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Application and Technological Advantages of Carbon Steel Pipes in Oil and Gas Transportation

Release time:

2025-08-23

Oil and gas transportation, as a core link in the energy supply chain, must traverse complex geographical environments such as land and sea, and withstand harsh conditions such as high pressure, corrosive media (crude oil, natural gas, sulfur-containing media), and extreme temperatures. This places extreme demands on the mechanical properties, sealing reliability, and long-term stability of pipeline materials. Carbon steel pipes (mainly made of low-carbon steel and low-alloy high-strength steel, with a carbon content of 0.05%-0.20%) have become the dominant material for global long-distance oil and gas pipelines, oil and gas field development pipeline networks, and urban gas distribution systems due to their excellent pressure-bearing capacity, mature welding technology, controllable cost, and strong environmental adaptability. As oil and gas exploration and development expands to deep sea, polar regions, and high-sulfur areas, carbon steel pipes are continuously supporting the safe and efficient development of the oil and gas transportation industry through material upgrades and process innovation.

I. Introduction

II. Core Characteristics of Carbon Steel Pipes: Adapting to Oil and Gas Transportation Needs

Outstanding High-Pressure Bearing Capacity: Low-carbon steel and low-alloy carbon steel pipes have a yield strength range of 235-800MPa (such as X80 grade pipeline steel), capable of withstanding high-pressure transportation conditions of 10-14MPa, adapting to the pressure requirements of long-distance high-pressure natural gas pipelines and avoiding the risk of media leakage.

Excellent Welding Performance: The low-carbon composition design reduces welding cracks and porosity defects, enabling efficient splicing through processes such as spiral submerged arc welding and straight seam high-frequency welding. The strength of the welded joint reaches more than 90% of the base material, meeting the sealing requirements of continuous long-distance pipeline laying.

Strong Corrosion Resistance Modification Potential: Through technologies such as internal anti-corrosion coatings (epoxy resin, polyurethane), external 3PE coatings, and cathodic protection, it can resist the erosion of sulfur-containing crude oil media, soil corrosion, marine salt spray, etc., extending the pipeline service life to 30-50 years.

**Cost and Supply Advantages:** Mature production technology, ample global production capacity, and prices 40%-60% lower than stainless steel and alloy pipes, significantly reducing material costs for oil and gas pipeline projects (accounting for 30%-40% of total investment). **High Fluid Transmission Efficiency:** The hollow circular structure results in low fluid resistance (friction coefficient ±0.02) and a smooth inner wall (roughness ±0.05mm), reducing energy consumption in oil and gas transportation and improving transmission efficiency.

III. Typical Application Scenarios in the Oil and Gas Transportation Field

(I) Upstream Oil and Gas Exploration: The "Lifeline" from Wellhead to Gathering and Transportation Station

Oil Well Casing and Tubing: Made of N80 and P110 grade high-carbon steel pipes, possessing both high strength and wear resistance, these pipes, after being lowered into the oil well, serve to cement the well, protect the wellbore, and transport crude oil. They can withstand downhole temperatures of 300℃, pressures of 20MPa, and formation fluid corrosion.

Oil and Gas Gathering and Transportation Pipeline Network: Internal gathering and transportation pipelines within the oilfield use Q235 and Q345 low-carbon steel pipes, connected by welding to form a distributed network. This network transports crude oil and natural gas produced from oil wells to processing stations, adapting to multi-branch, short-distance transportation needs.

(II) Midstream Long-Distance Transportation: Inter-regional Energy Corridors

Onshore Long-Distance Pipelines: Natural gas trunk pipelines (such as the West-East Gas Pipeline and the Central Asia Pipeline) use X70/X80 grade low-alloy carbon steel pipes, manufactured using spiral submerged arc welding (pipe diameter 1016-1420mm), with a single length of 12-18m, enabling continuous laying for thousands of kilometers, balancing strength and flexibility (to adapt to geological subsidence).

Subsea Oil and Gas Pipelines: Deep-sea oil and gas development projects use corrosion-resistant carbon steel pipes (such as X65 grade subsea pipeline steel), with an anti-corrosion coating and a concrete weighting layer on the outer wall, and a wear-resistant epoxy resin coating on the inner wall, capable of withstanding the pressure of 1000m deep seabed and the erosion of marine organisms, enabling the onshore transportation of oil and gas.

(III) Downstream Storage and Distribution: The "Capillaries" of Terminal Distribution Urban Gas Distribution Network: Urban natural gas branch pipelines use DN100-DN500 low-carbon seamless steel pipes, which are flexibly laid through flange and grooved connections to meet the decentralized gas supply needs of residential and industrial users. Their corrosion resistance meets the requirements for outdoor buried applications. Oil and Gas Storage Tank Connections: The inlet and outlet pipelines of oil refineries and LNG receiving stations use low-temperature resistant carbon steel pipes (such as 16MnDG), which can withstand temperature fluctuations from -40℃ to 200℃. Welded sealing ensures the safe connection between the storage tank and the transmission system.

IV. Key Processing Technologies and Adaptation

Forming and Welding Processes:

Spiral Submerged Arc Welded Pipe: Suitable for large-diameter long-distance pipelines (diameter 508-1420mm), high forming efficiency, uniform weld seam, and adaptable to flexibility requirements under complex geological conditions;

Straight Seam High-Frequency Welded Pipe: Suitable for small and medium-diameter pipelines (diameter 114-508mm), fast welding speed (up to 15m/min), high dimensional accuracy, suitable for mass production of urban gas distribution networks;

Seamless Carbon Steel Pipe: Manufactured through hot rolling and piercing process, free of weld defects, suitable for critical components such as high-pressure wellhead tubing and storage tank connections.

Anti-corrosion treatment process:

External wall 3PE coating: Composed of epoxy resin primer + adhesive + polyethylene layer, thickness ≥3.0mm, salt spray test corrosion resistance ≥30 years, the mainstream anti-corrosion solution for long-distance pipelines;

Inner wall coating: Epoxy resin powder coating (thickness 0.3-0.5mm), resistant to crude oil and natural gas media corrosion, reducing fluid resistance;

Catholic protection: Used in conjunction with the anti-corrosion coating, inhibiting electrochemical corrosion of the pipeline in the soil through sacrificial anode (zinc alloy) or impressed current.

Inspection and quality control process: Ultrasonic flaw detection, X-ray inspection, and hydrostatic testing (test pressure 1.5 times the working pressure) are used to ensure that welds are defect-free and pipelines are leak-free. A 100% pass rate is required before the pipeline can be put into use.

V. Application Cases and Development Trends Typical Cases West-East Gas Pipeline II Project: Utilizing X80 grade low-alloy carbon steel pipes with a diameter of 1219mm, a design pressure of 12MPa, and a total length of 8704km, continuous laying was achieved through spiral submerged arc welding. It is equipped with a 3PE anti-corrosion + cathodic protection system. After commissioning, the annual gas transmission capacity reaches 30 billion cubic meters, with a leakage rate approaching zero. A Deep-Sea Oil and Gas Field Project: Selecting X65 grade corrosion-resistant carbon steel pipes with a diameter of 762mm, a laying depth of 800m, an outer wall with an anti-corrosion coating + concrete weighting layer, and an inner wall coated with wear-resistant epoxy resin. It can withstand the corrosion of sulfur-containing natural gas and has a service life of up to 40 years.

Natural gas pipeline network renovation in a certain city: DN300 low-carbon seamless steel pipes are used, and rapid laying is achieved through a trench connection process. An epoxy resin coating on the inner wall improves corrosion resistance by 2 times compared to traditional pipes, and reduces maintenance costs by 40%.

Future Trends

High-strength Upgrade: Development of X90/X100 grade ultra-high-strength carbon steel pipes, with a yield strength exceeding 800MPa, allows for a 15%-20% reduction in pipe wall thickness, reducing material usage and transportation and installation costs, and adapting to high-pressure, long-distance transmission requirements.

Enhanced Corrosion Resistance: Promotion of acid-resistant carbon steel pipes (with added Cr and Mo alloying elements), suitable for high-sulfur, high-CO₂ oil and gas field development. Simultaneously, optimization of composite coating technology (such as zinc-aluminum-magnesium coatings) improves corrosion resistance life in extreme environments.

Intelligent Monitoring Integration: Fiber optic sensors and corrosion sensors are embedded in the inner wall of carbon steel pipes, combined with IoT technology to achieve real-time monitoring of pipeline leaks and corrosion levels, improving the safety management level of oil and gas transportation.

Green Manufacturing and Recycling: Carbon steel pipes are produced using a short-process steelmaking process, reducing carbon emissions. A recycling and reuse system for waste carbon steel pipes is established (with a recycling rate of over 98%), aligning with the green transformation needs of the oil and gas industry under the "dual carbon" goal.

VI. Conclusion

With its core advantages of "high pressure bearing capacity, reliable welding, controllable cost, and adjustable corrosion resistance," carbon steel pipes have built a complete application system for oil and gas extraction, long-distance transportation, and terminal distribution, becoming a core material support for the safe and stable supply of oil and gas energy.

As oil and gas exploration and development expands into more demanding environments, and with the advancement of the "dual carbon" goal, high-strength, highly corrosion-resistant, and intelligent carbon steel pipes will continue to push performance boundaries, providing crucial support for the efficient, safe, and green development of the oil and gas transportation industry and consolidating its irreplaceable position in the energy transmission field.

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