Titanium Tubing Technology Improvements And Continued Production Increases

This year, the pipe mill has focused on the development of titanium high-end pipes, seeking steady progress while adhering to principles and fostering innovation. It has coordinated various tasks such as stable production, project management, innovation, and growth promotion, which has further invigorated production, improved work quality, standardized construction levels, and strengthened core competitiveness and profitability. As of the end of June, the pipe mill's production and output have doubled, with various key tasks progressing steadily.

1. Steady progress in key tasks

Currently, the pipe mill's major project involving pipes has been delivered in its entirety. The installation, commissioning, and process validation of 17 sets of equipment related to the production capacity expansion of core products have been completed, and this equipment has entered the production stage. The 6,300-ton extrusion press and its supporting heating system, as well as auxiliary equipment for pipe straightening, forming, and surface grinding, have been accepted and are undergoing final process validation. Meanwhile, the work on mass production of extruded materials and large-diameter pipes with the 6,300-ton extrusion press is progressing in an orderly manner.

2. Efficiency improvement through process control

In response to the surge in demand for small-sized pipes and the heavy workload of research and trial production tasks, the pipe mill has implemented multiple measures to advance its work comprehensively. Production organization has been strengthened by adopting specialized production modes to reduce equipment downtime caused by changing specifications, thus increasing the effective working time of rolling mills and improving the efficiency of each process. The exploration of improved rolling tools has also increased the efficiency of rolling mills. Process quality control has been optimized, and material storage and turnover have been standardized to enhance execution efficiency. Detailed operation manuals have been developed for each process, and comprehensive training programs have been conducted on acid pickling, cleaning, extrusion, and safety production to elevate the overall skill level of employees and ensure smooth production operations. To meet market and customer demands, the pipe mill has prepared material stocks for commonly used pipe specifications, reducing inventory through reshaping and recycling residual and waste materials. Site storage areas have been redesigned to enhance lean material management. In the first half of the year, the pipe mill achieved an on-time delivery rate of 85.25% for contracts, an execution rate of 117.9% for production plans, and an 84.18% completion rate for key contracts.

3. Overcoming challenges to ensure production

In the first half of the year, the pipe mill strictly controlled equipment installation accuracy and schedule requirements, further enhancing equipment capacity and guarantee levels. Six sets of LD10, and LD15 cold-rolled pipe machines, and two sets of LD8 machines completed installation, commissioning, and process validation in a short time and entered production successfully. The installation of three 5-meter vacuum annealing furnaces was completed simultaneously, with their vacuum systems, heating systems, circulation cooling systems, and unloading systems passing acceptance in one go. In order to overcome the bottleneck of the rolling process in the production of a key task and enable rapid production of the newly added cold-rolled pipe machines, the pipe mill formulated detailed progress plans for equipment manufacturing, basic design, civil construction, equipment installation, and commissioning, and process validation. Preventive measures were formulated for potential risks. Currently, two LG15H cold-rolled pipe machines have completed installation, commissioning, and process validation and are about to commence production. Two LG10H cold-rolled pipe machines have entered the final stage of commissioning. Two hydraulic testing machines have completed installation, commissioning, and technical innovations and are equipped with pressure-unloading automatic control functions. In the first half of the year, the average equipment integrity rate of the pipe mill was 99.35%, and the maintenance rate decreased by 51.7% compared to the same period last year, saving 252,000 yuan on repair costs.

4. Process optimization for cost reduction and efficiency improvement

The pipe mill has improved the process for a heat exchanger tube, reduced the number of rolling passes in the short process, and achieved a significant increase in the qualified rate of eddy current inspection of finished products through the adoption of an annular hole design for final rolling. Process trials were conducted for a specific specification of extruded pipe blanks, solidifying the extrusion process. The second stage of sample production for a specific specification of pipes was launched, and the process design and optimization were completed for 12 specifications of the second batch of research samples. In the first half of the year, the first-time yield rate for major pipe specifications increased by 2%.

The pipe mill stated that it will continue to lead in action, strive for excellence in performance indicators, and be innovative in achieving results. It will continuously tap into its intrinsic potential to ensure the successful completion of production and operation goals for the entire year.