Corporation. New & Used Machinery

Transcription

1 ES ESteel Corporation. New & Used Machinery #101, 576-8, E-Dong, Sangrok-Gu, Ansan-City, Gyeonggi Provence, South Korea Tel : FAX : machinery@esteelcorp.com Φ mm x mm New SSAW PIPE MILL ES Summarize 1.1 This mill is adopts advanced technology from abroad. We design according to our advanced production experience, as advanced design, steady performance and adjust conveniently Forming Process First of all, hang the coil to the coil car, drive to the uncoiler, pinch with cone head, and can move coil to the requested center line through the operation button, and then operate knife aligned to coil, start support roller motor to rotate coil, uncoil the strip head with the blade, then sent to the pinch &leveler machine. Press roll press the strip and deliver forward, level the strip by roll, go ahead then a pair of vertical rolls make strip on the centerline. Then strip entry into the delivery machine, send strip to the forming, bend the strip to pipe through 1 #, 2 #, 3 # forming roll, make size through 4 #, 5 #, 6 #, 7 #, 8 # forming roll so get the specified spiral pipe. At the same time of 1

2 forming, weld the two contacting edges from inside and outside by Lincoln submerged arc welder. Set automatic ruler and cutting device in the pay-off table, so can cut and kick out the pipe to ensure continuous production. According to forming theory, during the SSAW production process, the strip of different width and thickness is suitable for producing different diameter pipe, the correlation shown in the following formula: cosα = B / πdm above: α for forming angle B for the strip width Dm for the pipe diameter, Dm = D (outside diameter of steel pipe)-t (thickness) In actual production we can calculate the required angle of the molding on the basis of the above formula, and then calculating the appropriate adjustment of feeding table by the value and the appropriate angle of forming, and then produce 1.3. Techniques process Spiral welded pipe production line process is as follows: Uncoiling Peeler and pinching seven roller leveling lateral strip guide shearing & butt-weld lateral strip guide edge miller 1 edge miller 2 lateral strip guide main drive pre-bending lateral strip guide forming internal welding external welding on-line UT cutting off kick-out pipe clean welding scrap repair welding X ray hydraulic testing end bevelling collecting storage From entry of coiler to cut-off & kick-out is the entire forming process, the unit will make SSAW as strip, is the main part of the whole process, only stop when combine the first coiler and the next coiler, this unit has a strong continuous. From cleaning the scraps &repairing welding to storage is essential finishing, testing process, is to ensure that pipe is up to the required standards, form a complete production and testing system with the main machines, which has a clear division of labor and close linking to ensure the performances of qualified products. 2 Purpose of steel pipe 2.1 High strength petroleum and natural gas transportation 2.2 Low pressure liquid pipe as gas and water transportation 2.3 Piling pipe for construction 2.4 Structural steel pipe 2.5 others 3. Quality The mill produce the steel pipe meet with GB , AWWA-C200, API 5L 4. Technical specifications 2

3 4.1 Raw Materials Steel coils: OD: Ø1000 Ø2600 mm ID: Ø mm Strip Width: 800 mm-2000mm Wall thickness: mm Steel grade: Q235, 16Mn, X70,X80,Max.X100 Weight: Max. 45 Ton Strip Camber: 10/10 mm/m 4.2 Finish Product Pipe specification: Diameter Range: Ø610 Ø 3048 mm. Wall Thickness: mm. Spiral angle: 45º - 82º Length: 6 13 m±0.5 The following is the Max. Wall thickness and Max. diameter data: mm Note: X X80; 3

4 X60; API--B 4.3 Working system Three shifts continuous working system, no holidays. Available working time is 4,500 hours, Repair total mill one time per year, 20 days/time. Every week, repair the components, change the shift within 20 minutes, for inspect the equipments and clean the workshop. Every year working time as below: 1) Calendar time: 8,760hours/per 2) Repair the total mill will take 20 days/year 480 hours/year 3) Every week repair one time will take 8hours/week 416hours/year 4) Change the shift time is 20minutes/shift 345hours/year No working time as 1,241hours/year 5) Every year working time is 7,500hours/year 6) Change the tools and others stop working time is 3,000hours/year 7) Available working time is 4,500hours/year 4.4 Production capacity (annual output) According to Ф mm, the steel coil width is 1550mm, forming angle is o, driving speed is 1.8m.min, weight of coil is 25 ton, the forming speed is 0.64m/min, so the production speed should be 0.35Ton/min, each pipe length is 12meter/6.6Ton,the year working time is 4,500hours, as the annual output be up to 50,885Ton 4.5 Workers quantity and their position Main section Uncoiler Butt-welding Edge milling Forming Cut off Repairing On-line UT: 1 End facing and beveling machine: 2 Hydro tester: 3 X ray: 2 4

5 Assistant: 5 Total: 23 workers/shift 4.6 Mill type Inlet swiveling, strip centerline location 4.7 Welding data: Internal welding: 1 DC AC 1200 External welding: 1 DC AC AC 1200 Speed: m/min 4.8 Driving speed: m/min 4.9 Forming type: Three roller bend, four row of out-control roller sizing Plant requirement Voltage: 220/380V Frequency: 50Hz Compress air: Mpa Water supply: Mpa 4.11 Total capacity: approx.1300kw 5. Production techniques Uncoiling Peeler and pinching seven roller leveling lateral strip guide shearing &butt-weld lateral strip guide edge miller 1 edge miller 2 lateral strip guide main drive pre-bending lateral strip guide forming internal welding external welding on-line UT cutting off kick-out pipe clean welding scrap repair welding X ray hydraulic testing end bevelling collecting storage 6. Equipment list: No. Description Qty Remark Main section 1 Uncoiler 1 2 Peeler and pinching machine 1 3 Seven roller leveller 1 4 Lateral Strip Guide 4 electrical 5 Shearing &Butt welding unit 1 6 Edge miller 2 5

6 7 Main drive 1 8 Pre-bending 1 9 Forming machine 1 10 Feeding table 1 11 Inside welding unit 1 12 Outside welding unit 1 13 Pay-off table 1 14 Flying cutter 1 15 Pipe drop unit 1 16 Hydraulic system 1 17 Electrical system 1 18 Buried parts 1 Finished section 1 Facing &Beveling machine 1 2 Hydrostatic tester Ton 3 Conveyor and platform Qty according to the plant requirement 7. Assistant equipments 1 Welder DC Lincoln Brand 2 Welder AC Lincoln Brand 3 Butt-welding unit (Share with the internal welder) 1 Lincoln Brand 4 Weld flux transportation and recycle equipment 1 China supply 5 Plasma cutter LGK China supply 6 X-ray tester 1 China supply 7 On-line UT 1 China supply 8 Laser seam tracking system 1 China supply 8. Mill Components description 8.1 Uncoiler (with coiler car) Load the steel coils, Uncoiling with double cone-head with double roller. Uncoiling by AC motor, 15Kw Centering by hydraulic Lift the coil by hydraulic There is the round plate avoid the coils is loosed Technical parameters: Width: mm Thickness: mm Coil internal diameter: Φ610-Φ760 mm Coil external diameter: Φ1300-Φ2600mm Coil weight: Max. 45T 6

7 Center cylinder: Φ200 X 900 mm 2pcs Double cone head lifting cylinder: Φ220 X 850 mm 2pcs Support roller diameter: Φ300mm Material of support roller: 42CrMo Hardness of surface: HRC Peeler & pinching machine Open the steel coil, and strength the head of coil by hydraulic Consist of peeler unit, pinch unit, movable cylinder and foundation. Peeler rotate by hydraulic Peeler open and close by hydraulic Peeler strengthen by three roller hydraulic Technical parameters: Width: mm Thickness: mm Coil internal diameter: Φ610-Φ760 mm Coil external diameter: Φ1300-Φ2600mm Coil weight: Max. 45T Peeler cylinder: Φ200/140mm Material of peeler: 65Mn Straightened roller diameter: Φ360 X 2100mm Pinch roller: Φ360 X 2100mm Material of roller: 42CrMo Pinch roller press down: Φ160mm cylinder Drive by DC 22kw, frequency converts Whole moving cylinder: Φ220/160mm, 2 pcs 8.3 Seven roller Leveller Level the steel coils and pinch the steel strip from the Uncoiler. Consist of pinch roller, leveler, support roller and driving unit. Level roller: Four up three down (the down three roller can individually adjust by hydraulic cylinder),φ300x2100mm Main motor: DC motor 22kw frequency converts, Level roller press down by AC 5.5kw Material of level roller: 60CrMoV Support roller diameter: Ф200mm 7

8 8.4 Lateral Strip Guide Center and guide the side of steel strip by electrical. Consist of drive unit, lateral side guide and basis. Technical parameters: Centered by AC 3KW X2 Support roller diameter:φ300mm Material:GCr15 Hardness:HRC58-62 Moving range: mm Driving screw pole: Tr100 X 4 Material of screw pole: 45 Hardness of screw pole: HB Characters: 8.5 Shearing & Butt-welding Shear both ends of the steel strip and butt-welding the two steel coils Consist of body, shearing unit, and press plate and support roller. Carriage drive by cylinder Press plate clamp by cylinder Strip thickness: mm Strip width: mm Steel grade: HR X100 Hydraulic shear force: 400T Blade material: 6Cr W2Si Welding head move by AC frequency converts Weld by automatic submerged arc welding Welding power: DC 1500+AC 1200 Welding speed: m/min 8.6 Edge milling machine Mill the two side of steel strip with beveled edge. Consist of milling head device, milling body device, press roller device. Milling speed:30-90 m/min. Driving by AC motor, 2 X 75kw frequency converts Milling head: Ф600mm Milling accuracy: Plate width tolerance:±0.5 mm, Width tolerance of length edge: ±0.3 mm Beveled edge angle tolerance:±2.5 Beveled edge form: X direction 30,Y direction 30,reserved length in the middle 6-8mm Steel strip speed:max. 3 m/min; 8

9 Milling blade press down: hydraulic Milling width adjusting mode: electric 8.7 Main Drive: Drive the steel strip to move forward to control the forming speed. Consist of the driving unit, golden sky, frame and cylinder. Speed: m/min Driving: DC 2 X75kw frequency converts Diameter of roller: 600mm Material of roller: 60CrMoV Driving force: Min. 300Ton Press down by hydraulic cylinder Ф450mm 8.8 Prebending Unit: Pre-bend steel strip single edge before entering into forming machine. Avoid any bend, hump before entering into forming machine. Roller own self protection function, which could achieve smooth running and delivery when plate thickness changes; Consist of pre-bend device, guide plate device, clamps and base. Prebending roller diameter: Ф300mm Material of roller: GCr15 Hardness: HRC58-62 Cambering roll form: two roller Press down: AC motor The form of rolling: bearing roll Roller: Ф160mm bearing roller The material of rolling: GCr15 Distance between up and down plate: 5-30mm 8.9 Forming machine: This machine is one of the key equipments. It s used to deform the steel strip to the shape of pipe prepared for welding. It adopts the Germany MEG type, adjust the height of 1# and 3# roller by electrical, adjust the distance between 1# and 3# by electrical. Adjust the angle of 1# and 3# by manual, adjust the 4# assistant roller by manual, 5#, 6# and 7# out-controlling roller by electrical. 9

10 Consist of foundation, lateral side guide, tension unit, forming roller 1#,2#,3# and out-controlling roller 5#, 6#,7# and 8#. Type: Inlet swiveling, left feed Adjustment: three roller bend, out-controlling roller can be adjusted. Strip location: center location Forming scope: Φ mm Forming angle: Forming roller: Dia.160mm, GCr15 Internal press pole material is 42CrMo Forming roller lubricate by dry oil. Foundation move by AC motor, 7.5kw Electrical lateral side guide: AC motor 2 X 3kw Forming roller moving by 1.5kw 2# roller press down by AC motor 7.5kw 2# roller press force: 200T Performance: Forming machine has good rigidity and security, can ensure long-term produce, form steadily. Adjustment unit adopts motor, operate freely and control main parameter easily. All the transportation unit adopts little gap screw pole, the unit can be agility, steady and credibility. All the components of forming machine adopts focus lubrication, can regular lubricate through individual lubrication pack. Before forming, there is the two row lateral side guide and prebend plate to make the steel strip can enter into the forming machine exactly and steadily. Forming machine adopts three roller bend type, that is 1# and 3# support, internal press roller press down to bend the strip, the 1# and 3# always point the central angle, the others out-controlling roller for control the diameter. Forming steadily. The internal press unit of forming machine is the main component, it adopts double worm clamp, can carry out remove the gap. Ensure to form steadily. Internal press pole is total forge, has total rigidity and good heat treatment. The internal press roller can be discharged The welding rod can lift by hydraulic jack. It always keep one position to ensure the welder to weld. The forming roller adopts GCr15 bearing roller, change freely and adjust freely. The foundation can turn as the force of pay-off table, then carry out to adjust the forming angle. The wheel of foundation adopts mechanical locking system, ensure the forming angel is steady. The turn round center shaft lubricate by focus lubrication. Roller lubricate by focus dry oil. 10

11 8.10 Feeding Table: The foundation of the equipments in front of the forming machine. It forms the required angle by hydraulic pressure cylinder. It is welded with section steel and steel plates. Swing cylinder: Ф160/110mm Forming angle: Pay-Off table: The foundation of the equipment behind the forming machine. It can rotate a mini-trim angle to correct the welding gap. Tuning angle: ± Flying cutter: Cut the welded pipe in a fixed length. Consist of foundation, carriage body, top wheel equipment and driving equipment. Cutting mode: Plasma cutting, LGK-200 Characters: Fixed length cut Buried parts Load the feed table and pay-off table. Consist of slide way and anchor bolts Internal welding equipment: Fix and adjust the internal welding head, ensure center the welding seam. Welding head move by AC reducer motor Welding power: DC-1500, AC-1200 Welding speed: m/min 8.15 External welding equipment: Fix and adjust the external welding head location, ensure welding wire up to the center of welding seam. Welding head move by AC reducer motor Welding power: DC-1500, AC-1200, AC-1200 Welding speed: m/min 11

12 8.16 Pipe Drop unit Kick out the steel pipe after cut off Consist of kick out unit, cylinder and foundation. Cylinder: Ф150/105mm 4pcs 8.17 Welding flux treatment and recycle Function: It used to internal and external welding, installed forming table and top operation table. The high pressure centrifugation fan feed the flux to flux bucket, discontinuous working. When the flux is full, the motor is stop. The flux supply based on gravity system. The dust separator adopts high pressure pulse, equipped felt bag, easy to clean the dust. Welding flux recycle system recycles the flux separately for internal and external. The high pressure centrifugation fan sucks to flux bucket, Internal welding spot welding adopts magnetic separator, can separate the 99% iron dust Welding flux feed system Consist of negative pressure system, dust separator, internal and external welding nozzle, welding flux feed and discharge unit, connectors. High pressure centrifugation fan: 15kw, discontinuous work Dust separator: pressure +50Mpa Filter area: 20m² Dust separator frequency: 98% Welding flux recycle system Consist of negative pressure system, dust separator, discharge unit, magnetic separator unit, welding flux storage, welding flux supply unit, internal and external nozzle. High pressure centrifugation fan: 18.5kw, continuous 24 hours Dust separator: pressure +50Mpa Filter area: 20m² Dust separator frequency: 98% Magnetic separator capacity: 1000kg/h Frequency: 99% iron dust Welding flux treatment Consist of heat box, storage box, driving unit, speed adjustor and temperature control unit. Function: dry the flux, and separate the flux and scrap. Type: YXH1-500 rotating dryer Welding flux capacity: 500kg Heat power: 13.5kw HCX-II flux magnetic separator Capacity: 1000kg/h 12

13 Power: 0.37kw ZZF vibration sifting machine Capacity: 1000kg/h Power: 2 X 0.25kw 8.19 Plasma cutter Type: LGK-200 Cutting wall thickness: mm Consist of cutting power, cutting head and spray nozzle X ray tester Technical specifications X-ray capacity: 225KV, 7mA Testing speed: 0.5-7m/min System sensitivity: dynamic sensitivity 3%, static noise reduction 1.8% Pipe end blindness: 100% no blindness Pipe end magnetic corrective: 100% remove deformation. It can testing real time and also can take the pictures when testing Consist of X ray tester body, X ray real time photo, X ray computerized photo process system, mechanical driving and electrical control, location monitor, marking unit, blindness removing system and magnetic corrective system Components description ceramic tube X ray tester Technical Voltage: 225kv Current: 7mA (Big focus), 3mA (Small focus) Focus size: 2.0 x 2.0(Big focus), 4.0 x 4.0 (Small focus) Coolant: cathode water coolant, water flux 4L/min Radial angle: 40º Penetrating power: 40mm Titanium X ray real time photo Effective: 145mm, Dpi: 48Lp/cm, CNT: 23: X ray computerized photo process system PIV processor, 1.8G, 60G HD, 256 ROM 17 screem, DPI 1280 X 1024 Function: real gather, real display Mechanical driving and electrical system Testing arm: up and down moving range: 1000mm Total length: 19.4m Pipe end elevation range: 20º Pipe carriage: traveling speed: 0-10m/min Function: load the steel pipe, transport it Location real monitor system Monitor the working station. 13

14 Blindness removing unit: carry out 100% no blindness Magnetic corrective: correct the pipe end magnetic disturb, remove the deformation Marking: mark the defect pipe 8.21 Hydrostatic Tester: Technical data Load capacity: 3500Ton Max. pressure: 21Mpa Keeping time: 10-15s Wave of standby pressure: 0-0.3Mpa Capacity: 2(Ф3048)-6(Ф610)pcs/hour 12M Inspect the steel pipe, check whether leakage under the request pressure, ensure the steel pipe working performance Consist of fixed testing head, movable testing head, tension beam, flexible testing seat, testing head, pipe hold device Testing techniques Feeding Filling testing discharge water discharge It must put in order when feed the pipe to platform, select the sealed collar as per the diameter and wall thickness, adjust the output pressure value as per the testing pressure, lifting equipment lift the height etc. Push the pipe in the storage to lifting and shield equipment manually, the shield equipment shields the pipe to fall to V roller, the lifting equipment lift pipe to make the same centerline between pipe and the testing machine, the side cylinder drive the main cylinder forward to extend, the adjustable test head comes up against the ends of pipe to push the pipe forward to moveable test head, at one time, the main cylinder fast fill the oil until the front end comes up against the moveable test head, open the filling valve and exhaust valve, when the exhaust pipe discharges the water, the exhaust is over and close the exhaust valve. Open the high pressure filling valve, filling high pressure water to pipe, at one time the pressure of main cylinder increase along with the pressure of pipe increase controlled by proportional valve to keep the test head cling the ends of pipe. When the pressure reach to required pressure, the pressure relay outlet signal to start pressure dwell, the time is 10~15s. The pressure dwell is over, the pressure of pipe unloads with unloading valve, open the exhaust valve to complete release the pressure. The moveable return, and push the pipe to adjustable test head with moveable cylinder and return, the lifting equipment fall to original place, the shield equipment in the place of discharging and the pipe roll to exit platform, that s over Hydraulic System Equip individual hydraulic system, include hydraulic station and all kinds of control valve, pipe circuit, pump motor. Hydraulic cylinder as the power source of whole system. 14

15 Electrical System PLC control,computer surveillance. Dynamic display, print and storage function. On-line print and historical date check. Proportional valve control oil&water balance during testing. Easy operation and maintenance Computer Display, Record, Print System: consist of industry control computer, monitor, and printer. Advanced net technology, Basic language development to achieve efficient reliable auto control, in-time hydrotester working condition and water pressure surveillance. Pressure date record, instant print out End Beveling Machine Technical data Main shaft speed: r/min Diameter of gearbox: 3500mm Blade feed quantity: 2-30m/min Speed: 2-30m/min V lift scope: mm Main drive: DC 75kw X 2 Outside size: mm End beveling to the beveled edge of pipe ends. Plasma cutter: 2pcs 8.27 Hydraulic system Drive & control all the hydraulic parts. The components adopt the Rexroth Technology by HUADE produce Electrical System: The machine control all the parts run. AC motor is SIEMENS PLC is SIEMENS DC speed regulation is SIEMENS Frequency convert is SIEMENS Inductor and Relay is OMRON 8.29 Others The important lubrication point adopts the dry oil. 9. Price 10. Delivery time Eight (8) months after the contract come into force. 15

16 11. Payment terms (T/T) %T/T for deposit when the contract comes into force %T/T within 2 months after the contract come into force % irrevocable L/C within 7 days after received second 30%T/T. Here in 30% against on Bill of Lading, the 5% released installation and commissioning. The balance is paid after the guarantee period. 12 Acceptance standard 12.1 According to the API related and technical agreement Acceptance according to produce two kinds of steel pipe, the diameter will confirm by both party. 13. Technical services 13.1 The guarantee period is one year. And will update the technical long terms We supply technical guiding with installation and commissioning. 16