Equipments

Heat induction pipe-bending mill 1420 for producing bent tubular elements with the following parameters:

Bending the camp in 1420 HD

Bend diameter - 426 to 1420 mm;
Wall thickness - max 40 mm (inclusive) at maximum diameter;
Bend angle - max 90°;
Bend radius – 2 DN to 35 DN.

 

СМ 2132 FZ process-specific CNC machine for machining bend ends:

СМ 2132 FZ process-specific CNC machine for machining bend ends

Facing pipe, ring and bent tubular element ends, OD: 426 mm to 1420 mm, optional shipping length;
Compliance with the specific requirements for flatness and perpendicularity of bent tubular elements like that of the piping;
Piping size edge preparation;
Multiple types of grooving

 

Special reconfigurable СМ2484Ф3.Н002 CNC machine – for machining bend ends:

Special reconfigurable СМ2484Ф3.Н002 CNC machine – for machining bend ends

This machine is intended for radial facing and edging, for removing weld reinforcement metal around the internal diameter of branches and pipes. Outside diameter is 325 mm to 1420 mm.

 

Bent tubular element end out-of-roundness shaping machine:

Bent tubular element end out-of-roundness shaping machine

- Bent tubular element shaping diameter 1020-1420
- Hydraulic cylinder force (at 63 MPa) at least 800t.
- Hydraulic cylinder stroke length for Ø1020mm-Ø1420mm 300 mm

 

SRMBI-1400 AWS Schäfer heat induction machine (Germany):

SRMBI-1400 AWS Schäfer heat induction machine (Germany)

Tubular billets of max 18 m length;
Bend diameter - 219 mm to 1420 mm;
Wall thickness - 7 мм to 100 mm;
Bend angle - max 180°;
Bend radius - 1.5 DN to 40 DN

Bending complex geometry tubular elements

 

The new engineering facilities operated at the plant make it possible to produce the following heat-induction piping elements:

New features of the plant

Bent tubular elements for air collectors and gas air cooling units (1.5 DN –3 DN);
Pump and compressor station piping elements;
Composite spacious structures for oil, gas, chemical and nuclear industries.

Advantages:
Decrease of field piping joints down to 70%; reduction of construction and reconstruction time; significant reduction of construction costs.

 

Automated SRF-4000 Rottler pipe end working center:

Automated SRF-4000 Rottler pipe end working center

Machining the 219 mm to 1420 mm items;
Machining shortened linear-length items;
Machining piping ends, rings, and bent tubular elements of optional length;
Compliance with bent tubular element flatness and perpendicularity requirements;
Piping end preparation for joints;
Other end grooving operations

 

Pipework fitting welding shop:

Pipework fitting welding shop

The welding and assembly stand equipped with universal three-axis platforms for assembling large-size 325-1420 mm piping parts and work pieces keeping dimensional accuracy according to the requirements set out in design drawings;
Root welds produced by the SST semiautomatic active gas arc welding method with joints properly filled and faced by automatic active and inert gas arc orbital welding machines using flux cored electrodes; Preliminary weld heating and thermal treatment with process parameter control eddy-current heaters.

 

KS-2х2 welding column:

KS-2х2 welding column

- Horizontal bar end load-carrying capacity – 180 kg;
- Horizontal beam up-down stroke – 2000 mm;
- Horizontal beam level stroke – 2000 mm;
- Core wire diameter – 2 mm…5 mm;
- Core wire feeding speed – 60 m/h…360 m/h;
- Core wire tilt angle – 0…30 deg.

 

KS-4х8 welding column. New solution – Tandem Twin submerged arc welding:

KS-4х8 welding column. New solution – Tandem Twin submerged arc welding

- The tandem twin submerged arc welding is a new high-performance welding method. With this solution used, the quality of circular and longitudinal joints is significantly improved while the costs are reduced.
While depositing doubly laid material but reducing groove angle, it is possible to decrease number of runs, to reduce weld material and ensure weld stability.

- Horizontal bar end load-carrying capacity – 500 kg;
- Horizontal beam up-down stroke – 4000 mm;
- Horizontal beam level stroke – 8000 mm;
- Core wire diameter – 2 mm…5 mm;
- Core wire feeding speed – 60 m/h…360 m/h;
- Core wire tilt angle – 0…30 deg.

 

Fitter's area:

Fitter's area
Fitter's area

Metl cutting and machining

 

Laboratory:

Laboratory
Laboratory
Laboratory

The laboratory is equipped with product parameter control tools and facilities satisfying the requirements set out in GOST, flow charts, and specifications

 

Protective coating shop:

Protective coating shop

The new polyurethane and epoxy protective coating technology is applied at the Neftegazdetal’s works that meets the complex fabricated production requirements of Gazprom Public Company and Transneft JSC. The hot air-free polyurethane and epoxy coat pressure spraying technology is used for protecting piping joints and units against corrosion.

The Protegol corrosion-proof coating system may be used at a wide range of storage, construction, and operating temperatures -60 °С to +120 °С inclusive.

The company employs only the highly skilled and trained personnel that have rather great experience in the following areas: metal working and welding technologies, operation of production facilities, IT solutions, engineering development, resource management, logistics, and corporative administration.

Neftegazdetal LLC continuously verifies the quality of finished products testing them for compliance with the requirements of Gazprom Public Company, Transneft JSC, and other sectoral research institutes.