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International Metal Tube Volume 1 Issue 2

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08 report • Fabtech 2008 report • Fabtech 2008 report • Fabtech 2008 report • Fabtech 20 Comment As many of us enter the festive season and look forward to the Christmas and New Year celebrations, the turmoil surrounding the financial aspects of our daily lives continues. It is at times like this that some companies will try to claw back funds set aside for items such as R&D, machinery & equipment upgrades or even marketing. Others however see this as a time to take courage and invest for the future. This latter option not only shows a confidence in your own product and in planning for the future, but also keeps you ahead of your competitors when the market does pick up. For us (the publisher) at International Metal Tube magazine, we too have to take a pragmatic approach to how we manage our costs. With our sole income being derived from the advertising in each issue, we are forced to find the middle road when it comes to what information is published. As we strive to include as much information as possible from as wide a spectrum of suppliers as possible, we applaud those who have the foresight to invest in IMT magazine. For 2009, IMT magazine will be taking a pro-active approach by giving additional support to the industry through our digital on-line version of the magazine, and this support will take the form of exclusive content that will only be available on the website www.internationalmetaltube.com <http://www.internationalmetaltube.com/> . For those of you who have not yet registered to receive the email alert when an issue goes live, now would be a good time. Email: imtmagazine@btopenworld.com <mailto:imtmagazine@btopenworld.com> with the email address you wish the digital alert to be sent to. IMT magazine wishes to thank all those companies and individuals who have contributed this year to the content of the magazine, and to you the readers we wish you a successful and prosperous 2009. 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 Holbrooks Printers Ltd, Norway Road, Hilsea, Portsmouth, Hampshire, PO3 5HX. Tel: 02392 661485 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 Industry News Products & Equipment News www.internationalmetaltube.com Fabtech Report People News Welding Toolbox Tube & Pipe Mills Cut Saw Profiles Events Bronx/Taylor Wilson IMT December/January 2009 1 Crimper on the road T he heavy goods vehicle initial bending of edges of steel that moved the sheets up to 50mm thick and 18m crossbeam of a new long which will be formed to crimping press for pipeline pipes by the two Europipe from the Siempelkamp downstream presses. factory to the port of Krefeld had The disassembly took almost an overall load of 355 tonnes. two weeks, with only five weeks After 11 months of available for assembly and startup development, four months of – but the first sheet was bent right construction, two weeks of on schedule. preliminary testing and the Four of 18 large construction subsequent acceptance test by components were transported on the customer, Siempelkamp sent low-loaders in a single night, the crimping press for Europipe followed by a day on the on its way to Mülheim. waterways of the Ruhr Valley. As the first of three presses the “With a pressing capacity of up to crimping press will carry out the 11,000 tonnes the crimping press Fully loaded, the special transporter truck had an all-up weight of 355 tonnes was hardly routine,” says Siempelkamp has decades of Siempelkamp project manager experience in the engineering, Sigfrid Buecher. “For the design and manufacturing of construction of this press we had metal forming presses. It supplies to reinforce the foundation of our plate bending presses for factory workshop.” manufacturing large-diameter Once assembled the machine pipes and half shells, measures 9x13x16m. “The real straightening presses, side-challenge was the transport of the member presses, heat exchanger press table and the crossbeam plate presses, hydro forming which at 166 tonnes and 216 presses, rear axle housing tonnes were too heavy for the presses as well as a highway bridges along the way,” comprehensive range of closed-Mr Buecher adds. die and open-die forging presses. Transporting the beams to the More information on port involved a 52m, 600hp rig Siempelkamp at: running on 160 tyres. Four mobile www.siempelkamp.com, cranes were used to lift the tel: +49/2151/92-4636, components from the truck onto email: the ship; the job was handled by a ralf.griesche@siempelkamp.com team of 30 staff members. fax: +49/2151/92-5683. Titanium plant A DuPont titanium tetrachloride Plans for the $30 million plant purification unit has begun were announced in October 2006. operations at its titanium dioxide site More information on DuPont at: in New Johnsonville, Tennessee. www.dupont.com, Most of its output will be used in the tel: 302-999-5226, production of titanium metal email: richard.a.straitman@ manufacturing industry. usa.dupont.com. FPS Method (pat.pend.). In-Line Diameter and Shape Contr ol For all Types of Pipe, Tube, Profile – Any Shape STEELMASTER gauges for hot and cold processes Hi-speed laser scanning. Measurement of diameter, ovality, height, width and diagonals. Possible measuring modes Standard measuring ranges: 60, 100, 150, 300, 500 mm* (2.4, 4, 6, 12, 20 in.) No. of measuring axes: 1...6 Measuring frequency: 1000/s for each axis Typical accuracy: +/- 0.005 ... +/- 0.1 mm (+/-.0004 ... .002 in.) *Largest product depending on centering Novel measuring method with Full Profile Synthesis. Captures also asymmetrical shape deviations of round, oval and polygonal products. PROFILEMASTER® gauges for cold processes Advanced vision technology (light-section). For any tube and profile of any shape and material. Full profile contour measurement. Profile and critical dimensions, radii and angles can be programmed (teach-in) and monitored. Any shape Standard measuring range: 25, 140, 300 mm* (1, 5.5, 12 in.) No. of cameras: 1...6 (standard 4) Measurable parameters: length, width, height, diameter, radii, angles Typical accuracy: +/- 0.01 ... 0.05 mm (+/-.0004 ... .002 in.) *Largest product depending on centering We Measure Quality Worldwide Zumbach Customer Service and Sales Offices in: Switzerland (H.Q.): Tel. +41 (0)32 356 04 00, E-mail: sales@zumbach.ch India: Tel. +91 20 3048 4801, E-mail: joseph@zumbachindia.com Argentina: Tel. +54 (0)11 4701 0774, E-mail: ventas@zumar.com.ar Italy: Tel. +39 0332 870 102, E-mail: zumit@zumbach.it Belgium: Tel. +32 (0)2 478 16 88, E-mail: zumlux@skynet.be Spain: Tel. +34 93 666 93 61, E-mail: gestion@zumbach.es Brazil: Tel. +55 (0)19 3849 5008, E-mail: vendas@zumbach.com.br Taiwan: Tel. +886 2 2630 5530, E-mail: zumfareast@giga.net.tw China: Tel. +86 (0)21 542 60 443, E-mail: office@zumbach.com.cn UK: Tel. +44 (0)870 774 3301, E-mail: sales@zumbach.co.uk France: Tel. +33 (0)1 64 24 46 31, E-mail: ventes@zumbach.com.fr USA: Tel. +1 914 241 7080, E-mail: sales@zumbach.com Germany: Tel. +49 (0)2238 8099-0, E-mail: verkauf@zumbach.de www.zumbach.com ZUMB.707.0083.E_JAN.08 A state-of-the-art tube bending machine is giving BAE Systems Submarine Solutions greater flexibility to fabricate the complex parts required to build the UK's Astute class nuclear-powered submarines. Supplied by Unison, the all-electric tube bender offers right and left handed bending capability, allowing BAE Systems to make parts from a single length of tubing. This avoids the need to join tube sections, eliminating time-consuming and expensive X-ray and crack-detection testing. The new 20mm machine increases the production capacity and flexibility of the pipe shop at the company's Barrow-in-Furness shipyard; it joins a number of hydraulic tube bending machines. As well as being the first right and left handed machine, this is the shipbuilder's first all-electric tube bender with position control achieved via servomotor-based movement axes. Fabricating complex tubular shapes is an everyday task for the pipe shop. In order to fit in all of the submarine's equipment, and most demanding applications UK – the nuclear powered attack maximise the free space available, including naval shipbuilders and submarine has been described as small-bore piping and tubing aerospace companies – and also “more complex than the space services such as hydraulic lines for its UK location. Failure to shuttle” with a million individual are routinely shaped to fit into the produce parts on schedule could components and 10,000 separate free spaces available next to lead to production delays, so design and engineering panels and bulkheads. having a machine out of service for requirements. Programs are simply loaded an extended period is not an "We are driven by a demanding from the design database, and option. The proximity of Unison's production schedule," says Kevin bends are then made precisely by headquarters in the UK would Johnston, integrated work team the servomotor movement axes allow an engineer to make a manager at BAE Systems with their closed-loop control service call within hours of a Submarine Solutions. "The mechanisms. No manual problem emerging. versatility of an all-electric tube intervention or adjustments of Another useful aspect of the bender, and one capable of making any kind are required. If the machine is its incorporation of both right and left handed bends, is tooling is already on the machine sophisticated software-based a major asset for my department, the setup operation takes about facilities that can be used for fault which will help us to keep major 15 minutes or less; typically at diagnosis. These include a camera shipbuilding projects such as least twice as fast as the setup that can be used to capture images Astute running smoothly." process for the company's or video of any operational To save space, the new tube hydraulic bending machines. problems. In combination with a bender incorporates on-machine As there are no hydraulic software 'black box' which guard panels. This will simplify pumps continuously running automatically stores the last 500 moving the machine if required, for significant current is only drawn instructions entered by the any reorganisation of the shipyard when the machine is making a operator, along with details of required for subsequent bend, so energy consumption is machinery positions from the servo construction projects such as the reduced substantially. motor sensors, Unison has access UK's Future Aircraft Carriers. BAE Systems chose Unison to detailed information to provide because of the company's remote maintenance advice. More information on Unison at: reputation – it pioneered the all- The Astute programme is the www.unisonltd.com, electric concept and has produced most demanding engineering tel: +44( 0) 1723 582868; email, machines for some of the world's project currently under way in the enquiries@unisonltd.com. Superior supply deal with Rautaruukki S uperior Technologies and downtime. Europe (ST-Europe) has There has also been signed a purchase component development with agreement with Hämeenlinna to improve induction Rautaruukki Corporation for the coil/impedor life when welding supply of specialised HF welding pre-galvanized products. consumables for its tube ST-Europe offers a wide range manufacturing plants. of HF welding consumables The objective was to establish including induction coils, an efficient delivery service with through/return flow impedors, formal guidelines to cover long ferrite rods, impedor casings, term and day-to-day orders for impedor support systems and Rautaruukki’s four tube maintenance products for HF manufacturing plants in Finland welding machines. and Sweden. ST-Europe has already staged technical workshops with More information on Superior Rautaruukki plants at Lappohja Technologies Europe at: and Virsbo focusing on improving www.st-europe.co.uk, operator awareness about weld tel: +44 1344 868860, area set-up and component email: sales@st-europe.co.uk, selection in a bid to reduce costs fax: +44 1344 426626. Plymouth sells stock on site Plymouth Tube Company has the 2008 SAE Motorsports been developing new services on Engineering Conference based on its website, plymouth.com. the paper entitled Terminology and The section of the site offering Manufacturing Methods of stock has been updated to show MIL/AMS-T-6736B Frame Tubing. stocks of prime 4130 material at Co-presenting the paper were significant savings, including Curt McDowell, general manager round, square and streamline 4130 of the Streator Mill, and ProMoly tubing produced to Mil-T 6736B technical expert Mike Danko. cond N. Plymouth recommends The SAE Motorsports Engineering checking the site frequently for Conference offers a technical other inventory listings. programme for working engineers Also new on plymouth.com is and engineering managers in the the Technical Tubecast section. motorsports industry. Here you will find videos of technical presentations covering More information on Plymouth all aspects of the company. Tube Company at: The expertise displayed on www.plymouth.com. plymouth.com is also in demand in More information on Plymouth the real world. Plymouth Tube Tube Company’s ProMoly team Company’s ProMoly team were via email at: invited to make a presentation at promoly@plymouth.com. www.internationalmetaltube.com IMT December/January 2009 5 W AddisonMckee has received an ‘Excellence in Action’ award in recognition of its outstanding business performance from Infor, one of the largest business Nine winners were selected from more than 60 nominations, with the awards being presented in five categories. AddisonMcKee was a winner in the ‘Innovation Award’ category. Christian Rogiers, AddisonMckee vice president of global marketing, says: “It is a tremendous honour to be recognized for a 2008 Infor award, especially as this particular achievement underpins the considerable focus we are currently placing on the development of lean manufacturing initiatives. “In 2007 AddisonMckee invested $250,000 in a lean manufacturing programme to improve performance, enhance manufacturing efficiency, and reduce lead times by 50%. The lean programme quickly brought the manufacturing lead-time of several processes down to 54% of 2006 baseline data, including: 100% increase in saw operations, 111% increase in bend tool throughput, 71% increase in segmented tooling throughput and 51% reduction in lead time.” Further afield, AddisonMckee, attracted considerable interest in its product range at the MTA Vietnam 2008 exhibition held in Ho Chi Minh City. The company presented a wide range of its tube manipulation technology, with a particular focus on models created for the automotive sector. Christian Rogiers says: “It was a pleasure to be able to showcase the innovations that make AddisonMckee the preferred name for tube bending and end-forming across numerous industries globally.” Roger Dutton, general manager, AddisonMckee-China, adds: “As a result of the rapid growth of the automotive industry across the Asian economies, many visitors to our booth were naturally interested in our CNC tube benders such as the all-electric DataBend DB75, a model heralded for its repeatability, reliability, accuracy and control.” More information on AddisonMckee at: www.addisonmckee.com, tel: +1 513 228 7076, e-mail: crogiers@addisonmckee.com, fax: +1 513 228 7226. Zumbach sensors as tough as steel Two profile measuring systems October/November). The systems comprehensive range of non- from Zumbach Electronics of are designed for use in harsh contact, on-line measuring and Switzerland have been environments in the steel and control instruments for commissioned at Wuppermann metals industry. dimensional parameters including Metalltechnik in Altmünster and As a pioneer of on-line diameter, thickness, eccentricity, Wuppermann Austria in measurement, Zumbach out-of-round and for physical or Judenburg (IMT Electronics manufactures a electrical parameters such as expansion, capacitance and dielectric strength. Multiple parameters of a production line can be monitored simultaneously. The measuring units are equipped with four CCD camera/laser modules; all the products are measured on-line, directly in the manufacturing process (cold measurement). The systems are an important step to guarantee a high quality standard for manufactured profiles. Wuppermann plans to buy a third system for a new production line to be commissioned in 2009. More information from Zumbach Electronics at: www.zumbach.com, tel: +41 (0)32 356 0400, email: sales@zumbach.ch, fax: +41 (0)32 356 0430. Royal visit for Swagelock H RH the Duke of York what you do and the markets in has visited Swagelok’s which you deploy your product.” site at Tromode on the Thomas Freund, Swagelok Isle of Man to mark the Company European director of opening of a state-of-the-art operations, said: “We are privileged 880m2 warehouse. to have the opportunity to host HRH The duke, who is the UK’s at our expanded premises. We special representative for work closely with the Department international trade and of Trade and Industry and other investment, unveiled a plaque to government departments to ensure commemorate the expansion, the continued growth of which will help the company meet manufacturing, which is the Isle of increased demand. Man’s second biggest sector. The Swagelok is the Isle of Man growth of our presence here is key operation of Swagelok Company, to ensuring Swagelok’s continued the Ohio, USA-based provider of success as an industry leader in fluid system technologies. Its fluid system technology and output helps to complete the that require quick turn-around on the sense that it has high services.” company’s line-up of piping and high added value and specialised technology, its employees have a regulator products for the oil, gas products. high level of skill and it is globally More information on Swagelock and petrochemical industries. It The Duke of York said: focused. It is a great pleasure to Company at: www.swagelok.com. also serves local niche markets “Swagelok is a classic business in come here and learn more about Koerner’s clean pickling plants Pickling tanks produced by Koerner under the KVK brand are exported to over 40 countries and are in use on every continent. With more than 25 years’ experience in this sector, Koerner began 10 years ago with the planning and erection of complete metal pickling plants for the hot-dip galvanizing sector and for other branches of industry such as pipe and tube plants. Koerner's engineers set new standards with the development of the KVK pickling system, a fully encapsulated pickling plant. This delivers an efficient pickling operation with optimum utilisation of the bath temperatures – and it meets all environmental requirements. Two plants of this type were built by Koerner in the Middle East in 2008 after the El Sewedy Group ordered them for their steel industries in Cairo and Jeddah. The buying decision was based on the fact that eight years ago Koerner built a similar galvanizing plant in Cairo which has operated with no problems ever since with no significant maintenance. Both of the new plants are able to galvanize parts up to 16 metres and they are reinforcing the principles of the KVK-system: • No fumes escaping from the encapsulated pickling area • Waste water-free operation • Fully automatic material handling With this type of pickling technology Koerner is helping to convert galvanizing facilities in clean industries with no emissions of toxic fumes or acidic waste water. More information on Koerner KVK at: www.kvk-koerner.at, tel: +43 3465 2513, e-mail: office@koerner.at, fax: +43 3465 2118. Groovy way to keep your cool www.internationalmetaltube.com As Iran's leading producer of seamless copper tube, Qaem Copper Industries supplies most of the air conditioning and refrigeration companies in the Middle East with tubing. Its products meet ASTM B280, EN1057 and other applicable tubing standards, helped by quality management to ISO 9001-2000. Among Qaem’s specialised offerings is inner grooved copper tube. Spiral grooves on the inner are typically up to three times those of comparable size plain tubing. This has been known to improve the thermal efficiency of some fin block heat exchangers by more than 30%. More information on Qaem Copper Industries at: www.qaemcopper.com, tel: +98 311 2222944, email: info@qaemcopper.com, fax: + 98 311 2220955. Las Vegas Fabtech 2008 was bigger and better than ever F abtech, the largest metal forming, fabricating and welding show in the USA, moved to Las Vegas this year – and maybe the new venue contributed to its runaway success because with 21,700 visitors, attendance was up 13% on the previous Fabtech at Atlanta. As well as the bright lights of Las Vegas, visitors were attracted by no less than 1,100 exhibitors, including 125 tube specialists. No less than 56% of those visitors were attending Fabtech for the first time, and the market’s global nature was reflected in the high proportion of overseas visitors; they comprised 16% of the total. The full title of the event is the Fabtech International & AWS Welding and Metalform Show, and this was reflected in the wide range of exhibitors. However, 32% of visitors indicated they were interested in tube/pipe fabricating large geographically, it becomes accomplished our goal of and/or welding, and17% were difficult to attract attendees from attracting attendees from the interested in tube/pipe producing. the West Coast or the South-East West Coast. They must have been pleased to to our typical Chicago location. "The tube and pipe industry is find that the Tube & Pipe Pavilion Factors such as time away from extremely important to Fabtech and offered 15% more exhibitors than the shop and cost of travel become represents the only Tube & Pipe the 2006 event. barriers to potential attendees. Yet exposition in North America. With Mark Hoper of the organising both of these regions are extremely the Las Vegas location, we were team says: "Las Vegas was a important manufacturing hubs able to deliver a whole in audience fantastic venue for the latest within the United States. to Fabtech exhibitors – 56% of the Fabtech, AWS Welding & “With that, we identified three attendees to Fabtech '08 in Vegas Metalform Show. Our reason for major manufacturing hubs within were first-time attendees.” adding Las Vegas, to the now the US – The Mid West, The The next Fabtech shows will be three-city rotation, was simple: to South-East, and The West Coast. held in Chicago, on 15-18 attract a new audience to event The Fabtech, AWS Welding & November 2009; and in Atlanta, on exhibitors, and make the show Metalform Show now has events 2-4 November 2010. more accessible to manufacturers scheduled in each of these More information of Fabtech at: on the West Coast. The US is quite regions. Las Vegas clearly www.fmafabtech.com IMT was out and about at the Fabtech show; here’s a selection of the exhibits that caught our eye… Adaptable magnets Walker Magnetics has more than 100 years’ experience in steel han­dling. At Fabtech it was promoting its range of lifting magnets and mag­net systems that are used for everything from loading and unloading cutting tables to handling steel parts and plates or bundles of structural steel products. More information on Walker Magnetics at: www.walkermagnetic.com Bending advice Pines Technology was at Fabtech to promote its comprehensive range of pipe-bending machines; it was also distributing the first issue of its newsletter which includes handy guides to choosing between hydraulic and electric benders and changing hydraulic oil. If you have a technical query in this area Pines might well be able to help – email asktheexpert@pinestech.com. More information on Pines Technology at: www.pinestechnology.com Hubtex sideloader Hotbox was majoring on its 2120 Series, a compact multidirectional sideloader, which offers capacities from 1,500-3,000kg. It is said to be ideal for the handling of long loads and pallets in confined areas, needing only 100mm of side clearance. All major driving and hydraulic functions are controlled via a single joystick. More information on Hubtex at: www.hubtex.com Smooth gripper Team Industries is well known for its pipe welding positioners and grippers. It was launching the WEHVHL 3000 Generation IV positioner which boasts smooth, hydraulically actuated height positioning and a self-levelling option to allow quick height adjustment while maintaining a selected angle on the gripper face. Options include wireless foot control, the ‘Thru Hole’ purge system and a 26in fan for enhanced operator safety and comfort. More information on Team Industries at: www.weldpositioner.com AddisonMckee unveils flexible Maestro Strong Hand’s tough table Strong Hand Tools, worldwide designer/manufacturer of quick-acting welding clamps and tables, magnets and pliers used Fabtech to launch the BuildPro series of welding tables. BuildPro tables are economically priced and designed to be modular, and easy to use. They are constructed of hardened steel plates with 5/8in holes in a 2in grid pattern. Each plate can be removed and reconfigured to extend the width of the tabletop to accommodate specific projects, both large and small. The BuildPro is the only inch-based table in the marketplace; Strong Hand can supply a wide variety of tools including sliding arm clamps, pliers, magnet squares and vices. The 1 3/4in spaces between the plates makes it easy to place clamps at any point on the tabletop, along the sides, at the ends, or in the center – wherever clamping is needed. And the BuildPro Table’s heavy-duty four-beam support base can support loads up to two tons. More information on BuildPro at: www.stronghandtools.com, email: pam@stronghandtools.com, tel: 800 989 5244, fax: 562 949 4875. A ddisonMckee used Fabtech to launch the Maestro controller which is claimed to be the most flexible bending machine control system on the market. Maestro is an optional text-based HMI targeted at the North American market. The existing icon-based HMI will remain a global option. Developed using feedback from AddisonMckee's global customer base, Maestro offers a user-friendly design, thanks primarily to its intuitive user interface, with enhanced diagnostic control for real-time troubleshooting. AddisonMckee President-Americas, Jim Sabine, says: "With the launch of Maestro, customers around the world will have increased options in front-end user interfaces via a new text-based HMI to complement our existing icon-based HMI. Additionally, the Maestro front end will be interfaced with our new Mk VI control system on all new AddisonMckee CNC tube bending machines beginning in early 2009. “The Mark series digital control platform is a proven and globally standardised system, designed to provide maximum bender utilisation and up-time due to its user-friendly diagnostic capabilities and ease of use." Maestro benefits from AddisonMckee's global support capabilities, including the ready availability of maintenance technicians and non-proprietary spare parts. More information on AddisonMckee at: www.addisonmckee.com, email: crogiers@addisonmckee.com, tel: +1 513 228 7076, fax: +1 513 228 7226. Pipeliner is based on experience M agnatech introduced a new, all digital Pipeliner at the AWS/Fabtech Show. It was developed based on many years of field experience with the original Pipeliner II. The Pipeliner II is the only Flux Core Arc Welding Process (FCAW) system to gain wide acceptance by pipeline contractors. Unlike the many systems on the market using the solid wire Gas Metal Arc Welding (GMAW) process, the Pipeliner II has repeatedly demonstrated that it can meet API 1104, as well as ASME and DNV standards. Contractors in Europe, Saudi Arabia, Qatar, Oman, Thailand and the United Arab Emirates have used the system for critical gas, oil and water pipeline jobs with the higher strength steels such as X-70, X-80 and above. Previous models used a floor-mounted push-only feeder, or mounted a smaller wire feeder and spool directly onto the weld head. The new model utilises a push-pull feeder for positive electrode delivery, while allowing use of standard 15kg wire spools. The FCAW process allows heavier wall pipe to be welded than is possible with mechanised system using GMAW as it doesn’t require a special narrow gap joint geometry. The weld head is adaptable to pipes measuring 6-60in. The digital model allows programming by position (degrees of rotation). A hand-held control pendant allows the operator to make changes to all parameters during welding to meet field fit-up conditions. Supervising managers can password-limit changes to each function and limit the total size of any change (for example a change in weave width could be allowed, but only to a maximum of +/-10%). The new system is sealed to IP23 standard for waterproof and dust proof operation on the pipeline right-of-way. This system is suitable for use on pressure and process piping as well as structural projects. More information on Magnatech at: www.magnatech-lp.com, tel: (860) 653-2573, email: info@magnatech-lp.com, fax: (860) 653-0486 Motoman robots on parade Possibly the most exciting innovation from Motoman at Fabtech was the dual-arm SDA10 robot which is slimmer and stronger than its DIA10 predecessor with significantly faster acceleration. With a shorter link distance between the P-point and flange, the SDA10 provides more flexible tool motion and a higher load carrying capacity. Its shoulder width is 30% narrower and its arms are set forward to maximize work envelope. This unique design makes the SDA10 robot ideally suited for a wide variety of assembly, part transfer, machine tending, packaging and other handling tasks that formerly could only be done by people. The revolutionary SDA10 features 15 axes of motion (seven axes per arm, plus a The SDA10’s actuator-based design means that the motor, encoder, reducer and brake for each robot axis are combined in one small, lightweight yet powerful package that is significantly smaller than a traditional AC servomotor drive. The SDA10 also features a 10kg payload per arm, a 1,970mm horizontal reach and 1,440mm vertical reach per arm, with a repeatability of +/-0.1mm. The two robot arms can work together on one task to double the payload or handle heavy, unwieldy parts, trays or pallets, or they can perform independent operations at the same time. A Motoman dual-arm robot can hold a part with one arm while performing operations on the part with the other arm, and can also transfer a part from one of its arms to the other. The ability to use dual independent arms to process parts makes end-of-arm tooling simple and less costly. Also in Motoman’s robotic The SDA 10’S two robot arms can work together on one task improved cycle times. The SIA20 robot features a 20kg, payload, 1,498mm vertical reach, 910mm horizontal reach and a repeatability of +/-0.1mm. It can straighten vertically to take up The SIA20’s footprint is 16% smaller than the previous IA20 only one square foot of floorspace and is just 330mm wide. Short axis lengths and extreme motion flexibility allow this slim manipulator to be positioned out of the normal working area – on the floor, ceiling, wall, an incline or on a machine without limiting the motion range of any axis. The SIA20 and SDA10 robots are both controlled by the Motoman NX100 robot programming pendant, which was also being promoted at Fabtech. Using graphics, rather than text, and a touch screen interface, an EasyLoad software wizard guides even non-programmers with minimal knowledge of robot operation through simple step-by­step procedures to create complete, custom robot programs for the desired machine tending process. Show visitors were also able to check out Weld Cell Wizard: a web-based tool that analyses capital equipment needs to help manufacturers select the best pre-engineered Motoman ArcWorld or FabWorld robotic welding system to meet their needs. It then lists them in the most cost-effective order. Weld Cell Wizard also analyses the number of workcells needed and the productivity effect of using multiple workcells. Use of Weld Cell Wizard on Motoman’s web site is free, but registration is required (at www.motoman.com/products/wor lds/configurator/). Manufacturers simply input basic information about their part sizes, payloads, part orientation/positioning needs, total number, length and size of welds with the required annual volume, and Weld Cell Wizard does the rest. More information on Motoman at: www.motoman.com, tel: 937 847 6200. Grace under pressure AWS Schaefer manufactures machines which produce bi-metallic clad pipes which in turn address the toughest jobs in the toughest environments, from oil pipelines to nuclear reactors. It’s easy – when you know how to control closing pressures of up to100,000 tons… I n an environment where an increasing number of pipelines have to be capable of withstanding the corrosive substances contained within crude oil and gas, the traditional stainless-steel and nickel alloys best able to resist corrosion result in a combination of high costs with relatively low strengths. To resist the inherent high dynamic loads placed on such pipe lines calls for very heavy walled pipe – but there is an alternative. AWS Schaefer has developed machinery to produce bi-metallic clad pipe, combining a corrosion resistant alloy (CRA) lining of approximately 3mm thick with an outside pipe made of conventional high-tensile ferrite steels to absorb the loads exerted on pipelines. The pipe calibration and lining machines are known as High-pressure Forming Centres (HFCs) and for the past 15 years the bi-metallic pipes they produce has been proving themselves in some of toughest environments in the world, resulting in a significant cost saving for end-users. HFCs are manufactured in a range of sizes to produce pipes from 2,000-13,000m in length, with diameters from 12-914mm and wall thickness from 1.5-38mm. They use tool locking pressures from 2,500-100,000 tons to produce 4-120 pipes per hour, depending on their length and diameter. The tool comprises an upper and a lower form; the lower form is moved on a sliding table to a loading position where the carbon-steel pipe to be calibrated, with the CRA pipe loosely installed, is placed in position in the lower form with a loading device. The sliding table then returns to the calibration position. The upper form of the tool is lowered by means of hydraulic cylinders to enclose the pipe. The closing force exerted by these cylinders must be sufficient to close the tool, taking into account deflections created during the long seam welding operation (the ‘banana effect’). The C-clamps then close over the complete tool length and both ends of the pipe are sealed by axial cylinders equipped with extension shafts and sealing heads. The two tool halves are then interlocked to withstand the huge hydraulic forces generated during the manufacturing process. This also ensures that no fluid can find its way between the CRA lining and the outer pipe. The pipe is filled from a reservoir and flushed with a water-emulsion mixture until all air has been removed. The axial force exerted on both pipe ends is increased by the HFC’s control programmed in proportion to the cross-sectional area of the pipe and the internal pressure, ensuring that the system remains sealed while the pipe circumference expands. As the internal fluid pressure increases the CRA pipe is expanded in a plastic deformation mode until it makes contact with the outer carbon steel. The internal pressure is then further increased until the carbon steel is expanded in an elastic mode and makes contact with the inner surface contour of the tool. The pressure is then increased to the calculated calibration value and held for a predetermined time. The internal pressure is then reduced and the axial cylinders are retracted. The calibrated pipe is almost completely emptied of fluid, the HFC’s water being collected and pumped back to the machines filter system before returning to the reservoir tank. At this stage the tool locking system is opened, the upper tool form is hydraulically raised and the sliding table, with the lower tool form, travels back to the loading/unloading position, ready for the calibrated pipe to be unloaded. The difference in behaviours of the elastically deformed outer pipe and plastically deformed inner pipe results in the desired compressive contact stress between both pipes. This provides a homogenous high contact level with enhanced anti­corrosion properties. Another advantage of this closed outer tool production process is that it ensures exact control of each pipe’s diameter, roundness and straightness. The utilisation of this process can result in dramatic reductions of project budgets when compared with the utilisation of full-thickness CRA pipes or other traditional methods of providing a bi-metallic pipe. More on AWS Schaefer at: www.aws-stg.de, tel: +49-(0)2739 8700 300, email: info@aws-schaefer.de, fax: +49-(0)2739 8700 310. Entry level launch by Rautomead C ontinuous casting technology specialist Rautomead, of Dundee, Scotland, has developed an entry-level RSCC copper rod casting machine that features the company’s proprietary casting technology at a competitive price. The new model has been designed for the production of CuOF and CuAg wire rod. It is available in two configurations: as a 4-strand machine for 8mm-diameter rod for high quality wire drawing applications; or as a 3-strand machine for 12­22mm diameter to make feedstock for Continuous Extrusion Technology. Output capacity is 3,600 tonnes per year; the newcomer features many of the technical features of the larger Rautomead RS wire rod casting machines and benefits from over 30 years of graphite technology continuous casting experience. These features include: * Graphite crucible technology to ensure low oxygen content (<5ppm) copper rod; * Electric resistance heating which is simple to maintain; * The ability to empty liquid metal from the furnace in the event of a power cut; * An automatic safety feature that lifts coolers out of the melt when the power is cut; * Automated coil formation of the point into production of the highest using drawings and information cast rod; quality oxygen-free copper. provided by Rautomead. * Automatic recording of the key To minimise customer operating parameters investment the RSCC model has More information about The RSCC model is designed been designed to give users the Rautomead at: for production of best quality option to arrange local www.rautomead.com, feedstock rod for the continuous manufacture and supply of tel: + 44 1382 622341, extrusion process. It provides selected component parts of the email: sales@rautomead.com, customers with a unique entry continuous casting equipment, fax: + 44 1382 622941. Fine work from Alpha The Alpha Air Classifier from machine can be gravity fed from minimal maintenance with low LLC, following its recent Sweco is ideally suited to the the top or in the main air stream specific energy consumption and acquisition of Ecutec SL based in production of fine materials such from below. It can be customised options to meet a wide variety of Barcelona, Spain. as mineral and chemical dry with stainless steel, ceramic or air classification needs. It is powders. polyurethane for wear protection designed to fit into narrow and More information on Sweco at: Sizes from 150 down to six and material requirements. awkward spaces. www.sweco.com, microns can be achieved; the The Alpha is said to require Sweco is a business unit of M-I tel: 1 859 371 4360. www.internationalmetaltube.com IMT December/January 2009 13 At home indoors and outdoors P rotem’s heavy-duty electric BB bevelling bench is equally at home on site or in the workshop. The BB will bevel, face and counterbore heavy-wall pipes individually or simultaneously. It can perform repeatable high quality weld preps on most metal pipes, including stainless, duplex and super duplex with an outside diameter from 3-16in (88.9-406mm). One-man operation is routine with the optional profile tracking device; the BB can machine oval pipes, leaving a root face of a consistent width to suit orbital welding heads. contact with the outside surface of the pipe to be machined by means of mechanical prismatic clamping. They automatically centre the pipe on the machine, but the jaws are not designed to bear the whole weight of the pipe. Additional jaws can be supplied for specialist jobs. Protem offers a choice of two electric drives to suit the machining requirements of the whole range of pipes covered by the BB 3-16. Version 1 is equipped with a 9.2kW asynchronous motor suitable for pipe wall thickness up to 19.2mm; versions 2 and 3 have a 22kW The BB 3-16 is delivered with one sliding door incorporating a window and safety sensors. The clamping jaws at the heart of the system are designed to be as rigid as possible to minimise vibrations and flexing which might otherwise reduce the machined bevel’s geometry and concentricity. The clamping jaws have a number of internal and external elements to maintain a firm asynchronous motor to handle wall thicknesses up to 25.4mm. Cutting speed is 100m/min. Feed is manual – the spindle is fed forward using the hand-wheel. To increase the life of the inserts and to reduce the noise level during machining Protem recommends a lubrication system integrated to a chip conveyor. A pump sprays an oil/water mix during the cut; a tank replaces the standard chips box. This option is activated by a push button When using fixed-height tube conveyors the machine can be equipped with a system of electrically powered cylinders, allowing its axis to be set at the height of the tube axis which rests on the conveyor. The frame is equipped with four screw-cylinders which can precisely set the height of the machining unit depending on the diameter to be machined. The cylinders are mechanically linked and again, this option is activated via a push button A semi-automatic clamping option allows the torque of the jaws to be adjusted from 20­170KN. This function is controlled by a rotating knob; the torque is shown on a display screen. An electrically powered semi­automatic feed system includes two sensors on the machine frame to detect the end of the feed stroke (this option is not available on version 1). An electric control panel is fitted, in line with EC rules, but automation inputs and outputs are provided for communication with a master automation system. Also new from Protem is the HPP 75kW hydraulic power pack. It’s designed to handle tough working conditions, with an outer damage to external components such as the manometer, colmation indicator, manifold distributor and hoses. The oil container is located on the top and supplies the booster pump which is coupled to the casing that minimises noise emission as well as protecting the internal components. This casing incorporates two handling bars to facilitate lifting operations and secure the unit during shipment. In adition four crane hooks are fitted. A 400-litre retention tank allows draining via bottom discharge in line with European safety rules. The power pack is designed to allow easy access to internal components for maintenance while minimising the risk of variable capacity pump. It is provided with a valve secured with a protective cap for pump maintenance without risk of leaks. Panels offer easy access to the booster pump and, on the other side, to the electric motor (which is mounted on silentblocs to avoid vibrations). Both panels are secured to the framework with CHC screws. An additional detachable panel on top of the unit allows access to the oil/air heat exchanger, fan, heating resistance and metallic oil filter. The oil tank on top of the Powerpack has three removable panels (right, left and top) to facilitate cleaning and oil changes. Hydraulic power packs such as the 75kW HPP will be put to good use with Protem’s new HSB range, including: US 150 HSB for 6-14in pipes; US 220 HSB (12-22in); US 420 HSB (22­30in); US 620 HSB (30-38in); and US 820 HSB (38-48in). The HSB machines are designed to be used in the field for the erection maintenance of pipelines. More information about Protem at: www.protem.fr, tel: + 33 (0)4 7557 4141, fax: + 33 (0)4 7557 4149 Master of all trades M azak Laser reckons its new Space Gear laser cutting machine offers the best of both worlds. It is able to cut flat sheet and plate at high speed and with great accuracy but also handles three-dimensional formed shapes and six-axis rotary fabrication of pipe, tube and structural steel. The Space Gear 48 can accommodate sheet material up to 2,500x1,250mm, while the larger Space Gear 510 can process 3,050x 1,525mm sheets. Axis travels are 2,785x1,270mm and 3,345x1,545mm in X and Y respectively. The Z axis for both machines is a generous 420mm with linear rapid traverse rates of 24m/min. Integrated into the Space Gear's base casting, a new-generation laser resonator provides a constant-beam-length delivery system for enhanced cutting performance. Power levels of the CO2 laser range from 1.5-4kW and the hybrid design of the Space Gear, with the table moving through a fixed portal, means there are fewer mirrors in the beam path, which provides a more stable laser beam with better cutting performance. A Space Gear machine with a 2.5kW resonator is said to have almost the same cutting capability as a 4kW flying optic laser machine. This reduces the capital investment required and cuts running costs by around 25%. Area sales manager Tim Aldous says: "The double-column design of the Space Gear allows excellent access to the work table for the loading of fresh raw material and the removal of finished parts. And small volumes of varying thicknesses can be processed The Mazak Laser Space Gear MkII is said to match the efficiently thanks to the machine’s ability to cut such a wide variety of material types and shapes." The compact two-axis head has a 7.5in focus lens capable of cutting any material and thickness, and also features a continuous rotation A axis and a +/-135° B axis for cutting complex profiles in hollow section material and bevels on plate material. Designed to access tight corners and joints, the head is equipped with a non-contact three-dimensional profile sensor to keep a constant distance between the nozzle and the workpiece. A low-power semi­conductor laser fitted to the cutting head can be used to indicate with a red spot the programmed cutting path for 2D and 3D part profile verification. Available as an optional extra, the sixth (C) axis is provided by a rotary workholding unit mounted on the Space Gear’s worktable. With this unit fitted pipe processing becomes simplified by means of the cylindrical interpolation function, which controls all six axes simultaneously and requires just benefit of being able to cut in up to six axes three program code lines. The four-jaw manual scroll chuck fitted to the rotary unit has a through-hole capacity of 160mm and can accept workpieces from 20-285mm diameter and weighing up to 65kg. The Space Gear MkII is equipped with the Mazatrol 64­bit CNC system; optimum speeds and power levels are automatically calculated to achieve high-speed cutting at up to 15m/min without any loss of the machine’s +/-0.001mm positioning accuracy. The precision cutting of 10mm diameter holes at a feed rate of 6m/min illustrates how well the Space Gear works, say Tim Aldous: "With the laser programmed to interpolate a series of perfect circles we can measure the performance of the actual cut against the programmed data. We achieved a deviation of less than 50 microns per hole – more than three times better than any competing laser." More information on Yamazaki Mazak Optonics at: www.mazaklaser.co.uk, tel: +(44)1905 755755, fax: +(44)1905 755001. Busy on the global market Yamazaki Mazak Optonics Europe is a subsidiary of Yamazaki Mazak Optonics Corp, which in turn is part of the Yamazaki Mazak Group, a leading international manufacturer of machine tools, including laser cutting machinery. In some of the world’s most technologically advanced manufacturing plants, Mazak produces equipment with a reputation for consistent quality and reliability. The Yamazaki Mazak Optonics plant produces CO2 laser cutting machines, CO2 3D laser processing machines, sheet metal CAD/CAM systems and flexible manufacturing systems including laser processing machines. We keep our customers’ business on the move. You can succeed if you design your production processes to be fast and ef. cient. Cranes and materials handling components from Demag Cranes & Components are decisive factors on the road to success. With speed and ef. ciency, uncompromising quality and intensive monitoring, we optimise value chains, ensure you are able to deliver and offer solid investments and ef. ciency thanks to our seamless service. SUCCESS FACTORS BLM makes its mark at EuroBlech 2008 B LM Group used EuroBlech 2008, the sheet metal technology show in Hanover, Germany, as a launch pad for the BLM Adige LT 8 Lasertube. This addition to BLM’s range of tube laser cutting and profiling systems is a clean-sheet design featuring power options up to 3.5kW power with a 2D or 3D cutting head. The LT 8 can handle round tube from 12-220mm or square section up to 200mm; it is capable of the intricate profiling in most metals. Fully programmable, courtesy of the Siemens 840D Solution Line digital numerical control, the LT 8 has two separate raw tube loaders; one for tube bundles, the other, on the opposite side of the machine, for single bars. There is a range of discharge systems for finished part lengths up to 8.5m with a minimum scarp length of 100mm. Other recent additions to the BLM Adige Lasertube range include the LT Jumbo, which is designed to process mechanical or structural components ranging in diameter from 75-508 mm and lengths up to 18m. It measures 48x20m wide and can handle mild steel, high-strength steels, alloys and stainless steel. More information on BLM Group UK at: www.blmgroup.uk.com, tel: 01525 402 555, fax: 01525 402 312. Exact measurement from Novotechnik A range of heavy-duty rotary potentiometers from the German sensor manufacturer Novotechnik has been launched by Variohm Eurosensor. They offer precision angle measurement in extreme environmental conditions and are offered with a choice of IP67 or IP69K protection ratings. The IPX series is available in single or true redundancy output versions with a choice of 120°, 200° or 350° electrical ranges and with independent linearity to +/-0.1%. The compact range has a hermetically sealed housing in standard anodised aluminium or optional stainless steel with a 79mm diameter and a 35mm length. The design includes a double ball bearing shaft support with a variety of stainless steel shaft options as well as a mounting flange, lever arm and other drive accessories. Electrical connection for each sensor channel is via an M12 threaded connector for IP67­rated use or with sealed PG style cable glands for IP69K. The range is based on the proven Novotechnik conductive plastics element and multi-finger wiper technology that offers more than 100 million cycles of service life and a positional repeatability to within 0.002% of the electrical range. In addition, excellent shock (to 50g) and vibration (to 5g at 2kHz) is available as standard. More information on Variohm Eurosensor at: www.variohm.com, tel: +44(0) 1327 351004, fax: +44 (0) 1327 353564. An inspector calls T he ISRA Vision Group is the world's largest supplier of surface inspection systems – every one of the top 10 steel producers rely on its products. Among these is Parsytech 5i, a new generation of decision-supporting analysis tools developed to handle surface inspection data. It has impressed users as a simple and fast implementation of application and user-specific productivity solutions. And now ISRA Vision Parsytech has launched Parsytec 5i++, which is said to provide the answer to increased production requirements of the steel and metalworking industry. Claimed benefits include shorter response times, even with complex applications; increased flexibility in the design of the user interface; and the ability to access all applications directly from within a web browser. Managing board member Michael Trunkhardt says Parsytec 5i++ “combines the success from our over 80 successful installations with the advantages of a powerful state-of-the-art software platform that provides our customers with the greatest possible flexibility and highest efficiency." Also joining the ISRA Vision line-up is EPROMI (Enterprise PROduction Management Intelligence), an extensive software architecture that supports decisions based on objective suggestions via the Expert 5i modules. Hans Jürgen Christ, CEO of ISRA Vision Parsytech, says: "Making fast, calculated, economic decisions at every level of the company makes access to all relevant information and their analysis absolutely necessary. This is where EPROMI, provides help." The EPROMI architecture provides all the available production data (surface, thickness, width, flatness, etc.) in a compressed and uniform, structured form. Standardised interfaces provide order, resource and planning data as well as information about material logistics and personnel planning from the MES and ERP systems for the EXPERT5i modules. The EXPERT5i modules analyze and weigh this information according to specific questions and generate knowledge-based suggestions for the decision-makers. Mr Christ adds: "Large steel manufacturers in Asia and Europe have already decided in favour of this turnkey architecture with sustained success and implemented it to a large extent – a decision that will pay off." More informatio on ISRA Vision Group at: www.isravision.com, tel: +49 (241) 9696 600 email: info@isra-parsytec.com, fax: +49 (241) 9696 500. www.internationalmetaltube.com IMT December/January 2009 19 Smooth changeover at AddisonMckee J ohn Brown, chief executive officer of world-leading tube bending and end-forming technology specialists, AddisonMckee, has announced his phased retirement from 1 January 2009. Over the past 25 years Mr Brown has played a major role in developing AddisonMckee into a world-class, multi-million-dollar technology manufacturer that is active in numerous other sectors including automotive, aerospace and shipbuilding. He will remain in the group as president of European and Asian operations during an extended interim phase to ensuring a smooth transition and the completion of several strategic projects. Joe Eramo, currently president of AddisonMckee in North and South America, will take over as global CEO. Mr Brown says: “Joe Eramo has demonstrated his leadership abilities and success by guiding the North American division of AddisonMckee to six consecutive years of record sales revenue and been the recipient of two widely recognised lean manufacturing awards.” Joe Eramo says: “John Brown has been instrumental in the globalisation of AddisonMckee and I look forward to the challenge of continuing the execution of our plans for the benefit of our customers and our associates.” Roger Dutton has been appointed general manager of AddisonMckee-China. He has been working in the Chinese marketplace since 1992, leading various tube processing organisations within the People’s Republic of China. CEO John Brown says: “Mr. Dutton will undoubtedly fuel the next level of growth for AddisonMckee in the Asia-Pacific region. This new appointment further demonstrates AddisonMckee’s commitment to this vitally important market.” A native of New Zealand, a citizen of Australia and a resident of China, Mr Dutton has worked and studied in Germany, the USA and Hong Kong. He says: “China, as a springboard into the Asia-Pacific region, has many advantages as the region’s transport sector continues to expand. At AddisonMckee we have a rich history in the region and we are ready to extend our offering, and the support that goes with it. “ More information on AddisonMckee at: addisonmckee.com, tel: +1 513 228 7076, email: crogiers@addisonmckee.com, fax: +1 513 228 7226. Collins named a fellow ASM International has elected Sunniva R Collins PhD, senior research fellow at Swagelok Company, a Fellow of the Society. Collins was honoured for her contributions to the technical advances in stainless steels used in fluid systems applications. The honour of Fellow was established in 1969 by ASM International to provide recognition of members for their distinguished contributions to materials science and engineering, and to develop a broad forum of leaders to serve as advisors to the society. Members are chosen by their peers; Collins joins 18 other society members in this year’s class. “Sunniva’s technical expertise and leadership have been instrumental in helping Swagelok grow in innovative ways,” says Dave Peace, vice president, engineering. “In addition, her work has resulted in impressive contributions to the overall science of metallurgy, specifically stainless steels. We are proud to have Sunniva as part of the Swagelok team.” Collins joined Swagelok in 1995 as a research metallurgist and has served in several engineering management positions, most recently as technical director for Swagelok Technology Services Company. In her current position, as the company’s first senior research fellow, she co-ordinates the company’s academic and governmental research initiatives. More information on Swagelok at: www.swagelok.com. Rautomead chairman appoints MD Sir Michael Nairn, chairman of Scottish-based continuous casting technology specialist Rautomead, has appointed Brian Frame as the company’s new managing director. A founder of the business in 1978, Sir Michael will remain with the company as active chairman. He says: “I am delighted to welcome Brian Frame to Rautomead. He has a strong technical background with international experience and comes to Rautomead from Texol Technical Solution, where he has been managing director for the past eight years.” Rautomead specialises in the development of continuous casting equipment for the production of non-ferrous metals and the sale of equipment for that purpose; more than 300 Rautomead continuous casting installations are in service in 47 countries. More information on Rautomead at: Rautomead.co.uk, tel: + 44 1382 622341, fax: + 44 1382 622941. Sales moves at Formtek Formtek Metal Forming has appointed Steve Freedman as regional sales manager for the Formtek Group. He will service Formtek’s customers throughout Canada, taking responsibility for sales of all of metal forming and coil metal processing products. Jack Pennuto Jr is the new Formtek sales manager for Formtek Cleveland. He will be responsible for establishing selling strategies for the Yoder, Dahlstrom, & Tishken Forming and Fabricating Lines, B&K Metal Construction Products and the Winpro Fenestration. Juan Franch has been named regional sales manager; he will service Formtek customers throughout Mexico. More information on Formtek at: www.formtekgroup.com, email: info@formtekinc.com. Next generation from Roland F ollowing the success of its analogue UFD detector, Roland Electronic has launched its successor, the digital UFD40 system. The UFD40 is designed to detect faults, butt welds and mechanical connections in wires, cables and small tubing made of metallic materials such as steel, stainless steel, copper, brass and aluminum. It is based on the eddy current measurement principle. The material to be monitored passes through an encircling coil A unique feature of the UFD40 autonomously, allowing the sensor; these are available to is its modular design and disconnection of the host PC. suit material diameter’s from multiple operating modes. All the Alternatively, parallel or 1-90mm. electronic circuitry for two fieldbus interfaces are available The UFD40 has features independent measuring channels for communicating with the typically available in classic is housed in a single IP 65 production equipment PLC. eddy-current fault detection module enclosure. systems designed for automated Each channel executes the production processes. These measurement functions include adjustable frequencies completely automatically. The More information on Roland and high- and low-pass filters, RS232 interface provides the Electronic at: as well as y-component and connection to the host PC which www.roland-electronic.com, vector analysis. This makes the serves as operating interface for tel: +49 (0)7236 93920, system able to monitor many the system and displays all email: info@roland­ different discontinuities with one measurement values. Each electronic.com, type of hardware. measuring channel functions fax: +49 (0)7236 939233. Applications: Production and processing all leads, wires, cables and small tubing. Technical data Enclosure: IP65 module housing Operation: Host PC Interface to PLC: Parallel I/O, Profibus DP, Profinet and other Fieldbus systems Interface to host PC: RS232 (Ethernet is under preparation) Sensor connection: Quick disconnect Range of material diameter: 1-90mm (0.039-3.54in) Material velocity: 0.01-10m/s (0.032-32.8ft/s) Power supply: 24V DC T he first step in making quality tube & pipe using ERW/HFI is a good weld. The process involves many variables, and measuring these variables is the first step towards controlling them. Xiris Automation’s Radian system is designed with this in mind; it promises to improve efficiency with yield targets of 25%. Xiris is nearing commercialisation of a non-contact, optical tube forming measurement system for the entry and exit of the weld box. Key process measurements the system will monitor include vee angle, mismatch, edge presentation, seam roll, bead height and bead width. The pre-weld measuring sensor is placed in between the last fin pass rollers and the induction coil while the post weld is placed before the scarfing tool. The sensor sends data to the controller for processing and analysis. This information is displayed on an operator viewing screen with active visuals and a HUD to alert the operator of potential problems. Standard IO is available to connect to the external w for signalling; the system is rounded out with a complete data management and reporting tool for meaningful SPC. Xiris vice-president Pierre Huot says: “It has by no means been an easy endeavour to clear the technical hurdles to meet the market needs; nevertheless we are quite excited about the value Xiris and this solution will bring to the industry”. More information on Xiris Automation at: www.xiris.com/tube, tel: 905-331-6660, email: phuot@xiris.com, fax: 905.331.6661. Two (2) – 500 Ton Drill Pipe and Casing Tube End Forming Machines PP-682-683 THE PUSH POINTER PEOPLE Since 1963 the George A. Mitchell Company has been producing state of the art Push Pointing equipment for the tube and rod drawing industry. Over the years, Mitchell has also been a leader in developing special cold forming processes and equipment for the production of various tubular parts, such as . . . ¦ VARIABLE WALL AXLE TUBES ¦ FUEL FILLER TUBES ¦ DRIVE SHAFT TUBES ¦ TRAILER AXLE TUBE END FORMING ¦ TURF AERATION TINES ¦ TUBULAR STABILIZER BARS ¦ BICYCLE FRAME & STEERING TUBES ¦ FOSSIL FUEL BOILER TUBES ¦ TUBULAR TIE RODS ¦ ALUMINUM BASEBALL BAT TUBES ¦ SHOCK ABSORBER RESERVOIR TUBES ¦ AUTOMOTIVE STEERING GEAR COMPONENTS ¦ TUBULAR INSTRUMENT PANEL BEAMS ¦ POWER STEERING ASSEMBLY CYLINDER TUBES ¦ DRILL PIPE AND CASING TUBES FOR OCTG PRODUCT George A. Mitchell Company – Youngstown, Ohio, USA e-mail: sales@mitchellmachinery.com www.mitchellmachinery.com www.internationalmetaltube.com IMT December/January 2009 23 Prevention is better than cure Tooling manufacturer Roll-Kraft has vast expertise in the field of tube, pipe and roll form mill maintenance; it has been sharing that hard-won knowledge with IMT. The overall message is clear: preventive maintenance will result in quicker change over, reduced downtime and scrap, longer tooling life and higher quality end product. L ubrication is the cornerstone of any mill maintenance programme. More than half of all bearing failures are lubrication related. It has been the experience of Roll-Kraft that tube, pipe and roll form mills should be greased according to a schedule based on service time, such as hours. Service time can easily be tracked with an hour meter. The guidelines listed below are not specific lubrication intervals applicable to all mills. Over the course of time, the schedule can be tailored to your specific needs based on such factors as mill configuration and operating environment. Mill components should be greased every 100 hours. Be sure all grease fittings are serviceable and the component or bearing is taking grease. Apply grease sparingly; more is not necessarily better. The following is a list of mill components that require lubrication (your particular mill might not be equipped with all the components listed; this list excludes AC and DC motors): Driven stand bearing blocks (inboard and outboard). Side pass rolls. Entry guide, seam guide, turkshead. Drive shaft universals joints (W style mills). Upper lead screws for top shaft adjustment. Coolant tank support rollers. Run out table rollers. Looper or floop accumulators (including pinch roll drive systems). Payoff reel bearings (greaseable style). Auxiliary equipment specific to your mill. Weld Rolls: Two-roll, ERW design welders should be lubricated every 100 hours. Three­, four-, or five-roll HF (high-frequency) design welders should be lubricated every 12 hours. Gearboxes • Check the oil level every 100 hours. • Check for oil leaks every 100 hours(repair any leaks, as needed). • Change the oil in gearboxes every 2,00hours. Driveline couplings • Grease every 2,500 hours. Electric motor bearings This includes AC and DC motors, coolant pump motors, rotary transformer bearings on ERW welders, fan motors, and hydraulic motors on auxiliary equipment. Bearings should be greased every 2,500 hours. Apply the grease sparingly, as over-greasing will force grease inside the motor housing which can cause internal electrical problems. With rotary transformers (ERW Welders) check the oil level every 100 hours and change the oil every 2,500 hours. MG sets Greaseable designs should be lubricated every 2,500 hours. For wet bearing cup designs, check the oil level every 100 hours; change the oil every 2,500 hours. Be careful not to over-grease either design, as excess grease will forced inside the motor housing which can cause internal electrical problems. Cut-off presses Every 100 hours grease the lube points on the ram swing arms, crankshaft bearings and sections of the accelerator system. Cut-off presses are often equipped with oil lube systems to lubricate the die and rail systems. Most oil lube systems include visual reservoirs for checking the oil level. Check the oil level every 100 hours, or as required, based on usage (some reservoirs might require refilling before 100 hours). Inspect all oil lines to ensure they are properly connected to their connection points, the connections are not leaking and oil is flowing through the line. Clean the oil reservoirs annually. Hydraulic accelerator systems • Check oil level every 100 hours. • Check for oil leaks every 100 hours. • Change oil and filters every 2,500 hours. Air line oilers Many pneumatic systems are equipped with airline oilers to lubricate the internal components of the system. Check the oil level every 100 hours, or as required based on usage. Check the operation of the oilers to ensure that the correct amount of oil is being delivered throughout the system. Central lubrication systems Due to the fact that weld rolls require more lubrication than the rest of the mill, a central lubrication system is ideal for ensuring proper lubrication of these rolls. A central system is completely separate from the main system. Advantages include reduced lubrication labour, lubrication usage and cleanup, as well as increased machine life and productivity. A timer, which is wired to the run circuit of the mill, lubricates the weld rolls during production, but not when the mill is idle. Central lube systems can also be used in the breakdown and fin sections of the mill. Preventive maintenance Many firms schedule a bi-annual or annual plant shutdown to perform basic inspections, repairs, and upgrades on their equipment. Tube, pipe and rollform mills are production oriented machines that require ongoing maintenance to ensure reliable and productive operation. When maintenance is only performed on an as-needed basis, the mechanical condition of the mill progressively declines, leading to poor product quality. Outlined below are guidelines for a preventive maintenance programme, based on industry best practice. They are not specific maintenance tasks applicable to all mills; for these contact the mill manufacturer. Plant shutdowns are ideal opportunities to clean the entire mill. A clean mill will make inspection and maintenance work much easier. Many plants use a pressure washer, connected to the coolant system to clean the mill. Such a setup does not add any water to the system and can be used for cleaning the mill at any time. Payoff reel • Inspect the bearings for roughness and excessive end play. • Inspect expansion arbors, linkage and hold-down arms. • Inspect turntable bearings and kingpin. • Inspect all lube points for broken or plugged grease fittings. • Inspect brake systems. • Inspect all powered components, hydraulic rams, expander, and hold-downs. • Check the alignment of the payoff reel with respect to the rest of the mill line. End Welding Equipment • Inspect the guide rolls for strip. • Inspect the surface condition of the guide rolls. • Inspect the guide roll bearings for roughness and excessive end play. • Inspect the hold-down clamps for strip. • Inspect the copper back-up plates and clamps (TIG weld machines). • Inspect the welding torch traverse system (rails, drive motor, belt, or lead screw). • Inspect all electrical cables and connections. • Inspect all air lines, hydraulic lines, and gas-shielding lines for leaks. • Inspect and clean the power supply; check for proper fan operation. • Inspect all lube points for broken or plugged grease fittings. Accumulator floop style An annual tune-up by the manufacturer should be an integral part of a preventive maintenance for the accumulator (vertical and horizontal designs). In addition, the following maintenance tasks should be performed every 2,500 hours: • Inspect all support and turnaround rollers (surface condition of the rollers). • Inspect the roller bearings for roughness and excessive end play. • Inspect all chain and gear drives. • Inspect all linkages, air lines, and hydraulic lines for leaks. • Inspect all pneumatic and hydraulic cylinders for leaks. • Inspect motors and pumps and the connection couplings (if a DC motor is used, perform the DC motor maintenance tasks outlined later in this document). • Inspect and clean the DC motor blower (if equipped). • Inspect all sensors and proximity switches. • Inspect all lube points for broken or plugged grease fittings. • Inspect all guarding. • Check alignment of the entry and exit end of the accumulator with respect to the entry end of the mill and the other auxiliary equipment. Accumulator loopier style • Inspect all support and turnaround rollers (surface condition of the rollers). • Inspect the roller bearings for roughness and excessive end play. • Inspect all support and turn-round rollers and drums in the unit. • Inspect the turn-round drums (crown must still be machined into the drums for proper tracking). • Check the alignment of turnaround drums within the framework of the accumulator. • Inspect the looper carriage cart, cables, cable winch, (motor and transmission) carriage rollers, bearings, track, and brake. • Inspect the framework of looper assembly for cracked or broken welds. • Inspect the pinch roll drive rollers for flatness. NB: If your mill is not equipped with a pinch roll drive, it is highly recommended that one be installed. Pulling the strip through the looper with the mill places a tremendous amount of additional stress on the tooling and the entire drive system. This can cause up to 50% more wear on the tooling and drive system components. • Inspect the motor and transmission (if a DC motor is used perform the DC motor maintenance tasks outlined later in this document). • Inspect the dancer arm and encoders that monitor the free loop of the strip before it enters the mill. • Inspect all lube points for broken or plugged grease fittings. • Inspect all guarding. • Inspect all sensors and E-stop limit switches. Entry guide • Inspect the guide rolls for wear (guide rolls should be replaced on a regular basis). • Inspect the guide roll shafts for wear. • Inspect the guide roll bearings for roughness and excessive end play. • Inspect the shaft mounting blocks for excessive play in the gibs. • Inspect the lead screws, side-to­side adjustment and height adjustment (if equipped). • Inspect surface smoothness of the horizontal lead-in roller. • Inspect the horizontal lead-in bearings for roughness and excessive end play. • Check the position of the entry guide; it should be mounted as close as mechanically possible to the first breakdown. Move the unit as required. • Check the integrity of the edge trim units (if equipped). • Check the position of the entry www.internationalmetaltube.com IMT December/January 2009 25 guide; it must be centred and at the correct height with respect to the entry end of the mill. • Inspect all lube points for broken or plugged grease fittings. • Inspect all guarding. Driven stands • Inspect OD of the driven shafts; allowable undersize wear is 0.001in per 1.000in OD of the shaft. • Inspect the bearings for roughness and excessive end play. NB: When replacing bearings, inspect the bore of the bearing block (for the outside race) and the bearing journal OD (for the inside bearing race). Always preload the bearing to the proper inch-pound rotational drag – do not preload bearings by feel. • Inspect the outboard tower bearings for roughness and excessive end play. • Inspect outboard tower bearing sleeves for excessive wear; allowable oversize wear is 0.001in per 1.000in ID of the original bore of the outboard sleeve. • Check the bearing block fit to the inboard and outboard towers. NB: If these bearing blocks do not have grease seals, it is recommended that seals be added. If seals are installed, a grease relief must be added to prevent the seals from blowing out when the bearing block is greased. The grease relief should be installed on the opposite side of the end caps from the grease fitting to ensure that the grease flows through both bearings. If the grease fitting is located in the centre of the bearing block move it to the end cap. • Verify that the top shaft is parallel to the bottom shaft. • Inspect the integrity of the top lead screw adjustment for the top shafts. • Inspect the jackscrews if the mills are equipped with Single Point Adjustment (SPA); if equipped with anti-back lash jackscrews the proper preload on the bearings must be maintained. • Inspect the driven shafts for straightness. • Verify the shoulder alignment: top shaft to bottom shaft and stand to stand. • Inspect all lube points for broken or plugged grease fittings. Side pass stands • Inspect the side pass shafts for wear and indentations from the bearings. • Check the fit of the side pass shafts to the shaft mounting blocks. • Inspect the shaft mounting blocks for excessive play in the gibs. • Inspect the lead screws and the side-to-side adjustment for looseness; eliminate any backlash. • Inspect the integrity of the foundation components, if the height is adjustable; be sure that the foundation can hold the side pass stand plumb and upright against the formation forces of the mill during normal mill operation. • Inspect the top tie bars (if equipped); all fasteners and lead screws must be in place. • Check the position of the metal line in the side pass stands; the metal line must be at the proper height and centred with respect to the driven passes per the tooling design and setup chart. • Check the position of the side rolls, if brass washers are used. NB: Consider switching from brass washers to thrust bearings on the side rolls. Thrust bearings allow the side rolls to rotate easier, reducing drag on the mill drive. Also, the thrust bearings eliminate the variable wear on the rolls and brass washers. • Inspect the framework of the side pass stands for coolant; be sure that the coolant can drain properly from the areas around the shaft mounting blocks. • Inspect all lube points for broken or plugged grease fittings. Seam guide (if applicable) Seam guide units have multiple designs. With design 1 two horizontal rolls set up in the same manner as a side pass stand for guiding the V-gap of the tube to the weld rolls. With design 2, two horizontal rolls set up in the same manner as a side pass stand with an insulated fin blade for guiding the V-gap of the tube to the weld rolls. With design 3 the insulated fin blade guides the V-gap of the tube to the weld rolls. Inspect design 1 like a side pass stand, as the configuration is similar. Inspect designs 2 and 3 in the same way as a side pass stand, as the configuration is similar, then inspect the insulation on the two halves of the fin blade guide (the fin blades must be completely insulated from the arbors on which the blades are mounted); inspect the finblades for wear; inspect the bearings on the assembly for roughness and excessive end play; and finally inspect the in-and-out adjustment for the finblades. Weld boxes—ERW type • If your ERW configuration has two bottom weld rolls follow the guidelines, as outlined for the side pass stands, for checking the integrity of the unit. • If your ERW configuration has live bottom shafts, inspect the bearings for roughness and excessive end play; be sure the bearings are properly preloaded and the seals are functional; check the shoulder alignment (the weld rolls must be parallel). • If your ERW configuration has only one bottom weld roll, inspect the shaft, bearings, and shoulder references for proper integrity. • Inspect all lube points for broken or plugged grease fittings. Weld Boxes - HF Type Many designs are used for HF (high-frequency) welding. These include two-roll units; flatplate, three-roll design; and three-roll, chuck design. Four- and five-roll units are often used on larger tube and pipe mills. For two-roll units, follow the guidelines as outlined for the ERW-type weld boxes. • Inspect the flat plate (separate clevises with separate adjustments), three-roll design as follows (these guidelines should also be followed for four- and five-roll weld boxes of this design): Inspect the slides, gibs, and lead screws if the back plate moves up and down, and side to side. Inspect each weld roll clevis for proper integrity (includes the slides, gibs, lead screws, and bored holes for the weld roll shafts). Inspect the weld roll shafts for proper OD and shoulder referencing for weld roll location. Inspect all lube points for broken or plugged grease fittings. • Inspect the three-roll, chuck design (weld rolls are usually individually adjustable) as follows: Most chuck-style weld boxes are mounted on a flat, intermediate plate; most move up and down, and some side to side – inspect the slides, gibs, and lead screws. Inspect the chuck; these units should have grease fittings to lubricate the internal scroll – disassemble the scroll and clean it, then inspect the scroll for excessive wear and end play. Inspect each lead screw in each of the three jaws of the chuck. Inspect each weld roll clevis for proper integrity (includes the slides, gibs, lead screws and bored holes for the weld roll shafts). Inspect the weld roll shafts for proper OD and shoulder referencing for weld roll location. Inspect all lube points for broken or plugged grease fittings. ERW rotary transformer • Inspect the bearings for roughness and excessive end play; be sure they are properly preloaded and lubricated. • Inspect the insulation between the two top copper electrodes. • Inspect the bolt hole threads for the top copper electrodes; replace any stripped-out threads or studs. • Inspect the slip rings and brushes. • Have a motor shop meg the rotary transformer to verify the integrity of the insulation (no current should be leaking to ground). • Inspect all electrical connections, including the connections of the heavy cables to the slip rings. • Inspect the motor, transmission and chain drive that rotates the transformer, allowing the copper electrodes to be trimmed. • Inspect the integrity of the trimming unit; a tight unit is a must for smooth trim cuts. • Inspect the oil coolant rotary couplings. • Inspect all hoses. • Inspect the pump, filters, and supply tank. MG Set • Have a motor shop meg the generator to verify the integrity of the insulation (no current should be leaking to ground). • Inspect the commentator and brushes, as well as all cables and connections. • Inspect the coupling between the AC motor and the gen-set. • Inspect the AC motor bearings for roughness and excessive end play. • Inspect the exciter generator; inspect the coupling (if equipped). • Service the exciter generator annually. • Inspect all lube points for broken or plugged grease fittings. High frequency (HF) welder components An annual tune-up by the manufacturer should be an integral part of a preventive maintenance programme for your welder. These welders require service from specially trained technicians and special test equipment is required. A tune-up will also allow the manufacturer to upgrade it to the latest changes. As part of your regular in-house maintenance programme, perform the following tasks every 2,500 hours: Check the distilled water level in the closed-loop cooling system; check the system for external and internal leaks. Check the water for contamination; determine the source of any contamination, correct the problem and recharge the system with clean distilled water. Inspect the heat exchanger for leaks. Inspect the temperature gauges and throttle valves for proper operation. Inspect the pump and motor. Lube the pump motor and pump (if it does not have sealed bearings) annually. Inspect buss bar arms; check the insulation between arms. Inspect the induction coil clamps and clamp fasteners. Scarf stands Two basic scarf stand designs are used: one-piece rotary design and single- and two-knife design. With a rotary design inspect the round cutting tool saddle, as well as the hold-down clamps. Inspect the limit or proximity switches used for rotation change of the unit. Inspect the motor and gearbox; lubricate the motor and gearbox annually. Inspect all lube points for broken or plugged grease fittings. Inspect the bearings or slip fit of the rotary unit to the fixed base; lubricate as required. With single- and two-knife design inspect the gibs and slides that incorporate the up-and-down feature of the stand; these areas must be tight to ensure steady, smooth cuts. Inspect the air cylinders (if equipped) for wear and air leaks. Check the cylinder air-line oilers for proper operation and adjustment. Inspect the air cylinder-to-knife mount slide linkage; some units use cams for this purpose; if equipped with cams, check the integrity of the cams. Inspect scarf knife hold-down clamps and fasteners. Inspect all lube points for broken or plugged grease fittings. Inspect the support rolls, bearings, shafts, and lead screw adjustments. OD bead winding equipment (where applicable) • Inspect the motor and gearbox; lube annually if the units are greaseable. • Inspect the fingers on the back plate. • Inspect the bearing for roughness and excessive end play. • Inspect the slip clutch. • Inspect all lube points for broken or plugged grease fittings. • Inspect the end cap/plate (where applicable) that fits over the fingers. • Inspect any lead rolls/ guides that guide the scrap on the winder. Ironing pass (where applicable) Most of these units are simply an inboard and outboard stand, similar in design to a forming and sizing stand, but not driven. If your plant is equipped with this style of ironing pass, follow the maintenance tasks outlined in the Driven Stand section. Some ironing passes are a three-roll design with an eccentric on the top roll for pressure. This design is also similar to a forming or sizing stand. If your plant is equipped with this style of ironing pass, follow the maintenance tasks outlined in the Driven Stand section. In addition, check the cam, or eccentric, adjustment. Coolant tank and coolant system This is the section between the forming and sizing stands where the tube or pipe is cooled. • Inspect all support rollers, bushing/bearings, shafts and support fixtures. • Inspect all lube points for broken or plugged grease fittings. If your unit is equipped with a top hold-down rack of rolls, inspect the rolls in the same way as the bottom support rolls and the linkage to the top rack. • Inspect the spray nozzles (if equipped); be sure the nozzles are not plugged or missing. • Inspect the valves, drains, and overflows. • Inspect all flex coolant lines on the mill; be sure all the lines are installed, coolant is flowing through the lines, the connections are not leaking and coolant is being supplied to each driven, side pass, weld roll, and turkshead. • Inspect the coolant pump and motor; lubricate as required. • Inspect the pressure and temperature gauges (if equipped). • Inspect and service the filtration system (if equipped); depending on the design of the unit, regular daily/weekly maintenance will be required, as outlined by the manufacturer. • Clean the coolant tank, remove all sludge and discard the material in a proper manner. Turkshead units There are four basic designs of turkshead units: single four-roll cluster; double four-roll cluster; two-roll horizontal; and two-roll vertical. Some units have rotational capabilities for twist control. • Inspect the back plates; these plates slide up and down, side to side. • Inspect the lead screws for excessive backlash. • Inspect the tooling clevises, including the fasteners, slides and gibs; check for wear on the inside face; check for wear in the roll shaft bores. • Inspect turkshead roll shafts to www.internationalmetaltube.com IMT December/January 2009 27 verify dimensions, OD and shoulder location. • Check the fit between the turkshead rolls and clevises if brass washers are used. NB: Consider switching from brass washers to thrust bearings on the turkshead rolls. Thrust bearings allow the turkshead rolls to rotate easier, reducing drag on the mill drive; they also eliminate the variable wear on the rolls and the brass washers. • Inspect the rotary adjustment (where applicable), be sure there is no end play in the assembly. • Inspect all lube points for broken or plugged grease fittings. Cut-off press Several designs of cut-off presses are used in the industry: single cut; double cut; hot saw; cold saw; plasma; and laser. Each design has unique maintenance requirements. The single and double guillotine cut are the most popular designs so the generic maintenance tasks for these two designs will be presented. • Inspect the encoder wheel and its assembly; the wheel should be flat, with no grooves. • Inspect the coupling between the encoder wheel shaft and the encoder. • Inspect the primary lower bed rails of the die. • Inspect the upper rails on the ram. • Inspect the links, bearings and crankshaft of the swinging ram. • Inspect the swinging ram for cracks. • Inspect the gibs on the die (upper and lower). • Inspect the wear plates and wipers (if equipped). • Inspect the assembly of the die (sleeves and posts, slides, die clamps, all major components). • Inspect the spare dies. • Inspect the brake and clutch assembly; adjust per manufacturer’s recommendations. • Inspect the air, oil and hydraulic lines for leaks. • Inspect the main drive motor bearings for roughness and excessive end play. • Inspect the V-belts from the motor to the flywheel. • If the accelerator incorporates a DC motor perform the DC motor maintenance tasks outlined below. • Inspect the accelerator drive system; check the connection shaft from the die assembly to the accelerator. • Inspect the central oil lube system for the die and related press lube points, which include the motor, pump, reservoir and all lubrication lines. • Inspect all lube points for broken or plugged grease fittings. • Inspect all guarding. DC drive motors Consider sending your DC motors to a qualified motor shop for service. The shop will clean, bake out and meg the motor, dress the commutators, replace the brushes and re-insulate the armatures and fields, if needed. They will also check and replace the bearings. If you decide not to send your DC motors out for service, conduct the following maintenance tasks: • Inspect the bearings for roughness and excessive end play. • Dress the commutator as outlined by the tool manufacturer. • Inspect the brushes; replace if necessary. • Meg the armature and fields to ensure there are no leaks to ground; if either component fails the test the motor will have to be sent to a motor shop to be baked out and re-insulated. • Inspect blower motors (if equipped); lube the motor and clean the fan blades. • If the motor is direct coupled to the transmission, inspect the couplings. • If the motor is belt driven, inspect the pulleys and belts. • Inspect the motor mount and frame for cracks and looseness. • Inspect all guarding. • Inspect the tack feedback generators, couplings, and mounts. AC drive motors AC motors are serviced in the same way as DC motors with the following exceptions except there is no commutator to dress and no brushes to replace. Transmissions There are two transmission designs used in the industry: M-style, in which the transmission is part of the inboard stand; and universal, in which the gear boxes are mounted on an intermediate base and connected to the inboard drive stand via universal driveshafts. The maintenance tasks for the M-style transmission are as follows: Perform the tasks outlined in the drive pass section of this document. Pull the covers and inspect the inside of the gearbox. Inspect the bearings and seals; pre-load any bearings that are replaced. Inspect the gearbox vents; they must be clear. Inspect the worm shaft, worm gear and transfer gears for wear. Inspect the oil transfer system to ensure oil is being delivered to the transfer idle gears for the top shaft. Inspect the seals and couplings between gearboxes. Inspect the coupling and pulley guards. The maintenance tasks for the universal style transmission, including auxiliary two-, three-and four-speed designs, are as follows: Inspect the bearings and seals; pre-load any bearings that are replaced. Inspect the worm shaft, worm gear and transfer gears for wear. Inspect the gearbox vents; be sure they are clear. Inspect the output and input shafts keyways. Inspect the drive shafts, U-joints, spline couplings and welded tubing between these components. Check the drive shaft timing (floating joint to floating joint, fixed joint to fixed joint); incorrect timing will result in variable speeds of the driven stands and the tooling installed on those stands. Inspect all guarding. Run out and dumptables (if equipped) • Inspect all carry out rollers. • Inspect the bearings for roughness and excessive end play. • Inspect the shafts for excessive wear. • Inspect the dump feature related components: arms, linkages, cylinders, flag switches or encoders and back stop rails. • Inspect the accumulation table components: collection rails, stops, conveyor belts, drives. Roll-Kraft offers a full line of services that include mill evaluation, mill alignment, mill maintenance, consulting and in­house training. More information about these programmes and services at: www.roll-kraft.com, Tel: 440 205 3100. Bronx/Taylor-Wilson extends its global reach With more than a century’s experience and a clutch of significant patents to its name, Bronx/Taylor-Wilson is basing its worldwide success on technical excellence and expertise. T he world's leading pipe producers rely on Bronx/Taylor-Wilson to create efficiency and maximise their finishing production to win a competitive advantage in the global marketplace. The Bronx know-how and tradition of developing customised solutions dates back over 100 years and continues today with technological advancements based on Bronx Engineering patents acquired in 1940. Whether it is processing cold or hot pipes over 600ºC; thin or thick walled tubes over 50mm; or low or high yield strength alloys of over 1000MPa, the capacity, productivity and tolerance of finished goods achieved on Bronx/Taylor-Wilson equipment remains unparalleled. Bronx was the first to incorporate a straightening machine in line with the cooling bed, and the company has remained at the forefront of technology. Today, the Bronx nameplate can be seen on machines installed in Russia, China, Brazil, Germany, the United States, Japan, Ukraine, Kazakhstan, Canada and the United Kingdom. In order to compete in today’s ever changing steel industry, it was clear that Bronx needed to extend its line-up to reach fresh markets. This required investment, not only in technology and innovation, but also in its most valuable asset – its people. With technical support staff additions in Europe, North America and Asia, Bronx now covers the globe to ensure that its customers get the service and technical expertise that they require to keep their finishing floors running at peak efficiency. That dedication has earned Bronx countless opportunities in a variety of markets. With over 1,000 straightening installations around the world, Bronx leads the global market. Since 2001 alone, the company has completed nearly 100 new straightening installations. And recently Bronx’s scorecard has included a flurry of activity involving straighteners and hydrostatic pipe testers. Interpipe, the leading producer of API pipe in Ukraine, has awarded Bronx several large projects. The heavy duty API-quality 6CR9 series pipe straightener for hot rolled carbon and alloyed steel tubes and pipes with plain ends in cold and warm conditions is made in accordance with API 5CT specification up to P110 grade. The outside diameter range is 73.02-177.8mm with a maximum wall thickness of 22mm and a length of 14,000mm. Interpipe has also awarded Bronx a 6CR11 for its API 5CT product. This machine can handle throughput with a maximum diameter of 377mm, a wall thickness of 25.4mm and length of 15,000mm. In addition, Bao Steel in China awarded Bronx orders for two 6CR11s and a 6CR12 to meet the demands of their finishing floor. Bronx has recently commissioned several additional straightener projects around the world, including a 10CR9 at Sinara and a 6CR11 at Volzhsky, both in Russia; a 6CR9 at V&M in Brazil; and a 6CR9 at V&M in France. The company is currently involved in the design of two special straightening machines for the Russian railroad industry. In addition to recent contracts and installations of straighteners, Bronx has also received several orders for its hydrostatic pipe testers. One such order is for the Almetievsk Pipe Plant in Russia. This pipe tester was designed for API 5CT product up to 219mm outside diameter at a pressure of 40MPa and/or 245mm OD at pressure up to 32MPa. In terms of supplying multiple products for finishing floor integration, IPSCO – which recently completed a new finishing floor in its Baytown, US facility – contracted Bronx for the installation of a rotary straightener, an end facer and a hydrostatic pipe tester for 2 3/8-7in products. Bronx/Taylor-Wilson’s commitment to the global marketplace is reflected in its recent accomplishments. The company has continued to invest in its global staffing and product technology to extend its reach around the globe. And to reinforce its position in the world steel industry, Bronx will be exhibiting at Tube Dubai. Specialists from the European and US offices will be on hand to discuss the company’s latest pipe finishing projects and technological advancements. More information on Bronx/Taylor-Wilson at www.btwcorp.com, tel: 330.244.1960, email: sales@btwcorp.com, fax: 330.244.1961. www.internationalmetaltube.com IMT December/January 2009 29 For the past 30 years Olimpia 80 has been designing and manufacturing facilities for high-quality tubing – and it still has some tricks up its sleeve O limpia 80, based in Borgonovo, Italy, has been successfully operating in the planning and implementation of plant and equipment for the production of high-quality tubes for over 30 years. Starting as a manufacturer of stainless-steel tubes, and manufacturing most of its own production equipment, the company developed into a manufacturer of custom-made equipment. Continuous research and development and a comprehensive grasp of production requirements has helped Olimpia 80 register a series of significant patents. As a result Olimpia 80 is able to provide everything from comprehensive practical training to specific technical advice about its products and their subsequent operation, helping customers achieve full productive efficiency within a short time. Technical back-up and after-sales service have always been high priorities for Olimpia 80. That includes control of the plant’s functioning parameters by means of the received data; supply of specialized personnel for on-site support; supply of any necessary components and spare parts; and the routine delivery of consumables direct from the company’s own warehouse. It’s a level of support that extends to Olimpia 80’s tube mills across the wide. Products Olimpia 80 is able to design and produce single components or complete tube lines for TIG, laser and high frequency welding, covering a size range from 5­609mm OD. The company also offers turnkey systems, personalised solutions and upgrades to existing systems. The product range at Olimpia 80 covers complete TIG lines for austenitic, ferritic and duplex stainless-steel tubes; special alloy tubes; copper, titanium and aluminium tubes; as well as other ferrous and non­ferrous metals. Olimpia 80’s laser welding lines are suitable for the production of austenitic, ferritic and duplex stainless-steel tubes, special alloy tubes and aluminium tubes. The company also offers the option of installing a combination of TIG and laser welding on the same line. Also on offer are in-line bright annealing machines which are suitable for low speed or the higher production speeds of laser tube mills. High-frequency, welded-tube lines from Olimpia 80 are suitable for the production of tubes in austenitic and ferritic stainless steel, low- and high-resistance carbon steel and aluminium in sizes from 10­609mm. The welding station guarantees absolute control of the tube edges, allowing high production speeds and optimal welding quality. In addition to standard lines, Olimpia 80 manufactures a range of special tube production lines. These include: • Mills for the production of flexible welded tubes with parallel weld corrugation, for tubes from 10-76mm OD and wall thickness from 0.15-0.35mm; • Lines for the production of round tubes with very thin wall thickness from 0.12mm, covering the size range up to 120mm OD and thickness of 0.5mm; • A ‘roll-less’ mill for thin-wall tube production, for tubes from 80-250mm OD and 0.5-1.5mm wall thickness; • Mills for the production of tubes for optic fibres and coaxial cables; • Mills for the production of spiral flexible tubes. Design and production All rolls and tools used in Olimpia 80 mills are designed and manufactured in-house. They include rolls for the production of Linear cage forming This tube forming system developed by Olimpia 80 makes use of the latest technologies, allowing the diameter of the produced tube to be changed without changing rolls. It is a unique, compact system comprising eight sequential stations – six operating as break-downs and two as fin passes. They achieve a final an almost complete joining of the tube. The 14 independent axes of rolls and the 13 of every fin pass, operated by computerised servomotors, help to obtain, an optimal position for the correct tube forming quickly and easily. Strip feeding is assured by a system of independent pinch-rolls mounted on the first six stands. More information on Olimpia80 at: www.olimpia80.com, tel: ++39 0532 862614, fax: ++39 0532 864584 www.internationalmetaltube.com IMT December/January 2009 31 Polished performance The group has recently set up a new company, Olimpia Surface, which was born from Olimpia’s 30 years’ experience in tube working. It answers the requirement for powerful, high-speed equipment for the satin finishing, scotch brite and mirror polishing of round and square tubes, flat sheets and coils. This innovative polishing technology offers some significant advantages: dry working, constant working pressure by automatic tool wearing compensation, automatic tool positioning and reduction of maintenance and costs. Olimpia Surface offers off­line satin and mirror polishing machines for round, square and rectangular tubes, as well as for single sheets or coil-to­coil systems. round, square and rectangular tubes, as well as for other profiles. All standard tube mills supplied by the company can be completed by a cassette system, allowing quick tooling changes. Olimpia 80 has also designed and built an innovative revolving stand system for rapid in-line roll changes. Each revolving stand is fitted with 12 rolls for the production of six different diameters. Changing a complete roll set takes only 15-20 minutes. Mill components Olimpia 80 offers a full range of tube mill components, including mill entry section equipment; strip accumulation systems; equipment for outside weld bead removal and for inside weld bead control, such as bead grinders, bead scarfing units and bead rollers. The company’s tube mill component range is rounded off by anti-twist units; in-line monitoring and control equipment; cut-off equipment; planetary brushing machines for round tubes; in-line brushing machines for square and rectangular tubes; tool deburring machines; and brush deburring machines. 4935 Hannan Road FOR SALE Complete Welded ERW Tube & Pipe Mills 10” x 10mm Roll Maker Pipe Mill (New 2003) Diameter Range: 2.5” – 10”, Thickness Range: 2mm – 10mm, Complete Mill. 5” x 127mm Kipco Stainless Tube Mill Year 1993, O.D. Size Range: 38.1mm – 127mm, Wall Thickness Range: .7mm – 3.1mm. 4½” (114mm) x .250” (6mm) Diameter Kusakabe Rafted Pipe Mill Line (New 1989) Year 1990, Model: KMP 21-114, Diameter Range: 21mm – 114mm (.820” – 4.500”), Line Speed: 20 – 100 Meters/Min, Thickness Range: 2mm – 6mm (.080”-.250”), Dual Rafted Design Mill, 100mm Diameter Shafts. 4” x .160” Jiangsu Tube Mill Line (New 2006) 15mm – 101mm Dia Range, .7mm – 4mm Wall Thickness, 35 Meters/Min Line Speed, Complete Mill. 3” x .220” Turek & Heller Tube Mill Model No. WU-45, Thickness Range: .065” - .220”, Line Speed: 80 – 200 FPM, 4½” Diameter Spindles, (2) 75 HP DC Motors, 4½” Diameter Spindles, Alpha Double Cut Cut-Off. 2½” x .125” T & H WU-25 Tube Mill Tube Diameter: ½” – 2.5”, Maximum Line Speed: 300 FPM. 2½” x .095 AEF Tube Mill Line/Solid State Welder Model K225, ½” – 2½” Diameter Tubing. .095” Max Wall Thickness, Accumulator, 1997 Thermatool 200KW Sold State Welder. 2” x .090” Itallani Tube Mill Tooling from .750” – 2.0”, Two (2) 75 HP DC Drives, 150KW Welder, Shear, End Welder, Kent Floop, Betaram Cut-off, Double Cut Die. 2” x .095 Yoder W Style Mill Line with Kent Floop .472” - .200” Dia Tube Diameter, .095” Max Wall Thickness, 1990, Mill W Style, Thermatool 300 KW Solid State Welder, Alpha Cut-Off, Tooling for Rounds, Squares and Rectangles, Mair Packag­ing Line. Tube and Pipe Equipment 76.3mm (3”) Diameter Mair Tube Packaging Line Year 1989 Year 1989, Tube Dimensions: 34mm – 76.3mm Diameter (1.35” – 3” Diameter), 60mm x 60mm Squares (2½” x 2½” Squares) Max, 75mm x 45mm Rectangles (3” x 2” Rectangles) Max, Thick­ness Range: 1mm – 3.6mm (.040” - .150”). 4” Sutton Six Roll Pipe Straightener Model 618, New in 1981, Wall Thickness: .050” - .300”, 30’ Entry & Exit Tables 4 ½” Dia Kent Rotary Floop Model R32HF, 15” Strip Width, 40 HP Drive, Controls 3” Dia Kusakabe Rotary Floop 10 ¼” Strip Width, 30 HP Drive. 3” Dia Kent Rotary Floop Model R229, 1.5” – 10” Strip Width, .028” – .134” Strip Thickness, 40 HP Drive 2½” x .150” Alpha Cut-Off Model 70-A-0-200, Single Cut Die, 20’ Run Out TableDie Accelerator, Bundling Conveyors. Adige TS70 Re-Cut Machine Year: 1989, Output Length: 200mm – 1.500mm, Diameter Range: 10 – 100mm, Cutting Speed: Variable Speed with AC Converter, Type of Cut. Slitting Lines 84” x .313”x 40,000lbs Delta Brands Slitting Line Thickness Range: .020” - .313”, Recoiler Drive 75 HP DC, Complete Line: Slitting Head, 8” Diam­eter Arbors, Sliding Outboard Housing, 2 Speed Gear Box. 72” x ½” x 60,000lbs Cincinnati Slitting Line Entry Coil Car, Mandrel Uncoiler, Peeling Table, Crop Shear, Two (2) Slitting Heads, 11” Diameter Arbors, Two (2) Scrap Winders, Recoiler, Motor: 225 HP DC, Exit 2-Arm Turnstile. 72” x .375” x 50,000lbs Paxson Dual Head Loop Slitting Line Year 1983, Thickness Range: .037” - .375”, 5 Cuts of .375”, 21 Cuts of .109”, 2 Slitter Heads, 12” Diameter Arbors & 9” Diameter Arbors, 150 HP Dc Drive, 5/8” Butech Scrap Choppers (New in 1990), Recoiler, 20” Diameter Hydraulic Drum, 125 HP DC Drive, 2 Speed Gear Box, Exit L-Type Coil Car, 2 Arm Exit Turnstile. Please send us your inquiry or for sale items today: sales@galcorp.com L ennartz has a well established reputation for manufacturing top-quality circular sawing machines which are able to tackle the toughest jobs. The Lennartz-Ohler design comprises a solid cast-iron base, two columns with a crosshead and a saw carriage, which is guided vertically between the cylindrical column guides. The saw blade and feed cylinders are located on the centre-line of the machine. Cutting forces are handled by heavy-duty vices and carriage guides with exceptionally large surfaces which also promise an extremely long service life. Vibrations are absorbed by the sturdy cast-iron body, helical spur-gear drive and worm gear. The vertical downward cutting force is produced by a pair of synchronized hydraulic cylinders while the weight of the saw carriage is compensated for. Material to be cut is clamped at both the inlet and outlet sides. A kerf (saw-cut) opening system ensures a contact-free return of the saw blade. A unique feature of Lennartz-Ohler circular saws is a six-step transmission combined with a frequency converter that allows any cutting speed to be selected between gear steps, resulting in low cutting speeds with high torque. As a result it is possible to cut material up to 1,500 N/mm - even stainless steel can be handled by combining the low cutting speeds with circular segmental saw blades. Unlike conventional circular saws, the Lennartz-Ohler design suits these as well as carbide-tipped saw blades. Lennartz-Ohler machines can cut solid material, single pipes or tubes in layers and material in bundles. The advanced transmission allows the use of significantly less powerful motors. For example, the Lennartz-Ohler K/KA 1000 is equipped with a 37kW motor. A comparable sawing machine with carbide-tipped saw blades would need about 90kW, so the Lennartz model offers a significant saving in power costs. More information on Lennartz at: www.lennartz.de, tel: +49 2191 9960-0, email: info@lennartz.de, fax: +49 2191 9960-60. Roche La Molière, France, manufactures the MDC10-TU-CFS automatic cutting line which straightens and cuts steel, stainless-steel and copper tubes and alloy materials from 3-10mm in diameter. The standard line includes a encoiler synchronised with the machine and two feeding stations with rollers or Caterpillar, a rotating straightener, and a slitting saw cutting unit. The cut tubes are straight to within 0.1mm/m. The feeding speed and synchronised; the whole operation is programmable via a touch screen. All the tools can be changed quickly – the straightener is equipped with two preset cassettes allowing tooling changes with the minimum inconvenience. A flying Ravni offers a full installation and training service, and it’s looking for agents. More information on Ravni Technologies at www.ravni.com, tel: +33 (0)4 77 50 57 80, fax: +33 (0)4 77 90 58 65. State-of-the-art cutting line at QSZ QualitätsSägeZentrum (QSZ), based in Remscheid, Germany, specialises in sawing equipment for users including pipe and steel mills. It has two factories equipped with automated band saws up to 530mm and circular saws up to 420mm for cutting pipes, beam blanks or solid material from steel, stainless steel and non­ferrous metal up to a diameter of 530mm. Both sites have rail connections. Materials handling is optimised with frequency controlled in-feed and discharge conveyors controlled by matching lasers to achieve a positioning accuracy of within 0.5mm. The sawing lines are automated of-the art KKS 1250 circular to allow one-man operation. featuring a Siemens PLC control Framag has supplied a state-system, centric main and auxiliary clamping devices, height-adjustable table and hydraulic support of bent or curved material. It can cut round material with diameters from 180-420mm and square bars between 160-400mm. Sawing blade diameters are 1,100-1,350mm. More information about QSZ at www.qsz-rs.de, tel: +49 2191 782050, email: info@qsz-rs.de, fax: +49 2191 7820520. More information about Framag at: www.framag.com, tel: +43 7683 5040-48, fax: +43 7683 5040-86, e-mail: w.steiner@framag.com. www.internationalmetaltube.com IMT December/January 2009 35 Paul Lake (left), managing director of BLM Group UK, pictured with the new Adige LT 722D Hydrostatic Testers Pipe End Finishing 6-10 Roll Straighteners Bar Straighteners