High-efficiency and precision turning solutions for large oil and gas pipelines
High-efficiency and precision turning solutions for large oil and gas pipelines
——Based on the successful application of DONGS CNC medium and large turning centers
Industry Challenges
1. An international oil equipment supplier undertook a 20km high-pressure oil pipeline project for an oil field and needed to batch process X70 grade alloy steel pipelines with diameters of 200-600mm and lengths of 3-5 meters. The core requirements included:
High reliability threaded interface:Meet the API standard thread sealing requirements and eliminate the risk of oil and gas leakage;
Complex end face groove processing:Realize burr-free forming of deep grooves and arc transition structures;
Efficient continuous production:Adapt to 24-hour uninterrupted operation to ensure the delivery of urgent orders
Processing Challenges
1.The workpiece size is large:Insufficient processing range of traditional equipment
2. High precision requirements:Need to meet the dynamic balance requirements of heavy-duty equipment
3. Efficient production:The average daily production capacity needs to be increased by 50% to cope with urgent delivery cycles.
Traditional horizontal lathes have insufficient rigidity and low clamping efficiency, which leads to large machining vibrations, frequent tool chipping, and a scrap rate as high as 8%.
DONGS SOLUTIONS
Select TCK700DY CNC turning center, key innovative design:
1.Heavy structure optimization
5-meter processing capacity:The integrated bed is matched with hydrostatic guide rails to ensure the rigid support of long workpieces and eliminate bending deformation;
Dual-mode tailstock system:The hydraulically driven tailstock and the spindle chuck are intelligently linked, shortening the clamping time of 5-meter pipes
Anti-vibration turret design:The wedge-shaped locking tool holder is used, and the tool runout during heavy cutting is lower than the industry average.
2.Intelligent function upgrade
Adaptive cutting system:Automatically optimize the speed/feed according to the hardness of the pipe to cope with the common material fluctuations of oil pipes;
Intelligent thread correction:Real-time compensation for pitch deviation caused by thermal deformation, with thread engagement reaching the highest API level;
Chip breaking control technology:The dedicated chip flute solution solves the problem of iron chip entanglement in long tube processing.
3.Exclusive process solutions
Rough and fine composite processing:The large-cutting-depth rough turning and precision forming cutter are used simultaneously to reduce the number of tool changes;
One-step molding of the sealing groove:Customized diamond-coated tools achieve precise control of the groove bottom R angle;
Online cleaning unit:The high-pressure cooling system simultaneously removes iron chips from the pipe end to avoid damage during secondary clamping.
Customer Benefits
Processing range expansion:A single machine can complete the processing of 3-5 meter pipes, reducing equipment investment;
No compromise on quality:The thread air tightness has passed the 30MPa high pressure test, and the customer's random inspection pass rate is 100%;运Dimension cost optimization:Equipped with grease automatic lubrication system, daily maintenance time is reduced by 70%.
Customer Testimonials
"TCK700DY's thermal error compensation technology allows us to maintain thread processing consistency even in a workshop with a temperature difference of 15°C. Its special fixture design for 5-meter-long pipes allows operators to complete positioning without the need for lifting assistance, greatly improving safety."
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