A Study on the Synthesis and Characteristics of ERW Steel Pipe

DOI: https://doie.org/10.10399/JBSE.2025416595

Shahnawaz Alam

Keywords:

ERW Pipes, High-Frequency Induction Welding, X-60MS Steel, Mechanical Properties, SAMSPI Framework, IoT Monitoring, Supply Chain Resilience, Vision 2030, Hydrogen Pipelines, Sustainable Steel Production.

Abstract:

Electric Resistance Welded (ERW) steel pipes, manufactured using High-Frequency Induction Welding (HFIW), are essential for oil, gas, construction, and petrochemical sectors due to their cost-effectiveness and durability. This study introduces a novel approach by combining optimized HFIW processes with the Scalable Adaptive Multi-Strategy SPI (SAMSPI) framework to enhance X-60MS grade ERW pipe production for Saudi Arabia’s Vision 2030 projects, such as NEOM and MGS-II. We explored how welding parameters—heat input (15.3–20.3 kW·min/m), squeeze force (19.49–79.50 kN), and annealing temperature (862–956°C) affect mechanical and microstructural properties. Optimal settings yielded a tensile strength of 599 MPa, impact toughness of 120 J, and hardness below 240 HV10, meeting API 5L standards. Higher heat inputs reduced weld zone hardness due to larger grain sizes (13 ± 1 μm). SAMSPI, a low-power Verilog HDL module (2.27 mW), increased production efficiency by 10%, saving $0.5M annually in monitoring costs for MGS-II. Supply chain analysis showed Electric Arc Furnace (EAF) and Direct Reduction Iron (DRI) technologies cut CO2 emissions by 25%, despite 40% import reliance and a 30% skilled labor gap. These findings enable sustainable ERW pipe production for hydrogen pipelines, supporting global net-zero goals and Vision 2030’s sustainability vision.

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