An API Tube Mill Machine is a sophisticated industrial device specifically designed for manufacturing tubes and pipes that comply with American Petroleum Institute (API) standards. These machines are essential for producing durable, high-quality, and precise pipes that are critical in oil, gas, and other high-pressure applications.
In summary, an API Tube Mill Machine is a sophisticated piece of equipment essential for producing pipes and tubes that meet the stringent requirements of the oil and gas industry.
The production capacity of the API Tube Mill Machine is influenced by several factors, including tube diameter, wall thickness, and the type of steel used. Nevertheless, the machine is highly efficient and capable of impressive outputs. For instance:
Steel Strips Specification:
Moreover, the steel strips used in the API Tube Mill Machine must meet strict specifications to guarantee the production of high quality tubes. These specifications include:
Main production line:
Raw material (steel coil) _uncoiling _ shovel feeding+leveling _ shearing and butt-welding _ horizontal accumulator _ non-power leveling _ roughly forming _ precision forming _ welding seam guide _ extrusion _ high-frequency welding _ deburr device _ medium frequency annealing device _ air cooling device _ water cooling _ sizing _ milling type flying cutting saw _ conveyor
Finishing line:
Conveyor _ straightening _ end facing and beveling machine _ Hydro test _ packaging
Machine Parts Details:
The API Tube Mill Machine comprises several key components, each designed for a specific function in the production process:
| Machine parts details |
| 1. Single Head Hydraulic Decoiler | ||
| 1.1 | Structure type | Single side, hydraulic expanding tightly |
| 1.2 | I.D. of steel coil | Φ610mm~Φ710mm |
| 1.3 | O.D. of steel coil | Φ1300mm~Φ2100mm |
| 1.4 | Width of strips | 238mm~520mm |
| 1.5 | Maxi. Load weight | ≤10,000kgs |
| 1.6 | Remark | l Coupled with disc brake
l Coupled with loading cart |
| 2. Shovel Feeder+Leveling System | ||
| 2.1 | Shovel feeding | l Press coil thread, with extension plate….send coil into leveling unit |
| 2.2 | Leveling | l It is used to rough-straighten steel coils and plates before sending them to subsequent processes. |
| 2.3 | Structure type | 2 units of pinch rollers, 5-roller leveling,
fully hydraulic control |
| 2.4 | Motor power | 11KW |
| 2.5 | Pinch feeding speed | 10m/min |
| 3. Shear And Butt-welder | ||
| 3.1 | Function | l Cut off the defective part at the beginning and end of the steel strip and the defective part in the middle of the coil.
l Cut the head and tail before butt welding, so that the butt welding joints are straight and aligned, which is beneficial to butt welding. |
| 3.2 | Structure type | Hydraulic shear + CO2 welding |
| 3.3 | Shear thickness | 2.0-6.0mm |
| 3.4 | Maximum cutting width | 550mm |
| 3.5 | Cutter material | 6CrW2Si |
| 4. Horizontal Accumulator | ||
| 4.1 | Main composition | It is used to store and drive the strip steel, and consists of horizontal rollers, vertical rollers, center rollers, transition rollers, etc. |
| 4.2 | Horizontal rollers | l Divided into 12 equal parts
l Roller material: Ф165mm solid type, GCr15, surface hardened, HRC 55-60° l The inner horizontal roller is passive, and the outer horizontal roller is driven by 11 single reduction motors to provide power for the accumulator filling. l There’re transition rollers between the inner and outer horizontal rollers. |
| 4.3 | Principle | l Pull in from the outside and discharge from the center
l Non-power, pulled out by the power of the main machine. |
| 4.4 | Accumulator diameter | Ф7M |
| 4.5 | Strip width | 238mm~520mm |
| 4.6 | Strip thickness | 2.0~6.0mm |
| 4.7 | Storage capacity | 400-1000M |
| 4.8 | Motor power | 5.5KW×11 SETS |
| 5. Mill-forming Machine | ||||
| 5.1 | Feeding guide | Leveling device | l 5-roller leveling, non-power
l Shaft material: 40Cr l Adjust type: hand wheel rotation |
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| Guide vertical rollers | 2 units, manual adjustment | |||
| Feeding device | 1 station | |||
| 5.2 | Requirements | Round tube range: Ф76-Ф165mm, T=2.0-6.0mm;
Square tube range: 50×50mm-130×130mm, T≤5.0mm. |
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5.3
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Roller groups | Horizontal stands | Universal stands | Vertical stands |
| 5 stations | 3 stations | 6 stations | ||
| 5.4 | Shaft dia. | Φ140mm | H:Φ140mm/V:Φ100mm | Φ100mm |
| 5.5 | Shaft material | 42CrMo | 42CrMo/40Cr | 40Cr |
| 5.6 | Transmission shaft | SWC industrial coupling | ||
| 5.7 | Stands material | Q345B steel welding annealing treatment | ||
| 5.8 | Adjust type | l The forming machine is divided into two parts: rough forming and precision forming.
l This unit adopts FFX forming process in the rough forming part, so the rough forming rollers can be shared and the roller wear is small. l Change rollers for different tube diameter in precision forming. |
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| 5.9 | Power transmission | From universal transmission joint to horizontal roller stands | ||
| 5.10 | Driven gearbox | Quantity | 8 gearboxes | |
| Material of gearbox | Q345 steel welding, annealing | |||
| Gear type | Spiral bevel gear (umbrella type) | |||
| Material of gear | 20CrMnTi, carburizing and quenching | |||
| Modulus | 16 teeth | |||
| 5.11 | Forming machine layout | Anti-pumping device, V, 5-roller leveling, V, H, H, U, U, U, RV, RV, RV, V, H, V, H, V, H
“H”represents the horizontal roller stands; “U” represents universal stands; “RV”represents the rotating vertical roller stands; “V”represents the vertical roller stands. |
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| 6. HF Welding Machine (IGBT) | ||
| 6.1 | Structure | The high-efficiency switch welder (all-in-one machine) is mainly composed of full-bridge rectifier, filter, modular power module (consisting of high-power IGBT and other power devices), secondary rectifier circuit, inverter circuit (consisting of MOS pipe), load and other components. |
| 6.2 | Power | 500KW |
| 6.3 | Welding speed | Max 50M/min |
| 7. Guiding and Extrude and Scraper | ||
| Welding section range | Guiding device, 3-roller extrusion device, scraping welding device, polishing, cooling system | |
| Guide device | Two-roller weld guide device | |
| Extrusion roller device | l Use three-roller extrusion
l The rollers on both sides are driven by motors to adjust the worm gear |
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| Scraping device | Double-knife planing, alternate or simultaneous use, no stopping to change the saw, can be quickly raised and lowered, can be adjusted forward and backward and up and down, easy to adjust | |
| Polishing device | Use a flat roller to polish the weld by extrusion | |
| 8. Medium Frequency Annealing Device (Online) | ||
| 8.1 | O.D of round tube | Φ76mm~Φ165mm |
| 8.2 | Round tube thickness | 2.0mm~6.0mm |
| 8.3 | Annealing temperature | 950 ℃ ± 50 ℃ |
| 8.4 | Temperature control accuracy | ± 4 ℃ |
| 8.5 | Heating width | 30mm |
| 8.6 | Power | 2×500KW |
| 8.7 | Annealing speed | 20M/min-50M/min |
| 8.8 | Equipment composition | l IF rectifier inverter cabinet, 2sets;
l Capacitance output cabinet, 2sets; l Center console, 1 set; l Rocker arm button control box, 2 sets; l Mobile trolley, 2 sets; l Water-water cooling system, 2 sets; l Cables for the connection between the IF rectifier cabinet and inverter cabinet, 2sets; l Thermometer, 1 set; l Gripping mechanism, 2 set. |
| 9. Air Cooling | ||
| 9.1 | Roller table length | 50M |
| 9.2 | Air-cooled roller table | Active pull-out stable frame, driven by motor 37KW |
| 9.3 | Function | Use air cooling to reduce the temperature of the steel pipe to room temperature |
| 10. Water Cooling | ||
| 10.1 | Water cooling tank length | 8M |
| 10.2 | Structure type | Sink and shower installed in machine bed |
| 10.3 | Function | Use water cooling to reduce the temperature of the steel pipe to room temperature |
| 11. Sizing Machine | ||||
| 11.1 | Function | Extrude the welded, scratched, calendered and cooled round pipe to the required diameter. | ||
| 11.2 | Requirements | Round tube range: Ф76-Ф165mm, T=2.0-6.0mm;
Square tube range: 50×50mm-130×130mm, T≤5.0mm. |
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| 11.3 | Roller groups | Horizontal stands | Vertical stands | |
| 5 stations | 5 stations | |||
| 11.4 | Shaft dia. | Φ140mm | Φ110mm | |
| 11.5 | Shaft material | 42CrMo | 40Cr | |
| 11.6 | Transmission shaft | SWC industrial coupling | ||
| 11.7 | Stands material | 35# cast steel, annealing | ||
| 11.8 | Adjust type | l Change rollers for different tube diameter
l Flat roller lifting and vertical roller opening/closing, adjusted by AC motor button control box |
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| 11.9 | Power transmission | From universal transmission joint to horizontal roller stands | ||
| 11.10 | Driven gearbox | Quantity | 5 gear boxes | |
| Material of gearbox | Q345 steel welded, annealing | |||
| Gear type | Spiral bevel gear (umbrella type) | |||
| Material of gear | 20CrMnTi | |||
| Modulus | 16 teeth | |||
| 11.11 | Sizing machine layout | V, U, V, U, V, U, V, U, V, U, speed measuring roller, 2 Turkish heads;
“V”represents the vertical roller stands; “U” represents universal stands. |
| 12. Main Driven Motor | ||
| 12.1 | Power | l DC 160KW×2 SETS
l Z4-250-42, 1000/2000rpm |
| 12.2 | Reducer model | l ZSY type hardened gear reducer
l 1 SET for forming machine l 1 SET for sizing machine |
| 13. Milling Type Flying Cutting Saw Φ165×6mm | ||
| 13.1 | Machine basement | Equipped with linear guides, drag chain brackets, buffers, etc. |
| 13.2 | Cutting saw structure | 4 rollers |
| 13.3 | Feeding system | l Profiling track feed system
l Polar coordinate system profiling feed l Feed control: AC servo motor, servo drive, 2×1.8KW |
| 13.4 | Milling cutting saw | l AC servo motor, variable frequency drive, 2×11KW
l Number of saw blades: 2 l Saw blade material: carbide TCT |
| 13.5 | Guide roller device | 4-roller guide, screw drive, electric adjustment |
| 13.6 | Clamp device | Clamping and loosening of the device: hydraulic drive |
| 13.7 | Transmission mechanism | Gear rack |
| 13.8 | Transmission control | AC servo motor, variable frequency control |
| 13.9 | Speed measuring roller device | l Speed roller lowering and lifting: pneumatic drive
l Speed sensor: encoder |
| 13.10 | Hydraulic pump station | Pressure: 12MPa |
| 13.11 | Electrical system | l System composition: operation console, electric control cabinet
l Equipped with human-machine interface HMI, motion controller, fieldbus communication, servo drive, remote diagnosis module |
| 13.12 | Cut length | 6-12M |
| 13.13 | Cut length accuracy | ±2.0mm |
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| 15. Straightening Machine | ||
| 15.1 | Tube diameter | Φ76~Φ165mm |
| 15.2 | Tube thickness | 2.0~6.0mm |
| 15.3 | Tube length | 6-12M |
| 15.4 | Straightening speed | Max 30-55m/min |
| 15.5 | Coil material | Q235, Q355, GI |
| 15.6 | Straightness of pipe end | ≤0.2% |
| 15.7 | Surface quality | no scratch |
| 15.8 | Straightening roller dia. | Φ260mm |
| 15.9 | Effective roller length | 460mm |
| 15.10 | Motor power | 37KW×2 sets |
| 15.11 | Straightening roller arrangement | l 2-2-2, all active
l 1 unit of guide roller |
