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SigmaTEK Systems, LLC, the world’s leading authority on CAD/CAM nesting and manufacturing process automation, announces an upcoming free webinar.
“Laser Tube & Pipe Cutting Solutions”
Date: Thursday, April 3, 2014
Time: 2:00 PM (Eastern)
- Maximize material usage and increase cutting time for round, square, rectangle, triangle tube/pipe and structural material (I-Beam, H-Beam, etc.)
- Learn the latest in laser or plasma nesting/cutting technology
- See SigmaTUBE® nesting technology
Information & Registration
Information: To register, or for more information, visit www.sigmanest.com.
Over the years Fontijne Grotnes has developed into a specialist in the design and manufacturing of Full Length Pipe Expanders for the pipe industry. The Expander guarantees a constant, reproducible process regarding diameter, straightness and mechanical properties.
Fontijne Grotnes is constantly improving the Full Length Pipe Expander for new market demands, like higher outputs, increased wall thickness’, higher material grades up to X120, stricter out of roundness and straightness tolerances.
Recently Fontijne Grotnes implemented several product improvements to fulfill new market- and product demands:
Dedicated Expander Heads
When size or quantities matters Fontijne Grotnes can develop a dedicated expander head, for optimizing production possibilities in wall thickness, material grade, or production quantity of LSAW pipes.
As example the special design of the expander head can result in increased radial force and optimized surface area between cone and jaw configuration in order to accept pipes with increased wall thickness. For one customer Fontijne Grotnes designed an Expander Head capable of expanding 18’’ pipe with a wall thickness of 32mm for X70 grade.
New Expander Head- and Die Handling Fixtures
Fontijne Grotnes has improved its head- and die handling fixtures to respond to customer demands. This latest development is more maintenance friendly and will improve changeover time significantly! The quick tool change system creates a defined position of the centre line of the Expander Head and controls the Expander Head rotation.
With this quick tool change system a changeover time reduction of 40% can be achieved. There is also modification set available for existing Fontijne Grotnes customers.
Optimizing Cost of Ownership
Because of increasing global competition and economic pressures, the total cost of ownership of the manufacturing process is an important aspect in the purchasing process.
With the use of the Fontijne Grotnes’ Pipe Expander savings can not only be achieved on lubricants and oil during the expanding process, but also on energy:
- The consumption of Expander Oil is kept to a minimum, by using an optimized expander head lubrication system in combination with a sophisticated head design. The system only uses 0.5 – 1.5 liter per (12 meter) pipe; the lowest oil consumption in the market! This results in saving more than 125,000 liter per year compared to competitive processes at a production rate of 500,000 t/yr.
- The expander head is well protected against dirt by seal arrangement. Washing of the expander head after each cycle is not required
SigmaTEK Systems, LLC, the world’s leading authority on CAD/CAM nesting and manufacturing process automation, announces the release of SigmaTUBE. A complete tube and pipe cutting software, SigmaTUBE supports round, square, rectangular, or triangular tube/pipe. In addition structural material such as I-beams, H-beams, C-channel, and angle iron are supported. Custom programs are available to fully maximize the advanced features of Mazak FabriGear, Trumpf, BLM, Bystronic, Amada, and other 3D tube and pipe cutting laser machines.
Key features include:
- Flexibility allows multiple cutting machines to be driven with a single solution
- Supports multiple assembly model configurations
- Simple model refresh provides updated design revisions
- Cutting technology table sets cutting condition parameters
- Operates seamlessly within the SolidWorks® environment
SigmaTEK Product Manager, James Lindsey comments:
“Tube and pipe cutting has traditionally lagged in terms of sophisticated nesting; this all changes with the release of SigmaTUBE. Powerful automatic, manual, and true shape nesting speed tube and pipe cutting processes and maximize yield. This of course translates into money saved through waste reduction. The industry’s most efficient nesting is achieved by calculating the best possible combinations based on actual geometry while common-line cutting cuts shared edges at the same time reducing time and pierce points.”
Thick wall chrome steel pipe joints, as used in the power industry for high pressure high strength pipe work, need to be pre-heated for welding and probably need a post weld heat treatment too.
Weld joints of this nature need to be purged of oxygen and welded in an inert gas atmosphere, to prevent oxidation, slag formation etc., that leads to loss of corrosion resistance and undesirable change to the metallurgy.
With the high temperatures and length of time at temperature needed in the pre-heat, weld and post heat treat cycles, most weld purging systems are unsuitable.
However, Huntingdon Fusion Techniques, HFT®, has now developed “HotPurge™” Pipe Purging Systems, for use up to 300ºC (572ºF) for 24 hours. (The material used is rated up to 700ºC (1,292ºF)
HotPurge™ is based on the company’s world famous Quick Purge®II design that has been in wide use for many years, but adapted for use at high temperatures.
This system is available for pipe internal diameters (i.d.) from 4 – 96” (100 – 2,500 mm). Each Hotpurge™ is made to size and has a tolerance of +/- ½” (12 mm) because of the restrictions of heat proofing material.
Features of the HotPurge™
1.0 The central large collar that dramatically reduces the space to be purged and makes it easier to reach the lower oxygen levels faster.
2.0 Four pull handles are securely attached to each dam, secured with the Kevlar thread that will withstand a pulling force of 1.000 lbs on each handle.
3.0 The most stunning feature of the the HotPurge™ system is the PurgeGate® to prevent over inflation.
PurgeGate® is a clever, world wide patented invention that allows users to simply connect the Hotpurge™ system to any source of compressed inert gas and simply turn it on to whatever flow or pressure they wish.
PurgeGate® will protect the dams from over inflation or bursting and allow the user to deliver whatever flow they like, using the one gas source.
No matter how high the user raises the pressure in order to deliver more flow, PurgeGate® prevents the pressure going to the inflatable dams, but allows the increased flow to make a faster purge.
PurgeGate® is guaranteed for life.
HotPurge™ Pipe Purging Systems can be used over and over again for specialist weld purges on power industry piping, that will keep the oxygen levels below 100 parts per million throughout the welding cycle.
For medium- to large-batch and mass production cutting-to-length of solids, tubes and profiles in most materials, German sawing machine manufacturer, KASTO, has introduced a new, automatic circular saw called KASTOgripspeed C10. It can be fitted with equipment for continuous stock infeed and with various outfeed options, including sorting of cut pieces.
The automatic, high performance circular saw, KASTOgripspeed C 10.
The high performance machine is designed to process materials up to a tensile strength of 1,400 N/mm². Tungsten carbide tipped saw blades of 360 mm diameter and either 2.5 or 2 mm thick minimise the kerf and hence the amount of metal lost as swarf. For some materials, coated or cermet blades are used.
All such blades have the additional advantage that thin or thin-walled materials can be cut safely and efficiently, expanding the range of applications for which the KASTOgripspeed C10 is suitable. Particularly helpful is infinitely adjustable workpiece clamping with a force of 2 to 12.5 kN for safely securing thin-walled tubes and profiles.
Cutting range of the saw is from 15 to 100 mm diameter for rounds or up to 80 mm for square stock. The smallest cut-piece length is 8 mm, while remnant length is only 65 mm. Material feed stroke is 500 mm, or up to 9,999 mm with multiple feed.
Saw drive power is high at 11 kW to ensure efficient cutting of all type of material. Infeed speed ranges from 10 to 4,000 mm/min and is infinitely variable. The same is true for blade speed, which is adjustable from 17 to 175 m/min. Contributing to short idle time is 10 m/min rapid lift of the saw blade at the end of each cutting cycle.
To maximise productivity, continuous material infeed and outfeed is needed. KASTO offers a wide range of roller conveyors and inclined magazines for bar lengths up to 12 metres. As an alternative to inclined magazines, loaders are available for bundles up to a maximum of 5 tonnes. There are also flat and universal magazines for rectangular and profile materials or for fully automatic processing of cutting orders of small to medium batch sizes.
Several possibilities are available for the outfeed side, including conveyors and various types of automated sorting systems.
LEADING AUTOMOTIVE COMPONENT SUPPLIER AUTOMATICALLY CHOOSES ADDISONMCKEE.
Global leader in the design, manufacture and supply of the world's finest tube bending and endforming technologies, AddisonMckee of Lebanon, USA; Brantford, Canada and Bamber Bridge, UK has recently installed an automated cell into a facility in the north of England.
One of the world’s largest international groups dedicated to the design, development and manufacture of metal components and structural systems for the automotive industry. Whilst AddisonMcKee’s unrivalled experience of CNC bending and forming technology made the company’s appointment to supply a fully integrated system a natural one, it was recently completed on time to the customer’s full satisfaction.
Two components were presented to AddisonMckee to process, one required only bending and drilling, but to be produced by a fully automated solution; the other component only needed forming and production was to be manually controlled. (To be automated at a later date.)
BENDING OPERATION. -
The bending cell incorporated a bunker system fed by pallets of cut 34mm diameter tubes, which were unloaded magnetically and processed within a buffer system, to a pick-up point were the tube was seam detected and presented ready for an ABB robot to collect. The robot with a double gripper held the new tube until the eB80bending machine had completed two symmetrical 1 x D bend on bend applications; it then removed the bent tube and inserted the new tube, and the bending process recommenced. The bent tube is then transferred by the robot to a combined inspection gauge and drilling fixture, if the component is deemed to be incorrect it is transferred to a reject chute; otherwise two holes are drilled and the component is transferred to a finished part stillage, which is mounted on a turntable system. When the stillage is full the turntable presents an empty stillage ready for the process to work continuously. Within any automated system, safety and process fault diagnosis are of paramount importance. AddisonMckee worked with and were assisted by Premier Automation to engineer a fully integrated robotic system that met all the customer’s logistics and health and safety requirements.
FORMING OPERATION. –
The component to be formed was a straight 50mm diameter tube that required three AddisonMckee machines to form both ends and trim to length. One end required a flat to be produced by a two hit 70RF machine and the other end required a 70SRF (selectable ram form). The SRF machine used three hits to produce an offset reduction to a size that allowed the 34mm bent tube to be inserted on the final welded assembly. After forming the resultant end deformation was trimmed to the correct length with an FM70TTPN (tube trim with pre-notch).
The tube bending machine innovator Unison will be demonstrating techniques for increasing the productivity of tubular parts fabrication at Fabtech. Throughout the show, users will be able to see demonstrations on an all-electric Unison machine capable of bending tubes and pipes up to 3.5 inches in diameter.
Unison employs numerous advanced techniques to help manufacturers to increase throughput and quality, and eliminate the potential for errors and scrap. One of the techniques is an innovative quick-change tooling system that dramatically speeds tooling changeovers. Covering all of the tooling components on the machine, it includes barcode identification to verify the changeover process. A fully validated, error-free, changeover from manufacturing one good part to another can be accomplished in less than three minutes for instance. The system is ideal for companies producing high value-added tubular parts, enabling expensive early-stage errors to be eliminated from the manufacturing process, and is of particular benefit for companies that manufacture parts to demand and in small batches.
Another new advantage on offer is a range of mechanical architecture and control software improvements that Unison has implemented to optimize tubular part fabrication times. These reduce the time required for intermediate handling and movement of the tooling that the machine performs before and after a bend by as much as 40%. As there might be four or five auxiliary movements for each bending move, as well as changes of tooling dies, these savings can add up to very large productivity gains - particularly for companies fabricating parts with multiple bends. This speed gain is complemented by Unison technical support, which helps clients to optimize their bending programs, by employing techniques such as moving several machine axes in parallel. Automatic collision checking software is also available to help with this process.
"All-electric bending technology has come to dominate the tube bending industry, and is making significant inroads into pipe bending markets - with machines now available for diameters up to 8 inches," says Unison's Jim Saynor. "Most users now understand that all-electric tube benders offer major advantages over hydraulically-powered machines, in terms of automatic and repeatable set up, and right-first-time/scrap-free production. However, the benefits of such a software-controlled architecture extend much further. They allow users to simulate offline to find the most efficient way to make parts for example. And to reduce the cycle times for parts by optimizing bending programs, plus many other benefits."
Visitors to Unison's stand will be able to sign up for an educational tour demonstrating the productivity gains that can be made using servomotor-controlled tube bending. Unison will take attendees to see how real-world users employ the precision bending technology - with a choice of applications including aerospace, automotive, subcontract manufacturing, shipbuilding, and oil and gas equipment manufacturing.
Unison will be part of Horn Machine Tools' display, on booth # S3961. www.unisonltd.com
NIPPON STEEL PIPE MÉXICO, S.A. DE C.V. (“NPM”), established by Nippon Steel & Sumitomo Metal Corporation (Chairman & CEO: Shoji Muneoka, “NSSMC”), Sumitomo Pipe & Tube Co., Ltd. (President: Rempei Nakanishi, “SP”), Sumitomo Corporation (President: Kuniharu Nakamura, “Sumitomo”) and Metal One Corporation (President: Naoto Matsuoka, “Metal One”), has completed the construction and commissioning of all its plant facilities and started its commercial operation in late May 2013 on schedule.
In Mexico, the production of automobiles (four-wheeled vehicles) has grown to the world’s eighth largest, turning out 3 million cars in 2012. With Japanese automakers’ commencement of production or the expansion of production capacities in Mexico, car production is expected to continue to show a sharp increase in the future. In response to such increase, also expected is a fast expansion in demand for middle- to high-grade steel pipes/tubes where NSSMC and SP have competitive strength.
NPM, as the core production base of automotive pipe/tube in Mexico, will work to keep up steady supplies of high -accuracy and -precision and high quality products for Japanese, North American and European automakers and auto parts makers in Mexico, and to expand and enhance customer services.
NSSMC, SP, Sumitomo, and Metal One will continue to develop and expand their overseas operations aggressively in order to respond globally to demand for automotive steel pipe/tube.
Having been manufacturing Tube and Pipe Weld Purging Systems since 1975 Huntingdon Fusion Techniques® (HFT™) has evolved the science of Weld Purging to new levels.
Along with other recently announced scientific developments in its Weld Purge Monitor® series, the Company has now reached the Fifth version of its Tube and Pipe Weld Purge System designs by launching the new PurgElite® range of Tube and Pipe Weld Purging systems for diameters from 1” to 24” diameter inclusive.
These systems are suitable for all industries using tubes and pipes from the very highly specialist Biogas and Semiconductor fields, right along to other industries such as those where the pipework is less critical.
In particular, PurgElite® systems can be used in high quality tube and pipework where the internal surfaces may be polished to ensure minimum entrapment and low corrosion resistance. With the new Intacal® specially designed in line purge valve and the synthetic hose protection, there are no metal parts to scratch the tube or pipe surfaces.
IntaCal® needs no setting or controlling, but is precisely manufactured for the PurgElite® method of weld purging.
This new range comprises 15 models for tube and pipe sizes from just under 1” to 24”, each one overlapping the range of the other so that all internal diameters from 20 mm up to 610 mm are covered.
The new series has a number of major advantages over previous weld purging systems and has taken into account the evolving technology in all market places where much higher specifications of materials and work finish are available and expected.
The groundbreaking key feature is the development of an in line purge gas release valve that is required to purge the chamber between the two dams once they are inflated. Intacal®
This leads to the advantages mentioned above, namely:
1.0 The ability to manufacture a 1” system
2.0 Absence of protruding metal parts that scratch the insides of electro polished tubes and pipes
3.0 Elimination of the burst bladder problems that occur with other systems
4.0 Greater flexibility because the complicated valves still used by others, have been eliminated.
5.0 Faster purging using less of the expensive inert purging gas
6.0 No complicated valve to set and to mis-function and no loss of time at the start up of jobs.
7.0 Lower manufacturing cost
Other features of the PurgElite® system include:
B. High Tech, high temperature resistant, synthetic gas hose
C. Glow strip positioning band
D. Ease of pulling around bends and elbows in complex tube and pipework systems
E. Selection of Low Vapour Pressure Materials
Low Profile Valve:
1” diameter tube and pipe weld purging:
For the first time it is possible to locally purge 1” diameter tube and pipe welds with an inflatable tube and pipe weld purging system, instead of having to fill up complete systems with expensive inert weld purging gas.
The 1” PurgElite® Tube Weld Purging System will be a valuable welding accessory to manufacturers of many stainless steel, Titanium and Nickel Alloy tubular systems.
Absence of protruding Metal Parts:
No scratching: Particularly of expensive electro-polished tubes and pipes:
Weldpurging is mostly carried out on Stainless, Duplex and Chrome steels as well as Nickel and Titanium alloys.
When internal tube and pipe surfaces are scratched by metal parts on old fashioned weld purging systems, there will be a loss of corrosion resistance that cannot readily be repaired.
As well as negating one of the critical purposes for which the material was selected, scratches cause interruptions to the flow of the gases or liquids inside and leave resting places where bacteria can multiply.
The absence of protruding metal parts with the PurgElite® system completely minimises the risk of scratching and damaging the insides of valuable tube and pipe systems.
Manufacturers of High Purity Systems and those with some other critical applications will use internally electro-polished tubes and pipes making the PurgElite® system even more valuable and more essential to prevent scratching.
Elimination of burst bladder problems:
Other types of inflatable pipe purging systems have large valves that are often set incorrectly leading to frequent problems of burst bladders.
The new PurgElite® system completely overcomes that problem with a different type of system completely, for inflation and purging.
The PurgElite® system of Tube and Pipe weld purging systems, has eliminated the old style inflexible metal braided hose and substituted it for a new technology high temperature resistant, flexible gas hose protector connecting the two purge dams.
This special high temperature resistant weld purge hose protection material is heat resistant up to 700 degrees. In the event of hot liquid metal droplets falling on the hose protection, it’s intumescent properties make a heat barrier to prevent damage to the purge hose, thus avoiding the risk of loss of purge quality and the potential loss of a weld joint.
The greater flexibility of the systems with this non metal hose gives operators the freedom to pull PurgElite® systems around tight bends and through complex tube and pipe fabrications.
Faster Weld Purging:
With the smaller volume, simple gas release valve that uses mathematically calculated designs, the purge gas will be released faster and in greater quantities permitting fast purging of the volume below the weld, without creating the turbulence and long purge times associated with other devices.
When used with one of the PurgEye® Weld Purge Monitors® the PurgElite® systems provide the operator with the perfect combination to purge and monitor oxygen content to achieve the fastest and most ideal conditions for welding to begin.
The savings made by using less of the expensive inert purging gas, along with the savings achieved with shorter purging time, will help to pay for these products in just one weld.
No complicated valve to set and no loss of time at the start up of jobs.
The specially designed PurgElite® valve system allows operators to use their systems immediately without having to follow complicated valve setting procedures. Such work causes loss of production time and invariably leads to errors and failed systems.
The PurgElite® systems are totally and simply plug and play. Plug in the inert gas supply and purge the weld, more than halving set up time.
Lower Manufacturing Cost:
The new low profile, mathematically designed PurgElite® gas purge valve is a single in line item that replaces a costly valve with elbow fittings and other connectors that may even separate during welding.
In addition, the high temperature resistant flexible connection hose replaces and expensive metal braided hose with costly fittings.
Summed together, these savings allow HFT to bring the PurgElite® range to the market place for lower costs than ever before.
High Temperature resistant hose:
The heat build up in the welding cavity is such that the gas hose connecting the two dams has to have a high temperature resistance.
PurgElite® weld purge systems have a newly developed synthetic material capable of withstanding a temperature of 700 º C (c 1,300ºF) that will withstand even hot metal dropping on it by building an intumescent layer.
Replaceable Glo Strip band:
Once PurgElite® systems are inside a tube or pipe system, they can be pulled around from Joint to joint and positioned correctly and easily. This has been made possible by the fluorescent glo strip fitted to the centre of the purging system.
Welders can see through the pipe joint into the internal dark area, whether clamped or tacked ready for welding and view the purge system as it comes into place, with the replaceable glo strip immediately below the weld.
Low Vapour Pressure Materials:
Employing latest material developments (HFT) has selected lower vapour pressure materials to ensure that the outgassing rate into the weld zone will be reduced to the barest minimum during welding to protect the molten weld pool from oxidation and the problems arising.
For larger diameters of Pipes, Huntingdon Fusion Techniques Limited manufactures its rugged Argweld® Quick Purge® Systems to suit diameters from 8” to 80” (200 – 2000 mm
Lord Green, Minister of State for Trade and Investment, has opened the new design and manufacturing facility of one of the UK's most successful machinery builders, Unison. Based in Scarborough, Unison makes machines for bending metal tubes and pipes, exporting over half of its output - mainly to America. The new facility will allow Unison to more than double its production capacity, which will help the company to enter new international markets that it is targeting in the high growth 'BRIC' countries.
Unison's new factory for manufacturing tube bending machines, in Scarborough.
Applauding Unison's export success, Lord Green emphasised the critical need for the UK to increase its manufacturing output, and to increase its export ratio. In his role as Minister of State for Trade and Investment he has visited over 50 countries and he noted how receptive world markets are to British goods and services, and the high regard in which many many countries hold British values, quality and technology. This effect has been greatly reinforced by the success of the London Olympic games and he urged British companies to capitalise on the major opportunities that exist.
"Unison makes specialist equipment that goes around the world. It's a perfect example of the kind of manufacturing that this country excels at and that we need to do more of," said Lord Green.
"We aim to make our new Scarborough facility the world centre for advancing tube bending technology," added Alan Pickering, Managing Director of Unison. "One of the first machines we are manufacturing in the new factory will be the largest 'all-electric' tube bender ever made - with the ability to bend pipes up to eight inches in diameter. This technology is opening up new markets for Unison - in this case it's destined for the shipyards in Virginia that build the US Navy's aircraft carriers and submarines."
Some of Lord Green's remarks during his visit to Unison:
"We've lived with a trade deficit for about the last 40 or 50 years, and we have to turn that around. The evidence is compelling that companies that get into export markets gain significantly: they grow faster and are more profitable, they last longer and create more jobs. So if we care about the future of this country we need to be more engaged with manufacturing excellence, service excellence, and to be more export oriented."
"We have to focus more attention on the fast growing parts of the world. Half of our exports go across the Channel, and that's good except that the highest growth markets are in Asia, Africa and Latin America. I've visited more than 40 emerging markets in the last couple of years and everywhere you go you hear that Great Britain has never stood in higher regard than it does now. We're welcomed because in their minds Great Britain stands for high technology, high quality, integrity of doing business, creativity, imagination and entrepreneurialism."
"Sometimes we don't think of ourselves as natural entrepreneurs, but the rest of the world does, and after the Olympics all the more so. Everywhere I go people say how incredible the Olympics was. All too often the next remark is 'but we don't see enough of you'. On average fewer British companies export compared with our European friends. So we have a challenge in encouraging and helping more British enterprises to take the world on, but we must achieve this if we are to leave behind the difficult times of the last four or five years."
Castings Services Group, (CSG) one of the UK's leading suppliers of quality civil engineering products has made further investment into its Pipes and Fittings division with the appointment of a new Sales Representative, Tom Marriott at their offices in South Derbyshire.
Tom, who has come from a sales estimator and customer service role at Electrosteel UK, brings a wealth of product knowledge as well as a good grounding in the supply chain process.
With his strong background in sales and customer service, Tom's new role will involve managing some of CSG's key accounts, providing technical support to the sales team, developing new business and consolidating existing business.
The pipes and fittings division, which mainly services the water and wastewater industries and accounts for 30 % of CSG's business, offers a large range of stock and quick turnaround times.
This coupled with an extensive portfolio of ancillary items such as; Viking Johnson couplings and adaptors, manifolds, bends, crosses, bellmouths and ‘Y' pipes, allows the pipelines team to meet the demands of even the most complex customer projects.
"It's good to be on board at CSG and I believe fostering customer relationships is key to this new role. CSG has an increasing industry reputation as an organisation that goes the extra mile in providing excellent customer service. I very much look forward to the challenges ahead."
Roger Fulton, CSG Managing Director added:
"Its good to welcome Tom to the team. His product knowledge and sales expertise will open up new business opportunities for us. We are confident he will be a valuable asset to the team."
CSG stocks include a wide spectrum of pipes and fittings from 80mm to 1000mm, as well as the facility to fabricate bespoke lengths. This is complemented with a large selection of coatings to suit specific purposes, suitable for both clean and dirty water applications.
All products are certified and compliant with latest BS:EN international standards.
According to estimates by the International Energy Agency (IEA), the energy demand of the world population will increase drastically in the coming years: in 2030, around 5.5 billion people will have access to the electricity supply – this is equivalent to growth of 1.5 billion consumers within only slightly more than two decades. To meet the increased energy demand, in addition to investment in renewable energies, the construction of new power plants and modernisation of existing facilities in particular are vital. One critical criterion here is to significantly improve efficiency in the power plant process. The requirements for the installed tube systems and tube materials are therefore also increasing, as they make a noticeable contribution to increasing efficiency. Schwarze-Robitec have developed special bending machines for precisely this application area, which bend high-strength, thick-walled high-pressure tubes as well as boiler tubes, tube coils and entire membrane tube walls accurately and both time and cost-effectively.
The requirements for liquid and steam line systems in modern power plants are increasing: significantly higher pressure, flow and temperature values result in increasing strain on the systems. At the same time, the legal constraints and requirements are intensifying. Leakages can result for example in costly repairs or – which is worse – investigations, fines and even a deactivation order from the relevant regulatory authorities. This makes the use of durable, safe and effective tube systems and solutions all the more important. Whereas thick-walled high-pressure tubes and pipes have been welded together for decades from various straight and pre-bent tube components, modern tube bending processes offer significant advantages with respect to safety, subsequent maintenance and the requirements of the present tube parameters as well as last but not least appreciable benefits in terms of manufacturing costs and times.
Efficient production of manifolds, steam and pressure lines
The semi-automatic SR 320 tube bending machine and the automatic CNC 320 HD from Schwarze-Robitec GmbH produce complex tube systems in one operation from a single tube for example for pressure and steam lines, manifolds and similar tubes. Being equipped with special tools, the machines bend thin and thick-walled tubes with a maximum diameter of 323.9 x 17.5 mm. With a tube size of 323.9 x 10 mm, for example, they have no problem producing a bending radius of 1.5 x D, which is equivalent to a bending radius of 485 mm in the example mentioned. The semi-automatic machines in the SR series are particularly suitable for the production of single bends and small series. The automatic, CNC-controlled machines are also suited to complex tube systems with several bends or large batch sizes. “Compared with the induction bending processes, our cold bending process offers huge time savings in the production process,” Schwarze-Robitec Plant Manager Jürgen Korte explains. “Whereas hot shaping of these work pieces takes around eight hours, our customers require an average of only six minutes for one bend.” Depending on the specific application, Schwarze-Robitec offer the machines from their heavy duty machine series for various diameters and wall thicknesses up to 610 x 21.4 mm. The machines are available in semi-automatic design with SR control and in automatic design with CNC control. All machines can be equipped e.g. with a tube magazine and tube feed and enlarged up to fully automatic bending cells.
Economical production of boiler tubes and tube serpentines
Very different but similarly exacting requirements now also exist for boiler tubes and tube serpentines in power plant construction. The production of smaller boilers with greater capacity, for example, requires the use of extremely tightly bent tubes. Depending on the tube diameter, it is not uncommon for the required minimum bending radius to be 1xD (sometimes under 1xD). The semi-automatic booster bending machines and automatic CNC pressure bending machines from Schwarze-Robitec are designed precisely for these requirements. The unique cold-bending process from Schwarze-Robitec offers utmost precision and surpasses the tolerance requirements for wall thinning and out-of-roundness e.g. of European standard EN 12952, American Society of Mechanical Engineers ASME B31.1 and all other international standards. The CNC-controlled booster bending machines are also equipped with a tube positioning device, which facilitates fully automatic bending of tube systems. For efficient processing of very large and complex tube serpentines, Schwarze-Robitec offer the CNC TWIN series machines: this machine series, which is available in three different sizes up to diameter 88.9 x 11 mm, uses two vertically and horizontally movable bending heads (1x left-bending, 1x right-bending), which alternately bend the tube clockwise and anticlockwise. Consequently, the tube serpentine does not need turning after each bend, which ensures quick and economical production processes and the manufacture of large leg lengths. “Of course, our machines also guarantee the processing of high-strength materials, for example such as high temperature steel alloy T91,” Managing Director Bert Zorn adds. Moreover, they are able to produce different bending radii within one tube system. Furthermore, adding a Terminal End Bender to the machine is easily possible.
Precise processing of complex tube walls
Schwarze-Robitec also offer a specialised bending technology for the bending of entire membrane tube walls, which is common in the construction of modern boilers and power plants: the FL machine series processes tube walls with a maximum width of 3,600 mm and a length of 25,000 mm or more quickly and accurately by means of the compression bending process. The machines are equipped with a most modern CNC control, which also takes into account e.g. the springback when bending the membrane tube wall. Only recently, the bending specialists delivered one of the world’s largest membrane tube wall bending machines to an Indian customer. With this machine, costumers are able to bent tube walls precisely in particularly large dimensions, the users secure considerably reduced costs and production times as well as lower installation costs. Equally, this machine offers the option of diagonal bending. “Overall, we have been developing and producing tube cold bending machines designed especially for the specific requirements of power plant construction for over 45 years,” Schwarze-Robitec Managing Director Bert Zorn summarises. “Every machine is a customised solution, which we adapt precisely to the individual production needs of the customer.”
Unison has received an order from Newport News Shipbuilding (NNS), the supplier of nuclear-powered aircraft carriers and one of two shipbuilders of nuclear-powered submarines for the US Navy, for an all-electric CNC machine capable of bending large-bore tubing and piping up to eight inches in diameter (219mm OD). The machine will be the first of its type ever built, extending the shipbuilder’s range of precision software-controlled bending facilities to include fabrication of larger diameter pipes that previously could only be bent on very high torque hydraulic machines. Unison believes that it will be the largest and most sophisticated all-electric pipe bender ever designed.
Groundbreaking machine extends scope of all-electric bending to 8-inch diameters
NNS, a division of Huntington Ingalls Industries (NYSE:HII), has more than six years of experience using Unison’s all-electric tube benders. The shipbuilder first began using this technology in 2007, when it took delivery of three Unison machines to help fabricate tubing and piping systems for the Ford-class aircraft carriers that were then about to enter production. The first of this new generation of carriers – Gerald R. Ford (CVN 78) – is nearing structural completion.
All-electric benders offer numerous advantages over the type of hydraulically powered machines traditionally used in heavy industries such as shipbuilding. Their precision servomotor-based motion control means that they can be configured automatically using parts data downloaded from the design database over a network, and are easy to operate and very quiet.
The machine's bending axes are driven by closed-loop servomotors under software control to facilitate fast setup and to provide accurate and repeatable bending performance. This automated approach eliminates operator error and the need to produce trial parts, and minimises creation of expensive scrap material. It also contributes significantly to manufacturing flexibility and rapid changeover; this is especially important in the shipyard working environment where many of the tube/pipe components are fabricated as needed and often in batch sizes of just one.
Under the terms of the order from NNS, the new machine will be equipped with Unison’s unique laser-controlled spring-back measurement and correction system. This ensures bending precision by automatically compensating for the natural tendency of metal pipes and tubes to spring back slightly after being bent – providing a tool that delivers right-first-time manufacturing even when fabricating just one part.
According to Jim Saynor of Unison, “This latest order from Newport News Shipbuilding highlights the flexibility of our bending machine control technology. Through collaboration and the support of our partners in the USA, Horn Machine Tools, we have gained a thorough understanding of the needs of this prestigious shipbuilder, and have helped and advised them on numerous aspects of pipe and tube fabrication. Our software-based approach to bending control provides a fully scalable solution that can easily be extended to large diameter pipes, such as this order for an 8-inch machine.”
The new Unison 8-inch machine is scheduled to be completed in Q4, 2013.
A recent innovative Moorgate development in London will provide contemporary office, residential and retail space. The property located within the Bank Conservation Area will be the new eight-storey building behind a retained Victorian façade.
Allies and Morrison Architects that have drawn up the plans for the development have commented on the project saying ‘Designed to integrate happily within the character of the surrounding area, the development occupies a city block of approximately 2,060sqm which will be consolidated into a single unified building. The facades of 8-10 Moorgate and 17 and 16 Tokenhouse Yard are to be retained, refurbished and incorporated into the scheme. The Moorgate facade will form the principle frontage and entrance to the office building, while 17 Tokenhouse Yard will contain a number of small residential units.’
The modern extension of the building was developed by Waterman and William Hare structural engineers, which have contracted Barnshaw Section Benders to supply quality bends for the project.
Barnshaws benders provided 400 beams, largest of which was 610x305x179 UB. Altogether the beams weighed 360 tonnes and formed the structure of the Moorgate building. Barnshaws managed to deliver the curved material very quickly, it only took the benders 10 weeks.
Severfield Watson Structures have taken on a wonderful job- Park House development that required Barnshaws’ bending expertise.
The development is set to be a spectacular eight-storey office space with only six internal columns, creating City-standard spaces, including two upper floors underneath the curved glass roof. This most sought-after commercial location will also include eleven retail units that feature shop fronts twice the average height for the area. In addition, there will be luxurious residential apartments with their own entrance.
Barnshaw Section Benders were awarded the job due to excellent quality supplied to the contractors in the past and also as the bends were processed tighter than competitors could offer. Barnshaws supplied the development with 138 pieces of various curving, largest of which were:
457x191x98 Universal Beam,
660x32 Circular Hollow Section,
305x305x97 Universal Column, and
450x250x16 Rectangular Hollow Section.
Barnshaws is known to offer exceptional service: tighter and better quality bends, faster than competitors, innovative and collaborative when it comes to getting invested in the project and advising clients on what is most effective. Barnshaw benders offer a variety of services that can be found on the company’s website (www.barnshaws.com).
Barnshaw Section Benders have just supplied a curved pipe that formed the stem of a flower design in the Chelsea Flower Show starting on 21st May.
Chelsea Flower Show is attended by the royal family on opening day every year as it is one of the biggest and most prestigious flower shows in the UK and has been held in Chelsea since 1913. The show features innovative outdoor living areas and garden ideas to try at home.
Barnshaws was awarded with this creative project due to the benders’ innovative recommendation to have the pipe induction bent to benefit from minimum ovality.
The job consisted of curving 5’’ NB SCH 40. Barnshaws induction (hot) bent the stainless steel pipe to achieve S-bend with 600 x 690 radius.
Barnshaws hot bending capacity range is very impressive and includes tubes up to 711mm (28" x 30mm thick), rectangular hollow section up to 500 x 300, square hollow sections up to 500 x 500, beams up to 610 wide and channels up to 430 wide. No other company in the world offers such a range of sections and unusual forms.
Oil and gas contractor Bonatti has selected an EFD Induction post-weld heat treatment (PWHT) solution to help build the world’s longest 13% Cr onshore pipeline.
The corrosion resistant pipeline is part of the In Salah Southern Fields project (ISSF) in the Algerian Sahara desert. This in turn, is phase two of the larger In Salah Gas (ISG) project, which first came on-stream in July 2004. ISG, a joint venture between Statoil, BP and Sonatrach, is Algeria’s third largest gas development, and currently has an annual production capacity of around 9 billion cubic meters.
“This is a significant project for several reasons,” says Stefano Migliavacca of EFD Induction in Italy. “To be selected by such a prestigious company as Bonatti confirms our ability to satisfy the most stringent criteria. The project also underscores the industry-wide acceptance of our PWHT solution for corrosion resistant alloys.” A proven solution in a tough environment—an EFD Induction PWHT unit in use on advanced, corrosion-resistant alloy pipe in the Sahara desert. Daytime summer temperatures can reach 60°C, but plunge to below freezing at night. The dry gas harvested in the southern In Salah fields is unusually corrosive due to its high CO2 content, which can be as high as 10%.
The Bonatti order involves two complete PWHT systems for on-site operation in the Saharan desert. Each system is truckmounted, and comprises an EFD Induction ‘Minac’ 70/110 power source, specially designed induction coils for 8”-12” and 16” pipe, and chiller and quench units. The two PWHT systems will be used for butt-to-butt welding of 13% Cr and 13% Cr to duplex steel. “Welding these heterogeneous
materials is a technically advanced task,” says Migliavacca. “But when used in conjunction with PWHT, such welding offers tremendous benefits. 13% Cr pipe, for example is extremely cost-effective because its strength means that lighter wall thicknesses can be used. Duplex on the other hand is extremely resistant to corrosion.” PWHT of 13% CR and duplex flowlines is necessary in order to minimize the risk of hydro- gen induced stress cracking (HISC). Such cracking is caused by the presence of hydrogen in the pipe’s heat affected zone. Although precautions are taken during the fabrication and welding stages to minimize hydrogen content, PWHT is still deemed the best way to achieve safe levels. “A big factor behind Bonatti’s decision is our proven experience in this specialized PWHT area,” adds
Migliavacca. “Our colleagues at EFD Induction in the UK, Jon Philpott in particular, had previously devised a PWHT solution for another In Salah contractor. It involved the supply of three truck-mounted PWHT units, which have now been operating in the tough Algerian environment for months. Philpott’s expertise contributed greatly to the Bonatti solution, and helped convince them that EFD Induction was the right
The PWHT units built for Bonatti are currently undergoing final testing. “We hope to get the units into action as soon as possible,” says Migliavacca. “ISG is after all a critical project. Its seven fields not only supply key foreign and local markets with gas, it also involves the world’s first full-scale carbon dioxide capture undertaking at a gas field. It’s an honor to be part of such an exciting and meaningful initiative.”
To accurately bend steel or stainless steel tubes and tube systems must accept long auxiliary processing times for the generally unavoidable measuring and adjusting process. This is because the rebound behaviour of the materials can differ widely – even if the tubes come from a single batch. The production of prototypes and individual items is similarly time and labour-intensive. The Springmatic optical measuring system provides a remedy here: the new development from Schwarze-Robitec, which is integrated into the bending tool, measures the bent tubes directly whilst tensioned on the bending machine and immediately starts the required further bending process if desired or saves the required correction value for subsequent bends.
Instead of removing the tube after the bending process, checking it on an external measuring system then retensioning it for subsequent bending, tube processing companies can bend, measure and adjust in a single stage with the aid of Springmatic. Immediately after the bending of a tube, the new optical measuring system that Schwarze-Robitec is integrating into its bending tools records the rebound value, from which the CNC control of the tube bending machine calculates the required subsequent bending angle. Subsequent bending is carried out immediately afterwards – either fully automatically if desired or after clearance by the machine operator. “This integrated form of dimensional stability check and tube post-processing takes only a few seconds per work piece on average. This is contrasted with around three to five minutes required for measuring and adjusting in the conventional way,” Schwarze-Robitec Plant Manager Jürgen Korte reports.
Broad range applications
When developing the measuring system, the tube bending specialists from Cologne placed particular emphasis on a very broad range of applications: Springmatic reliably checks both thick and thin-walled tubes in the broadest range of materials and diameters. The system can be integrated into almost any bending tool and combined with almost all tube bending machines from Schwarze-Robitec. “The measuring accuracy from Springmatic is naturally equivalent to the accuracy of conventional external systems,” Schwarze-Robitec Managing Director Bert Zorn adds. “Furthermore, users not only save up to nine tenths of the auxiliary processing times previously required; in individual item and prototype production, they additionally benefit from a noticeable material saving as almost every component is now also a useable bulk component. These advantages have an effect particularly in tube production for the automotive, machine and plant engineering, and shipbuilding industries.”
Mobil SHC 500 range of high performance hydraulic oils can help reduce energy consumption of equipment by up to 6.2%
Mobil SHC™ 500 hydraulic oils have been proven to offer maintenance professionals significant energy efficiency benefits in hydraulic equipment.
Compared to standard mineral alternatives, Mobil SHC 500 Series can help reduce hydraulic system’s energy consumption by up to 6.2 percent*, a saving marked by the ExxonMobil ‘Energy Efficiency’ logo on packaging. The Mobil SHC 500 Series are supreme performance hydraulic oils formulated from synthesised, wax-free hydrocarbon base fluids combined with a carefully engineered super- stabilised additive system. They are exceptionally high quality, wide-temperature, shear-stable hydraulic oils with controlled low-temperature pumpability properties and maximised anti-wear protection for high-pressure vane, piston and gear pumps used in steel plants.
The increased hydraulic efficiency potential of Mobil SHC 500 can result in an overall reduction in CO2 emissions, helping reduce the environmental impact of metallurgical operation
The increased hydraulic efficiency, impressive system cleanliness and durability offered by the Mobil SHC 500 can help maintenance staff decrease machine maintenance, extend oil drain intervals, and potentially reduce hydraulic system energy consumption by up to 6.2 percent*. Additionally, the increased hydraulic efficiency potential of Mobil SHC 500 can also result in an overall reduction in CO2 emissions, helping reduce the environmental impact of metallurgical operations. In addition, Mobil SHC 500 Series deliver outstanding low and high temperature performance, providing an extra margin of equipment protection above and beyond the capabilities of comparable mineral oil-based products. This benefit resonates with the steel industry that is subject to extremely high operational temperatures and, therefore, demanding sufficient heat-resistance from the lubricants in use. Also, at -400C Mobil SHC 500 is four times thinner than similar viscosity index conventional mineral hydraulic oils**, allowing it to circulate around the hydraulic system faster at start up, ensuring the lubricant is in place to protect machine components.
“Given the high operating temperatures and heavy loads, steel mills are a challenging environment for lubricants to operate in,” said Andrea Jacobsen, Industrial Marketing, Europe, Africa & Middle East, ExxonMobil Lubricants and Petroleum Specialties Company. “The benefits offered by the Mobil SHC 500 series are further proof of how Mobil Industrial Lubricants’ application expertise and portfolio of synthetic products can help steel mills worldwide reduce unscheduled downtime, increase productivity, safety and reduce costs.”
*Energy efficiency relates solely to fluid performance when compared with conventional reference oils of the same viscosity grade in hydraulic applications. The technology used is able to achieve up to 6.2 percent efficiency compared with the reference when tested in a hydraulic system under controlled conditions. Efficiency improvements vary based on operating conditions and application. ** Based on comparative -400C Brookfield, ASTM D2893 test results, between Mobil SHC 525 and Mobil Univis N 46.
Cartacci Ltd has recently installed new lines in some major markets like United States, Brazil and India, though without losing of view Italian market.
On the U.S. market it is now in testing phase the pipes straightening machine mod. RDT10V3UP with ten rolls and completely automatic setting, placed in molding tube line: it will process API tubes of different diameters range from 2 "to 7"; on this type of product Cartacci has acquired considerable experience during last years. The system for rapid and automatic setting (Machine Set System), based on a perfect synchronization between the mechanics and electronics, guarantees a high optimization of production changes, essential for mills with high productivity such as this line.
For Brazilian market, last November Cartacci has launched an important line for drawn tubes production, which is characterized by the wide range of processed tubes with diameters from 2" till 9". The equipment is composed by one drawing bench of 150 tons, one automatic straightening machine with 10 rolls mod. RDT10V3/4 directly connected with multiple cutting line. The whole line, ranks among the most advanced lines that are currently used in the production of drawn tubes in Brazil.
Cartacci is also present on Indian market with the installation of No. 3 drawing benches and No. 2 straightening machines (all Cartacci brand) that, disused by one Italian customer for the renew of all machinery, has found a new use on the plant of one important Indian tubes producer, by this way reflecting the reliability of Cartacci machinery, even more than 30 years after their initial installation.
Remaining on the Italian market, Cartacci has recently started a new complete line for drawn tubes with diameter’s range from 1.5" till 5": the line is composed by one straightening machine mod. RDT10V2 with ten rolls and completely automatic setting, one cutting line with multiple cut by five heads (for the maximum versatility of cuts setting) and by one packaging machine mod. IMPC130 with completely automatic setting: inserting the characteristics of wanted bundle's form, within few seconds the machine reaches the set-up needed, without requiring the operator to set the long manual operations.