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

International Metal Tube Volume 1 Issue 3

___Magazine Data___

Preview • Boru 2009 Preview • Boru 2009 Preview • Boru 2009 Preview • Boru 2009 Previ Comment At a time when we are constantly being reminded of business closures or companies seeking protection from their creditors, we see that some companies are actually doing rather well in the current economic climate, not least because they had the foresight to plan for leaner times. This forward planning will undoubtedly put them in a good position for the coming 12 months and this positive aspect is reflected within the news pages of this issue and via the companies that include their marketing message. For all businesses this type of interaction has to be two-way, and we would urge our readers to support those companies which are featured within this and every issue of IMT. Looking ahead – and again helping those companies which are actively supporting the metal tube and pipe industry – we have some excellent trade shows to look forward to, including Tube Russia (Moscow, 12-15 May); Tube Southeast Asia (Bangkok 13-15 October); and Fabtech/AWS (Chicago 15-18 November). IMT will be at Booth R15 at the Bangkok show and Booth 4050 at Chicago. To arrange a meeting at either of these shows please contact me as soon as possible via email: imtmagazine@btopenworld.com. PRINTED BY Holbrooks Printers Ltd, Norway Road, Hilsea, Portsmouth, Hampshire, PO3 5HX. Tel: 02392 661485 The next issue of IMT will include updates on tube & pipe drilling, piercing, punching and collaring; copper tube production and suppliers; and Tube Russia. Editorial contributions for consideration should be sent to imtmagazine@btopenworld.com to arrive no later than 9 April. 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 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 www.internationalmetaltube.com IMT February/March 2009 1 Toolbox People Tube Russia Formtek boosts efficiency with a range of new equipment A s part of its plan to meet or exceed the heightened demands of the roll forming industry, Formtek, has taken delivery of a new five-axis, dual-chuck, machining center for its Cleveland plant. This, with Formtek’s existing CNC equipment and other machines on order, will enable the company to produce roll tooling more efficiently by eliminating many of the time-consuming steps currently involved in tooling manufacture. It will also enhance the quality and consistency of the tooling produced. With its Yoder, B&K, Dahlstrom, Tishken, and Lockformer brands Formtek is the largest provider of tooling and equipment to the roll forming industry. Tishken Products of Cleveland, Ohio has recently supplied an edge conditioning system designed to convert drop cuts and narrow mults into saleable products. The Tishken STR40 system can condition strip edges up to 4in wide by ¼in thick and as small as ½in wide by 1/16in thick. At speeds up to 250fpm, the system economically produces edge-conditioned, straightened, and cut-to-length product. The versatility of the system, with its recently updated drivetrain and digital controls including batch production capabilities, is reflected in decreased changeover time and increased net production capability. Tishken Products Company, founded in 1921, is a leading supplier of high-quality roll forming machinery and tooling to the automotive, appliance, building products, metal service center and metal processing industries. Its equipment is in use in plants throughout the world. Sample parts are submitted to customers for approval before equipment and tooling are released, leading to proven quality and customer satisfaction. Tishken Products Company is registered and certified to ISO 9001: 2000. More information on Formtek at: Tel: +216 292 4460 Fax: +216 2922898 info@formtekgroup.com www.formtekgroup.com More information on Tishken Products Company at: Tel: + (216) 292-4460 sales@formtekcleveland.com www.tishken.com BLM snaps up wire bending company BLM SPA of Cantù, Italy, a leading manufacturer of tube bending and end forming machines and systems, has bought Officina Meccanica Montorfano Sas. This allows BLM to complement its product line-up in the tube bending field with highly productive machines for the bending of wire, small-diameter bar and tube, strip/profiles, and armoured heating elements. For more than 40 years Montorfano has specialised in the manufacture of multi-head machines for wire bending. Its first patent for this type of machine was granted in 1965; its first three-axis CNC machine was launched in 1979. The company currently offers a Montorfano DH2030 CNC bending machine equipped with bi-directional bending units range of 18 standard machines industries, and in the production capable of bending wire and bar of household appliances, indoor from 1-33mm in diameter. These and outdoor furnishings, machines are widely used in the bathroom accessories, and automotive and construction equipment for shops and stores. Visit us at Boru 2009 More uptime. More output. From the welder with a 5-year warranty. All Weldac solid-state welders now come with a 5-year warranty for their inverter modules, driver cards included. Since its launch the Weldac has become a proven solution; a welder that’s boosting productivity at companies worldwide. Weldac’s unrivalled reliability is based on a robust design and robust components. In fact, our IGBT transistor solution makes the Weldac virtually short-circuit proof. To learn more about Weldac, its proven reliability, and the warranty, just write to us at: sales@no.efdgroup.net The Weldac 1800 – for API pipes up to 26” OD. EFD Induction | www.efd-induction.com | Putting the smarter heat to smarter use. Up up and away with Siempelkamp’s fast forger S iempelkamp has won an order for a 25/30MN press for the open-die forging and bending of aluminium alloys used in the aircraft industry. The two-column open-die forging press will produce finished forgings or semi-finished forgings to be used in subsequent closed-die forging processes. The press has a capacity of 25MN for forging and 30MN for upset forging. The maximum press stroke is 2,400mm; the 6m press table can be moved horizontally up to 6.5m. This stroke is needed for the forming of large structural parts. The press replaces an older model that was due to be refurbished. However, in-house evaluations led to the conclusion that a new press would make better financial sense. The new press also offers a higher throughput, an improved quality of forging and enhanced reliability. A technical highlight is that the central press cylinder is integrated into the upper cross beam and the piston is mortised into the cross beam. In conjunction with a guiding system in the x-axis, this design guarantees exact guidance of the cross beam over the entire press stroke, even at high eccentric loads. The weight of this cross beam is less than that of a rotating cross beam, which speeds up the throughput. This design is also cost-effective. Siempelkamp presses of this design have proven themselves worldwide for more than 30 years. They are well suited to short delivery times because Siempelkamp manufactures large components in its own foundry – a 14-month lead time was a decisive factor in winning this order. Delivery is scheduled for late 2009 with the press coming on line early next year. Siempelkamp has teamed up with Oilgear Towler and Glama on this project. Siempelkamp will engineer and manufacture the press mechanics and die changing devices. A challenge that had to be met during the design process was that the height of the press had to be less than 10m because of an overhead crane runway. An automatic die rotating and clamping device is integrated into the cross beam. The die change takes place via a transversally moving saddle with three positions and a saddle magazine with four positions. Oilgear Towler of France is supplying the hydraulic direct drive (which is designed for a maximum operating pressure of 420 bar) as well as the electrical controls. Glama is supplying a rail-bound manipulator and a stationary lifting and turntable for material handling. The forging press will comply with the CE press safety standard defined in DIN EN 14673 2007-04. Company profile Siempelkamp has vast experience in the engineering, design and manufacture of metal forming presses. Its line-up includes plate bending presses for manufacturing large-diameter pipes and half shells; straightening presses; side-member presses; heat exchanger plate presses; hydroforming presses; rear-axle housing presses; and a comprehensive range of closed-die and open-die forging presses. Customised presses with high pressing forces are Siempelkamp’s core competence. The Siempelkamp Group is an internationally active technology supplier with three business branches – machinery and plant manufacturing, foundry and nuclear technology. As system supplier of presses and press lines for the metal industry as well as turnkey plants for the wood-working industry, Siempelkamp enjoys international standing. The group employs almost 2,500 people worldwide. More information on Siempelkamp at: Tel: +49 2151 92 4636 Fax: +49 2151 92 5683 ralf.griesche@siempelkamp.com www.siempelkamp.com Some like it hot – Emerson helps keep it that way E merson Process Management’s Smart Wireless technology was chosen by Terminals Pty to monitor temperatures in a 900m-long, 8in (200mm)­diameter heat-traced pipeline used for unloading bitumen from ships at its Geelong terminal in Australia. Electric heaters are fitted along the pipeline to maintain the bitumen at 160oC, keeping it fluid. If a heater fails a cold spot could form, causing the bitumen to solidify. This would plug the line, with expensive consequences. Bitumen terminal project manager Joe Siklic explains: “We needed to monitor the bitumen line to make the operators aware of cooling anywhere in the line from the ship to the storage facility, which could result in an emergency shutdown. Any delay in unloading could keep a ship at the pier longer than planned with demurrage costing up to $43,500A (€23,500) per day.” The wireless technology was selected, for its lower initial cost their destination. If there is an operators would be warned. This More information on and minimal maintenance when obstruction transmissions are re-wireless network has proved to be Emerson Process Management at: compared with hard wiring. Eight routed along the mesh network reliable, compatible with existing Tel: +41 (0) 41 768 6111 Rosemount wireless temperature until a clear path to the smart control equipment, and cost Fax: +41 (0) 41 768 transmitters are evenly spaced wireless gateway is found. effective. The amount of structure 6300infocentral along the pipeline, sending All of this happens on the wharf is minimal, and that @ap.emersonprocesscom temperature readings at one-automatically, without any is another benefit.” www.EmersonProcess.com minute intervals to a smart involvement by the user, providing wireless gateway on shore. This redundant communication paths Company profile channels data to the AMS suite and better reliability than direct, predictive maintenance software line-of-sight communications Emerson Process Management, an Emerson business, is a leader in used for instrument configuration between individual devices and the automation of production, processing and distribution in and performance monitoring. their gateway. This self- industries including chemical, oil and gas, refining, pulp and paper, Collected data is also organising technology optimises power, water and wastewater treatment, metals and mining, food forwarded to a SCADA system in data reliability while minimising the terminal control centre via power consumption. and beverage and pharmaceutical. fibre optic cable. “This is an ideal application for The company combines state-of-the-art products and technology Due to the self-organising wireless,” says Mr Siklic. “Since with industry-specific engineering, consulting, project management nature of this technology each numerous paths exist to carry the wireless device acts as a router transmissions, the network would and maintenance services. Its brands include PlantWeb, Fisher, for other nearby devices, passing easily compensate for a Micro Motion, Rosemount, Daniel, DeltaV, Ovation, and AMS Suite. the signals along until they reach transmitter failure, and the Saritas management were well represented at the groundbreaking ceremony for the company’s new site in the Gebze Industrial Zone. T he steady growth of Boru, Turkey’s international tube, pipe, fitting and machinery fair (previewed elsewhere in this issue) reflects the success of its domestic industry. And as Boru reaches its fifth year, Saritas Celik Sanayi ve Ticaret is celebrating its 50th anniversary by launching a $120m investment project near Istanbul. Saritas is 100% owned by the Saritas family; under the demo room has been incorporated for customer training and product presentations. leadership of managing director facilities will include Saritas supplies stainless steel Selcuk Saritas the company has comprehensive stocks of a wide in thicknesses from 0.40-100mm become the largest stainless- range of stainless grades – services include cutting to steel service supplier in Turkey, including duplex series and state- length, slitting, grinding, brushing Eastern Europe and the Middle of-the-art processing lines. and plasma cutting. It is certified East. It is determined to retain Saritas was founded in 1957. It by TüV Sud to ISO 9001, ISO 14001 that dominant position and to has been dealing with stainless and OHSAS 18001. expand its presence in the steel since the 1970s and has global market. focused on stainless-steel flat More information on Saritas at: The 160,000m site is in the products since the 1980s. In 1998 Tel: +90 216 466 4900 most prestigious industrial zone the company opened its first Fax: +90 216 466 4916 in the Gebze Industrial Zone. It is service centre, in Dudullu saritas@saritas.com.tr scheduled to come on line in 2011; Industrial Area, Istanbul. www.saritas.com.tr More information on Orbitalum Tools at: Tel: +49 (0) 7731 7920 Fax: +49 (0) 7731 792500 tools@orbitalum.com www.orbitalum.com O rbitalum Tools has oficially opened its new headquarters in Singen/Hohentwiel, Germany. Employees have been working at the new building since last October; now managing director has officially taken delivery at a ceremony attended by regional politicians and managers from partners, customers and suppliers, as well as Orbitalum employees and their families. Orbitalum Tools, formerly known as Georg Fischer Rohrverbindungstechnik, has been part of Chicago-based Illinois Tool Works for more than three years; it once again increased its profits last year. The company is ISO 9001:2000 certified and is strongly geared towards sustainability. It produces and markets portable pipe and tube cutting and pipe-end preparation machines for the plant engineering industry. Equipment produced in Singen is used in a range of industries including food and beverages, chemicals, pharmaceuticals and electronics, as well as in power plants, pipeline construction and shipbuilding. Steady growth over the past few years led ITW to invest some €4m in the Singen site. The building offers 4,200m2 of floorspace, of which 1,100m2 is currently devoted to administration – and it is designed so that additional floors can be added on demand. A Innovative tube connector meets key standard T he instrumentation products division of Parker Hannifin has won international approval for its innovative high-pressure Phastite tube and pipe connection system. Following testing by TüV Rheinland it has been certified to the ISO 19879:2005 hydraulic applications standard. This covers “metallic tube connections for fluid power and general use – test methods for hydraulicfluid power connections”. And in the UK, Phastite has been granted Type Approval by Lloyd's Register. This provides unbiased, third party verification of a product’s conformity to the producer’s specification and relevant national and international standards, and is based on a design assessment and an agreed programme of performance testing, to demonstrate the product’s suitability for use in general marine, offshore and industrial piping systems. Phastite offers a straightforward assembly method for high-pressure connections up to 1,379 bar (20,000psi), that can greatly reduce installation costs compared with welded or cone­and-thread fittings. Testing for ISO 19879 included pressure tests to 150% of the Phastite’s rating; leak and vacuum tests; and cyclic endurance. Parker's Sheldon Banks says: "ISO 19879 is an important qualification for many users in the oil, gas, petrochemical, power and marine industries — key markets for Phastite. We are delighted to receive this approval, which adds to independent approvals from users in areas including offshore and onshore processing facilities." Phastite fluid connectors are available in a wide range of sizes and shapes for metric or imperial tube and pipe applications up to 1in/25mm.They work on a compression assembly principle, using a novel form of toothed profie to make the seal. The fittings are supplied as one-piece components. To make a joint, all that's required is to insert the tube, then push the collar along the fitting body until it reaches a dead stop. This operation is performed by a simple handheld hydraulic tool and takes a few seconds. The tool requires no skill to use, and ensures right-first­time connections. Phastite's sealing mechanism is based on a series of defined internal ridges that create a secure seal by radial compression, without weakening the tubing surface. The ridges effectively grip in a way that retains all of the tubing's strength. These profiles also make the fitting particularly suitable for vibration-prone environments. More information on Parker Instrumentation Products Division, Europe at: Tel: +44 (0)1271 313131 ipd@parker.com www.parker.com Profile: Parker Hannifin With annual sales exceeding $12bn, Parker Hannifin is the world's leading diversified manufacturer of motion and control technologies andsystems for the mobile, industrial and aerospace markets. It employs 62,000 people in 48 countries. Parker has increased the annual dividends paid to shareholders for 52 consecutive years. New generation of pipe induction bending machines F or decades, the plant manufacturer AWS Schäfer Technologie has been building machines and equipment for the mechanical forming of pipes for power stations and ship building, as well as for the oil and gas production industry. With its latest SRMBI series of Induction Bending Machines, AWS Schäfer has reached a milestone in the bending of high-performance and high-strength materials. The induction process uses a medium-frequency inductor to heat an austenitic or ferritic pipe to a temperature at which the yield strength of the material to be formed is greatly reduced, thus allowing the pre­determined geometry of the pipe be formed. The objective of the bending process is to produce pipe bend sections with: • The absolute minimum of wall thinning on the exterior (extrados) of the bend; • A cross-sectional form within acceptable ovality tolerances; • The desired geometrical form, with respect to radii and angular requirements. Requirements for bent pipes, in particular in the energy producing industry, become ever stringent. When producing steam lines, super-heaters and manifolds, the majority of power plant manufacturers have already initiated the replacement of conventional materials, such as P22, with high-performance materials such as P92 or Alloy 600. Due to their chemical composition (high-quality chrome/nickel/molybdenum alloys), pipes made from high-performance materials have much higher long-term rupture strength, pressure resistance and corrosion resistance. And they can be used under operational conditions of up to 750°C with minimal loss of their mechanical properties. In pipe production the enhanced mechanical properties and strength of the new materials offer impressive savings in materials. For example, the wall thickness of a P92 pipe can be reduced by 60%, compared with pipe made from conventional materials. However, the manipulation and forming of pipe made from high-performance material with reduced wall thickness presents experienced plant and machine manufacturers with a new challenge. AWS Schäfer’s SRMBI series is designed to meet that challenge. Its induction bending machines feature powerful hydraulic drives to handle the most demanding jobs. SRMBI machines produce bends with the highest precision and quality; they are equally effective with high-strength, high-performance materials and low allowed steels. Advanced performance includes three-dimensional bends, as well as bends with tight radii of 1.4 x D with wall thinning of no more than 12.5% of the original material thickness at the extrados of the bend. Bends forms of up to 182° at tight bending R/D ratios and ovality tolerances which do not require rework with additional equipment offer a considerable time and cost saving in comparison with conventional machines. The machines are equipped as standard with a newly designed braking technique developed in-house by AWS Schäfer. Depending on the pipe diameter, radii to be bent, as well as material and thickness, trapezoidal forces occur throughout the bending process which can cause changes to take place in machine position. This in turn can result in deviations from the desired bending geometry. But AWS Schäfer’s machine features the new braking system and redesigned, robust structure, fitted out with a hydraulic feeding force that can be set with variable speed, position and force during the bending process. As a pipe workpieces. result the SRMBI series is said to This means the repeatability guarantee perfect positioning of bends is nearly absolute, precision with the correct feeding providing users with the process force at the required speed, even security which is now when working on the heaviest of fundamental when the task is demanding and errors are so expensive. The machine design enables precise bending of the most popular pipe dimensions: diameters from 50-1,660mm and wall thicknesses from 3-120mm. All of which will give this new generation of machines great potential in a number of industrial fields. The bending process is controlled by software which allows the operator to pre-select a geometry and to easily and quickly program bending parameters via a touch screen. A video screen at the control desk allows the entire bending process to be easily monitored at all times, providing additional security for the operator throughout the bending process. An integrated printer is provided, allowing the printing of all important bending parameters at any time. Precise optimal bending temperatures are ensured by the use of laser optical pyrometers which scan a given section of the pipe during bending, producing real-time accurate temperature measurement of the heat zone. More on AWS Schäfer at: Tel: +49 (0)2739 8700 300 Fax: +49 (0)2739 8700 310 info@aws-schaefer.de http://aws-stg.de BLM’s two-in-one bends tube to left or right T he latest generation all-electric BLM Elect CNC tube bender is essentially two machines in one, because it can be switched quickly into a right- or left-hand bend configuration. This can save secondary bending operations or even the need for a second bending machine. The Elect’s multi-stack tool mounting facility also allows multi-radius and variable-radius bending of the same tube in a single set-up. Bends with very little straight between them, even compound bends, can be accommodated, as can tight bends – even those with a radius less than the tube diameter. The inherent precision and control of all the axes positioning is said to guarantee consistent, highly accurate, bends. All critical machine setting parameters are managed by the Siemens 840D SL CNC. This new ‘solution-line’ control system, which interfaces with BLM’s VGP3D graphical programming and simulation software, provides automatic, interpolated simultaneous movement of all reached consistently. nine machine axes. This The VGP3D software creates eliminates ‘dead time’ within the the part program and displays tube bending cycle, ensuring that on-screen the shortest and most optimum output rates are efficient bending cycle in real-time. Any possible collision points are highlighted and alternative strategies are proposed on-screen. This collision avoidance routine is said to eliminate expensive machine downtime, tool damage and material wastage. The software simulation cycle gives the actual time it will take to bend the component on the machine, contributing to more precise cost estimations. After a tooling change the BLM Elect automatically initiates a single ‘machine protection cycle’, which runs at 20% of normal speed and power. This ensures that should a collision be caused by operator error – for example, fitting an incorrect clamp die or pressure die – it will not damage the machine or tooling. The BLM Elect has a robust bend head and machine frame, with a compact integrated gearbox to increase the clearance area around and beneath the bend head. This enables more complex components to be completed in a single cycle, unlike machines with a fully external gearbox. The new range is designed to de-skill the tube bending process which is usually so reliant on individual operator expertise, with changeovers typically taking three to four minutes. Its precise calibration cycle means that it is set right first-time so a first-off part, and all subsequent parts, will be to specification. Two models are available: the Elect-63 with a maximum tube OD capacity of 63 mm (2mm wall thickness in steel) and the Elect­80 with a maximum tube OD capacity of 80mm (2mm wall thickness in steel). Both models have an optional variable radius/boost bending facility. The BLM Elect is also said to be inexpensive to run, with the reduced power consumption of an all-electric machine typically producing savings of 70%-plus compared with conventional hydraulic machines. More information on BLM Group at: Tel: +44 (01525) 402 555 312sales@blmgroup.uk.com www.blmgroup.uk.com Small machine – large demand I n its first three months of sales, the small, ergonomic, energy-saving TruBend Series 7000 press brake has become the most successful new product that Trumf has ever launched. The number of units sold is about three times above the average of previous market launches. Mathias Kammüller, head of the Trumf Machine Tool Business Field, is not surprised by this success: "Purchasers of the TruBend Series 7000 recognised that the new concept would contribute considerably to waste of space and energy. Heiko Witte, technology manager with Prokutec in Raubling, Germany, certainly does not miss the days when small parts had to be produced on an oversized machine. The approximately 500mm-wide TruBend 7018 has been a welcome addition to Prokutec's production line. "I can now use it to acquire and produce small parts that we were not able to do in the past,” he explains. “Therefore, the TruBend 7018 is the perfect addition to our existing machine fleet." The primary advantage of the small machine is its speed, which is due to Trumf’s new strategy when it comes to the beam and the back gauge: less mass combined with a powerful drive. Thanks to the back stops made of light carbon fibre (CFK), the back gauge achieves an acceleration of up to 20m/s². The beam of the TruBend Series 7000 can maintain this speed because of its electrical torque engine, which operates up to three and a half times as fast as the beam on a conventional bending machine. The ergonomic concept of the TruBend Series 7000 benefits operators because faster bending requires the highest level of concentration. "Just the fact that you can sit down makes the work so much easier, even after hours of bending work," says Witte. Even the lighting arrangement makes the operator's work easier: LED diodes light up the work area as well as the space behind the beam without emitting heat, and this also supports the operator's ability to concentrate. Kammüller concludes: "Ergonomics, energy efficiency and productivity were the main focal points at the last Euroblech show in October 2008. The fact that not only the TruBend Series 7000 was so well received, but the new laser-punch combination machine – the TruMatic 7000, for example – also enjoyed a warm reception, shows us that we have correctly positioned ourselves, and our innovations are just what users are looking for at the moment." More information on Trumf at: Tel: +49 (0) 7156 3030 Fax: +49 (0) 7156 303 30309 www.trumpf.com Sales of the TruBend Series 7000 are running at three times the average of previous market launches. Ava-Matic end former cuts costs and risk A va-Matic UK is launching what is claimed to be the most competitively priced end forming machine on the market. Uniquely, it features the side loading of tools, eliminating the need for lifting equipment and enhancing health and safety. With a price of just £7,900 (ex­ a top access. This requires lifting expansion and reduction is bends with no need for tube equipment which can be awkward compatible with existing Ava­ clamping. The expansion or and time consuming. The operator Matic machines; in most cases it reduction of the tube is innately might need to lift up to 27kg, will accept other manufacturers’ adjustable with only a small range which is hazardous and can tooling too. The practical user- of tooling needed to cover tube contravene health and safety friendly design makes use of sizes up to a diameter of 6in regulations. work/storage platforms and (153mm). Other features of the AV65S enables tool changeovers to be A wide range of expansion and include a PLC which can run the performed with rapid efficiency. reducing tools are available off the machine in semi-automatic mode The AV65S’s small footprint suits shelf and special/bespoke tool Serco works on-site S erco was set up in 1984 to supply reliable flange and valve facing equipment that meets the technical requirements for on-site machining works. The company is based in Montelimar, among the nuclear and petrochemical plants of the Rhone Alpes industrial valley. Its range of portable machining equipment can handle boring and surfacing, grinding and lapping for the maintenance of flanges, safety valves, sealing valves, high-pressure valves, flat seats, conical seats, manholes and diesel engines. Serco units are positioned and locked by means of a column/arm system clamped on the outer part of the surface to be machined (allowing internal machining). Machine set-up is fast and easy, offering parallel and concentric alignment within a 0.01mm. A powerful air motor rotates the tool rotation, or hydraulic motors can be More information on Serco at: specified, with two-speedradial Tel: +33 (0)4 7501 4298 automatic feed. Fax: +33 (0)4 7501 7962 www.serco-tools.com Electric end-former on the rack U nison has developed an all-electric end-former for automating the refurbishment of automotive steering-rack mechanisms. It uses programmable servomotors to drive the end-forming dies into position, and provides a more flexible and efficient means of handling the process than traditional manual and hydraulic methods, which involve changing dies between forming operations. Re-Go Autoparts, the specialist steering component remanufacturing company, has taken delivery of the first machine; it reports that the end-forming process that takes up to three minutes with conventional technology can now be completed in less than 10 seconds. Re-Go remanufactures components for automotive power steering systems under the Leno trade name. Founded some 30 years ago as an automotive spares supplier, the company has grown to become one of Europe’s leading suppliers of steering racks, steering boxes and steering pumps to vehicle repair and servicing organisations and specialist parts distributors. It employs more than 50 people at two sites: its headquarters and rack-and-pinion manufacturing plant in Tonbridge, Kent, and a warehouse and logistics centre in Wevelgem, Belgium, where it also manufactures steering pumps. Re-Go is a recent convert to the versatility of all-electric tube bending technology. About a year ago the company sought a new tube bending system. After researching the market it decided that Unison’s all-electric approach offered the most flexible solution, which in the long run was likely to prove far more cost-effective than traditional manual or hydraulic systems. It subsequently invested in a multi-stack version of one of Unison’s 16mm Breeze tube bending machines, which is used to produce a variety of small, complex parts, such as hydraulic brake pipes and power steering tubes. According to Re-Go director Gary Martin: “Our experience with the Unison tube bending machine proved extremely positive, and we very quickly became fans of digital control. The machine’s programmability enables us to accommodate small production batches without incurring the delays associated with changing tool sets on traditional tube bending machines, and its accuracy and repeatability help ensure product quality. “However, even with the best will in the world, we found it difficult to subsequently form the ends of tubes accurately – especially on some of the more sophisticated parts that we produce – without spending a considerable amount of time on the process. Which is why, when we caught sight of a prototype of Unison’s new end-former machine during a visit to their facility, we promptly expressed interest in purchasing a custom-built version.” Unison’s new end-former is a fully-integrated three-axis system housed in a compact cabinet. It provides software-controlled four-stage end forming by automatically flaring, compressing and reducing the ends of the steel tube used in vehicle steering racks, ranging from 6-10mm. The motive power for the machine’s main drive is provided by a Baldor servomotor. The four stages and clamp are actuated by SMC pneumatic cylinders, all connected to a Baldor MintDrive intelligent drive with a built-in motion controller. Overall machine control is handled by a PLC, with all user input commands and operational status feedback provided by a Baldor HMI panel. The all-electric end-former is said to offer numerous advantages over conventional hydraulic end formers: it is quick and easy to set up, and is more energy efficient, quieter and faster. The machine’s use of closed-loop servomotor control is designed to ensure excellent end forming accuracy and repeatability. The first machine was installed at Re-Go’s Tonbridge plant last November, and its performance has surpassed the company’s expectations. Gary Martin explains: “Quite apart from experiencing a dramatic improvement in productivity, we are now able to put the finishing touches to our products by creating very high quality tube ends, synonymous with the Lenco trade name. The machine is also proving very easy to use – so much so, in fact, that we can now fabricate complex variants of steering rack tubes which previously proved impossible.” More information on Unison at: Tel: +44 (0)1723 582868 Fax: +44 (0)1723 582379 enquiries@unisonltd.com www.unisonltd.com Company profile: Unison Unison is a world leader in tube bending and end-forming technology. Founded in 1973 to design and build computerised control systems for industrial processes, the company rapidly gained specialist knowledge of automated tube bending. In 1995 it launched its first proprietary all-electric tube bending machine, and today produces a wide range of servo-controlled machines, spanning tube diameters from 20-200mm. Based at Scarborough, North Yorkshire, the company is the UK’s only manufacturer of CNC tube bending equipment. Three routes to optimum annealing W hen producing welded pipes to API, ISO and other standards the weld and heat affected zone (HAZ) must be normalised. The aim of the heat treatment is to re­establish a homogeneous and fine-grained microstructure in the HAZ. To achieve this it is important to limit the temperature on the external surface of the pipe closest to the coil to avoid grain re-growth, and to reach high enough austenitisation temperature in a sufficiently wide zone at the inner surface. The width at the inner surface must cover the width of the HAZ, which is greatest at the surfaces. EFD Induction has designed three systems that will optimise these parameters: • Seam Annealing with Horizontal Tracking – This system can be supplied with fully automatic or manual tracking. The coils are adjusted according to the weld seam in a horizontal plane. • Seam Annealing with Orbital Tracking – With this system the coil will follow a twist in the seam, keeping a constant distance between the induction coil and the weld seam. Orbital tracking is most common for large OD pipes. This system can be supplied with automatic or manual tracking. • Travelling Seam Annealer – To reduce scrap in shut-down situations, the last section of the seam annealer is movable up or downstream. When the line has stopped this section of the seam annealing system can then be used for seam annealing of pipe that has not been correctly seam annealed. During normal operation the travelling section is part of the normal seam annealing installation. EFD Induction is a supplier of seam annealing equipments for the Normalising process (N), Normalising; Quenching and Tempering process (NQT); and Normalising, Quenching and Normalising process (NQN). One of EFD’s many installations is at Baoshan Steel in Shanghai, China. This mill is designed for a maximum OD of 24in and a maximum wall thickness of 19.6mm. This mill is able to run pipes using the Normalising, Quenching and Normalising process. More information on EFD Induction at: Tel: +47-3550 6000 Fax: +47-3550 6008 sales@no.efdgroup.net www.efd-induction.com Coil end welder suits TIG mills K ent has launched a coil end welder which is designed to be affordable for TIG mills and other lines that run at slower speeds and do not change coils as often. A precision manual shear is used to cut the coil ends; powered wedge clamps hold the strip ends while an automatic TIG weld is made. The weld is made on a bias to pass through tooling better – this also keeps the welded edges from coming together at the weld area in the mill. Larger more automatic machines are available, as well as accumulators to allow non­stop operation. More information on Kent Corporation at: 9601 York Alpha Drive North Royalton, Ohio 44133 Tel: 440-237-9286 Fax: 440-237-5368 fax Mark Costello Markfc@sbcglobal.net Solid service from Emmedi E mmedi, the welding and annealing Division of Saet Group, has developed the Mosweld range of solid state welders. They are based on Mosfet-type inverters able to work at up to 450kHz. Typical working frequencies in tube welding process are 300-450kHz, making mosfets a cost-effective choice for this application. They can also work at frequencies as low as 200kHz. The new welder comprises a transformer, power supply, welding head, cooling system and control desk. The power supply is a three-phase full-bridge thyristor rectifier; filters are inserted to reduce the harmonic components that could affect the welding process. A system control board communicates with the inverter through optical fibres. The inverter is a current-fed type, composed by a proper number of 25kW modules connected in parallel. The output oscillating circuit is directly connected to the inverter. Hardware and software protection is incorporated in the individual modules and the system as a whole to limit component failures. Mosweld offers a number of benefits, including: high efficiency; modular design; easy maintenance; protection against short circuits; much lower voltages inside the cabinets compared with oscillator-tube technology; power components that will not become obsolete; use of the same coils as the classic oscillator tube welder; and long-term reliability. The modular structure and a comprehensive diagnosis system allow quick and easy maintenance to reduce production stops. A digital control system has been developed for optimum phase locking with the ability to deal with changes of frequency due to load variations. As part of its after-sales operation Saet Group offers Teleservice, which allows its engineers remote access to welding units installed at customers’ plants. Turkish show has inter-continental appeal Boru is fast securing itself an international reputation as a significant tube, pipe, fitting and machinery trade show that bridges Europe and Asia. Last year’s show was opened by Mevlüt Vural, general manager of Istanbul Water and Sewerage Administration; Bilal Arslan, general manager of Istanbul Gas Distribution Industry Co; Ömer Faruk Dogan, Turkish Foreign Trade Deputy Undersecretary; Phillip Knight, ITA executive secretary; and Hüseyin Boz, general manager of the organisers, Ihlas Fuarcilik. B oru 2009, the dedicated exhibition of tube & pipe and auxiliary technologies, will be held at the Istanbul Expo Center, Turkey from 5-8 March. Now in its fifth year, the show will feature the latest developments in tube and pipe machinery and products, tools and equipment, process technology, raw materials and accessories for all kinds of tubes and pipes. Industry professionals from Europe, the Middle East, Asia and Africa, as well as traders from all around the world, will have plenty of opportunities to develop new and existing business relationships and export opportunities in the region’s dynamic market – the show is supported by a range of Turkish government agencies. Organiser Ihlas Fuar predicts that Boru will attract about 250 exhibitors this year. Major global companies that have booked space include Emmedi, EFD Induction, Gallium, Hisen Equipment, Inductoterm, More information on Boru 2009 at: Tel: +90 212 454 2503 Fax: +90 212 454 2506 www.borufuari.com SMS Meer, ThyssennKrupp, Buhlmann, Duferco and CHTPZ. More than 20,000 visitors are expected from over 30 countries. Despite the global financial crisis, Turkey remains a promising tube and pipe market for foreign investment, with a range of under way. BORU 2009 EXHIBITOR LIST HALL 9 STAND COMPANY NAME PRODUCTS D-120 INAL Plastic pipe D-120/A SUYAP Plastic pipe D-117 GALLIUM Machinery E-116 PALA PLASTIC Plastic pipe D-118 ZETA Fittings and machinery E-115 AKANSU Plastic pipe D-115 BUHLMANN Tube, pipe, fittings C-118 SMS MEER Tube, pipe, fittings D-113 SAMPA Machinery C-117 ELSIM Engineering B-117 GOKTAS Tube pipe A-117 BIZIMTEKNIK Fittings E-112 HISEN Welding furnaces E-110 UKRAINIAN PAVILION (3 companies) Tube, pipe, fittings E-113 ESEN PLASTIC Plastic pipe D-111 OZPLAS Plastic pipe D-109 NOKSEL Stainless steel C-113 NETBOR Plastic pipe C-111 PILSA Plastic pipe B-109 HATBORU Tube,pipe A-115 LEMSER: REBO Tube and pipe OMP Tube and pipe USM Tube and pipe AGR Tube and pipe EONMETALL Tube and pipe A-113 IGDAS Natural gas distribution A-111 AZOTSM Nonferrous metal process Plant A-109 PRAGYA Machinery A-107 E-BERK Fittings A-105 ALANUR Plastic pipe A-103 JAKKO Plastic pipe E-108 TERMO MACHINE Machinery E-104 SAREM Machinery E-102 GULKAR Plastic pipe E-102/A DEMIR PLASTIC Plastic pipe E-107 NIHAT UYAR Tube pipe D-104 AKIN PLASTIC Plastic pipe D-101 ELMAKSAN Machinery C-103 TOSCELIK Steel pipes B-103 CAGLAR PLASTIC Plastic pipe D-102 EPAS Casting C-102 KARTES Hand appliances C-101 OZBAL Tube pipe B-101 TMK Tube plant COUNTRY Turkey Turkey India Turkey Turkey-China Turkey Germany Germany Turkey-Italy Turkey Turkey Turkey Taiwan Ukraine Turkey Turkey Turkey Turkey Turkey Turkey Germany Italy Italy Italy Malaysia Turkey Ukraine India Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Turkey Russia STAND COMPANY NAME D-100 TEKMAK C-100 BIRLIK MAKINA C-119/A SPRINGER A-115/A SOLVEY E-114 DURANLAR D-099 SIMDEX E-099 DEFOTECH E-116/B SSP B-113 ALKAS GROUP E-106 P100 A-118 DPM E-119/B YUNION D-120/B AYKUT METAL E-117 3R SOFTWARE E-118 TUM PLASTIK B-118 3S MUHENDISLIK B-115 ECE GROUP B-117 PRIZMA TRANS C-113/A ASTERM D-117/A BUDIN E-116/B WORTELBOER E-108/B FELS C-108/C LINSINGER C-103 C-115 A-112 C-113 E-099 C-114 C-115 N/A N/A N/A N/A N/A N/A N/A C-115 GRIND MASTER MEMARAN BEHTARH MERT PLASTIC MIMKA IMS 3M MEMARAN BEHTARH TUBELINKS TUBENET WORLD PIPE LINE METAL EXPO STEEL GRU METALWAY RUSMET MFG MACHINERY C-115/A CAPCO C-115/B AUGUST BELECHER KG B-117 DUFERCO B-117/A JESCO PRODUCTS COUNTRY Machinery Turkey Machinery Turkey Fittings Germany Medical pipes Turkey-Germany Turkey Tube and pipe France Tube and pipe Italy Stainless steel Germany Tube and pipe Turkey-Germany Association Turkey Tube and pipe Turkey Machinery Taiwan Metal pipe Turkey Software Germany Plastic pipe Turkey Engineering Turkey Machinery Turkey Fittings Turkey Tube and pipe Turkey Machinery Turkey Tube and pipe The Netherlands Fittings Germany Tube and pipe Austria Machinery India trader Iran Plastic pipe Turkey Forklift Turkey Association Turkey Software Turkey trader Iran Website USA Website Finland Magazine UK Organiser Russia Publisher India Publisher Germany Publisher Russia Machinery Germany Saw Germany Machinery Germany Tube Factory Switzerland Tube Factory Switzerland D-109 IRAN SADID INDUSTRIAL GROUP Oil, tube and pipe Iran A-114 ILTA ARVEDI Stainless steel Italy A-104 DANIELI Machinery Italy A-106 WAFIOS Machinery Germany A-108 SCHULZ Tube, pipe, fittings Germany A-110 TENARIS Tube, pipe, fittings Italy A-101 MARCEGAGLIA Tube, pipe, fittings Italy A-105 DNIEPROPETROVSKY Tube, plant Ukraine A-103 ILJIN LIGHT METAL Tube, pipe, fittings Taiwan B-101 OMK Tube plant Russia B-103 STEEL TECH Steel pipes Malaysia B-107 CONDOROIL Oil industry Italy B-109 VOESTALPINE Tube, pipe, fittings Switzerland B-113 ADA YAPI Engineering Turkey C-101 PIMTAS Plastic pipe Turkey C-107 ELEKTROSAN Tube, pipe Turkey C-109 MULTI METALS Tube, pipe, fittings India C-111 POWER MASTER Machinery India C-111/A JINDAL STEEL Steel pipes India C-113 FRAMAG Machinery Austria Including November 15–18, 2009 McCormick Place | Chicago, Illinois USA COSPONSORS INDUSTRY PARTNERS Measuring profits Pierre Huot explains how non-contact optical measurement devices can increase the efficiency of ERW/HFI tube mills and improve process yield W elding tube and pipe efficiently depends on a number of factors, including material type, gauge, edge condition, tooling setup and weld heat. Optical tube measurement during setup and production can cut wastage by 25%. The tube and pipe industry has always been fragmented and unpredictable as firms with deep pockets acquire or merge with complementary or competing fabricators. Companies have also closed plants to relocate their assets to countries offering lower costs. As a result some experienced mill operators have been lost. In mature markets the remaining players are expanding while in emerging markets new fabricators are coming online, increasing these regions’ prominence on the world stage. In the midst of such powerful market forces producers have little bargaining power, but the right technology will minimise risks. Daily challenges Tube mill operators, mill supervisors and quality-control managers face a range of daily challenges in their efforts to produce high quality tubing. A common problem is strip edges entering the welding area out of true (non parallel). This produces a step mismatch, which causes irregular sizing downstream through the sizing area. One cause of this is improper setup in the breakdown, forming and fin section which should ensure proper presentation to the welding section, and strip rolling in the breakdown section. It may cause the strip to ride high on one side, although this can also be caused by negative tension in the tube mill. The back pressure causes the material to buckle, and as the energy needs to be released the material follows the path of least resistance, up the side of a forming roller. There can be two kinds of edge misalignment. The first one, as mentioned above, is a ‘trending’ error; the second is an intermittent error which is a wrinkle in the strip material over a short distance. This can be the result of misaligned breakdown passes, improper edge preparation or possibly a problem with the raw material. Lost runtime from setup Mechanical error due to the mill or tooling being in poor condition, or to mill misalignment, reduces the production-line yield. Similarly, there are setup steps that impact on the changeover time and add to the waste stream: • During setup, sections are cut from the mill to check for weld integrity. The mill then has to be rethreaded and repeated if the check fails. This cuts efficiency and increases material waste. • Obtaining the correct apex angle as part of the setup involves running material through the mill before the apex angle is properly set, which also contributes to reduced efficiency and more waste. • At setup, the last fin pass roller and the squeeze rollers in the weld box need to be bottomed out and in alignment. • If the alignment is not done properly at setup the sizing section may not develop enough positive tension, especially during reshaping. The tension before the weld roll can be negative, which is harmful to edge presentation and welding. The importance of the V Knowing what the V angle should be for a given tube size and material, and the gap values along the V leading to the apex, will enhance efficiency. What happens in the V is all important because it can affect weld quality and speed. High-frequency current density is highest in the edges near the apex of the V and at the apex itself. Encouraging high-frequency current flow in the V depends on the V dimensions and the angle of opening. Two conditions must be met to obtain the best electrical conditions for the weld: • The greatest possible proportion of the total high-frequency current should flow in the V. • The edges in the V must be parallel so the heating of the seam is uniform. With parallel edges the oxides and other impurities are squeezed out in both directions. In general terms a V angle of 2­7° is desirable for carbon steel. In process this angle could oscillate, thereby changing the position of the apex point with respect to the weld pressure centreline. This oscillation could be due to improper setup, worn forming rollers or material spring-back, which could implicate the raw material supplier. Weld faults It is generally agreed that weld faults can be caused by these factors: • V forming angle • Welding speed • Welding power • Squeeze force • Frequency If clean smooth edges are presented to the welder in the right fashion, the operator need worry only about running too hot or too cold. Keeping customers The ERW/HFI industry has low switching costs, and unsatisfied clients can find alternative suppliers relatively quickly. A burst seam during process or in the field can lead to liability risks, not to mention the time and money involved in audits and containment by both producer and client. The solution Two main challenges facing mill operators are controlling the strip and presenting the edge precisely through the squeeze box, and precise temperature control. A non-contact measurement device will assist the operator during setup and in process, leading to increased efficiency, yield and profit. Optical measurement devices offer a range of benefits in the infeed V-forming area and in the outfeed of the weld box during setup and process. Infeed – setup: • Align the last fin pass and squeeze roller bottom angle • Align the forming rollers for optimum edge presentation and V angle Infeed – process: • Measure the V angle and gap values in the V • Predict the apex point relative to the weld pressure point • Measure the mismatch between the two strips • Measure the seam presentation. • Measure the seam roll from centerline Outfeed – setup: • Align the weld squeeze rollers • Set the welding parameters to the welding speed by measuring bead geometry as an indicator of temperature Outfeed – process: • Measure the bead geometry for temperature control • Measure the bead centreline peak • Measure the mismatch between the side walls • Measure for weld skips, gaps, defects • Measure the outfeed seam presentation In process these measurements The Xiris advantage Optical measurement equipment depends on the quality of the acquired image – mill operators should look for a company that has in-house optical design capabilities because this allows increased accuracy without ramping up costs. Reliability and repeatability are key factors so look for a firm with a track record for uptime and performance – and one that is willing to continually invest in R&D and improve its product and upgrades. A specialist that focuses its resources on a single market can offer a faster service and better solutions. Another essential resource for quality control and inspection is a powerful SPC engine to crunch through the data and build reports. Xiris offers every one of these benefits, making it uniquely positioned to serve the ERW/HFI industry with optical measurement systems for inspection and quality control. Xiris is trusted by world-class companies which value their brands, such as Sony and Panasonic because it is a leader in the field of quality control and optical design, with a software suite designed for high speed applications and SPC. With 18 years’ experience in vision systems and 10 years’ experience in optical disk inspection and quality control, Xiris continually innovates to consistently deliver affordable reliability and performance. The company has an intimate understanding of what it sells; as a result it is able to build redundancy in its systems to minimise any downtime. Clients in 35 countries are supported by an in-house service team which takes pride in a fast, effective response to inbound requests. should stack against a set of threshold values for lower limit, warning limit, set point and upper limit. To ensure precise control data measurements in the realm of 50µm (0.002in) and 100µm (0.004in) are required, with intervals between data of 10mm (3/8in) or less. An inline measurement system provides the added benefit of logging the measurement data and outputting to data charts, histograms, scatter diagrams, time-stamp diagrams and control charts. This gives quality and improvement managers insight into the material flow through the mill, helping them tune the setup and process parameters to improve efficiency and yield. Benefits to producers Non-contact optical measurement devices offer clear benefits to tube and pipe producers. Measuring the infeed forming will provide a faster determination of where the parameters need to be, allowing faster adjustment to the set point values. Controlling the V angle and presentation will ensure better fusion in the weld box. Cutting the time it takes to set the mill for forming and temperature will reduce the amount of unwelded material and rethreading, while alerting the operator of a potential problem will expedite corrective action and improve the tonne/hr throughput. QC and QA can result in enhanced analysis and reporting for internal process improvement and external client assurance. Furthermore, producing the same throughput with less tonnage and energy is not only profitable, but environmentally responsible. • Pierre Huot, who has an MBA and a degree in engineering, is vice-president of Xiris and leads the development team for company initiatives. He has 16 years’ experience in automation and vision system solutions. The cost of scrap Market averages for scrap rates from a typical mill range from 2- 5% annually. Industry averages for steel as a cost of goods approach 75%. A mill that makes a $10m with 4% scrap would make $20m with 2% scrap. More information on Xiris at: Tel: +1 905 331 6660 Fax: +1 905 331 6661 phuot@xiris.com www.xiris.com/tube Save time to save money A nything that leads to lost mill time, whether during changeovers or normal operation, will hit your bottom line. Roll-Kraft runs through the common causes of lost time, and offers some common-sense solutions. . No written procedures for set-up All tube and pipe mill operations must have written procedures for everyone to follow; these also provide a tool for troubleshooting when problems arise. You cannot afford to have each operator setting up the tube mill by his or her own ‘feel’. The machine and the tooling, as well as the steel, are fixed factors in the mill set-up equation. The only variable is the human factor – which is why it is so important to have written procedures in place, to impose discipline on the process. . No set-up chart for the operators to follow Setting up using a ‘seat-of-the­pants’ approach, or ‘tweaking’ the mill, costs valuable set-up time. Operators must work the tooling the way it. and the tube/pipe mill, were designed. This means setting up to the parameters of the set-up chart. . Lack of formal training Formal training helps develop the procedures for tube/pipe mill operation and maintenance and keeps everyone working towards the same standard. . Failing to set up the numbers from the last set-up This can be done with a Single Point Adjustment (SPA) feature, whereas if the tube mill has been set up by the set-up chart and procedures outlined, you can simply write down the numbers from the digital readout on the SPA units and set up to where you left off last time. Setting up to the numbers can save as much as 75% on your total set-up time, assuming all the other items listed in this guide are in order. In the absence of SPA feature, rim clearances from the driven and idle passes can be documented to set up to the next time. . Mill in poor condition Does your mill have a good maintenance programme? Is your mill in need of a rebuild, or upgrade? A poorly maintained mill will cost valuable time and scrap when trying to setup and operate the machine. The mill must be dependable if you are to avoid wasting time sorting out mechanical problems during normal operation and setup. How much could you save? Let’s assume your mill rate is save up to 75% on set-up time Example: The standard set-up example saving even 15 minutes $2,000 per hour. Let’s also just by setting back up to the time is four hours. This amounts to will cut wastage – and boost profits assume that the rest of the mill numbers that were documented $8,000 of mill time. If you can save – by $500. And that’s in addition to is in good shape, with the right from the last successful 75% this figure would fall to $2,000 the value of the end product and procedures in place. You could production run. – a saving of $6.000. In this savings on reduced start-up scrap. 28 IMT February/March 2009 www.internationalmetaltube.com . Poor alignment Is your mill in good alignment? Some 95% of all tube related problems involve mill condition, set-up and alignment. Most mills are aligned at least on an annual basis. . Poor tooling Is your tooling in good condition? Do you have a tooling maintenance programme? You must know at all times how much life is left in your tooling before the next scheduled re-work. Running the tooling until it can not produce tubing any more will not only waste valuable mill time, but produce scrap and affect delivery schedules Any of these factors will cost valuable time on the mill, depending on the severity of the condition. The fact of the matter is, the more you take action in advance, the less downtime you will have on the mill. Roll-Kraft’s latest Ardcor Mini Mill is a universal-type roll former designed for the sections and price-conscious buyer while retaining the durability and precision found in the company’s conventional roll formers. To accommodate an optional Raft-type operation, each roll stand is driven individually by spring-loaded, quick-disconnect universal shafts. Each roll stand is driven by a double output shaft gear reducer. The reducer includes hardened and ground steel spur gears and bronze worm gears. All machines are available with any number of stands and raft combinations to suit clients’ present and future requirements. 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 European director for Swagelock S wagelok Company of Solon, Ohio, USA has appointed Deric Wallace as regional director, Europe. He will be responsible for all aspects of business development and sales and service support within the region. Wallace joined Swagelok in 1996 as a project manager. In 1999 he became manager of the European Technical Centre at Swagelok AG in Switzerland and in 2003 he was promoted to business development manager for the European region. In 2007 Wallace was named regional manager for Europe, Middle East, and Africa. Swagelok is a major developer and provider of fluid systems, including products, assemblies, and services for the research, instrumentation, pharmaceutical, oil and gas, power, petrochemical, alternative fuels, and semiconductor industries. Its manufacturing, research, technical support, and distribution facilities support a global network of more than 200 sales and service centres in 57 countries. More information on Swagelok at: www.swagelok.com Shaffer’s at your service Formtek has appointed Bob equipment industry, having In his new role Mr Shaffer will More information on Formtek at: Shaffer as its new director of installed systems and provided oversee customers’ aftermarket Tel: +216 292 4460 customer service. He has more service support throughout needs in terms of on-site Fax: +216 2922898 than 25 years’ experience in the North America, Europe, Asia service, training, spare parts info@formtekgroup.com tube mill and roll forming and Africa. and rebuilds. www.formtekgroup.com Full of eastern promise Among the highlights of our next issue will be an update on Tube Russia 2009, which will offer visitors an insight into the latest trends and technologies, covering raw materials, tubes and accessories, tube manufacturing machinery and control systems. This show attracts professionals, including engineers, technicians, buyers and production managers from a wide range of industries. More exhibitors are booking space as IMT goes to press and the following list does not include the national pavilions from China, Italy or Russia, but it indicates the global nature of this show. Don’t miss IMT April-May 2009 for full details. Tube Russia 2009 Exhibitor List EXHIBITOR ABBEY INTERNATIONAL ABP Induction Systems Gatos Ajax Tocco Magnethermic Corp Allied Mineral Products Europe Andritz-MAERZ Attl a spol sro Továrna ne stroje AWS Schäfer Technologie Bossi Braun Maschinenfabrik Bronx/Taylor-Wilson Buhlmann Bultmann Can-Eng Furnances CCPIT Machinery CCS Services CMEC International Consarc Engineering Controle Mesure Systemes Danobat Disa Industries Disa Moscow Maschinenfabrik Gustav Eirich Elmaksan Elterma Eonmetall Eurolls Faccin Ferro Crtalic Foundry Equipment & Supplies Assn Fours Industriels Framag Oskar Frech Friedrich Giessereitechnik EXHIBITOR COUNTRY STAND USA 7-6 C07 Germany 7-5 C19 Germany 7-5 C16 USA 7-5 B23 Netherlands 7-6 D02 Germany 7-5 A25 Czech Republic 7-6 D11 Germany 7-5 B16 Italy 7-4 A04 Austria 7-5 B01 USA 7-6 B07 Germany 7-5 C15 Germany 7-5 A01 Canada 7-6 B09 China Hall 07 Switzerland 7-5 B25 China 7-6 D04 UK 7-6 B01 France 7-6 D15 Spain 7-5 Denmark 7-5 C01 Russia Hall 07 Germany 7-5 B15 Turkey 7-4 A12 Poland 7-6 B05 Malaysia 7-5 C22 Italy 7-5 A25 Italy Hall 07 Slovenia 7-4 A06 UK 7-5 B21 France 7-5 B02 Austria 7-5 B20 Germany 7-5 C17 Germany 7-5 C16 Froch Europe Gemco Engineers General Insulation Europe Gertner Service Giesserei Verlag Gostol-TST Gräbener Maschinentechnik Guss-Ex Heinrich Georg Maschinentechnik Heinrich Wagner Sinto IMS Messsysteme Inductotherm Group Europe Intras IOB Industrie-Ofen-Bau Ipsen International ITA ITS Benda Iwamet Otto Junker KCI Koerner Chemieanlagenbau Künkel-Wagner Kurtz Laempe & Mössner LAP Linn High Therm Linsinger Maschinenbau Lippmann M&D Gertner Mahler Maicopresse Mair Research Metallurgical Council of CCPIT MWE Magdeburger COUNTRY STAND Netherlands 7-4 A02 Netherlands 7-6 C32 Germany 7-5 A08 Germany 7-5 A25 Germany 7-5 A06 Slovenia 7-4 A06 Germany 7-5 B12 Poland 7-5 Germany 7-5 A25 Germany 7-5 B05 Germany 7-5 A09 UK 7-6 B01 UK 7-5 B29 Germany 7-5 A07 Germany 7-5 A14 UK 7-5 B19 Czech Republic Hall 07 Poland Hall 07 Germany 7-5 A12 Germany 7-5 C20 Austria 7-5 A19 Germany 7-5 A11 Germany 7-5 B08 Germany 7-5 B03 Germany 7-5 A25 Germany 7-5 B06 Austria 7-5 A24 Germany 7-5 B04 Austria 7-5 A25 Germany 7-5 B02 Italy 7-4 A14 Italy 7-5 A25 China 7-6 C11/7-6 D24 Germany 7-5 B01 Tube Russia 2009 Show Plan International Metal Tube To start receiving your FREE copy of IMT magazine please complete in full the registration form below, for individuals outside of Europe we will be providing the magazine in a digital (cover to cover) version to ensure the fastest delivery. The printed version is however available outside of Europe via a subscription. To receive your free copy simply return this form either by fax on +44 (0)1268 711567 or post it to: Hartswood Media, Hallmark House, 25 Downham Road, Ramsden Heath, Essex, CM11 1PU, United Kingdom. I reside outside of Europe and would like to receive a printed version of the magazine and would like to subscribe at the discounted rate of £100.00 per year (Outside UK a sterling draft is required, or add £10 to cover charges). I do not want to receive a printed version of the magazine but I do want to access the online version of International Metal Tube. Section 1 Type of Business: . D Non-Ferrous pipe producer . H Pipe End User . A Ferrous tube producer . E Tube/Pipe Supplier . I Machinery/equipment . B Non-ferrous tube producer . F Tube/Pipe Buyer & lubricant supplier* . C Ferrous pipe producer . G Tube End User . I Other *Please note, we will not include machinery/equipment & lubricant suppliers in our circulation list. A separate database for free copies will be maintained and used on a rotational basis. Section 2 Job Title/function: . D Engineering Management . H Maintenance Management . A Corporate Executive . E Mill Director/Manager . I Sales/marketing: . B Management . F Purchasing . J Other: . C Production Management . G Product R&D Management Section 3 Purchasing Responsibilities: . A Ferrous tube . E Tube/pipe manufacturing machinery . I Plant engineering & maintenance . B Non-ferrous tube . F Process technology tools/equipment . J Other . C Ferrous pipe . G Measuring/control technology . D Non ferrous pipe . H Testing Section 4 Do you influence/authorise purchasing decisions? Yes . No . Please tick Section 5 what is your company’s main area of activity/application? Please tick a maximum three boxes: . A Automotive . F Chemical & pharmaceutical . K Utilities . B Non-automotive transport . G Petrochemical . L Agriculture . C Aerospace . H Mining . M Nuclear . D Defence . I Construction . N Other . E Oil and gas . J Food & drink Section 6 Number of Company Employees: . A 1-49 . D 250-349 . G 1000+ . B 50-99 . E 350-499 . C 100-249 . F 500-999 If you wish to receive further promotions from us or other carefully selected companies, please tick the boxes: . post . fax . email Important: To process your registration this form must be completed, signed and dated 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