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INNOVATION INSPIRAL WELDED PIPETECHNOLOGY
High-ProductivitySpiral Pipe Plantsand Finishing Lines
1 Spiral Pipe Plants2 Finishing Lines for Spiral Pipes3 HF Pipe Welding Plants4 Finishing Lines for Automotive
Tubes
Complete solutions for HF and spiral pipewelding plants
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TUBING THE WORLD WITH DANIELI W+K
DANIELI W+K is located in Dortmund, Germany, and has been successful in the international pipe plant business since 1968. The company forms part of the global operating group DANIELI & C.Officine Meccaniche SpA, Italy.
DANIELI workshops worldwide offer an extensive range of individual manufacturing solutions.
Wide Range of Programs from a Single Source
We deliver both complete plants and single machines for the production of longitudinally-welded (HF) and spiral-welded pipes (SAW), and we focus in particular on offering innovative and customized solutions. Our core business covers development, planning, design and also includes manufacturing, assembly and commissioning. Complete finishing lines, turnkey supplies and comprehensive after-sales service as well as upgrading solutions complete our extensive portfolio for the tube and pipe industry.
SchwerinHamburg
Bremen
Hannover
Düsseldorf
Wiesbaden
Erfurt Dresden
Magdeburg
Mainz
Stuttgart
München
Saar-brücken
Kiel
Berlin
Potsdam
Dortmund
> Innovative and economical solutions offering the highest plant productivity and energy efficiency
> High plant availability and security through process-reliable systems and integrated state-of the-art automation components
> Two-step production process for high output: the strip is formed and tack-welded at high speed. SAW final welding by multiple final welding stands
> Simultaneous final multi-wire SAW welding for inner and outer welding seam
OCTG Applications:
1 Offshore2 Onshore3 Underground pipelines
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Spiral pipe mill technology
HIGHLIGHTS
Automation System & Safety
> Automated quick-setting solutions with reproducible process parameters in all plant areas, such as strip preparation, pipe forming, cutting, finishing, high user-friendly operating and monitoring systems
> Production data management for efficient manufacturing processes, supported by e.g. material tracking, cross seam tracking, continuous quality control, performance by higher-level automation systems Level 2 and Level 3
Technical Data
1. Visualization HMI Operator’s PC 2. Visualization HMI Mobile Panel
Final product Spiral pipes (HSAW)
Steel grades Max. X100
Final application Line pipes for gas, oil water
International Standards (e.g) API 5L, AWWA, Aramco, EN 10208
Outside pipe diameter range 406.9 to 3,048.0 mm (16“-120“)
Wall thickness range 6.4 to 28.0 mm
Pipe length 8.0 to 25.0 m
> Comprehensive production quality control systems: automatic welding gap control, laser-controlled strip edge tracking, pipe OD measuring
> Quick dimensional changing times for high plant flexibility using motorized, automatically parameterized settings according to the individual pipe diameters
> Single machinery, such as coil preparation stands, edge millers, plasma cutters, pipe inside cleaning stations, bevelling machines, etc.
> Turnkey supply in cooperation with the DANIELI Group
> Innovative drive systems to fullfill the continuously increasing demands for energy-efficiency
> Integrated safety solutions according to international regulations by implementing customized automation to provide for safe operation functions and plant monitoring
Automatic Coil Opening and Strip Preparation
DANIELI W+K delivers complete logistics to handle the entry coil and prepare the strip for insertion into the following strip preparation section.DANIELI W+K‘s automized strip preparation section enables a very fast coil change-over minimizing downtimes to < 15 min.When changing coil or strip dimensions, easy
1 Automatic Coil Opening and Strip Preparation
2 Spiral Pipe Forming and Welding3 2-Step Production Process
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Spiral pipe millinnovations
Spiral Pipe Forming and Welding
DANIELI W+K’s unique pipe forming system ensures high quality of spiral-welded pipes. The forming unit consists of an infinitively adjustable 3-roll bending system with an outside guiding cage, enabling a very precise and automatic welding gap control.A laser-controlled strip edge tracking system serves for exact positioning of the SAW welding
2-Step Production Process
In addition to the conventional one-step spiral pipe production process, DANIELI W+K offers their high-efficiency two-step production solution.In the 1st step high speed continuous forming and tack-welding takes place. Final pipe welding is effected in the 2nd step by installing a set of SAW final welding stands, thus high final pipe output is achieved.
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1 2FIRST STEP SECOND STEP
and quick settings are achieved by using comprehensive automation systems. Strip centering and control process is also automized.The high-quality and saleable cross seam is produced by a preliminary SAW tack welding process and subsequent final welding by using three SAW welding heads.
heads ensuring a high accuracy during the entire final welding process. Thus excess weld beads are minimized.DANIELI W+K’s spiral forming and welding technology guarantees for process reliabiliy even at high wall thicknesses of 25.4 mm (1“) and extremely high material strengths.
Smooth and slip-free pipe transportation is ensured by DANIELI W+K’s unique orthogonal roller system. The complete process is automated: from tack-welding up to the final SAW spiral welded pipe.
Plant solutions from a single source: Production of spiral – welded API pipes
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Spiral pipe welding and fi nishing line, 2-step production process
1 Coil transport carriage/decoiler2 Strip straightening machine3 Forming unit4 Flyng pipe cutting carriage5 Pipe transport system6 SAW fi nal welding stands7 Outside welding8 Single pipe ultrasonic testing stand9 Pipe end bevelling machine10 Rewelding Section11 Visual inspection
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Scope of supply and servicesCoil Preparation
> Automated coil opening and preparation stand
> Plasma cutting unit to cut the coil tongue
> Sturdy design for heavy coils
> Safe coil handling
> Offline or online solution
Strip Preparation
> Providing an automated and safe strip preparation, e.g. decoiler, strip levelling machine, strip-edge milling machine
> Automated strip center stabilizing unit
> SAW strip cross seam welding station
Forming & Tack-Welding
> Innovative 3-roll bending system
> Welding gap control system
> Inside SAW tack welding system, fitted to sturdy beam
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1 Strip edge miller2 Pipe forming & SAW welding section3 Plasma cutting carriage4 Control desk5 SAW Final welding stands
> Pipe OD measuring system
> Laser seam tracking system
Pipe Cutting Machine
> High-efficiency plasma cutting unit with carriage
Final SAW Welding Stands
> State-of –the-art final welding stands
> Inside and outside helical SAW welding system
> Pipe transport by orthogonal roller conveyors
Submerged Arc Welding (SAW) & NDT Testing Systems
> Integration of the latest technologies for continuous quality control as well as for inside and outside welding processes
Finishing Line
> Complete finishing line for line pipes according to international standards such as API, GOST, ARAMCO, SHELL
Electrics &Automation
> Automated setting system with reproducible roll positioning for all process parameters
> Pipe tracking and product management system
> Automation systems Level 2 or Level 3
> Fault analysis and troubleshooting via teleservice
Additional DANIELI W+K single machines
> Edge milling machines
> Pipe end bevelling machines
> Pipe inside cleaning stations
> Test ring cutting stations
Upgrading Solutions and After-Sales Service
> Modernisation and process optimization of existing lines
> Comprehensive after-sales support
Wide Range of Equipment & Services from a Single Source
DA
NIE
LI W
+K
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0-ENDANIELI W+K
Hauert 12A44227 DortmundGermanyTel (49) 231.7922110Fax (49) [email protected]
DANIELI HEADQUARTERS
WORLDWIDE DANIELI COMPANIES
WORLDWIDE OFFICES AND SERVICE CENTERS
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