When welding is being carried out on a pipe, there are a lot of things to keep in mind. Some of these are vitally important, and if done correctly can affect the entirety of the weld. Pipe welding can be quite complex work that requires a lot of skill, but pipe rotators make that work much easier.
The design details are given includes such items as materials and their characteristics. Adaptation methodology the parts relation with the whole device and the effect of the finished product upon which an inqiusitmined can make collection of fact in future which related to this project.

 

TABLE OF CONTENT
Title page                                                                                                                                         
Approval page                                                                                           
Dedication                                                                                                               
Acknowledgement                                                                                                           
Abstract                                                                                                                                           
Table of contents                                                                          

CHAPTER ONE
Introduction                                                                                                           

• Background of the project                                             
• Objective of the project
• Significance of the project
• Application of the project                       

CHAPTER TWO
Literature Review                                                                                      

• Pipe rotator overview                                                                 
• Types of pipe rotator                                                       
• Difference between conventional and self adjusting rotators
• Pipe rigid support                                     

CHAPTER THREE               
Design methodology                                                                                

• pipe rotator wheels                                              
• design diagram of the system                                                    
• Electric Motor Selection                                                                          
• design specification
• materials      
• pictorial diagram of the work                                                  

CHAPTER FOUR                 
RESULT ANALYSIS                                                                                    

• construction procedures                                                                                    
• assembling of sections                                                                             
• testing of system operation
• lubrication and maintenance                                                                                         

CHAPTER FIVE
5.1      conclusion
5.2      recommendation
5.3      references

 

CHAPTER ONE
1.1                                                        INTRODUCTION
pipe rotators offer exceptional torque capacity and accessibility for set up.  They are designed to provide full rotation of large offset loads for pipe spooling / pipe welding applications that require positioning and mechanized welding. The manual (pinned) and optional powered centerline adjustment allows for clearance of elbows, branches and fittings that may require a large swing radius for full rotation. pipe rotators are most often integrated with a mechanized welding solution to add further production enhancements. This unit has an assisting pressure column for pipe clamping, and can be used for fabrication of LONG pipes with high eccentric loads.
This unit has a tiling angle of 45º and assisting pressure column for pipe clamping, and can be used for fabrication of SHORT pipes with Load & Rotation capacity: 1 ton, Pipe diameter: 20 up to 1,000 mm, Variable speed: 80 up to 2,400 mm/min, Single phase: 220 V, 60/50 Hz, 1 P

1.1                                          BACKGROUND OF THE PROJCT
A pipe rotator positions the cylindrical jobs whether on light or heavy fabrication shops, the use of a pipe rotator provides increased production with reduced labour because it requires less usage of lifting or crane facilities, which also reduces idle time.
Adaptable for both automatic and manual welding works, using this type of welding machine helps attain exceptional quality circumferential joints on shells. It is mainly used for welding of pipes, API pipes, heat exchangers, mounted vessels, boilers, LPG bullets, barrels, pressure vessels and tanks.
Pipe rotator or Turning Rolls as they are sometimes called are useful accessories in welding fabrication workshops, designed to keep in place and to rotate heavy cylindrical parts around a horizontal axis, at a constant and steady turning speed in front of a welding head. Alternatively they may be rotated in steps until a needed position is reached, and then locked in place for making a longitudinal weld with a welding head mounted on a traveling carriage.
Pipe rotator permit to perform circumferential welds in a vertical plane. They are also used for surfacing (cladding), or depositing by welding a filler metal of useful properties on the external or on the internal surface of a hollow cylinder.
Pipe rotator is usually arranged in sets including a pair of identical rolls, one of which is rotated by an electric motor through a reduction gear box, known at the powered or drive unit while the other is idle, so arranged that the distance between the rolls can be adjusted to accommodate cylinders of different diameters, and mounted on a fabricated frame of simple shape. Usually a pair of such frames must be arranged on the shop floor at some distance from one another, to accept the cylindrical body in need of welding.
Weight capacity and diameters that can be supported are the major parameters that define rotators. Other characteristics involve wheel and surface materials, power and surface speed available.
The free turning of the part on the rolls should be ascertained before the start of the welding operation, to verify that no protrusions interfere with the motion. Also the longitudinal weight distribution should be checked to prevent overloading.
Special attention should be paid to avoid instabilities that may cause the work piece to overturn. Minute inaccuracies of positioning may involve translation of the work piece along its axis.
None parallel or out of square turning rolls may cause drag forces that tend to move the work piece unpredictably.
Ppipe rotators are supplied with steel, rubber or polyurethane. Although  pipe rotators are simple positioners, they should be maintained in proper service condition at all times. One should approach every job and every part with care, seriously and thoroughly, possibly following a standard check list, and learning from previous experience.
Pipe rotators are used in large scale welding factories for elevated efficiency and safety in the work stations. The welding turning roll is also known as self-aligned rotators or self-aligning rotators. Other names applicable to this equipment is conventional  pipe rotator or pipers, they are all the same type of welding devices though they work at different capacities.
The following is a brief but hopefully informative insight into the world of turning rolls, which will seek to at least give you a basic understanding of the same and their application.

1.2                                             OBJECTIVE OF THE PROJECT
The objective of this work is to fabricate a pipe rotator that does the following:      

• Pipe Rotator provides pipe movements with wheels of rail travel.
• Using a pair of pipe Rotator allows the pipe to be safely supported and rotated, assisting in multiple welding tasks.
• These Rotator is used for lining up the pipe and rolling for welding.

1.3                                         SIGNIFICANCE OF THE PROJECT
When performing a weld on a pipe, usually the weld must cover the circumference of the pipe evenly. It’s also important for the weld to be of a high quality and strong, as a lot of pressure could be put on the pipe depending on what the final work is meant for.
When pipe welding is done by hand, the welder must move around the pipe slowly as they carry out the work. Without a pipe rotator, this is difficult and necessary work in order to get the correct weld.
Using a pipe rotator enables the tank/vessel to be turned at desired speeds enabling the welder to carry out the work far easier & more efficiently, giving a higher quality weld to form roll steel tubulars.

1.4                                          APPLICATION OF THE PROJECT
They are used largely in various industrial domains that include fabrication industries, conventional power industries, nuclear industries, offshore oil industries, petrol/chemical and gas industries.
Their application consists mainly of holding large work pieces in place while they are being operated on. Work pieces are trapped firmly in the middle of the rollers and remain in place until adjusted. The rollers that make up this industrial equipment are able to automatically align themselves around the work piece without the need for manual manipulation of the rollers.

 

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