High Frequency Welded Pipe Mill 4mm In Thickness HG114

HG114 High-Frequency Welded Pipe Mill Line is designed to produce welded pipes of 50～101.6mm in diameter and 1.0～4.0mm in wall thickness as well as square and rectangular pipes and deformed pipes of the corresponding size. Adopting roll pass design, the production line can manufacture welded steel pipes with good quality machining and high precision assembling.

Ⅰ. According to the designing guideline of improving the operating character & environment and the safety & producing character, reducing the cost of the roller to guarantee high efficiency, HG114 production line adopts the double-radius hole style of design.

Ⅱ. Main Parameters and Specifications

1. Material Specifications:

Conforming to the YB189-64 standard .

Material: Low carbon steel and low alloy constructional steel

• Mechanical properties: σ_b≤520Mpa,σ_s≤340MPa
• Strip Width:160～320mm
• Strip Thickness:1.0～4.0mm
• Inner Diameter of Coils:φ480～φ510mm

Outer Diameter of Coils:φ1000～φ1600mm

Coil Weight:≤5T

2.(1)  Round Pipe Diameter:φ50～φ101.6mm

(2)  Wall Thickness of Pipes:1.0～4.0mm

(3)  Fixed Cutting length:4～6m

(4)  Pipe-cutting Precision:0～3mm

3. Forming Speed:20～60m/min

4. Power, Water & Air Supply

1	Power	Power Volume of the Line	Approx.800KW
		Power Source	380V/50Hz/3phases
2	Circulation Cooling Water	Flow	30T/h～40 T/h
		Pool Volume	60m3
3	Compressed Air	Flow	5m3/min
		Pressure	5～7kg/ cm2

5. Workshop: 8m wide, 100m long, at least 5m high from Ceiling Rails to Ground.

Ⅲ. Production processing:

Coil Loading →Cutting and Welding → Accumulator → Forming, HF welding, Deburring, Cooling, Sizing, Straightening →STD Cold-cutting saw →Transmitting → Packing → Storage

Ⅳ. Equipment composition and specification for each parts:

 

1. Single Mandrel Hydraulic Decoiler:

 

The decoiler is of the structure of double expansion and cantilever mandrels. It contains two main parts: main body and the fixed base. The main body is equipped with pneumatic system to satisfy the needs of expanding, contracting and braking of the mandrels.

 

 

 

OD of coil	Φ1000-1600mm
ID of coil	Φ480-510mm
Width of strip	160-320mm
Thickness of strip	1.0-4.0mm
Weight of strip	Max 5T
Expansion Type	Hydraulic increases
Break	Pneumatic driving

• Straight head machine and pinch leveling machine

Structure: The upper pressure roller device is controlled by a hydraulic cylinder, and the motor is actively driven, which drives the belt to rotate during unwinding. The blade controlled by the hydraulic cylinder is retractable and swingable according to the diameter of the steel coil to be disassembled, and it can adapt to the removal of the steel coil of various sizes. Coil OD Φ1000-Φ1600mm Coil width: 160-320mm Press roller transit motor AC3 Kw(simens,beide)   Structure Profile welding

 

 

3. shear and welder:

 

Automatic Cutting & Welding Machine is used to cut the irregular ends of the strips and then connect the strips by welding.

Strip width	160-320mm
Welding thickness	1.0-4.0mm
Cutting Type	Hydraulic shear
Welding Mode	Automatic

 

4. Spiral accumulator

 

This unit is main include in press& carry material device, accumulator assemble, carry off material unit, electric control unit.

It is main include frame, electric motor, brake unit, circling direction transfer power axle of the reduce velocity, press & carry roll, pressure air system of guide roll, inspected velocity unit; it can supply the strip steel to accumulator and the mean times it will transfer the carry velocity information to electric control system, when we demand stop carry the material to this unit, it will stop roll to the electric motor and press& carry material roll by the break, and also could adjust the velocity to carry electric motor and the unit carry material velocity.

Accumulator frame assemble: include the electric motor, frame , inner circle roll, out circle roll and pressure roll. It can be used to storage the strip steel material from press& carry unit and it could be draw from the center send-off material roll.

Send-off material device: include frame, guide direction rolls, guide out roll of high or lower place. It can carry the strip steel to shape system and send the carry out material velocity information to electric control device.

Technical parameters:

working style: change circle

Advantage: storage material more, no strike to strip steel suface.

steel coil thickness:1.0-4.0mm;

width:160-320mm

carry material going velocity:Vmax=180m/min

hydraulic oil pressure:7Mpa

directly electric motor power of the press & carry:22KW

the electric motor of the accumulator frame : 37KW

5. Forming & Sizing Mill

 

Forming & Sizing Mill adopts roller type forming principle and high-frequency induction welding. The strip is fed into the forming machine by the feeding device in the mill and the forming roller continuously rotate and press the strip into the required shape. Due to the skin and the kindred effect, the high-frequency current is concentrated on the weld joint that is heated rapidly and reaches the welding temperature. The tube seam is welded under the pressure of squeeze rollers. The finished welded tube with required size can obtained after the cooling, sizing and primary straightening.

 

Forming Pipe OD.	Φ50mm～φ101.6mm
Forming Pipe Wall Thickness	1.0-4.0mm
Forming speed	30-60m/min
Number. of forming stands, horizontal	7
Number. of forming stands, vertical	9
No. of sizing stands, horizontal	5
Number. of sizing stands, vertical	5
Turks Head	2 sets with single head
Shaft dia. and material of horizontal roll stand	Φ100mm, Material 40Cr
Shaft dia. and Material of vertical roll stand	Φ60, Material 40Cr
Bur Scraping Cutter	2 Sets
Main motor	110kw+132kw

 

6.Weld seam Anneal machine

 

(1) Basic requirments:

Pipe OD:Max φ101.6mm

Thickness:4mm

Max:40M/M

Skill requirements:Heat both sides of the weld (about 15mm in total width) to 900-950 degrees, and then cool naturally to room temperature.

(2) Equipment contain:

Each welded pipe production line needs the following two sets of pipe seam annealing equipment, including each set:

(1) A microcomputer controlled thyristor medium frequency power supply, power 500kW, frequency 2500-4000Hz.

(2) A mechanical positioning adjustment device for fixing inductor and output transformer.

(3) Temperature and speed detection, display, closed loop control device set

(4) Closed circuit water cooling system (optional)

(3) Facility requirements for users:

1. Power supply: three-phase four-wire 380V + 5% capacity 1200KVA AC incoming line requirements with cable cross-sectional area ≥600mm2

2. water supply:

The inlet pressure is greater than 1.5 kg and less than 2.5 kg

Water carring capacity>50m3/Hour

Water temperature>4℃＜40℃

Water quality:Softening the pH of circulating water:6.5-7.5

(4) Space requirments:

Indoor placement: each set covers an area of 2 meters × 8 meters No corrosive gas, no conductive electric explosion dust, no severe vibration

 

(5) Main features of main circuit

Computer control or large scale integrated circuit control, grades are optional.

Constant power regulation reduces the influence of power grid fluctuations and pipe diameter changes, and the heating temperature is stable.

With a variety of software and hardware anti-interference measures, and a variety of fault detection and protection functions, the equipment can work stably for a long time.

The inverter bridge adopts thyristor series connection, which makes the equipment work more stable and reliable.

The tank circuit part adopts voltage doubler circuit. Increased output voltage improves efficiency.

The quenching transformer not only plays the role of impedance matching, but also improves the safety performance by isolating the output voltage from the earth.

7.  After-sales service Before the equipment is adjusted and accepted, we will be responsible for free replacement of all components that can be damaged. The warranty period of our company’s equipment is one year. During the warranty period, we are responsible for free replacement of components damaged under normal operation and use, and we are responsible for replacement and maintenance of components damaged under abnormal operation, but the cost of the components By the demand side. During the quality guarantee period, if the equipment fails, we will send someone to the buyer to deal with the technical failure within 48 hours after receiving the notice if the traffic conditions permit. After the warranty period expires, if the equipment fails, we will still be responsible for repairs, but the cost of replacement parts will be borne by the purchaser.

 

7 Cold Saw

It is used to precisely cut the pipe to length automatically under the condition that the pipe continuously delivered from the mill at high speed. 1 drive motor:22KW/1500rpm servo motor(Japan Yaskawa) 2 feeding motor:5.5 KW/2000rpm servo motor(Japan Yaskawa),with break system 3 cutting motor:22 KW/1470rpm induction motor (variable frequency) 4 cutting reducer:special reducer for cold saw(speed ratio 7.6)

 

 

8. Flat head chamfering machine

This system adopts PLC to control automatic pipe splitting, step-by-step transfer, clamping, feeding and retreating, pushing and other actions.

The pipe management system first dials in two pipes and automatically separates them into the two pipe position slots.

After automatic left push, step the double station again to enter the right cutter head, the right automatically clamps, advances, retracts, loosens the clamp, and then steps the double station.

After the automatic right push, step the double station again to enter the left cutter head, the left automatically clamps, advances, retracts, loosens the clamp, and then steps the double station, and the exit tube enters the packing.

In automatic continuous operation, the actions of flattening, clamping, feeding, retracting, and loosening clamps will move simultaneously at the same time.

Processing steel pipe diameter:50mm-101.6mm

Processing steel pipe wall thickness: 1.0-4.0mm

Maximum tube length of flat head:6m

Flat head speed: 8-12 pieces / min

Flathead machine cutter motor:15KW(simens,beide), level 6, 2 sets

Stepping power: 11KW(simens,beide ,beide), 4 levels, 1 set (variable frequency motor )

 

9. Hydrostatic testing machine

Technical scheme and quotation of Φ50～Φ101.6mm four-station hydraulic press

1.  Overview;

The equipment is arranged in the finishing part of the straight seam steel pipe production line, and is used for water pressure test of the straight seam welded steel pipe. The technical level meets the requirements of the ASTM standard for steel pipe hydrostatic test.

2. Technical parameters:

Diameter range of test steel pipe: Φ50～Φ101.6mm

Length of test steel pipe: 4～6 meters

Test steel pipe material: low and medium carbon steel

Maximum test pressure of steel pipe: 5MPa (50bars)

Holding pressure time (can be set): 2～5sec

Number of roots per test (four stations): 4 roots

Sealing form: radial seal

Pressure test medium: emulsion/water

Low-pressure water filling method: pre-filled water

Pressurization method: pressurization cylinder pressurization

Equipment installed capacity: ≈90KW

Efficiency (holding pressure 5S): The maximum production rate is 12 pieces/min (1/2″ pipe), but the air supply pressure from the air compressor to the equipment shall not be lower than 0.6Mpa;

2. Work flow:

Upper pipe → align → chain transport to the water pressure center → clamp → fixed and mobile end test head extends to seal both ends of the steel pipe → low-pressure water fills with water, exhausts → closes the water filling valve and exhaust valve → pressurizes → protects Pressure→Relieve pressure→Retract the fixed and mobile end test head→Clamp to loosen→The chain sends out the steel pipe→The water is empty→The material is discharged

3. Equipment performance:

The pressure test machine designed and developed by our company has three processes: inner wall flushing, pressure test center, and air water device; the pressure test machine is a four-station pressure test system, horizontal, two experimental seat structure, chain conveying in and out.

3.1. Flushing system: includes alignment and flushing functions; the pipe fittings are transferred from the feeding platform to the alignment roller table by the transfer mechanism, and a low-pressure centrifugal pump extracts industrial fresh water, which is connected to four stations through various valve pipelines for flushing Head, clean up the impurities in the steel pipe before starting to suppress, to prevent the remaining impurities in the steel pipe from damaging the seals on the equipment;

3.2. Four-station fixed and mobile test seat: when the pipe fittings are tested for pressure, the pipe fittings are sealed by the sealing device (using radial seal) on the test seat, and the low-pressure water filling valve, exhaust valve and high-pressure control valve controlled by the four-station are opened. Or close to realize the pressure test function;

3.3. Sealing test head: It adopts polyurethane radial seal, and replaces the corresponding sealing device according to different specifications;

3.4. Clamping device: consists of two sets of pneumatic clamping; cylinder-driven automatic centering clamping, replacing the center block to adapt to different specifications of steel pipes;

3.5. Chain conveyor: It is used to transport the pipe from the waiting material rack after washing to the pressure test center position, and send the steel pipe after pressure test out of the working position. A chain device driven by a cycloid reducer is used to pass through the chain. The claw realizes the positioning of the steel pipe;

3.6. Low-pressure water filling: The combination of low-pressure centrifugal pump and air pressure water storage tank is used for pre-filling, and the pressure test tube is quickly filled and exhausted when working;

3.7. High-pressure water injection: using a combination of booster cylinders and pipeline accessories to achieve four-station booster;

3.8. Water emptying device: use cylinder lifting to empty the pipe fittings after pressure test

 

 

 

10. transit table

 

The finished pipes run along the Roll Table and to be automatically moved onto the Bench. Then simple Packing Machine packs the pipes in hexagon shape.

The simple packing machine contains container and pneumatically driven alignment equipment.

11. 400KW Solid State H.F.Welder

 

 

 

12. Electric control system

 

13. Hydraulic station

 

14.Roller :

The material :Cr12