Today, the production-engineering company LLC "Ural Engineering Center" is ready to carry out modernization or equip new technological equipment for scale removal systems.
Competencies
- Experience in scale removal since 2002, meeting the strict requirements of enterprises;
- Expertise in implementing engineering solutions in sheet, section, and pipe rolling production, extending the life of wear-prone components, including for "sticky" scale removal;
- Knowledge and experience with calculation software from leading equipment manufacturers;
- A proven nozzle calculation method based on practical experience;
- Scale removal systems optimally equipped with domestic and imported components;
- Currently, there is a solution for localizing the production of scale removal systems in Russia.
Partnership Options with Enterprises:
- Design, manufacture, supply, and installation of a comprehensive scale removal system;
- Engineering calculations and services;
- Supply of shut-off and control valves and distribution equipment (including analogs of INOXIHP, Dr. BREIT, Scoda, HydroSystem, Tiefenbach, Hauhinco, Oilgear, Schroedahl, and others).
Components of Supplied Scale Removal Systems:
- High-pressure pump station;
- Water flow control equipment;
- Discharge collectors;
- Automation and Instrumentation (ASU and KIP);
- Power equipment.
Pump stations are equipped with multistage centrifugal or plunger pumps. Variable frequency drives for electric motors are widely used (excluding high-pressure accumulators).
In its projects, LLC "Ural Engineering Center" collaborates with key pump equipment manufacturers such as Sigma (Czech Republic), Karcher/Woma (Germany), KSB (Germany), Livgidromash (Russia), and Synergia (Russia). Suppliers of frequency converters include Siemens (Germany) and CHEAZ (Russia), with electric motors from Siemens (Germany) and Elsib (Russia), among others.
Pump stations are equipped with auxiliary systems: lubrication, filtration, and unloading circuits.
Water flow control equipment is designed to connect scale removal collectors to the pressure line. Ural Engineering Center manufactures various types of scale removal valves and blocks: spool and seat, with hydraulic or pneumatic drives. Patents have been obtained for key solutions.
Discharge collectors can be linear or circular. Ural Engineering Center designs and manufactures collectors with nozzles from leading manufacturers such as Everloy (Japan), Lechler (Germany), Spraying Systems (USA), and Tetra (Russia).
Automation and Instrumentation (ASU and KIP) performs tasks such as pump station control, billet detection, activation/deactivation of the scale removal process, system parameter registration and archiving, process visualization, equipment diagnostics, and the generation of alarm and warning signals. Programming is carried out using Siemens controllers or others upon customer request.
Completed Project Example
In 2014, at the Sinarsky Pipe Plant (SinTZ), part of the Pipe Metallurgical Company (TMK), a scale removal system was implemented in pipe rolling mill No. 3 (T-3) as part of the plant's investment program for technical re-equipment. The new equipment is designed to remove scale from pipe billets exiting the walking beam furnace. The goal of the modernization was to improve the surface quality of the pipes produced and increase the longevity of the piercing and reduction rolls of the pipe rolling unit.
The equipment complex of the scale removal installation at T-3 includes hydraulic and electrical systems, five high-pressure pump units, two centrifugal pumps, and a filtration system for water purification. The scale removal process is fully automated and controlled from an operator panel.
An original method for selecting the energy parameters of nozzles and determining the geometry of the nozzle installation on the collector was developed for the design and engineering of circular collectors to simulate the spatial spray field and minimize mutual interference. This method allowed the design and manufacture of efficient circular collectors for the scale removal system supplied by Ural Engineering Center for the pipe rolling unit at "Sinarsky Metallurgical Plant" (Kamenka-Uralsky).
"The new scale removal system was implemented at the plant following global trends in metal surface cleaning methods and meets the principles of maximum efficiency both in producing high-quality products and in extending the lifespan of rolling tools," noted SinTZ Managing Director Vyacheslav Popkov.
References
EVRAZ-NTMK. "NTMK" (Nizhny Tagil)
- 2018 — Modernization of the scale removal system at the Central Bar Mill, replacing the scale removal collectors with Everloy nozzles and replacing scale removal valves with proprietary hydraulic-controlled equipment.
Group PJSC "MMK". "Magnitogorsk Iron and Steel Works"
- 2002 — Manufacturing, repair, and restoration of scale removal valves for the 2000 Mill, SPC-10.
- 2007-2021 — Manufacturing, repair, and restoration of scale removal valves and plunger pumps for scale removal on section mills 170, 370, and 450 by Danieli.
- Since 2008 — Modernization of scale removal valves for mills 4500 and 2000.
- 2013 — Design, manufacture, and supply of scale removal collectors for roughing groups at SPC-4, SPC-10, and furnace scale removal collectors at SPC-9.
- 2013-2021 — Modernization and repair of scale removal valves for the 5000 Mill.
- 2018 — Supply of scale removal equipment for the 2000 Mill SPC-10 in partnership with SIGMA DIZ SPOL.S.R.O. (lubrication equipment, scale removal valves (blocks), pump unloading system, scale removal collectors with Lechler and Everloy nozzles).
TMK. "Sinarsky Metallurgical Plant" (Kamensk-Uralsky)
- 2011-2013 — Comprehensive scale removal for the hot cutting line at pipe rolling shop No. 3 for pipe billets Ø120-Ø160 mm (pump station with plunger pumps, scale removal valves and collectors, automation, and power equipment).
Mechel. "Chelyabinsk Metallurgical Plant" (Chelyabinsk)
- 1997 — Manufacture and supply of scale removal valves for the 1700 Mill.
