The flash butt welder weighs in excess of 180 tonnes, is positioned at the start of the pickling line and is used to join two rolls of steel together before continuing along the pickling line.
The initial part of the project was to dismantle the welder into modules to allow it to be transported by road to Sulzer's Avonmouth Service Center where it was fully dismantled and inspected to perform a complete appraisal.
The findings and recommendations were then communicated to allow the customer to take a decision on the viability of the refurbishment project.
One major design change was to the machine handling and control systems, which had to be reconfigured due to the steel strip flow being in the opposite direction in Llanwern. A completely new electrical wiring system and software was installed along with all new hydraulic and pneumatic piping.
In addition, new hydraulic valve stands with upgraded hydraulic pumps were also incorporated into the refurbished machine.
While this work was being completed in Avonmouth, in Llanwern the existing machine had to be removed to install new foundations in preparation for the arrival of the refurbished welder.
Careful coordination between Sulzer and Tata Steel ensured that the site would be ready and the project timetable would be maintained.
With the upgrades complete, the entire welder was reassembled at Sulzer Avonmouth to ensure that all the modifications had been successful and that the operation of the machine met the required Operational Engineering Standard. The fully functioning welder was then dismantled into modules for the final time for the short journey across the Severn Estuary before being reassembled in the Llanwern Works.
The Sulzer engineers completed the assembly and the connections with the rest of the production line before functional testing and initial welds were completed. Full production took less than two weeks following delivery to the site.