TECHNICAL PROPOSAL FOR 200,000T/Y USED BAR ROLLING MILL ... · 30TON/HR ROLLING MILL PROJECT -2- I. GENERAL 1.1 PREFACE This offer sheet covers the supply of the equipment and materials

TECHNICAL PROPOSAL

FOR

200,000T/Y USED BAR ROLLING MILL

DANIELE (TAIWAN) OCT. 2008

Project No. 98001

30TON/HR ROLLING MILL PROJECT

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CONTENTS

I. GENERAL .................................................................................. 1

II. DESIGN BASIS......................................................................... 4

III. ATTACHMENT...................................................................... 21


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I. GENERAL

1.1 PREFACE

This offer sheet covers the supply of the equipment and materials for a Bar

Mill Project capable of producing 200,000 tones per year of Deformed Bar

with product size of D10, D12, D16, D19, D22, D25&D32. and Rung Bar

with product size of ∮9.5mm～∮32mm

1.2 Plant description

The main features of the rolling process and equipment composing the

Plant are described in the following article.

The layout and Mill capacity of the Plant is shown in the attached

”General layout and calculation plan”

1.3 General features of the rolling Mill Process

This rolling mill is provided with necessary equipments for

rolling of bars. Capacity of the rolling mill is 200,000tons/y.

Production ratio of the different bar sizes can be selected freely,

according to distinct market demands.

40tons/hr, top fired, Pusher type Reheating Furnace, energy

saving technology and easy operation procedure are applied

Arrangement of mill stands is all tandem Horizontal type mill.

The Roughing Rolling Mill is driven by AC 1,500HP motors, and

Intermediate Mill is driven by AC 1,500HP motors, but the Finishing

Rolling Mill are driven by DC 1,200HP motors with Control SYS. Total

capacity of AC&DC motors is 3,100kw.

Low tension rolling is applied by Loop Control System in the Finishing

mill depending on the size of the products.


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CACULATION PLAN OF MILL CAPCITY ROLLING RATE (250,000T/Y)

Products Billet Annual Production

Size Area Unit-W Size Length WeightNo.

(mm) (mm2) (kg/m) (mm) (m) (kg)

Fin. RollingSpeed

(m/sec)

Pass Time

(sec)

Pause

(sec)

RollingCycle Time

(sec)

ProductYield

(%) (%) (T/Year)

Expected Rolling Hours

(hrs)

1 D10 78.5 0.617 120 4 450 10.8 61 10 71 96 20 30000 1200

2 D12 113.0 0.888 120 4 450 7.78 30 15 45 96 20 36000 1200

3 D16 176.7 1.387 120 4 450 5.8 25.88 15 40.88 96 10 35000 1000

4 D20 314.2 2.466 120 4 450 5.23 16.18 15 31.18 96 10 40000 1000

5 D22 380.1 2.984 120 4 450 5 15.6 15 30.6 96 10 18000 460

6 D25 490.90 3.853 120 4 450 3.29 14.1 15 29.1 96 10 18000 450

7 D32 804.25 5.313 120 4 450 3.29 14.1 15 29.1 96 10 18000 450

TOTAL 100 200000 5760


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II. DESIGN BASIS 2.1 Product Mix and Rolling Rate

2.1.1 Product Mix

Product mix for annual production of 200,000 tons is described as the

table “Calculation Plan of Mill Capacity”.

2.1.2 Rolling Rate

With regard to rolling rate, please also refer to the table “Calculation

Plan of Mill Capacity”.

2.1.3 Others

Product length of bars: 12M or others

2.2 Billet

Billet: Continuously cast billets or hot rolled billets

Kind of steel: Low alloy steel for the manufacture of steel bars for

reinforcement, rolled steel for general structure.

Section 100～130 mm sq Length 4m ± 10 mm Weight 314～450kg

Camber (bow): Max.25mm in 4000mm length

Rhomboidity (right angularity): Less than 3%

Twist: Less than 1 degree per meter

Temperature of billet discharged: 1100℃ (Engineering basis)

Note: The billet above shall have the quality suitable for final products. In

order to attain high productivity, that is, improvement of rolling

efficiency and material yield, etc. which are resulted from high rolling

Rate and most suitable cutting of bar products , etc., it should be

essential to well control the billet tolerance and conditions.


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2.3 Rolling Capacity

2.3.1 Rolling Hours Required

Rolling Hours Requires=5760 Hrs/Year

With regard to rolling hours required, please refer to the table to

“Calculation Plan of Mill Capacity”.

2.3.2 Annual Working Hours

8 hours/shift×3 shift/day×300 day/year=7200Hr

If operating rate is 80%

Operating Rate 0.8=Rolling hour required/Annual working hour

Rolling hour required=0.8×7200=5760Hr

This operating ratio is considered to be easily attained.

2.4 Steel Grades

The steel grades which are to be processed on the mill are as follows.

a. Deformed bar

D10~D32 Steel bars

Applicable standards:

JIS 20-2525＆24-2536 “Rolled steel for general structure”

b. Rung bar

∮9.5mm～∮32mm Steel bars JIS G 3101&JIS G4051

2.5 Rolling Speed

Actual rolling speed: Max. 11 m/sec

2.6 Rolling Method

1. strand rolling

Deformed bars: D10, D12, D15, D20, D22, D25 &D32mm

Rung bars : ∮10, ∮12, ∮16, ∮ 20, ∮25 &∮32mm


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2.7 Site (Environmental) Conditions

1) Ambient temperature:

Max. 35 deg. C (more than 15℃)

Electrical control room and pulpits will be kept in 20~30℃

2) Relative humidity: Max. 98%

3) Altitude: Less than 1,000 m above sea level

2.8 Layout

Please refer to attached GENERAL LAYOUT.

1) Rolling Mill

The billet is charged on the Billet Charging Bed by the Billet Yard Crane, and

transferred to the Reheating Furnace by the Billet Charging Roller Table. And

the heated billets are discharged from Reheating Furnace and processed

through Roughing Mill Train, Intermediate Train, Finishing Mill Train.

The Cant Rolling Mill comprises a total of 11 stands(17 pass), divide in roughing

mill with 2 stands (8 pass), intermediate mill with 5 stands (5 pass), finishing

mill with 4 stands (4 pass).

The Roughing Rolling Mill and Intermediate is driven by AC motors, but the

Finishing Rolling Mill are driven by DC motors with vector inverter.

All stands are arranged in horizontal arrangement.

2) Cooling bed

On the Cooling Bed, products are cooled down to desired temperature, while

maintaining the straightness.

3) Cutting & Finishing System

a. For Deformed bar

Those products are then discharged from the Cooling Bed and further

processed by Cutting and Finishing System.

All products are cut to length by cold shear transferred to receiving conveyor.

At the end of the conveyor, a conveyed table is located which transfer the

products to AUTO bundling area then to shipping area.

2.9 Utilities Conditions


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The utilities having characteristics or conditions as described hereunder will be

utilized for the plant operation and supplied by the Customer in sufficient

quantities at termination points described hereunder.

1) Electric power

Normal Electric power

- Power receiving: One (1) line

- Supplied power: AC3.3kv/3 phases /50HZ/3,000KVA and AC560V/3

phases /50HZ/1,500KVA

- Voltage fluctuation: Within ±5%

- Frequency fluctuation: Terminals of 3.3kv and AC560V receiving switch

and distributing panel in the electrical equipment

room of the plant.

2) Cooling water

a. Direct cooling water (350 T/hr)

- pH valve: 6.5 to 8.5

- Suspended solid: Max. 20 mg/lit

- M-alkalinity as Ca Co3: Max. 300 mg/lit

- Total dissolved solids: Max. 1,500 mg/lit

- Total hardness as Ca Co3: Max. 300 mg/lit

- Fe: Max. 3 mg/lit

- Cl: Max. 200 mg/lit

- So4: Max. 200 mg/lit

- SiO2: Max. 50 mg/lit

- Temperature: Max. 32℃

- Pressure: Max. 4 kgf/cm2

Design pressure: 3 kgf/ cm2 at the battery Limit of the building


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3. SCOPE OF SUPPLY SUPPLIER CUSTOMER REMARK

Country of origin ITEM NO. EQUIPMENT NAME Q’TY Supply

Country Remarks Supply

M1 REHEATING FURNACE (FN.) TAIWAN Type:40Ton/hr M101 -01 Charging Roller Way 1set TAIWAN -02 Hyd. Unit 1set TAIWAN -03 Main Pusher 1set TAIWAN -04 Furnace (Case) And Alloy Rail 1set TAIWAN -05 Waste Chimney 1 p TAIWAN -06 Blower 40HP AC Motor 2 s TAIWAN -07 Heavy Oil Burner 8 p TAIWAN -08 Temperature control for Furnace 1 s TAIWAN -09 Heater for Heavy Oil Tank 1 s -10 Refractory Bricks/Blocks 1Lot ---- -11 Duct 1 s TAIWAN M2 MILL MECHANCAL SECTION M201 ROUGHING MILL TRAIN (RM.) 2 s M201 -01 Horizontal 3HI-Mill Stand With Base Plates 2 s DANIELI 1#～8#Pass -02 Roll (∮455x1500L) 6 p TAIWAN -03 Chock 12 p DANIELI -04 Fiber Bearing (Bakelite) 12 p TAIWAN -05 Reducer Gear Box 1 s DANIELI -06 Flying Wheel With Bearing 1 p DANIELI -07 Gear Coupling (Motor-Reducer-P. Stand ) 2 s DANIELI


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SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY

Supply Country Remarks

Supply

-08 Joint Shaft (Pinion Stand-Mill Stand) 6 s DANIELI -09 Cant Table (Guide In & Out) 1 s TAIWAN -10 Approach Roller Table (FN→RM) 12M 1 s TAIWAN -11 Oil Lubrication System 1 s DANIELI -12 Repeater 2 s TAIWAN M202 INTERMEDIATE MILL TRAIN (IM.)2 HI M202 -01 Roller Bearing Mill Stand With Base Plates 5 s DANIELI 9#～13#Pass -02 Roller Bearing Roll (∮350 x 800L x 6pass) 10 s DANIELI -03 Roller Bearing Chock 20 p DANIELI -04 Roller Bearing 20 p DANIELI -05 Reducer Gear Box (With Pinion Stand) 1 s DANIELI -06 Flying Wheel With Bearing 1 p DANIELI -07 Gear Coupling (Motor-Reducer) 2 s DANIELI -08 Joint Shaft (Reducer-Mill Stand) 10 s DANIELI -09 Joint Shaft Coupling For Reducer 4 p DANIELI -10 Joint Shaft Coupling For Stand 4 p DANIELI -11 Approach Roller Table (RM→IM) 36M 1 s TAIWAN -12 Oil Lubrication System 1 s DANIELI -13 Repeater 4 s TAIWAN M203 FINISHING MILL TRAIN (FM) M203 -01 Horizontal Mill Stand With Base Plates 4 s DANIELI 14#～17#Pass


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Supply

-02 Roller Bearing Roll (∮300 x 600L x 4pass) 8 p DANIELI -03 Roller Bearing Chock 16 p DANIELI -04 Roller Bearing 16 p DANIELI -05 Reducer Gear Box (With Pinion Stand) 4 s DANIELI -06 Cardon Shaft 8 p DANIELI -07 Gear Coupling (Motor to Reducer) 8 s DANIELI -08 Oil Lubrication System 1 s DANIELI M204 GUIDING DEVICE M204 -01 Delivery guide for Rough Mill 4 s DANIELI -02 Guide Through for Rough Mill 4 s DANIELI -03 Entry & Delivery Guide for IM & FM 9 s DANIELI -04 Guide Through for IM & FM 9 s DANIELI M205 SHEAR MACHINE M205 -01 Flying Shear 1 s DANIELI -02 Dividing Shear 1 s DANIELI M3 COOLING AND CUTTING SECTION M301 RUN IN GUIDING EQUIPMENT 54M M301 -01 Run In Guiding Through (54M) 1 s DANIELI -02 Pinch Roller 1 s DANIELI


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Supply

M302 COOLING BED 42M/9M M302 -01 Cooling Bed 42M 1 s DANIELI -02 Cooling Bed Drive Unit 25HP 1 s DANIELI -03 Bar Collecting Device 1 s DANIELI -04 Bar Traversing Devise 1 s DANIELI -05 Run Out Roller Table 42M 1 s DANIELI M303 COLD SHEAR M303 -01 Cold Shear (power-300ton) 1 s DANIELI M4 BAR FINISHING SECTION M401 TRAVERSING FACILITIES FOR BAR M401 -01 Cold Shear Run Out Table 1 s DANIELI -02 Traverser 1 s DANIELI -03 Product Transfer 1 s DANIELI -04 Shipping Table 1 s DANIELI -05 Auto Bundling 1 s DANIELI M5 SIMPLE PARTS M501 FOUNDATIOM BOLTS AND GAUGE

PLATE

M501 -01 Foundation Bolts (Steel Bar) 15 t -02 Installation Liner (Steel Plate) 5 t


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Supply

M502 SAFETY COVER M502 -01 Safety Cover (5 tons Steel Plate&5 tons Angle

And Channel ) 10 t

M503 WORKING DECK M503 -01 Working Deck (Steel Plate) 5 t M504 PIT AND DUCT COVER M504 -01 Pit And Duct Cover (5 tons Steel Plate&5 tons

Angle And Channel ) 10 t

M506 CROP CHUTE AND BAG M506 -01 Crop Chute 1 s -02 Crop Bag 1 s M507 MISCLLANIOUS ITEMS M507 -01 Supporting For Detectors 1 s -02 Scrap Box 1 s -03 Dust Box 1 s -04 Tool For Election 1 s -05 Tool For Operation And Maintenance 1 s -06 Coiler For Mis-Rolled Material 1 s


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Supply

M6 PIPING M601 OUTDOOR PIPING M601 -01 Outdoor Piping For Utilities

(Air 200M,Oil 100M,Water 300M) 15 t

-02 Indoor Piping For All Utilities (Air 800M,Oil 300M,Water 500M)

25 t

-03 Valve And Piping Accessories 1 s E2 POWER RECEIVING & DISTRIBUTION

SYSTEM

E201 -01 3.3 KV Power Receiving Switch And Distributing Panel

3 s TAIWAN

-02 Power Factor Compensation Equipment 1 s TAIWAN -03 Main AC Motor 1,500HP/60HZ/3,300V/10P 2 s TAIWAN -04 Main DC Motors 1,200HP/600V 1 s TAIWAN 600rpm～1,200rpm -05 Main AC 1500HP On/Off Panel 2 s TAIWAN -06 Vector Inverter (For RM &IM AC) 2 s TAIWAN -07 Converter For DC Motor 1200HP 1 s TAIWAN -08 Transformers for AC(1,500KVA/3,300v) 2 s TAIWAN -09 Transformers for AC(1,500KVA/560v) 1 s TAIWAN -10 Transformers for AC(500KVA/220v/440v) 1 s TAIWAN E3 MILL LINE DRIVE CONTROL SYSTEM


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Supply

E301 -01 Operation Desk 2 s TAIWAN -02 PLC Control For Mill Line 1 s DANIELI -03 Sensor Control-Photocell 12 s DANIELI E4 CABLING, WIRING, BUS, DUCT &

PIPING

E401 -01 Power Cable And Accessories 1 s -02 Control Cable And Accessories 1 s -03 Instrument Pipe And Fitting 1 s -04 Cable Duct, Tray, Conduit Tube And Fitting 1 s -05 HV & LV Cable 1 s -06 Cabling Material & Accessories 1 s -07 Piping Material & Accessories 1 s E4 LIGHTING AND SOCKET OUT SYS. E502 -01 Lighting Transformer & Distribution Board 1 s -02 Socket Outlet Switch 1 s E6 COMMUNICATION SYSTEM E601 -01 Paging System 1 s -02 Closed Circuit T.V. System 1 s -03 Mil Status Indication Lamp 1 s -04 Clocks 1 s -05 Telephone System 1 s


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Supply

-06 Loud Speaker System 1 s E7 MAINTENANCE TOOL AND

INSTRUMENT

E701 -01 Tools And Instrument For Election 1 s -02 Tools And Instrument For Maintenance 1 s E8 FIRE DETECTION AND FIGHTING

SYSTEM

E801 -01 Fire Detection System 1 s -02 Fire Fighting System 1 s E9 AUXILIARY SYSTEM FOR BUILDING E901 -01 Air Conditioning System 1 s -02 Ventilation System 1 s -03 Lighting Protection System 1 s S OTHER SUPPORTING FACILTIES S1 ROLL SHOP S101 ROLL SHOP EQUIPMENT S101 -01 Roll Turning Lathe 4 s -02 Guide Roller Lathe 1 s -03 Universal Tool Gridding Machine 1 s


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Supply

-04 Drilling Machine 1 s -05 Double Ended Gridding Machine 1 s -06 Rid Cutting Machine 1 s -07 Tools 1 s S2 MACHINE SHOP & LABORATORY S201 -01 MACHINE SHOP EQUIPMENT 1 s S202 -01 MECHANICAL LABORATORY Tension & Compression Load Tester 1 s S3 TRANSPORTATION EQUIP MENT S301 TRANSFER CAR S301 -01 Transfer Car For Roll Shop 1 s -02 Transfer Car For Shipping Yard 1 s S4 CRANE AND HOIST S401 -01 OHT Crane For Billet Yard With Lifting

Magnet 10t 1 s

-02 OHT Crane For Mill Yard 10t 1 s -03 OHT Crane For Bar Product Yard 10t 2 s -04 Crane Trolley Wire 1 s


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Supply

S5 PULPIT S501 -01 Furnace Control Room 1 s -02 Main Control Room 1 s -03 Cold Shear Control Room 1 s -04 Bar Finishing Control Room 1 s S6 COMPRESSED AIR SUPPLY FACILTIES S601 -01 Compressed Air Station 12M3/min 3 s -02 Receiver Tank 10 s A SPARE PARTS & CONSUMABLES A1 SPARE PARTS -01 Roller For Rough Mill 455∮ 24 s TAIWAN -02 Roller For Intermediate Mill 350∮ 40 s TAIWAN -03 Roller For Finishing Mill 300∮ 36 s TAIWAN -04 Roller Bearing Chock For Intermediate Mill 40 s DANIELI -05 Roller Bearing Chock For Finishing Mill 36 s DANIELI -06 Roller Bearing For Intermediate Mill 40 s SKF -07 Roller Bearing For Finishing Mill 36 s SKF -08 Fiber Bearing (Bakelite) 40 p TAIWAN -09 Cardon Shaft For Finishing Mill 10 p DANIELI -10 Joint Shaft For Rough Mil 6 p TAIWAN


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Supply

-11 Joint Shaft For Intermediate Mill 10 p TAIWAN -12 Guide Plate 60 p TAIWAN -13 Reducer Gear For Intermediate Mill 1 p DANIELI A2 SUPPLY OF UTILITIES -01 Cooling water DCW, ICW -02 Lubrication Oil -03 Grease -04 Hydraulic Oil -05 Fuel Oil -06 Electric Power -07 Gases A3 MATERIALS -01 Erection Material A4 ITEMS EXCLUDED FROM SUPPLIER’S

SCOPE

-01 Civil Work & Building -02 Equipment Foundation -03 Erection Work -04 Wiring Work -05 Piping Work


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Supply

-06 Water Treatment Facility -07 Drainage Pump -08 Fire Fighting Facilities -09 Lighting -10 Communication System -11 Simple Structure -12 Crane / Transportation Equipment -13 Air Conditioning & Ventilation -14 ITV -15 Roll Shop Equipment -16 Maintenance Equipment -17 Laboratory -18 Sewage Facility -19 Template -20 Consumables -21 Tools -22 Grounding Material 1 s


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CT-001:BILLET CHAGE BED CT-002:40T/H HEATING FURNACE

CT-004:40T/H FURNACE MAIN PUSHER CT-003:40T/H FURNACE MAIN PUSHER HYD,UNIT


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CT-005:40T/H HEATING FURNACE

CT-008:40T/H HEATING FURNACE SIDE PUSHER

CT-007:40T/H HEATING FURNACE

CT-011:3 HI ROUGH MILL REDUCER GEAR


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CT-009:40T/H FURNACE BLOWER




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CT-013:3 HI ROUGH MILL STAND





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CT-026:PINCH ROLLER

CT-025:FLYING SHEAR

CT-027:1 IN→2 OUT INTERMEDIATE REDUCER GEAR


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CT-028:1 IN→2 OUT INTERMEDIATE REDUCER GEAR CT-029:1 IN→2 OUT INTERMEDIATE REDUCER GEAR

CT-030:2 HI INTERMEDIATE MILL STAND CT-031:2 HI INTERMEDIATE MILL STAND


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CT-032:2 HI INTERMEDIATE MILL STAND




Documents

TECHNICAL PROPOSAL FOR 200,000T/Y USED BAR ROLLING MILL ... · 30TON/HR ROLLING MILL PROJECT -2- I. GENERAL 1.1 PREFACE This offer sheet covers the supply of the equipment and materials