lsaw presentation june 2010

8/8/2019 LSAW Presentation June 2010

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CALVERT GROUP

Year 2010

SAWL PIPE MILL PRESENTATION


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The registered capital and total investment of

US$50 million and US$98 million respectively.

Covering a land area of 170,000 m2.

Company is conveniently located on Yangtze

River Delta Region

Main Shipping Port, 10 kilometers away from

Yangzhou Port.

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About Us


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Calvert Group has been well know for spiral

welded pipe and casing & tubing. 2009 was

the beginning of the most advance Longitud

e Weld Mill in the worlds today.come see f

or your self.!

The Company spent less than one year and a

half from the groundbreaking date to fullload commissioning:

Groundbreaking date: April 31, 2008

Full load commissioning: August 31, 2009

67mm thick x 22 meter press

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Diameters rang : 457.2 (18) to 1524 (60)

Wall thickness range : 6.0mm to 67.0mm

Material Grade : API 5L - A to X80 and EN10208 L245 to L555

Annual Production : Tonnage capacity Annually 380,000 @ 20 diameter

East Bay Lineest Bay Line

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State-of-Art Equipments


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This state-of-art plant has the advanced hydraulic tester, X-ray flaw detector, ultrasonic flaw detector, physical & chemical lab, and other

testing equipments. The MES control system is adopted to manage the production and dispatching. And the SCADA system is adopted

to collect data and monitor the process to realize the integrated and real-time production management.

Ultrasonic phase array tester Monitor & Control Center

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PREQUALIFIED & APPROVED PROCEDURES

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The Company operates the most advanced JCOE pipe production line in the world and installed the most automatic process

control from plate feeding, pipe forming, pipe delivery, to data collection, CCTV monitoring and testing data SCADA system

which is available 24/7 via internet

Process Flow Diagram

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The steel plates will be traceable by their bar codes, specifying the specification, material, plate No and batch No, marked on the

plate body and filed into the SCADA system at their entry. After the pipes are manufactured and warehoused, they will be transferred

and traced through the customer quality system. The bar codes can not only indicate the pipe quality, but also monitor the

manufacture processthe multi-times scan during the manufacture process can trace the manufacture route, pipe classification and

finished product storage area. We keeps electronic file of each steel pipe it manufactured combining its steel plate info and

inspection result for future use and reference of the customers.

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SCADA (Supervisory Control and Data Acquisition) is adopted to collect technical and quality data at each major process and monitor

the process with WinCC system, and thus indicate the real time operation status of the machines, control the technical index,

diagnose the failure part and ensure the normal operation of the process. The SCADA system can also collect physical & chemical

testing result and online testing result, and than file the testing results into the database after the bar codes for reference of the

related departments or customers.

SCADA

monitor

interface

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MES (Manufacturing Execution System) can assist SCADA to monitor the manufacture process from the aspect of management

procedures. MES manages and analyzes the contract signing, production planning, quality control, marketing & sales process,

inventory, finance etc. By analyzing the data it collected, MES system can provide the managers with necessary management

guideline as production capacity, pricing and production planning. The customer may monitor on line the real time equipment,

process and quality related data.

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OA (Office Automation) can realize no-paper office, and office automation by virtue of LAN. It can also provide remote support to

the out-of-office officers and sales staff through WAN. OA can improve office efficiency, reduce operation cost, and enhance

product competitiveness.


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This system is designed to monitor the real time plant operation, especially the major equipments.

The customers may observe the plant production on line when authorized.

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During the forming process, the steel plates are uniformly deformed with little residual stress and less vulnerability to

scratches. This process can customize steel pipes for the clients regarding to the diameter and wall thickness.

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Weld cross section seam

The tack welding and interior/exterior welding can improve welding speed and quality and control weld efficiency.

Tack weldingExternal welding

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Full length mechanical expansion guarantees the preciseness of pipe dimensions, straightness, and improve the internal

stress distribution.

Full length mechanical pipe expansion

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Phase array ultrasonic flaw detector

This process uses the phase array ultrasonic detector to provide reliable and precise inspection results. Different from the

conventional ultrasonic equipments, it can not only detect the location of the flaw, but also the shape of it .

Phase Array Ultrasonic Flaw Detector

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The Company has a PPF5200/130 CNC forming machine, whichproduces steel pipes using JCOE process; a closed loop tack welder; a interior welding machine (4 welding heads), a exterior welding machine (5 welding heads), an upgraded expansion machine, and a phase array ultrasonic flaw detector.

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Plate Detection Equipment

The multi-channel automatic digital ultrasonic flaw detector can scan the whole

plate surface. The special dual-crystal straight probe and inspection gate can save and print out the flaw wave.

Ultrasonic flaw detector for steel plate

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Plate Edge Milling Machine

Mill the two sides of the plate to meet the requirements concerning width, edge parallel degree and groove shape.

Specification

Milling units : 4 sets

Diameter of cutter head : 800mm

Groove types : X type, straight type, single bevel

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Crimp the edges of the plate for required curvature.

Specification:

Nominal pressure of squeeze head : 220MNMovement for each squeeze : 2200mm (max)

Thickness range of steel plate : 6-64mm

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Edge Crimping Machine



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Bend and form the crimped steel plate using JCO formingprocess into open pipe blank.

Forming Machine

Specification:

Nominal pressure : 52000KN

Main cylinders : 6

Diameter of formed pipe : 508 -1524mm

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Tack Welding Machine

Perform constant full length tack welding with MAG on the formed steel pipe.

Specification

Adjustment for roller beam : Mechanical adjustment

Roller beams : 9

Welding method : CO2/Ar MAG welding

Welding tracking system : Laser tracking


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Interior Welding Machine

Weld the inside longitudinal seam of the tack welded pipe with fixed welding heads by moving the pipe.

Specification

Welding heads : 4

Welding current : Direct Current 400-2000A

: Alternating Current 300-1200A

Welding head tracking system : Mechanical tracking


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Exterior Welding Machine

Weld the outside longitudinal seam of the inside welded pipe with fixed welding heads by moving the pipe.

Specification:

Welding heads : 5

Welding current : Direct current 400A-2000A

: Alternating current 300A-1200A

Welding head tracking system : Laser tracking

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Expanding Machine

Expand, straighten and round up the pipe on the full length basis to improve the dimension preciseness and internal stress

distribution of the steel pipe.

Specification:

Nominal tensile force : 1600 ton

Expanding frequency : 15-18 seconds for each time

Expanding ratio : 0.8%-1.5%

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Hydrostatic Tester

Using the end face sealing technology, it can increase pressure rapidly while recording the pressure curve automatically.

4000 3 50 Mpa 25MPa

25MPa

Specification:

Maximum load-bearing capacity : 4000 ton

Testing pressure : 3-50 Mpa

Seal form : end pressure 25Mpa

: radial pressure 25Mpa

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End facing Machine

Level the pipe end with rotating cutter heads for the required groove and edge.

Specification

Pipe end groove : flat end or beveled end

(subject to the specification)

Wall thickness range : 6.0-50mm

Diameter range : 508-1524mm

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Automated Ultrasonic Inspection Equipment

The advanced phased array automated ultrasonic inspection equipment consists of four inspection system: L-system, T-system,

HAZ-system, and E-system. Yalian is by far the first and the only company adopting phased array ultrasonic flaw detector in China

for online inspection.

Specification

Testing method : pulse echo method

Detection channels : 24

Probe : phase array probe

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X-ray Real-time Imaging and Pipe End Filming Inspection System

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Magnetic Particle

Flaw Inspector

Detect the flaws at the pipe end with

alternating magnet yoke magnetization method.

CJE-220HP Alternating Magnet Yoke Magnetic Particle Flaw Inspector

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Quality Assurance

Equipped with Ultrasonic Flaw Detector for Steel Plate, Ultrasonic Flaw Detector for Welding Seam, X-ray Flaw Detector, Aut

omatic Weighing and Length Measurement Equipment, Hydraulic Tester, Magnetic Particle Flaw Inspector etc., the production line can realize 15 100% quality inspections.

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1.) 100% physical and chemical test for the steel plates by furnace batches

2.) 100% inspection on the plate dimensional

3.) 100% automated ultrasonic testing for the steel plates

4.) 100% automatic ultrasonic testing on welding seams before expanding

5.) 100% ultrasonic testing on end welding seams before expanding6.) 100% industrial TV inspection on welding seams before expanding

7.) 100% hydrostatic test

8.) 100% automatic ultrasonic testing on welding seams after hydraulic test

9.) 100% ultrasonic testing on end welding seams after hydraulic test

10.) 100% shooting on the end welding seams after hydraulic test

11.) 100% industrial TV inspection on welding seams after hydraulic test

12.) 100% magnetic particle testing on the end welding seams after hydraulic test

13.) 100% automatic weighing and length measurement

14.) 100% inspection on the pipe dimension

15.) 100% physical and chemical test for the steel pipes by furnace batches

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Quality Assurance


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The physical and chemical laboratory is equipped with advanced equipments for inspection and experiment purposes, such

as microcomputer controlled electro hydraulic servo universal tester, microcomputer controlled metal pendulum impact tester,

direct-reading spectrometer, large metallurgical phase microscope, drop weight tear tester, hydraulic blasting tester etc.

Microcomputer controlled electrohydraulic servo universal tester1000kN

Main function:

Test the tension, compression, bending and other

properties of the metal materials with auto-contro

lled strength, distance, speed etc.

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Quality Assurance


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Main function: determine the impact tolerance ability of the metal materials, featured by strong impact power,

automatic pendulum movement and high efficiency.

Microcomputer Controlled Metal Pendulum Impact Tester (600J)

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Quality Assurance

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Main function:

Analyze the carbon and sulfur contents in steel, cast iron, copper, alloy, cement, porcelain, sand and other solid

materials with the latest burning technology.

HF infrared C-S analyzer

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Quality Assurance

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Vickers

Main function: determine the Vickers hardness value of the metal materials, which can be converted into o

ther hardness value automatically.

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Quality Assurance

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Large-size metallurgical phase microscope

Main function: digital photo taking and automatic metallographic analysis system with the magnification of 321600ca

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Quality Assurance

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Direct-reading spectrometer

Main function: make prompt quantitative analysis on 30 elements of solid steel & iron and alloy with high precision.

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Quality Assurance

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Drop weight tear tester5000J

Main function: test the dynamic tearing and drop weight tearing of metal materials with strong impact power.

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Quality Assurance

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Hydraulic blasting test

91423.8mm X80API Spec 5L YL09A42132.5MPa 34.1MPa1950mm : 1020mm

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Quality Assurance

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Measure the length and weight of the pipe, and save and print the data automatically.

Automatic weighing and length measurement equipment

Weighing scope: 70022000kgWeight accuracy: commercial level III

Length accuracy: 2mm

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Quality Assurance

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Product Scope

inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.520 508

22 559

24 610

26 660

28 711

30 762

32 813

34 864

36 914

38 965

40 101642 1067

44 1118

46 1168

48 1219

50 1270

52 1321

54 1372

56 1422

58 1473

60 1524

Diameter Wall Thickness (mm)

Product Scope Table (a)Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.

Pipe Length: 812.2m

Grade: X80 / L555

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inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5

20 508

22 559

24 610

26 660

28 711

30 762

32 813

34 864

36 914

38 965

40 1016

42 1067

44 111846 1168

48 1219

50 1270

52 1321

54 1372

56 1422

58 1473

60 1524

Product Scope Table (b)Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.

Pipe Length: 812.2m

Grade: X70 / L485


Product Scope

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inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.520 508

22 559

24 610

26 660

28 711

30 762

32 813

34 864

36 914

38 965

40 1016

42 106744 1118

46 1168

48 1219

50 1270

52 1321

54 1372

56 1422

58 1473

60 1524

Product Scope Table Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.

Pipe Length: 812.2m

Grade: X65X56 / L450L390


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Product Scope

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inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5

20 508

22 559

24 610

26 660

28 711

30 762

32 813

34 864

36 914

38 965

40 1016

42 106744 1118

46 1168

48 1219

50 1270

52 1321

54 1372

56 1422

58 1473

60 1524

Pipe Length: 812.2m

Grade: X52X46 / L360L320


Product Scope Table (d)Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.

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Product Scope

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inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5

20 50822 559

24 610

26 660

28 711

30 762

32 813

34 864

36 914

38 965

40 1016

42 1067

44 1118

46 1168

48 1219

50 1270

52 1321

54 1372

56 1422

58 1473

60 1524


Product Scope Table (e)Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.

Pipe Length: 812.2m

Grade: X42B / L290L245

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Product Scope

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CONTACT

Calvert Group

Ave Louise 287

1050 Brussels, Belgium

Telephone: +32.2.554.0400

Fax: +32.2.644.6064

Email:

[email protected]

[email protected]

lsaw presentation june 2010

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