SYSTEM SOLUTIONS FOR THE

MANUFACTURE OF LARGE PIPES

FORMING
LARGE PIPES
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LARGE PIPES CONNECT THE WORLD
Complete turnkey solutions for large pipe manufacture implemented with the
expertise from Schuler.
FORMING THE FUTURE
With Schuler, you lay the foundations for
success in economical, efficient and highly
productive manufacture of spirally and
longitudinally welded large pipes.
We develop turnkey production lines for
large pipes on your behalf whether it be
pipelines for crude oil, natural gas, water or
large pipes in the petrochemical industry,
in wind energy systems or in the construc-
tion industry.
Not only do we offer the necessary experi-
ence, we also provide the appropriate
worldwide service for any required solution
and projects of all scales. We ensure that
we maintain our position of leadership in
quality by permanent innovations and
investments in research and development.
At Schuler, we regard turnkey solutions
for manufacturing large pipes as a highly
integrated overall concept: from innovative
layouts and designs through to intelligent
production principles. Our goal is for you to
be able to produce in an environmentally
friendly way, minimizing your use of
resources. In this way, you can benefit
during every phase from our extensive
groundbreaking expertise in large pipe
manufacture and from our competence.
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FORMING LARGE PIPES
Schuler works on redefining its boundaries on a constant basis, and setting new standards as it does so.
This is our tradition; this is our future.
Experience grows with success. We've combined it, and turned
it into an unmistakable concept.
Dr. Markus Ernst, member of the Board of Management of Schuler AG
As a technological pioneer and world
market leader with more 170 years of
experience in forming technology, Schuler
has attracted customers right from the
beginning with quality and expertise,
unique performance and convincing
service. With Schuler, you benefit from
outstanding expertise in R&D, engineer-
ing, large machine construction and
project handling.
Our customers include automotive manu-
facturers and suppliers as well as compa-
nies from the domestic goods, packaging,
energy and electrical industries. In addi-
tion, Schuler is a leader in the market for
forging and coining technology. Schuler
does not just provide complete system
solutions for large pipe production,
but also in the aerospace and railway
industries. We are represented worldwide
with our own sites and branches in forty
countries.
With ATIS, Schuler has a well-known
and experienced technology and market
partner in the area of large pipe produc-
tion. ATIS provides additional expertise
in the conception of turnkey projects and
contributes its major experience to their
implementation.
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FORMING THE FUTURE
SPIRAL PIPE WELDING MACHINE
Everything from a single source: turnkey pipe plants for producing
spirally welded large pipes
Pipe lengths up to 24 m can be achieved with Schuler spiral pipe welding machines. Diameters range from 450 mm
to 3,500 mm (18" 140"), wall thicknesses 6 mm to 25 mm (1/4" 1").
The key to your success: We plan and
implement complete production plants
for manufacturing spirally welded large
pipes turnkey for you. The machines
meet the most demanding requirements
in terms of diameter tolerances or
welding gap, as well as delivering out-
standing availability and productivity.
Schuler offers progressive and high-
performance solutions, precisely adapted
to your requirement profile and tailor-
made to your specific requirements from
planning and consulting through to startup.
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FORMING LARGE PIPES
Online process
Combined forming and welding machine
Here, the pipe forming is directly followed
by submerged-arc welding from the inside
and outside.
Offline process
Separate forming and welding machine
After pipe forming and subsequent tack
welding, the submerged-arc welding
process is performed from the inside and
the outside on separate welding stands;
speeds up to 12 m/min.
Modernization
Conversion of existing online machines to
the offline process
The objective of this conversion of existing
machines is to increase quality and
productivity as well as to improve working
safety and energy efficiency.
1 Tack welding spiral pipe mill
2 Coil preparation stand
3 Pipe inspection stand
4 Pipe inside cleaning
5 Tab plate welding stand
6 Submerged arc final welding stand
7 Tab plate removal stand
8 Test ring cutting device
9 Pipe inside suction
10 Pipe inspection stand
11 Hydrotester
12 Ultrasonic testing machine
13 X-ray stand pipe end
14 Pipe end beveling machine
15 Pipe weighing system
16 Inspection stand manufacturer
17 Inspection stand customer
18 Cross seam repair stand
19 X-ray stand weldseam
20 Manual pipe welding stand
21 Pipe conveying system
22 Cross transport system
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Your production benefit with the coil
preparation stand:
Enormous reduction in coil changes and
downtimes
Increasing the safety at work
No crane transfer required any longer
Safe coil opening without springing apart
Integrated into the spiral pipe mill
Max. API quality X100
Exact 90 cut at the start of the strip
Coil weight max. 45 t
Coil outer diameter 1,300 2,200 mm
Coil inner diameter 720 800 mm
Strip width 1,000 2,050 mm
Strip thickness 6 25.4 mm
Speed:
Coil unwinding 0.3 6.0 m/min
Plasma cutter 0.1 3.0 m/min
COIL PREPARATION STAND
Schuler ensures a significant simplifica-
tion in handling during the coil change
at the same time as improving quality and
optimizing procedures. Not only does this
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FORMING THE FUTURE
enable you to reduce unproductive
downtimes, it also ensures consistently
higher efficiency throughout the production
process. Furthermore, you sustainably
increase the safety of work on the stand.
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Your production benefit with the forming
station:
Automation of key procedures resulting
in more efficient change of dimensions
Adjustments driven servo motors with
absolute encoders
Visualization at the control panel
All parameters saved in the SCADA
database
Gap scanner
Digital measuring of outer diameter
Outer and inner calibration system
Strip width 1,000 2,050 mm
Material tolerances acc. to DIN 1016
Strip width tolerance 0 + 20 mm
Strip camber max. 15 mm*
Telescopic effect max. 100 mm
Specific coil weight max. 22 kg**
Material quality max. API quality X100
FORMING STATION
Greater safety and efficiency in forming:
With its forming station, Schuler offers
a significant lead in process safety. All
relevant working steps are automated.
FORMING LARGE PIPES
* per 10 m length ** per mm strip width
Settings are no longer made manually,
but are undertaken directly at the clearly
laid-out control desk instead; the settings
are then implemented by servomotors.
This ensures a consistently reproducible,
high level of product quality.
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LONGITUDINALLY WELDED
LARGE PIPES
For the most exacting requirements: System solutions
for producing longitudinally welded large pipes
FORMING THE FUTURE
With Schuler machines for longitudinally welded large pipes, it is possible to product lengths up to 18 m;
diameters from 406 mm to 1,625 mm (16" 64") are possible, and wall thicknesses from 12 mm to 70 mm (0.48" 2.76")*.
* Other dimensions on request
Irrespective of whether your machine
should be designed for longitudinally
welded large pipes with a bending press
or with U-O-presses Schuler provides
you with the innovative and forward-
looking production technology for this,
outstandingly adapted and individually
tailored to your product dimensions.
Not only are we your expert for efficient
modernizations in order to optimize the
performance of existing pipe plants, we
are also the ideal technology partner for
complete turnkey solutions. Whichever
approach you take the best idea is to get
the expertise and experience of Schuler
on your side right from the outset.
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FORMING LARGE PIPES
1 Sheet edge milling machine
2 Sheet roller train
3 Crimping press
4 Sheet roller train
5 Linear feeding J-press
6 Pipe roller train, cross
transport
7 Tack welding machine
8 2 Inside welding machine
9 Cooling line
10 2 outside welding machine
11 Ultrasonic testing system
12 X-ray
13 Expander with pre-washing
and post-washing
14 Calibrating press
15 Cutting machine for
test rings
16 End processing machine
17 Hydrotester
18 Ultrasonic testing system
19 X-ray
20 End beveling machine
21 Final testing
Bending presses
Schuler bending presses (step process)
are universally applicable for pipes with
diameters from 406 mm to 1,625 mm
(16" 64"). Pipes in this dimension range
can be formed either using a bending
element or with a broad bending shoe.
This ensures fast and efficient production.
C-U-O-presses
U-O-presses primarily represent a
solution when the highest possible
production output of a particular pipe
dimension range is to be achieved.
As with the bending presses, the C-press
is also configured as the crimping press
for pipe forming; together with the
tacking press it ensures consistent pipe
forming, while this concept provides
optimum passage through all the indi-
vidual pipe production stations.
Modernizations
Presses and machines from Schuler are
also highly suited for complete moderni-
zation concepts or for replacing individual
machine components in existing pipe
plants.
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FORMING THE FUTURE
CONVENTIONAL PIPE FORMING PRESS
Schuler pipe forming technology tried
and tested for more than 20 years, and
used all over the world. Lateral sheet
feed, adjustable bowing compensation and
high flexibility are particular features of
these presses.
The various pipe diameters can be
produced without time-consuming die
changes.
LFJ-PIPE FORMING PRESS
The modular concept referred to as the
linear feeding J-pipe forming press
represents a further development of the
conventional pipe forming press. This
unique development means that Schuler
has an exclusive and attractive product
highlight in its portfolio. It is characterized
by an almost direct sheet feed, and bowing
compensation is not required. The modular
structure ensures straightforward transport
and input into the press without difficulty.
Your production benefit with the modular
LFJ-press:
High productivity because the panel is
loaded at the same time as the open-
seam pipe is unloaded
High productivity because bending shoes
can be used
High flexibility by using the bending
element no die changes or lower die
setting required
High process reliability due to simplified
press design no need for bowing
compensation
Simple transport and trouble-free
integration into existing production lines
because of modular structure
Simple structure with scope for future
uprating by extension for bending longer
pipes
Automatic die change and die adjustment
available as an option
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FORMING LARGE PIPES
Your production benefit with
C-U-O-presses:
High productivity for set pipe dimension
Optimized die setting
Simple integration into existing produc-
tion lines
Modernization option for existing
machines
Comprehensive, tried-and-tested
operating concept
Pipe weight max. 30 t
Pipe diameter* 406 mm 1,625 mm
(16" 64")
Wall thickness * 12 mm 70 mm
(0.48" 2.76")
Pipe length * up to 18.3 m (60')
Standard e.g.: API 5L
C-U-O-PRESSES
The particular advantage of the C-U-O
process is its high output of pipes with one
dimension. The individual forming steps
are adapted to this in order to produce a
good quality open-seam pipe. In this way,
the subsequent production steps can be
carried out optimally.
* Other dimensions on request
In order to increase productivity further,
all systems can be equipped with an
automatic die change system. All Schuler
press types have an energy-efficient drive
concept and press control system.
Tried-and-tested press technology in
divided tie rod construction. This means
the disadvantages of a C-frame design are
avoided, and reproducible crimping results
are achieved even after long use.
Press design adapted for optimum transport
and optimum U-forming of the contoured
sheets.
Simple plate design for cost-effective con-
figuration of the press, including dynamic
step switching and parallel control. Patented
Schuler ring technology with an option for
additional production increase.
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PERIPHERAL SYSTEMS AND
MACHINES
Keeping every detail in sight
Systems from Schuler are unique. With our
tailor-made range of peripherals, you can
choose from numerous possibilities to
have your system planned individually
down to the most painstaking detail, and
to design it completely according to your
requirements.
LINE CONTROL
Higher-level controller for monitoring the
individual machines, machine components
as well as the entire pipe manufacturing
process with graphical display on a
central computer using line visualization.
The status of production is displayed simply
and at a glance with various colors.
MATERIAL TRACKING
The Schuler pipe identification system
ensures optimum material tracking.
Connected to the line control, it guaran-
tees a smooth process as well as direct
allocation of the key production figures
to every single pipe that is produced. The
data for the individual pipes can be called
up directly and made available for quality
assurance.
Schuler expertly covers the entire market
spectrum of course from handling
through to cleaning, from the coil through
to the pipe in accordance with the standard.
It goes without saying that you can also
receive all Schuler solutions as individual
units for integration. Simply contact our
FORMING THE FUTURE
Schuler peripheral components:
Line control
Material tracking
Pipe handling
Ultrasonic test stand
X-ray test stand
Pipe cleaning device
Cross seam welding stand
Cross transport
Coil handling
Inspection stand
Offline welding stand
End beveling machine
Hydrotester
Pipe handling Ultrasonic test stand Pipe cleaning device
customer service, on your doorstep
worldwide we will be happy
to help you.
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Using the new, patented process, it is
possible to degauss large pipes com-
pletely during their production using an
alternating magnetic field with a field
intensity of up to 80 kA/m. As a result, the
arc is not deflected by residual magnet-
ism when the ends of the pipe are being
OFFLINE WELDING STAND
Fully automated process Welding seam
tracking device Automatic flux supply
and recovery system Video camera
system Welding parameter database
HYDROTESTER
Ball aligning heads Inside sealing or face
sealing both possible Water hydraulic
control system Variable holding time
Connected to PID data system Automatic
pipe positioning Automatic test sequence
Visualization with database for all pipe
parameters Full automatic pipe feeding
END BEVELING MACHINE
Automatic clamping with correct force
according to the diameter Infinitely
coverage for all diameter ranges Short
change over time Concentric clamping
Energy recovery by using the latest
inverter technology
Welding speed max. 3.4 m/min
Inside welding
3 x DC / AC or power
Wave / square Wave
Outside welding
2 x DC / AC or power
Wave / square Wave
Material quality max. API quality X100
Pipe diameter 18"140"
Pipe length 8 24 m
Closing force max. 50,000 kN*
Water pressure max. 400 bar
High pressure control range 33 300 liters/min
Cutting speed max. 90 m /min
Face plate feed
Speed
5 50 mm /min
Face plate drive
Servo motor
max. 200 kW AC
Schuler global innovation:
Patented process for degaussing large pipes
welded together. This means the quality
and load capacity of the welds are
improved, allowing them to withstand
much higher pressure.
The welded pipes are pushed through an
electromagnetic coil for degaussing
FORMING LARGE PIPES
without delays in production. The process
is suitable for spiral welded pipes with
wall thicknesses up to 30 mm and a cross
section from 1,422 mm (56") to 3,500 mm
(140"). Longitudinally welded pipes in the
usual diameter range from 16" to 64" can
have a wall thickness up to 70 mm.
* Higher closing forces on request
Offline welding stand End beveling machine Hydrotester
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Deutschland
YOUR CONTACT FOR ALL TASKS
The collected expertise of Schuler for all process steps. Packaged
appropriately for the tasks and requirements of our customers
worldwide.
FORMING THE FUTURE
Reference machines
Service companies
Schuler is your technology partner for
complete turnkey machines. However,
we also provide you with our special
planning and consulting expertise for
every detailed task. In this way, we support
our customers in optimally configuring the
entire production process, and provide
advice in every single process step from
the sheet store to the final check on the
finished pipes. We offer you our entire
expertise entirely in accordance with your
specific requirements, and tailored to your
needs.
We use the latest technologies such as
3D-CAD and corresponding simulation
technology to design and optimize the
layout of production halls and the line
control system.
All details are decisive for economical and
forward-looking production whether it
is a matter of building planning, supply
routes, material flow or data exchange.
At Schuler, you will find the best points
of contact for all questions relating to
production. Simply contact our customer
service!
Ultrasonic testing machine 2012 GEIT-V&M Brazil
Ultrasonic testing machine 2011 STS Spain
Spiral pipe machine upgrade 2010 Bender-Ferndorf Germany
Ultrasonic testing machine 2010 VSB-Vallourec & Sumitomo Tubos Brazil
Spiral pipe plant offline 2009 / 2010 Topworth India
Ultrasonic testing machine 2009 / 2010 VAM Drilling France
Spiral pipe plant offline 2008 / 2010 United Spiral Pipe USA
Spiral pipe machine 2007 / 2008 Altumet Algeria
Ultrasonic testing machine 2007 Hai-Long China
Ultrasonic testing machine 2006 Tubos Soldados Atlntico Brazil
Spiral pipe machine upgrade 2006 Alfapipe Algeria
Ultrasonic testing machine 2006 Hai-Long China
Radioscopy machine 2005 / 2006 Tubos Soldados Atlntico Brazil
Spiral pipe plant online 2005 AZIZ Saudi Arabia
SCHULER EXPERTISE IN SELECTED REFERENCES
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Deutschland
FORMING LARGE PIPES
More than 900 Schuler Service employees are working for our custom-
ers all over the world round the clock. They provide assistance in
startup as well as maintenance and servicing. Reference machines
Service companies
Planned service companies 2014/2015
Foreign agencies
HIGHER PERFORMANCE DUE TO
OPTIMUM SERVICE: SCHULER
Five building blocks in success. Schuler Service relies on
productivity, safety, expertise, partnership, future.
HOW TO KEEP YOUR MACHINE IN TOP
FORM ALL THE TIME
Schuler stands for outstanding perfor-
mance and the highest quality. We set
ourselves the same goal in service too.
The five building blocks of productivity,
safety, expertise, partnership and future
mean that our unique service offering is
precisely tailored to our customers'
needs. More than 900 highly qualified
employees worldwide ensure that your
machines function smoothly. In the final
analysis, this adds up to productivity
and unrestricted availability safety
throughout the entire service life of your
machine.
Productivity
Safety
Expertise
Partnership
Future
Germany
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Schuler Pressen GmbH
Bahnhofstrae 41 73033 Gppingen Germany
Tel. + 49 7161 66307 Fax + 49 7161 66729
Schuler SMG GmbH & Co. KG
Louis-Schuler-Strasse 1 68753 Waghusel Germany
Tel. +49 7254 988 563 Fax + 49 7254 988 339
largepipes@schulergroup.com
www.schulergroup.com / largepipes