Content on this page requires a newer version of Adobe Flash Player.

International Metal Tube Volume 2 Issue 10

___Magazine Data___

IMTInternational Metal Tube The industry magazine for tube and pipe producers and processors April/May 2010 Volume 2 number 10 IMTInternational Metal Tube The industry magazine for tube and pipe producers and processors April/May 2010 Volume 2 number 10 . Valve World - Global mission to save life . RSA - Unit cost reduction concepts . Geothermal Energy - Gold fever in Earth-Dorado NEWS ROUND UP • GLOBAL NEWS ROUND UP • GLOBAL NEWS ROUND UP • GLOBAL NEWS RO  Can your supplier ship within 24 hours? Sandvik stock supply at DC Venlo | Ricardo Odekerken | Shift Leader | Sandvik Distribution Center Venlo, Europe Protect yourself and your customers from delivery delays. As a global leader, Sandvik has the capability to ship high quality hydraulic and instrumentation tubing within 24 hours from strategically located distribution centers in North America and Europe. Based on these delivery capabilities, a global producer of heat tracer tubing bundles, with manufacturing plants on both continents, has selected Sandvik as its supplier. Hundreds of customers and distributors have also chosen Sandvik for our ability to deliver anywhere in the world with ease and reliable timeliness. Sandvik also offers several hundred tube combinations in varying lengths, grades, forms and wall thickness – a complete range of superior quality tubing that fulfills even the most demanding requirements. CHALLENGE YOUR EXPECTATIONS www.smt.sandvik.com  Contents Comment We have now passed another highly successful Tube Düsseldorf and many companies are hoping to build on the investment made by their participation. This can in some cases be a matter of months while others will have to look forward to protracted negotiations. All of this comes at a time when many countries face in-depth scrutiny of their financial status and speculation as to whether they will be the next to be tagged as financially at risk. Tube Düsseldorf went with a bang in more ways than one with the Icelandic eruption causing chaos for both exhibitors and visitors alike. I myself was lucky to get back to the UK in a little over 19 hours but many who had to travel for example, to the USA faced many arduous hours or even days trying to get home. Recently many of our readers operating in the automotive, ship building, commercial vehicle, aerospace and construction industries have asked us to give more coverage to the crossover between strip products, tubes/pipes and sheet metal use. This is something we will address in the near future and would welcome further input. Looking forward our next issue, coverage will include the following; welding technology and consumables, cutting & sawing technology (and consumables), copper tube production & processing as well as laser technology for tube & pipe producers and processors. Vince Maynard IMT Contact Information PUBLICATION MANAGER & EDITORIAL CONTROLLER Vince Maynard +44 (0) 1732 505724 Mobile +44 (0) 7747 002286 Fax +44 (0) 1732 860052 imtmagazine@btopenworld.com EDITORIAL ADVISOR Dave Richmond editorial@internationalmetaltube.com TRANSPORT & LOGISTICS EDITOR David Young editorial@internationalmetaltube.com CIRCULATION June Bray Fax 01268 711567 PUBLISHER - PAUL BARRETT hartswoodmedia@aol.com REPRO BY Anton Print Solutions antonprint1@btconnect.com www.antonprintsolutions.co.uk DIGITAL CONVERSION BY Print to Digital PRINTED BY Manor Creative, Eastbourne, East Sussex, UK Tel: 02392 661485 www.manorcreative.com PUBLISHED BY Hartswood Media Hallmark House 25 Downham Road Ramsden Heath Essex CM11 1PU United Kingdom T- + 44 (0) 1268 711560 F- + 44 (0)1268 711567 www.internationalmetaltube.com IMT International Metal Tube www.internationalmetaltube.com 2 Industry News 9 10 Company News MACH 2010 12 Products & Equipment News 22 Cover story: Valve World 24 GeoThermal IMT April/May 2010 1  Industry News Improve Automated Pipe Weld Inspection Innovative X-ray pipe and tube inspection Advances in digital X-ray detectors, the creation of digital image processing and archiving software platforms and the use of composites technology have allowed us to develop innovative solutions for the automated X-ray inspection of tubes and pipes. These solutions allow significantly faster inspection, while also making automated inspection much easier by the creation of comprehensive workflows. As Andreas Beyer, product manager, X-ray testing machines , at GE Sensing & Inspection Systems, explains, “Current X-ray pipe inspection systems use a long iron boom to support either the X-ray tube or the X-ray detector from the inside of the tube to be inspected. A synchronized manipulation system on the outside of the pipe supports the corresponding X-ray detector or X-ray tube to create the X-ray shooting set-up. Advances in all components of this type of inspection system have allowed significant increases in inspection speeds, greater flexibility and improved workflow.” Support boom technology now incorporates composite materials so that lighter booms of smaller diameter can carry heavier payloads. The DXR 250RT-E 8” Xray detector from GE improves throughput with higher sensitivity and a very fast frame acquisition rate in a small panel housing of just 260mm x 260mm x 114,3mm. When these innovations are supported with the proven technology of the GE ISOVOLT Titan E X-ray generator, the GE VISTAPLUS V digital image processing software and GEs Rhythm Archive long term storage software, the result is a powerful turnkey inspection solution for a wide range of applications, enabling single wall inspection of very small pipe diameters down to 380mm and increasing inspection speeds over conventional systems by up to a factor of four. More information on GE Sensing & Inspection Technologies, visit: www.gesensinginspection.com GE Sensing & Inspection Facebook Business twitter.com/GE_SensInsp www.flickr.com/photos/ 36760597@N08/ IIn--LLiinee Diiaameetteerr aand SShaapee Conttrroll STEELMASTER Gauges for Hot and Cold Rolled Products • Any shape • Standard measuring ranges up to 300 mm • 1 up to 6 laser / camera modules Ask us for additional information: askme@zumbach.ch Switzerland • Argentina • Benelux • Brazil • China • France • Germany • India • Italia • Spain • Taiwan • UK • USA www. zumbach.com STEELMASTER Gauges Hi-speed laser scanning. Measurement of diameter, ovality, height, width and diagonals. PROFILEMASTER® Gauges Advanced vision technology (light-section). • Standard measuring ranges up to 500 mm • 1 up to 6 measuring axes • Measuring frequency: 1000 / s for each axis New! Measuring solutions for round and non-round products. Captures also asymmetrical shape deviations of round, oval and polygonal products. • Possible measuring modes  Industry News Despite the Icelandic volcano… nice to hear a success story…. L L ennart Claesson, Managing Director of Herber Engineering AB, wore a huge smile after the runaway success of the all new, 21st Century ‘all electric’ automated mandrel tube bending production cell at the recent Tube Dusseldorf Exhibition. To Mr Claesson’s obvious delight, his stand was virtually over run with prospective customers during the event 24/7. The state of the art production cell combines; loading of full- length tubes, sequential bending, cutting, deburring, endforming, measuring and stacking of several different shaped components, one after the other. Whilst at the same time improving the production area making it a safer, noise free, efficient, clutter free environment. All this plus, 3D bending simulation and an anti-collision test programme to find the most efficient, and cost-effective way to bend several components in sequence prior to going into full production. Customers were very impressed and commented on how quiet, yet how robust, and stable the cell is. Others found making time and energy cost savings of up to 80% very impressive. Add to this; no oil disposal required as we use Irmco petroleum–free mandrel lubrication technology. Hence, no noise, no heat generation and up to 40% less machine build components compared with alternative hydraulic machines. Combine this with the accurate, repeatability and huge reduction of waste material savings, cutting investment pay back time. Setting new low cost industry standards and boosting profitability. For customers that could not make the exhibition due to the volcanic dust cloud! -visit Herber and take a closer look! You will be made very welcome when you visit our purpose built factory, showroom and offices. More information on Herber Engineering AB tel: 46 370 699573 Multiflex - a winning combination M M ultiflex is able to load multiple tube configurations up to 6 tubes with diameters ranging from 8mm to 90mm and a maximum thickness 6mm. When it comes to square or rectangular sections, the machine can work in dimensions from 10mm x10mm to 65mm x 65mm. The system includes a planetary de-burring device efficient for any condition and for all profiles, even for short parts (minimum 50mm). Featuring a greater degree of flexibility, and combined with the reliable, CNC-controlled working process makes MULTIFLEX the right choice to manage production batches requiring different dimensions and frequent changeovers. The machine offers a number of advantages: A measuring system after the cutting process for complete production certification, and where different lengths can be worked on from the same bar. Finished parts can then be sorted out and unloaded in different positions. Fully automatic changeover and the clamping of all loaded bars is independent, thereby maintaining an smooth workflow even when there are slight variations in the bar diameters. The system also includes a palletising device, the RT100, which collects and stacks cut lengths, and a blowing system situated after the cutting process to eliminate scraps inside the tubes. More information on BLM Group tel: + 39 031 7070200 fax: + 39 031 715911 pr@blm.it www.blmgroup.com www.internationalmetaltube.com IMT April/May 2010 3  Industry News Advanced tube bender systems for the A350 a P P FW Aerospace has ordered a high- specification tube bender from Unison to support its production contract for the Airbus A350 XWB aircraft - which is scheduled to enter service in 2013. The precision bending machine will be employed by the leading aerospace supplier to manufacture the fuel and bleed air tubing systems for the wings and fuselage. The machine, which will be delivered in the third quarter of 2010, will extend the tube fabrication capabilities of PFW Aerospace's manufacturing facility in Farnborough, UK. Its all-electric architecture will support the company's lean manufacturing strategy and save costs by reducing material waste, lowering energy consumption, and speeding machine set-up. PFW Aerospace's Farnborough site already has a number of hydraulically-powered and hydraulic-electric tube benders. The new all-electric Unison machine will provide additional features to support the A350 project work. Among the advanced capabilities made possible by the machine's servomotor-based architecture is precision bending at extremely slow speeds. This attribute will be used in particular on titanium tubing parts, to exert fine control over material flow and the finished wall thickness. Slow bending also helps titanium tubing to be bent with small radii - down to a single diameter of the tubing - another attribute required for some project components. Cutting waste of costly materials such as titanium was a further major selection criterion. Hydraulic bending machines need to be set up with care, and it's common to make a trial part and then have to apply a correcting adjustment to the setup before starting production. With the batch sizes at PFW typically 10 to 15 parts - this approach can result in significant scrap costs. The exact repeatability of set-up offered by the closed-loop servomotor architecture of the all-electric machine means that parts will almost invariably be produced right-first-time. One other major factor in the selection process is the lifecycle support, which includes remote diagnostics, will be provided by Unison - the only UK manufacturer of all-electric tube benders. "We are very pleased to acquire this advanced bending machine, which will be a valuable boost to the lean-manufacturing capability of PFW Aerospace," said John Porter, Operations Director at PFW Aerospace in Farnborough. Over the last few years PFW Aerospace has been evolving from a production company to an innovative service company with in-depth engineering 4 IMT April/May 2010 www.internationalmetaltube.com  r will produce tubing aircraft r will produce tubing aircraft a major milestone in the ompetence. This project for cand Oberpfaffenhofen in The energy consumption of company's business Airbus, which involves both Germany, Filton in the UK, and the Breeze machine is very low. development. esign and production for three dXi'an in China. The production This is because the servomotors The A350 tubing systems are major A350 packages - wing and phase of the contract will take that control the motion only being developed at PFW fuselage fuel tubing systems, and place at PFW Aerospace's consume any significant amount Aerospace facilities in Speyer the fuselage bleed air system - is manufacturing facilities in of energy when actually Farnborough and Speyer. performing a bend. A About PFW Aerospace The machine being built by Unison is a single-stack tube bender from the company's conventional hydraulically powered bender, by contrast, typically consumes energy PFW Aerospace is a full service Headquartered in Speyer, Breeze range that can handle continually as the system's fluid provider in advanced Germany, the company employs tubing of up to 25mm in diameter. has to be maintained at pressure. metallurgical solutions for the over 2000 globally with It features a very high A comparison made by Unison of global aerospace industry. The production locations in France, specification to give fine control two similarly-rated tube bending company is considered as world the UK, Turkey and China as over bending. Key features machines showed that an all- market leader for aerospace well as offices in the USA. include the ability to dynamically electric machine reduced power tubing systems. The overall control the carriage boost and consumption by around 90%. product portfolio furthermore More information on PFW pressure die during the bending includes structure components, Aerospace cycle - to allow operators to More information on Unison Ltd cargo loading systems and tel: +44 (0) 1252 370666 optimise bending programs for tel: +44 (0) 1723 582868 auxiliary fuel tanks. www.uk.pfw.aero difficult materials such as thinenquiries@ unisonltd.com wall titanium tubing. www.unisonltd.com www.internationalmetaltube.com IMT April/May 2010 2010 5  Industry News A fresh breeze sweeps through TUBE 2010 D D hatec, fresh back from their first outing at Tube 2010 where they successfully demonstrated a range of solutions to control all logistic operations in the supply chain of line pipes, from factory to construction site. In Dhatec’s perspective, “logistic operations” is interpreted in the widest sense of the word. All pipe movements within a factory environment, as well as outside in the field are included in their Task Environment. Exhibits at their stand included the latest product developments such as the Pipe Stop. This new pipe storage system is the first highly durable system to improve safety, offer adjustability and reduce material stress in pipes. The Pipe Stop has a high stacking capacity that is backed up by calculations and practical testing. Dhatec develops and manufactures products that take care of line pipe quality during manufacturing, coating, handling, transport and storage. Their product program does not only aim to maintain pipe quality, but also to improve the efficiency and safety of each process. In addition, Dhatec assists project managers to organize the Dhatec’s pipe transport system, System88 (also shown at the stand) logistics of pipeline projects. developments are launched every possibilities for products to Their knowledge and experience year and products are constantly stimulate sustainability. provides project managers with customized to comply with the advice for damage prevention and latest customer demands and More information on on site safety. specifications. Special sizes are Dhatec B.V. at The strength of the company no more a problem than extreme tel: +31 497 542 527 is based on innovativeness and conditions. In addition, Dhatec Cindy.verhoeven@dhatec.nl flexibility. New product offers renting and recycling www.dhatec.nl wire 2012/Tube 2012 D D ates for wire 2012 and Tube 2012 in Düsseldorf now fixed: 26 to 30 March 2012 After the two world-leading fairs wire, International Wire and Cable Trade Fair, and Tube, the International Tube and Pipe Trade Fair, came to a successful close the new trade fair dates for 2012 have now been set: 26 to 30 March 2012 will see the two fairs for the wire, cable and tube processing industries held at Düsseldorf Fairgrounds already for the 13th time now. In 2010 69,200 trade visitors came to Düsselorf from over 100 countries to gather information on the latest technologies and applications from the over 2,400 companies exhibiting here. 1,219 exhibitors came to wire to present their current machinery, plants and equipment for the production and processing of wire and cable. New materials and innovative manufacturing technologies for tube and tube processing were presented by the 1,181 companies exhibiting at Tube 2010. Constantly updated information for exhibitors, visitors and press representatives can also be found in the periods between fairs on the two web portals: www.wire.de and www.Tube.de. For more information: Petra Hartmann-Bresgen Kathrin Kleophas tel: +49 (0)211/4560-541 tel: +49 (0)211/4560-544 fax: +49 (0)211/4560-87 541 fax: +49 (0)211/4560-87 544 email: HartmannP@messeduesseldorf. de email: KleophasK@messeduesseldorf. de 6 IMT April/May 2010 www.internationalmetaltube.com  IMT April/May 2010 7www.internationalmetaltube.com Ethernet boosts tube bending performance U U nison has launched a new version of its all- electric tube bender. Incorporating real-time Ethernet control and major new software, the machine takes the advanced shape forming capability and flexibility of servomotor- controlled bending to a radical new level. The machines bend faster, exploit advanced multi-axis synchronisation to support very sophisticated roll-forming, improve the tool adjustments that can be employed during bending to generate ultra-precise shapes, and offer a visual collision checking programming feature as standard. The architecture is available on all-electric bending machines for tubing diameters to 180mm. Machines can be fitted with single- or multi-stack tooling, and two or more bend heads. The open architecture also provides immense flexibility for configuring cells: the network supports physically large processes; and one controller can handle up to hundreds of motion axes, sensors, etc. Novel bending cell Unison has employed the flexible architecture in a large bending cell for tube manufacturer RathGibson. Roll-forming is used to create custom heat exchanger parts under software control. It eliminates much of the expensive tooling and set-up time conventionally required. The software automatically calculates the required tube length and machine can produce U-shapes parts for any heat exchanger to be issues a command to a saw. A cut with 15m+ leg lengths, a swinging made using just a single software- tube length is fed onto the cell cantilever structure supports controlled tool, and in a single conveyor and positioned with the tubing as it is processed. The stage of under 10 minutes aid of reflection sensors. As the automation allows the majority of including annealing. Unison’s all-electric tube bending machines will revolutionise your tubular part production. Servomotor technology gives you total software control of the bending process. You can bend with exacting precision. Scrap is virtually eliminated! The control system is so simple, virtually anyone can set-up the machine and repeat components at will. All-electric machines also slash electricity costs: tested against an equivalent hydraulic bender, the Unison machine consumed 90% less! Scarborough-based Unison are the originators of the all-electric tube bending machine, leading the world in the development of the technology. We offer machines for 10-180 mm diameter tubing. Tube bending freedom is just a step away: call us today for references in your sector. Is tube bending holding your business back? t: +44 (0)1723 582868 e: sales@unisonltd.com w: www.unisonltd.com See Unison's machinery range at www.unisonltd.com  Industry News Zinc Elephant³ makes screw joints safer D D ue to the massive expansion of offshore wind-power generation, the demand for high-strength hot- dip galvanized bolts, threaded joints, fasteners and other small parts - referred to in the industry as centrifugal parts - is growing Process controlled operation of the Zinc Elephant³ guarantees complete tracking of production. expotentially. For galvanizing large amounts of these products Zink Körner has developed the Zinc Elephant³. The combination of a high-capacity furnace and rapid handling of the baskets and frames achieves throughput rates of up to 5t per hour. All process steps, from picking up the baskets and racks, immersion in the molten zinc bath, centrifuging through to quenching in a water bath - are automated. All parameters, such as the immersion time are process controlled, allowing the Elephant to achieve excellent uniformity of the zinc layer. Before a basket is immersed and after boiling up, the surface of the zinc bath is automatically skimmed. This ensures that the surfaces of the galvanized parts are completely free of contamination. Thus Zink Körner fully complies with the extremely exacting requirements the rotor industry places on the quality of galvanized parts. As the parts are handled very gently during galvanizing, damage is minimized. Therefore threaded bolts and similar parts do not require rethreading. This considerably reduces the effort and cost of reworking. The integrated process control system captures all plant situations and stores the data relative to each individual basket. Each batch is completely trackable, meaning a high degree of security for the operator. The parts can be pretreated without the use of acids, thus avoiding hydrogen embrittlement and the resulting brittle fracture of the steel. This makes the system perfectly suited for the treatment of high-strength steels, which are commonly used in offshore applications. Thanks to the applied regenerative burner technology, energy consumption can be reduced by up to 20 percent. As the burners never operate under excess-air conditions, the amount of arising zinc ash can be cut by up to 70 percent. This brings down both zinc consumption and the effort required for zinc ash removal. More information on Zinc Elephant tel: +49. 2331. 800 6-0 fax: +49. 2331. 800 6-10 www.koerner-hagen.com info@koerner-hagen.com Zink Körner GmbH designs and manufactures the complete array of hot-dip galvanizing equipment for bulk material, tubes and pipes, miscellaneous small parts and centrifugal parts. The supply range comprises complete galvanizing plants, including pretreatment and handling equipment. The company provides design, engineering, manufacture, assembly, commissioning and after sales service and maintains a worldwide network of branches and licensees. Zink Körner has launched many pioneering developments during its company history. For example, as early as at the beginning of the 1970s the company built the first automated centrifugal galvanizing plants. The company took another innovative move when it developed dedicated burner technology for hot-dip galvanizing applications. Within the Group, Wire Körner GmbH designs heat treatment equipment for wire and narrow strip. TVT Kordt GmbH develops plants for thermal process technology, with a focus on industrial furnaces for the heat treatment of steels, special steels and non-ferrous metals. About Zink Körner 8 IMT April/May 2010 www.internationalmetaltube.com  Company News USM , A potted history in welded steel tube consumables M M ore than 30 years ago, USM became the first dealer in Europe to offer TDK Japan’s impeder cores. They had developed a ground breaking ferrite core (IP1 Grade) specifically for high frequency welding. Up until then, tube makers had been using antenna rods, the obvious downside, being they consumed a massive amount of energy, caused frequent line stops, high scrapage rates and a low production yield. Subsequently we were one of the first European companies to introduce mechanical fixing carbide inserts for exterior tube scarfing of welded bead. These were Titanium coated (CVD), radiused with multi cutting edges (4, 6 and 8 cutting sides) and replaced the old method of brazing the carbide tips onto the steel shanks No radius loss through re-sharpening, longer insert life, better quality of scarfed tubes, less consumption and also far safer for the operators’ health, since the dust had a high cobalt content. Later additions to our portfolio included ceramic scarfing inserts for cold rolled furniture steel tubes, specially shaped ferrite cores, (i.e. horse shoe shaped). Titanium coated high speed circular saw blades and ceramic welding rolls followed. In conjunction with TDK and partners, USM changed the ferrite’s electromagnetic characters – by reducing the Curie temperature to get higher density and permeability and lower core loss. We also developed large diameter ferrite cores with the consequent power savings, increased efficiency and higher production yields. Today USM is at the forefront of product innovation with new and custom made solutions that meet and excel worldwide standards. We aim to build long term business relationships with our customers with a combination of new product development, our long established reputation and our free consultancy service More information on USM SRL Tel: +39 (0) 39 387282 Onlyfewformingprocessescandowithoutlubricants. www.werbeform.de OESTVARIOL: tubedrawinglubricants OESTROBINOL: tubebendinglubricants Comprehensive source in India S S hubhlaxmi an Indian manufacturer of s.s.welded and seamless pipes and tubes. Certified to ISO 9001:2000, PED 97/23/EC & AD 2000 MERKBLATT WO for manufacturing quality stainless steel seamless, welded pipes, tubes and ‘U’ tubes. Our manufacturing premises span over 427,188 Sq. Ft. Area in Umbergaon (Gujarat) is about 150Kms from Mumbai Airport. We have an extensive quality assurance facility to test each and every product. The company has the latest manufacturing and testing equipment of world class Standard & Equity qualified and experienced personnel to manage the inspection at various levels. Manufacturing Range:1) NB Sizes: 1/4" NB to 8” NB 2) Schedule: 5, 10, 40, 80 3) OD Sizes: 1/4" NB to 8” NB 4) Thickness: 0.6mm TO 6.00mm 5) Grade: 304, 304L, 309, 309s, 310, 310s, 316, 316L, 317, 317L, 321, 347, 347H, 409L, 430, 430Ti, 436, 904L, Duplex Steel and as per the Customer Drawing & Requirement. 6) Standard: ASTM A 249, 312, 269, 213, 558 & also as per DIN Standard. More information on Shubhlaxmi Metals & Tubes PVT Ltd tel: +91-22-23893301 / 02 / 03 fax: +91-22-23864199 npshah@shubhlaxmigroup.com www.shubhlaxmigroup.com www.internationalmetaltube.com GeorgOestMineralölwerkGmbH&Co.KG72250Freudenstadt/GermanyTel.+49(0)7441/539-203info@oestgroup.comwww.oestgroup.com Tubedrawingwithvirtuallynoresidues Chlorine-freebendingofstainlesssteeltubes Reliablemetalformingprocesses  MACH 2010 Next generation tube ben make debut at Mach 2010 U U nison is launching a new range of all- electric tube bending machines, these incorporate both a real-time Ethernet control system architecture, and a major new release of programming and control software. The machines take the advanced shape forming capability and flexibility of servomotor-controlled bending to a radical new level. The new UK- built Breeze machines bend faster, exploit advanced multi- axis synchronisation capabilities to support very sophisticated roll- forming, improve the tool adjustments that can be employed during the bending An all-electric architecture provides tube benders with significant performance benefits in terms of set-up speed, repeatability, lower energy consumption and noise reduction compared with traditional hydraulically powered machinery ‘ ’ cycle to generate ultra-precise part shapes, and offer a visual collision checking programming feature as standard. They also feature an open architecture that is easily adapted to integrate application-specific capability or build work cells. All electric architecture An all-electric architecture provides tube benders with significant performance benefits in terms of set-up speed, repeatability, lower energy consumption and noise reduction compared with traditional hydraulically powered machinery. Unison pioneered all-electric tube bending in the 1990s, and has played a seminal role in establishing the trend that today sees software-controlled, servomotor-based bending machines the number-one choice for virtually all small-tomedium diameter applications involving high precision, small batch sizes, and expensive tubing materials. At the heart of the new Breeze machine range, is a real-time machine and motion system based on the deterministic Ethernet-compatible Powerlink protocol. A 100Mbits/second network links all of the servomotor drives required to control bending operations. The speed of the network makes it possible to coordinate the movement of the various servomotor axes used during bending - such as the carriage, plane of bend, and clamp roller - more rapidly, allowing Unison to improve the speed of bending for many common tasks by typically around 10%. Much improved diagnostics The quality of bend shapes and wall thickness can also be improved thanks to finer real- time control over the motion profiles used by key bending axes which move as the rotary draw bending process takes place such as the carriage and the follower die. Real-time interpolation of multiple axes is also supported by the machine's new motion control architecture. In particular, this allows Unison to equip machines with extremely flexible roll-forming tools that are able to vary the radius of bending with great precision during the bending 10 IMT April/May 2010 www.internationalmetaltube.com  ding machines cycle. Other benefits include much-improved diagnostics and data collection which can assist with both programming and maintenance, and easy connection to factory networks for changing programs, reporting production metrics, etc. Unison is also releasing major new programming and operating software for the tube benders. Among dozens of new and improved features in v10 of its Unibend package is a collision checking capability that helps users to program the machine for new parts. Bending operations are visualised using a 3D model of the machine. If users see any potential collision problems, bend sequences can be reversed, and intervening carriage and rotation movements can be employed to ensure the part can be manufactured easily. Programming itself can be achieved typically in a couple of minutes by entering new ISO, XYZ or YBC values (distance tube is pushed out, rotation, and degree of bend), linking from CAD or measuring machines, adapting an existing template, or interactively teaching the machine. The versatility of Unison's software-controlled tube bending machinery is very high, and this attribute is improved by the new networked control architecture. Almost all tube bending machines are configured around a base design to suit the user's intended applications, including or excluding facilities as required. Unison is currently seeing a substantial increase in demand for work cells that integrate tube bending with other processes. The new Ethernet architecture provides almost unlimited flexibility for configuring and building integrated machines and cells: the control network can be very long allowing physically large processes to be accommodated with ease; and one network controller can handle up to hundreds of motion axes and other control system resources such as sensors. The networked nature of the control system architecture makes it easier to upgrade systems later in their lifecycle, to integrate processes such as loading, end forming and unloading for example. "In a word, this new architecture gives us more versatility. Users are looking to increase the degree of automation of processes, to cut costs and allow them to hire from a wider pool of labour," adds Alan Pickering of Unison. "The major upgrades to software and hardware embodied in this release give us a more versatile and finely programmable This new architecture gives us more versatility. Users are looking to increase the degree of automation of processes, to cut costs and allow them to hire from a wider pool of labour ‘ ’ platform. This makes it possible to give customers no- compromise packages that deliver exactly what they require, and offer upgrade capability during the machine's lifetime." Unison can supply the new architecture on all-electric tube bending machines capable of handling tubing with diameters up to 180mm (7 inches). Machines can be fitted with single- or multi- stack tooling, and with two or more bending heads. More information on Unison Ltd at 01723 582868 enquiries@unisonltd.com www.unisonltd.com www.internationalmetaltube.com IMT April/May 2010 11  Products & Equipment News Presentation at the Tube 2010: the new sawing centre RASACUT MXS for tubes and sections with an output of up to 11,000 pieces per hour. Various concepts for a reduction of unit costs The equal triangular distribution of the gripping power ensures a careful unit handling and high precision during the sawing process. T T he most important figures of last year's production of crude steel and tubes would appear to come to the same conclusion: the dramatic collapse on the global market, and the increase in both capacity and production in China. China is offering low prices for its excess production onto the export markets, particularly in the field of seamless drawn tubes, with the European Union being a very important target market. However, when looking at the quarterly figures for the years 2009 and 2010, a clear strengthening of the market recovery can be seen. This is reflected in tube production and ‘down the line’ processing by an increased willingness to invest. Most experts see an urgent need for action, specifically in the modernisation of production facilities that impact effectively in the reduction of unit costs in the cut to length production of tubes and sections. RSA Entgrat- u. Trenn- Systeme, a specialist company in the cut to length production and preparation of tubes and sections, recently presented at the Tube 2010 event, three concepts identifying the continuing reduction of unit costs. This includes two new sawing centres which RSA developed for various needs of the market. Concept one Concept one for a reduction of unit costs, is based on increased productivity by means of a drastic increase in output performance. This is realised with the sawing centre RASACUT MXS. In triple cut the sawing center achieves, dependent on the unit dimensions, an output of up to 11,000 pieces per hour. The sawing center is designed for tube diameters of 6mm up to 20mm in triple cut, and 8mm up to 45mm in a single cut. These dimensions are often to be found in the automotive industry, together with the special demands on accuracy, surface quality and purity. Applications typically are line tubes and the visible elements in the car’s interior, e.g. headrest tubes. Thus, the sawing centre 12 IMT April/May 2010 www.internationalmetaltube.com  ‘ the quarterly figures for the years 2009 and 2010, a clear strengthening of the market recovery can be seen. This is reflected in tube production and ‘down the line’ processing by an increased willingness to invest ’ RASACUT MXS can be configured or expanded according to the requirements of the customer. Modules are available for deburring or chamfering for 100% control of the fixed lengths, as well as for cleaning and stacking. The sawing centre feeds the unit pieces, as well as transferring them to the follow-up processes via NC axes with speeds up to 5 m/sec. The reliable handling before, during and after the sawing process ensures an accuracy of +/- 0.2mm, this careful treatment of the surface makes certain that chrome plating can be safely achieved afterwards without any problems. This is of course, extremely important to suppliers in the automotive industry, who need to achieve 100% control after each unit is sawn, processed and measured. Concept two Concept two for unit cost reduction is the sawing centre Rasacut EC itself. Companies involved in the mass production of fixed lengths are the target application group of this development. In many companies the daily number of units is on a level where only band saws or semiautomatic circular saws pay dividends. Up to now, many companies in this group this size have been unable to amortize investment costs for automated sawing centers over an reasonable period. The RASACUT EC is extremely competitive, makes no concessions either to the robustness of the machine or the quality of the saw cut. Round tubes of 8mm up to 80mm diameter, and rectangular tubes with a cross section of 10mm x 15mm up to 70mm x 80mm and a wall thickness between 1mm and 6mm are automatically singled from the tube bundle, fed to the saw and transferred to follow-up processing modules. The fixed lengths of 20mm up to 3,000mm are sawn with an accuracy of +/- 0.1mm. The RASACUT EC is designed for a three-shift operation. Due to their construction, all stand for a high degree of consistency with With a speed of up to 5 m/sec the handling transfers the fixed lengths to follow-up modules. Subsequently the units are automatically singled for a defined processing of each piece. regard to accuracy, cutting angle and quality of the cut surface. Concept three The third concept for a lasting reduction of unit prices: optimum interaction of machine and tool. The right selection of the suitable saw blade in combination with the specific tooth geometry, and the right cut parameters create the best conditions for highest productivity and quality. RSA, a systems manufacturer of sawing centres and saw blades, is offering this comprehensive know-how. Interested parties can get to grips with test production under realistic production conditions, free of charge, in the plant at Lüdenscheid. More information on RSA Entgraf-u, Trenn-Systeme GmbH tel; +49 2351 9955 fax: +49 2351 995300 Tiemo.krause@rsa.de www.rsa.de Presentation at the Tube 2010: the new sawing centre RASACUT EC is the ideal entry level into the auto- mated cut-to-length production. www.internationalmetaltube.com IMT April/May 2010 13  Products & Equipment News Elect - all-electric tube bender T T o complete its product range, BLM SPA introduces its tube bender model ELECT. The machine is available in many configurations up to diameter 80, all-electric, right and left hand, variable radius, and boostbend with VGP programming. A powerful CNC with visual 3Dgraphic software (VGP) controls and moves the 9 axes of the machine, allowing any kind of bending for tubes with diameters from 4mm up to 80mm with less than 1D radius. The ability to assemble up to 4 tools with different diameters and radii on each of the two bending heads, increases the versatility of the machine and optimises production change in a matter of seconds. Its electronic control eases the interpolation and optimisation of the axes increases the productivity up to 30% in comparison with similar non-electric machines. This new model extends our range of electric machines to satisfy any kind of bending need, especially in the field of metal and office furniture, indoor and outdoor furniture and complex car and motorcycle components such as exhaust pipes and systems. The many advantages of our ELECT range and of our all electric technology, include: • Production increase from 20% up to 50% in comparison with homogeneus equipment. • Drastic reduction of the programming and tools set-up time: the quick change of the tools is made without set-up, the electrical axes auto-adjust the position • The experience of the operator does not affect the final result: continuous quality guaranteed thanks to the automatic CNC adjustment which memorizes all the parameters and enables their use without the need of any mechanical adjustment. • Repetitiveness and quality of the machining steady in time: all the machine movements are controlled and repetitive finite accuracy, including the clamping, pressure die and mandrel retraction. • Zero scrap: tool set-up tests are no longer needed, the first part off is correct. • Fast and safe programming thanks to our VGP 3D which shows on video the real feasibility of the parts, showing cycle times and if there might be any impact zone, simulating all the working cycles and choosing the most suitable one for the production of the components. • Sure and free-of-charge cycle time estimation: for subcontractors or design offices our software for visual programming, VGP3D, enables to define in advance and surely the production time and the relevant production costs. • Reduction of handling costs: with the function of left-right hand bending, the combination of variable and fix radius bends, it is possible to optimise both just-in-time production, and optimise the space in the workshops, and remove all those cases full of semifinished parts lying in the warehouses waiting to be finished. • Increase of all the possible machining: it is possible to produce particularly complicated parts with CLR < 1D thanks to the pushing device up to 2000kg, whose power can be modulated with different intensity while the bending and thanks to the adjustment of the clamping strength according to the require stresses to avoid any mark • Low enviromental impact: ELECT energy-consumption is very low in comparison to conventional technologies, infact, it uses power only when the axes are functionning. Silent and require little maintenance, zero hydraulic oil. ELECT is the new reference on the market for the bending of tubes of high added value and quality. More information: Giovanni Zacco - BLM GROUP Communications Via Selvaregina, 30 - 22063 Cantù (Co) Italy tel: + 39 031 7070200 fax: + 39 031 715911 www.blmgroup.com - e-mail pr@blm.it In-line gauges for diameter, ovality and shape T T hanks to new developments in high- tech laser optics, Zumbach Electronics introduced at the TUBE 2010 the new ODAC 550 laser scanner with HLF (High-accuracy Large Field) technology. This technology allows for the first time to generate a highly collimated and accurate measuring field of 550mm (22 inch) without any dead zone. It also means that the tube position in the field has no effect to the readings. There are single axis or multiple axis systems available, both in static or in oscillating configuration, applicable for hot or cold processes. Applications cover solutions for Quality Control (NDT) in cold status to hot processes aka MPM sizing mills, SRM mills, conveyors, pilger mills, piercing mills, radial forges, extrusion presses and others. The sophisticated protection/cooling system guarantees reliable operation More information from Zumbach Electronic AG tel: +41 (0) 32356 0400 sales@zumbach.ch www.zumbach.com and minimal maintenance. Featuring a 550mm (22 in.) measuring field, high-tech optics (HLF), and CSS (calibrated single scan) technology. They offer 1000 true measurements, accuracies to within a few 0.01mm and the EPM method/software for polygonal deviations 14 IMT April/May 2010 www.internationalmetaltube.com  Profilemaster® SPS 140-N4 Meas Profilemaster® SPS 140-N4 Meas Products & Equipment News In-line measuring systems for profiles and tubes, no matter what their shape Technology at the cutting edge P P rofilemaster® systems are based on the latest technology with laser contouring and CCD camera vision and processing. They capture the full product circumference/section and measure and monitor the relevant profile dimensions, angles and radii. The range of Profilemaster® gauges include versions for small precision profiles starting from a dimension of 2mm (.08 in.), cold formed tubes and profiles as well as medium size products, hot or cold, up to dimensions of approx. 250mm (10 in.). Depending of the process, maximum product temperature and size range, a number of standard models are available. Special systems are custom built to individual specifications. Featuring the latest “light cut” technology and modular design with 1 up to 6 laser/camera modules, depending on type of profiles. They are highly accurate to within 0.01mm, fully static and include easy “teach in” from CAD product files. With no wearing parts, they are close to zero maintenance and have integrated protection and an air cleaning system. More information on Zumback Electronic AG tel: +41 (0) 32 356 0400 sales@zumbach.ch www.zumbach.com T T he latest LT8 laser cutting system for tubes and profiles from Adige SPA is really turning a few heads with its flexibility and innovative machine software. The new LT8 machine is a benchmark in lasertube cutting machines, with a capacity in round tubes up to 225mm. It’s interesting to note there has been no compromise on its performance on smaller tube and section and at the same time offers both speed and productivity. The machine management software of the LT8 system has been purpose- developed with the twin objectives of optimising the working cycles and, with its new interface, making it easy, safe and simple for the operator to use. ‘No loss in producivity’ The idea of equipping the LT8 system with two different loading stations – one front and one back – is a simple but efficient breakthrough. When current production processes call for maximum flexibility, the dual loading system on the LT8 allows its users to change from a long production run, and introduce from the second loader a small but urgent job with no lost changeover time. Or whilst one job is being run from one loader, the second loader can be pre- loaded. Once the existing job is finished, it switches seamlessly to the next job in the second loader, with no loss in productivity. The support and unloading of the cut pieces on a lasertube system is a truly critical phase, and the LT8 achieves this in the most efficient way for the part being processed. As such, there are several different options to suit the wide variety of tube shapes and sizes that can be accommodated within the LT8’s range. For instance short pieces can be off-loaded directly onto a front conveyor discharge; longer components can be discharged, both to the front and rear, at various points along the unloading system into appropriate storage bins/areas. A unique gripper vice on the unloading system, acts as both a centring guide for long work- pieces, and as a rapid-extraction device to remove small pieces and scrap ends from the cutting zone, thus enhancing both the discharge process and productivity. ‘three dimensional head’ Laser cutting of larger tube with increased wall thicknesses, really emphasises the unusual cut produced by the standard 2D laser cutting head. The larger tube market demands a traditional ‘flat-face’ mitre, chamfered edges and chamfered holes etc. so the 3D cutting head option is really a ‘must-have’ choice on the LT8. Flexibility The LT8 is one of the fastest cycling laser tube cutting systems available on the market, but in the modern market place even this not enough. More and more often batch sizes are getting smaller, so changeover times becomes just as important as cycle times to real productivity. With its automatic settings for changeover, slick tube handling with no ‘dead-time’ in cycle, dual-loading system, and choice of unloading positions, the LT8 has the flexibility critical in order to guarantee maximum production up-time. More information on Adige/BLM Group tel: +39 031 7070200 fax: +39 031 715911 pr@blm.it www.blmgroup.com www.internationalmetaltube.com IMT April/May 2010 15  Products & Equipment News Copper tube failure mechanisms A A number of potential failure mechanisms are possible in power plant heat exchanger tubing. To compound the identification challenges, the failure mechanisms common in copper alloys are quite different than those for stainless steels and high-performance alloys. First we look at copper alloy tubed condensers. The most commondamage mechanisms for copper alloys from the steam side areammonia grooving and stress corrosion cracking. Ammonia Grooving. When hydrazine and similar derivatives are used to assist with oxygen scavenging, these degrade into ammonia compounds. Admiralty, aluminum brass and, to a lesser extent, 90-10 copper-nickel, are sensitive to selective corrosion by ammonia compounds. As ammonia is one of the non- condensable gases, the steam drives them into the air removal zone. This is commonly where most damage is done. The ammonia combines with the condensate and concentrates on the support plates, running down the surfaces. The ammonia solution attacks the tube surface adjacent to the support plate, creating circumferential grooving. Stress Corrosion Cracking (SCC) When the tubing has high residual stresses, another mechanism can speed the failure process - stress corrosion cracking (SCC). Both admiralty and aluminum brass are susceptible to ammonia-induced SCC. The tube straightening process during manufacturing generates the residual stresses. This failure mechanism can propagate quite rapidly. A condenser having tube failures caused by both ammonia grooving and SCC is not uncommon. The failure mechanisms on the cooling water side of the heat exchanger are quite different, given the significant difference of the cooling medium. The mechanisms are usually erosion related, corrosion based, or a combination of the two. This article is to be presented in it's entirety at the ASME Power Conference July 13-15, 2010, by Dan Janikowski. More information on Plymouth Tube tel: 630-393-3550 sales@plymouth.com Ultrasonic large tube tester provides high speed reliable inspection T T he GRP-PAT-PB Portal from GE Sensing & Inspection Technologies is an ultrasonic, full body tube and pipe tester, featuring a portal arrangement which can carry up to two carriages, depending on throughput requirements. It is a turnkey solution using phased array scanning for detecting longitudinal, transverse and oblique (±15°) flaws and for measuring wall thickness and checking for lamination defects. The GRP provides a total inspection solution for the steel industry for hot rolled tubes, particularly for OCTG pipes, and is suitable for the inspection of pipes between 60-600mm diameter, at a circumferential speed of 2m/s with a pitch of 120mm per revolution. As Wolfgang Kemnitz, product manager for ultrasonic testing machines, explains, “The GRPPAT- PB Portal allows the ultrasonic coupling to be effected from above, which is very much in line with the transverse pipe transportation design of many new plants. Moreover, the application of phased array and the use of the paintbrush algorithm allow a flexible scanning system, as the size of the virtual probes, the track pitch on the tube surface, the overlap of ultrasound fields and the beam angle are all electronically controlled. ” In operation, the probe carriage moves along the axis of the tube, which is rotated on spin roller blocks. The carriage is typically equipped with five gimbal-mounted ultrasonic probe-holders, each of which holds a phased array probe. The probes are individually positioned on the tube surface and are held in the same position for 1-2 revolutions of the tube, with coupling provided by a water delay path. The carriage is then accelerated to its test speed. It is halted at the end of the tube and before they are lifted off the surface, each probe remains in position for 1-2 revolutions to minimize the length of untested ends. The carriage then returns to the start position. All operation, driving and control of the phased array probes is carried out by a front end electronics system, while data acquisition, display and evaluation is carried out by a back end electronics system, which, typically, can be located in the operator’s cabin. Data display includes on-line A-scans and online graphics. More information on GE Sensing & Inspection Technologies visit: www.gesensinginspection.com GE Sensing & Inspection Facebook Business twitter.com/GE_SensInsp www.flickr.com/photos/367605 97@N08/ www.internationalmetaltube.com 16 IMT April/May 2010 www.internationalmetaltube.com  Products & Equipment News Meeting deep marking demands T T echnifor’s XF530p has been designed specifically for industry sectors that require deep marking of parts, such as oil & gas, mining, materials handling, ship building, construction and transport. This portable unit provides the concentrated power to mark material deep enough to clearly show through most surface finishing processes, including painting, zinc plating or shot blasting. Offering a large marking area of 200 by 50mm, the XF530p can mark flat, angular and radial material to a depth of up to 0.4mm. The portable unit can generate serial numbers, logos, Data Matrix codes and so on, using the same percussion technology as Technifor’s integrated marking machines, which run around-the-clock on automated production lines. With adjustable ergonomically designed twin handles that can be orientated horizontally or vertically and featuring built-in start buttons, the XF530p is well balanced, easy to manoeuvre and marks accurately and efficiently on all material types and surfaces. By the very nature of the process, the deep marking unit The Technifor XF530p deep marking solution has been designed for heavy industry applications requires enough mass to ensure that it does not push away from the surface being marked. However, Technifor has used its considerable product design knowledge to keep this to a manageable 18kg for the XF530p. Using the supplied keyboard, the XF530p is programmed via a UC500 controller, which features a 5.7 inch backlit screen capable of graphical previews. The integrated, intuitive and user- friendly software allows the fast creation of marking files, with icons, pop-up help and on-screen graphic preview. Over 1000 marking files can be held in memory, with fixed text, variables, date and time, counters and so on. Files can also be imported or exported via a USB drive. Peter McCullough, UK Sales and Marketing Manager, says the XF530p portable deep marking solution provides a number of significant advantages. “Part marking and identification can meet defined quality standards for traceability and can also make it easier to locate and identify components or assemblies, as well as record fixed assets,” he says. “The XF530p provides all of these benefits to companies that manufacture heavy parts, such as columns and joists for the construction industry or threaded tube and fittings for customers in the oil & gas field, for example: being portable, it allows the marking operation to be conducted in situ, which is a significant advantage because the object being marked is heavy and/or awkward to manipulate.” More information on Technifor at: Tel: +44 (0) 1926 884422 sales@technifor.com www.technifor.com Double head wire bending machine D D H2010VGP is the new automatic, all- electric, double head CNC-bending machine with 3D graphical interactive programming software (VGP3D), latest evolution of the DH 2000 range. These machines offer top performance solutions for the bending of wire, bars, tubes and armoured electrical resistances. Complex wire and/or tube shapes both with coil feeling, and straightened cut to length bar, can be machined in just one cycle, giving double productivity rates compared to machines with a single bending head. Among the benefits: are left/right bending even with the variable radius facility on the same head and with the same tooling. The central clamping unit allows you to bend more complex shapes such as, closed parts, ends with eyelets and ends that reverse back into the inside of the closed parts. Plus the ability to bend a “double” part (symmetrical or same) and to cut them apart after bending. The DH2010VGP combines the solid mechanics of the double head bending machine with the latest hardware and software motion control developments. Compared to the previous generation, the machine offers a wide range of advantages: the implementation of the VGP3D programming and simulation software. The elimination of hydraulic parts with reduced power consumption, thanks to the latest Siemens drivers with regenerative feedback. A Siemens touch screen and a new revolver for wire straightening device with six positions The main applications for this machine range are the following: automotive, furniture, household appliances, hospital fixtures and industrial applications. More information on BLM Group tel: +39 031 7070200 fax: +39 031 715911 pr@blm.it www.blmgroup.com www.internationalmetaltube.com IMT April/May 2010 17  Products & Equipment News Flexible endworking of ARLA endworking station with integrated facing head technology Welded and Drawn Stainless Steel Tubing come in the size range of .188" - 4.00" (4.775mm - 101.6mm) OD by .016" - .0218" (.406mm - 0.554mm) Wall. pipesand tubes T T he flexible endworking of pipes and tubes is crucial for the production process. ARLA Maschinentechnik GmbH build CNC controlled endworking machines which are available for single sided and double sided machining. The machine is based on a solid frame, with one or two precise machining units including a unique concentric workholding technology. Thus, this machine works like two separate CNC lathes operating independently for every side. The principal difference is that this endworking concept comprises a fixed workpiece and revolving tools. All machining units are directly driven by servomotors and are therefore rigid, powerful, and designed for high torques. In order to realize several machining steps, the units are built with integrated motor spindles, optionally available with tool changing systems. Typical applications are: OD & ID turning, facing, planing, tapping, beveling, threading, grooving, chamfering, boring, drilling, milling. The new series of ARLA spindle units can be used either with HSK interface or with integrated facing heads. The machining of complex contours with a single tool system is realised by facing heads which are implemented in ARLA's DUX machining units. The clamping systems, which are used in ARLA's endworking machinery, are available as ARLA endworking station with integrated facing head technology independent units either pneumatically or hydraulically actuated. According to the model size the max. outer diameter is between 5 and 410 mm (max. pipe size 1/4" ... 16"). Due to the mechanically synchronous fast and concentric clamping technology a high clamping force is achieved between 10 and 175kN. With reference to the workpiece design, changeable jaw sets are used to reduce the diameter accordingly without readjusting the center. It is also possible that workpieces may be clamped and also held in a special release position for radial and axial adjustment purposes. More information on Arla Naschinentechnik GmbH please contact Dr. Andreas Laschet tel: +49 2267 6585-0 info@arla.de www.arla.de Mill spotlight A A lot has changed since Plymouth Tube Company acquired the Trent, WI facility a little more than 2 years ago. One thing that has not changed is Trent's commitment to quality and customer service, in addition to remaining true to lean manufacturing and principles of manufacturing excellence. The Trent Mill maintains a 91.5% rating for 2010 and is committed to continuing this trend. Plymouth Tube – Trent manufacturer of choice for exotic grades and hard to find alloys. Grades manufactured by Trent include 304, 304L, 316, 316L, 321, AL6XN, 17-7, 625, 21-6-9 plus many others at customer request. Trent also will provide your tubing to most specifications including: ASTM, ASME, MIL-T, AMS, in addition to other unique specifications required for your specialised application. Trent's More information on Plymouth Tube - Trent tel: 630-393-3550 sales@plymouth.com 18 IMT April/May 2010 www.internationalmetaltube.com  Products & Equipment News Automatic straight strip joiner W W ith minimum disruption to the production process being paramount nowadays, the strip joiner model “OTO GAL 8016” welds the incoming strip with the outgoing one – effortlessly and automatically. A single blade shear cuts the ends of the strips exactly, preparing the edges in the best way possible for the subsequent welding phase. The welding bead is not removed because as it does not interfere with the subsequent accumulation and forming phases of the strip. The automatic cycle can be interrupted at any time, to carry out any manual operations required and can be started again automatically, semiautomatically or manually. An independent control panel is used to select the cycle required and to check correct execution. A logical cycle throughout the process 1. The strip being processed is at a pass-line height of 1300mm, born by special rolls. The tail end of the strip is positioned under the shear blade automatically by end-of-coil photocells on the mobile vice, and on the pinch-roll. Upon completion, the support rolls lower to a pass- line height of 1250mm, the working height of the strip joiner. 2. The fixed vice on the outlet of the strip joining unit utilises hydraulic controls, to centre the tail end of the strip axially by means of straighteners and blocks it with its clamps. 3. The shear, which at the beginning of the cycle is already in the tail end cutting position, blocks the tail end of the coil by means of its strip press, the strip width being measured by dedicated pneumatic sensors. After this operation is completed, the tail end of the coil is cut and the strip press opens so that the shear unit can move towards the coil inlet to prepare for the joining phase of the new coil. 4. The front end of the new coil is inserted in the strip joining unit and its position is controlled automatically by the beginning-ofcoil photocells on the mobile vice and on the pinch-roll. width and define its position transversally 5. The mobile vice on the inlet of the strip joining unit, by means of hydraulic controls, centres the front end of the strip axially by means of straighteners and blocks it by means of its clamps. In the same way, the shear strip press lowers and blocks the strip. The mobile vice opens and moves towards the coil inlet after the overtaking table has lowered. The mobile vice closes again on the strip, blocking it with the straighteners and the clamps. The shear sensors measure the width of the strip and define its position transversally. Once the shear strip press raises, the mobile vice, and by means of a hydraulic command, aligns the two strips. 6) The shear, after lowering the strip press, cuts the front end of the new coil. The strip press then opens again and the shear unit remains in this position. 7) The welding unit moves to the strip joining position and the mobile vice pulls the strip of the new coil to the welding position. A slight off-set is left between the edges, whose value can be adjusted by means of a mechanical limit switch that acts on the movement of the shear unit. At the same time, the overtaking table rises again, which is thus ready for the following coil insertion phase. 8) The strip presses of the welding unit close on the strip and the edges to be welded are born by a copper plate with forced water cooling system. The two torches are adjustable in all directions and are driven by an electric motor with variable speed. The starting position of the torches is defined by the values read by the feelers of the shear. A number of different welding cycles can be selected from the control panel. Once welding conformity has been checked, the operator gives the enabling signal to continue the cycle, which consists in positioning all the units so that the coil can be completely unwound. 9) Trims left after cutting the tail end and front end are collected by a dedicated container under • www.internationalmetaltube.com IMT April/May 2010 19  Products & Equipment News the strip joiner. encoder. Their function is that of longitudinally compared to the line. The mobile vice unit is made keeping the strip aligned during The unit is positioned longitudinally entirely of welded steel. The guide shearing and welding. During the by means of a pair of hydraulic rolls are made of tempered and stand-by phase, they open cylinders. The shear fits a blade for cemented steel. The guides and automatically with a hydraulic cutting the leading and tail end of the welding vice are born by bases quick-release system so that the the coil and is operated by a pair of that run on ball bearing guides strip can pass through. On the appropriately sized hydraulic longitudinally and transversally inlet, the vice is equipped with a cylinders. The blade also has an compared to the line. The unit is mobile horizontal roll at the electrically controlled device that positioned longitudinally by a pair bottom that lowers during the controls the clearance between the of hydraulic cylinders. Transversal shearing and welding phase, plus blades based on the thickness of positioning with hydraulic control a fixed roll at the top. The vice is the strip to be cut. The shear unit and position transducer means closed hydraulically. also fits the strip width measuring that any misalignments of the The shear unit too is made of device, which consists of two edges to be welded can be welded steel. The guide rolls are pneumatic sensors, which, by straightened-up. The rolls of the made of tempered and cemented means of a linear transducer, vertical guide are adjusted by steel. The whole unit runs on ball define the exact position of the means of an electric motor and bearing guides arranged strip. On the inlet, there is a roll that feeds the strip once the front end has been cut. On the outlet, there is another roll that works on three positions: high, to support the strip during the accumulation phase in the accumulator, intermediate, for shearing and welding and low, for rejecting trims left after cutting the front end. The Welding torch positioner’s torches can be adjusted in all directions and are driven by an electric motors with inverter control to be able to adjust their feed speed. The edges to be welded are born by a copper plate with forced water cooling system. A generator is included for welding the tail-front end of the strip; the choice depends on the material to be processed. The strip joining unit is in any event designed for MIG/TIG welders with PULSED ARC and programmer. More information from Oto Mills at: tel; +39 (0) 522 481211 fax: +39 (0) 522 964188 otoinfo@otomills.com www.otomills.com Ultrasonic large tube tester provides high speed reliable inspection T T he GRP-PAT-PB Portal from GE Sensing & Inspection Technologies is an ultrasonic, full body tube and pipe tester, featuring a portal arrangement which can carry up to two carriages, depending on throughput requirements. It is a turnkey solution using phased array scanning for detecting longitudinal, transverse and oblique (±15°) flaws and for measuring wall thickness and checking for lamination defects. The GRP provides a total inspection solution for the steel industry for hot rolled tubes, particularly for OCTG pipes, and is suitable for the inspection of pipes between 60-600mm diameter, at a circumferential speed of 2 m/s with a pitch of 120mm per revolution. As Wolfgang Kemnitz, product manager for ultrasonic testing machines, explains, “The GRPPAT- PB Portal allows the ultrasonic coupling to be effected from above, which is very much in line with the transverse pipe transportation design of many new plants. Moreover, the application of phased array and the use of the paintbrush algorithm allow a flexible scanning system, as the size of the virtual probes, the track pitch on the tube surface, the overlap of ultrasound fields and the beam angle are all electronically controlled. ” In operation, the probe carriage moves along the axis of the tube, which is rotated on spin roller blocks. The carriage is typically equipped with five gimbal-mounted ultrasonic probe-holders, each of which holds a phased array probe. The probes are individually positioned on the tube surface and are held in the same position for 1-2 revolutions of the tube, with coupling provided by a water delay path. The carriage is then accelerated to its test speed. It is halted at the end of the tube and before they are lifted off the surface, each probe remains in position for 1-2 revolutions to minimize the length of untested ends. The carriage then returns to the start position. All operation, driving and control of the phased array probes is carried out by a front end electronics system, while data acquisition, display and evaluation is carried out by a back end electronics system, which, typically, can be located in the operator’s cabin. Data display includes on-line A-scans and online graphics. More information on GE Sensing & Inspection Technologies visit: www.gesensinginspection.com GE Sensing & Inspection Facebook Business twitter.com/GE_SensInsp www.flickr.com/photos/3676059 7@N08/ 20 IMT April/May 2010 www.internationalmetaltube.com  The ‘Ideal’ hydraulic draw bench V V ioli Srl has for many years, specialised in the design and production of industrial machinery for the manufacturing of metal tubes, bars and wires. These machines are typically and successfully used in the various drawing, winding, straightening and cutting processes. One of their leading products is the TRI30 – an ideal draw bench to process tubes and bars with circular cross sections, and/or with complex profiles whilst meeting high quality standards and accuracy critical to the finished product. Technologically advanced, thanks to the use of top-level components and innovative design solutions covered by patent, the TRI30 draw bench is fully controlled by PLC for both working phases and safety protection; the truck carries pliers which are perfectly aligned in order to eliminate any bending deformities on the metal structure during operation. The speed of the traction is adjustable, and using the bench is made extremely simple by the use of a joystick placed on the control panel. This effectively allows the operator to manage all the steps of the process. The replacement of the jaws is exceptionally simple and is achieved through a system of fast anchorage. The TRI30 is very compact with a total length of about 2 meters and may be equipped with a opposite bank for the use of anchored spindles. The TRI30 is also available with a proportional pump with adjustable flow. Violi srl today is actively supplying a comprehensive and versatile range of machinery in many international markets, More information on Violi S.R.L. Meccanica Industriale tel: 0039 0575 810487 fax: 0039 0575 815903 sales@violimacchine.it www.violimacchine.it High Speed, repeatable inspection for small bore tubes T T he ROTA 25 and ROTA 40 rotary inspection systems from GE Sensing & Inspection Technologies, are already accepted as being the most technically advanced inspection systems in the world for nuclear fuel element tubes. They now find extensive applications in the inspection processes during manufacture of sub-sea umbilicals, as well as in the inspection of heat exchanger tubes. They are used to inspect hot rolled, pilgered, and cold drawn tubes for the oil and gas sector, as well as pressure and precision tubes for power generation plant and even for precision bars. As Peter Olthoff, sales manager for rotary inspection systems, explains, “GE’s rotary test systems have their origins in the high-precision testing of pipes and heat-exchanger tubes for nuclear applications in the 1960s. Today, this technology, featuring rotating ultrasonic probes, is applied in a variety of applications inspecting pipe from 5mm to 450mm in diameter and up to 40m in length, such as for quality control during production of the umbilicals, which must provide reliable operation in harsh and demanding off-shore environments.” With single section probe holders for individual high precision adjustment and motorised bench/transport mechanisms, ROTA 25 and ROTA 40 offer reliable, repeatable inspection at high speeds. They provide turnkey, tailor-made online inspection systems, About GE Sensing & Inspection Technologies GE Sensing & Inspection Technologies is a leading innovator in advanced measurement, sensor-based and inspection solutions that deliver accuracy, productivity and safety to customers in a wide range of industries, including oil & gas, power generation, aerospace, transportation and healthcare. The business is part of GE Energy Services and has more than 40 facilities in 25 countries worldwide. incorporating workpiece, conveyor, testing bench and water coolant systems, and are equipped with single probes to meet specific inspection requirements. In one inspection cycle, they are capable of detecting various crack-type defects throughout a material cross section, as well as dimensional divergences in internal and external diameter, wall thickness, ovality and eccentricity. More information on GE Sensing and Inspection Technologies visit www.gesensinginspection.com GE Sensing & Inspection Facebook Business twitter.com/GE_SensInsp www.flickr.com/photos/3676059 7@N08/ www.internationalmetaltube.com IMT April/May 2010 21  BLISSart. The Art of I.D.-scarfing.  Market Leadership In our vibrant corporate culture, in which everybody is fully committed to a continuous process of improvement, change is seen as an opportunity. For more than three decades this has meant reaching for the top when it comes to innovative inside tube scarfing systems of the highest quality. Today we are the global market leader and a strong partner for technological innovation as well as process solutions designed to enhance efficiency. We offer a multitude of specialized tools to be able to satisfy the highest requirements of the most varied target groups. Continuous system optimization efforts are developed from a user perspective and help our customers obtain sustainable production advantages. It is these systems that are the cornerstone of our success in the industry and that have made us a trailblazer nationally as well as internationally. Reaching the Top.  Real innovation means going where nobody else has gone before.*  An der Hasenjagd 8 D-42897 Remscheid Tel. +49 (0) 2191-9982-0 Fax +49 (0) 2191-9982-24 info@blissenbach.de www.blissenbach.de *All quotes by mountaineer Reinhold Messner.  Valve World Global mission to save life The increasing scarcity of water is one of the biggest challenges of this century. The valve, sealing and pipeline industry has long recognised the problem and it’s economic importance and are already making a valuable contribution to supplying people the world over with water. T T he world’s water supply situation is already dramatic. 1.2 billion people do not have access to clean drinking water and almost one in six of the world’s population is affected. Add to this the 2.6 billion people who lack adequate sanitation, plus the shortage of water in agriculture and you have a really depressing scenario. Of all the world’s large regions, Africa is in the most dire situation when it comes to water. Over 300 million people have no access to adequate drinking water, and water for domestic use and agricultural production is often in short supply. As a result, the UN’s Intergovernment Panel on Climate Change (IPCC) has forecast that by 2050, up to 600 million people on the continent will suffer from climate change induced water shortages. 20% of Central Asia’s glaciers will melt by 2050 Parts of Asia are also affected by the shortage of water, as the central Asian climate has in recent decades, warmed at a higher than the global average. Glacier melting has accelerated and experts assume that up to 20% of Central Asia’s glaciers, which serve as freshwater reservoirs, will melt by 2050. Southern Asia is badly hit by this development. Himalaya’s glaciers will, to a large extent, have disappeared by 2035. Then again countries in Europe and America are also experiencing reduced water resources. According to the UN Environment programme, the annual worldwide investment in water developments totals US $80 billion. A doubling of this sum will be necessary in the foreseeable future to improve both the supply of water and the disposal of wastewater. The world wide market volume of construction work, machinery, plants and services in the water/wastewater is estimated at being US$ 460 - 480 billion. Seawater desalination Valve and pipeline manufacturers are involved at virtually all stages within the water supply system: at the extraction point, water treatment, transport and supply. The gradual depletion of water resources means that water catchment is becoming increasingly more and more important. Seawater desalination plants are one hope for the future as they offer an inexhaustible potential. According to the Royal Academy of Engineering, desalination will play a major role in the future. The reverse osmosis uses high pressures and therefore, needs high pressure valves, pumps and piping. In view of the rapidly increasing importance of such plants, manufacturers are pressing ahead with the developments of their products. A vital process, as salt induced corrosion is a major technological problem. The west coast of America, where higher temperatures caused by the greenhouse effect may well lead to acute water shortages, is increasingly turning to seawater desalination plants. This is the conclusion of a study conducted by “Climatic Change”. It predicts winters will become warmer which, as a consequence, will diminish the snow cover in the mountains on the west coast. Up to now, the summer thaw has provided the coastal region with water. If in future, the precipitation falls as rain rather than snow, it will go unused as the water immediately flows away, resulting in a dramatic shortage of water in the hot summer months. Example San Francisco Bay: it is planned to build a reverse osmosis plant costing US$ 105 million – the plant is designed to convert seawater into drinking water. It will the first development of its kind in the Bay and is expected to go live in 2014. Even Spain is committing itself to seawater desalination, as the water supply in the Iberian Peninsular is becoming critical. The gradual depletion of water resources means that water catchment is becoming increasingly ‘ more and more important The Flowserve Group has received orders to equip new plants for a combined value of 2.2 million euros. A new plant, the biggest of its kind on the continent, is being planned for Australia, as the country’s southern and eastern ’ regions are threatened with drought. Thiess, an Australian company, and its joint venture partners will construct a desalination plant, a 2.1 billion euro investment for the 22 IMT April/May 2010 www.internationalmetaltube.com  Government of the State of Victoria. Once building work has been completed towards the end of 2011, the plant will supply 150 billion litres of drinking water annually to Melbourne and the region’s other towns and cities. The development includes the operation of an 86 kilometre long pipeline connecting the plant to Melbourne’s water network. Tyco Water, a division of Tyco Flow Control, is also involved in the building of Australia’s largest desalination plant. The company will supply 6200 steel pipes. Three and a half million people will be provided with drinking with drinking water once the plant is up and running. Oil-rich states Around half the seawater desalination plants are located in Arab countries according to the University of Bochum, Germany. The reason is obvious as desalination plants are energy intensive and doesn’t present a problem to the energy rich states. This has been recognised by Fujairah, one of the seven Emirates that make the United Arab Emirates. Where to meet the increasing demand for energy and water, the Emirate has built a combined power station and seawater ‘The hybrid plant produces simultaneously, electricity and drinking water’ desalination plant in Qifda. The hybrid plant produces simultaneously, electricity and drinking water. The whole complex produces 656MW and 455 million litres of drinking water per day. However, the water treatment process is not the only important aspect. Drinking water has to be taken from its source to the regions where it is sorely needed. Valves are therefore vital for the pipelines. After the initial supply of needle valves to the plant in Fujairah, Erhard GmbH, has also won a contract worth several millions to provide valves for the new pipelines – 100 butterfly valves designed for high pressure up to 81 bar. The new pipelines will increase the plant’s daily capacity from 455 to 1045 litres/day. To do this, two parallel 180 km long pipelines with a diameter of 1600mm are being constructed. The pipelines, will secure the water supply in one of the world’s hottest regions goes on stream this year. Turkey pipeline In Turkey, the government has backed a mammoth development to provide the Turkish people with an adequate source of water. A 128km long pipeline now runs from a drinking water reservoir located to the south of the capital city on the River Kizilirmak near Kesikkopru all the way to the north of Ankara. When fully operational, 9000ltrs of drinking water per second will be pumped to Ankara. A difficult undertaking: “The topography of the land didn’t make the job any easier” explained Attila Kokel from Erhard. “Differences in altitude and inclines of up to 500 metres had to be overcome. The complexity of the pipeline route made it obvious from the start that the valve technology had to meet the highest demands”. Almost 2500 butterfly, needle, ball air and diverse other valves were ordered in the Ankara development. Valve manufacturers operating in the water supply industry have to be flexible, as they are helping to provide a basic human need. The Ankara pipeline was originally planned to go into operation in 2010. However a drought in Turkey, led to the capital s 3.7 million population having to endure water shortages meaning the completion date had www.internationalmetaltube.com to be brought forward. Valves have become increasingly vital for tourist projects in regions where water is a scarce commodity. The $1 billion Ayla Oasis development in south Jordan will include an artificial lagoon adding 17 kms to the seafront near Aqaba. Scheduled for completion by 2017, the Arabian Venice themed complex on the banks of the Red Sea, which includes up-market hotels, an 18 hole golf course and a marina, will attract holidaymakers from all over the world. Its vital for the resort that the water level in the lagoon is constantly maintained at an exact height. The gigantic project will be supplied with EPC coated non- return and butterfly valves, bronze bushings and shafts as well as duplex SS seat rings – demands on material and technology are high in salty sea water. Manufacturers will have to continue to focus on the supply of water to needy countries. Consequently, they will make a fundamental contribution to providing the world’s population with the elixir of life – water. More information on Valve World Expo at tel: +49 (0)211 4560 541 hartmannP@messe-duesseldorf.de IMT April/May 2010 23  Geothermal Energy Gold fever in Earth-Dorado The natural elements such as the sun, wind, sea and hydro power spring to mind when thinking of renewable energy. Often overlooked, is geothermal energy which, in contrast to the other forms of energy, is readily available, and what’s more, it’s infinite. W W ith the growing importance of geothermal energy, it is becoming increasingly significant for process machine and plant manufacturers – that equipment such as valves, pumps, pipes, water treatment plants and heat exchangers, are indispensable in generating this form of energy. Negative headlines have given geothermal energy an undeserved, dubious reputation for many people: The Landau power plant was shut down in August and September last year because of slight tremors in the surrounding region – experts presumed that the power plant in Rhineland-Palatinate was the source of the quakes. However, trial operations have been given the go ahead once more, with all the stricter requirements having been fulfilled. A small earthquake as a consequence of drilling led the Swiss government to stop a geothermal energy project, and a small quake brought an end to a similar project in the federal state of California. “The public image of geothermal energy has been affected by a few drilling incidents”, admits Stefan Dietrich, a communication consultant for the Geothermal Association. In fact, drilling several kilometres deep in regions with natural seismic activity is indeed risky, as ground movements can be triggered artificially. 24 IMT April/May 2010 www.internationalmetaltube.com  The Valve World Expo presents continual growth, outstanding innovations and the highest level of technology at the new Düsseldorf location as of 2010. Valves and the entire palette of accessories, as well as the preceding and succeeding technologies take centre stage. The Valve World Conference, as the most important event of the industry, analyses the future of the markets against the background of fascinating developments and scientific evaluations. Düsseldorf turns it on! www.valveworldexpo.com Now get all the congress and trade fair information daily on your mobile! Simply use the QR-Code Reader of your camera phone. Sponsored by: Supported by: www.valveworldexpo.com Now get all the congress and trade fair information daily on your mobile! Simply use the QR-Code Reader of your camera phone. Sponsored by: Supported by: 7th Biennial Valve World Conference & Expo Düsseldorf, Germany 30 Nov - 02 Dec 2010  Geothermal Energy Geothermal energy may have had a ‘mixed press’ but seen from a global perspective, a noticeable or even dangerous quake is seldom the result. On top of it all, the chances offered by an environmentally friendly, inexhaustible source of energy with low emissions, used day and night regardless of the weather, are huge. Also take into account, the many expensive energy imports and associated dependencies that would also be avoided. Hence, the rising costs of energy and state subsidies for renewable energies are making geothermal energy increasingly attractive in Central Europe. Hot water generates energy Power companies like Vattenfall are discovering the potential of geothermal energy in Germany. The first power plant, located in Neustadt-Glewe, didn’t go online until 2003. It has an installed capacity of 230kW and a net output of 75kW and supplies households in the small town of 6,700 inhabitants with electricity. Since 2003, further power plants The use of geothermal energy to generate heat and electricity is steadily on the rise in ‘ Germany ’ in Germany have started winning electricity and heat from geothermal energy. A plant worth 17 million euro, with a capacity of 550kW was put into service in the federal state of Baden-Wuerttemberg. The Kalina Cycle is used here as in many other geothermal power plants. Instead of using one single medium, a working fluid made from ammonia and water is used in this cycle. The ammonia-water mixture boils across a range of temperatures at a constant pressure. More energy can be recovered as it is extracted from the ammonia- water mixture, when it passes through the heat exchangers than with conventional working fluids. The efficiency of a geothermal power plant using the Kalina Cycle, is accordingly significantly higher compared to one using the Organic Rankine Cycle, and ensures a good degree of efficiency even at low temperatures. Gate and safety valves With an investment volume of 21 million euro, the geothermal power plant in Landau is one of the major geothermal projects in Germany. It produces 3MW of electricity and – just like all other comparable plants generates power from hot water found thousands of metres below the surface. The water has a temperature of around 160°C at a depth of 3,000 metres, and is conveyed to the surface through a well, where heat exchangers power turbines to feed district heating. Water is subsequently channelled back under the surface again through a second well, where it heats up again. Geothermal plants are thus able to supply energy around the clock. As a principle, all elements of the Landau power plant are secured by a gate valve. Numerous valves were placed, particularly in the thermal water circulation. These safety valves have an important task – if the pressure gets too high, thermal water is released by opening the valves. The valves have to withstand certain conditions. In the case of the Landau power plant, water with a temperature of 160°C flows upwards with a pressure of at least 20 bar. Moreover, the water from the Upper Rhine Graben is very saline – three times more than the North Sea. The requirements for the fittings are higher than for instance, the Bavarian geothermal power plants, where the water has the quality of tap water. Approximately 120 valves and gates are used in the Landau plant. As 8 to 10 inch pipes are used in the Landau plant, valves with according nominal diameters of DN 250 and DN 300 have to be used. Stainless steel of the type V4A, or 1.4401 (X5CrNiMo17-122), is used where the valve seats and gates are exposed to corrosive forces. The gate valve and valves between ranges of 2.000 to 10.000 psi are found at the wellhead, comparable to counterparts used in the oil industry. The valves at the wellhead are relatively heavy – in Landau, up to 250 kg. In addition, the Landau geothermal power plant also uses butterfly valves for the district heat extraction, ball valves for the drain lines, 26 IMT April/May 2010 www.internationalmetaltube.com  New technologies will make it possible to utilise hot rock formations which possess either no water ‘ resources at all, or only low amounts of water ’ needle valves for the sensors, as well as check valves to secure the pumps. The Unterföhring thermal plant has two wellheads, as is usual for such plants. Each one has its one valve. Pressure meters supply operating data and control the temperatures and pressure in the well. The energy centre is also equipped with various control instruments and valves. Huge potential These plants are merely the top of the metaphorical icebergs – and a large number of new projects have already been launched. Geothermal energy has “huge potential” concludes Nicola Moczek, director of the German Geothermal Association. “the use of geothermal energy to generate heat and electricity is steadily on the rise in Germany,” adds president Hartmut Gaßner. Bold predictions assume that there is sufficient geothermal energy to cover Germany’s entire electricity load whilst delivering two and a half times as much heat. “New technologies will make it possible to utilize hot rock formations which possess either no water resources at all, or only low amounts of water,” says Stefan Dietrich of the Geothermal Association. “In principle, that would mean that even deep geothermal energy could be used everywhere”. One of the major disadvantages however, is that 1 kW/h of geothermal energy costs twice as much to generate as wind energy, and three times as much as electricity from a coal power station. USA generates the most Other countries are already utilising geothermal energy to a far greater extent. With an installed total output of over 3,000MW and a worldwide market share of 30 percent, the USA is the world’s foremost producer of geothermal energy. US companies launched over 120 new projects in early 2009, within the space of half a year. The total volume of investments being worth approximately US$15 billion. As soon as the projects are implemented, total geothermal capacity in the USA will double to nearly 6,000MW. So far, geothermal energy merely makes up 1 percent of the USA’s energy mix. However, the www.internationalmetaltube.com IMT April/May 2010 27  Geothermal Energy US Department of Energy expects the amount to double. The US government is pushing the development of the energy source. Nearly US$500 million of the economic stimulus programme will flow to geothermal businesses. Support programmes have been running for several years and tax breaks offer further incentives. While the USA may have the largest total capacity of geothermal energy, Iceland leads the way on a per capita basis. Iceland has an installed capacity of 200MWe. Five geothermal power plants cover the entire electricity requirements of Iceland’s population, alongside a few hydroelectric power stations. In Reykjavik, pavements are even heated in winter, as the volcanically active island has an abundance of geothermal resources. This form of generating power has a long tradition in what can be considered to be the model country for geothermal energy. The Svartsengi power plant has been generating electricity from geothermal heat for 30 years and the plant’s capacity has reached 76.5MW. Conditions in the region are ideal. At a drilling depth of 1,000 to 2,000 metres, temperatures already reach over 200°C. In Germany, a lot more effort is needed to exploit geothermal sources. For example, temperatures reach 150°C at a depth of 2,800 metres in Offenbach an der Queich, or at approximately 3,000 metres in Landau - the deeper the borehole, the higher the costs. Drilling costs consume the largest part of an investment, namely three quarters of the expenditure. In contrast, operating costs are seen as relatively low.The Svartsengi plant, which generates heat and electricity, is a good example of low operating costs. Depending on the well, either steam is used, or a mixture of steam and gas. The steam is separated from the water and then flows to the turbines to generate electricity. Additional turbines generate even more electricity. Eighty percent of the water volume flows back into a well, whereas the remaining 20 percent is diverted overground. This has led to the creation of one of Iceland’s most famous sights, namely the blue lagoon. Minerals in the water gave the lagoon next to the power plant an intensive shade of blue. Iceland’s cheap energy Not only does Iceland’s power generation profit from the island’s volcanic activity, but also its job market. More and more industry is setting foot on the island, thanks to the wealth of this energy source. Iceland isn’t the only country which is playing a major role for geothermal energy. Mexico, Japan, Italy, the Philippines and New Zealand are especially suited to make use of this form of energy. Today, geothermal energy plays the greatest role on the Philippines, in front of coal and oil. In some countries the utilisation of geothermal energy is still in its early stages. In Northern Ireland, GT Energy is planning the country’s first geothermal power plant. From 2011 onwards, it will complement the district heating network, which was erected on basis of energy won from biomass. Hot water from a depth of 3,000 metres will be used to generate heat and electricity. Valves, heat exchangers, pumps, a water treatment plant and a biomass boiler will be needed to realise this project. The UK is constructing its first commercial geothermal energy plant in Southern England. Here, hot water from a depth of between 3,000 to 4,000 metres shall generate 3MW of energy. Experts presume that the project will be able to cover ten percent of the United Kingdom’s electricity requirements. Water with a temperature of 150°C will flow to the surface in the so- called Eden Project, the plant will go online in 2012. The race for the best geothermal technologies has already started. Companies such as Honeywell International, General Electrics and Schlumberger are investing in research and development projects. In the end, a technology has to be developed which will make geothermal power not only usable in the open countryside, but also in the middle of an average town and companies are working on solutions which will lower the risks close to zero. Geothermal energy still has to tackle various obstacles on its way to the top. How geothermal energy is catching on in Germany In Germany, the utilisation of deep geothermics, i.e. heat from beneath 400 metres down, has only been extracted over the past few years. According to the German Federal Association of Geothermal Energy, the respective heat generation doubled in 2009, whereas the generation of electricity, which began in 2007, has risen by eleven percent. In contrast to other forms of renewable energy, Germany is not yet top of the pack. The umbrella organisation, the Federal Association for Renewable Energy expects geothermal pumps will increase capacity to 12,2 TWh by 2020. This would be an increase of nearly 240 percent compared to 2009. “Growth forecasts for heat generation from deep geothermal sources are even better“, declares Stefan Dietrich from the Great Britain is constructing its first commercial geothermal energy plant in Southern ‘ England. Here, hot water from a depth of between 3,000 to 4,000 metres shall generate 3MW of energy Association of Geothermal Energy. By 2020, it will grow from the current 0,2 to 14 TWh – seventy times as much in eleven years. In total, geothermal energy would generate 2/3 percent of heat in Germany and continue to ’ grow its share. The industry also expects strong growth in the electricity sector. Installed capacity is expected to rise from 8MW to over 600MW by 2020, whereas power generation will rise to 4,000GWh, 200 times as much as in 2009. “That would merely be 0.7 percent of Germany’s total power consumption, yet it is nonetheless a promising path of growth for the years following 2020,” says Dietrich. More information on this subject tel +49 (0)211/4560-541 fax +49 (0)211/4560-87 541 HartmannP@messeduesseldorf. de 28 IMT April/May 2010 www.internationalmetaltube.com  ALL THE TOOLS YOU NEED. ALL IN ONE PLACE. North America’s Largest Metal Forming, Fabricating, Welding and Finishing Event When it comes to getting the tools you need to improve productivity, increase profits and find new ways to survive in today’s competitive business environment, nothing compares to FABTECH. One week, one convenient location, one opportunity to keep your business on the cutting edge. REGISTER TODAY: www.fabtechexpo.com NOVEMBER 2-4, 2010 GEORGIA WORLD CONGRESS CENTER | ATLANTA, GEORGIA  All-electric tube forming machines: unique in VGP3 a very intelligent programming software: versatility and capability, delivers precise, deskills the bending process and features a repeatable, right-first-time bends at a much real-time, graphical visualisation of the lower running cost. component being bent.