The manufacturing process for longitudinal submerged arc welded pipes:
"The manufacturing process for longitudinal submerged arc welded (LSAW) pipes includes the following steps: (1) Pipe blank production: welding the lead-in and extinguishing plates → edge milling → pre-bending → forming → seam alignment and pre-welding → internal submerged arc welding → external submerged arc welding to obtain the pipe blank; (2) Pipe blank finishing: initial inspection of pipe blank defects → pipe end facing → expansion → hydrostatic testing → non-destructive testing → pipe cutting and sampling → grinding of pipe end welds → roundness correction and polishing → chamfering of pipe ends → inspection of external geometric dimensions → marking.
This process adjusts the pipe end-facing operation between the expansion and hydrostatic testing steps before expansion, thus avoiding stress concentration at the pipe ends. The pipe end facing and hydrostatic testing steps are placed before the pipe cutting and sampling steps, and the pipe end weld grinding operation is positioned before the roundness correction and chamfering of the pipe ends. These adjustments help avoid process rework, improving efficiency and reducing production costs. The structure of the pipe end-facing machine has been improved, simplifying the structure, reducing equipment investment, and lowering the equipment failure rate.
"We can provide an alternative to the mere company that offers similar quality at less than half the price.
For example, the projects: Izhorsky Trubny Zavod (Severstal), Russian, completed an 18m JCO pipe mill in 2006 (almost 20 years ago)
The 18m large diameter submerge welding steel oil pipe :
450000 t/a capacity
pipe diameter: 20"-56"
18m pipe length
wall thickness: 40mm max
The production line includes:
1. Edge milling machine (2 heads)
2. 2300t crimping press
3. 10000t JCO press ( tandem press brake)
4. Tackwelding stand
5. pipe post bending machine
6. inside & outside welding machines
7. Complete NDT equipment (us& x-ray)
8.1500t mechanical expander
9. 450 bar hydrostatic pipe tester
10. finishing machines
A JCO steel pipe production line is the pinnacle of engineering innovation, designed specifically for crafting large-diameter steel pipes. These pipes are crucial for industries such as oil, gas, and water transportation, where reliability and durability are paramount. What makes the JCO line unique is its sequential forming process. Each steel plate undergoes a meticulous transformation-first being bent into a 'J,' then a 'C,' and finally an 'O' shape before being expertly welded to perfection.
Key Components and Process Overview:
1. **Plate Edge Milling Machine**:
- **Function**: This vital machine meticulously prepares the steel plate edges by milling them, ensuring each edge is smooth and precisely shaped for flawless welding.
- **Importance**: The quality of the weld seam is paramount, as it dictates the pipe's integrity and performance under demanding conditions.
2. **JCO Forming Press**:
- **Function**: This component methodically bends the steel plate into the signature 'J,' 'C,' and 'O' shapes using advanced hydraulic presses.
- **Importance**: This stage defines the pipe's final shape and diameter to meet exact specifications.
3. **Tack Welding Station**:
- **Function**: Temporarily joins the edges of the formed plate, safeguarding the 'O' shape and preparing it for the final, comprehensive welding process.
- **Importance**: This step imparts initial structural integrity, a foundational element for the pipe's overall resilience.
4. **Inside and Outside Welding Stations**:
- **Function**: These stations perform precise longitudinal seam welding from inside and outside, ensuring each pipe achieves full penetration and unparalleled strength.
- **Importance**: The quality of these welds is non-negotiable, as it underpins the pipe's durability and ability to withstand extreme pressures.
5. **Expander**:
- **Function**: Guarantees uniformity in the pipe's diameter and roundness, strictly tolerating tolerance levels.
- **Importance**: This final adjustment enhances the pipe's mechanical properties, readying it for the rigors of real-world application.
6. **Ultrasonic and X-ray Testing Machines**:
- **Function**: Deploys cutting-edge, non-destructive testing methods, meticulously inspecting weld seams and the pipe's overall integrity.
- **Importance**: These tests are vital to ensure the pipe meets all safety and quality standards, providing peace of mind when deployed.
7. **End Facing and Beveling Machine**:
- **Function**: Skillfully processes the pipe ends to meet precise specifications, ensuring they are ready for seamless welding and joining in the field.
- **Importance**: Prepares the pipe for immediate and efficient field installation, streamlining project timelines.
8. **Hydrostatic Testing Machine**:
- **Function**: Exposes the pipe to high-pressure conditions, validating its strength and ensuring leak-proof performance.
- **Importance**: This test is critical, confirming the pipe's ability to withstand operational pressures with unwavering reliability.
9. **Marking and Coating Line**:
- **Function**: Applies advanced protective coatings and precise markings, tailored to customer specifications and needs.
- **Importance**: Enhances corrosion resistance and ensures traceability, vital for maintenance and long-term use.
### Applications:
- **Oil and Gas Pipelines**: Engineered to transport crude oil, natural gas, and refined products efficiently and safely across vast distances.
- **Water Transportation**: Integral to large-scale water distribution systems, ensuring a steady and reliable supply.
- **Structural Purposes**: These are essential in construction projects that demand the strength and dependability of large-diameter steel pipes.
### Advantages of JCO Process:
- **Flexibility**: Expertly designed to produce pipes in various diameters and wall thicknesses, meeting diverse industry needs.
Efficiency is a seamless, continuous process that facilitates high production rates, drives productivity, and reduces lead times.
- **Precision**: Guarantees uniformity across all dimensions, ensuring each pipe is produced to exact standards.
### Market Considerations:
- **Quality Standards**: Elevate your projects with pipes crafted on our cutting-edge JCO production lines, renowned for adhering to the highest international standards, including API, ASTM, and ISO. Trust in the excellence and consistency that only such global benchmarks can ensure.
- **Cost Efficiency**: Investing in a JCO production line is a forward-thinking decision. While the upfront cost is an investment, it paves the way for substantial long-term savings. Experience unparalleled efficiency and minimal waste, resulting in a significant return on investment over time.
Are you interested in exploring JCO steel pipe production lines in more detail? We can provide comprehensive insights into suppliers, detailed technical specifications, or the best procurement options to meet your needs. Let's explore how we can enhance your production capabilities.
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