porta-millopmanual

P. O. Box 472110, Tulsa, OK 74147-2110 USAToll Free: 800-725-7311918-447-1288 Office918-447-0188 Faxwww.mathey.com

______________Machine Model

_____________________Serial#

Register product online @ www.mathey.com <http://www.mathey.com>

Porta-Mill Parts & Operating Manual

Contents

Section Page

1 Introduction 2

2 Safety Tips 4

3 Parts List 6Porta-Mill Technical Diagram 7

4 Tool Bit Information 8Tool Bit Diagram (Figure 1 and 2)Tool Bit Chart (Figure 3)Carbide Grade Comparison Chart(Figure 4)

5 Power Drive Information 10

6 Installation and Operation 11Set-Up and OperationMandrel Chart (Figure 5)Installation of Torque Bar (Figure 6)

7 Straight Bevels and Square Landson Horizontal Pipe 12

8 Bevel/Land Description 15Straight 37 1/2˚ BevelCompound Angle Bevel“J” BevelsSquare Shoulder CounterboringTapered Counterboring

9 Pipe Wall Information 17Thin WallHeavy Wall

10 Beveling Procedure 18(Vertical Position)Pipe in Vertical Position - Face UpPipe in Vertical Position - Face Down

11 Maintenance 18

12 Troubleshooting Chart (Figure 7) 19

Warranty 20

1

Section 1 - Introduction

Virtually all industries use pipe to convey liquids and gases, from steam and airutility systems in large industrial plants, to chemicals and fuels in processingplants. Various codes and accepted practices govern the methods used to joinpipe to pipe and pipe to fittings. Practically all critical systems, where leaks cannot be tolerated, use butt-welding to join pipes of 2 inches and larger.

When mating pipe ends or fittings, a circumferential groove, known asa weld groove is required. The sides of the groove, which areformed by the chambered end, are called bevels. The groove isfilled with weld metal during the welding process. It is criticalthat the weld metal deposited in the weld groove be of theproper chemistry so that the weld joint is as strong as thepipe itself. Impurities such as scale, slag, oil, grease orother debris adversely affect the quality of the weld.Mechanical imperfections such as imperfect bevelangles on the pipe ends, misaligned pipe boresand poorly designed weld joints will alsoimpact weld quality. The welder can notcontrol the chemistry of the filler metal,since that is a function of the electrodemanufacturer, however— the welder cancontrol the cleanliness of the weld areaand the quality of the weld joint, giventhe proper tools.

Eighty-five percent of all pipe end preparation is done using saddle typebeveling machines, torches and hand grinders. It is very labor intensive whentorches and hand grinders alone are used to cut the pipe. The result is a less thandesirable pipe end preparation. The grinding operation does not yield a


2

Porta-Mill comes with:

Mandrels for its operating range

Service Key needed for operation

Facing Tool and 37 1/2ß Beveling Tools

Hard Polyurethane Storage Box

Torque Bar

Parts and Operating Manual


Another means of accurately preparing the pipe is to machine the pipe in alathe or boring mill. The cost of doing the work in this type fashion is veryexpensive, as these type of machines are not available at the work site. Thecost of handling the material is very expensive and time consuming.

The demand for quality in welded pipe systems appears on the increase andlarge investments are being made in automatic welding systems. Therefore,increasing productivity and weld quality—thus reducing rejected welds. Theautomated welding all require a machine weld end prep as a prerequisite.

Obviously, the best solution to the problem is to use field portable machineswhich can shape the pipe ends with the same degree of quality and accuracythat can be achieved on a lathe. Mathey Dearman, in its endeavor to help thepipefitter, has purchased the Porta-Mill line of portable pipe cutting andbeveling machines. Porta-Mill, in addition to being portable, is very simple tooperate. Experienced or inexperienced craftsman can operated the tool withlittle or no training.

All Porta-Mills are mandrel mounted so that the end of the pipe is in relation tothe bore of the pipe and not in relation to the outside surface of the pipe.Models 20, 31, and 48 Porta-Mills are designed to be driven with one of severalcommercially available Power Drives. The Power Drives can be used for otherapplication when not used on the Porta-Mill. Our aim is to provide the enduserwith the maximum degree of versatility without sacrificing portability of thetool or the quality of the end result.

No need to purchase expensive cutting inserts or experience downtime whilewaiting delivery. The cutting tools used in Porta-Mill are brazed carbideformed tools. The standard 37 1/2 degree Beveling Tool and Facing Tool canbe purchased at any industrial supply store. The brazed carbide tools can bereground by any experienced machinist.

3

Type of pipe and preparation that can be done with Porta-Mill End Preparation. (A, B and C) can bedone concurrently. J Prep (D), Counterbore End Preparation (F) are done as a secondary operation.

AA

D

B

E

C

F


4

Section 2 - Safety Tips

1. Read all parts and operating manuals prior to attempting operation of the equipment.

2. When using rotating equipment, basic safety precautions should always be followed to reduce the risk of personal injury. Always operate the tool only in accordance with specific operating instructions.

3. Make sure the pipe is secured properly to stop it from rotating prior to installing the Porta-Mill

4. Never operate the Porta Mill without the Torque Bar installed.

6. Never use the Porta-Mill beyond its rated capacity.

7. Check the electrical cord of the Power Drive for rips, tears or exposed wiring prior to use.

8. Check the operating voltage of the Power Drive prior to pluggingthe electrical cord into the electrical outlet.

9. Discontinue the operation of the Power Drive if it is operating erratically.

10. Disconnect the Power Drive prior to inspecting or replacing the cutting tools or performing any maintenance.

11. An experienced electrician should perform maintenance of Power Drive.

12. Follow the periodic maintenance instruction in the manufacturer sparts and operating manual.

13. Do not override or put inoperable any safety devices of the Power Drive.

14. Never operate the Power Drive in the rain or standing water.

15. Always disconnect the Power Drive when not in use.

16. To avoid unintentional starts, do not carry or handle the Power Drive Tools with your finger on the power switch.

17. Never set a rotating tool on the worktable while it is rotating.


5

18. When setting a rotating tool on the workbench after use,make sure the tool is placed on the bench in a manner thatwill not cause the tool to rotate.

19. Never let visitors or untrained personnel near operating tools.

20. Do not operate power tools when tired.

21. Protective equipment such as eye protection, steel-toed shoes and gloves should be worn to protect the operator.

22. Always wear eye protection in the work area.

23. Never wear loose clothing when operating power equipment.

24. Never over reach when working, always keep proper footing.

25. If possible keep spectators away from the immediate cutting area.

26. On pipe which has been frame cut, grind away sharp notches and protrusions to prevent jamming of the tool bits on a notch or protrusion.

27. Always check the direction of rotation for the Power Driveprior to cutting. The Power Drive should be rotated counter-clockwise as viewed from the pipe end.

28. Always start the Power Drive with all tool bits clear of the work piece.

29. Keep Tool Setscrew tight to prevent jamming tools orSetscrew against the Power Drive Housing.

30. Use the Porta-Mill Torque Bar supplied with each unit to absorb Power Drive torque during operation.

31. During straight beveling operation, a burr may be left around the inner perimeter of the cut. Use extreme caution when removing the tool from the pipe to prevent hands being cut on the burr.

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6

Section 3 - Parts List

1

2

3

4

5

6

10

11

12

13

14

15

16

17

18

19

20

21

22

23“A”

“B”

24

2627

1

2

3

4

5

6

7

8

9

Item Description Model 31 Model 48 Quanity RequiredNo. Part No. Part No. Model 31 Model 48

Not Shown


7

Section 3 - Technical Diagram(Continued)

Porta-Mill Pipe Beveling Machine


8

Figure 2

The above tool bits are normallyused in one of the Land Sockets(B) or Tool Holders.

Figure 1

The above tool bits are normally used in one of the BevelSockets (A) or Tool Holders.

Lt indicates maximum lengthLr indicates length for various pipe sizes.

Section 4 - Tool Bit Information

Tools Bits used in Porta-Mill are generally referred to as brazed tools.Their construction consists of a carbide insert brazed to a mild steel shank.The geometry of the pipe is determined by the configuration of the brazedtool. All Porta-Mills are designed to rotate clockwise. The tool bits shouldalways be mounted so that the face of the carbide is inserted in thedirection of rotation (on your left when looking down on the machine).The carbide insert of the brazed tool can be reground if dull— providedthere are no cracks or nicks that can not be removed during the regrindingprocess. The proper bevel or land angle should be maintained by a skilledmachinist with the appropriate grinding equipment. If the weldingprocedure permits light cutting fluids should be used to improve workfinish and extend the tool life. Use only sharp tools of the proper length.Tool Bit Shanks should be well supported within the Tool Head Sockets.

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9

The above tools are supplied with each machine.The tools can be reordered by part number. All tools not listed are accessories.

(Figure 4)

Carbide Grade Comparison Chart

(Figure 3)

Tool Bit Chart Brazed Tool Model Pipe Size Lt Lr Provides Part

Number Number in / mm in / mm in / mm Number Number

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11

Section 6 - Installation and Operation

Set-Up and Operation

Step 1 To select the correct mandrel see chart below.

(Figure 5)

Mandrel Chart

Step 2 Select the brazed tools for the pipe diameter (see figure 4). Use only sharp tool bits.

Step 3 Mount the Torque Bar as close to the end of the pipe as possible without interfering with the beveling tool bit. The Torque Bar should be as close to level as possible.

Step 4 Installation of Torque Bar (see figure 6).

A. Grasp the handle of the Torque with right hand with the chain hanging on your left.

B. Place the end of the Torque Bar above the left side of the pipeabout 1"- 2" (25-50mm) back from the end of the pipe.

C. Move the Torque Bar from right to left with the chain hanging over the centerline of the pipe.

D. Move the chain in a clockwise direction around the pipe.E. Engage the chain into the round notch in the top of the Torque Bar.

The 110 VAC Motor Control Box is shipped with a 3-prong plug.

(Figure 6)

Torque Bar


12

Section 7 - Straight Bevels and Square Lands on Horizontal Pipe

Step 1 Check the pipe bore for irregularities. Remove any protrusions from the pipe bore with a grinder. Remove any chips or slag

Step 2 Expand the Mandrel of the Porta-Mill to approximately a 1/4" (6mm) under the pipe bore by gasping the Front Mandrel Expander Cone and turning the Shaft Handle (20) clockwise.

Step 3 Insert the Mandrel into the pipe bore so that the tool bit will be approximately 1/2" — 1" (13-25mm) from the end of the pipe. Take care to straddle the defects in the bore as much as possible.

Step 4 Tighten the Shaft Handle (20) clockwise until the Mandrels are snug against the inner wall of pipe.

Step 5 Insert the Bevel Tool Bit(s) into the Bevel Socket (A) so that the Tool Bit extends just beyond the outside diameter of the pipe.

Step 6 Using the 3/16" Allen Wrench tighten the Tool Bit Screw (23) clockwise until it is tight.

Step 7 Insert the Land Tool Bit into Land Socket (B). Press the Land Tool Bit far enough into the Land Socket (B) so that it does not interfere with the beveling process.

Step 8 Using the 3/16" Allen Wrench tighten the Tool Bit Screw (23) clockwise until it is tight. (Leave the Land Cutter retracted at this time.)

Step 9 Rotate the Shaft Handle (20) counterclockwise and move the Porta-Mill forward, until the Bevel Tool Bit is approximately 1/4" — 1/2" (6-13mm). Take care to straddle the defects in the bore as much as possible and tighten securely.

Step 10 Rotate the Shaft Handle (20) clockwise and tighten the Mandrels securely against the inside wall of the pipe.

Note: Do not use a Cheater Bar to tighten the Shaft Handle.

Step 11 Rotate the Tool Head Body (8) counterclockwise to make sure the Beveling Tool Bit clears the end of the pipe.

Step 12 Check its rotation prior to installing the Power Drive to make sure it is rotating in a counterclockwise direction.


13

Step 13 Push the Power Drive Unit on to the 3 5/8" Ø round Drive Ring (6) of the Porta-Mill Tool.

Note: The Pawls located in the Drive Ring do not have to be in perfect alignment, as the Pawls are spring loaded. The Tool Head should be manually rotated until the Pawls of the Power Head are engaged in the slots of the Tool Head.

Note: Do not use a Cheater Bar to tighten the Shaft Handle.

Warning: Power Drives fitted with the large Drive Rings and Drive Pawls should not be allowed to engage the Tool Head Drive Ring under impact.

Step 14 Connect the Power Drive to the air source or electrical outlet.

Step 15 Recheck the rotation of the Power Drive to make sure it is in a counterclockwise direction.

Step 16 Press the power switch of the Power Drive and hold in that position.

Step 17 Slowly rotate the Feed Nut (2) clockwise.

Note: The Tool Head (8) should make one (1) full rotation after each adjustment of the Feed Nut.

Step 18 Constant pressure should be applied to the Bevel Tool Bit.

Note: Allowing the tool bit to skip lightly of bevel can cause workhardening of the material.

Note: A light cutting fluid can be applied to the cutting surface to extend the life of the tool bits

Step 19 Rotate the Feed Nut (2) counterclockwise when the bevel is near completion until is no longer cutting the bevel on the pipe.

Step 20 Disconnect the power source from the Power Drive.

Step 21 Remove the Power Drive from the Porta-Mill.


14

Step 22 Using the 3/16" Allen Wrench rotate the Tool Bit Screw (23) counterclockwise until the Land Cutting Tool Bit moves freely inthe Land Bevel Socket "B".

Step 23 Adjust the Land Tool Bit until the land is achieved. The length of the land is governed by the amount of tool bit extension.

Step 24 Push the Power Drive Unit on to the 3 5/8"Ø Round Drive Ring (6) of the Porta-Mill Tool.

Step 25 Connect the Power Drive to the air source or electrical outlet.

Step 26 Recheck the rotation of the Power Drive to make sure it is in a counterclockwise direction.

Step 27 Press the Power Switch of the Power Drive and hold in that position.

Step 28 Rotate the Feed Nut (2) until the desired bevel and/or landis completed.

Note: If chatter occurs during the cutting process, try using two tool bits to cut the bevel face. The use of cutting fluids and varying the speed of the Power Drive or using a lighter or heavier feed can eliminate chatter in most cases.

Warning: If the tool bits jam into the pipe end, release the Drive Power Switch immediately and break the jammed tool bit free manually. Do not try to break it free with the Power Drive, as it may damage the gearing in the Power Drive. If the pipe end is gouged due to the jammed tool, rotate the feed nut very slowly until the gouge is completely removed.

Warning: Never use the Porta-Mill without the Torque Bar, as injury may result. In locations where the pipe being beveled is close to adjacent structures or other pipe, the torque can be taken up by letting the Power Drive Housing rest against the adjacent pipe or structure. Under no circumstances use the handle of the Power Drive to take up the torque.


15

Step 29 Disconnect the Power Drive from the power source.

Step 30 Remove the Power Drive from the Porta-Mill. When repetitive end prep operations on pipes having outside diameter and wall thickness — no further adjustment are necessary.

Section 8 - Bevel/Land Description

Straight 37 1/2 Degree BevelsStraight bevels are shaped by using the AR10 style tool bits in a Bevel Socket "A".For heavy wall thicknesses of pipe, set the tool bits so that one overlaps the other.If the shanks of the tool bits need to be trimmed for other than standard wallthicknesses, take care in measuring the amount that the bit needs to be shortened.As much of the tool bits as possible should be supported in the Tool Head Sockets.Grinding the shank to provide chip clearance for the most extended tool bit isrecommended.

Compound Angle BevelsCompound Angle Bevels are shaped the same way as heavy wall thickness StraightBevels, except that the most extended tool bit is replaced with a 10 degree Bevel Cutter. For most applications, the shank will need to be trimmedto the proper length, depending on Porta-Mill model and pipe size. When used asshown above, the resultant bevel will consist of a 37 1/2 degree by 10 degree forthe outer bevel.


16

J Bevels

The amount of land extension is governed by the amount of extension of the LandCutter. For most operations only one tool bit is needed. If chattering develops, twoJ Bevel Tool Bits may be required to overcome chatter. On rough-cut pipe, we

recommend that the bevel be started with the cheaper AR10 Tool Bits. Insert the "J" Bevel Tool Bit when some of the roughness has been machined off.

Square Shoulder Counterboring

The deep square Shouldered Square Counterbore is used for consumable weldinginserts and etc. The Shouldered Square Counterbore is made by inserting the D10 ToolBit in to the Land Socket and setting the tip of the tool to the desired depth. It isimportant that a cut be taken from the pipe end s entire circumference. Caution shouldbe excerised to prevent the tool from feeding too deeply causing the tool to jam.


17

Tapered Counterboring

The Tapered or Blended Counter is used in the Land Socket. This counterboringoperation is accomplished by first roughing in the bore with a D10 Tool Bit and thenusing the Tapered Counterbore Tool Bit with the angle required. All slag or otherprotrusions should be remove before attempting this process. Caution should beexcerised to prevent the tool from feeding too deeply causing the tool to jam.

Section 9 - Pipe Wall

Thin Wall Pipe

The mandrel can force thin wall pipe out of round, due to the pressure exerted by the expanding Mandrel Assembly. This not only causes an uneven cut, but it alsocauses the Mandrel to slip in the pipe. To prevent the distortion of the pipe, wesuggest that an external pipeline clamp be fitted around the pipe. The clamp shouldbe back far enough from the pipe end so that the Torque Bar can be installed. Thelegs of the Mandrel can then be located in the pipe— so that when expanded, the legswill apply pressure to the inner wall of the pipe opposite the contact points of theexternal pipeline clamp.

Heavy Wall Pipe

To bevel pipe with a wall thickness greater than 3/4" (19mm), the Bevel Cutting Bitsshould be set at different radii, so that the cutting faces overlap. Heavy wall pipefrequently has flat spots and other irregularities on the pipe inner surface. It isrecommended that the operator inspect the pipe interior before inserting the Mandrel.The legs of the Mandrel should be placed in a way to avoid weld seam or otherirregularity. Variations in wall thickness will result in variation in land width.Measuring several points in the inner wall of the pipe and placing the Mandrel Legsso that they are at an average diameter can minimize variations in land width.


18

Section 10 - Beveling Procedure

Pipe in the Vertical Position Face Up

Follow the same procedure as in Straight Bevels and Square Lands on HorizontalPipe . Use extreme caution when starting to operate the machine, because the weight of the Tool Head and Power Drive will cause the tool to feed rapidly into the material.

Pipe in the Vertical Position Face Down

Follow the same procedure as in Straight Bevels and Square Lands on HorizontalPipe . You will need assistance in holding the Torque Bar and Power Head in position.

Section 11 - Maintenance

1. Use only sharp tools of the proper length.

2. If welding procedures permit, use light cutting fluid to extend the life of the tool bit.

3. Clean the serrations on the underside of the Torque Bar to improve its grip on the pipe.

4. Keep the chain dry to improve its grip on the pipe surface.

5. Inspect the area where the Mandrel Jaw meets the front and rear Mandrel Expander Cone for chips or scale.

6. Clean the Tool Head Bearings and apply a light coat of clean oil to the gears, bearing and mandrel shaft.

7. Clean the threaded the thread of the Mandrel Shaft and Feed Nut and apply a light cost of gears to the bearing and Mandrel Shift.

8. Remove the Tool Bits and clean dirt and chips out of the Tool Head Sockets.

9. Mathey Dearman does not warrant the Power Drives used to drive Porta-Mill. The operator should consult the manual furnished with the Power Drive for maintenance and repair instructions


19

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Section 12 - Troubleshooting ChartSymptom Possible Cause Corrective Action


WARRANTY

If any merchandise sold hereunder (except merchandise manufactured by otherpersons or firms) by Mathey Dearman, Inc. (the "Company") is not in accordancewith specifications shown on the order within customarily accepted tolerances, or isdefective on account of workmanship or material, and if such merchandise isreturned at the (or at the Company s option, is returned to a repair facility authorizedby the Company), within ninety (90) days after the Company s date of shipmentthereof, the Company will, at its option, replace or repair the merchandise. Thisagreement, however, is upon the conditions: (A) That the customer promptly notifythe Company in writing of any claim under this agreement, setting forth in detail anysuch claimed defect. (B) That the Company be afforded a reasonable opportunity toexamine the merchandise and to investigate the claimed defect at the Company smanufacturing facility or at an authorized repair facility, the Company shall not be,in any event, liable for damages beyond the price paid by the customer for suchdefective merchandise; specifically but without limitation, the Company may fulfillits obligations under this Agreement by tendering such purchase price at any time.THE COMPANY SHALL NOT BE LIABLE FOR CONSEQUENTIAL,INCIDENTAL, PUNITITVE, OR EXEMPLARY DAMAGES. This agreementdoes not obligate the Company to bear any transportation charges in connection withthe replacement or the repair of defective merchandise. As to any item manufacturedby other persons or firms, the Company agrees to present a request for adjustment forrepair to such manufacturer, and the customer agrees that the liability of theCompany shall not exceed any adjustment with respect to which such manufactureraccepts responsibility. THE ABOVE AGREEMENT IS IN LIEU OF ALLWARRANTIES, EXPRESSED OR IMPLIED AND IT IS AGREED THAT THEREIS NO EXPRESSED OR IMPLIED WARRANTY BY THE COMPANY AS TOTHE FITNESS, MERCHANTABILITY CAPACITY, OR EFFICIENCY OF ANYMERCHANDISE SOLD, AND THAT THERE ARE NO ORAL OR WRITTENEXPRESSED OR IMPLIED WARRANTIES MADE IN CONNECTION WITHANY SALE BY THE COMPANY. No modification or addition to this agreement,either before or after the contract of sale, shall be made except on written authorityof the President or Vice President of the Company.

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