CALVERT GROUP

Year 2010
SAWL PIPE MILL PRESENTATION

CALVERT
GROUP
CALVERT
GROUP

About Us

The registered capital and total investment of

US$50 million and US$98 million respectively.

Covering a land area of 170,000 m2.

Company is conveniently located on Yangtze

River Delta Region

Main Shipping Port, 10 kilometers away from

Yangzhou Port.
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Calvert Group has been well know for spiral

welded pipe and casing & tubing. 2009 was
the beginning of the most advance Longitud
e Weld Mill in the worlds today….come see f
or your self….!

The Company spent less than one year and a

half from the groundbreaking date to full
load commissioning:

Groundbreaking date: April 31, 2008

Full load commissioning: August 31, 2009

67mm thick x 22 meter press

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Certification of API 5L φ508 (X65), φ914 (X70) and φ1219 (X80)

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State-of-Art Equipments
Diameters rang : Φ457.2 (18”) to Φ1524 (60”)
Wall thickness range : 6.0mm to 67.0mm
Material Grade : API 5L - A to X80 and EN10208 L245 to L555
Annual Production : Tonnage capacity Annually 380,000 @ 20” diameter

West Bay Line East Bay Line

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State-of-Art Equipments
This state-of-art plant has the advanced hydraulic tester, X-ray flaw detector, ultrasonic flaw detector, physical & chemical lab, and other
testing equipments. The MES control system is adopted to manage the production and dispatching. And the SCADA system is adopted
to collect data and monitor the process to realize the integrated and real-time production management.

Ultrasonic phase array tester Monitor & Control Center

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PREQUALIFIED & APPROVED PROCEDURES

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State-of-Art Equipments

The Company operates the most advanced JCOE pipe production line in the world and installed the most automatic process
control from plate feeding, pipe forming, pipe delivery, to data collection, CCTV monitoring and testing data SCADA system
which is available 24/7 via internet

Process Flow Diagram

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State-of-Art Equipments
The steel plates will be traceable by their bar codes, specifying the specification, material, plate No and batch No, marked on the
plate body and filed into the SCADA system at their entry. After the pipes are manufactured and warehoused, they will be transferred
and traced through the customer quality system. The bar codes can not only indicate the pipe quality, but also monitor the
manufacture process—the multi-times scan during the manufacture process can trace the manufacture route, pipe classification and
finished product storage area. We keeps electronic file of each steel pipe it manufactured combining its steel plate info and
inspection result for future use and reference of the customers.
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State-of-Art Equipments
SCADA (Supervisory Control and Data Acquisition) is adopted to collect technical and quality data at each major process and monitor
the process with WinCC system, and thus indicate the real time operation status of the machines, control the technical index,
diagnose the failure part and ensure the normal operation of the process. The SCADA system can also collect physical & chemical
testing result and online testing result, and than file the testing results into the database after the bar codes for reference of the
related departments or customers.

SCADA
monitor
interface
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State-of-Art Equipments

MES (Manufacturing Execution System) can assist SCADA to monitor the manufacture process from the aspect of management
procedures. MES manages and analyzes the contract signing, production planning, quality control, marketing & sales process,
inventory, finance etc. By analyzing the data it collected, MES system can provide the managers with necessary management
guideline as production capacity, pricing and production planning. The customer may monitor on line the real time equipment,
process and quality related data.
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State-of-Art Equipments
OA (Office Automation) can realize no-paper office, and office automation by virtue of LAN. It can also provide remote support to
the out-of-office officers and sales staff through WAN. OA can improve office efficiency, reduce operation cost, and enhance
product competitiveness.
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State-of-Art Equipments
This system is designed to monitor the real time plant operation, especially the major equipments.
The customers may observe the plant production on line when authorized.
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State-of-Art Equipments
During the forming process, the steel plates are uniformly deformed with little residual stress and less vulnerability to
scratches. This process can customize steel pipes for the clients regarding to the diameter and wall thickness.
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State-of-Art Equipments
The tack welding and interior/exterior welding can improve welding speed and quality and control weld efficiency.

Weld cross section seam

External welding Tack welding

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State-of-Art Equipments
Full length mechanical expansion guarantees the preciseness of pipe dimensions, straightness, and improve the internal
stress distribution.

Full length mechanical pipe expansion

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State-of-Art Equipments
Phase array ultrasonic flaw detector
This process uses the phase array ultrasonic detector to provide reliable and precise inspection results. Different from the
conventional ultrasonic equipments, it can not only detect the location of the flaw, but also the shape of it.

“Phase Array” Ultrasonic Flaw Detector

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State-of-Art Equipments

The Company has a PPF5200/130 CNC forming machine, which

produces steel pipes using JCOE process; a closed loop tack w
elder; a interior welding machine (4 welding heads), a exterior w
elding machine (5 welding heads), an upgraded expansion mac
hine, and a phase array ultrasonic flaw detector.
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State-of-Art Equipments

The multi-channel automatic digital ultrasonic flaw detector can scan the whole
plate surface. The special dual-crystal straight probe and inspection gate can save and print out the flaw wave.

Plate Detection Equipment Ultrasonic flaw detector for steel plate

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State-of-Art Equipments
Mill the two sides of the plate to meet the requirements concerning width, edge parallel degree and groove shape.

Specification

Milling units : 4 sets

Diameter of cutter head : Φ800mm
Groove types : X type, straight type, single bevel

Plate Edge Milling Machine

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State-of-Art Equipments
Crimp the edges of the plate for required curvature.

Specification:
Nominal pressure of squeeze head : 2×20MN
Movement for each squeeze : 2200mm (max)
Thickness range of steel plate : 6-64mm

Edge Crimping Machine

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State-of-Art Equipments
Bend and form the crimped steel plate using “JCO” forming process into open pipe blank.

Specification:
Nominal pressure : 52000KN
Main cylinders :6
Diameter of formed pipe : Φ508 -Φ1524mm

Forming Machine
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State-of-Art Equipments
Perform constant full length tack welding with MAG on the formed steel pipe.

Specification
Adjustment for roller beam : Mechanical adjustment
Roller beams :9
Welding method : CO2/Ar MAG welding
Welding tracking system : Laser tracking

Tack Welding Machine

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State-of-Art Equipments

Weld the inside longitudinal seam of the tack welded pipe with fixed welding heads by moving the pipe.

Specification
Welding heads :4
Welding current : Direct Current 400-2000A
: Alternating Current 300-1200A
Welding head tracking system : Mechanical tracking

Interior Welding Machine

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State-of-Art Equipments

Weld the outside longitudinal seam of the inside welded pipe with fixed welding heads by moving the pipe.

Specification:
Welding heads :5
Welding current : Direct current 400A-2000A
: Alternating current 300A-1200A
Welding head tracking system : Laser tracking

Exterior Welding Machine

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State-of-Art Equipments

Expand, straighten and round up the pipe on the full length basis to improve the dimension preciseness and internal stress
distribution of the steel pipe.

Specification:
Nominal tensile force : 1600 ton
Expanding frequency : 15-18 seconds for each time
Expanding ratio : 0.8%-1.5%

Expanding Machine
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State-of-Art Equipments
Using the end face sealing technology, it can increase pressure rapidly while recording the pressure curve automatically.

技术参数：
Hydrostatic Tester
最大承载力 4000吨 Specification:
试验压力 3 ～ 50 Mpa Maximum load-bearing capacity : 4000 ton
Testing pressure : 3-50 Mpa
密封形式 端面 25MPa以下
Seal form : end pressure ≤ 25Mpa
径向 25MPa以上 : radial pressure ≥25Mpa
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State-of-Art Equipments

Level the pipe end with rotating cutter heads for the required groove and edge.

Specification
Pipe end groove : flat end or beveled end
(subject to the specification)
Wall thickness range : 6.0-50mm
Diameter range : Φ508-Φ1524mm

End facing Machine

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State-of-Art Equipments

The advanced “phased array” automated ultrasonic inspection equipment consists of four inspection system: L-system, T-system,
HAZ-system, and E-system. Yalian is by far the first and the only company adopting “phased array” ultrasonic flaw detector in China
for online inspection.

Specification
Testing method : pulse echo method
Detection channels : ≥24
Probe : phase array probe

Automated Ultrasonic Inspection Equipment

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State-of-Art Equipments

X-ray Real-time Imaging and Pipe End Filming Inspection System

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State-of-Art Equipments

CJE-220HP Alternating Magnet Yoke Magnetic Particle Flaw Inspector

Detect the flaws at the pipe end with

alternating magnet yoke magnetization method.

Magnetic Particle
Flaw Inspector
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Quality Assurance

Equipped with Ultrasonic Flaw Detector for Steel Plate, Ultrasonic Flaw Detector for Welding Seam, X-ray Flaw Detector, Aut
omatic Weighing and Length Measurement Equipment, Hydraulic Tester, Magnetic Particle Flaw Inspector etc., the productio
n line can realize 15 100% quality inspections.
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Quality Assurance

1.) 100% physical and chemical test for the steel plates by furnace batches
2.) 100% inspection on the plate dimensional
3.) 100% automated ultrasonic testing for the steel plates
4.) 100% automatic ultrasonic testing on welding seams before expanding
5.) 100% ultrasonic testing on end welding seams before expanding
6.) 100% industrial TV inspection on welding seams before expanding
7.) 100% hydrostatic test
8.) 100% automatic ultrasonic testing on welding seams after hydraulic test
9.) 100% ultrasonic testing on end welding seams after hydraulic test
10.) 100% shooting on the end welding seams after hydraulic test
11.) 100% industrial TV inspection on welding seams after hydraulic test
12.) 100% magnetic particle testing on the end welding seams after hydraulic test
13.) 100% automatic weighing and length measurement
14.) 100% inspection on the pipe dimension
15.) 100% physical and chemical test for the steel pipes by furnace batches
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Quality Assurance
The physical and chemical laboratory is equipped with advanced equipments for inspection and experiment purposes, such
as microcomputer controlled electro hydraulic servo universal tester, microcomputer controlled metal pendulum impact tester,
direct-reading spectrometer, large metallurgical phase microscope, drop weight tear tester, hydraulic blasting tester etc.

Main function:
Test the tension, compression, bending and other
properties of the metal materials with auto-contro
lled strength, distance, speed etc.

Microcomputer controlled electrohydraulic servo universal tester（1000kN）

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Quality Assurance

Main function: determine the impact tolerance ability of the metal materials, featured by strong impact power,
automatic pendulum movement and high efficiency.

Microcomputer Controlled Metal Pendulum Impact Tester (600J)

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Quality Assurance

Main function:
Analyze the carbon and sulfur contents in steel, cast iron, copper, alloy, cement, porcelain, sand and other solid
materials with the latest burning technology.

HF infrared C-S analyzer

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Quality Assurance
Main function: determine the Vickers hardness value of the metal materials, which can be converted into o
ther hardness value automatically.

Vickers
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Quality Assurance

Main function: digital photo taking and automatic metallographic analysis system with the magnification of 32×～1600×ca

Large-size metallurgical phase microscope

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Quality Assurance
Main function: make prompt quantitative analysis on 30 elements of solid steel & iron and alloy with high precision.

Direct-reading spectrometer
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Quality Assurance

Main function: test the dynamic tearing and drop weight tearing of metal materials with strong impact power.

Drop weight tear tester（5000J）

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Quality Assurance

φ914×23.8mm ：X80
API Spec 5L ：YL09A421
32.5MPa ：34.1MPa
1950mm : 1020mm

Hydraulic blasting test

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Quality Assurance

Measure the length and weight of the pipe, and save and print the data automatically.

Automatic weighing and length measurement equipment

Weighing scope: 700 ～ 22000kg

Weight accuracy: commercial level III
Length accuracy: ≤±2mm
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Product Scope

Product Scope Table (a)

Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.
Pipe Length: 8～12.2m
Grade: X80 / L555
Diameter Wall Thickness (mm)
inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5
20 508
22 559
24 610
26 660
28 711
30 762
32 813
34 864
36 914
38 965
40 1016
42 1067
44 1118
46 1168
48 1219
50 1270
52 1321
54 1372
56 1422
58 1473
60 1524
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Product Scope
Product Scope Table (b)
Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.
Pipe Length: 8～12.2m
Grade: X70 / L485
Diameter Wall Thickness (mm)
inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5
20 508
22 559
24 610
26 660
28 711
30 762
32 813
34 864
36 914
38 965
40 1016
42 1067
44 1118
46 1168
48 1219
50 1270
52 1321
54 1372
56 1422
58 1473
60 1524
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Product Scope

Product Scope Table ©

Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.
Pipe Length: 8～12.2m
Grade: X65～X56 / L450～L390
Diameter Wall Thickness (mm)
inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5
20 508
22 559
24 610
26 660
28 711
30 762
32 813
34 864
36 914
38 965
40 1016
42 1067
44 1118
46 1168
48 1219
50 1270
52 1321
54 1372
56 1422
58 1473
60 1524
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Product Scope

Product Scope Table (d)

Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.
Pipe Length: 8～12.2m
Grade: X52～X46 / L360～L320
Diameter Wall Thickness (mm)
inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5
20 508
22 559
24 610
26 660
28 711
30 762
32 813
34 864
36 914
38 965
40 1016
42 1067
44 1118
46 1168
48 1219
50 1270
52 1321
54 1372
56 1422
58 1473
60 1524
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Product Scope

Product Scope Table (e)

Standard: API 5L / ISO 3183 / GB/T9711 / DNV OS-F101 etc.
Pipe Length: 8～12.2m
Grade: X42～B / L290～L245
Diameter Wall Thickness (mm)
inch mm 6.0 7.1 7.9 8.7 9.5 10.3 11.1 11.9 12.7 14.3 15.9 17.5 19.1 20.6 22.2 23.8 25.4 27.0 28.6 30.2 31.8 32.0 34.9 36.5 38.1 44.5
20 508
22 559
24 610
26 660
28 711
30 762
32 813
34 864
36 914
38 965
40 1016
42 1067
44 1118
46 1168
48 1219
50 1270
52 1321
54 1372
56 1422
58 1473
60 1524
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CONTACT
Calvert Group
Ave Louise 287
1050 Brussels, Belgium
Telephone: +32.2.554.0400
Fax: +32.2.644.6064

Email:
TCC@CALVERTGRP.COM
BR@CALVERTGRP.COM