1 Unit Process
Unit Production Operating Procedures
Uncoiling — Shearing & Butt Welding — Feeding Guidance — Forming — Welding Tracking — Welding — Preliminary Sizing — Solution Treatment — Sizing & Straightening — Inspection — Inkjet Printing — Length Cutting — Coiling — Underwater Airtightness Testing
2 Scope of Application
2.1 Product Specifications: φ6-28mm, wall thickness 0.4-1.5mm.
2.2 Welder Maximum Output Current: 400A.
3 Startup Preparation
3.1 Check water, electricity, gas supply, and controls:
(1) After turning on the main power, verify indicator lights on all control panels;
(2) Inspect gas valve switches on the production line and ensure protective gas meets requirements;
(3) Check water supply for cooling/lubrication points.
3.2 Verify sheet material compliance.
3.3 Confirm buffer belt length meets standards.
3.4 Inspect cutting discs; replace damaged ones with corresponding specifications.
3.5 Replace welding torch electrodes and install them properly.
3.6 Check the drive motor’s fan.
4 Pipe Manufacturing
4.1 Start the cutting machine, verify normal operation, reset its position to zero, and set pipe length per process card.
4.2 Select "Linked" mode for normal welding; use "Jog" mode for manual adjustments.
4.3 Power on the welder and select the required torch.
4.4 Adjust protective gas flow rates via "Gas Adjustment" according to process parameters.
4.5 Press "Auto Run" to start the unit, switch "Main Arc Start" to "ON," and calibrate electrode current/voltage, welding speed, and voltage control parameters per specifications.
4.6 Open cooling water valves and start □□/grinding wheels.
4.7 Fine-tune welding parameters based on real-time conditions.
4.8 Monitor unit operation and document actual welding parameters.
4.9 Perform reverse bending tests as per process card.
5 Shift Change
5.1 Shutdown for shift change:
(1) Press "Auto Stop" to shut down the unit and turn off the welder;
(2) Close protective gas and compressed air valves;
(3) Disconnect main power;
(4) Complete records and clean the unit.
5.2 Non-stop shift change:
(1) Complete records and clean the unit;
(2) Hand over duties to the next shift supervisor.
Automatic Welding Technical Operating Procedures
1. Strictly inspect incoming materials; reject non-compliant items and document quality checks.
2. Verify tube steel grade, heat number, and specifications against the *Production Process Flow Card* before production. Ensure quality meets standards and maintain mutual inspection records.
3. Adjust the entire production line’s center and position rollers slightly higher/wider when changing specifications.
4. Set the unit to "Jog" mode for threading and calibrate roller positions.
5. After threading past the welding torch, replace electrodes, adjust parameters based on material and wall thickness, then switch to "Auto" mode.
6. Adjust forming rollers to achieve outer diameter and straightness per process card.
7. Monitor welding quality, adjust parameters as needed, and maintain original parameter records.
Pipe Cutting Technical Operating Procedures
1. Obtain/replace cutting discs and grinding wheels.
2. Set cutting length per process card.
3. Measure pipe outer diameter, length, and straightness; inspect weld quality and report data to welding supervisor.
4. Replace empty protective gas cylinders promptly, store empties in designated areas, and log usage.
5. Regularly check sizing section and equipment during production.
6. Adjust grinding wheel positions based on weld conditions.
7. Mark qualified pipes and attach *Production Process Flow Cards* before transferring to storage.
8. Perform reverse bending tests as required and document results.
9. Number each pipe per process card.
10. Label substandard/scrap pipes and transfer to designated areas.
11. Coordinate with welding supervisor during roller changes, threading, and debugging.
12. Perform daily maintenance; report malfunctions to maintenance promptly.
13. Clean the sizing section, control cabinets, nearby distribution boxes, and 1-meter area before shift end.
Online Bright Annealing Technical Operating Procedures
1. Set annealing furnace current, voltage, and power per material, welding speed, and *Heat Treatment Process*.
2. Verify protective gas compliance; adjust pressure or replace cylinders if needed.
3. Open cooling water valves for sufficient furnace cooling.
4. Monitor furnace conditions and submit samples for inspection as required.
5. Observe hydrogen bubbles at the outlet during annealing.
6. Maintain annealing records.
Guangdong Henkel Technology Co., Ltd.
Recommended Reading: *High-Speed Precision Welded Pipe Lines*
Hotline: 189-4243-7326
