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Messrs.
Specification
for
February, 2019
TABLE OF CONTENTS
1. OUTLINE ........................................................................................................................................... 2
2. DESIGN PHILOSOPHY ................................................................................................................... 2
3. ADVANTAGES AND TECHNICAL FEATURES OF FFX MILL LINE ................................... 2
4. DESIGN PARAMETER .................................................................................................................... 4
4.1 MATERIAL SPECIFICATIONS ............................................................................................................ 4
4.2 SPECIFICATIONS OF PRODUCTS ....................................................................................................... 4
4.3 LINE SPECIFICATIONS ..................................................................................................................... 6
4.4 UTILITIES......................................................................................................................................... 6
5. LINE COMPOSITION ...................................................................................................................... 7
6. DETAILED SPECIFICATION OF EQUIPMENT ........................................................................ 8
6.1 ENTRY SECTION .............................................................................................................................. 8
6.1.1 Uncoiler .................................................................................................................................................. 8
6.1.2 Pinch roll and Leveler ........................................................................................................................... 8
6.1.3 Shear and End Welder .......................................................................................................................... 9
6.1.4 Spiral Strip Accumulator .................................................................................................................... 10
6.1.5 Hydraulic unit ...................................................................................................................................... 11
6.1.6 Edge shaver .......................................................................................................................................... 11
6.2 MILL AND WELDING SECTION ...................................................................................................... 12
6.2.1 Forming Mill ........................................................................................................................................ 12
6.2.2 Welding Section ................................................................................................................................... 15
6.2.3 H.F. Welder .......................................................................................................................................... 16
6.2.4 Water coolant ....................................................................................................................................... 19
6.2.5 Eddy Current Tester............................................................................................................................ 19
6.2.6 Sizing Mill ............................................................................................................................................ 23
6.2.7 Marking Equipment ............................................................................................................................ 25
6.3 ROLL CHANGE EQUIPMENT ........................................................................................................... 26
6.4 CUT-OFF SECTION ......................................................................................................................... 26
6.5 END FACING & CHAMFERING SECTION ........................................................................................ 31
7. ELECTRICAL EQUIPMENT ........................................................................................................ 35
7.1 FF ROLL POSITIONING CONTROL SYSTEM.................................................................................... 35
7.2 MOTOR LIST .................................................................................................................................. 36
8. HYDRAULIC PUMP UNIT ............................................................................................................ 37
9. TOOLS .............................................................................................................................................. 38
10. GENERAL TERMS ....................................................................................................................... 39
10.1 PAINTING WORKS ........................................................................................................................ 39
10.2 TRIAL OPERATION ....................................................................................................................... 39
10.3 GUARANTEE ................................................................................................................................ 39
11. SUPPLY RANGE ........................................................................................................................... 39
11.1 SCOPE OF SUPPLY ........................................................................................................................ 39
11.2 OUT OF SCOPE ............................................................................................................................. 40
12. FINAL ACCEPTANCE TEST...................................................................................................... 43
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Total Emission Solution NAKATA MFG. CO., LTD.
Offer No. 30Q2213-07 March 11, 2019
1. Outline
This specification is of an ERW mill line for producing the round, square and rectangular pipes. The
slit strip mounted on the Uncoiler, travels through the End Shear and Welder, the strip Accumulator,
the Forming mill that rolls the strip to the round shape, and is electrically welded to the tube or pipe by
the High Frequency Welder. Then the round tube or pipe travels through the cooling zone, the sizing
mill which sizes it to be exact round, the Roll Box which shapes it to be square/ rectangular cross-
section, and finally is cut into the required length by the Flying Cut-off Machine. The Cut-off tube or
pipe travels to run-out table.
2. Design philosophy
On the design of this equipment we take the following matters very importantly.
FFX Mill, introduced herein, has a rational and epoch-making forming system utilizing the advanced
「FEM Simulation Technique」 as well as 「unique roll common-use technology」. It is needless to
say that roll change at Breakdown (BD) section is unnecessary, and moreover there is no other mill
than FFX mill in the world which has a superior forming function and a stable operativity. We are
confident that FFX Mill will make a new development in ERW tube production in the 21st century.
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Total Emission Solution NAKATA MFG. CO., LTD.
Offer No. 30Q2213-07 March 11, 2019
Flexible forming technology is the newest and most powerful technology in this epoch, which makes
less roll change, reasonable forming and line compact.
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Total Emission Solution NAKATA MFG. CO., LTD.
Offer No. 30Q2213-07 March 11, 2019
4. Design parameter
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Offer No. 30Q2213-07 March 11, 2019
Product Mix
Remarks:The cluster rolls for pipe size range of φ21.7~28.6mm shall be changed for every
pipe size.
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Offer No. 30Q2213-07 March 11, 2019
Line speed will be determined by combination of pipe size and pipe length.
The above mentioned speeds are calculated with standard pipe (no inside bead scarfed).
4.4 Utilities
1) Electric power
Power Supply : 380 V 50Hz 3P
Control Voltage : 220 V 50Hz 1P
2) Compressed air : Min. 0.4MPa
3) Industry Water : 0.3MPa
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5. Line Composition
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Offer No. 30Q2213-07 March 11, 2019
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Offer No. 30Q2213-07 March 11, 2019
6.1.2.4 Leveler
Function:
Prevents wave at the coil top to facilitate welding with the preceding coil.
Roll Six (6) rolls, Φ90mm x 250 mm
(3 top rolls + 3 bottom rolls)
Up/Down Hydraulic cylinder & screw jack
Drive motor AC motor 3.7Kw
Function:
Shear and End Welder are used for joining the tail end of preceding strip and the nose
end of succeeding strip.
The equipment operates semi-automatically. The equipment operation is divided into
feeding, shearing, gap adjustment, and welding of strips which are performed
automatically.
Type Shear: Hydraulic down-cut shear(swing)
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Offer No. 30Q2213-07 March 11, 2019
Function:
The strip accumulator is applied for having enough coil volume as storage in order to
secure
the enough welding time during the coil joining works.
Strip feeding speed Max. 140 m/min.
Winding speed Max. 70 m/min.
Winding power AC 22Kw with gear box
Size 3600 x 2200 x 3450 mm
(Horizontal x vertical x height)
Air supply 4.5 kg/cm2
Strip storage volume Max. 350m
Composition:
Entry unit:
Upper & bottom guide roll Φ100mm x 3 pcs.
Side guide roll Φ65mm x 2 pcs.
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Offer No. 30Q2213-07 March 11, 2019
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Offer No. 30Q2213-07 March 11, 2019
Flexible forming concept is applied in the mill breakdown section. Automatic coupling and uncoupling
mechanism between U-joints and roll shafts is adopted in the Fin pass and Sizing sections.
Furthermore, Outer beads are scarfed and chopped into small pieces.
All these technologies make the operator work lighter and safer.
Roll Arrangement
EG1 PR EG2 BD1 BD2 BD3 BD4 RV FP1 FPS FP2 SG SQ
CL1, 2, 3
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2) Fin Pass
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Offer No. 30Q2213-07 March 11, 2019
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Main transformer
(1)capacity 3P 200kVA shield(contact preventing plate)
Y-Δconnection
(2)Primary voltage 380V-400V-420V 3tap
(3)Second voltage 170V
(4)Cooling Naturally air-cooling oil-filled transformer
Attachment
(1)High frequency output cables 1 set
(2)Heating station(load matching system include) 1 set
(3)Work coil adapter, cover 1 set
(4)Work coil 6pcs.
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Offer No. 30Q2213-07 March 11, 2019
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Offer No. 30Q2213-07 March 11, 2019
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DISPLAY UNIT
19inch touch panel display with monitor arm
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Offer No. 30Q2213-07 March 11, 2019
BZ-SB2L3 TM-100A3
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Offer No. 30Q2213-07 March 11, 2019
SZS1 SZ1 SZS2 SZ2 SZS3 SZ3 SZS4 SZ4 SZS5 SZ5 TH1 TH2 TH3 TH4 MR
Cooling
Table
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Offer No. 30Q2213-07 March 11, 2019
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Offer No. 30Q2213-07 March 11, 2019
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Offer No. 30Q2213-07 March 11, 2019
In order to reduce the roll-change over downtime further more, Nakata’s original quick-
change system is applied in FP and SZ sections. Every universal joint is mounted on an
Auto U-Joint rest structure, which eliminates the dangerous and cumbersome operator’s
works at site. The cassettes of FP, SZ sections are moved in and out by using the “traversing
device”; the coupling between the universal joints and the roll shafts is carried out
automatically.
In-line Cassettes are pulled out by hydraulic cylinder and are craned out after uncoupling
universal joints and roll shafts.
Off-line Roll Change over and Roll pre-set is executed by crane and men power. After pre-
setting, the spare cassettes are set on the rails for waiting quick-change.
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Offer No. 30Q2213-07 March 11, 2019
In this section the pipe is cut into the pre-set length by the flying cutoff machine continuously and
is transferred to the run-out table.
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(2) SUS300series
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Function
This line is provided for machining the both ends of tube by facing.
Feature
- Two (2) units of machine.
- One (1) walking system
- End aligning rolls and end stoppers with air nozzle to remove dust on the pipe
- Hydraulic power units.
- Two (2) sets facing tools
- Electric control panels (AC & PLC) & One (1) operating desks.
Specification
- Type of facing head : Single head per each machine
- O. Diameter : 21.7 mm – 65.0 mm
- Thickness : 1.0 mm – 2.0mm
- Length : 4.0 m – 8.0 m
- Spindle revolution : 0 - 800 rpm
- Cutting length : 0 – 6mm
- Head feeding : By mechanical cam
- Pipe end aligning roll : Three (3) rows / urethane coated rolls
- Walking beam : By AC inverter motor with worm reducer
- Motor power
For spindle : AC inverter motor 7.5kw x Two(2)sets
For walking : By 11Kw hydraulic system
For aligning : By air cylinder for 2nd adjusting
- Cutting tool : Tungsten carbide, triangular type
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Offer No. 30Q2213-07 March 11, 2019
FLOW CHART
Pipe In
Pipe
Walking
(Double)
Pipe End
Pipe Clamp
Aligning
Head Forward
Facing
Head
Backward
Pipe Unclamp
Pipe Out
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Offer No. 30Q2213-07 March 11, 2019
Function
Remain bead and chip after facing of pipe inside pipe should be blow out by compressed air.
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Offer No. 30Q2213-07 March 11, 2019
Skid table
- Type : Steel frame & skid plate with slope
- Slope : 0 - 3°
- Surface : Harden steel plate attachment
Aligning table
- Type : Steel frame
- Aligning motor : 2.2 KW
- Surface : Harden steel plate attachment
Elevating conveyor
- Type : RS Chain or RF chain
- Drive : 3.7kw Geared motor
- Speed : Appx. 6m/min
- Q’ty of Chain conveyor : 1 set
Kick in device
- Type : By walking system
Chain conveyor
- Type : RS Chain or RF Chain with ball caster
- Drive : 3.7kw Geared motor
- Speed : Appx. 6m/min
- Q’ty of Chain conveyor : 1 set
- Optional item : Slope table for round pipe
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Total Emission Solution NAKATA MFG. CO., LTD.
Offer No. 30Q2213-07 March 11, 2019
7. Electrical equipment
Touch Screen
Panel
Personal Computer
M M M M
PG PG PG PG
All of Computers, Monitor screens, Sequencers (PLC) and AC motors are connected with a high
speed link.
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Offer No. 30Q2213-07 March 11, 2019
(4) Visualized roll positioning situation indicated on the screen by convenient software.
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Function
To supply the hydraulic power to actuate the cylinders used in machines.
Specification
Item Specification
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9. Tools
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Offer No. 30Q2213-07 March 11, 2019
The painting works shall be executed at our factory in 2 times of primary coating and 1 time of finish
coating. The color to be painted shall be basically followed the Buyer’s suggestion, but if nothing
particular, our standard colors are 25G6/2 for machine body and 5Y7/1 for control panel shall be
painted.
10.2.1 After the completion of machine manufacturing, the trial operation will be executed at our
factory under presence of Buyer and ship out the machine upon qualified.
10.2.2 The supervisory service to be dispatched to the Buyer’s site after the machine delivery shall
be discussed and agreed upon separately.
10.3 Guarantee
10.3.1 Above mentioned equipment is guaranteed by the Seller for a period of 18 months after the
trial operation at the Buyer’s site or 24 months after the date of the Bill of Lading whichever
comes earlier. But the guarantee period of commercial components including electrical
equipment shall be conformed to such vendor’s standard.
Seller’s obligation under this guarantee is strictly limited to repairing or replacing any part or
parts of its manufacture which upon inspection by Seller if required, proves to have failed in
normal usage due to faulty material and faulty workmanship.
The items to be deemed as consumable and wearing parts are not included in this condition.
1) Secondary (mill inner) electrical wiring and tubing works of machine portion which is supplied
from Japan (excluding the work from control panel to operation desk and any panel to terminal
box on machine)
2) Painting works for supplying items
3) Standard seaworthy packing
4) Document (including pipe mill line operation instruction etc.)
5) English language is applied in the touch panel, operation panel, name plate and others
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Total Emission Solution NAKATA MFG. CO., LTD.
Offer No. 30Q2213-07 March 11, 2019
1) Electric power source, Primary (mill outer) electrical wiring works (from power source to
control/operation panel)
2) Pneumatic source
3) Water supplying equipment
4) Primary piping works (till 1 m closing to the mill)
5) Foundation civil works
6) Mortar finishing work
7) General tools
8) Pit cover, safety fence, deck and pit corner metal
9) Any operation & lubrication oil
10) Spare parts unlisted in this proposal
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Total Emission Solution NAKATA MFG. CO., LTD.
Offer No. 30Q2213-07 March 11, 2019
Q'ty BI BD DD Supply
1. Entry Section
1.1 Uncoiler 1 unit S S S S
1.2 Pinch Leveler 1 unit S S S S
1.3 End Shear welder 1 unit S S S S
1.4 Strip accumulator 1 unit S S S S
1.5 Edge shaver -option- 1 unit S S S S
4 Welding Section
4.1 Seam Guide Stand (SG) 1 unit S S S S
4.2 Squeeze Roll Stand (SQ) 1 unit S S S S
4.3 Ironing Stand (IR) 1 unit S S S S
4.4 Outer Bead Scarfer with winder 1 unit S S S S
4.5 Water Cooling Table 1 unit S S S S
4.6 High Frequency Welder 1 unit S S S S
4.7 Eddy Current Tester 1 unit S S S S
5 Sizing Section
5.1 Sizing Stand (SZ1 / SZ5) 5 units S S S S
5.2 Rest for Sizing stand 5 units S S S S
5.3 Sizing Side Stand (SZS1 / SZS5) 5 units S S S S
5.4 Turks Head Stand (TH1 / TH4) 4 units S S S S
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Offer No. 30Q2213-07 March 11, 2019
7 Cutoff Section
7.1 Cutoff machine 1 unit S S S S
7.2 Run-out table 1 unit S S S S
9. Electrical Equipment
Entire Line Control system 1 set S S S S
Roll positioning control system (BD ~ SZ) 1 set S S S S
Drive motors, Main Drive Panel 1 set S S S S
Operation Desk 1 set S S S S
11 Tools
11.1 FF Rolls (BD-CL) 1 set S S S S
11.2 Forming rolls for FP/SQ/SZ/TH (φ65.0) 1 set S S S S
11 Spare cassette
11.1. Spare cassette for FP (FP1, FP2, FPS) 1 unit S S S S
11.2 Spare cassette for SZ (SZS1/SZS5,SZ1/SZ5,TH1) 1 unit S S S S
11.3 Spare yoke for TH (TH2/TH4) 1 unit S S S S
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Offer No. 30Q2213-07 March 11, 2019
14 Spare parts
14.1 Mechanical & Elect. Spare Parts - OUT OF SCOPE - S B
16 Supervising
16.1 for Installation 1 set S
16.2 for commissioning 1 set S
16.3 for training 1 set S
Note: Please kindly note that this specification may be amended somewhere, if it is necessary in design
stage in order to improve the function and performance of the equipment.
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