TECHNICAL SPECIFICATIONS

 

 

 

 

  SWAGING & EXPANSION MACHINE

 

 

 

 INDEX

 

1.    OBJECTIVE

 

2.    PIPE SPECIFICATIONS

 

3.    DESCRIPTION OF REQUIREMENTS, OPERATION

 

4.    technical specification, SCOPE OF SUPPLY   

 

5.    SPECIAL SPECIFICATION FOR THE swaging AND EXPANSION machine

 

6.    TECHNICAL INFORMATION AND DOCUMENTATION

 

7.   Preliminary TestING

 

8.  Final testing

 

9.  Commissioning and Training

 

10. Price, terms of payment, and delivery time

 

 


1. - OBJECTIVE

 

The following specification gives the basic requirements for the supply of one “SWAGING AND EXPANSION MACHINE” for ends of steel pipe, 2 3/8” – 13 3/8”.

 

 

2. - PIPE SPECIFICATIONS

 

Pipes to be process are:

·         Seamless pipes.

·         Steel : All API grades

·         Diameter and thickness and maximum hook due to swaging: See appendix 1.

·         Main length: the minimum length of the pipe is 3 meters (10’).

 

·         Maximum of straightness:

Maximum bending: 2.0 mm/m                                        

Maximum deviation from the linear

Straight lines over the total length:10 mm

 

·            Maximum difference between minimum and maximum diameter at the same end:

                       Maximum difference in outside in the not swaged area: +/- 1% of nominal OD

                       Maximum difference in outside in the swaged area:      See APPENDIX 1.

  

·          Hooked end:

                       Maximum hooked end 1.0 mm to 3.0 mm

·             Surface condition: as rolled and quenched and tempered.

·             Wall Thickness deviation: Average Wall thickness +/- 12.5%.

·             Diameter deviation: Nominal diameter +1.0% - 0.5%.

 

 

3. - DESCRIPTION OF REQUIREMENTS, OPERATION

 

3.1 BASIC EQUIPMENT REQUIREMENT:

 

·         Max swage length: 120mm.

·         Equipment set up is easily accomplished for different pipe diameters.

·         Master dies for swaging and expanse are “unit assembled”, thus facilitating the changeover process from swaging to expanse or vice versa.

·         Centering and leveling of pipe as well as height adjustment is easily accomplished from either side of the machine. 

·         Speed and pressure of the hydraulic cylinder is also easily adjustable from high to low pressure.

 

 

 

 

 

3.2 Layout Swaging and Expansion Machine

 

 

 

 

 

 

 

 

  3.3 GENERAL DESCRIPTION OF THE SWAGING AND EXPANSION MACHINE

 

The swaging and expansion machine consists of: A pipe handling unit, expansion master set unit, swage master set unit, main hydraulic cylinder for expansion and swaging, power pack with working pressure 180 – 300 bars and operator control panel.  The pipe feed table is adjustable for various diameters of pipe.

 

 

Electrical requirements:  440/3/60 VAC, to supply the main induction motor and hydraulic unit. The expansion or swaging cycle is completed by a PLC program. 

 

 

4. TECHNICAL SPECIFICATION AND SCOPE OF SUPPLY

 

      The swaging and expansion machine consists of the following components:

 

·         One operator control console.

·         One hydraulic unit.

·         Two sets of swaging dies for 4 sizes of pipe.

·         Two sets of expansion dies for 4 sizes of pipe.

·         One pipe handling unit.

·         One set of master swaging dies.

·         One set of master expansion dies.

·         Complete information of all devices including:

a) Operating Manual.

b) Maintenance Manual.

c) Electrical Schematics.

d) Electronic Circuit Drawings of all electronics boards.

e) Wiring List and terminal blocks diagram.

 

Note: Additional die sizes are priced separately.

 

 

5. SPECIFICATIONS FOR THE SWAGING AND EXPANSION MACHINE.

 

I.     SWAGE and Expanse Pressure

 

          Description:

         swaging machine

Range……………………4 ½” to 13 3/8” Diameter pipe (For expanse/ Upset)

Range……………………2 3/8” to 13 3/8” Diameter pipe (For Swaging)

Horizontal press………...380 - 500 Tons

Hold Down Press……….180 - 200 Tons

Pipe handling…………….Included

 

 

     II. Cycle Time:

 

Total cycle time of the line is 50 – 80 seconds per pipe depending on diameter.

Pipe to pipe handling time is 15 – 25 seconds depending on pipe diameter and length.

The cycle time of the swaging machine is less than 45 - 55 seconds

The cycle time of 60 - 80 seconds consist of the following item:

Kick – in to the swaging line (transfer time)

Forwarding for the swaging machine (Pipe in-feed)

Pipe centering, swaging  (swaging time)

Moving back (Pipe out-feed)

Kick – out of the pipe from swaging line (transfer time)

 

III. Equipped with:

 

Operator control panel

100 HP, Electric skid mounted hydraulic unit                                  

3000 – 4500psi pressure

Auto stroke adjustment

440/3/60 electrics (380/3/50 also available)


 

  IV. SAFETY EQUIPMENTS.

         

Emergency stop button

The emergency stop button shall be easily accessible by the operator to stop all the movement of the machine. The button shall be installed on the control panel of the machine.

·         Covers

      Rotating components such as motor, shafts, rollers, and the other rotating  

     components shall be covered in order to prevent operator from touching those

     components.

·         Signs

      All sharp places, which my hurt or injure operators by movement or both

     machine and operator, shall be covered or painted clearly for operator to see.

 

6. TECHNICAL INFORMATION AND DOCUMENTATION

 

·       Manufacturer shall provide 2 sets of operation, maintenance and trouble shooting manuals in English.

·       All system software shall be documented.

·       Manufacturer shall provide all installation and interconnection diagram, cable list, bill of materials, etc.

·       The proposal shall clearly specify the limits of its scope.

·       Assembly drawings and sub assembly drawing will be provided for wearing part identification and ordering.

·       All final drawings will be issued in paper ( 2 copies) and Electronic Auto CAD files. All the documents shall be issued in MS office format. All documents will be submitted between 2 weeks after test and commissioning machine.

 

7. PRELIMINARY RECEPTION TEST

 

1.    The swaging machine will be tested before shipment.

2.    Swaging test shall be done on different samples.

     The sizes of the test pipe may change in the range of APPENDIX 1.

3.    Full security and electrical / electronics protection tests shall be performed.

4.    Only after satisfactorily fulfilling these tests will the unit be allowed to ship.

 

8. FINAL TESTING

 

Several “good” ends of different pipe sizes shall be swaged in the plant before the machine will be allowed to ship and before the test documentation will be prepared justifying the performance of the unit. 

                       

9. COMMISSSIONING AND TRANING

 

     If desired, classroom and floor training can be done along with production testing and

    commissioning of the machine. 

 

 

11. Price: 258,600 USD

 

The total price includes the following major items:

·         One operator control console.

·         One hydraulic unit.

·         Two sets of swaging dies for 4 sizes of pipe.

·         Two sets of expansion dies for 4 sizes of pipe.

·         One pipe handling unit.

·         One set of master swaging dies.

·         One set of master expansion dies.

·         Complete information of all devices including:

a) Operating Manual.

b) Maintenance Manual.

c) Electrical Schematics.

d) Electronic Circuit Drawings of all electronics boards.

e) Wiring List and terminal blocks diagram.

g) Test documentation.

 

           Terms and Conditions:

           Delivery: 12 – 16 Weeks Ex-shop.

           Payment term: Due with order 45%, Due upon shipment 45%, Balance after installation and run-off in plant. 

           Warranty: 1 Year after test and commissioning

       

 


APPENDIX 1

 

Figure 1 shows the schematic view of Tenaris BLUE. Table 1 shows the dimensions of the swaged ends of Tenaris BLUE.

 

Figure 2 shows the schematic view of NJO. Table 2 shows the dimensions of the swaged ends of NJO Ends.

 

Figure 3 shows the schematic view of Expansion PUNCH NJO BOX CONNECTION. Table 3 shows the dimensions of swaged ends of expansion Punch Box Ends.

Values in “PIPE DIMENSIONS” and “SWAGED END DIMENSIONS” are for reference purposes for the supplier. Values in the “Length and Weight of Swaged end” are to be taken into consideration for the induction heating system. The lengths and the weights of the stress relieving are stated in the “Stress Relief”, which are the most important figures.

 

 

 

 

 

 

 

 


 Figure 1: Schematic view of Tenaris

 


 

 Figure 2 shows the schematic view of NJO

 

Table 1: Swaged end dimensions for Tenaris Blue ends

Figure 3 shows the schematic view of EXPANSION PUNCH NJO

 


 

 

Table 2: Swaged end dimensions for PUNCH NJO ends:


 

Table 2: Swaged end dimensions for PUNCH NJO ends:

 


 

 

 

 

 

 

 

 

 

 

 

 

 

INSTALLATION AT THE PLANT

 

 

 

 

 

 

CHANGING MASTER DIES SWAGING TO EXPANSION (PUNCH), RUN PRODUCTION

 

 

 

 

 

PROJECT PROPOSAL:

 

 

 

1.  SWAGING AND EXPANSE MACHINE (UPSET)

2.  PIPE HANDLING SYSTEM