Method and Walking Beam Furnace for the Intermediate Heating of Pipes in Hot Rolling Mills

This invention relates to a method of intermediate heating of pipes, or the like, in the hot manufacturing thereof. Moreover, the invention provides an intermediate heating furnace in hot rolling mills for pipes or the like, to carry out said method.

The hot pipe-manufacturing process comprises the following main steps:

Heating of round or square billets from the ambient temperature up to the milling temperature (about 1280.degree. C.).

Rough-rolling of billets. On completion of this step, the rough-rolled pipes have a temperature of about 700.degree.-1000.degree. C.

Heating or cooling of the rough-rolled pipes to a temperature of 920.degree. to 980.degree. C. (temperature equalization).

Final sizing.

The rough-rolled pipes formed in the plug-mill and exiting from the respective mill at temperatures of 700.degree. to 1000.degree. C. are either heated or cooled in an intermediate treatment furnace, generally of the walking beam type, so as to have a substantially uniform temperature, for example of 930.degree. to 950.degree. C., at the beginning of the successive step of final sizing. This equalization of the temperature of the rough-rolled pipes prior to their final sizing is of particular importance for those pipes that must have high qualitative and metallurgical characteristics.

The intermediate heating furnaces used heretofore for the purposes specified above have a substantially uniform temperature throughout their length, which temperature is substantially the same as the desired discharge temperature of the rough-rolled pipes from the furnace. However, since the rough-rolled pipes enter the furnace at different temperatures, they will acquire the desired discharge temperature after different periods or distances from their introduction into the furnace; therefore, they will be maintained for different time periods at the temperature existing in the furnace. The length of the heretofore known furnaces is established as a function of the lowest temperature of the rough-rolled pipes upon their introduction into the furnace. As a consequence, a relatively high number of rough-rolled pipes that were at a higher temperature upon their introduction into the furnace, are maintained in the furnace at a costant discharge temperature for so long a time period as to cause in the grain thereof undesired metallurgical changes impairing the quality of the final product. This quality, therefore, cannot be maintained strictly constant, whereby a greater quantity of pipes will be rejected upon qualitative inspection.

The invention aims to overcome these disadvantages and it resides substantially in the fact that the pipes are first introduced into a forehearth which is formed in a first portion of the intermediate heating furnace, at the inlet side thereof, wherein the temperature is maintained below the outlet temperature and below the temperature which would cause metallurgical changes in the grain of the steel constituting the pipes. The pipes which are cooler than said forehearth will be heated up; the pipes which are at a temperature proximate to that of said forehearth will maintain their temperature during the whole or a fraction of the whole stay thereof in said forehearth, however with no change in the grain thereof; the pipes which are hotter will be cooled down and, though their temperature is maintained during a certain time period above the grain-impairing temperature, their grain will not be impaired because the latter phenomenon occurs when the temperature is constant, and not when it is decreasing.

The stay of the pipes in the forehearth is such that, at the outlet therefrom and inlet into the successive section of the furnace, the temperature differential between the various pipes in nullified or at least minimized and is equal or very proximate to the temperature of said forehearth. In a successive section of the furnace, the pipes are heated up from the temperature they had reached in the forehearth to the desired temperature of discharge from the furnace, through a constant heating step, which prevents the grain from undergoing metallurgical changes despite of the high temperature, because this phenomenon occurs only if said temperature is constantly maintained during a certain period. Small differences between the temperatures of the pipes upon their introduction into the second section of the furnace may entail the establishment of a constant temperature which might be dangerous for the grain of some pipes, but such a constant temperature lasts only a limited time so that the grain undergoes no undesired change.

To carry out the above method, the invention provides an intermediate heating furnace, particularly of the walking beam type, in hot rolling mills for pipes or the like, said furnace being located between the plug-mill and the sizing mill, and substantially characterized in that it comprises, at the inlet side of the furnace, a forehearth which is preferably devoid of burners and is heated indirectly by the successive furnace chamber which is provided with one or more burners.

A particular problem in the intermediate heating of pipes or the like in the hot manufacturing thereof, resides in the fact that between the plug-mill and the intermediate furnace there may be a certain number of rough-rolled pipes, generally one to four depending upon the particular installation, having a temperature ranging from 700.degree. to 1000.degree. C., which pipes shall be introduced into the intermediate furnace to equalize their temperature to the outlet temperature of about 920.degree. to 980.degree. C. In case of disactivation of the sizing mill downstream of the intermediate furnace, the pipes in said intermediate furnace cannot be discharged therefrom, and said pipes between the plug-mill and the intermediate furnace cannot be introduced into the furnace and must be discharged as waste material with resulting loss of product, because they will cool excessively and the intermediate furnace, when the normal cycle is resumed, has not a sufficient thermal capacity to heat them up to the temperature of about 920.degree. to 980.degree. C., i.e., the temperature that the pipes must have when reaching the sizing mill. In fact, intermediate furnaces for equalizing the temperature of the rough-rolled pipes are low-cost furnaces, generally of the walking beam type, wherein a control system with a processor or with pyrometers for regulating the thermal cycle would be too expensive. However, the furnace must ensure the utmost reliability as to the temperature of the rough-rolled pipes discharged therefrom.

To overcome this disadvantage, according to the present invention, some recesses or grooves are left available, i.e. empty, at the inlet side of the furnace either in the stationary beams and in the walking beams during the normal operation, so that, when the pipes existing between the rough-roller or plug-mill and the furnace are to be introduced into the furnace with no possibility to discharge as many pipes therefrom due to any trouble in the apparatus downstream thereof, said available grooves can be used to accommodate said pipes that, otherwise, could not be introduced into the furnace and should be discharged. Upon resumption of the normal operating conditions, before starting the rough-roller and, therefore, conveying more rough-rolled pipes into the furnace, a few normal operating cycles are carried out so as to discharge the exceeding pipes, corresponding to the grooves to be left available during the normal operation. Thereafter, the normal loading of pipes into the furnace and simultaneous unloading therefrom is resumed.

To achieve the object of having said available emergency grooves at the inlet side of the furnace without affecting the normal course of the loading, progressing and unloading cycles of the pipes, and to meet the emergency requirements, the intermediate heating furnace according to the invention, usually a walking beam furnace, is provided ai its interior--just after the inlet door for the rough-rolled pipes, or the like--with a charger device which advances each introduced tube, above the stationary and walking beams and over the length thereof comprising the grooves to be left available for any emergency, while the walking beams are lowered, to a position permitting the walking beams, in the successive lifting step, to pick up the pipe from the charger device by means of the first groove that is devoid of pipes. Successively, the walking beams are advanced and are lowered to lay down on the stationary beams the last picked up pipe in a range with the pipes introduced previously, so as to leave the required empty grooves on the stationary and the walking beams. During this latter advancing and lowering movement of the walking beams, the leading pipe of the range of pipes is transferred onto the roller discharge pathway so that said pipe can be discharged from the furnace.

The charger device, therefore, permits the pipes to be charged into the furnace at the same rate they are discharged therefrom and the cycle described above, therefore, meets the normal operating condition, while having at the inlet side a certain number of free grooves. In case of disactivation of the sizing mill and, therefore, discontinuance in discharging the rough-rolled pipes from the intermediate furnace, said available free grooves can accommodate, by action of said charger device, the rough-rolled pipes existing between the plug-mill and the intermediate furnace, thus avoiding the discarding thereof and, therefore, the relevant loss of production and obtaining a considerable saving of energy because, once introduced into the furnace, the pipes keep their heat that, otherwise, would be lost. For this purpose, the charger device will deposit the rough-rolled pipes into the grooves left available and will position them therein as they are introduced into the furnace whereas the trailing pipe is left on the charger, this result being obtained by merely raising and lowering, and not by translating, the walking beams that pick up each pipe from the charger device and lay it down onto the fixed beams and into the empty grooves while no pipe is discharged from the furnace.

These and other characteristics of the invention and the advantages resulting therefrom will be apparent with greater details from the following description of some preferred embodiments thereof shown by way of nonlimitating examples in the accompanying drawings, wherein:

FIG. 1 is a diagrammatic vertical longitudinal sectional view of a walking beam furnace constructed according to this invention and used as intermediate furnace in a hot rolling mill for pipes.

FIGS. 2 to 8 are fragmentary sectional views similar to FIG. 1, showing some operational successive positions of the charger device and walking beams of the furnace, during one cycle of movements of the latter.

FIG. 9 is a diagrammatic vertical cross-sectional view of the furnace.

FIG. 10 is a diagrammatic vertical longitudinal sectional view of a further embodiment of a walking beam furnace according to the invention.

FIGS. 11 to 13 are fragmentary sectional views similar to FIG. 10 of some operational successive positions of the charger device and walking beams of the furnace, in one cycle of movements of the latter during the normal operation.

FIGS. 14 to 19 are fragmentary sectional views similar to FIGS. 10 to 13 of some operational successive positions of the charger device and transfer walking beams of the furnace during the emergency operation, wherein pipes are introduced into the furnace while no simultaneous discharge of pipes is effected therefrom.

With reference to FIGS. 1 to 9, the intermediate heating furnace in a hot rolling mill for pipes is formed by a walking beam furnace comprising stationary or fixed beams 1 and transfer walking beams 2. The fixed beams 1 and walking beams 2 are formed at the top side thereof with pipe-carrying grooves or recesses each adapted to accommodate one rough-rolled pipe T coming from the plug-mill and to be transferred to the sizing mill. The numeral 3 indicates the rotatable door for the introduction of the rough-rolled pipes into the furnace, and the numeral 4 indicates the powered roller-pathway for the transfer of the pipes.

The walking beams 2 are carried by a support structure 5 resting in a known manner, through bottom horizontal and longitudinal rails 105, on corresponding supporting wheels (not shown) mounted on carriages 6 which rest, in turn, through rolling wheels 106, on inclined fixed rails 7. The horizontal movement of the walking beams 2 forwards (in the direction indicated by the arrow F) and backwards is obtained by moving the support structure 5, for example, by the action of the actuating hydraulic cylinder 8, on the supporting wheels of the stationary carriages 6. The upward and downward vertical movement of the transfer walking beams 2 is obtained by moving the carriages 6, for example, by means of the actuating cylinder 9 and leverage 10, back and forth over the inclined rails 7.

In the exemplary embodiment illustrated herein, the transfer walking beams 2 extend toward the inlet door 3 only to the third groove of the fixed beams 1, i.e. they can pick up--as the leading pipe T at the inlet side--the pipe T accommodated in the third groove of the fixed beams 1 from the inlet end thereof. Between the inlet door 3 and the transfer walking beams 2, there is provided an assembly of charger walking beams 11, which are of comparatively short length and are formed--in this exemplary embodiment--with two pipe-carrying grooves. These charger walking beams 11 perform a cycle of movements which is similar to that of the transfer walking beams 2, in co-operation with the first section of the fixed beams 1 at the inlet side, and they may be actuated for this purpose in any suitable manner.

In the illustrated exemplary embodiment, the charger walking beams 11 are secured to supporting structures comprising uprights 12 and crosspieces 13 and are slidably guided, through guiding uprights 112, within tubular guides 14 swingably mounted about horizontal axes on the furnace structure. Each supporting structure 12, 112, 13 of the charger walking beams 11 is imparted a reciprocating raising and lowering movement and a reciprocating movement in the direction of advance F by means of a crank 15 which is pivotally connected thereto and which is actuated by a suitable motor-reducer 16.

The frequency of the movements performed by the charger walking beams 11 is higher than that of the movements of the transfer walking beams 2, so as to obtain the following operations, shown in the FIGS. 1 to 8:

It is assumed that a rough-rolled pipe T' to be heated, introduced into the furnace through the door 3 and shown with hatching lines in the FIGS. 1 to 8, is in the first pipe-carrying groove of the fixed beams 1, and that the transfer walking beams 2 are in their lowered and rearmost position and the charger walking beams 11 are in their rearmost and partly raised position, with their first pipe-carrying groove in co-axial and flush relation with the first pipe-carrying groove of the fixed beams 1, as shown in FIG. 1. Thereafter, the charger beams 11 pick up the first pipe T' which has been fed to the first pipe-carrying groove of the fixed beams 1 (FIG. 2) and move forwards in the direction of the arrow F (FIG. 4) to deposit the pipe T' into the second pipe-carrying groove of the fixed beams 1 (FIG. 5). The charger beams 11, then, move back to their original position (FIG. 5) and thereafter, with an upward movement and a translatory movement in the direction of the arrow F, pick up by means of their second groove the pipe T' from the fixed beams 1 (FIG. 6) and transfer said pipe to the third pipe-carrying groove of the fixed beams 1 (FIGS. 7 and 8). From this position onwards, the transfer walking beams 2 take over and, with an upward movement (FIG. 3) and a translatory forward movement (FIG. 5), will position the pipe T' into the fourth pipe-carrying of the fixed beams 1 while the last pipe Tu at the outlet side of the furnace is discharged onto the roller pathway 4 to be taken out of the furnace (FIG. 1).

In case of emergency, when the sizing mill downstream of the furnace is disactivated, the roller pathway 4 will be devoid of pipes and the first three pipe-carrying grooves of the fixed beams 1 at the inlet side are empty, while the transfer walking beams 2 are in their lowered rearmost position. Therefore, three more pipes can be introduced into the furnace with the following procedure: Through the door 3, the first of three pipes is introduced into the furnace and is positioned in the first pipe-carrying groove of the fixed beams 1, while the charger beams 11 are in their rearmost and partially raised position. Said first pipe is then lifted by the charger beams 11 and translated in the advance direction F to be laid down into the second pipe-carrying groove of the fixed beams 1. Thereafter, while the charger beams 11 move back to their initial position, a second pipe is introduced into the furnace through said door and is accommodated in the first pipe-carrying groove of the fixed beams 1. By means of a successive cycle of movements of the charger beams 11, said two pipes are advanced one step so as to transfer the first pipe into the third pipe-carrying groove of the fixed beams 1 and the second pipe into the second pipe-carrying groove of the fixed beams 1, thus clearing the first pipe-carrying groove of the fixed beams 1 which will accommodate the third pipe which is introduced into the furnace through the door 3. Therefore, the first three pipe-carrying grooves of the fixed beams 1 are also filled with the rough-rolled pipes which are between the plug-mill and the intermediate furnace and which, otherwise, should be discarded as waste material with resulting considerable loss of production and energy. Upon resumption of the normal conditions, i.e. when the sizing mill downstream of the furnace starts working again, three normal feeding cycles of the transfer walking beams 2 and charger walking beams 11 will be performed, in synchronism with each other and without introducing any new rough-rolled pipes, so as to get rid of the previously introduced pipes which are available in the first three pipe-carrying grooves of the fixed beams 1, whereby to restore the conditions of FIG. 1.

Of course, the transfer walking beams 2 may pick up pipes T from either the second or the fourth or fifth pipe-carrying groove of the fixed beams 1, and the charger beams 11 may then be formed with either one or three or four pipe-carrying grooves.

The walking beam furnace according to the invention, used as an intermediate heating furnace between a preceding plug-mill and a following sizing mill for pipes, comprises, at the inlet side, a forehearth 17 which is, preferably, not provided with burners and is heated indirectly by the successive chamber 18 of the furnace, which is provided with one or more burners 19. The forehearth 17 has such a length and a temperature whereby the rough-rolled pipes coming form the preceding plug-mill and having temperatures ranging from 700.degree. and 1000.degree. C. will substantially uniformize their temperatures while traveling through the forehearth 17 of the furnace so as to enter the successive chamber 18 substantially at the same temperature, which is lower than their temperature at the outlet of the furnace. The temperature in the forehearth is kept below the level which causes metallurgical changes in the grain of the material of the pipes, for example a temperature of about 800.degree.-850.degree. C. Therefore, the pipes which are introduced at a lower temperature are heated in the forehearth 17 up to the temperature, for example, of about 850.degree. C., whereas the pipes which are introduced at a higher temperature are cooled down in the forehearth 17 to substantially the same temperature, for example, of about 850.degree. C. As a consequence, in the successive chamber 18 of the furnace, all the pipes are heated substantially to the same desired discharge temperature, for example, to a temperature between 920.degree. C. and 980.degree. C. Practically, the forehearth 17 is dimensioned on the basis of the hottest rough-rolled pipe to be charged and to be cooled (taking also into account the thickness thereof), whereas the successive chamber 18 of the furnace is dimensioned and operated so that, at the outlet thereof, the pipes have substantially the same desired discharge temperature, however without staying in the chamber 18 at constant temperature and/or for too long time periods such as to entail a danger of metallurgical changes in the grain thereof.

The walking beam furnace according to the exemplary embodiment of FIGS. 10 to 19 is substantially similar to that of FIGS. 1 to 9, the same or the equivalent parts being indicated by the same reference numerals. The portion of the fixed beams 1 toward the inlet at the introduction side, corresponding to three grooves in the example, according to the invention, is located at a lower level than the remainder portion for operational requirements to be explained below. Again, the walking beams 2 are carried by a supporting structure 5 resting, through bottom rails 105, on corresponding bearing wheels 106 which, however, are mounted on bell-crank supports 20, 120 pivoted at 21 and actuated parallelly to the rails 105 by a hydraulic actuating cylinder 22. The horizontal movement of the transfer walking beams 2 onwards, i.e. in the feeding direction indicated by the arrow F, and backwards is obtained by moving the supporting structure 5, for example, by means of the hydraulic actuating cylinder 8 over the bearing wheels 106 of the stationary bell-crank supports 20, 120. The vertical movement of the transfer walking beams 2 upwardly and downwardly is obtained by displacing the wheels 106 or by rotating the bell-crank supports 20, 120 by means of the hydraulic actuating cylinder 22. The numeral 4 indicates the powered roller pathway to discharge the pipes to be conveyed out of the furnace.

The furnace is provided with a charger device comprising a door 23 having an "L"-shape in cross section and capable of oscillating on a pivot 123 located at the corner of the "L" so that the concavity of the "L" is facing upwards at all times. The door 23, in the position thereof overturned outwards (see FIGS. 12 and 16), receives a pipe coming from the rough-roller through a chute 24 and falling into said concavity. While moving to its position fully overturned into the furnace (FIGS. 10, 11, 13, 14), said door 23 introduces the pipe into the furnace to load said pipe onto the charger device proper. This charger device comprises a bearing carriage 25 resting through wheels 26 on guides 27 formed in the outer structure of the furnace below the hearth 28 of the furnace, so that the carriage 25 can slide over said guides 27 along the length of the furnace. The carriage 25 is actuated by external movers, preferably a hydraulic actuating cylinder 29. The carriage 25 has secured thereto uprights 30 each carrying a pipe-carrying support 31 comprising a pipe-receiving groove. The number of uprights 30 and supports 31 is generally the same as that of the walking beams 2. Said uprights 30 are passed through the hearth of the furnace by means of suitable slots having such a length as to permit the longitudinal movement of the uprights 30 over the required amplitude.

In a normal operational cycle, the pipe T coming from the rough-roller is, as shown in FIG. 10, at the bottom of the chute 24, on the lever arms 32 which, thereafter, are oscillated to lay down the pipe T onto a successive chute 33, as shown in FIG. 11. Thereafter, as shown in FIG. 12, a stop member 34 is lowered by the action of the oscillatable door 23 which is overturned so that its concavity faces said chute 33, whereby the pipe T will no more be restrained and will fall into said door 23. The door 23 is then rotated, still maintaining its concavity facing upwards, to the position shown in FIG. 13 whereby the pipe, now within the furnace, will roll off the door 23 to be received in the groove of the charger device 31. The door 23 assures a partial seal during its rotation and a prefect seal when in its forthcoming pipe receiving position (FIG. 12) and in its pipe delivering position onto the charger device (FIG. 13). The door actuates the stop member 34 mechanically by means of its lug 223.

The charger device 31 having a pipe in its pipe-carrying groove, is moved, when the walking beams are in their lowered position, in the direction F to the first available groove behind the range of pipes already charged in the furnace, as shown in FIG. 10. The walking beams 2 are then raised to pick up the just-charged pipe and the previously charged pipes, as shown in FIG. 11. The walking beams 2 are then advanced in the direction F, while the charger device 31 is moved backwards empty and ready to receive the next pipe to the charger, as shown in FIG. 12. The walking beams 2 are then lowered to discharge the last pipe of the range of pipes onto the roller pathway 4 which will carry the same out of the furnace, while all the other pipes will be laid down into the respective grooves of the fixed beams 1 after moving one step forwards in the direction F. Three grooves on the fixed beams 1 have been left empty. The cycle described above will then be repeated, while in the meantime a new pipe has already been charged into the furnace.

In case of an emergency, when the pipes cannot be discharged from the furnace, the last pipe T' which had been charged into the furnace and has arrived at the first available groove of the walking beams 2 behind the range of the previously charged pipes according to the normal cycle described above, as seen in FIG. 11, is laid down by the walking beams 2 onto the fixed beams 1, without previously advancing the walking beams 2 in the direction F. Thus, said pipe will be laid down into the first of the available grooves which are formed in the fixed bemas purposely fro such an emergency, and at the same time the pipe which was ready to be discharged from the furnace will not be discharged onto the roller pathway and, therefore, will be retained in the furnace.

In FIG. 14, the pipe T' charged last before the occurrence of the emergency is already in the first available groove formed in view of an emergency in the fixed beams 1, the walking beams 2 being in their lowered position, while a second pipe T" is on the charger device. The second pipe T" is then brought by the charger device to such a position whereby it will be laid down into the second available groove of the walking beams 2, when the latter will raise without moving longitudinally of the furnace, and thereafter said pipe T" is laid down into the second available groove of the fixed beams 1 when the walking beams 2 are lowered, again without moving longitudinally. The charger device is then moved backwards, while the walking beams are in their raised position, to repeat its cycle and bring a third pipe T"' in the last available groove, as seen in FIGS. 16, 17 and 18. A fourth pipe T.sup.IV is then introduced and left on the charger device, as seen in FIG. 19.

The portion of the fixed beams 1 comprising the grooves which are left available in the normal operational cycle and which are occupied by the pipes in the emergency cycle, has a smaller height than the remaining portion of said fixed beams, whereby the charger device, which shall move in the direction F above the first-mentioned length of the fixed beams, may also have a smaller height. This permits the walking beams 2 to have a shorter vertical stroke during the normal cycle.

When the emergency is over and the normal cycle is resumed, the walking beams will move vertically and horizontally with the movements of a normal cycle, as specified above, however without introducing any more pipes. The walking beams, in this cycle for restoring the normal operating conditions, perform a longer vertical stroke to permit the pipes to clear the greater height of the fixed beams between the portion thereof accommodating the emergency grooves and the remaining portion thereof. When the number of pipes discharged from the furnace is the same as the number of pipes introduced during the emergency cycle and as many grooves have been made available by transferring the pipes therein toward the furnace chamber, the normal cycle described above is resumed wherein one pipe will be introduced each time one pipe is discharged, and the vertical stroke of the walking beams will be reduced by the additional amount which was necessary to clear the greater height of the fixed beams at the portion thereof comprising the emergency grooves.