Pacific Roller Die Company, Inc.

PRD Cross Seam Welding Machines, are specifically developed for Spirally Welded Pipe Mills for manufacture of pipe to meet API standards for strip joining. These machines reduce the outside welding time on the joint, resulting in increased overall productivity and efficiency of the mill.

The range covered with PRD CSWM s are:
Diameter 609 mm to 3 048 mm
Pipe Length 6 m to 25 m
Material Thickness 9 mm to 25 mm
Material Grade Up to X 80

PRD CSWM s are equipped with PLC and PC controls which enable the machine to start in “learn mode” then continue the welding process in automatic operation as long as pipes of the same characteristics are being produced.

Standard equipment on the CSWM includes an Urhan & Schwill welding system complete with flux recovery unit. Different system components are available at the request of the customer.

Main CSWM components are:
• Welding Column
• Welding Systems
• Cross Seam Positioning and Transport Cart

Welding Column
The welding column with 2,000 mm horizontal movement and 1,700 mm vertical movement is designed and constructed to be sturdy and rigid. The column is so designed that during the welding process it moves along the axes of the pipe.

Welding Systems
The welding torch holder is designed to follow and copy the surface of the pipe, provided that the spiral welding seams do not cause the misalignment of the torch at the ends of the cross seam.

Cross Seam Positioning and Transport Cart
During the welding process, pipe is rotated and carried along by means of a pipe transport cart. All movement of the cart itself and the welding column are provided by means of servo motors which ease the utilization of the PLC + PC System.

When the pipe data is input into the system through the PC control, the welding path is calculated automatically and the welding process starts.

Having fully computerized controls, PRD Hydrostatic Pipe Testing Machines are suitable for pipe applications to meet any internationally known standards, including those of API and AWWA. Hydrostatic Pipe Testing Machines can be used with pipes produced by the electric resistance welding (ERW) process as well as pipes produced by the submerged arc welding (SAW) process.

The range covered with PRD HPTM s are:
Pipe Diameter to be Tested ½” (12.5 mm) to 120″ (3048 mm)
Pipe Length 4 meter to 20 meter
Max. Applicable Test Pressure 210 Bar
Max. End Load 3 000 Ton

Main HPTM components are:
“Tension Beams
“Head Stock
“Tail Stock
“Water Fill, Pressure and Vent System
“Pipe Lifting and Positioning System
“Control Station

PRD End Facing and Beveling Machines are suitable for pipe applications to meet any internationally known standards, including those of API and AWWA. End Facing and Beveling Machines can be used with pipes produced by the electric resistance welding (ERW) process as well as pipes produced by the submerged arc welding (SAW) process.

The range covered with PRD EFBM s are:
Pipe Diameter 20 (508 mm) to 120″ (3048 mm)
Pipe Length 4 meter to 20 meter
Material Thickness 5 mm to 25 mm
Material Grade Up to X 80
Cutting Angle 30 degrees with +5, -0 tolerances

Main EFBM components are:
“Pipe Clamps
“Spindle and Cutting Head Assembly
“Positioning System
“Pipe Rotating Unit
“Drive and Hydraulic System
“Controls and Tooling

PIPE CLAMPS
Two pipe clamps, top and bottom, are made of machined steel in sections. The top clamp is fixed while the bottom clamp can be vertically adjusted by means of hydraulically driven cylinders to fix the pipe in position. Bolt-on Inserts are fixed onto the clamps. Different bolt-on inserts are needed for each diameter of pipe.

SPINDLE AND CUTTING ASSEMBLY
The spindle is made of forged steel. A faceplate holding the cutter assembly with cutter heads is mounted onto the spindle by a flanged connection. The cutter assembly is mounted on the faceplate in such a way that any positioning of the cutter heads along the faceplate axis is possible. Cutter heads are complete with insert-type cutting tool holders. The complete assembly is mounted on a large anti-friction tapered-roll bearing, which is sealed and lubricated by a gear pump.

POSITIONING SYSTEM
Positioning of the faceplate and cutter heads feed is accomplished by means of servomotors and gear reducers. All high-speed in and out movements of the faceplate and fine and course feed of the cutter heads are controlled through the operator panel provided by the beveling head which allows continuous inspection by the operator during beveling.

DRIVE and HYDRAULIC SYSTEM
The faceplate and cutter head assembly is furnished with a variable speed, high torque, DC drive. Each beveling head has an independent drive and hydraulic system complete with hydraulic pumps, motors, reservoir, filters, valves and controls.

CONTROLS and TOOLING
All beveling head and pipe positioning controls are provided through an individual operator control panel located by the beveling head itself. The PLC system allows automatic operation for pipes having same characteristics.

Cutter head assemblies are designed and positioned on the face plate to bevel the pipe ends and to machine a flat surface perpendicular to the horizontal axis of the pipe. This is accomplished by one facing tool (fixture) which is stationary and one bevel tool (fixture) which is floating with respect to the cam follower provided.