PROPOSAL
OF
TUBE MILL 9.5mm TO 40 mm
MODEL ITL-TMPR 40 X 3 –100
“COMPACT MODULAR DESIGN”
Index.
November 15, 2018
Index......
TECHNICAL DESCRIPTION:......
LIST OF EQUIPMENTS:......
DESCRIPTION OF THE EQUIPMENTS:
Double Pay Off Reel:
Hydraulic Shear :
Manual Welding Table:
Horizontal Spiral Accumulator with Pinch Roll:
Mill Entry Guide:
Leveler Non-Driven:
Stamping Unit:
Horizontal Stands:
Vertical Guide Roll Stands:
Seam Guide:
Welding Unit:
Bead Scraper & Bead Winder:
Tube Cooling Section:
Turk Head:
Die Head(Optional) :
Flying Cut Off FCS - 75 :
Ejector & Conveyor:
Base Plates:
Collecting Troughs:
Main Drive:
Electrical:
High Frequency Welder (Optional) :
Tube Mill Rollers (Optional) :
TUBE MILL ROLLERS:......
INCLUSION:......
EXCLUSION:......
PRICE :......
COMMERCIAL TERMS AND CONDITIONS:......
SUPERVISION OF ERECTION AND COMMISSIONING:
Special Notes......
November 15, 2018
TECHNICAL DESCRIPTION:
Product range / ERW Round pipes from 9.5mm to 40 mm with wall thickness from 0.7 to 3.0 mm.Special feature / Compact Modular Design
Materials / Hot pickled / Cold Rolled M.S. Strips having yield strength of Max. 42Kg/ sq. mm.
Production Speed / 100m/min – Max speed
based on size 25 mm OD x 1.6 mm wall thickness (The speed will go down with change in dia. and wall thickness)
Strip Width / 30mm - 125 mm
Strip Width Tolerance / ± 0.1mm
Strip Thickness / 0.7mm to 3.0 mm
Roll Shaft / 60 mm of alloy steel harden and ground
Coil ID / 508 to 610mm
Coil OD / Max. 1600 mm
Coil Weight / 2000 Kg on each arm max
Finished Tube Length / 5 to 7 mtrs.
Electric supply / 415 ± 5% V, 3 phase, 50 cycles
A. C. Supply.
Control Panel / 24 V DC
Air Supply / 6 to 7 bar at the place of working
Drive / 2D.C. Motors
Drive Power / 40 + 40 KW
Color / Apple Green RAL 6011
Roll Setting / Bottom Line Setting
LIST OF EQUIPMENTS:
S. No. / EQUIPMENTS / QUANTITY1 / Double Payoff Reel / 1 No.
2 / Hydraulic Shear & Manual Welding table / 1 No.
3 / Horizontal Spiral accumulator with Pinch Roll / 1 No.
4 / Mill entry guide / 1 No.
5 / Stamping unit (Optional) / 1 No.
6 / Leveler -Non driven / 1 No.
7 / Horizontal stands / 13 No.
8 / Vertical stands / 12 No.
9 / Seam guide / 1 No.
10 / Welding unit / 1 No.
11 / Bead scraper & Bead winder / 1 Set
12 / Cooling section / 1 No.
13 / Turk head / 2 No.
14 / Die Head Assembly(optional) / 1 No.
15 / Cold Cut Off Saw FCS - 75 / 1 No.
16 / Ejector & conveyor / 1 No.
17 / Base plates / As required
18 / Collecting troughs / 8 No.
19 / Main Drives
20 / Electrical control panel / 1 No.
21 / H.F. Welder (150 KW) / Optional
22 / Rollers / Optional
Note : Optional items are not included in the offer , can be quoted separately if required.
DESCRIPTION OF THE EQUIPMENTS:
Double Pay Off Reel:
The function of the un-coiler is to hold the coil as the strip is being paid off: Additionally, in
order to ensure that the strip runs off smoothly, it has to exercise a steady braking effect on the
strip of coil.
The Un-coiler shaft, which carries the expanding mandrel, is provided with a brake. The
expansion/ contraction is through a threaded spindle operated manually.
Provided on the expandable mandrel, are 4 segments which can be adjusted by hand and have
two coils retaining crosses.
Type / ManualStrip width / 30 mm – 125mm
Thickness / 0.7 – 3.0 mm
Coil Weight / Max. 2000 kg
Coil I.D. / 508 - 610 mm
Coil O.D. / 1600 mm
Hydraulic Shear :
Shearing unit cuts the strip at square ends before joining both the strips together as a
continuous feed to the mill.
Means of Shearing / HydraulicOperation / By Hand Cylinder
Manual Welding Table:
Type / M.S. Fabricated constructionStrip clamping / The strip is clamped suitable and has guides on both sides
Welding / To be done manually on A.C.
Welding transformer of 400 amp capacity.
Grinding / By portable hand disc grinder
The welding set and portable hand grinder is to be provided by the Client.
Horizontal Spiral Accumulator with Pinch Roll:
The function of the spiral strip accumulator is based on the length difference of an equal number of strip windings, at different coiling diameters.
Maximum operating speed of Tube Mill 100 m/min
The strip accumulator mainly consists of the following main machine units: -
- Entry strip guide unit
- Entry pinch roll unit
- Actual accumulator
- Exit strip guide unit
- Electrical control
Feeding Speed / 260 m / min Approx
Mill Entry Guide:
It is installed before the mill and guides the strip which is fed to the mill for the formation of the pipe.
Type / 2 sets of horizontal rolls2 sets of vertical rolls
Rollers / Alloy steel hardened and ground
Rolls arrangement / Two horizontal rolls at entry
Two horizontal rolls at exit
Four vertical rollers (set of two) in between the horizontal rolls
Leveler Non-Driven:
The function of the non-driven leveler is to flatten the incoming strip from accumulator and
feed it to the tube mill so as to remove any kinks or folds formed during the storage of the strip
in the accumulator.
Type / 5 rolls (3+2)Rollers / Alloy steel hardened and ground
Rolls arrangement / Bottom rolls are fixed while top adjustment
rollers are adjustable manually by threaded spindle
Drive / Non- Driven
Stamping Unit:
It is similar in construction of forming horizontal stand of cantilever deigned fitted with rolls
having provision for fixing company logo and deign to give stamping mark on every meter
of the pipe length company logo is to be arrange by the client as per our design.
Horizontal Stands:
The horizontal stands in the pre-forming and forming mill help to form the open seam pipe continuously and also size the pipe to the correct size and shape in the sizing section after welding and cooling.
Arrangement / Pre-forming -4 Forming -3Sizing -5 Ironing -1
Stand / chrome plated guide rods
Chokes / C I
Shaft / Alloy Steel hardened & ground Dia. –60mm
Bearing / Roller bearings on both side
Vertical adjustment / Lower chokes with shafts are fixed and height adjusted by adjusting screws.
Both top chokes with shaft can be raised / lowered by operating threaded spindle individually
Mounting of stands / Both the rear and front stands are fixed on base plates and located on keys. The front stand is removed for roll changing and could be refitted because of easy location.
Drive / All the horizontal stands are driven while the ironing roll is non-driven.
Pre-forming- The bottom rolls are driven and the first four top rolls are non-driven.
Forming & Sizing -All the top and bottom rolls are driven
Vertical Guide Roll Stands:
One VGR Stand is put in between the horizontal stands so as to maintain the formation of the pipe already achieved in the proceeding horizontal stand.
Arrangement / Pre-forming & Forming -7Sizing -5
Stand / Graded C.I.
Slide blocks / M.S.
Shaft / Alloy Steel hardened & ground
Rollers mounting / The rollers are mounted on vertical shafts on bearings.
Vertical adjustment / The adjustment of rollers in vertical plane can be done manually by threaded spindle
Seam Guide:
The function of the seam guide installed before the welding roll is to provide a steady seam for
the pipe entering the weld zone.
Construction / M.S. FabricatedType / Two roller system;
Top roller is with fin
Bottom roller is without fin
Roller Adjustment / Bottom roller is fixed Top roller is adjustable in horizontal and vertical plane.
Shaft / Alloy Steel hardened & ground
Welding Unit:
The open seam tube emerging from the tube mill is continuously welded by high frequency welder through welding roll assembly.
In the welding stand the edges of the slit tube, heated Ito welding temperature are squeezed together, forming the closed tube.
Type / 2 rollsConstruction / C I Graded
Shaft / Alloy Steel hardened & ground
Bead Scraper & Bead Winder:
The double de-beading stand, provided after the welding stand serves to plan off, the hot weld
flash, formed during welding. The flash trimming coming out is collected by winding on a scrap
winder for ease of disposal.
Type / Double tool typeOne works at a time, while the second one is astandby.
Construction / M.S. Fabricated
Tool mounting & its operation / The tool is mounted on a slide which can be adjusted in horizontal as well as vertical plane.
The lifting of tool is done manually by a cam, as well as by pneumatic cylinders automatically when the mill stops.
Tube Cooling Section:
The cooling line serves to cool the tube after the welding process in order to avoid distortion
after sizing.
Construction / M.S. Fabricated, type closed through and chamber.Cooling Media / Soluble oil provided from soluble oil circulating system
Length / 2.5 Meter
Cooling Arrangement / The cold soluble oil solution is sprayed on the hot incoming pipe from top side so that the pipe is cooled down while traveling at the mill speed.
Turk Head:
Function / To straighten the pipe coming out of the sizing millType / 2 rolls in horizontal plane
2 rolls in vertical plane
Pin / Alloy Steel materials, hardened andGround
Adjustment / In all the three planes
Die Head(Optional) :
The Die Head assembly is used for specially making Square and rectangular sections.
Flying Cut Off FCS - 75 :
ITL offers state of the art High Speed Burr Free Cold Fly Cutoff Carriage Saw to use in-line with
conventional and High Speed Tube Mills up-to 120 met/ min speed to get 20 cuts of 6 met long
pipes with cut length accuracy as good as +/- 3 mm with least burrs and perfect square cuts
without any dimple.. Eco friendly machine has been designed to offer least per cut cost as it
consumes very low power (machine uses very low overall power of 32 KW as against
conventional similar saws which uses 60 to 75 KW) and offers more number cuts before re-
sharpening of HSS Saw blades. For thick wall and tough steel tubes, TCT saws Blades can be
used. Highly user friendly computer programmed needs very few data to enter by mill operator
with Fool proof and fault diagnostic features.
Machine has been designed to keep minimum inertia load of shuttle which reciprocates at very
high speed. With High Technological & Metallurgical combined properties aluminum Alloy has
been used to bring down moving shuttle weight from conventional shuttle design of around a
tons to only 325 kgs. Rake is mounted on the machine bed and Pinion on back lash free
reduction Gear Box fitted with Low Weight Servo Motor. With the rotation of Pinion, Shuttle
moves forward or reverses very precisely to offer close tolerance cut length.
Depending upon tube size , saw blade size can be selected to economize tool cost as small
diameter cutters are much cheaper , also after re-sharpening saw blade size reduces and can be
used for small diameter tube without any difficulty. Depending upon saw blade diameter,
machine automatically adjusts Saw Head stroke.
Models Suitable for pipes range / ½” to 2 ½’’ NB or 15to 75 mm ODSuitable for / Square sections up to 65 x 65 mm
Rectangular sections up to 80 x 50 mm.
Shuttle travel stroke Length (maximum) / 4 Meters
C/L of tube from Ground floor / 900 mm approx.
Machine Approx. Wt / 3500 kg
Machine overall Dimensions / 6000 (L) x 2000 (W) x 1600 (H
Total Power Input rating / 32 KW
Range of Tube Length to be cut / 4 – 12 meters
Length Cutting accuracy / +/- 3 mm
Saw blade / HSS or TCT from 350 to 400 diameter
Micro Mist Spray System / UNIST USA for TCT saw Blades (Optional)
PLC controlled Automatic Centralized Lubrication System
Maximum 120 mtrs./ min. speed can be achieved ON-LINE for 3/4” dia x 1 mm thick wall tube with 6 met cut length (20 cuts/min).
Ejector & Conveyor:
The machine frame of the conveyor roll is of welded construction. A few conveyor rollers are driven through geared motor as group drive, while some are non-driven. The run out conveyor is designed as a unit ejecting on both sides.
Drive / Geared motor 1 HPLength / 12m
Air / 6 to 7 Bar
Line Speed / 200 m/ min
Base Plates:
The base plates are of M.S. Fabricated construction made out of channels and plates. The base plates are used for mounting gear boxes, horizontal and vertical Ii roller stands, weld roll assembly, Turk head and other auxiliary equipment.
Collecting Troughs:
The collecting troughs are installed at both sides of the ejecting table and serve to collect the ejected tubes. These are welded from channels with inserted wooden pieces in order to avoid damage of the tubes.
Main Drive:
The mill drive is through D.C. Motors, while all the Ii remaining auxiliary drives are A.C. Motors. The main drive consists of:-
D.C. Motors 40KW With Thyristor .Control. / 2 No.Worm Reduction Gear Boxes. / 12 No.
Propeller shafts / 20 No.
Couplings, shafts, plumber blocks, etc. / As required
Base plates / As required
One D.C. Motor with a set of five gear boxes drives the sizing mill section while the other D.C. Motor with a set of 7 gear boxes drives the pre-forming and forming mill section. Both the D.C. Motors are synchronized.
The 1st four bottom rolls are driven while remaining all top and bottom rolls are driven. This is PLC controlled.
Electrical:
The Electrical consists of the following items :-
1. D.C. Motors with thyristor control and synchronization facility; PLC Control.
2. A.C. Motors.
3. Control panel to house AC and DC controls.
4. Operating desks.
5. Electrical cables for connecting motors from panels through control desk(In Client’ Scope).
All the electrical system and devices will have protective devices as per standard Electrical Regulations.
The system will have the necessary instruments as required for ease of operation. The indicating lamps and other safety measures will be incorporated. The Electrical will be of standard and reputed make conforming to International standards.
High Frequency Welder (Optional) :
Capacity 150 KW complete with all standard accessories. This is not included in our offer. We can offer this equipment separately.
Tube Mill Rollers (Optional) :
The tube mill rollers are not included in this offer but we can offer the complete set of tooling separately.
TUBE MILL ROLLERS:
TM-40 TUBE MILL
SHAFT DIA- ø 60 mm- Material HcHcr D-3 one set of 58 Rolls
Sr. No. / Size in mm O.D. / Finish wt in / Price in IREx- works Indore
1 / 12.70 / 295 / 1,28,700.00
2 / 15.90 / 308 / 1,34,100.00
3 / 19.00 / 320 / 1,39,500.00
4 / 22.20 / 335 / 1,46,700.00
5 / 25.40 / 351 / 1,53,900.00
6 / 28.00 / 369 / 1,61,100.00
7 / 32.00 / 389 / 1,71,000.00
8 / 35.00 / 411 / 1,79,100.00
9 / 38.00 / 436 / 1,90,700.00
Total 9 Sets Rs. / 14,04,800.00
The M.S. Spacers for Horizontal and Vertical stands are to be made by the client.
INCLUSION:
Supply of the equipments is in accordance with the above specifications and description.
Two complete sets of Instruction Manuals will be provided as follows:-
- Maintenance and Instruction manuals
- Drawings for spare parts
- Machine General Arrangement drawings
- Foundation drawings
- Hydraulic, pneumatic and water schematics
- Electrical circuit diagram.
EXCLUSION:
Items not included in offer are not in our scope of supply.
Customer has to arrange sufficient Electrical Power for operation of the equipment to a point or points, designated by ITL. At each point, the power is to be terminated at a fused main Disconnect Switch furnished and installed by customer.
All civil engineering construction drawings, including foundation details embedded steel, conduit layouts, piping layouts, cabling schedule etc has to be arranged by customer.
All labor and material for erection and commission of equipments, including the following: -
All foundation and foundation bolts
Coping angles and embedded steel
Electrical wiring and conduits between power sources, drive motors and operating control panels.
Inter connecting hydraulic and pneumatic piping between power units, operating valves and cylinders or motors.
Earth and Earth Leads.
All operator's platform, walkways etc except where specifically included in the equipment specifications.
The following operating materials and services :-
Oil and grease for hydraulic power units, gear boxes and bearings respectively
Compressed Dry air
Emulsion cooling & recirculation system
Cooling water & recirculation system
All raw materials for the operation of the equipment.
H.F. Welder – (In Client’s Scope).
Tube Mill Rollers. – (In Client’s Scope).
Erection and commissioning of the plant and equipment, if not ordered on us separately.
COMMERCIAL TERMS AND CONDITIONS:
Basic price:(Ex Work Indore) / ITL-TMPR 40 x 3 -100 Rs. 1,24,30,000.00
(Rupees One Crore Twenty Four Lacs and Thirty Thousand only)
Payment: / 30% advance with techno-commercially clear order.
Balance 40% in 4 installments of 10% each on monthly basis or as mutually agreed.
Balance 30 % cost of equipment and 100 % Taxes and duties against Proforma invoice before dispatch. The equipment can be inspected at our works before dispatch.
Taxes & Duties: / Not included in price. Extra as applicable at the time of dispatch.
Excise Duty @ 12.36 % (12% + 2% + 1%).
Sales tax @ 2% against ‘C’/ ‘D’ Form otherwise full rate @13% shall be charged (For sale in M.P., VAT @13%).
Service Tax @ 12.36 % (12% + 2% + 1%) applicable only on commissioning charges.
Packing & Forwarding / 2% of the order value (excluding taxes and duties) on wooden base where ever required and fully covered with polythene. In case the documents are routed through bank in that case the Packing & Forwarding charges will be @ 4% of the order value.
Validity and Delivery: / Validity - 30 Days from date of offer or to be re-validated.
Delivery - 4 to 5 Months (Delivery will be counted from the date of receipt of final techno-commercially clear order and advance.
Freight : / The Material will be dispatch till Jebel Ali Port. Transportation from Jebel Ali to your work in your accounts and in your scope.
Cancellation: / Orders once placed cannot be cancelled without our prior consent in writing and on the expressed condition that all expenses incurred till the time of cancellation will be reimbursed by the Purchaser. Our decision in the matter will be final & binding. The amount of advance received will be adjusted towards such costs and deficits if any will be charged to the Customer.
Insurance: / Extra @0.5 % of invoice value if it is to be arranged by ITL or you can arrange for it on getting dispatch details from ITL.
Inspection: / Material can be inspected at our works prior to dispatch. Intention of the purchaser to inspect prior to dispatch must be specified in his purchase order. If it is not specified in purchase order, ITL will treat the same as a waiver of inspection. Normally, 10 days notice period will be given to carry out inspection. Failing at which ITL, will make shipment without Purchaser's inspection.
Guarantee: / We stand guarantee for the satisfactory performance of this machine for a period of 12 months from the date of commissioning or 15 months from the date of dispatch, whichever is earlier. If during this period any part thereof, if found defective due to faulty design, faulty workmanship or inferior quality of material, the same will be replaced/ rectified by us, free of cost. However, this guarantee will be subject to, the equipment being used on double shift basis and does not include, damages due to faulty operation, lack of maintenance, improper storage, deterioration, normal wear and tear and also does not include consequent losses. The clause is applicable only if Erection and Commission supervision is done under our expert team
Force Majeure Clause: / ITL Shall not be stand liable under the contract arising out of Quotation and Order Confirmation, where fulfillment of their obligation are delayed, hindered, prevented by the causes like natural calamities, fires, wars, riots, accident, order by Govt. or any other cause beyond our reach.
Jurisdiction & Arbitration: / All orders placed on ITL shall be subject of jurisdiction of Indore Courts. Any disputes referred to arbitration as per Indian Arbitration Act. The venue of arbitration shall be Indore only.
SUPERVISION OF ERECTION AND COMMISSIONING: