Production Range:

ROUND PIPE                : 1.88” - 5” (48-127mm)

SQUARE PROFILE        : 2”x 2” – 4”x 4” (40x40 – 100x100mm)

RECTANGLE PROFILE  : 2”x 1.25” – 4” x 2” (50x30 – 150x50 mm)

THICKNESS                  : .060” – .25” (1.50-6.35 mm)

SPEED                          : 262 fpm (60 meter/min)

 

Main Components:

1.         Strip Uncoiler

2.         Crop and Strip Joining Group

3.         Horizontal Strip Accumulator

4.         Strip Entry Leveling

5.         Forming Group

6.         Guiding Rolls/Seam Guide

7.         Welding Group and Chip Removing

8.         H.F  Solid State Welder

9.         Cooling Tunnel

10.       Calibration /Sizing Group

11.       Turk’s Heads (Profiling-Straightening Group)

12.       Cold Saw Group

13.       Stowing

14.       1 set tooling

 

Strip Coil Size:

Coil OD                         : 40” – 80” (1000 – 2000 mm)

Coil ID                          : 20” – 24” (508 – 610 mm)

Coil width                    : Up to 16” (Up to 400 mm)

Coil thickness              : .060” - .25” (1.50 – 6.35 mm)

Coil weight                  : 22000 Ibs (10 ton)

 

Production Tolerance:

OD tolerance               : ± .0060” (± 0.15 mm)

Accuracy                      : .040 mm; at 3.28 ft/l (1mm; at 1 m/l)

Length Tolerance         : - 0 / + .040” (- 0 / + 1 mm)

 

Main Technical Features:

Accumulator speed     : 400 fpm (120 meter/min)

Line speed                   : 200 fpm (60 meter/min)

Line direction              : L/R

Line Height                  : 37.4” (950 mm)

Power Supply voltage : 440V / 3 ph / 60 hz (440V / 3 ph / 60 hz)

Strip weight                 : 22,000 Ib (10,000 kg)

 

Air temperature           : -59 F /+ 113 F (-15°C /+ 45 °C)

Comp. air pressure      : 72 psi, 1000 l/min (5-7 Bar, 1000 l/min)

Hydraulic oil pressure : 1750 psi (120 bar)

 

HF Solid state welder  : 400 kw

Form group motor      : 90 kw

Finn-pass motor          : 90 kw

Accumulator power    : 82.5 kw

Caliber group motor   : 160 kw

SAW                             : 52 kw

Vertical stand mov.     : 1.1 kw (11)

Stowing                       : 2.2 kw (3)

 

Strip Uncoiler with Coil Car:

Loading weight            : 22,000 Ib (10,000 kg)

Strip coil OD                : 40” – 80” (1000mm - 2000 mm)

Strip coil ID                  : 20” – 24” (508 mm – 610mm)

Strip width                   : Max 16” (Max 400 mm)

Internal clamping of coil: Hydraulic

Brake system               : Pneumatic disc

 

Crop and Strip Joining Unit:

Shear cutting system  : Hydraulic

Strip thickness             : .060” – .25” (1.50 mm – 6.35 mm)

Strip width                   : Max 16” (Max 400 mm)

Clamp system              : Hydraulic & Pneumatic

Welding system           : Manuel MIG-MAG (Excluded welder machine)

 

Horizontal Accumulator:

Type                              : Winding from out, opening from inside, automatic.

Loading capacity         : 135,000 Ib (60,000 kg)

Drice type                    : 11x7.5 kw motor

Average speed Feeding: 400 fpm (120 meter/min)

Accumulator OD         : 26 ft (8 meter)

 

Forming Group:

Strip coil width            : Max 16” (Max 400 mm)

Strip / tube thickness  : .060” - .25” (1.50 –6.00 mm)

Strip entry straightener: 5 rolls with hydraulic

Electric motor             : 90 kw AC (2)

Shaft diameter            : 3.543” (90 mm)

Shaft material             : AISI / SAE 4140

                                    EN 42CrMo4

                                    DIN 1.7225

Heat treatment and precision grinding will be done

Chassis material         : EN S355JR

                                   SAE A633 Gr. A,C,D

Gear material             : 8620

Gear box                     : 1/3 - 1/5 ratio

Distributor gear boxes : Helical gear

Power transmission    : Cardan shaft

Upper press                 : With electric motors

Vertical stands            : 7 pcs

Side stands                  : 7 pcs

Break-Down stand      : 4 pcs

Fin-Pass forming stands : 3 pcs

 

Guide Rolls/Welding Group/OD Scrapping Group:

Guide:

Number of rolls           : 2 rolls

Rotation                      : 360⁰ circular

 

Welding Group:

Number of rolls           : 4 rolls

 

HF Solid State Welder:

Main components:

H.F solid State Welder,

Adjustable Welding Table with X,Y,Z movement.

Heat Exchanger

 

H.F solid state welding machine specification:

H.F. Output Power      : 400 kW at inductor

Supply Voltage            : AC  3ph, 400V 50Hz

Different Supply Voltage: On request

Power regulation        : 0 – 100 %

Rectifier System          : Controlled by 3 phase SCR bridge

Output Stabilization    : By Thyristor Control automatic voltage

Regulator                    : ± 1% at Net variation ± 10%

Residual Ripple            : Less than 1% at any power out put

Cooling method          : Water to water by Stainless Steel heat exchanger

Max temperature         : 29°C

 

Heat exchanger:

Closed loop

Stainless steel water pump

Stainless steel water tank and heat exchanger

Low level sensor

U – PVC pipe installation

 

Scrapping Group:

Main pressure             : Pneumatic piston

Adjusting pressure      : Manual

Scraping group consist: 2 pcs

 

 

Cooling Tunnel:

The length of the tunnel is 6000 mm

 

Calibration/Sizing Group:

Tube thickness                        : .060” - .25” (1.50 – 6.35 mm)

Electric motor                         : 160 kw AC

Shaft diameter                        : 3.543” (90 mm)

Shaft material                         : AISI / SAE 4140

                                                EN 42CrMo4

                                                DIN 1.7225

Heat treatment and precision grinding will be done

Chassis material                     : EN S355JR

Gear material                         : 8620

Gear box                                 : 1/3 - 1/5 ratio

Distributor gear boxes           : Helical gear

Power transmission                : Cardan shaft

Sizing stands                           : 4 pcs

Side idler stands                      : 4 pcs

 

Turk’s Heads (Profiling-Straightening Group)

Number of stations     : 4 pcs

Acting move                : 360-degree circular

Acting system              : Manual

 

Encoder Group (Length Measurement)

Upper roller adjustment         : Pneumatic pushing

Bottom roller adjustment       : Undriven, adjustable

Measurement system             : Incremental encoder

 

Cold Flying Saw Group (Single Head)

Cutting style                : Cold cutting - Burr-free

Installed Power            : 51.8 Kw

Saw rotation motor    : 18.5 kw x 3000 rpm

Saw car movement     : 30 kw x 2000 rpm servo

Max line speed            : 262 fpm (100 meter /min)

Tube thickness            : .060” - .25” (1.50 mm - 6.35 mm)

Round tube                 : 1.88” x 5” (48 mm - 127 mm)

Square tube                 : 2” x 2” – 4” x 4” (40X40 mm-100X100 mm)

Rectangular tube        : 2” x 1.25” – 4” x 2” (50X30 mm-150X50 mm)

Clamp Movement       : Hydraulic

Saw Type                     : TCT – HSS

SAW OD                      : 450 mm – 600 mm

 
Stowing:

Type                            : Overturn

Tube length                 : 14 – 40 ft (4000 – 12000 mm)

Packing size                 : 20” X 20” (500x500 mm)

Package weight            : Max 16,500 Ib (Max 7500 kg)

Power                          : 2.2 kw (3)

 

Electrical and Electronic Systems:

PLC                              : industrial PC CodeSys

HMI                             : Jmobile PC Runtime

IO                                : Crevis input output

Communication protocol: EtherCAT

Servo                           : Nidec+HPB motor

Switching equipment  : ABB, Schneider Eelectirc, Omron, Siemens

Driver                          : Control Techniques

 

Electrical cabinets and panels will be coated with electrostatic powder paint.

Complete units of electrical and electronic systems required for the mill, will be supplied.

Automation, power cabinet pulpit desks.

Starting from the low level the automation system of the plant is composed by:

• Motors

• Motor Drives (in this case inverters);

• Plant sensors and actuators;

• PLC

The above components (except for motors, sensors and actuators which are assembled each machine) are located on the following electrical cabinets:

1. Power Cabinet for Forming, sizing, saw, conveyor control

2. Power Cabinet for Strip welder and Accumulator, control

 

Man-Machine interface:

a) Strip Joiner control (for automatic) and Accumulator control desk

b) Mill control desk with display interface; controls the whole line including h.f solid state welder, saw and run out conveyor.

Accumulator and H.F Welder; PLC Siemens

Main control system; PLC control by Control Techniques Driver

Hydraulic Group:

Equipment supplied                :  Uncoiler, Pinch Roll, Strip Joiner, Brake,

Tank capacity                          : 300 liters

Working pressures                  : 120 bar / 1740 psi

Type of pump                          : Variable displacement pump

Number of AC motors             : AC 7.5 kW

Type of Cooling                       : oil to water heat exchanger

Various                                    : Unit supplied pretested at max operating pressure but without oil on the tank

Equipment supplied                : Saw

Tank capacity                          :160 liters

Working pressures                  : 80 bar / 1160 psi

Type of pump                          : Variable displacement pump

Number of AC motors             : AC 5.5 kW

Type of Cooling                       : oil to water heat exchanger

Various                                    : Unit supplied pretested at max operating pressure but without oil on the tank

Line Power:

HF Welder                               : 400 kw

Form group motor                  : 90 kw AC

Finn-pass motor                      : 90 kw AC

Accumulator power                : 82.5 kW

Caliber group motor               : 160 kw AC

SAW                                         : 51,8 kw

Vertical Stand movement       : 1.1 kw (11)

Stowing                                   : 2.2 kw (3)

Total power                             : 930 kw

70% will be used in production.

 

Obligations of Seller:

1.         General appearance of each equipment.

2.         The main equipment spare parts list.

3.         General layout of the line and anchor connection details.

4.         Electric, hydraulic and pneumatic layouts schema.

5.         User manual.

6.         Installation and commissioning.

7.         Trainings.

 

Obligations of Buyer:

1.         Preparation of the territory under the line based on data schemas electrical, hydraulic lines and cables.

2.         The materials required for the service

3.         Liquids, greases, and oils

4.         Electrical power supply

5.         Air Supply

6.         Cooling towers or chiller

7.         Lifting system and crane

8.         Coils for tests

9.         The international and local travel costs, meal costs and hotel costs (Separate room for each staff and min 3-star hotel)

10.       CE standards for safety barriers

 

Tooling (Included in the Price)

Round              Square                         Rectangle

5” (127mm)     4” x 4” (100x100mm)    6” x 2” (150x50mm)

 

Delivery Time and Type:

Delivery time                           90 working days

Delivery type                           FOB Kocaeli ports

 

Warranty:

One year mechanical and electric & automation guaranteed.

Except for user and operator errors.