Operations
HFW Pipe Mill
50 Ton Entry
Utilizing the largest coils available in the industry optimizes production runs to ensure product consistency.
Zip Welder
Coil to coil joining enhances production of consistently high quality custom pipe.
Accumulator
The world's largest Accumulator - the "clock spring" configuration of coiled skelp holds 25 revolutions or wraps of steel. This is equivalent to approximately 150 tons or 3000 linear feet (915 meters). The Accumulator improves quality by allowing continuous operation of the Mill resulting in consistent welding parameters and quality.
Edge Milling
Four Head, Computer Controlled Edge Milling Equipment employs the latest HFW Pipe Manufacturing Technology to establish a clean, precise skelp edge for presentation to the welder.
Round Forming
Edge Bending and Computer Controlled Round Forming Equipment provide optimum positioned skelp for minimum edge working and consistent pipe shape for all diameters.
Welding Capacity
Thermatool Model VT 600 (600 kW @ 410 kHz) Welder with a Weld Station Squeeze Stand is one of the largest capacity, Direct Contact, High Frequency Electric Resistance Welders in the industry today.
Seam Annealing
Seam Annealing, using Solid State Induction Process Equipment consisting of four interchangeable 500 kW variable frequency statipower units, provides complete heat penetration of the weld and heat affected zone cross section. Heat treatment and subsequent air cooling transforms the weld area into a fine-grained microstructure with excellent mechanical properties.
Traveling Cutoff
The Traveling Cutoff and Length Optimization Equipment work in concert to optimize steel usage and maximize pipe lengths, resulting in fewer field girth welds.
Mill Control Ultrasonic Shear Wave & Weld Profile Inspections
Six-channel Ultrasonic weld area inspection unit provides critical through wall inspection of the weld area. The weld profile unit monitors the thickness of the pipe in the trim area and displays the thickness of both the weld and pipe body. Both inspection systems are positioned in the manufacturing line for precise mill control during pipe production.
Beveling
The Facing and Chamfering System has been integrated into the finishing floor, beveling pipe at the highest throughput rates available in the industry. The machines are controlled through touch screen operator interface panels and provide a proprietary O.D. tool following system for bevel uniformity and an unprecedented level of pipe end finish quality and repeatability. All conveyor rolls after beveling are polyurethane coated to protect the beveled ends.
Hydrostatic Testing
Each pipe is hydrostatically tested at 100% SMYS to a maximum test pressure of 5,000 psi for a minimum duration of 10 seconds or to our customer's specifications. (Offshore pipe is tested for a minimum of 20 seconds.)
Final Acceptance Ultrasonic Inspection
Eight-channel ultrasonic inspection units with couplant monitors, visual and audible alarms, automated marking systems, and laser-assisted tracking are located after the hydrostatic test equipment and provide end-to-end inspection of the weld area with all eight transducers.
Laser Length
Laser Length Measuring Device provides precision accuracy of pipe lengths and automatically records the length to the individual pipe computer record.
Bar Code Labeling
labels with both conventional 3 of 9 as well as two-dimensional (PDF 417) bar codes are attached to the I.D. surface of each pipe for tracking. The conventional bar code consists of the traceable Pipe ID number. The two-dimensional bar code is encoded with all of the pipe data that is printed on the label. The label is in addition to required paint markings.
SAW Pipe Mill
Spiral Pipe Operations
Stupp Corporation combines state of the art equipment with highly skilled and experienced personnel to meet the TOTAL requirements of the market and the individual needs of our customers. Stupp's spiral mill has the capacity to produce DSAW pipe ranging from 24" to 60" in diameter and in wall thicknesses through 1 inch. Our mill is certified to ISO 9001 and API Q1 for API-5L products. This expansive capability is further complimented by Stupp's ability to produce API-5L through X-80.
Coil Prep Station
At the coil preparation station, the leading end of the coil is precisely cut to provide an edge that can be effectively joined with the trailing end of the previous coil being processed. This allows for a continuous pipe making operation.
Forming Station
The edge milled coil is introduced into the three roll edge pre-bending assembly and then into the forming assembly, which consists of three forming roll banks and several outside cage rolls. This forming assembly combines the strength and precision to form the exact outside diameter and the other dimensional properties of the desired pipe for tack welding at a rate of up to 40 feet per minute. This operation provides a continuous weld seam that is strong enough to keep the desired pipe OD and shape and along with the forming technique eliminates the potential for systemic ovality after welding. The spiral welding process provides superior straightness when compared to other processes and the application of a tack weld during forming sets the stage for superior final weld quality versus a single stage spiral process in which the final weld is applied at the forming assembly under conditions in which the edges of the strip are in motion relative to each other.
Plasma Cutoff
The precisely spiral-formed pipe feeds into the plasma cutoff station. As the pipe passes through the unit and approaches its final length, the cutoff unit begins to travel at the same speed parallel to the longitudinal axis of the pipe. At the same time, the unit's plasma cutting torch is rotated at the precise cutting speed required for optimal pipe end quality for further processing. Upon completion of the cutting, the pipe is assigned a unique pipe number that provides the traceability required by API and our customers.
Tab Plate Welding Station
In preparation for final welding, an end tab plate is welded onto each end of the tack welded pipe's ID. This tab serves as the starting and ending points for the final welding operation thereby ensuring weld arc stability and consequently consistent weld quality throughout the entire length of the weld including pipe ends.
Final Welding Station
The pipe is then presented to the final welding station where the full length of the tack welded seam is precision Submerge Arc Welded (SAW) to completion. Superior SAW quality is achieved first by precise tracking of the weld seam in order to maintain the alignment of the ID and OD welds, second, by careful real time electronic tracking of the weld parameters and finally by precisely automated conveyance of the pipe under the welding heads.
Hydrostatic Testing Station
During the hydrostatic testing procedure, the pipe is filled with water and subjected to the specified pressure for a minimum of 10 seconds. The testing is accomplished in a 5,000 PSI ultra-modern 80' long testing unit and is performed to ensure that the weld integrity of the pipe is inviolate.
Ultrasonic Testing Station
After hydrostatic testing, a demanding regimen of non-destructive tests are performed to further ensure the integrity of the pipe weld and pipe body. An ultrasonic shear wave inspection of the full length of the weld zone and the heat affected zone is made. After ultrasonic evaluation is complete, pipe ends are inspected by X-Ray in a separate operation.
End Beveling Station
Each pipe end is beveled to the specified profile bevel (bevel angle - 30 to 35 degrees and root face of .031 to .904).
Bar Code Labeling
Barcode labels with both conventional 3 of 9 as well as two dimensional PDF 417 bar codes are attached to each pipe. The conventional bar code consists of the traceable Pipe ID number. The two-dimensional bar code is in addition to the paint markings and can be removed upon request of the customer. This allows for pipe tracking from coil utilized through production and yard movement as well as coating and shipping.
Quality Assurance
Stupp Corporation's Metallography Laboratory offers complete lab services for chemical, mechanical and metallurgical testing. Equipment includes:
- Thermo Electron Corporation (ARL 3460) Spectrometer for product chemistry analysis
- Tinius Olsen 120,000 pound tensile machine with Satec electronic strain gauges and computer graphic software
- Tinius Olsen pendulum Charpy impact test equipment with FTS Digitally Controlled refrigeration units
- Richmond 600 Numerically Controlled Milling Machine providing the highest speed and precision in producing various mechanical test samples
- NewAge Industries Vickers Hardness Tester (HSV-30) performing automated hardness traverses across the weld area
Coating Facility
Complementing the Stupp Corporation Baton Rouge manufacturing complex is Bayou Companies, Inc., the most modern pipe coating facility in North America.
