Φ219-1220mmFrontal-swinging Spiral Welded Pipe Line
1. Forward:
Thisunit is the forming unit designed and manufactured by our company afterresearch and absorption of advanced technology at home and abroad. Usage ofGerman MEG forming method enables the back-swing welding car produce pipecontinuously with high efficiency, stable performance by advanced design.
2. Production introduction
2.1 Product usage
1) API 5L high strength petroleum, gas transportationpipeline;
2) Low-pressure fluid transportation pipeline, gas pipeline and drain line;
3) Piling-pipe in the engineeringconstruction;
4) Pipe in the industrial structure;
5) Pipe for other uses.
2.2 Productquality
The quality of pipes produced are in accordance with USA API-5L and China National StandardsGB9711.1-1997.
2.3 Technical performance¶meter
1) raw material:
Coil O.D. | Φ1200-Φ1500 mm |
Coil I.D. | Φ508-Φ760 mm |
Coil width | 400-900 mm |
Coil thickness | 5-12 mm |
Coil material | Q235-A |
Max. coil weight | 15 t |
Crescent bend | ≤10/10000 mm |
2) product data:
Pipe diameter | Φ219-Φ1220 mm |
Pipe wall thickness | 5-12 mm |
Spiral angle | 40°-78° |
Pipe weight | Max4.5 t |
Pipe length | 8-12 m |
Pipe thread pitch | Max1400 mm |
3.Machine mode, Technical parameters, Process flow, Delivery listand Line introduction:
3.1 mill data
Mill form | frontal swinging type, intermittent production, centering loading coil and positioning |
Preparation period of host unit | mill stopping and butt loading coil |
Forming style | three-roller bending forming, external control roller sizing |
Forming direction | right spiral forming |
Forming angle scope | 40°～78° |
Max. thread | ≤1400mm； |
Pipe discharging | swing carrier roll to discharge pipe |
Welding way | Double-side sub-merged arc automatic welding |
Welding speed | 0.8-2.1 m/min |
Delivering speed | 0.6～2.4m/min |
Installed capacity | ～210KW |
3.2dynamic parameter
voltage | 220/380 v |
Tap water | 0.2-0.4 Mpa |
Compressed air | 0.4-0.6 Mpa |
3.3process flow:
uncoiling→pinching&leveling→manualside guide→cutting& butt welding →manual side guide→rotary shear→electricside guide→main drive→ pre-bending guide board→forming→inside welding →outsidewelding→flying cutting→ kick off→deslagging and repair welding → (beveling&end-facing) →(hydrotesting)→collection
4.Annual output:
（three shifts） 10,000～20,000MT/A
5.Equipment list:
5.1hostmachine area
N/N | Equipment Description | Qty. | Approx. W.T.（t） | Remark |
1 | Uncoiler | 1 |
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2 | Pinching&leveling machine | 1 |
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3 | Manual side guide | 1 |
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4 | Cutting& butt welding | 1 |
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5 | Electric side guide | 2 |
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6 | Rotary shear | 1 |
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7 | Main drive | 1 |
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8 | Pre-bending guide board | 1 |
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9 | Forming machine | 1 |
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10 | Frontal axle | 1 |
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11 | Inside welding device | 1 |
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12 | Outside welding device | 1 |
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13 | Rear axle | 1 |
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14 | Flying cutter | 1 |
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16 | Buried parts | 1 |
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17 | Host hydraulic (electric) system | 1 |
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Total weight |
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18 | hydrotester | 1 |
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19 | Beveling& end—facing machine | 1 |
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Total weight |
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5.2purchaseditems
N/N | Equipment Description | Qty. | Remark | Weight （t） |
18 | Inside welder DC-1500 | 1 | LINCOLN | 1 |
19 | Outside welder DC-1500 | 1 | LINCOLN | 1 |
20 | Buttwelding car | 1 | China brand | 0.5 |
21 | Air plasma cutter | 2 | China brand | 1.6 |
22 | automatic weld flux transportation & recycling device | 1 | China brand | 4 |
23 | Weld flux dry and magnetic separation device | 1 | China brand | 1 |
23 | Air compressor | 1 | China brand | 0.5 |
24 | cable | 1set | China brand | 1 |
Total weight | 10.6t |
5.3totalweight of the equipment:
Approx.
6. Host machine of Ф219～Ф1220 SSAW pipe mill
6.1uncoiler
Function: used to supportand rotate the coil initiatively to peel the coil head coordinating with theshovel knife, and feed the strip forward to pinching&leveling machine
Structure: composed ofdouble coneheads, carrier roll assembly, shovel knife and support roll
Motor: power 7.5kw.
Supporting roll: dia.φ220, length 950mm, material 45, hardening and tempering HB220－260, quenching hardness HRC40-45.
6.2pinching&levelingmachine
Function: used to levelthe strip and feed it to shear& buttwelding position and delivery machine
Structure: double-roll pinching five-roll leveling, driven bycycloidal planetary gear speed reducer to feed the material.
Motor: power 7.5kw,pinching roll dia.φ160, length 900mm,material 42 CrMo, hardening and tempering HB220－250,quenching hardness HRC53-57.
6.3side guide（manual and electric）:
Configuration: consist of side guide and its base, screw guidedrives to adjust the width.
Cycloidal reducer drive screw transmission, motor power 1.1 KW
Vertical roll material 42CrMo, quenching hardness HRC52-58.
function:to ensure steel strip aligned with centerline.
6.4cutting&buttwelding:
Configuration:consists of frontal& rear pressing plate, machine body and moving device.
Function:to plasma cut off the strip end&tail and buttweld them
Trolleymovement: by cylinder stretching
Welding way: semi-auto SAW butt welding
6.5rotaryshear
Structure:consist of two supports, on which equipped with the shear blade to cutpassively
Sawblade dia.: φ320, material 6CrW2Si, thermal refined HB229-285, quenchinghardness HRC57-60.
Function: to cut off the rough edge of steel strip
Clearanceadjustment: screw guide adjusts vertically while turbine worm adjusts left andright
6.6 main drive
Function:to supply forward feeding power to the whole spiral pipe line
Configuration:is made of machine body, speed reducer, coupling, and motor.
Speed regulation: AC VF speedregulation
Delivering speed: 0.8-3.0 m/min.
Deliveringroll dia.: φ300, material 42CrMo, quenching hardness HRC52-58.
Motor power: 15KW
6.7guide board
Function:to prebend the strip and feed it into forming unit.Configuration: is made of upright post, up&below guide board.pre-bending roll material 42CrMo, quenching hardness HRC52-58.
6.8forming machine
Function:one of the key equipments, to force steel strip into required pipe shapewaiting for welding.
Unit form: adopt Germany MEG form, 1#, 3# roll forming angle isadjusted by angledemodulator;manual screw guide drives to transverse movement.
Configuration: is made of 1#、2#、3# forming roll, 4#、5#、6#、7#、8# outside control roll, base , side guide andrevolving axle and tension apparatus.
Adjusting way: three-rollbending, outside control roll adjustable
Position method: centerpositioning
Forming scope: Φ219～Φ1220mm
Forming angle: 40°～78°
6.9 frontal axle:
Structure:process the welded section steel and steel plate.
Function:equipment base before forming, can adjust forming angle
Oilcylinder: φ100/70×500
6.11 rear axle:
Structure:process the welded section steel and steel plate. carrier of equipment afterforming, with function of fine-runing, pipe cutting and output.
Oilcylinder: φ100/50×310.
Oilcylinder: φ110/80×400.
6.12 host buriedparts: rail of the host machine.
Including shim plate, guide rail and bolt
6.13flying cutting car
Function:carrier of cutting pipe to length.
Cuttingway: plasma cutting
Configuration: consists ofbase, pneumatic system, machine body, top wheel device and walking mechanism
6.14inside weldingdevice
Used to fix andadjust inside welding tool, to ensure welding seam aligned and weld the seam
6.15outsidewelding device
Usedto fix and adjust outside welding tool, to ensure feed the weld wire to seamcenter
6.16 Host hydraulic system:
Hydraulic pump station isthe work system of eack hydraulic device thay reply on hydraulic power. It isused to supply pressure medium with controllable direction, pressure and flowto each action element(as hydraulic cylinder, motor. etc.), to reset andachieve recycling work
6.17 electric control
Control mechanism ofindividual equipment single-action and linkage.
