View
216
Download
0
Category
Preview:
Citation preview
8/8/2019 LSAW Presentation June 2010
1/48
CALVERT
GROUP
CALVERT GROUP
Year 2010
SAWL PIPE MILL PRESENTATION
8/8/2019 LSAW Presentation June 2010
2/48
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.
CALVERT
GROUP
About Us
8/8/2019 LSAW Presentation June 2010
3/48
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
CALVERT
GROUP
8/8/2019 LSAW Presentation June 2010
4/48
8/8/2019 LSAW Presentation June 2010
5/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
6/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
7/48
PREQUALIFIED & APPROVED PROCEDURES
CALVERT
GROUP
8/8/2019 LSAW Presentation June 2010
8/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
9/48
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.
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
10/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
11/48
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.
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
12/48
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.
State-of-Art Equipments
CALVERT
GROUP
8/8/2019 LSAW Presentation June 2010
13/48
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.
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
14/48
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.
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
15/48
Weld cross section seam
The tack welding and interior/exterior welding can improve welding speed and quality and control weld efficiency.
Tack weldingExternal welding
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
16/48
Full length mechanical expansion guarantees the preciseness of pipe dimensions, straightness, and improve the internal
stress distribution.
Full length mechanical pipe expansion
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
17/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
18/48
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.
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
19/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
20/48
State-of-Art Equipments
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
CALVERT
GROUP
8/8/2019 LSAW Presentation June 2010
21/48
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
CALVERT
GROUP
Edge Crimping Machine
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
22/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
23/48
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
State-of-Art Equipments
CALVERT
GROUP
8/8/2019 LSAW Presentation June 2010
24/48
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
State-of-Art Equipments
CALVERT
GROUP
8/8/2019 LSAW Presentation June 2010
25/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
26/48
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%
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
27/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
28/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
29/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
30/48
X-ray Real-time Imaging and Pipe End Filming Inspection System
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
31/48
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
CALVERT
GROUP
State-of-Art Equipments
8/8/2019 LSAW Presentation June 2010
32/48
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.
CALVERT
GROUP
8/8/2019 LSAW Presentation June 2010
33/48
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
CALVERT
GROUP
Quality Assurance
8/8/2019 LSAW Presentation June 2010
34/48
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.
CALVERT
GROUP
Quality Assurance
8/8/2019 LSAW Presentation June 2010
35/48
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)
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
36/48
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
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
37/48
Vickers
Main function: determine the Vickers hardness value of the metal materials, which can be converted into o
ther hardness value automatically.
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
38/48
Large-size metallurgical phase microscope
Main function: digital photo taking and automatic metallographic analysis system with the magnification of 321600ca
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
39/48
Direct-reading spectrometer
Main function: make prompt quantitative analysis on 30 elements of solid steel & iron and alloy with high precision.
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
40/48
Drop weight tear tester5000J
Main function: test the dynamic tearing and drop weight tearing of metal materials with strong impact power.
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
41/48
Hydraulic blasting test
91423.8mm X80API Spec 5L YL09A42132.5MPa 34.1MPa1950mm : 1020mm
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
42/48
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
CALVERT
GROUP
Quality Assurance
CALVERT
8/8/2019 LSAW Presentation June 2010
43/48
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
CALVERT
GROUP
CALVERT
8/8/2019 LSAW Presentation June 2010
44/48
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
Diameter Wall Thickness (mm)
Product Scope
CALVERT
GROUP
CALVERT
8/8/2019 LSAW Presentation June 2010
45/48
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
Diameter Wall Thickness (mm)
CALVERT
GROUP
Product Scope
CALVERT
8/8/2019 LSAW Presentation June 2010
46/48
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
Diameter Wall Thickness (mm)
Product Scope Table (d)Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.
CALVERT
GROUP
Product Scope
CALVERT
8/8/2019 LSAW Presentation June 2010
47/48
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
Diameter Wall Thickness (mm)
Product Scope Table (e)Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.
Pipe Length: 812.2m
Grade: X42B / L290L245
CALVERT
GROUP
Product Scope
CALVERT
8/8/2019 LSAW Presentation June 2010
48/48
CALVERT
GROUP
CONTACT
Calvert Group
Ave Louise 287
1050 Brussels, Belgium
Telephone: +32.2.554.0400
Fax: +32.2.644.6064
Email:
TCC@CALVERTGRP.COM
BR@CALVERTGRP.COM
Recommended