MORGAN WIRE ROD 5.5 MM TO 12 MM TWO STRAND.
Capacity is 200,000 for Carbon Steel
Can use one strand and roll stainless steel.
This mill has roll grinder also for grinding rolls for mono blocks.
Ref. 51278
API PIPE MILL 20" X 1/2"
Mill Specification
Pipe Sizes – 168.3mm, 219.1mm, 273.1mm, 323.9mm, 355.6mm, 406.4mm, 406.4mm, 457.0mm, 508mm, 200mm x 200mm, 250mm x 150mm, 250mm x 250mm.
Pipe Thickness – 3mm to 12.7mm
Pipe Grade – X42 to X80, C350, C450.
CHS Pipe length 18.3 Metres
Specifications – API5L Grade B & X42, ASTM A53 Grade B, AS/NZS 1163 Gd C350 L0, AS1396, ASTM Grade 2
Mill speed – 13 metres/minute to 30 metres/minute depending on material being manufactured.
Mill Details – Modified and upgraded Torrance design & built. Commissioned in 1966.
Grade O/D Remark, W/T Remarks
X42Min. 168.30mmMax508.00mmMin . 3.00mmMax12.70mm
X52 Min.168.30mmMax508.00mmMin. 4.00mmMax12.70mm
X65Min.168.30mmMax508.00mmMin. 5.00mmMax11.00mm
X70Min.168.30mmMax508.00mmMin. 6.40mmMax10. 10mm 10.1mm for sizes above 406.4mm
X80Min.168.30mmMax508.00mmMin. 6.40mmMax10.10mm 10.1mm for sizes above 406.4mmO / DW / T
Major Mill Upgrades
2006 ReplacementBevellers - change to quick change over tooling head and outside following
Reduce Bevel defects, reduce the internal burr, speed up change over times Inverter
1989 Replaced No. 1 & No. 2 Annealer
Inverter System and increased Annealer Capacity
2004 Replaced No 3 Annealer
Replaced unreliable Tocco unit
2004 Replaced Inverter in Thermatool (Mill Welder)
ToolingReplaced unreliable Power Supply
2009 Replaced cut-to-length System on Mill Cut-Offs
Replaced unsupported technology
2010 Replaced Edge Trim Scrap Conveyor
Replace old conveyor
2009 457mm Replacement Tooling
New set of rolls purchased for the Epic Pipe Rolling
2008 S&S Bearing Block Replacement
CapacityMake easier to set-upReplaced
2001 Additional Crane in the finishing line bray
Back-up Crane
Lots of other smaller project through-out the life of the Mill
Mill Entry Area
Brief Details:
Original Toarrance design of the coil held between two cones – extensive modification to strengthen and to be able to retract the Peeler Plate.
Edge Trim, Scrap Chopper & Table after Edge Trim
Brief Details:
Original Torrance Edge Trim units and Scrap Choppers.
2 fully reconditioned Edge Trim units and 2 fully reconditioned Scrap Choppers spare units are available.
Break Downs
Brief Details:
Original Torrance design.
All Breakdown Rolls are less than 5 years old.
Full set of engineering drawings are available.
Forming Cage
Brief Details:
Internal Forming mandrel – based on modern “forming flower” design .
No edge wave created.
Full set of engineering drawings are available.
Preform & Fin Pass Section
Brief Details:
Four Roll Cluster Tooling sets, for all CHS pipe sizes, based on modern “forming flower” design.
Wide fin blades to ensure that the presentation to the contact welder is as per the recommendation by Thermatool for high frequency welding.
Very stable welding conditions created.
Full set of engineering drawings are available.
Weld Station
Brief Details:
Weld Station with remote head roll adjustment. Installed in 1996.
Squeeze rolls of a four roll cluster design.
Full set of engineering drawings are available.
Welder – Thermatool VT300.
Scarfing & Internal Scarfing Chopper
Brief Details:
Canticut system with a chopper to cut the internal swarf into small pieces. These are then are washed out of the pipe at the Preliminary inspection area.
Full set of engineering drawings are available.
A full unit is available as a spare.
OD Trim Winder
Brief Details:
Trim is wound onto the wider and when the coil is finished the head rotates over a scarp bin, the wider then tilts and the tynes collapse so that the swarf is released and dropped into the bin.
Engineering Drawings are available.
Annealers
Brief Details:
Inductoheat Units:
No 1 & No 2 units are 500kw 1Khz to 3Khz parallel inverter units installed in 1989.
No 3 units is a 500kw 1Khz to 3Khz series inverter units installed in 2000.
All units are temperature controlled.
Size & Straightening
Brief Details:
Four Roll Cluster Tooling sets, for all CHS pipe sizes.
Design allows manufacture of 168.3mm & 219.1mm pipe without an off-line straightening unit.
No 4 S&S is driven by servo motors to control straightness.
Full set of engineering drawings are available.
Cooling Tank
Mill UT and Stencilling
Flying Disc Cutter - Brief Details
Heavy Duty Flying Disc Cutter, installed in 1996. Unit is very robust and reliable.
Cut-to- length system installed in 2010. This allows a cut accuracy of -0mm +25mm.
Full set of engineering drawings are available.
Motor Control Centre
Brief Details:
All Mill Drives are 55kw AC drives with individual Variable speed drive units, installed in 1996.
Mill controlled by ABB Procontic T200 PLC with remote I/O units. Citect is used as the SCADA system.
Full Electrical engineering drawings are available.
Tooling Sets
Full sets of Mill Rolls for: 168.3mm, 219.1mm, 273.1mm, 323.9mm, 355.6mm, 406.4mm, 457.0mm,
508mm (6,8,10,12,14,16,18 & 20 inch), 200mm x 200mm, 150mm x 200mm & 250mm x 250mm.
DEDC – Sample Cutting & Flattening Test
Brief Details:
Torrance Double Ended Disc Cutter, installed in 1982. Used for cropping the Lead & Tail pipes and for cutting test samples.
Bevellers
Brief Details:
Bevelling Machines, installed in 1996. Updated in 2006 with double outside following (Lan & Bevel tools independent following of the pipe)
with Caromat Capto Quick Change tools.
Unit is very robust and reliable. Quick & easy to set-up and change from one pipe size to another.
Bevellers
Brief Details:
Beveller Caromat Capto Quick Change tools for all pipe sizes.
Hydrotester
Brief Details:
Modern design Hydrotester.
Maximum test pressure – 34MPa
Pressure is reached by a Hydraulic to Water Intensifier controlled by modern servo value equipment and controller. Last upgrade was installed in 2008.
Full set of engineering drawings are available.
Final Ultrasonics
Brief Details:
Double Head unit so that one unit can be calibrated off-line to minimise change over times.
Krautkramer Electronics. The electronics are not longer supported by Krautkramer.
Full set of engineering drawings are available.
Weigh, Measure & Stencil
Laboratory Equipment
Central Hydraulic System
Brief Details:
Modern design Hydraulic System.
The system supplies the hydraulic requirements for the whole factory.
Boosted suction system where all hydraulic oil is filtered before being pumped out into the factory.
Full set of engineering drawings are available.
Material Handling - Pettibones
Brief Details:
Supplied by Pettibone.
1 unit manufactured in 1984
2 units manufactured in 1995
Spares : Coil Cones , Scrap Choppers, Edge Trim Units
Compressors, Air Drier, Air Filter & Air Receivers
Ref. 51282
BIRDSBORO, 18" WIDE 20 HI WF MILL, MODEL NUMBER: ZR-33-18 AND SPECIALTY STEEL MILL
Specialty/Tool Steel Rolling Mill
Manufactured by: Birdsboro
Cross Country Design
Entry/End Product
Stainless Steels: 200-300 series, 400-500 +200/300
Tool Steel: A2, D2, A13, H11, HIGH SPEED M1, M2 TYPE CPM 9V, 10V,
M4, REX 20, T15 REX 76
Entry material: Billet
Section: 3.25” x 3.25” Up to 4.00” x 4.00"
Length: 10’ Min – 19.5’Max.
Weight: 3.25" x 3.25” 360 lb - 680 lb
4.00" x 4.00” 550 lb - 1200 lb
Production:
Capacity: 13,000 TPA
Long Product: . 625" - 2.375"
Coiled Product: . 312" - .656"
Coil Size: 44" ID, 48-50" OD - 780 LB MAX.
Mill layout:
Furnace Charge Table
Reheat Furnace,
Mfg. Salem Brosius, gas Fired 4 Zone, up to 2600 degree F
Breakdown/Roughing Mill
Single Stand 18" x 56” Two High Reversing
Equipped w/ Roller Bearings, motorized Screwdowns
Drive Assembly:
Direct driven Pinion gear reducer 1150HP, 80-200 RPM, 700 V DC
Control: GE Solid State up-grade 1999
Crop Shear - Mfg. United Engineering & Foundry
300 Ton Capacity
(Front cut)
Intermediate Mill - 1
Three stands: 14" x 30” Two High design
Drive assembly: Pinion gear reducer, 1750HP, 600V, DC
Intermediate Mill – 2
Two stands: 12” x 24” Two high design
Drive assembly: Pinion gear reducer, 700HP, 700V DC
Pre Finish Mill
Single stand, vertical design 10” x 20”
Individually, top driven
Drive assembly: Pinion gear reducer, 350HP, 700V, DC
Finishing Mill
Seven stands 10” x 20” Two High design
Drive assembly: Pinion gear reducer - 1500 HP 700V, DC
Coiled product:
Two Pouring reels Max coil weight 780 lb.
Long product
Cooling Bed 130’ L x 16’ Walking beam design
Auxiliary & support equipment available:
Substation, HV switch gear, motor control centers & distribution transformers
Logic control drives & MG sets (4000+ HP)
Solid State 250V, 500KW DC power supply
Air compressor & dryer
Mill rolls cut/uncut
Spares
Notes:
Complete mill is roller bearing design
Ref. 51269
DEMAG, 39” X 84 ½” BLOOMING & SLABBING MILL
Age: 1980
Mfg: Demag
Products Previously Rolled:
Stainless and Carbon Steel
Ingots: Up to 21” square
Slabs: 5” thick x 43” wide
Rolled to thin slab 1.57” thick x 41 ½” wide
High Lift: 41 ½”
Equipment:
1200 Ton Mechanical Hot Shear:
Max. Opening: 16 ½” sq.
Hot Shear Conveyor:
20 rolls
14” diameter
Furnace Exit Table:
Length: 38 ½’
No. of Rolls: 16
16” dia. X 51” face
Approach Table No. 1:
Length: 64’
No. of Rolls: 26
16” dia. X 51” face
Approach Table No. 2:
Length: 41’
No. of Rolls: 17
14” dia. X 79” face
Front Rev. Table:
Length: 26’
No. of Rolls: 12
15 ¾” dia. X 98” face
Front Manipulator with (2) Side Guides and Lifting Fingers
2-Hi Mill Stand:
Mill Rolls: 39.3” dia. max. x 84.64” face
Bearings: Roller
Post Size: 34 ¼” x 21.65”
Screwdowns: Electromechanical, 230 V. DC
Two High Lift Spindles with Spindle Carrier
One 2-Hi Pinion Stand
Motor: Previously driven by single motor, 6800 HP, 60/120 RPM
Note: The slow speed single motor or over/under drive motors available upon
request.
Back Reversing Table:
Length: 26’
No. of Rolls: 12
15 ¾” dia. x 98” face
Back Manipulator:
(2) Side Frames and Lifting Fingers
Run Out Table No. 1:
Length: 35’
No. of Rolls: 12
14” dia. x 84” face
Run Out Table No. 2:
Length: 73’
No. of Rolls: 24
14” dia. x 60” face
This equipment was used for a short period, dismantled, reconditioned, and has been in storage for several years.
There is a large quantity of spares, including three sets of two each top and bottom roll chocks and bearings.
All auxiliary motors are MD 800 Series. The weight of the equipment is approx. 1,500 tons.
Ref. 51294
