WELSPUN

Plate & Coil Mill

DIVISION OF WELSPUN GUJARAT STAHL ROHREN LTD. (WGSRL), WELSPUN CITY-ANJAR (INDIA)

Welspun Gujarat Stahl Rohren Ltd. Building on Engineering Excellence

Process flow
INPUT SLAB RECEIVING SLAB STORAGE YARD SLAB INSPECTION PRIMARY DESCALING SLAB PROCESSING HEATING FURNACE TURN TABLE LAMINAR COOLING CROP SHEAR DESCALING AT EXIT LASER WIDTH GAUGE & X-RAY THICKNESS GAUGE REVERSIBLE FINISHING MILL STAND DESCALING AT ENTRY VERTICAL EDGER

EXIT STACKLE COILER FURNACE

ENTRY STACKLE COILER FURNACE

DOWN COILER

COIL STRIPPING

COIL INSPECTION

WEIGHING & MARKING

COIL STORAGE

DISPATCH

HOT LEVELLER

COOLING BED

PLATE ULTRASONIC TESTING SAW CUTTER HOT PLATE STORAGE EDGE MILLING

DIVIDE SHEAR (CUT TO LENGTH)

LABORATORY

DISPATCH

PLATE STORAGE YARD

PLATE MARKING & WEIGHING

PLATE INSPECTION

Product Capability
y Plates
 Thickness: 6 to 150 mm  Width: 1500 4500 mm  Length: 6 18 m  Plate Weight: Max 35 t

y Coils
 Thickness: 5 to 25 mm  Width: 1500 2800 mm  Length: 80 850 m approx  Inner diameter of coil: 900 mm  Outer diameter of coil: 2300 mm max  Coil Weight: Max 50 t

MILL PRODUCTION LINE

y Event duration
Seq. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Event Slab Charging (Double Row) Walking Beam Cycle (4 Nos @ 60 sec) Slab request to Discharge complete Slab Transfer upto Turn Table (@ Avg 2.1 m/s) Turning (For cross rolling) Centering & Transfer to Mill Broadside per pass duration (@ 1.5 m/s) Pass-to-pass delay for Broadside passes Turning & Centering (For cross rolling) Roughing per pass duration Pass-to-pass delay for Roughing passes Holding time (Variable w.r.t. hold thickness & RHF temp) Finishing per pass duration (2.5 to 4.5 m/s speed) Pass-to-pass delay for Finishing passes Plate Transfer from Mill to Leveller (@ Avg 3 m/s) Plate Levelling duration per pass ( @ 1 m/s for 30m length) Plate Transfer to Cooling bed entry table Duration (Sec) 480 240 80 80 10 20 2 8 50 4 8 7 (w.r.t. rolled length) 8 70 45 70

PRODUCTWISE TIME STUDY

y GK3 Project
SLAB SIZE : 247 X 1930 X 4500 22.22 X 3724 HOLD THK : 115 mm RESUME TEMP.: 850 C Average time for 2 PC TCR 21' 30" slab Wt 17 MT No. of pcs per Hr. 5.5 93.5 MT No. of pcs per Shift @ 6.5 Hrs 35.75 607.75 MT No. of pcs per Day 107.25 1823.25 MT No. of pcs per Month @ 25 Days 2681.25 45581.25 MT No. of pcs per Year 32175 546975 MT

PRODUCTWISE TIME STUDY

y GK3 Project
PLATE 1

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 140 SECS 600 SECS FIN : 17 PASSES 240 SEC PLATE 2

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 140 SECS 600 SECS FIN : 17 PASSES 240 SEC NEXT PAIR TCR START

PLATE 1 : 1180 SECS (19' 40") 320 SECS PLATE 2 : 1180 SECS (19' 40")

2 PC TCR : 1470 SECS (24' 30")

PRODUCTWISE TIME STUDY

y KM Project
SLAB SIZE : 247 X 1930 X 4500 22.56 X 3245 HOLD THK : 115 mm RESUME TEMP.: 850 C Average time for 2 PC TCR 21' 30" slab Wt 17 MT No. of pcs per Hr. 5.7 96.9 MT No. of pcs per Shift @ 6.5 Hrs 37.05 629.85 MT No. of pcs per Day 111.15 1889.55 MT No. of pcs per Month @ 25 Days 2778.75 47238.75 MT No. of pcs per Year 33345 566865 MT

PRODUCTWISE TIME STUDY

y KM Project
PLATE 1

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 120 SECS 580 SECS FIN : 11 PASSES 160 SEC PLATE 2

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 120 SECS 580 SECS FIN : 11 PASSES 160 SEC NEXT PAIR TCR START

PLATE 1 : 1060 SECS (17' 40") 320 SECS PLATE 2 : 1060 SECS (17' 40")

2 PC TCR : 1270 SECS (21' 10")

PRODUCTWISE TIME STUDY

y SAUDI ARAMCO Project

SLAB SIZE : 247 X 1930 X 4500 19.05 X 3050 (WITHOUT EDGER) HOLD THK : 70 mm RESUME TEMP.: 900 C Average time for 1 PC TCR 08' 40" slab Wt 17 MT No. of pcs per Hr. 6.6 99 MT No. of pcs per Shift @ 6.5 Hrs 42.9 643.5 MT No. of pcs per Day 128.7 1930.5 MT No. of pcs per Month @ 25 Days 3217.5 48262.5 MT No. of pcs per Year 38610 579150 MT

PRODUCTWISE TIME STUDY

y SAUDI ARAMCO Project

PLATE 1

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 140 SECS 200 SECS FIN : 11 PASSES 160 SEC NEXT SLAB START

PLATE 1 : 700 SECS (11' 40")

PRODUCTWISE TIME STUDY

y EPCO Project -1

SLAB SIZE : 200 X 1700 X 4000 13.08 X 2804 (WITHOUT EDGER) HOLD THK : 65 mm RESUME TEMP.: 930 C Average time for 1 PC TCR 07' 50" slab Wt 17 MT No. of pcs per Hr. 7.6 76 MT No. of pcs per Shift @ 6.5 Hrs 49.4 494 MT No. of pcs per Day 148.2 1482 MT No. of pcs per Month @ 25 Days 3705 37050 MT No. of pcs per Year 44460 444600 MT

PRODUCTWISE TIME STUDY

y EPCO Project-1
PLATE 1

SLAB REQUEST SLAB DIS COMPLETE 70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS SLAB RHF TO MILL 140 SECS MILL TO HOLDING 170 SECS HOLDING TIME HOLD TO FINISH
NEXT SLAB START

FIN : 11 PASSES 140 SEC

PLATE 1 : 650 SECS (10' 50")

PRODUCTWISE TIME STUDY

y EPCO Project -2
SLAB SIZE : 200 X 1700 X 4000 18.82 X 2786 (WITHOUT EDGER) HOLD THK : 85 mm RESUME TEMP.: 880 C Average time for 2 PC TCR 13' 50" slab Wt 17 MT No. of pcs per Hr. 8.6 86 MT No. of pcs per Shift @ 6.5 Hrs 55.9 559 MT No. of pcs per Day 167.7 1677 MT No. of pcs per Month @ 25 Days 4192.5 41925 MT No. of pcs per Year 50310 503100 MT

PRODUCTWISE TIME STUDY

y EPCO Project-2
SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH
PLATE 1 70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 120 SECS 340 SECS FIN : 11 PASSES 150 SEC PLATE 2

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 120 SECS 340 SECS 150 SEC NEXT PAIR TCR START

PLATE 1 : 810 SECS (13' 30") 200 SECS PLATE 2 : 810 SECS (13' 30")

2 PC TCR : 1010 SECS (16' 50")

PRODUCTWISE TIME STUDY

y TRINIDAD Project -1

SLAB SIZE : 247 X 1900 X 4100 22.23 X 2776 & 20.62 X 2776 (WITHOUT EDGER) HOLD THK : 90 mm RESUME TEMP.: 870 C Average time for 2 PC TCR 15' 20" slab Wt 17 MT No. of pcs per Hr. 7.8 117 MT No. of pcs per Shift @ 6.5 Hrs 50.7 760.5 MT No. of pcs per Day 152.1 2281.5 MT No. of pcs per Month @ 25 Days 3802.5 57037.5 MT No. of pcs per Year 45630 684450 MT

PRODUCTWISE TIME STUDY

y TRINIDAD Project-1
PLATE 1

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 140 SECS 400 SECS FIN : 11 PASSES 160 SEC PLATE 2

SLAB REQUEST SLAB DIS COMPLETE SLAB RHF TO MILL MILL TO HOLDING HOLDING TIME HOLD TO FINISH

70 SEC 120 SECS BS : 4 PASSES; R : 3 PASS 140 SECS 400 SECS FIN : 11 PASSES 160 SEC NEXT PAIR TCR START

PLATE 1 : 900 SECS (15' 00") 200 SECS PLATE 2 : 900 SECS (15' 00")

2 PC TCR : 1100 SECS (18' 20")

PRODUCTWISE TIME STUDY

y TRINIDAD Project-1

SLAB SIZE : 247 X 1900 X 4100 22.23 X 2776 & 20.62 X 2776 (WITH EDGER) HOLD THK : 90 mm RESUME TEMP.: 870 C Average time for 2 PC TCR 18'00" slab Wt 15 MT No. of pcs per Hr. 6.6 99 MT No. of pcs per Shift @ 6.5 Hrs 42.9 643.5 MT No. of pcs per Day 128.7 1930.5 MT No. of pcs per Month @ 25 Days 3217.5 48262.5 MT No. of pcs per Year 38610 579150 MT

PRODUCTWISE TIME STUDY

y TRINIDAD Project-1
SLAB SIZE : 247 X 1900 X 4100 22.23 X 2776 & 20.62 X 2776 (WITHOUT EDGER) HOLD THK : 90 mm RESUME TEMP.: 870 C Average time for 2 PC TCR 15' 20" slab Wt 15 MT No. of pcs per Hr. 8 120 MT No. of pcs per Shift @ 6.5 Hrs 52 780.5 MT No. of pcs per Day 156 2340.5 MT No. of pcs per Month @ 25 Days 3900 58500 MT No. of pcs per Year 46800 702000 MT

PRODUCTWISE TIME STUDY

yTRINIDAD Project-

PRODUCTWISE TIME STUDY

y PDVSA TRIAL-1
SLAB SIZE : 223 X 1930 X4500 17.48 X 2783 (WITHOUT EDGER) HOLD THK : 58mm RESUME TEMP.: 940 C Average time for 2 PC TCR 07' 50" slab Wt 15 MT No. of pcs per Hr. 7.8 117 MT No. of pcs per Shift @ 6.5 Hrs 50.7 760.5 MT No. of pcs per Day 152.1 2281.5 MT No. of pcs per Month @ 25 Days 3803 57037.5 MT No. of pcs per Year 45630 684450 MT

PRODUCTWISE TIME STUDY

y PDVSA TRIAL-1

PRODUCTWISE TIME STUDY

y PDVSA TRIAL-2
SLAB SIZE : 247 X 1930 X 4500 15.88x2000 (WITHOUT EDGER) HOLD THK : 58 RESUME TEMP.: 940 C Average time for rolling 9'40" slab Wt 17 MT No. of pcs per Hr. 6.2 105.4 MT No. of pcs per Shift @ 6.5 Hrs 40.3 685.1 MT No. of pcs per Day 120.9 2055.3 MT No. of pcs per Month @ 25 Days 3023 51382.5 MT No. of pcs per Year 36270 616590 MT

PRODUCTWISE TIME STUDY

y PDVSA TRIAL-2

PRODUCTWISE TIME STUDY

y 2PCS TCR(STRAIGHT)
SLAB SIZE : 250X2500X5100 22X2500 HOLD THK : 115 mm RESUME TEMP.: 850 C Average time for 2 PC TCR 21' 10" slab Wt 25 MT No. of pcs per Hr. 5.7 142.5 MT No. of pcs per Shift @ 6.5 Hrs 37.05 926.25 MT No. of pcs per Day 111.2 2778.75 MT No. of pcs per Month @ 25 Days 2779 69468.75 MT No. of pcs per Year 33345 833625 MT

PRODUCTWISE TIME STUDY

y 2PCS TCR(STRAIGHT)

PRODUCTWISE TIME STUDY

y A-36(30MM)STRAIGHT
SLAB SIZE : 250 X 2600 X 6750 30 X 2600 (WITHOUT EDGER) HOLD THK : RESUME TEMP.: C Average time for Rolling 6' 10" slab Wt 35MT No. of pcs per Hr. 9.74 340.9 MT No. of pcs per Shift @ 6.5 Hrs 63.31 2215.85 MT No. of pcs per Day 189.9 6647.55 MT No. of pcs per Month @ 25 Days 4748 166188.75 MT No. of pcs per Year 56979 1994265 MT

PRODUCTWISE TIME STUDY

y A-36(30MM) STRAIGHT

PRODUCTWISE TIME STUDY

y 3PC TCR (GK3 WE)
SLAB SIZE : 247 X 1930 X 4500 22.22 X 3724 (WITHOUT EDGER) HOLD THK : 115 RESUME TEMP.: 850 C Average time for 3 PC TCR 29' 20" slab Wt 17MT No. of pcs per Hr. 6 102 MT No. of pcs per Shift @ 6.5 Hrs 39 663 MT No. of pcs per Day 117 1989 MT No. of pcs per Month @ 25 Days 2925 49725 MT No. of pcs per Year 35100 596700 MT

PRODUCTWISE TIME STUDY

y 3 PC TCR(GK3WE)
SLAB SIZE : 247 X 1930 X 4500 22.22 X 3724 (WITHOUT EDGER) HOLD THK : 115 RESUME TEMP.: 850 C Average time for 2 PC TCR 24' 0" slab Wt 17MT No. of pcs per Hr. 5 85 MT No. of pcs per Shift @ 6.5 Hrs 32.5 552.5 MT No. of pcs per Day 97.5 1657.5 MT No. of pcs per Month @ 25 Days 2437.5 41437.5 MT No. of pcs per Year 29250 497250 MT

PRODUCTWISE TIME STUDY

y 3PC TCR (GK-3 WE)

PRODUCTWISE TIME STUDY

y

SUZLON 33MM
SLAB SIZE : 247 X 1930 X 4500 33 X 3000 (WITH EDGER) HOLD THK : 85 mm Average time for 2 PC TCR No. of pcs per Hr. No. of pcs per Shift @ 6.5 Hrs No. of pcs per Day No. of pcs per Month @ 25 Days No. of pcs per Year RESUME TEMP.: 860 C 14' 30" 8.25 53.625 160.875 4021.875 48262.5 slab Wt 17 MT 140 MT 912 MT 2735 MT 68372 MT 820463 MT

PRODUCTWISE TIME STUDY

y

SUZLON 33MM

PRODUCTWISE TIME STUDY

y A-36(30MM)
SLAB SIZE : 250 X 1850 X 4100 30 X 2500 (WITHOUT EDGER) Average time for Rolling 07' 10 " slab Wt 15 MT No. of pcs per Hr. 8.3 124.5 MT No. of pcs per Shift @ 6.5 53.95 809.25 MT No. of pcs per Day 161.9 2427.75 MT No. of pcs per Month @ 254046 60693.8 MT No. of pcs per Year 48555 728325 MT

PRODUCTWISE TIME STUDY

y A-36(30MM)

PRODUCTWISE TIME STUDY

y

A-36(13MM)

SLAB SIZE : 200 X 1700 X 4100 13 X 2100 (WITHOUT EDGER) Average time for Rolling 06' 00" slab Wt 10 MT No. of pcs per Hr. 10 100 MT No. of pcs per Shift @ 6.5 65 650 MT No. of pcs per Day 195 1950 MT No. of pcs per Month @ 254875 48750 MT No. of pcs per Year 58500 585000 MT

PRODUCTWISE TIME STUDY

y

A-36(13MM)

PRODUCTWISE TIME STUDY

y

BASIC 1

PRODUCTWISE TIME STUDY

y

BASIC 2

Thank You