A tube bending cell based on a Unison all-electric machine has just fabricated its five millionth part at Olicana Products Ltd. As each part has six bends, the Unison machine has made over 30 million bends since installation in 2004! The cell makes one tubular frame complete with fixing holes every 11 seconds.

30 mill

This tube bending cell based on a Unison all-electric machine has just made its 30 millionth bend at Olicana Products - the Yorkshire based tubular parts manufacturer.

Based near Leeds, Olicana Products specialises in tubular parts for mid to high volume applications, and works for clients predominantly in the furniture and bathroom sectors, as well as the high volume automotive sector through its new manufacturing arm Autotubetech LLP.

The Unison tube bending machine and cell has needed only routine maintenance since its installation. It has operated for nine years - producing parts typically on a two-shift schedule - during the day, and overnight on an unmanned 'lights-out' shift. All that's required for production to continue overnight is for the input hopper to be filled before staff leave. In the morning, up to 2000 finished parts are stacked and ready for shipping.

"We try to develop long-term supply relationships with clients, and are happy to invest in automation to ensure that we deliver a superior service," says Rupert Pearson, Managing Director of Olicana Products Ltd. "In this case the cell allows us to make large quantities economically, but also to respond flexibly and quickly to changes in demand, and to re- program easily to put new parts into production rapidly."

"Durability and reliability are central elements of Unison's design philosophy, and the incredible volumes that this cell has produced really demonstrate these attributes," adds Unison's MD Alan Pickering. "The application also highlights the solutions-oriented aspect of Unison's service. This completely custom cell allowed Olicana to make a step-change increase in its productivity, which is something we strive to achieve with every new application."

The cell consists of an input hopper and loader arm, Unison's 5 axis bender, a custom all- electric punch/press developed by Unison, and a robot arm. The articulated arm manages movements within the cell. The hopper loads a tube into the bender. After bending the robot transfers it to the press/punch, and then takes the completed part away, while the next one is operated on. The finished part is then hung on a rail, ready for shipping.

Olicana's cell makes several different products for the same application. To ensure that a bad batch cannot be manufactured - due to an inadvertent human error of loading the wrong program or the wrong tube length - Unison's design team employed the Japanese principle of 'poka yoke' to guard against errors. Photocell sensors detect tube length. If the length is incompatible with the bending program, an alarm is raised and production stopped.

Olicana runs several Unison all-electric tube bending machines. It has a second production cell designed by Unison which has been operating since 2009, and which has also fabricated a very large number of multi-bend parts.

Unison has numerous customers that fabricate parts in very high volumes. Another UK client's machine recently produced its 10 millionth part, fabricating components that typically have two bends - reaching a total of some 20 million bends!

Published inEquipment

According to a recent academic paper, titled “The China Toll”, the United States lost more than 2.7 million jobs to China in the years between 2001 and 2011. Haven Manufacturing, the well-known Georgia based manufacturer of machinery and equipment for tube and bar processing, is doing their part to fight the trend of continued American job and manufacturing loss to Asia.

dual blade cutting

Last year Oddello Industries, a Tennessee based manufacturer of high quality metal, tube, pipe, composite, and MDF components for OEMs in a variety of industries, purchased a dual-blade cutoff machine from Haven as part of the development of a process to manufacture several individual parts from 1” square tube to be packaged, along with a variety of sheet-metal stampings, into high quality adjustable mattress foundations. The state of Tennessee alone has lost well over 56,000 manufacturing jobs, more than 2% of the state’s total employment, to China based companies in the past decade. Oddello, by partnering with proven America based equipment suppliers like Haven Manufacturing, has shown itself to be able to compete for, and win, business back from China based manufacturing concerns. Oddello’s capable engineering staff partnered with Haven’s engineers to develop a fully programmable process which couples a piercer, designed and manufactured by Criterion Machinery, with a Haven Servo Dual-Blade Shear Cutoff machine. The resulting process has proven able to process nearly 15 miles of tube per day into 38 unique parts (SKUs) within length tolerances that never exceed 0.0015 inch.

The Oddello-Haven collaboration has proven so successful that Oddello’s management recently decided to expand the tube stamping and cutting operation. Not only is this great news for the company and its employees, but it is great news for the people and community of Morristown. The additional jobs and income provided by the expansion will undoubtedly improve the quality of life for many people in the region. The original Haven cut-off machine has proven so reliable and efficient that the company has ordered an additional Haven Model 873 Servo Dual-Blade Shear Tube Recut Machine to handle increased demand from both new customers and the customer for which this process was originally designed. The Haven 873 is capable of cutting tube from square or round stock, in lengths from 2” up to 120” and employs a programmable closed-loop servo drive to assure accuracy.

Published inMachinery

energexEnergex Tube, a division of JMC Steel Group, announced today that they have agreed to a deal with Metal One Corporation, offering semi-premium connections for use in North American oil and gas drilling.

"This agreement brings together two companies that are both focused on better servicing the OCTG market," said Randy Boswell, president of Energex Tube. "With Energex Tube's diversified tubular portfolio combined with Metal One's strong family of connections and well-established technical service network, I envision this as the beginning of a long and prosperous partnership."

Metal One's proprietary connections will be offered in North America by Energex Tube. These connections include, but are not limited to:

  • GEOCONN - A semi-premium casing connection in sizes 4.5" OD through 20" OD, for use in drilling with casing applications and SAGD (steam-assisted gravity drainage), as well as geothermal wells.
  • SUPERMAX - A tubing and casing non-upset connection in sizes 1.900" OD through 4.5" OD, with better clearance and improved work string capability.

"The Metal One connections enhance the value of our products and provide tubing and casing connection solutions for our North American E&P customers," added Boswell. "We are certainly excited about the opportunity to team up with a global company like Metal One and work together to better serve customers."

Published inProduction
Commencing Commercial Operation of Automotive Steel Pipe/Tube Business in Mexico

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.

prof vertical optHaving 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.

purgeeye opt

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.

Greater Flexibility:

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

Published inEquipment
More production capacity fuels international expansion of tube bending innovator

The UK manufacturer of all-electric tube bending machines, Unison, has opened a new facility in Scarborough. Purpose-fitted for machine design and manufacture, the building more than doubles the production capacity of this fast growing company, and accelerates machine building times by around 15%.

"The new facility has allowed us to expand every major department in Unison - we now have more software and hardware development engineers, and more manufacturing and sales staff," says Alan Pickering, Managing Director of Unison Ltd. "Our investment positions us well to cope with the growth in demand that we have been experiencing, as well as our projected expansion into new markets that we are targeting in BRIC countries."

Located close to Unison's previous building, the new facility gives Unison over 2,200 square metres of manufacturing space, along with two acres of surrounding land. The building interior has been remodeled to increase Unison's manufacturing efficiency and capacity.

One of the most important new features is a dedicated flow line for building machines, fitted with a gantry crane to simplify handling and installation of large components. Tube bending machines now progress through six sequential assembly cells with application-specific tooling for each stage of the build cycle, from the basic preparation of the mechanical chassis and equipment cabinets, through the installation of electrical and mechanical components, to cabling, system commissioning and test, and finally customer acceptance. At the end of the line, machines can be rolled into containers for shipping. In the old facility, assembly time for a typical machine was 12 weeks. The organization and higher efficiency of the new flow line will reduce this to 10 weeks for a majority of the smaller machine sizes that Unison builds.

Another key new feature is an expanded metalworking machine shop, including a brand new £300,000 investment in another five-axis CNC machining centre, to speed the fabrication of the metalwork components and tooling required for the bending machines. This brings in-house some components previously made by sub-contractors, further helping to speed delivery times.

Unison is growing rapidly, thanks to its focus on the most advanced sector of this metalwork machinery market - all-electric machines with their computer-controlled bending - plus the company's willingness to invest in design which has continually extended the scope of the bending technology into larger tube and pipe sizes. All-electric bending machines, rather than the traditional hydraulically powered machines, have now become the de-facto standard in all of the precision metalwork fabrication markets that Unison specialises in, including aerospace, automotive production, shipbuilding, oil and gas, and small-batch manufacturing.

"We already have the reputation as the pioneer of all-electric tube bending, and we aim to make our new Scarborough facility the world centre for advancing this technology," adds Alan Pickering. "We recently manufactured the world's largest-ever all electric tube bender - with the ability to bend pipes up to eight inches in diameter - a size that some said could not be achieved. And we are now starting to design a machine with more than double the power. With the accuracy, repeatability and speed of set-up advantages of all-electric technology, we expect to start taking market share from more hydraulic machine competitors in the near future."

In addition to larger size machines, a key element of Unison's philosophy is to assist clients in re-engineering their manufacturing processes alongside the acquisition of a new machine - to multiply productivity. This is achieved by Unison's vision of their machines as elements of the wider manufacturing process, and the availability of Unison software and hardware engineering development resources to enable new bending machine investments to form part of more integrated design-to-manufacturing solutions, and to optimize bending performance.

"If we just sell a tube bending machine, we can invariably promise the user a payback in terms of a defined percentage improvement in manufacturing efficiency as well as definable cost savings in operator times and reductions in scrap," adds Alan Pickering. "However, if the client works with us to analyze and research the process thoroughly it's often possible to deliver automation that has a much bigger impact - with the potential to make a step-change in the efficiency of the company's operations. That's our goal, and we can point to a number of applications where this is happening. It means extra work for us, but it's an approach that is opening doors."

As examples, one client is now achieving an almost threefold increase in productivity thanks to a re-engineered process based on Unison bending machines and accessories. And, Unison has just helped another client to almost double the manufacturing productivity of a key volume part, by helping the user to optimize the movements of the machine's tooling and handling axes.

Published inEquipment

transfluid develops an economical process for forming tubes of up to 325mm diameter

pipe pi tool

Complex requirements that place increasing demands on efficiency are mission-critical challenges for tube forming applications too. This is particularly true for shipbuilding. The high investment in the tooling needed for forming machines has been an unnecessary cost driver – until now. A corresponding tool had to be available for every possible combination of tube geometry and diameter. The engineers at transfluid Maschinenbau GmbH already recognized this back in 2011. At that time they developed an efficient solution for the tool- independent forming of tube ends with the first CNC rotary forming machine. With a second, new process the company is now marking a further milestone in forming – without the tooling complexity.

A flaring machine that does not require special tool inserts
“We have managed to develop a flaring machine that has a positively guided cone. The machine only requires aclamp for flanging jobs”, is how Gerd Nöker, Managing Director of transfluid, summarizes the technical innovation. Effective attention to detail allowed the engineers from South Westphalia to develop the technology to reach a commercially viable level. This means that the flaring cone no longer corresponds with the forming geometry, as with conventional systems. The benefits include a lower investment in – and stock of – tooling, minimum setup times and a manufacturing process optimized to the cycle-time; because the shape is sometimes achieved in two forming stages – or the flange is fitted to the tube end by welding.

Freely swinging for a wide range of options
Because the flaring cone is located on a rotating shaft it is relatively difficult to control. This is why the cone is allowed to swing freely and only the axial feed is used as a “control medium”. This makes the construction of the whole machine simple and robust, and all forming options remain open during the forming process itself. The first machine, which was recently delivered, is capable of flanging tubes of 42.4 to 325 mm. The transitional radius between the tube and flange can be freely selected and the radius can be very angular or well rounded. Special, cost-intensive tooling has now become a thing of the past.

Published inEquipment
Michigan Seamless Tube in South Lyon is expanding again, adding production capacity to the plant.

Seamless Tube Pipe, a manufacturer of carbon and alloy seamless cold-drawn pipe and tube, announced that its parent company Optima Specialty Steel has committed $25 million in capital to expand MST's operations and increase production capacity.

As part of the capital improvement project, MST will use $19 million to fund the acquisition of a highly-specialized cold pilger mill and the construction of a new facility to house the mill. The 14,400-square-foot building will also accommodate all of the related tools and processing equipment required to fully integrate the mill into the production process. As the first of its kind for MST's product mix, the mill leverages a unique, cost-effective forming process enabling the company to achieve improved tolerances and longer lengths to meet its clients' specifications.

The remaining $6 million will be used to purchase a new, 377-foot atmosphere controlled furnace. The state-of-the-art furnace will improve material flow and reduce production time. Together, the new mill and furnace will diversify MST's product line, allowing it to expand its operational footprint in the markets it serves.

“The introduction of a new cold pilger mill and atmosphere controlled furnace enables us to expand our already robust tube and pipe offerings while simultaneously increasing our capacity by an additional 700-1300 tons of product each month,” stated Les Whitver, vice president of operations for MST. “We are deeply committed to growing our presence in South Lyon and are thrilled that this project will allow us to offer a wider selection of products at highly competitive prices, creating jobs for the community in the process.”

The $25 million capital improvement project is the latest in a series of investments OSS has made in MST over the past two years designed to maintain the company's position as an innovative leader in the specialty pipe and tube market. Past upgrades include a $1.5 million addition of oxygen fuel burners to MST's hot mill, a $6 million investment to construct the company's fifth pickle house, and the installation of a new $4.5 million quench and temper line.

MST anticipates the new furnace will commence operations in April 2014. The cold pilger mill is projected to be fully operational in early 2015.

Visit www.mstube.com for more information.

Published inProduction

Sharon TubeSharon Tube, a division of JMC Steel Group, announced today that a ribbon-cutting event will celebrate the April 1, 2013 relaunch of the Sharon Tube brand. On June 11, 2013, Sharon Tube will welcome employees and their families, customers, local dignitaries and the media to gather at the precision tube facility to commemorate Sharon Tube's history and celebrate its new state-of-the art manufacturing process.

Media Day festivities begin at 9 a.m. on Tuesday, June 11, with the ribbon-cutting ceremony and a welcome speech given by JMC Steel Group's CEO, Barry Zekelman. Mercer County Commissioner Brian Beader, an advocate for domestic manufacturing, will then deliver the keynote speech. Sharon Tube President Bill Perrine will offer closing remarks, speaking to Sharon Tube's relaunch and bright future as a world-class DOM manufacturing facility.

Following the keynote speeches, guests will be given guided tours of the plant to see the recent expansion of the DOM manufacturing facility firsthand. A picnic lunch will be provided following the tours.

For more information about Sharon Tube's Media Day event, please contact Jelani Rucker at 312.275.1626 or This email address is being protected from spambots. You need JavaScript enabled to view it.">This email address is being protected from spambots. You need JavaScript enabled to view it.

Published inProduction

alanThe UK based pioneer of all-electric tube bending machines, Unison, is celebrating a record business quarter. The company made six machine sales during Q1 - worth over £1.5 million in total.

"The surge in sales comes after the prolonged downturn due to the credit crunch, and is due in large part to the sustained marketing efforts we made throughout the period," says Alan Pickering, Managing Director of Unison. "We've been taking interested parties on 'technology tours' around the facilities of existing users. This close-quarters contact has really helped potential users to understand the benefits of the advanced type of machinery we make, which is software-controlled and very versatile."

All six of the machines are destined for overseas clients in the USA, Germany, Holland and South Africa - for applications ranging from aircraft manufacture to general metalworking fabrication.

Unison welcomes the increase in its overseas business, which already accounts for over half of the company's output.

"Up to now we've been focusing our international sales efforts in just a few key countries," adds Pickering. "Expanding that international footprint is the next big step for Unison, and we believe these orders are the first of a large number this year - as we currently have an extensive enquiry list."

Unison also points to the continued investment it has made in engineering development over the last two years. "You can view a recession as purely negative, and cut back on spending until it's over, but Unison tried to see the downturn as an opportunity for engineering development," adds Pickering. "Over the last 18 months we have taken several major steps forward in technology, including upgrading the electrical architecture of our tube bending machines to an advanced industrial Ethernet network, and integrating a major new tooling facility that allows our machines to both bend and cut tubes in one continuous process."

Unison is taking on several new staff to help it meet the higher levels of demand, in departments including mechanical and electrical engineering design.

One aspect that is helping to win orders is the very low energy consumption of Unison's 'all electric' machines compared with traditional hydraulically powered benders. Unison machines only consume any significant amount of energy when actually performing a bend. By contrast, a conventional hydraulically powered bender typically consumes energy almost continually, as the system's fluid has to be maintained at pressure.

Published inProcessing
EVRAZ North America to Begin Heat Treat and Threading Expansion at Calgary

EVRAZ North America announced Board approval of its plan to expand heat treat and threading capacity at its Calgary, Alberta, tubular facility. The multimillion dollar project, which will commence next month, includes expanding heat treat capacity by over 150 percent and threading capacity by about 40 percent. Work is expected to be complete in the fourth quarter of 2014.

"The Calgary expansions will allow us to offer a more comprehensive product portfolio to meet growing needs for premium OCTG products," said Tigran Atayan, Executive Vice President–Tubular Products Group for EVRAZ North America. "This project, as well as the premium threading line expansion already underway at our Red Deer facility, demonstrates our strong commitment to customers in Western Canada."

EVRAZ tubular facilities manufacture a wide range of oil country tubular goods, including carbon and alloy products and premium connections, as well as small and large diameter line pipe, all of which meet or exceed standards set by the American Petroleum Institute (API). In addition to Red Deer and Calgary, EVRAZ operates pipe-making facilities in Regina, Saskatchewan; Camrose, Alberta; Portland, Ore.; and Pueblo, Colo.

Steel tubing company to build facility in Cheyenne

A California-based company announced it will expand its operations and build a new facility near Cheyenne.

Searing Industries, based in Rancho Cucamonga, Calif., will construct a new 200,000-square-foot building in the Swan Ranch Rail Park. Workers there will make welded steel tubing.

The rail park, located southwest of Cheyenne and west of Interstate 25, is a Granite Peak Development industrial park.

The plant will have some of the latest equipment like a state-of-the-art tube mill. It converts raw steel material in coil form to round, square and rectangular tubing.

About 50 people will work there at first. A few key employees will come from the California operation, but the company plans to hire local people for jobs in maintenance, for the office and shipping areas, in forklift operations, and as electricians and general laborers, company President Lee Searing said Friday.

Richardson Construction of Cheyenne, the project’s general contractor, has started to build the new facility. Work should be done in August or September.

“We think this a really good thing for Cheyenne, and we’re very pleased,” said Randy Bruns, chief executive officer of Cheyenne LEADS. The private, not-for-profit group is the economic development arm for the city of Cheyenne and Laramie County.

Cheyenne LEADS partnered with Granite Peak Development to create an incentive package to help Searing Industries with its expansion.

The facility will be about two-and-a-half stories tall and about the size of Sierra Trading Post, which is located in the Cheyenne Business Parkway on the east side of town, Bruns said.

The steel tubing company’s products can be used on such things as motorcycles and the framework of an office building.

The late Richard Searing and sons Lee and Jim Searing created Searing Industries in 1985.

The elder Searing was one of the first employees to run a tube mill in the United States, dating back to 1948. He owned three tubing operations before he and his sons started Searing Industries. When he died in 1998, the company continued with the brothers’ leadership.

“We look forward to the opportunity to expand into the Cheyenne community and continuing to service clients from the Cowboy State,” Lee Searing said in a news release.

The company did not disclose how much the facility will cost.

Searing Industries is one of the country’s most respected and sought-after manufacturers on the West Coast, according to a news release from Cheyenne LEADS.

The new facility is being built on land served by rail lines. BNSF Railway operates a rail service there now, and Union Pacific Railroad will do so in the future.

Searing Industries would not have come here without access to rail service and without Granite Peak Development, Bruns said.

Company officials had considered other sites, Lee Searing said Friday. He agreed that access to rail service is a big plus.

“We are extremely excited about the opportunity to grow Searing Industries,” Searing said.

Construction of the steel tubing facility is “a whole package of good things,” Bruns said. “Any time we get capital investment and new jobs, it’s good. But beyond that, this is a very good company.”

The heavy manufacturing company will help diversify the area’s economy, Bruns said. Heavy manufacturing jobs, in particular, are very good jobs and create a lot of spinoff economic activity, he said.

“This is a family-run company, and they’ve got a strong set of business values and ethics,” Bruns said.

Coil Tubing Technology Announces 2013 1st Quarter Results

Coil Tubing Technology, Inc. (OTCQB: CTBG), a leading provider of enterprise-class coil tubing products and services, announced that the Company has filed its Form 10-Q with the Securities and Exchange Commission reporting results for the 1st quarter 2013.

The Company's financial condition and results of operation are as follows:

We had total revenues of approximately $1,804,000 for the three months ended March 31, 2013, compared to total revenues of $2,265,000 for the three months ended March 31, 2012, a decrease in total revenues of $461,000 or 21% from the prior period. Total revenues included $1,760,000 of rental revenue for the three months ended March 31, 2013, compared to $2,215,000 for the three months ended March 31, 2012, a decrease in rental revenue of $455,000 or 20% from the prior period. The decrease in rental revenue was mainly due to a decrease in customer demand. We anticipate that the demand for our rental tools will be less for the next quarter based on current oil and gas drilling data in our service areas and an increase in competitive pricing to maintain our market share.

We had gross profit of approximately $950,000 for the three months ended March 31, 2013, compared to gross profit of $1,389,000 for the three months ended March 31, 2012, a decrease in gross profit of $439,000 or 32% from the prior period. Our gross profit was 53% of revenue for the three months ended March 31, 2013, compared to 61% for the three months ended March 31, 2012.

We had total general and administrative expenses of approximately $564,000 for the three months ended March 31, 2013, compared to total general and administrative expenses of $443,000 for the three months ended March 31, 2012, an increase in general and administrative expenses of $121,000 or 27% from the prior period. The increase in general and administrative expenses was primarily due to the increase in compensation expense of $113,000 for the extending the life of the stock options for key management personnel.

We had total selling and marketing expenses of approximately $473,000 for the three months ended March 31, 2013, compared to $519,000 for the three months ended March 31, 2012, a decrease of $46,000 or 9% from the prior period, which decrease was mainly due to decreases in sales commissions, automobile expenses and travel.

We had a net loss of approximately $66,000 for the three months ended March 31, 2013, compared to net income of $423,000 for the three months ended March 31, 2012, a decrease in net income of $489,000 or 116% from the prior period. The decrease in net income was attributable to a decrease in total revenue and an increase in operating expenses, principally a $113,000 increase in stock option expense, for the three months ended March 31, 2013, compared to the three months ended March 31, 2012.

As of March 31, 2013, we had total assets of approximately $8,454,000, which included total current assets of $3,365,000, consisting of $1,142,000 of cash, $2,157,000 of accounts receivable, net, and $66,000 of other current assets; and long term assets including $3,541,000 of rental tools, net; $535,000 of property and equipment, net; and $1,013,000 of intangible assets, net, consisting of our rights to the patents.

We had total liabilities of approximately $1,202,000 as of March 31, 2013, which included total current liabilities of $820,000, consisting of accounts payable of $485,000; accrued liabilities of $128,000; current portion of notes payable of $207,000; and long term liabilities consisting of $207,000.

We had net cash provided by operating activities of approximately $101,000 for the three months ended March 31, 2013, which consisted of non-cash items including $335,000 of depreciation and amortization, $113,000 of stock based compensation, and $18,000 gain on sale of equipment; offset by $66,000 of net loss, $388,000 of increase in accounts receivable, $8,000 of increase in other current assets, $78,000 of increase in accounts payable and $55,000 of increase in accrued liabilities.

We had $94,000 of net cash used in investing activities for the three months ended March 31, 2013, which included the purchase of $102,000 of rental tools and $50,000 of property and equipment; offset by $58,000 in proceeds from the sale of lost tools. Our principal recurring investing activity was the funding of capital expenditures to ensure that we have the appropriate levels and types of equipment in place to generate revenue from operations.

We had $18,000 of net cash used in financing activities for the three months ended March 31, 2013, which included $21,000 of proceeds from notes payable offset by $39,000 of payments on related party notes payable.

Mr. Jason Swinford, CEO of Coil Tubing Technology, Inc., commented, "During 1st quarter 2013, we experienced a downturn in the rental of our patented coil tubing products in the oil and gas sectors which in turn negatively impacted the Company’s overall results. We have adjusted our personnel and related expenses to better match our projected revenue stream as we anticipate that sales for our products will remain the same for the 2nd quarter of 2013 with upward movement in the 3rd quarter of 2013.”

Primary and fully-diluted net income per share for the 1st quarter ended March 31, 2013 was $.004. Primary and fully-diluted net income per share for the 1st quarter ended March 31, 2012, was $.03 and $.02, respectively.

Mr. Jerry Swinford, Chairman of Coil Tubing Technology, Inc., commented, "Our immediate plans are to continue our growth by meeting expected demand for our rental tool products in our current geographic markets and further expanding into international markets similar to what we accomplished in Canada during 2012. We anticipate entering markets in Mexico, the Middle East and Southeast Asia in 2013 and 2014. This approach to diversifying in new sales areas will improve our customer visibility and financial results.”

Tuesday, 14 May 2013 13:00

New mill for Bolivia

New mill for Bolivia

OTO just completed the production of a 1 ½” high productivity tube mill for delivery to Ferrotodo, a leading tube manufacturer located in Santa Cruz, Bolivia.

This is the third tube mill that OTO havesupplied to this customer in ten years of extremely fruitful collaboration. With this mill in place Ferrotodo will increase their share in the export market, and in particular, the automotive industry.

The tube mill has been installed with the aim of entering in the automotive industry, and will principally be used for the production of headrests, and the main frame for the seats for two top car manufacturers.

The machine is capable of manufacturing tubes in the range from 10mm up to 38mm, with  thicknesses up to 2mm, and the capability to process special high resistance steel, the mill is also able to produce stainless steel tubes.

Among the various features, the mill will be capable to produce tube having very robust tolerance in diameter in order to satisfy the extremely stringent requirements of the automotive industry. This is the fourth mill of this specific size that OTO has manufactured so far, and one more is on order for  delivery to South America next year.

Published inMachinery
Trilogy Takes Over Representation of Schwarze-Robitec in North America

Trilogy Machinery, Inc. becomes the exclusive North American distributor for Schwarze-Robitec tube bending machines.

Schwarze-Robitec is one of the world’s leading manufacturers of tube cold bending machines. The traditional company from Germany, which was founded in 1903, develops and produces tube and pipe bending systems for the automotive, shipbuilding and offshore industries, power plant construction and the chemical industry as well as special bending solutions for many other sectors of industry.

The bespoke quality products will now be sold throughout North America exclusively by prestigious partner agency Trilogy Machinery, Inc. “For our customers in the USA, Canada and Mexico, we have gained the ideal partner in Trilogy, which will now continue the successful work of Charles Russell Jr. and Tony Granelli,” Schwarze-Robitec Managing Director Bert Zorn reports. “Agency president Allan Flamholz has worked in the area of metal processing machines for over 33 year and has exact knowledge of the latest market requirements.

With his trained team, he offers the best possible advice for our entire range of products and solutions.” In addition to customer advice and customer care, the new appointment of Trilogy Machinery includes the complete sale including import of bending machines and tools.

Published inMachinery
Siemens Subsea Products adopts all-electric tube bending for production of subsea hydraulic flying leads

Siemens Subsea Products has chosen an all-electric tube bender from Unison to improve the quality and speed the production of the small-bore hydraulic tubes it uses on subsea hydraulic flying leads with Multiple Quick Connections (MQC), Cobra Heads and associated offshore oil and gas recovery equipment. The tubes feature complex bends of extremely high accuracy, and until now the company has either fabricated them manually or bought them in as pre-formed sub-assemblies.

Siemens Subsea Products produces a wide range of subsea electric, fibre optic and hydraulic power and control systems for offshore oil and gas subsea applications. Its hydraulic workshop at Kongsberg in Norway operates world-class fabrication and assembly processes, producing systems for direct sales and third-party suppliers. As part of its strategy to expand manufacturing capabilities in this specialist field, the company recently reviewed tube bending automation, starting by comparing the performance of a number of leading hydraulic and all-electric tube bending machines.

According to Terje Barth Andersen, Technical Advisor for Subsea Products in Siemens, "It was quickly apparent that electric tube benders offer a number of advantages over hydraulic machines; including more accurate and repeatable results, lower energy consumption and lower noise. In the all-electric sector, Unison's machines stand out from the competition because they allow much faster tool changeover - which is important for us because we produce many of our tubes in very small batch sizes. Another key factor behind our choice was Unison's willingness to develop a machine configuration specifically for our needs."

The tube bender supplied to Siemens Subsea is a 25 mm model based on Unison's popular Breeze platform of all-electric machines, and incorporates a 'rise and fall' pressure die which enables it to perform right- and left-handed bending; this increases manufacturing flexibility and throughput by allowing long and complex parts to be produced from a single length of tubing in one continuous cycle. Installed at Siemens' Kongsberg facility at the end of last year, the machine is currently undergoing commissioning and due to commence operation during January 2013.

The subsea equipment produced by Siemens Subsea is designed for long term deployment - many of the systems have a design life of 30 years and are intended for operation at depths up to and beyond 3,000 metres. As a consequence, the tubes used within the equipment that convey hydraulic fluid for power and control purposes are subject to extremely high internal and external pressures and need to be manufactured to exceptionally high standards. A key requirement is to minimise stressing of the tubes at their bend points - which could lead to in-service failure - by avoiding use of small bend radii. Whereas many conventional tube bending machines are incapable of handling large bend radii, the Unison machine supplied to Siemens features 'full stroke' programmable positioning of the pressure dies and clamps, enabling it to create bends with a CLR (centre-line radius) up to five times the diameter of the tube, with fully automatic set up.

All critical movement axes on the Unison tube bender are controlled by precision servomotors, enabling fast and repeatable fabrication of parts with accuracies to within fractions of a millimetre. The machine is also capable of generating the high torque needed for bending tubes fabricated from exotic alloys such as Inconel, Duplex and Super Duplex, which are used extensively for subsea applications to improve corrosion resistance.

Siemens Subsea's first project involving the Unison machine will be the South Belut Project production of 800 tubes, all made from 316 and requiring complex bends and orbital welding in both ends, for use on umbilical termination units known as MQCs. These are used on various subsea structures, including Christmas trees, and Siemens' versions can accommodate up to 13 hydraulic lines, demanding extremely tight manufacturing tolerances. Each tube is designed on a Inventor 3D CAD system, and the company generally then produces a prototype to verify its accuracy and feed any necessary corrections back into the production process to ensure the quality of subsequent parts. Automating the tube bending process is set to accelerate this procedure - the CAD system and bending machine are linked by a production computer network - and will help Siemens Subsea Products maintain the fully traceable manufacturing records needed for this industry.

Terje Barth Andersen points out that the accuracy and throughput capabilities of Unison's tube bender offer major economic benefits to companies working with expensive materials. "We calculate that the machine will pay for itself in less than two years, based solely on the number of tubes that we can now process in-house instead of purchasing as ready-made parts. Furthermore, the machine's automated set-up capabilities and control software flexibility will help us significantly reduce scrap material by 'right first time' manufacturing. We also envisage selling excess tube bending capacity to the market, making this an even more cost-effective investment."

Steve Haddrell of Unison adds, "This order from Siemens Subsea Products demonstrates a growing awareness of the benefits of all-electric tube bending. The traditional market for high-performance machines of this type is in the aerospace industry, where precision bending of exotic alloy materials is a common requirement. But companies serving the offshore oil and gas industries also face similar demands, as their products are used in ever more hostile environments."

Published inMachinery
Mobil SHC™ 500 helps steel operators improve energy efficiency
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.

Messe Essen Will Bring International Joining Technology on to the South American Market

SS BrazilAfter the successful premiere in 2011: The BRAZIL WELDING SHOW will invite the specialist world of welding technology to São Paulo for the second time in the autumn. In the most important industrial centre in Brazil, Messe Essen will, with its Brazilian partner Aranda Eventos e Congressos and the ideal sponsor DVS - Deutscher Verband für Schweißen und verwandte Verfahren e. V. ("German Welding Society"), stage the foreign subsidiary of the world's premier SCHWEISSEN & SCHNEIDEN fair in the biennial rhythm. In the autumn of 2013, it will take place on October 1 - 4. A large number of trade visitors may be expected: Corte & Conformação de Metais, South America's largest trade fair for metal processing, will run at the same time. In 2011, both fairs attracted around 13,000 decision takers from international companies.

Brazil is a growing market with optimum prospects for joining technology. Bundesverband der Deutschen Industrie (BDI - "Federal Association of German Industry") is expecting that, by 2030, the BRIC state will invest more than Euro 2.8 trillion in infrastructure and construction projects - above all, in airports, roads, railways and waterways. According to BDI, the energy sector is also to be extended with the focus on gas and oil. With the BRAZIL WELDING SHOW, Messe Essen is opening up to the joining industry the opportunity to exploit a booming market.

Federal Government Will Promote German Cooperative Booth

Because of the good response to the premiere, Messe Essen and its joint venture partner Aranda Eventos e Congressos have considerably enlarged the BRAZIL WELDING SHOW 2013 - now to an exhibition area of 10,000 square metres. German companies which would like to introduce their welding technology innovations to the growth market of Latin America will also be able to present themselves together at the international trade fair. On the initiative of DVS, a cooperative booth will be set up at the BRAZIL WELDING SHOW 2013 and will be promoted by the Federal Ministry of Economic Affairs. Registrations will be possible until May 31, 2013.

More information at: www.brazil-welding-show.com  or www.messe-essen.de 

The 9th edition of Tube Southeast ASIA

Your meeting point with a targeted audience

The 9th edition of Tube Southeast ASIA returns to Bangkok in 2013 as the region's foremost tube and pipe trade exhibition for manufacturers and processing companies. Linking you to a targeted audience of key decision makers from Thailand and around the region, Tube Southeast ASIA 2013 is your ideal platform to market your latest tube and pipe machinery and equipment, new technology and manufacturing solutions.

ASEAN - one region - ten countries - infinite opportunities

ASEAN provides attractive opportunities, as it offers a market of approximately 600 million consumers, who are now becoming important players on the global landscape. As it works towards regional economic community by 2015, some analysts project that by then the region will collectively represent the world's tenth largest economy.

The economic vigour of Southeast Asia is largely due to its growing status as a manufacturing and production hub, with many multinational companies increasingly considering the region as an alternative manufacturing base or a key area in which to expand existing operations.

New ‘Parker Grade’ 6MO instrumentation tubing

The design of fluid instrumentation systems for use in harsh and corrosive environments  has been boosted by an optimised new grade of 6Mo tubing.

The mechanical characteristics of the new ‘Parker Grade’ 6Mo tubing have been optimised to ensure integrity of connections made using instrumentation compression type fittings from the Instrumentation Products Division of Parker Hannifin – the global leader in motion and control technologies. Parker’s long history in specialpurpose alloy tube fittings has enabled it to build up a wealth of expertise and knowledge about corrosion resistant materials such as 6Mo. The company has played a formative role in the industry  take-up of the alloy, which is now the material of choice for many instrumentation tubing systems on new and refurbished North Sea oil and gas production platforms. Containing at least 6 percent molybdenum, 6Mo alloy is a super-austenitic stainless steel. The material is more resistant to chloride-induced pitting, crevice attack and stress corrosion cracking than standard 300 series or duplex stainless steel, making it ideal for offshore applications demanding durability and reliability in a hostile environment. Parker produces 6Mo versions of various types of instrumentation tube fittings, together with a series of 6Mo tubing clamps, and can also machine instrument valves and manifolds in the material.

Many instrumentation system designers specify two ferrule compression fittings for the assembly of small-bore tubing, with the 6Mo version of Parker’s A-LOK design proving a popular choice for today’s offshore projects. As with all two ferrule fittings, the rear ferrule needs to be harder than the tube it is gripping so that it ‘bites’ into the tube material during assembly helping to create a reliable, pressure-tight seal. Parker hardens the rear ferrule of 6Mo A-LOK fittings using its unique Suparcase process, which provides marketleading corrosion resistance.

However, when ordering instrumentation tubing, customers often simply specify an ASTM standard to their supplier. These standards do not always guarantee an optimum material property for a high integrity tube and fitting combination. The result can be tubing that is harder than necessary, for example, and therefore less than ideal for use with twin ferrule compression fittings.

As part of its ongoing commitment to helping users improve the integrity and corrosion resistance of instrumentation systems, Parker ensures that all tubing stocked by the company and its distributors is fully compatible with its range of fittings. After exhaustive testing and analysis of 6Mo tubing, Parker has defined a stringent specification and tolerances for its manufacture that allows the material’s properties to be controlled very precisely.

By collaborating with its supplier and auditing the company to verify compliance, Parker is able to provide the new Parker Grade 6Mo tubing with mechanical characteristics that are optimally matched to the capability of its 6Mo instrumentation fittings. According to Paul Shaddick, Product Manager for Parker Hannifin’s Instrumentation Products Division, “Extending  the reach of our quality control standards to encompass the manufacturing processes used by our supplier of 6Mo alloy tubing is a major step forward in our product development strategy. Our customers can now obtain all the 6Mo instrumentatio connection technology they need for an offshore project from a single source, secure in the knowledge that the components are compatible. This simplifies component procurement and distribution, helps speed installation, and eliminates  potential leak paths in 6Mo compression fittings.”

Parker Grade 6Mo instrumentation tubing is available in a wide range of imperial and metric sizes up to 1 inch/25 mm OD, and its 6Mo A-LOK two ferrule compression fittings are  suitable for the majority of topside applications involving pressures up to 413 bar/6,000 PSI.

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