ES-11223 127mm ~ 273mm Seamless Tube Production Plant Information about an exclusive method of pipe making Availability of equipment at the pipe rolling area in the manufacturing sequence of their production for the purpose of making hot-deformed, case, drilling pipes; pipelines tubes; hollow sections; rolled clutches; torque bars serving international standards and customization demands. The primary blanks for seamless steel pipe making are the blanks of Martin ingots and of cut continuous cast bars in the process of continuous casting steel. 1. Staging area Before production start-up the ingots or continuous cast bars are passing quality control and are weighted on the scales installed into the roller conveyor. Equipment: scales, roller conveyor. 2. Ingot heating This is realized in role continuous double three-zone furnaces Nr.1 and Nr. 2. Technical data of a role continuous furnace: - furnace type three-zone, continuous - feed width 4,8 m - feed length 20,75 m - feed height: - continuous zone 0,90-0,83-1,27 m - welding zone 1,27-2,60 m - soaking zone 1,30-1,90 m - furnace capacity 15-34 t/h - one-time charging 76-120 pcs - waste of metal up to 3% - fuel natural gas - specific fuel consumption 72,04-73,98 kg/t - furnace power 7,26-17,55 Gcal/h - furnace efficiency 39,23-40,3% Ingots canting is made by a canting machine. Equipment: role furnaces Nr. 1 and Nr.2 (two furnaces) canting machines 2 pieces 3. The ingots or continuous cast bars uniformly heated by the length and section to the needed temperature are advanced to a piercing mill for the purpose of getting cartridges and their further flattening-out on Pilger mills. Technical data of the piercing mill: - rolls diameter at over clamping 800-850 mm - roll s barrel length 950 mm - number of revolutions of operating rolls 53 rev/min - feed angle (regulated) 3 0 30-5 0 30 - flattening-out speed (regulated) 5 0 +/-2 0 - main mill drive s power 2500 kw - work holder diameter 107-270 mm - cartridge diameter 275-420 mm - cartridge length 1800 3400 mm Equipment: roller conveyor to the piercing mill; kicker; a piercing mill.
Pilger mills purpose The obtained cartridges are advanced along the roller conveyor and are passed by the kicker to the Pilger mills. The Pilger mills are purposed for flattening-out of the cartridges into a tubing stock. The Pilger mill is made up of two operating stands. Both stands are arranged in a parallel manner to each other and share the common drive of the electric direct current motor with regulated number of revolutions and fitted with a flywheel. The stands are connected to the main clutch that couples the rotor rod with the inferior gear pinion neck of the pinion standby means of a protective spindle. In the pinion stand there are two chevron gears to the wobblers of which coupling spindles are connected by means of articulated semi-couplings, those coupling spindles pass the rotation to the operating rolls. An operating stand consists of two closed-type beds with two Pilger operating rolls placed into cushions with bushings. Every Pilger stand is equipped with a triblet-changing and triblet-cooling device of an off-the-mill triblet charging. In the process of hot Pilger rolling metal deformation is done between the rolls with variable section gage. The area of gage cross-section diminishes in the deformation process. The deformation takes place in the presence of backing-up pressure that prevents moving of the tubing stock in reverse direction and secures progressive motion in a tray about 50 meters long consisting of cast iron sections. The total length of the tubing stock obtained from the flattened-out cartridge came from the Pilger mill is exposed to end cutting and cutting to specified length sections on a disc saw and then, when hot, is exposed to stamping on stamping machines. Technical data of Pilger mill: - stand type two closed-type beds in the form of rigid rectangular frames for assembling of a couple of rolls with a variable section gage. - diameter of flattened-out tubing stocks 140-282 mm - Pilger rolls diameter 670-740 mm - drive power 2500 kw - number of revolutions 60-120 rev/min - flywheel diameter 7000 mm - flywheel weight 52800 kg - feeding apparatus type with hydro-pneumatic braking Technical data of the feeding apparatus: - diameter of rod (piston) of the feeding apparatus (large) 550 mm (small) 360 mm - maximum stroke of the feeding apparatus rod 1500 mm - maximum stroke of the feeding apparatus 6795 mm - maximum air pressure 12 atm - feeding apparatus lubrication system circulatory - lubricant type machine oil - oil volume in the feeding apparatus tank 250 l - weight of moving parts of the feeding apparatus 2787 kg - cartridge turn to an angle 100-120 degrees Equipment: Pilger mill 2 operating mills included in production and one mill reserved; feeding apparatus 2 pieces; trays made of cast iron sections 2 trays; a triblet-changing and a triblet-cooling devices 2 pieces; disc saws 2 pieces; stamping machines 2. Before reducing and calibrating the tubing stocks for clutches are delivered by the roller conveyer to the reheating continuous furnace Nr.3 where they are heated up to the needed temperature uniform by length and section.
Technical data of the reheating continuous furnace Nr.3: - furnace type - reheating continuous furnace with an inclined feed - feed length 7,2 m - feed width 13,58 m - fuel type natural gas - one-time furnace charging 30-47 pcs - heated tubes diameter 140 282 mm - heated tubes length 6-13 m - furnace capacity 10-50 t/h - waste of metal up to 2% - furnace efficiency 1,99 9,95 Gcal/h Equipment: a roller conveyer, a continuous furnace. Calibrating and reducing of tubing stocks. The calibrating and the reducing mills are purposed for obtaining final geometric parameters of the heated tubes outside diameter, wall s width and length. Technical data of the calibrating and the reducing mills: - quantity of operating rolls in a stand 2-rolls - rolls diameter 550 mm - rolls width 350 mm - shaft diameter 230 mm - rolls material alloyed iron - by rolls location in the stand alternately inclined to opposite sides on-the-miter 45 to horizon and on-the-miter 90 to each other - by rolls bearing location with rolls on two bearings with regulated rolls attitude - drive system with individual drive - each stand motor power from 50 kw and more (up to 75 kw) A calibrating mill consists of five stands. It serves for calibrating tube stocks of diameter from 152 to 273 mm. A reducing mill consists of nine stands. It serves for reducing tube stocks of diameter from 127 to 152 mm. Equipment: calibrating mill one; reducing mill one. After calibration and reduction all the pipes are passed for further cooling by a roller conveyer and a kicker to a fridge (a chain conveyer). Technical data of a chain conveyer: - length 32,6 m - width 12 m - quantity of sections 2 pcs - quantity of chains in every section 6 pcs - step between chains 2,0 m - chain step 225 m - star wheel diameter 450 mm - chain velocity 0,5 1,5 m/min - electric motor type 11-82 - electric motor power 13 kw - star wheel number of revolutions 0,37-1,11 rev/min After cooling all the pipes are passed by a roller conveyer from the fridge to straightening machines for leveling. The pipe leveling is done through 7-rolled straightening mills 2 mills.
Technical data of a straightening mill: - diameter of tube for leveling 38-240 mm - wall s thickness up to 50 mm - max diameter of tubes with wall s thickness 12,0 mm 240 mm - max diameter of tubes with wall s thickness 15,0 mm 220 mm - max diameter of tubes with wall s thickness 50,0 mm 160 mm - leveling velocity 0,47-1,2 m/sec - roll s length 600 mm - roll s diameter 360 mm - number of idle rolls 3 pcs - number of driving rolls 4 pcs - angle of rolls setup 24 0 32 30 0 32 After leveling on straightening mills the tubes are passed by a roller conveyer to a maintenance room (an overhaul stillage) where they are identified by wall s thickness, length, outer diameter, quality of inner diameter, quality of outer surface and hot stamping, the control of tubes curvature. Then the tubes are passed to the finishing area. The quantity of the main integral units needed for production of hot-deformed, case, drilling pipes; pipelines tubes; hollow sections; rolled clutches; torque bars with the help of Pilger mills 26 pieces. The total weight of the equipment of the pipe rolling area of hot finishing of the maintenance room is about 3,5-4 thousand tons. To the above listed it is necessary to add fitment of the calibrating mill and the reducing mill with stands with rolls for each produced tube diameter; with machines of roll shop for preparing the rolls and the triblets, with special machines models KZH-2613, KZH-50, KZH-2617MF1 for welding and facing of the rolls for Pilger mills, etc. 1. Storage of billet
Reheating furnace No 1 Piercing mill
Piercing mill Piercing mill
Pilger rolling mill (1) Pilger rolling mill (2)
Reheating furnace No 2 Sizing rolling mill
Tube-straightening machine Cooler, chain conveyor
1 Storage of billets 2 Furnaces No. 1 and No.2 3 Tilter 4 Piercing mill 5 Pilger mils No. 1 and No.2 6 Cutting machines (disc saws) 7 Stamping machine 8 Furnace No.3 (reheating furnace) 9 Calibrating mill 10 Reducing mill 11 Straighteners 2 units 12 Cooler (fridge)