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WILSON BYARD 2000T SPIRAL WELD PIPE MILL
YEAR OF MANUFACTURE: 2000
* IN PLANT - UNDER POWER
The Byard 2000T Spiral Weld Pipe Mill is the latest Generation Spiral Mill
designed by Byard Ltd. As the World's leading supplier of Spiral Pipe Mills
they are continually involved in upgrading and refining the Spiral Pipe
making Technology. Since 1964, Byard has supplied over 50 Spiral Weld Pipe
The Byard 2000T Mill was completely redesigned in 1990 and features many new
improvements particularly the increased strip width (2000mm), Lincoln or
Esab Tandem Welding Plant, Laser Weld Guidance System, David Brown Radicon
GearBoxes, and thicker strip capability (upto 25mm). All these improvements
have led to a significantly higher output capability and wider pipe
As of June 1996, Byard has manufactured over 40 Byard 2000T Spiral Weld Pipe
Mills. Each mill has been upgraded and improved as they have installed and
Designed and constructed by Byard within their Livingston Facility to
exacting requirements, the Byard 2000T will enable the Purchaser to produce
Spiral Weld Pipes to Internationally recognized standards such as API, AWWA,
ASTM, British, ISO and DIN Standards.
Byard Ltd. - Excellence in Spiral Pipe Making:
As a long established company and World leader in Spiral Pipe manufacture,
the Byard Mill incorporates the unique experience which can only be gained
from a practical, first-hand knowledge of the spiral weld pipe manufacturing
Byard 2000T Spiral Mill - Flexibility:
Flexibility is the key element of the Byard 2000T Spiral Mill Design
Philosophy. The Mill is designed to manufacture a very large range of pipe
diameters and thicknesses. These are produced from Steel Coil upto 2000mm
wide and 40 tonnes in weight. The Mill can also manufacture pipe from steel
plate particularly in thicker wall thicknesses where plate is more commonly
The Mill can also be operated with a minimum of labour of 3 per shift, and
who can be trained by Byard engineers within a four (4) week period.
Byard 2000T Mill - Transportability:
The Mill is constructed in modular form and can be easily dismantled in a
six (6) week period, transported to another location and re-installed in a
four (4) week period. This means that it can be set up near a contract site
and can therefore help to minimize pipe shipping costs. This is particularly
relevant in large diameters or long production runs. Byard has extensive
experience in moving Pipe Mills to site.
Byard Pipe Mills are readily adaptable, and have been sold to both
developing and also fully industrialized countries. A full list is detailed
on the back cover of the Byard brochure.
Quality Standard and Quality Pipes:
Byard Ltd. is an Approved ISO 9001 Supplier of Spiral Weld Pipe and Pipe
Mills. They operate a rigorous Quality Assurance System which ensures that
their Pipe Mills are designed and Constructed to the Highest Standards
Their Manufacturing Facility in Livingston Scotland, houses a Byard 2000T
Spiral Weld Pipe Mills, it is always open to inspection, and should you
require a practical demonstration of a Byard Mill in operation.
Other Byard Pipe Making Equipment:
Byard also supply other pipe making equipment such as a Hydrostatic Test
Machine which ensure that the Pipe's meet the relevant test pressure
characteristics. They also manufacture a Pipe Socketing Machine (Belling
Press) which cold forms pipe sockets for Water Pipe per British Standards.
They can also supply an X-Ray Testing System to test the weld. We would be
pleased to provide you with a Technical Specification for any other
Equipment that you may find of interest.
TEMPORARY TECHNICAL SPECIFICATIONS AS PER OEM CATALOGUE:
The Capability of the Byard 2000T Spiral Pipe Mill is detailed later; a
brief summary is as follows:
Pipe Diameter Range: 24" - 120"
Pipe Thickness Range: 5 to 25 mm
Pipe Length: Standard up to 20
meters(above with extension table)
Steel grade: upto API X70 (thickness
Strip width: 760 to 2000 mm
Capacity: Rated at over 60,000
tonnes per annum
Welding Technology: ESAB Tandem(5 Rectifiers)
Welding Speed: 1,000 mm - 1,600 mm per minute
Plasma: Hypertherm Max 200
Main Drives: 2 No. David Brown Radicon
135,000 Nm gear boxes
Edge Milling: Included
Pre-Bending: Supplied as standard
As you can see, the extensive range and capability of the Byard 2000T Spiral
Weld Pipe Mill enables customers to make a very wide variety of pipe for
many different applications.
Total power requirements: 1200 kVA
Electric's: 380V, 3 Ph, 50 Hz
Floor space requirements: as per drawing to be provided
Weight of machine, approx.: 160 t
SCOPE OF PRODUCTION CAPACITY:
Range of Diameters and Thicknesses:
The Byard Mill is capable of producing pipes from either flat steel plate or
coil steel strip of various material grades and in a range of sizes and
thicknesses as shown in the attached table. As one can see, the Mill is
capable if many different thicknesses and diameters and provides the
Engineer with a wide variety of choice.
Estimated annual production tonnage based upon pipes of equal length,
produced by in a two (2) shift basis, with 4800 working hours per year can
be found in the table, as you can see the output can exceed 65,000 tonnes
Input Material Range:
The width of steel coil or plate which can be processed by the Mill varies
from a minimum of 900mm (35.4") to 2,000mm (79").
Steel coils of external diameter 2,000mm (79") and internal diameter 610 mm
(24") can be utilized up to a maximum weight of 40 tonnes.
Pipe length up to 12 meters can be produced with the standard pay-off table;
other length requirements being satisfied by the addition of pay-off table
The Mill can process Pipe in all material grades upto API X 70 or equivalent
A table illustrating the relationship between the diameter; thickness; strip
width; and steel grade is given in on the attached file.
SPACE REQUIREMENTS & SERVICES FOR MILL OPERATIONS:
The standard Byard 2000T Spiral Weld Pipe Mill encompasses a floor plan area
as shown in figure 7. The purchaser is responsible for providing a solid
reinforced concrete base of depth 200mm (8") over this floor area, and also
over any areas in which steel coils are to be stored.
At its highest point the mill stands 4.5 meter from the floor. When
producing a pipe diameter of 2000mm the minimum craneage height is as shown
in figure 8.
The positioning of the Ancillary Mill Equipment, such as welding rectifiers,
electronic control console and cabinet, and flux recovery components is
typically as shown in the overall floor area indicated in figure 7. The
Byard 2000T Spiral Weld Pipe Mill is of a modular construction and is made
up of five (5) key sections. It can be readily dismantled, transported and
reassembled, at a suitable site, to enable the economic production of pipes,
with minimalized transportation costs.
The Byard Mill consists of a Rear Feed-In Section, Front Feed-In Section, a
Formation Section, a Gate Section and Pay-Off Table.
Rear Feed-In Section:
The Rear strip feed-in section is designed to decoil the coil or plate and
flatten it in preparation for the Front feed-in section. This section
features the coil lifting frame, feed-in drive section and coil flattening
Front Feed-In Section:
The Front Feed-in Section is designed to receive the coil from the Rear
feed-in section and butt the coils together at the coil butting station and
Mill the edges of the coil/plate. The Main drive station drives the coil at
a uniform speed and power into the Formation station.
Both the Rear and Front-in Sections are positioned on floor mounted rails to
enable the coil strip feed angle (Helix Angle) to be adjusted, dependent
upon the size of pipe to be manufactured and the width of coil steel strip
to be used.
The Formation Section features the three (3) banks of formation rollers
which are used to form the steel coil strip into the spiral pipe diameter to
be produced. At this point the Formation Boom carries the internal submerged
arc weld head and Laser Guidance System which produces the inside spiral
weld pass to join the strip edges and make the pipe.
The newly formed pipe then passes through the Gate Section which houses the
external submerged arc weld head. This produces the final sealing weld and
completes the welding process.
The welded pipe then traverses through the Gate Section to the Pay-Off Once
the pipe length required has been manufactured, a Plasma Arc Cutting Tool
cuts the pipe to the required length. The Plasma Cutting head follows the
pipe as it moves down the pay-off table and the resultant cut is square.
By using a moving Plasma head the cut can be performed whilst the pipe is
being manufactured. This significantly improves the output of the machine.
Once the pipe is cut the "throw off" arms are activated and the pipe is then
"kicked off" the pay-off table and onto an intermediate storage rack
(supplied by client).
Byard Ltd. supply all the components and equipment necessary to manufacture
the Spiral Pipe on the Mill, Plasma and suitable compressor to operate the
Flux recovery unit.
MILL COMPONENT DETAILS:
In order to accurately describe the Byard 2000T Spiral Pipe Mill there now
follows a detailed description of each main component section. Where
Propriety items are used we have given general description, Manufacturers
Literature is available on request.
REAR FEED SECTION:
Coil Lifting Frame:
The coil is lifted and supported by a robust Coil Lifting Frame which
features a machined and hardened roll. The lifting frame is hinged to allow
the roll to be inserted into the coil eye. The Coil lifting frame has a hook
which allows it to be lifted by an overhead crane and positioned in the rear
The rear feed section provides a mounting frame into which the coil lifting
frame can be fitted, supporting a maximum steel coil weight of 40 tonnes.
Helix Angle Positioning System:
At the very back of the Rear feed-in section the Helix Angle setting
hydraulic cylinder is mounted. This is securely fixed to the Rear Feed frame
at one end, and it locates in an adjustable floor rail with the exact angles
preset in the floor bar.
Variation of fixing position and actuation of the hydraulic cylinder allow
positioning of the Rear Feed and Front Feed section as a homogeneous
structure, to any helix angle between 45 and 82 degrees relative to the Pipe
Formation section (the setting angle is determined by the size of pipe being
manufactured and the width of steel coil being used.)
When the steel coil has been located in the Rear Feed Section, its
transverse position in relation to the main structure can be adjusted by
actuation of hydraulically operated side guide plates which are fitted to
Feed-In Drive Rolls and Gear Boxes:
The steel coil strip (or plate) is fed into the straightening section. These
machine hardened rolls are powered by David Brown Radicon Triple Reduction
Shaft mounted gearboxes fitted with D.C. electric drive motors with integral
The top roller, vertical position/pressure can be adjusted to suit the
thickness of steel coil strip used; by actuation of hydraulic cylinders
fitted to the roller ends. The bottom roller position is non-adjustable.
Feed-In Guide Rollers:
Prior to the flattening roll section guide rollers are fitted to allow
positioning of the strip edge into the rollers. Both side guide rollers are
adjustable. One by means of an actuator, the other by hydraulic cylinder.
The Rear Feed-In section also houses the flattening roll section. This is to
flatten the coil and ensure that it is fully decoiled and suitable for
spiral pipe production.
The flattening section comprises a five roller arrangement, the two bottom
rollers of which can be adjusted vertically by means of hydraulic cylinders.
These are operated by a simple switch and can be moved very easily.
Immediately after the flattening section, a side guide roller system similar
to that used at the feed section is used to aid positioning, as it leaves
the flattening roll section and enters the front feed-in section of the
FRONT FEED SECTION:
Cross Butt Welding Station:
This Station joins the leading Coil "tall end" to the Following Coil front.
>From the flattening roller section the steel coil strip feeds into the
cross-butt clamping frame. This consists of an upper and lower steel beam
fabrication, both individually adjustable by actuation of hydraulic
cylinders This construction enables the leading steel coil strip "tail" and
the incoming steel coil strip "front", to be clamped. This allows accurate
end trimming and edge preparation using the Oxy-acetylene burning equipment
fitted at this location.
After the ends have been trimmed, they are brought together and clamped
hydraulically. They are then welded together, using a LINCOLN or ESAB AC/DC
TANDEM WELDING EQUIPMENT fitted with a control box, and submerged arc Tandem
head which is similar to that used at the main internal/external pipe
welding locations. Also at this point a copper backing is utilized to
minimize underside butt repair.
The strip then passes through the Milling section of the machine, where the
strip edge can be prepared for welding by edge, single V, or double V
milling, as necessary.
The Milling cutters are mounted on a moveable and floating arrangement. This
allows the cutting head to accommodate the small variations in strip width
and ensures a uniform preparation. The swarf is removed from the plate into
a hopper located underneath the Mill. A wire brush is located after the main
drive "clean" the beveled coil.
Main Drive Rollers:
The Main Drive Rollers which follow on immediately after the Milling Section
drive the steel coil strip at a constant speed and power into the Pipe
The main drive comprises of a machined and hardened top and bottom drive
roll. These are 700 mm in diameter and are mounted in spherical roller
bearings and substantial housings. Each Drive is powered through a flexible
The Main Drive is powered by two independent Main Drive Gear Boxes. These
are high efficiency David Brown Radicon Triple Reduction "H" series
gearboxes fitted with D.C. electric motors and forced cooling fans.
The drive rolls are capable of feeding strip through at varying speeds from
0mm to 2,500 mm (0"-100") per minute. Drive Rolling pressure is applied by
hydraulic cylinders attached to the top drive roll, operated from the floor
mounted "operators" console. Drive pressure is indicated on a gauge next to
the gear box.
Each drive unit is controlled using state of the art "Eurotherm" 590 Series
digital drives, which allow pre-programming of all necessary drive control
parameters, and continuous monitoring of the drive condition. In the
unlikely event that a major fault develops in either of the drives during
operation, the system illuminates the drive "fault" light located on the
main drive electrical control cabinet and closes the drives down until the
fault is rectified.
Full fault diagnostic capability is fitted as standard to the drive modules
which can be interrogated using the simple to operate push button menu
access system and L.C.D. display panel.
Main Drive - Electrical System:
The main drives and associated electrical/electronic components are housed
in a steel, forced ventilated cabinet, which can be sited in any convenient
location within reasonable proximity to the Spiral Weld Pipe Mill (The Mill
main electrical supply is fed directly to this cabinet).
Strip - Side Guide Rollers:
At various locations within the Front Feed Sections, the strip is guided by
side guide rollers; these are actuator operated on one side & hydraulic
cylinder operated on the other.
The strip is also guided above and below by roller bars. The clamping
pressure applied by the top roller bar height are adjustable by operation of
attached hydraulic cylinders, while the bottom roller bars remain fixed.
Both the Rear and Front Feed Sections are manufactured in substantial steel
fabrication which are mounted on roller assemblies. These roller assemblies
run on a floor mounted curved steel plates known as "floor bars" which allow
both sections, when bolted together, to move radially relative to the
Formation section. This sets the Helix Angle required for pipe manufacture.
OPERATORS CONSOLE AND CONTROLS:
The main Operators Console is located near the Mill and allows the
Supervisor or Operator to control the many aspects of the Mill. The Drive
motor electrical control, milling motor control and other ancillary motor &
hydraulic controls, required for operation of the Pipe Mill are contained in
a steel, floor mounted console.
The operators console is normally sited in a position where the operator can
view all the key operations and ensure that all the various operations are
working effectively and safely. The Operators Console features an Emergency
stop button which allows the Mill to be stopped immediately.
PIPE FORMATION SECTION:
The Pipe Formation is where the coil is formed into Pipe and the inside weld
head is located.
The Pipe Formation Section is a substantial steel machined and fabricated
table with a top mounted moveable steel boom; onto which the formation
rollers are set. At the end of the Boom the inside welding head is located.
Three banks of rollers are used to form the pipe. The front set is mounted
onto the formation table top, under the incoming steel strip.
The second bank of rollers is mounted onto the boom section, above the
incoming steel strip on the underside of the boom arm. The boom arm is
adjusted to suit the sickness and width of the incoming steel strip. The
third bank of rollers are mounted onto the formation table and they can be
adjusted by actuator, horizontally, to form the required bend in the strip.
All rollers are fitted with spherical roller bearings and held in a forked
mounting which can be adjusted to the Helix Angle of the incoming steel
The boom section is mounted on the formation table using high tensile steel
bolts. Its position can be varied, along the formation table, by slackening
of these bolts and operating the actuator provided, to obtain the setting
necessary to suit the weld point position.
A steel "invert" roller is provided under the strip seam, at the internal
weld point, to maintain the correct position of the edges. The roller is
securely frame mounted with manual and hydraulic adjustment of position,
height and Helix Angle.
Small Pipe Formation Boom:
In order to manufacture the full range of diameters and thicknesses it is
necessary to supply two booms. A main one for pipes in the Range
600mm-3,000mm diameter. A second boom which has a smaller "neck" is required
to form pipes in the Range 400mm-900mm. There is a Range where either boom
can be used i.e. 600mm-900mm depending on wall thickness.
WELD GUIDANCE SYSTEM:
Byard and a major International Laser Guidance and Welding Company have
developed a new fully automatic Weld Guidance System. It has been previously
installed on 5 Mills Worldwide and is working very satisfactorily. The
guidance system, which utilizes a very sophisticated laser on both the
internal and external welding heads controls the "gap" of the plate/coil the
position of the welding heads and other key parameters. The entire system is
computer controlled and continually monitors the state-of-the-pipe welding.
The Laser system eliminates the need for the gap controller and external
welding engineer. Due to the high quality of this system the resultant weld
speed and quality are also improved.
Inside Welding Head:
The LINCOLN OR ESAB AC/DC Submerged Arc Welding equipment, consisting of a
welding head (tandem wire operation) mounted on a three axis cross slide
adjustment and fitted to a control box is mounted on the boom end. The
LINCOLN and ESAB rectifiers which supply the power to the weld head are
located in a convenient location in reasonable proximity.
Flux Management and Recovery System:
The Flux and recovery hoses are located on the boom end, together with the
welding equipment. The vacuum flux recovery unit is floor mounted in any
convenient location to suit the equipment, whilst the flux feed is
controlled from a pressurized hopper system (compressed air @ 20 P.S.I.).
This flux management system utilizes Nilfisk Industrial Vacuum equipment.
Control of the "gap" between the incoming strip edge and the formed strip
edge, is automatically controlled by the weld guidance system by actuation
of hydraulic cylinder attached to the Pay-Off Table. This provides radial
movement of the Gate & Pay-Off Table sections to optimize the strip edge
prior to internal welding (The Gate Section and Pay-Off Table when
assembled, produce a single homogeneous structure).
The Gate section is designed to support the newly formed pipe and maintain
the dimensions and tolerances of the pipe. The external welding head is
located on top of the Gate section and this provides the external weld. The
Gate section is connected by a pivot to the Formation table; this enables
the gate section to move thus allowing the gap operator to open and close
This section comprises a double gate arrangement complete with upper and
lower roller assemblies to guide and support the newly formed pipe through
to the external weld location and subsequent pipe cut-off position. All
rollers are manually adjustable for position and Helix Angle.
The Gate height is controlled and adjusted from the operators console by
means of lead screws with electric motor drives attached.
The Welding platform is sited between the double gate sections on top of the
adjustable crossbeam assemblies. An operator's station is sited on the
welding platform and all the welding head controls are activated from this
The welding equipment is situated on the welding platform. The Welding
Equipment is identical to the internal arrangement i.e. Lincoln or Esab
Tandem Equipment; Rectifiers, Control box, Tandem Head with the flux supply
and recovery also from the same central system.
The finished and welded pipe leaves the Gate Section and traverses down the
Pay-Off Table. The Pipe cut-off section is an integral part of the Pay-Off
The table comprises of a number of roller box assemblies, frame mounted,
which contain pairs of pipe support rollers, each manually adjustable to
suit pipe diameter and Helix Angle. The Pay-Off Table frame is mounted on
rollers which allow radial positioning by the gap control operator. The
movement is achieved by a hydraulic system which moves the pay-off table
thus opening and closing the gap.
The standard Byard 2000T Pipe Mill is supplied with a pay-off table capable
of supporting Pipes upto 18 meters long. If the client requires a longer
pay-off table then they can be supplied at additional cost in standard 12
Plasma Pipe Cut-Off System:
When the pipe has reached the desired length, as pre-set by a limit switch
mounted at the table end, the cut-off trolley is automatically energized.
The Plasma cutter then attaches itself to the pipe and proceeds to traverse
down the table together with the pipe. The cut-off trolley carries the
cutting head of The Lincoln Air Cutter cutting system supplied with the
mill. This provides the necessary capability of cut as the pipe itself is
still "spiraling" down the Pay-Off Table, during the cutting operation.
Pipe Throw Off Arms:
When the pipe cut is complete, the finished pipe is "thrown off" the Pay-Off
Table using Hydraulically operated thrown off arms. These are activated by
the operator. The pipe is then rolled onto a pipe storage rack (not within
the Mill Scope) and thereafter taken to the inspection bay.
AUXILIARY PLANT SYSTEMS:
Hydraulic Power System:
The hydraulic power system which supplies the cylinders located at the
various positions throughout the Spiral Weld Pipe Mill is powered from a
central custom made hydraulic pump unit.
The pump unit comprises of a dual feed arrangement, to supply:
- The requirements of the main drive hydraulic cylinders directly; and
- All other hydraulic cylinders within the mill.
This together with local pressure regulating the valves allows the setting
of individual cylinder working pressures at the various cylinder positions
throughout the mill.
All hydraulic valves used within the mill are standard Vickers components
which are available around the world.
Compressed Air System:
In order to service the requirements of the flux management system, a rotary
screw air compressor with integrated refrigerant dryer is supplied with the
As part of supply of a Spiral Weld Pipe Mill, Byard Ltd. provides a boxed
tool kit encompassing a range of standard equipment and any special tooling
required for operation of the mill.
A comprehensive manual is supplied with each Spiral Weld Pipe Mill to
(i) Set up and Operation of Mill Manual;
(ii) Electrical/Hydraulic circuit details;
(iii) Component lubrication requirements;
(iv) List of local suppliers for proprietary equipment;
(v) Detailed "spares" drawings.
ADDITIONAL EQUIPMENT AVAILABLE (at extra cost)
PAY-OFF TABLE EXTENSION OPTION:
Although the Byard 2000T Spiral Mill is capable of pipes upto 80m-100m in
length, the standard Pay-Off Table supplied with the Mill accommodates pipes
upto 18 meters in length.
If pipe length in excess of 18 meters are required, this can easily be
accommodated by fitting a series of 12m Pay-Off Table extensions. This will
allow very long pipe length to be produced.
PLATE FEED TABLE OPTION:
The standard mill supply configuration provides a steel coil lifting frame,
suitable for use with coil weights upto 40 tonnes. If however the purchaser
requires a steel plate feed table, this can be
supplied upon receipt of information regarding the details of plate to be
National Machinery Exchange
158 Paris St
Newark NJ 07105-3833
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