Operations
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 ERW 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.
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 Coating LLC, the most modern pipe coating facility in North America.
