Double-Wall Spiral Welded Pipe for Large-Diameter Load Bearing
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Solution Overview
Problem
Current spiral welded steel pipes with single-layer walls face challenges in large diameters, requiring excessive thickness for pressure resistance, leading to high steel consumption and cost, and production inefficiencies due to delivery constraints and reduced load-bearing capacity, along with elliptic deformation issues.
Innovation Solution
A double-wall spiral welded pipe is created through spiral roll welding of a double-layer composite steel belt with supporting steel bars, allowing for continuous rolling and welding, reducing material usage, and enhancing structural strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the pipe wall is increased to meet water pressure and external load requirements for large diameter pipes, then the load-bearing capacity is improved, but the steel consumption and cost increase significantly
Solution Approach 1:
The patent employs a composite structure consisting of an inner steel pipe and an outer concrete layer, creating a steel-concrete composite pipe. The inner steel pipe provides water pressure resistance, while the outer concrete layer provides external load bearing capacity. This composite approach allows the use of thinner steel walls compared to pure steel pipes, reducing steel consumption while maintaining overall structural strength.
2Volume of moving object
If the diameter of the steel pipe is increased to 3 m, then the water conveyance capacity is improved, but the wall thickness must be increased to 30 mm, resulting in high cost and production inefficiency
Solution Approach 1:
By using the steel-concrete composite structure, the pipe can achieve the required external load bearing capacity for large diameters without requiring excessively thick steel walls. The concrete layer compensates for the reduced steel thickness, enabling production of large diameter pipes with thinner, more manageable steel plates that can be supplied as coils or belts for continuous manufacturing.
3Volume of moving object
If the diameter of the spiral welded pipe reaches 2.5 m, then the water conveyance capacity is improved, but the ability to bear external load is reduced and elliptic deformation occurs
Solution Approach 1:
The outer concrete layer provides the necessary external load bearing capacity for large diameter pipes, preventing elliptic deformation under self-weight and external loads. The concrete acts as a protective shell that maintains the circular shape of the pipe, while the inner steel pipe continues to provide water pressure resistance.
4Ease of manufacture
If straight welded pipes are used instead of spiral welded pipes, then the manufacturing process is simplified, but the welded seam ability to bear internal pressure is weaker and wall thickness must be increased by 10%-25%
Solution Approach 1:
The concrete layer provides external support that compensates for the weaker internal pressure bearing capacity of straight welded seams. This allows the use of straight welded pipes with thinner walls, as the concrete externally reinforces the structure, enabling the overall system to achieve the required strength without increasing steel wall thickness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The double-wall design reduces material and production costs, improves load-bearing capacity, facilitates smoother welding, enables efficient transportation, and extends pipe life while maintaining structural integrity and reducing construction costs.
Implementation Method 1
the contacted supporting steel bars and the adjacent steel belt layers can be welded together through the welding groove
Data Source
AI summary
A double-wall spiral welded pipe includes a first steel belt layer and a second steel belt layer which have equal widths, are arranged in parallel and align with each other; at least two supporting steel bars perpendicular to the first steel belt layer and the second steel belt layer are arranged between the first steel belt layer and the second steel belt layer; the supporting steel bars are arranged on end parts of two sides of the first steel belt layer and the second steel belt layer and extend together with the first steel belt layer and the second steel belt layer; and the first steel belt layer, the second steel belt layer and the supporting steel bars on the end parts of the two sides are mutually welded to form a double-layer composite steel belt with a rectangular section in an extending direction.