Roller Forming Machine For Producing Round Steel Pipes With Wall Thickness From 2m To 6m

Roller Forming Machine for Producing Round Steel Pipes with Wall Thickness from 2m to 6m

Processing Range:

Round pipe production range: φ60-φ165mm
Square pipe production range: 50×50-125×125mm
Rectangular pipe production range: 40×60-150×100mm
Wall thickness: 2.0-6.0mm (round pipe), 2.0-5.5mm (square pipe)

Product Overview:

This line is primarily designed for producing electric-welded steel pipes with diameters ranging from 60 to 165 mm and wall thicknesses of 2.0 to 6.0 mm. It can also produce square, rectangular, and special-shaped pipes within the range of round pipes. By adding necessary equipment, it can subsequently produce API 5L pipe. This production line was designed and manufactured by integrating similar equipment from both domestic and international sources, taking into account my country's national conditions, and through bold innovation and extensive consultation with users. It boasts economical, reliable, and stable operation.

Steel Pipe Production Range

Production Process:

Uncoiling → Straightening, Clamping and Leveling → Shearing and Butt Welding → Looping → Forming, High-Frequency Welding, External Burr Removal, Online Zinc Refilling, Cooling, Sizing, Rough Straightening → Flying Saw Length Adjustment → Inspection and Collection → Packaging → Weighing → Labeling → Storage

Equipment Performance:

This hydraulic press has four major process steps: inner wall flushing, chain bed conveyor, pressure test center, emptying device, hydraulic system, and electrical system.

1)Flushing System: Includes alignment and flushing functions. A feeder device feeds the pipes quantitatively from the loading platform to the alignment station for alignment. A low-pressure centrifugal pump draws fresh industrial water, which is connected to the flushing head through various valves. This water removes impurities from the pipe before pressure testing begins to prevent residual impurities from damaging the seals on the equipment.

2) Chain Bed Conveyor Mechanism: Considering the wide range of cut-to-length lengths for pressure-tested steel pipes, the chain bed conveyor structure adopts the following configuration: the chain bed mechanism consists of two sets of independently driven chain beds. One set is fixed to the base with a fixed seat, maintaining its immobility. Support mechanisms are installed on the sides of the chain beds to prevent small-diameter steel pipes from bending when placed on the chains. Another set of chain beds is fixed to a movable seat (with support mechanisms installed on the sides) and moves to the corresponding position as steel pipes of different cut-to-lengths are used, ensuring smooth delivery of different cut-to-length steel pipes to the pressure-testing center. This structure facilitates pressure testing of steel pipes of varying cut-to-lengths without disassembling the chain beds and other mechanisms.

3) The dual-station pressure-testing center consists of a fixed seat, a movable seat, a fixed base, a pressure test head, a clamping device, a low-pressure water system, a high-pressure water system, and other components.

The pressure-test movable seat consists of a support, a main cylinder moving mechanism, a valve body, a latch mechanism, an exhaust valve body, and a main cylinder mechanism. The support is a welded structure that primarily supports the aforementioned components. Cylinder 5 in the main cylinder moving mechanism drives the valve body forward, allowing the pipe end to enter the pressure test head assembly. The latch mechanism is used when the pressure test pipe length is changed. The movable base is moved to the specified position by an AC2.2kW motor according to the specified length. The latch mechanism inserts a cylindrical pin into the corresponding position on the fixed base to position the movable base. The main pressure test cylinder assembly maintains balanced water and oil pressures when the pipe length increases. The exhaust valve body expels air from the pipe when water is flushed into the inner wall of the pipe. After exhaust, the air is released through the cylinder and the valve body is closed, ensuring stable pressure holding values and durations.

The pressure test fixed base consists of a support, valve body, water filling valve, cylinder adjustment mechanism, and water piping system. The main cylinder adjustment mechanism uses the cylinder to adjust the valve body to allow the pipe end face to enter the test head. The water filling valve opens the valve body to allow low-pressure water flushing to the pipe and closes the valve body to increase pressure and maintain pressure. The clamping device consists of a clamping mechanism, rollers, a wheel assembly, and a support. The clamping mechanism is operated by a hydraulic cylinder, which clamps the steel pipe on both sides and moves synchronously. The roller assembly adjusts the clamping mechanism's position according to pipe length. The roller assembly can be adjusted in height to suit pipe diameters, ensuring that pipes of varying diameters are always centered in the water pressure.

The test head is a radially sealed fitting made of polyurethane. The seals are replaced with corresponding seals for different pipe sizes. The hydraulic cylinder-driven automatic centering clamp allows for interchangeable center slips to accommodate pipes of varying sizes. This ensures excellent pressure sealing and a long service life. Three sets of test head assemblies are included: Φ60, Φ119, and Φ165. Other sizes can be customized or provided by the customer.

The water pressure system consists of a low-pressure water injection system and a high-pressure water filling system. The low-pressure water injection system utilizes a single-stage, single-suction centrifugal pump for automatic water supply from a low-pressure water tank, with an automatic air valve switching function. The high-pressure water filling system consists of a high-pressure plunger pump, a check valve assembly, and a bypass valve system. It performs radial pre-seal pressure testing and increases internal pressure within the steel pipe. It serves to pre-seal large-gap seals or directly increase and maintain pressure based on test pressure.

The water-draining device consists of an air blowing device, a lifting device, and a material retaining device. After the pressure is applied, the lifting device lifts the steel pipe, allowing the water inside the pipe wall to flow out. During this process, the material retaining device holds the pipe in place to prevent it from rolling. The air blowing device removes water and other impurities from the pipe wall.

Hydraulic System:

This system consists of an independent hydraulic station. The hydraulic oil should be changed every six months, and the tank should be cleaned of debris and refilled with clean oil.

Hydraulic System Performance Characteristics:

System pressure is configured according to area and usage requirements and is located nearby.

The hydraulic station tank has an external hydraulic oil cooling system and an oil collection trough on the top surface of the tank.

The hydraulic station utilizes manifold connections, and valve components are from Beijing Huade Hydraulics.

The hydraulic station is equipped with an oil level alarm system that automatically sounds an alarm when the oil level drops to a certain level, ensuring the oil level in the tank is maintained. The piping is neatly arranged, secure, and in compliance with requirements, making it easy to disassemble the unit and perform piping maintenance.