of%20the%20weld.

Stainless Steel EFW Pipe | SS 304/316 EFW Pipe (oshwin.com)

PHMSA: Stakeholder Communications - Manufacturing Process (dot.gov)

What are the main equipment in the erw pipe production line? (eastern-steels.com)

2/7/ 7:26:08 AM

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