The pipe mill process
A number of interacting operations are part of the overall pipe mill process. Three main process categories can be defined
Production
production machines are the key factor to the quality of thepipes which need to be produced as a general contractor for turnkey pipemill solutions haeusler offers all key machines as in house products therefore all critical sections of the haeusler pipe millprocess are produced from one source these key machines can also be used for the modernization of existing pipe mills all parameters which must conform to the relevant standards are set here based on their physical requirements and the factors which influence the process there are three production steps which have a main influence on the pipe quality
Quality Control
The inspection stations include all process steps in which the pipe is inspected as requiredby the different international standards
Pipe Transport
Pipe transport within the plant is essential for the efficiency and flexibility of a pipe mill since it forms the link between the various individual steps
Forming of pipes
In a haeusler pipe mill, forming is carried out in two steps: roll bending of the plates into cylindrical shells and the following post-bending of the remaining straight ends. this quick and efficient forming process ensures top quality and short cycle times. roll bending with the haeusler 3 roll bending machine rms after the milled plate is automatically fed and aligned in the machine the cnc controlled roll bending sequence starts in two to three forming steps the plate is formed into a cylindrical shell during pipe conveying the next plate can be loaded only haeusler rms offer the unique option to produce pipes in two different processes
FORMING WITH A PRE STRESSED TOP ROLL
The conventional way of rounding large pipes in a diameter range of 20 to 64 is to use a pre stressed top roll in combination with a variable bottom roll distance this guarantees optimum utilization of the installed bending power while maintaining a consistent pipe quality the complete diameter range of the plant can be covered using two to three top rolls which can be quickly chaned
FORMING WITH SUPPORTED TOP ROLL A HAEUSLER INNOVATION
as a result of the further development of the RMSS HAEUSLER added the supported top roll which opens up an extended wall thickness range for pipes diameters from 16- 32” this new feature combines the advantages of roll bending with capacities previously reserved press forming processes
POST BENDING ON THE HAEUSLER NABM
Using the efficient post bending machine nabm the remaining straight ends are rounded by using forming rolls.the post bended pipe is ready for welding.WELDING OF PIPES
The welding of the pipes is one of the most demanding production steps within the pipe mill. It is done in three steps: Continuous root welding (GMAW) 2. Internal submerged arc welding (SAW) 3. External submerged arc welding (SAW)CONTINUOUS ROOT WELDING WITH THE HAEUSLER CRWM
the open pipe will be fed through a hydraulically controlled cage for proper alignment of the edges and continuous root welding. to weld the pipe without offset and with homogeneous seam are the main quality criteria within this process. additional to the pipe assembling the root weld serves as backing for the following internal welding. simultaneous closing transporting and seam tracking of the pipe as well as controlling the welding parameters are run by an easy to use cnc system. the integrated digital weld control and laser tracking systems ensure high and reproducible pipe quality.
INTERNAL AND EXTERNAL WELDING
Both internal and external welding is carried out by stationary multi wire submerged arc welding while the pipe is transported on a carriage & or internal welding the multiple wire welding head is mounted at the end of a self supporting boom in which the supply for wires and flux are integrated . for external welding these components are fitted on to agantry with a height adjustable operator platform the speed of the pipe carriages is precisely controlled to match the welding parameters The flux supply and recovery system as well as the electrical grounding system are integral parts ofall haeusler welding stations. Depending on the required output two or more internal and external welding stations are integrated into the production line
QUALITY THROUGH FULL BODY PIPE EXPANDING
Expanding is the final forming step in the production of pipes – it defines the final shape Of the pipe in order to meet the required standards.FULL BODY PIPE EXPANDER CMR
During expanding the pre washed pipe is fed over a tool which radially expands the pipe Step by step. The tool is fitted on to a boom and contains Radially expanding segments which are pushed by a hydraulically actuated cone This processe xpands the pipe to achieve the required tolerances for out of roundness and straightness . Haeusler offers the complete equipment including pre washing pipe expanding Expander tools post washing and water treatment.
