Manufacturing Process
Tata Pipes-Idler Tubes production process begins with slitting of wide Steel Hot Rolled Coils to the width required for the production of customer specific section dimensions. The slit coil is then fed through the mill and is shaped into a round tube by a series of forming coils. The converging strip edges of this round tube are squeezed together and welded using high frequency induction welding. After this the external excess weld bead is removed and the tube then passes through a set of shaping rolls where it is shaped to its final form, exactly sized to the required dimensions followed by cutting to the desired length and bundling in a fully automatic process.
Quality Control
The quality of our product is controlled during the manufacturing process. It starts with slitting the strip edges, continues with speed and temperature control during the HFIW process and is followed by non-destructive eddy current testing directly after welding. Off-line drift and flattening tests are conducted after this – all as per ISO 9000:2002 quality management system.
Idlers for Belt Conveyors
Steel tubes are extensively used as idlers for belt conveyors. The tubes are made from the steel manufactured by Open Hearth basic oxygen, Electric Furnace or combination of these processes. These tubes are manufactured by one of the processes - Seamless or ERW (Including HFIW). The height of the internal fin of the ERW pipes should not exceed 1.7mm. The maximum Phosphorus and Sulphur contents are limited to 0.005%.
General Technical Specifications and Tolerances IS : 9295
| Section Type |
Grade |
Mechanical Properties |
Outside Dimension |
Thickness |
Dimensional Tolerance |
| YST |
UTS |
% of Elongation |
Ovality |
Eccentricity |
Weight |
| Mpa |
Mpa |
|
|
| ERW IS: 9295 |
210 |
210 |
330 |
20 |
+/- 0.8% |
+/- 10% |
<168.30D-0.5mm
>168.30D-1.0mm |
Not More Than 5% |
L
+10%, -8% |
|
240
310 |
240
310
|
410
450
|
18
15 |
M & H
+/- 10% |
|
| |
|
| Length |
6.0 m + 0.05 m. Customized length ranging from 6 m to 11 m may be supplied. |
| Straightness |
Minimum 1 : 1000th of any length measured along the centre line (mill straightened condition) unless otherwise specifically arranged. |
| End Finish |
Plain ended – Mechanically sheared, mill –cut finish without further machining. |
| Surface Finish |
Black without any surface treatment of oiling or varnishing. |
| Raw Material |
Sulphur content : 0.05% max, phosphorus content : 0.05% max, equivalent carbon percentage well within specified weldability limits with matching physical properties. |
| Weldability |
Tata Pipes Idler Tubes are weldable with standard M.S. Electrodes without any pre-heating. |
| Packing |
Bundled by sealing metal strap, and each bundle is labeled for size, measurement, Lot no. etc. Approximate weight of each bundle is 1.5 Mt (+/- 500 kg). |
| Identification |
Marking of "TATA PIPES" emblem on surface punched/stenciled/sticker pasted on all Idler Tubes. Standard BIS mark is also put on the sections. |
| NOTE |
Tata Pipes Idler Tubes in customized size, grade, length, surface finish and end finish may be delivered as per agreed supply conditions. |
| |
3.65 |
4.05 |
4.50 |
4.85 |
5.40 |
6.30 |
7.10 |
63.5 |
|
|
|
|
|
|
|
76.1 |
|
|
|
|
|
|
|
88.9 |
|
|
|
|
|
|
|
101.6 |
|
|
|
|
|
|
|
108.0 |
|
|
|
|
|
|
|
114.3 |
|
|
|
|
|
|
|
120.0 |
|
|
|
|
|
|
|
127.0 |
|
|
|
|
|
|
|
133.0 |
|
|
|
|
|
|
|
139.7 |
|
|
|
|
|
|
|
152.4 |
|
|
|
|
|
|
|
159.0 |
|
|
|
|
|
|
|
165.1 |
|
|
|
|
|
|
|
168.3 |
|
|
|
|
|
|
|
193.7 |
|
|
|
|
|
|
|
219.1 |
|
|
|
|
|
|
|
| |
Existing product range |
| |
Product range under development |
