Case Study Details - Agriculture & Food

Basic Information

Overview

Applications of Pipe, Elbow, and Hopper for Agriculture & Food: The material is ordinary steel SS 400. The equipment is for conveying animal feed. The pipes are used for conveying animal feed such as corn, wheat, beans, and cassava. The purpose of use is to convey animal feed. The type of wear is abrasion and friction, leading to penetration. The expected service life is approximately 4-6 months.

Industry

Agriculture & Food

Location

Lopburee, TH

Component/Workpiece

Pipe, Elbow, and Hopper Hardfacing

Business Type

Integra - Combination

Job Type

Fabrication of 310x310x4500 chute tubes and hoppers, including on-site installation. Fabrication of 310x310x5000 chute tubes and hoppers, including on-site installation. RFQ_1180000314_Nozzle ring plate cement, item01,561-RM1 15 EA PJ1005-1_ Production of conveyor pipe E1 to tank 1, including on-site installation PJ1005-2_ Production of conveyor pipe E3, including on-site installation PJ1005-3_ Production of conveyor pipe E7 TOP, including on-site installation PJ1005-4_ Production of conveyor pipe E7, including on-site installation PJ1005-5_ Production of conveyor pipe E7 TOP, including on-site installation Production of Hopper slide pipe C9 to tank 3, including on-site installation (working at height) PJ1005-6_ Chain shackle CCY09 leaking (with liner) 5 pieces, including on-site installation PJ1005-7_ Chain shackle CCY08 leaking (with liner), including on-site installation PJ1005-8_ Chug pipe C9&C11-A (with liner) 10 sheets, PJ1005-9_Shooting tube, C9&C11-C (with liner) 8 sheets, PJ1005-10_Shooting tube, C10 & C8 into tank A (with liner) 10 sheets, PJ1005-11_Shooting tube, C10&C8-B (with liner) 8 sheets, PJ1005-12_Shooting tube, C10&C8-C (with liner) 8 sheets, PJ1005-13_Shooting tube, C9&C11-C new part, PJ1005-14_Shooting tube, C10&C8-B new part PJ1005-15_C10 & C8-C Chut Tube - New part manufactured. PJ1005-16_CCY26 Chain Underbody Leak (Liner installed) - 1 Job. Cut 200*250mm sheets, 2 pieces, ready for installation. PJ1005-17_CCY37 Chain Underbody Leak (Liner installed) - 2 pieces, ready for installation. PJ1005-18_Created Chut Tube under Drum, 6M long, ready for on-site installation. PJ1005-19_C9 Hopper Flap Box Tube for Tanks 3 and 4, ready for on-site installation. PJ1005-20_C8 Slide Hopper Tube for Tank 3, ready for on-site installation. PJ1005-21_C9 Slide Hopper Tube for Tank 3, ready for on-site installation. Manufacturing and installing Hopper & chutting tube for PL4BK01 BTG-LR1 conveyor. Manufacturing and installing chutting tube for Line 2 sieve. Manufacturing and installing chutting tube for Lines 1 & 4 (two sides) - 2 sets. Manufacturing and installing chutting tube for Line 3 sieve. Replacing Chain plate 16WI1PC and installing on-site chutting Hopper Mix MM1HOP02. Manufacturing new parts. Ready for on-site installation. Manufacture of chute tubes for PL2FLB11/FTB57 and service access panels. Ready for on-site installation. Manufacture of Flatbox tube P2FB07, 3.5 meter square tube with 4-sided hardplate. Ready for on-site installation. PJ1005-1_ Hopper PL1BKE01, PJ1005-2_ Hopper PL2BKE01, PJ1005-3_ Hopper PL3BKE01, PJ1005-4_ Hopper PL4BKE01, BTG-SK_Hardplate 100 5+3 patching 200x200 mm. with M10 rivet set and complete wrench set for securing the patching, BTG-SK_RFQ11236-BTG-SK SSB01 Hardplate patching 12 inches 300x300 mm, Repair shaft and machine BTG-LR2, Repair housing and machine BTG-LR2. 24 Items Hopper, Flap box access. PL5FLB07, 1 Set, ready for installation. Pipe from Hopper before chain CI1CCY13, 1 Set, ready for installation. Pipe for conveyor CI1BKE02, 1 Set, ready for installation. Screen valve BTG-NM, 2EA. Screen valve BTG-NM, 1EA. Repair_M: Hire someone to repair the Extruder swing door. Repair_M: Hire someone to refurbish the Hopper beforehand. Live Flight 4: 1. Production of leaking pipe from tank GD2BIN05, Qty 1 Job, 8-inch pipe, total length 6,730 mm, ready for on-site installation. 2. Production of conveyor pipe from tank GD2BIN04, Qty 1 Job, 8-inch pipe, total length 6,170 mm, ready for on-site installation. 3. Production of hopper and conveyor pipe from tank GD2BIN08, Qty 1 Job, 8-inch pipe, total length 6,800 mm, ready for on-site installation. 4. Production of rotary pipe BI1RDT01, Qty 1 Job, 8-inch pipe, total length 7,030 mm. Ready for on-site installation: 5. Production of hopper for conveyor belt BI1BKE02 Qty 1 Job, 8-inch pipe, total length 5,000 mm. Ready for on-site installation. 6. Production of hopper for conveyor belt WI2BKE01 Qty 1 Job. Ready for on-site installation. 7. Production of hopper for conveyor belt WI3BKE01 Qty 1 Job. Ready for on-site installation. 8. Production of hopper for conveyor belt WI2BKE03 Qty 1 Job, 2EA. Ready for on-site installation. 9. Production of hopper for conveyor belt WI2BKE02 Qty 1 Job. Ready for on-site installation. 10. Production of hopper for conveyor belt WI2BKE03 Qty 1 Job, 10-inch pipe. Ready for on-site installation. BTG-SK Hardplate 100E 6+4 patching 12 inches 300x300 mm. No holes. BTG-LR4_Shuttle pipe WI1CCY18, length 1,810 mm. Ready for on-site installation. Hardplate. 100E 5+3 patching 12 inch 300x300 mm. 10 EA New Main Housing Production 1 EA New Main Housing Production 2 EA BTG-LR2_Repair shaft and machine (Small) Fab hopper Animal feed BEX ejection 1 Job RFQ13132-BTG-SK Q3003 _Hardplate 100 5 3 patching 200x200 mm 10EA RFQ13133-BTG-SK SSB01_Hardplate 100E 6+4 patching 12 inch 300x300 mm. BTG-LR2_Manufacture milling machine according to design 1 EA Sunfeed_Construction of conveyor pipe 14.1 M and trouser legs (550+600+500=1.65M) with on-site installation (bean ejection pipe for Extuder) BOQ Ans assembly (Onsite) for BTG

OEM

Simatex

Type of Wear

Abrasion

Impact

Problem Description

The challenge the customer was facing

The wear and tear is caused by friction and abrasion from animal feed, such as hard corn, leading to punctures. The expected service life is approximately 4-6 months. Customers use insulation materials or scraps of fabric to patch leaks and then use silicone sealant. These repairs are time-consuming due to the frequent presence of multiple leaks, and involve the expense of disposing of the spilled animal feed.

Previous Service Life

6mo 1w 30d 24h

Competitor

Local supliers

Welding Alloys Solution

How WA solved the challenge

Procedure: - Fabrication & Installation of Hardplate Pipe (Dia. 850 mm, L=14 m) - Design & Engineering: Design a pipe with a diameter of 850 mm (≈ 33.5 inches) and a total length of 14 meters. - Specify the material as WA Hardplate 5+3 (Hardness 58–60 HRC). - Prepare shop drawings and divide the pipe into sections for easy transportation/installation. Material Preparation: Verify the hardplate material according to specifications (thickness, hardness, certificate). - Clean the surface before cutting. Plasma Cutting: Cut the hardplate to the designed size. - Control the size and tolerance to match the design. Rolling/Forming: Bend the sheet into a cylindrical shape with a diameter of 850 mm. - Check for roundness and alignment. - Fit-up & Welding: Assemble the seams. (Longitudinal Seam) - Weld using a method appropriate for hardplate (controlling distortion and dilution). - Flange Installation: Install flanges on both sides, check alignment and bolt hole spacing. -Inspection & Quality Control: Check size, roundness, and straightness. - Inspect welds (visual inspection as appropriate). Dismantling Existing Pipe: Remove existing pipes from the site (in-situ). - Prepare plywood to place on the 4th floor roof to prevent roof collapse. - Check the condition of the supporting structure, including the crane that will lift the workpiece down. - Installation (In-situ): Install new pipes into the system, align with existing equipment, tighten flange nuts and check for leaks. - Final Check & Handover: Check overall 5S compliance and paint the workpiece. Hand over the project with the inspection report and nameplate of job.

Product Category

Wear Pipes & Tubes

Product Description

Pipe , Elbow , Hopper Hardfacing And Hardplate Patching

Job Duration

18mo 14w 30d 24h

Technical Advantages

WA solutions improve work efficiency and extend service life. From the original 6 months, they can help customers use their systems 3-4 times longer. Wear resistance, hardness, welding quality, and repairability reduce downtime. Extended service life also improves safety for those who regularly repair leaks. After a pipe puncture, customers typically have to temporarily cover it with rags or insulation, a high-risk and risky task. Pipes puncture daily, with 50-200 leaks.

Service Life

18mo