Φ160 Hot-Finished Seamless Tube Production Line Project
1, SUMMARY
1.1 The summary of the project:
The buyer decided to build a new φ160 Assel floating mandrel mill. The main equipments includes two conic-rolls hot piercing mill, Assel floating mandrel mill, high-pressure descaling, three-roll sizing mill (10-stand), chain-type cooling bed, Based on the buyer’s technical requirement including layout of whole plant, technical index, supply range, non-supply range, technical service range, drawing and design, We agreed as under all details.
1.2 The specification of finished products:
① the range of outside diameter: φ73mm~φ114mm wall thickness: 5mm~8mm
the range of outside diameter: φ114mm~φ133mm wall thickness: 8mm~10mm
the range of outside diameter: φ133mm~φ160mm wall thickness: 10mm~25mm
the range of each length: 6.5meter~12meter
② main steel grade of production: Carbon Steel, Low Alloy Steel
③ Standard of Seamless Steel Tube:;
Linepipe: ASTM A106/A53/API SPEC 5L
Boiler Tube: ASTM A179/A192,etc.
Mechanical Tube: ASTM A159, etc.
OCTG: API SPEC 5CT
1.3 the precision tolerance :
O.D. tolerance: -/+1%
W.T. tolerance: 5~20mm -/+12%
Above 20mm -/+8%
1.4 the billet details:
φ90mm~φ180 hot-rolled round billet
the length of billet: Min. 1.2meter~Max. 3.5meter
1.5 the standard of the project:
it takes the standard of design to design, manufacture, test and packing. We follow Chinese national standard and Chinese machinery department standard as under,
International Standard Organization ISO
Chinese national standard GB
Chinese professional standard ZB
Machinery department standard JB
Metallurgy department standard YB
We, PRECESE, design, manufacture, test, packing follow the rules as under,
GB/T13384
GB985
GB986
GB923
SDZ014
GB1182-1184
GB1031
GB10095
TY231-4
GB1800-1804
GB191
GB700
GB1591
GB699
GB976
GB981
GB3077
Others: all screw, thread, shaft, plug all follow the metric system by GB standard.
2, Two conic-rolls hot piercing mill
2.1 Main Index of the equipment:
Diameter of roll: φ600~φ750mm
The length of roll: 520mm
Feeding angle (adjustable): 6°~9°
Rolling angle: 15°
The running speed of roll: Max. 110rpm
Main Motor: 1250KW, 10KV, 765RPM, AC, 2 sets
The rate of reducer: i= 7.5~8.5
The model number of reducer: ZLY-800
The flange press: human power, electric & mechanical way
The life distance of guide plate: 250mm
Index of centering roll setting:
1, hydraulic type
2,number of steadiers: 5
3, adjustment distance range
3.a. hold pointing rod: φ55~φ150mm
3.b. hold raw tube hollow: φ85~φ200mm
Index of piercing trolley:
1, main gearing: chain type; wheel move type;
2, move speed of trolley: Min. 2m/s
3, adjustment distance range of point rod: 200mm
Index of holding rolls and transit material:
1, two positions of holding rolls, hydraulic driving
2, the first one is main driving, the rest are passive ones.
3, star-type electric material transit.
The way of pushing billet: cylinder type
2.2 Main Index of the tube shell:
O.D. of Tube Shell: 95mm~190mm
W.T. of Tube Shell:10mm~30mm
Length of Tube Shell: 3.5meter~6meter
2.3 Buildup of the equipment:
Mainly includes piercer main driving, billet pusher, host machine of piercer, centering roll set, piercing trolley, hydraulic pressure system, oil lubricating system, high Voltage and low Voltage electric-control system.
Main driving includes main motors, main reducers, barrel coupler, universal-joint spindle and its bases. The main function is transferring the driving power through rolling moment to the rolling rolls.
The billet pusher includes loading groove, pushing cylinder, pusher rod, billet cover. It pushes the billet which centered well from loading groove to hot piercer for rolling by cylinder power. The centering line, the length of pusher can be adjusted according to the billet size.
Host Machine includes piercing stand, piercing rolls, roller setting, balance setting, loading and output guide, guiding disc setting, frank-pressure setting, loading groove and output groove. The stand contains base, cover and make it to be sealed frame, the material of frame is casted steel, the property is very stable; the rolls put at the right side and left side of the stand, the rolls can move inside of stand to adjust the size according to the production request. Upside guide plate can be adjusted through movement of the square hole at the cover of guide base. Piercing mill is the elongation device that make heated billet into seamless tube hollow. The gap of rolls and guide plates can be adjusted according to the production request. The gap between rolls and guide plates can be controlled by screw pole screw, lockup back controlled by oil cylinder, then it can make sure the reduction of gap between screw pole screws and make sure the balance power of rolling, make sure the stability of rolling. Loading and output guide groove is make sure the stability of input and output of material , make the centering line at the same line without huge movement.
The centering-point rolls set includes centering-point rolls, holding set, transit set and steadiers. The centering rolls hold the pointing rod at the same line with rolling line. During the rolling, the centering rolls will open its clamp one by one when the pointing rod go inside of the piercer, and meanwhile hold the raw tube hollow, makes sure the tube hollow move along with the pointing rod and make sure its good straightness. After piercing rolling, the holding rolls move upside and centering open fully, the material transit move the material to the material table.
The pointing rod trolley contains piercing trolley, portal frame setting, driving, withdraw tube device, transit roll, cooling setting. The pointing rod installed at the front flange of the trolley, it moves through chain driving; before rolling the head of rod put inside of gap between rolls and guide plates which built the profile, meanwhile the trolley has been locked inside of portal frame; So, the pointing rod is the important device which must withstand the axial force of rolling. The key damage of rod is the strength of rod and coupler of trolley. After piercing, the withdrawn of point rod will be done when trolley move back, point rod will be cool down when the water spread, the water from inside pipeline, and the transit device transit the material into table.
Hydraulic system includes oil pump station, valve, pipeline of hydraulic station. It supplies power for material transit, rolls, flank pressure, balance setting, loading and output guide groove, lockup of guide plates, centering rolls, rolls hold setting and material transit.
Oil lubricating system includes oil box, pump, valve and pipeline of the station. It supplies lubricant and cooling condition for gear and bearing of reducer.
Electric control system
1, Power Supply System
Low Voltage power supply is three phase 380V, AC, 50Hz, two sets
High Voltage power supply is three phase,10KVAC, 50Hz
2, Electric Driving
Main driving adopt 2 sets of 10KV high-voltage wound rotor type motor and start-up of water electric-resistance.
The power supply system of trolley adopt frequency conversion velocity modulation system.
The motor of pump of hydraulic system, lubrication system, transit roll and adjustment motor adopt normal AC driving method.
3, Control System
Electric control adopt PLC control system or master controller, mainly execute the procedure control and adjustment of whole mill, execute relative equipments and relative professionals’ coupling, chain-action to make sure the whole mill running according to production requests smoothly, precisely and correctly.
4, Safety Interlock
When the main driving, oil lubrication system works well, the main driving will get power supply safely; when the oil pressure, oil temperature, oil level beyond the alarm alert level, the panel and operation room light and sound will be on, it will maintain some time.
If the alert can’t be removed, the main driving will stop moving after previous tube produced, and meanwhile give out the reason of disability.
If the main currency work beyond the limited currency or work more than safe time when beyond, the main driving system will be cut automatically and showed disability alert.
When the piercing working, the trolley will be in the lock situation, then the billet pusher will be allowed to work; when the adjustment situation is on, the lock is off.
Main motor cooling system is OK, the main motor can work.
The transit device turn back to zero, the piercing trolley can work smoothly; when the trolley at lock situation and non-zero level, lift-roll, transit hook not allowed to work.
5, Power supply and environment condition
Power supply condition 10KV AC-/+5% 50Hz-/+2%
380KV AC-/+10% 50Hz-/+2%
220KV AC-/+10% 50Hz-/+2%
Sea level <1000m
6, Predict of Electric Panel Quantity
High voltage closet of main motor: 2 sets
Water electric-resistant start-up closet of main motor 2 sets
Low voltage controller 3 sets
Electric panel 2 sets
7, equipments and material test and quality standard(electric professional standard)
GB50052-95
GB50054-95
GBJ65-83
GB50055-93
GB50254-96
GB50168-92
GB50093-2002
GB50052-95
CECS49: 93
GBJ232-82
2.4. Supply range:
1, main driving: main motor (1250KW/10KV) 2 sets, barrel coupler 2 sets, reducer 2 sets, cardan shaft 2 sets, base 4 sets
2, main host machine: base, cover 1 sets, roll assembly 2 sets, flank pressure assembly 2 sets, balance assembly 2 sets, guide barrel 1 set, upside and downside guide plate assembly 1 set.
3, auxiliary parts: billet pusher, transit material table.
4, piercing trolley of rod: trolley, portal frame, driving setting, transit roll
5, centering roll set: 5 steadiers, hold-roll setting, material transit, base plate
6, hydraulic station: pump station, valve, pipeline of station
7, electric control system: main operation panel, power cabinet, control panel
8, high voltage system: phase receiver, control panel, power cabinet
9, oil lubrication station: 1 set
2.5. Non-supply range:
1, the medium of hydraulic and lubrication station
2, installation material: base screw, washer, screw nut, packing steel, water, gas, electricity, liquid and its pipeline, cable, walking bridge in the mill.
3, tooling of piercing mill includes guide plates, pointing rod, PM plug, etc.
3, Assel floating mandrel mill
3.1 Main Index of the equipment:
Floating mandrel mill; quick-open type; sealed Assel stand
Diameter of roll: φ330~φ400mm
The length of roll: 380mm
Feeding angle: 0~20°
Rolling angle: 0°
Main Motor: 600rpm, 760V, 2000KW, DC
Pushing mandrel bar setting:
1, ready pushing way: clamping rolls
2, pushing mandrel way: cylinder
3, movement method: wheel roll
Backstage of Assel mandrel mill:
1, open and close of tube cover: cylinder
2, the movement way of mandrel and tube shell: single driving motor of wheel roll
3, transit material: cylinder type
4, withdraw the mandrel: chain-driving
5, cooling way of mandrel bars: water cooling
3.2 Main Index of the tube shell:
O.D. of Tube Shell: 85mm~175mm
W.T. of Tube Shell: 5.5mm~25mm
Length of Tube Shell: Max.11.5meter
3.3 Buildup of the equipment:
Mainly includes main driving, front stage, host machine of mandrel mill and the back stage of mandrel mill, hydraulic pressure system, oil lubricating system, electric-control system with high voltage and low voltage.
Main driving part is the same as piercing mill.
Front stage of Assel floating mandrel mill includes loading groove, tube cover part, mandrel pusher, mandrel transit roll, mandrel cooling system.
Main host machine includes stand assembly, roll assembly, quick-open setting, angle-adjustment setting, downside roll adjustment setting, cooling setting and lubrication setting.
Main stand consists of two steel rings, the material is casted steel, strength is strong and stability is also good; three rolls put inside of the stand with 120°angle, and rolls can move smoothly within guide rail, the gap between rolls can be adjusted as per production request then lock up, make sure the stability of rolling, quick-open setting is to open the stand quickly when the rolling job is over to avoid triangle defective of tube. The angle adjustment setting is for different material, size and other production requests.
The back stage of the mandrel mill includes roll holding setting, tube cover part, transit setting, mandrel withdraw setting, mandrel lubrication setting, tube cutter for head and end, material table, transit rolls. The backstage function is to withdraw the mandrel bar from the raw tube hollow, move them back to frontstage for cooling, and cut their head and end, move to next step.
Other parts refer to Piercing mill’s data.
3.4. Supply Range:
1, Main driving: main motor (2000KW/760V) 1 set, barrel coupler 6 sets, reducer 1 set, cardan shaft 3 sets, base 3 sets
2, main host part: Assel stand 1 set, roll assembly 3 sets, quick-open setting 2 sets, angle adjustment setting 1 set, downside rolls adjustment setting 1 set, cooling 1 set, lubrication setting 1 set
3, the front stage of Assel mill: material loading groove, cover assembly, mandrel pusher, mandrel transit roll, tube head cutter, tube end cutter, material table, transit roll
4, the hydraulic station: pump station, valve , inside pipeline
5, the electric control system: main control panel, power cabinet, control panel, DC cabinet
6, oil lubrication station: 1 set
3.5. Non-supply range:
1, the medium of hydraulic and lubrication station
2, installation material: base screw, washer, screw nut, packing steel, water, gas, electricity, liquid and its pipeline, cable, walking bridge in the mill.
3, tooling of Assel mandrel mill includes mandrel bar, rolls, adjustable pad
4, high-pressure descaling
4.1 Main Index of the equipment:
The working pressure: 18Mpa
High-pressure pump: 90KW, 2 sets
4.2 buildup of the equipment:
Descaling setting, pump unit, spray unit, spray ring, high-pressure valve, high-pressure pipe, lubricating system.
5, Three-roll 10-stand tube sizing mill
5.1 Main Index of the equipment:
Diameter of roll: φ380mm
The length of roll: 142mm
The number of stands: 10 stands
The gap of stand: 370mm
The temperature of rolling: 900~950℃
Main Motor: Z4-250-41, 750~1000rpm, 440V, 110KW, DC, 10 sets
The loading speed: 0.5~1.2 m/s
The out speed: 0.7m/s
The consumption of water: 50m3/h
The cooling water pressure: 0.3~0.4Mpa
The overload ratio: 2.2
The reduction rate of each stand: 1%~3%
The Max. reduction of whole sizing mill: 23%
5.2 Main Index of the tube:
O.D. of Tube: 73mm~160mm
W.T. of Tube: 5mm~25mm
Length of Tube: 6.5meter~12meter
5.3 Buildup of the equipment:
10-stand Sizing mill includes stand setting, host machine, roll change setting, main driving.
1, stand setting
Sizing stand is key part of the sizing mill, it’s the tooling to make O.D. sizing happened. It includes inside driving system, stand assembly, water pipeline, dry-oil pipeline, etc.
Inside driving setting is key part of sizing stand, it includes gear-type coupler, two pairs of spiral gear wheel, bearing, one main driving shaft, two slave driving shafts, rolls, seal etc. components. When the stand installed inside of sizing mill, main driving shaft will connect with inside gear ring and give running power to main driving shaft, then main driving shaft pass power to two slave driving shafts.
Stand assembly is the backup equipment of inside driving setting, includes two casted steel stands connected by strong screw, and one of them is adjustable screw which can do position job.
2, host machine of sizing mill
Main host machine contains C-type main base assembly, loading guide assembly, output guide assembly, cooling water pipeline. It’s base equipment of stand and main driving, it includes main components as under
A, C-type main base assembly includes main driving shaft assembly, quick water spray assembly, press cylinder assembly, C-type main base.
Main driving shaft assembly is transition axis assembly of driving rolling torque, totally 10 sets. They installed at the 10 positions in the base, the one side of main driving assembly connected into coupler and reducer’s coupler, another side connect with sizing stand.
Press cylinder assembly contains hydraulic cylinder and its base. Hydraulic cylinder installed in the base by screw, press cylinder installed in C-type base with 90°angle opposite to base, oil cylinder connect to presser, when the oil cylinder works, it will press 10 stands fix at whole sizing mill.
B, loading guide assembly
It includes guide base and guide.
C, output guide assembly
It includes guide base and guide.
3, Roll change equipments
Roll change setting is to change rolls according to tube size, oil lubrication maintain, or other production requests. It contains stand withdraw setting, transit roll setting.
A. stand withdraw setting
Stand withdraw includes two sets of long-distance hydraulic cylinder, beam clamp, pusher, draw hook, slipper, base.
B. transit roll setting
Transit roll includes guide roll, base, guide press plate.
4, main driving equipment
Main driving equipments includes main motor, main reducer, coupler.
Main motor lays two layers and put at mal-position, every layer put 5 main motors. Upside motors connect to main reducer is barrel type gear coupler , its length is longer, so it needs base for the coupler to make sure the stability. Downside motors connect to barrel type gear coupler directly.
5.4. Supply Range:
1, main stand, main driving setting( including reducer, coupler, shaft) 10 sets
2, 10 sets sizing stand, lock setting, roll change setting
3, hydraulic system
4, main motors 10 sets
5, DC setting
6, PLC control adopt SIEMENS S7-300
7, upper computer adopt SIEMENS WINCC
5.5 Non-Supply range:
1, the medium of hydraulic and lubrication station
2, installation material: base screw, washer, screw nut, packing steel, water, gas, electricity, liquid and its pipeline, cable, walking bridge in the mill.
3, tooling of sizing mill includes rolls, backup sizing stands
4, commutator transformers for DC motors
6, chain-type cooling bed
6.1 Main Index of the equipment
Size of the cooling bed:12.5meter (width)*20meter(length)
Chain driving: 2.2KW
Transit setting of material: 5.5KW
The model of pin-cycloidal: BWET163-87X17-2.2/4
6.2 Buildup of the equipment
Chain-type cooling bed contains loading transit roll, star-type transit device, cooling bed structure, output material table, transit roll for output.
Loading transit roll take the tubes from sizing mill, loading transit roll transport the all tubes into mechanical buffer, and meanwhile send information to star-type transit device, put the all tubes into cooling bed, then do cooling down job for all tubes. Chain-type cooling bed includes main driving, positive driving chain assembly, passive chain assembly, cooling bed setting, chain-holding device, it moves the tubes step by step slowly to make the cooling averagely; during the cooling, this setting can make the tube avoid bending, after cooling down, the tubes being moved to next step.
6.3. supply range:
1, main driving (including driving shaft, pin-cycloidal reducer)
2, chains
3, positive and passive chain wheel and its cooling bed, transit rolls
4, loading and output transit rolls and its material transit setting
5, electric control system
6.4. Out of supply range:
1, the medium of hydraulic and lubrication station
2, installation material: base screw, washer, screw nut, packing steel, water, gas, electricity, liquid and its pipeline, cable, walking bridge in the mill.
7, the information the seller must supply:
7.1 provide groundwork drawings within 30 days after signed the contract
7.2 provide layout drawing based on the plant drawing by the buyer
7.3 provide the drawings of the damageable and consumable
7.4 provide the model of standard parts, quantity and supplier
7.5 provide the spare parts for installation, adjustment
7.6 provide technical service when the installation starts by the buyer
7.7 corporate with the buyer for installation and commissioning.
8, the parts the buyer have to prepare
8.1 responsible for all tooling of tube mills (PM plug, PM rod, guide plate, guide barrel, mandrel bar)
8.2 sizing stands
8.3 do the groundwork after got the drawings from the seller
8.4 purchase all components for installation based on the list by the seller
8.5 responsible for water supply, power supply, hydraulic supply, pneumatic supply and their installation
8.6 responsible for the corporation of staff, equipments, and material
9, Installed Capacity:
9.1. installed generation capacity: 6700KW (includes DC installed generation capacity: 3275KW)
9.2. its not includes all furnace, high-pressure descaling, water treatment, crane, air-pressure machines, light power use, repair power use.
