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International Metal Tube Volume 2 Issue 9

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pipe producers and processors Comment As we are now in the final stages of preparation for Tube Dusseldorf, it is still sad to know just how many companies that supply the metal tube, pipe production and processing industry are struggling to make ends meet. This does not just apply to the small to medium sized company, but many that are seen as major players are also having to make serious cut backs. There is however some good news, and this will be reflected in the new products and equipment on display at Tube Dusseldorf. Some of those companies have already released basic information, and this can be seen in this issue of IMT. Of particular note, I would urge you to at least make sure you visit the companies listed below, all who have indicated that they will have something new or innovative to be discussed. However, for the most up to date and informative data on Tube/Wire 2010 please visit www.messe-duesseldorf.com. data M Sheet Metal Solutions GmbH - Hall 4 Booth F19 Machinery International Corporation - Hall 4 Booth 4D09 TRACTO-TECHNIK GmbH & Co. KG - Hall 5 Booth E 21 Oto Mills - Hall 6 Booth 6E30 TeZet Technik AG - Hall 5 Booth A21 (Wafios booth) PROTEM GmbH - Hall 6 Booth F24 Unifit - Hall 01 Booth E33 Herber Engineering AB - Hall 5 Booth B09 Ernst Blissenbach GmbH - Hall 6 Booth A41 Zumbach Electronic AG - Hall 5 Booth C27 E Büker Rohrtechnik GmbH - Hall 6 Booth A23 Binder Edelstahl - Hall 4 Booth G01 Sandvik Materials Technology AB - Hall 3 Booth D04 EFD Induction a.s - Hall 6 Booth C26 Galaxie Corporation - Hall 6 Booth F21 Please remember that you can also visit IMT magazine in Hall 7 Booth 70D27, in our April/May issue we will also include a review of what was new at Tube Dusseldorf, Tube & Pipe Inspection, measuring, testing & marking, Stainless steel focus plus Coating, pickling & galvanizing technology. Contributions for this issue should be with me no later than April 22nd, and finally may I wish all those who are exhibiting/visiting a good Tube 2010 Dusseldorf. Vince Maynard IMT Contact Information PUBLICATION MANAGER DIGITAL CONVERSION BY & EDITORIAL CONTROLLER Print to Digital Vince Maynard PRINTED BY+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 Manor Creative, Eastbourne, East Sussex, UK Tel: 02392 661485 www.manorcreative.com PUBLISHED BY Hartswood Media Hallmark House 25 Downham Road Ramsden Heath Essex CM11 1PU United Kingdom T- + 44 (0) 1268 711560 F- + 44 (0)1268 711567 www.internationalmetaltube.com PWC surveypredicts growinggreen focus M ore than half the documenting all emissions in respondents to their supply chain. PricewaterhouseCoo “However, when they do these per’s recent survey of emissions will be factored into the 48 transport and logistics price of products. Increased executives expects alternative awareness of consumers about energy to accounts for up to 80% sustainability will change of their overall energy mix in some consumer behaviour and in turn, countries. The majority of global supply chains.” respondents see the reduction of Nearly 60% of respondents CO2 emissions and other believe that their home and work emissions (such as nitrogen oxide environments, will become more and noise) as a target in the short integrated, with travel distances and long term. And nearly 70% of diminished. Over 45% of respondents expect that by 2030 respondents even expect a all emissions will be tracked in reduction in individual mobility. the supply chain and factored into Although 60% of those the price of the product. surveyed think that consumers Klaus-Dieter Ruske, partner will prefer locally produced and transportation and logistics products by 2030, respondents do leader at not expect a reverse of PricewaterhouseCoopers, says: globalisation by 2030. Even so, “Energy prices, climate change 59% think that transportation and regional sourcing will drive a costs will be the dominant factor fundamental shift in the transport in the location of production sites. and logistics sectors by 2030. A further finding is that more Transport and logistics flexible and efficient usage of companies, from express mail transport modes will emerge. The services to airlines, will face more majority of respondents anticipate than just technical problems that autonomous and self-through tracking, evaluating and controlled systems such as agent systems and automatic guided vehicles will revolutionise freight transport; 60% predict that a concentration of transport capacity, for example through the use 60-tonne-plus ‘mega trucks’ or ultra-large container ships will counter increasing costs. Half of respondents believe road transportation will take a greater share of total freight transport. More information on PricewaterhouseCoopers at: tel: + 44 (0) 20 7212 1002 www.pwc.com/uk Wolf Maschinenbau chose the EMO show 2009 in Milan to launch the Wolf Center Measuring Device (Wolf CMD). This digital centring device allows fast, precise and process-safe adjustment of one axis to the other. The Wolf CMD facilitates electronic measurement of the position of the machine's unit head. The Wolf CMD’s software compact and rotates around the controls height adjustment and existing part. Central clamping is fine adjustment so process safety not necessary, making the sensor of the system is guaranteed. In- universally adaptable. house, Wolf has reduced setting time by 60% by using the CMD. More information on Wolf The sensor has a Maschinenbau at: measurement range of 0.5mm tel: 0 7135 936 9836 and a resolution of >0.01µm. It is www.wolf-maschinenbau.com Wold CMD is fast precise and safe Plymouth Tube Co. announces the premier power gen event of the year! Steve Bohnenkamp, Vice Some of the topics to be covered President of Sales & Marketing, include: announces the premier power gen Condenser Theory and Function event of the year - The 2010 Test Codes and Methods Condenser Life Cycle Seminar, Condenser Failures co-hosted with Conco Systems, Material Specifications Plastocor,Inc. and Retubeco! Protective Coatings Join us on September 13-15, Retubing Activities 2010 at the Georgia Tech Hotel and Conference Center, located For more information about the in the heart of mid-town Atlanta, event including: Registration, GA. This long-awaited seminar Agenda, Speakers, Lodging and will help solve your most Contact Information - Visit the challenging condenser problems. official seminar website at. Now is your opportunity to meet www.condenserseminar.com. and learn from some of the most More information on Plymouth brilliant technical experts in the Tube Co. Contact industry. Space is limited, so if Janet Miles you want to be up on the best- Marketing Specialist practices for your condenser, tel: 630-791-2748 register now jmiles@plymouth.com 2 IMT February/March 2010 www.internationalmetaltube.com Kochs rolls ahead in the East with ground breaking ‘Star Drive’ design S umitomo Metals Kokura (SMK) is to replace the existing three-roll finishing block of its specialty bar mill in Kokura, Japan by a three-roll block of the latest generation produced by Friedrich Kocks & Co of Hilden, Germany. Following modernisation the mill will consist of the roughing mill, the intermediate mill and the finishing mill. More than 20 years ago SMK pioneered the implementation of a combined Kocks’ three-roll finishing block into its existing rolling mill. Then as now, the decision to introduce three-roll technology has been made on the basis of the reliability, and the excellent results of this technology, as well as the quality of the finished products in terms of roundness and tolerance. The fundamental reasons for this investment are the improvement of quality, as well as the production capacity for special steel bar which are both strategically very important for SMK. The monthly production of the bar mill will be increased by 10% to 90,000t/m. SMK predicts that the long-term demand for special steel bar will increase along with requests for higher quality steel grades. The heavy duty design of the new reducing and sizing block, allows rolling with higher rolling forces as well as better product quality combined with temperature controlled rolling. Considering the decrease of rolling efficiency for the production of high-quality steel grades, the RSB will increase the efficiency of the whole rolling mill and at the same time will assure competitiveness by reducing energy consumption. • Kocks has also received an order from China National Petroleum Corporation (CNPC) for a stretch reducing block and a rotating hot saw. They will form the core of a welding tube plant at CNPC’s subsidiary Baoji Petroleum Steel Pipe Co (BSG). CNPC is China's largest oil and gas producer with operations in 29 countries. BSG was established in 1958; it was the first Chinese manufacturer of tubes using the submerged arc welding method and now produces 1.25 million tonnes of steel tubes per year. With its new welding tube plant, BSG leads the way for tube production in China and will be its first manufacturer of welded and stretch-reduced tubes. The plant will be able to continuously weld and stretch reduce in a single step – the tube will be in the welding line and in the stretch reducing block at the same time, which will significantly boost the plant’s output to a predicted 300,000 tones per year. The range will include tubes with diameters of 60.3­177.8mm with wall thicknesses of 4.83-13.72mm, meeting international standards for applications in the oil and gas industry. The three-roll stretch reducing block features a ground-breaking ‘star drive’ design which will roll the full range of finished sizes from a mother size of 193.7mm diameter. The block will incorporate up to 24 stands with a nominal roll diameter of 360mm. The last three stands will be adjustable finishing stands, the rest will be non-adjustable reducing stands. A quick changing system will considerably reduce the required number of stands for optimum production. An RHS 1000 rotating hot saw will be installed between the SRB and cooling bed to allow the production of various tube lengths with excellent length tolerances. This means complex batch conveyors and saws behind the cooling bed can be omitted, reducing investment and maintenance costs. Kocks will also supply roll shop and electrical equipment, automation systems as well as basic engineering for local production, which is obligatory in China. This will include supervision of assembly and commissioning, training of operators and the transmission of process know-how. Commissioning of the new tube mill is scheduled for the second half of 2011. More information on Friedrich Kocks & Co at: Tel: +492103 790151 fax:+492103 54028 vdHeiden@kocks.de www.kocks.de Successful Schweissen & Schneiden Show Weld-Tech had a busy time at the Essen Schweissen & Schneiden show. For the firm’s fifth outing the 120m2 stand was shared by Weld-Tech and its German importer, DWT. The resulting combination of tools for pipe welding and beveling machines proved to be a popular one with show-goers. Both DWT and Weld-Tech export most of their output throughout the world; over the years they have found many common distributors. This allows them to offer customers a complete package to optimise production and assembly operations. These products have helped More information on Weld-Tech at: Headlining the stand were Weld-Tech expanded its tel: +45 4619 4647 Weld-Tech’s WT SC clamp, GM1 distribution network in the Far fax: +45 4619 4642 oxygen monitor and the new Type East, South America and weld-tech@weld-tech.com 210 purge gas tool. Australia. www.weld-tech.com More agile budgeting and forecasting for steel manufacturer I nfor, the leading provider of business software for mid-market customers, today announced that Hadley Group, one of Europe’s largest, privately owned cold rolled steel manufacturers, has extended its portfolio of Infor solutions with an investment in Infor PM 10 (Performance Management) software. Hadley Group will deploy PM10 for more agile budgeting and forecasting within its manufacturing sites in the UK and Germany in early 2010, and later roll it out to staff in Dubai and Thailand. Hadley Group has outgrown using Excel spreadsheets for budgeting – a manual process which typically takes more than three months to conduct every year. The Hadley Group rolls more than 125,000 tonnes of steel every year for international customers in industries including automotive, construction and aerospace. It chose PM 10 because it could easily integrate with its existing Infor ERP Baan 5 software to provide some of the essential data feeds for the PM solution. PM 10 was also chosen because of its ability to deliver a complete end-to-end performance management solution, including budgeting, forecasting, planning, consolidation, reporting and analysis all from a single database to ensure data integrity. In order to help users readily adopt the new system, Hadley Group needed a solution that retained the spreadsheet familiarity which would ensure a smooth transition to PM10. “In the current economic climate, moving to a rolling three month budgeting schedule, as opposed to analysing out-of-date annual plans, makes perfect sense for better business planning. Our adoption of PM 10 goes hand in hand with a change in our culture as we shift focus from a constant, time intensive analysis of our financial information to management by exception,” explains Mike Collier, business systems manager, Hadley Group. To help identify these exceptions within the business, Hadley Group has also invested in Infor PM Application Studio for enhanced business intelligence. Beyond performance management, The Hadley Group is also piloting an upgrade from Infor ERP Baan 5 to Infor ERP LN, the latest version of Baan. This is currently being conducted in a test environment in the UK before adopting and rolling out to other sites. Collier concludes: “Technology is pervasive throughout our group – from the barcodes that track our goods-in right through to the PCs we have in the canteen that staff use to book time off for their own holidays. 2010 is a busy year for us with the roll out of our new PM and BI solution, the deployment of the Infor ERP software to more of our international operations, together with the evaluation of ERP LN. Hadley Group is constantly looking to improve its performance amidst tough trading conditions, and we are very confident of success.” Infor provides more than 70,000 customers a better, more collaborative relationship with their business software provider. Infor software is simple to buy, easy to deploy and convenient to manage. It is software created for evolution, not revolution. There is a better way, to find it visit www.infor.com More information on Infor please contact: Richard Moore Infor Public Relations, EMEA +44 121 615 8189 Richard.moore@infor.com “The Spirit of St Louis” - exceeding the standards As demands increase in the Aerospace Industry, Plymouth Tube Company remains a leader in innovation, testing and product development of stainless steel tubing. Having served the aerospace industry since the "Spirit of St. Louis" we will always strive to meet and exceed customer expectations in an evolving marketplace. Plymouth Tube gained Napcap accrediation for Heat Treating, as well as the laboratory activities which verify the heat treating. These include: room temperature tensile, rockwell hardness, and metallography. By manufacturing in accordance with Nadcap approved processes, you can be assured that materials produced and tested are to the highest standards set by the Global Aerospace Industry. Several distinct advantages PTCA provides include: Uniform Mechanical Properties - Reduced Product Inconsistencies ­Compliance with Global Aerospace Standards. For more detailed information about sizing, grades of specifications of stainless steel tubing both welded and drawn, please contact us as listed below Plymouth Tube Co Janet Miles +630 791 2748 jmiles@plymouth.com Unifit Fittings & Burak Boru forge ahead... T urkey is now the world’s 11th biggest producer of raw steel, with an annual output of 25,8 millions tons, UNIFIT BORU BAGLANTI, the manufacturer and wholesaler of seamless steel pipe fittings and flanges established in 2005, has an important part to play in country’s steel industry. In addition, our sister company BURAK BORU, Turkey’s biggest seamless carbon steel stockiest, supplies all UNIFIT’s product ranges and provides an entire pipe range to the highest quality and standards During the recent global crisis period, UNIFIT actually increased its production capacity by more than double given high client end demand. With new semi-full automatic induction machines for elbow, new oil pressure cold forming tee and reducer machines, and cap forming machines, our production capacity has increased up to 800 tons per month. Currently we are in the process of installing forging machines for the production of forged steel flanges. With our state-of-the-art technology production facility and experienced staff, we manufacture our UNIFIT branded products to the highest quality standards. All UNIFIT products are manufactured in accordance with Directive PED/97/23/EC ­ANNEX I, CHAPTER 4.3. With new machines, we already produce in the most common standards such as EN, DIN and ASTM norms, with a wide product range including seamless and welded steel elbows, equal tees, reducing tees, CONC. & ECC. reducers and caps. Once the test of flange production finishes, we will start to mass production in order to satisfy our client’s needs with UNIFIT branded high quality products. Using standard Euro-pallets during delivery, we give the same New addition to the management Rainer Steven, a acknowledged expert in the field of abrasion protection, has joined the management team of the company Scholten GmbH & Co. in Wülfrath. This long-established company is responding to new challenges on fast changing markets on which it intends to continue growing further in the future. Thanks to his specific experience in this business sector, Rainer Steven will actively contribute to driving the company towards the future, with cutting-edge solutions, tailored to the individual customers’ needs in the abrasion and corrosion protection sector. After a clearly defined period of transition, the 56-year old is set to take over the general management. For the past 10 years, Rainer Steven was successfully working as a manager in the field of ceramic wear protection solutions. In addition to his commercial activities, he also co­developed patented wear protection solutions. More information on Sholten GmBH & Co at: www.scholten-gmbh.de careful attention to packaging and protection, in order they arrive in pristine condition. UNIFIT Fittings are extremely competitive, and we currently export to Western Europe (U.K., Spain, Belgium, The Netherlands, Austria), Middle-Eastern Europe (Poland, Latvia, Romania, Bulgaria), Middle East and Northern Africa. Burak Boru and Unifit Fittings together manage a 70.000m2 area (of which 30.000 m2 is covered) manufacturing complex close by to major high-ways and cargo ports, thereby giving us a big logistics advantage. In addition the sister compay, BURAK BORU, occupying the leader position in the sector of seamless steel pipes trading with its stock and sales volume, has been supporting many industrial sectors like automotive, HVAC installations, construction, and naval architecture, with the experience of 25 years in the steel sector. All the materials we supply, are tested in the manufacturing factory and are certificated according to EN, DIN, ASTM, API and GOST norms. Burak Boru Co., aim to improve the quality of service with total quality management system, and have been certified by ISO 9001:2000. More information contact: Unifit Fittings - Turkey info@unifit.com.tr www.unifit.com.tr Burak Boru - Turkey tel: +90 216 581 81 00 fax: +90 216 593 04 09 info@burakboru.com.tr www.burakboru.com.tr Efficient blast cleaning of different size steel pipes T he experience and know how of the Rösler team convinced Terex cranes, a world wide leading crane manufacturer, to purchase the new pipe blaster RDR 500 for their plant in Zweibruecken where lattice boom cranes are manufactured. At this location, Terex® produces lattice boom cranes with a payload of more than 300 tons which can move under full load (“pick & carry”). At the Zweibruecken site the CC 8800-1 TWIN is built. The biggest and strongest crane in the world, it can lift 3200 tons and still move under full load. An essential section of this type of crane is the lattice boom that is fabricated from steel tubes of different diameters and lengths. The new tube/pipe blaster RDR 500 allows Terex® to de-scale and de-rust tubes with a length of up to 18,000mm and a diameter of up to 500mm prior to flame cutting. Processing trials ensure a stable and consistent blast process A major factor in the decision for the RDR, was that Rösler has already supplied a number of nearly identical tube blast systems to OEM’s, as well as steel trading companies. Another important point was that Rösler was able to adapt the machine design to the Terex® requirements by conducting processing trials in the Rösler test lab. The trials showed that the required degree of cleanliness, according to the Swedish Standard of SA 2.5 (“near white”) surface conditions are achieved in the machine, with travel speeds from 2.0 to 6.5 m/min, due to the two high performance Hurricane® H42 blast wheels which are driven by 22 kW motors. These easy to maintain, single disc blast wheels, are mounted sequentially on the blast chamber. The blast chamber itself is fabricated from wear resistant manganese steel. The precisely defined blast angle ensures that the required blast results are consistently achieved in the specified time, even with tubes with a relatively large diameter. Optimum interface between blast and flame cutting operation Since the Terex® specifications only call for the blast cleaning of the outer tube surface, the open tube ends are masked. However, Rösler also offers solutions for applications where blast cleaning of the inside and outside of the tubes is required. Transport of the tubes through the blast machine which is equipped with an entrance and exit vestibule, takes place with two 18 meter long roller conveyors with a rated load of 500kg per running meter. The blast cleaned tubes are directly transported from the exit vestibule into the flame cutting system. Since the supplier of the flame cutting system, HGG Profiling Equipment BV from the Netherlands, and Rösler have had a long term and friendly cooperation, the interface issues between the controls of the two systems could be easily resolved. Maintenance made easy Besides blast performance and a very robust machine construction, the maintenance friendly design of the tube blaster was another factor that convinced Terex® to buy the Rösler equipment: Very large inspection/maintenance doors in the entrance and exit vestibules as well as in the blast chamber allow easy, and ergonomic access, to all areas requiring maintenance. The maintenance door in the blast chamber is protected against wear from the blast by slide-in manganese plates, which cover the inspection door without showing any gap. As an all-round supplier, Rösler GmbH is an international market leader in the production of surface finishing, shot blasting machines, painting systems and preservation lines as well as process technology for the rational surface finishing (deburring, descaling, sand removal, polishing, grinding…) of metals and other components. Besides the German plants in Untermerzbach and Bad Staffelstein, the Rösler Group has branches in Great Britain, France, Italy, The Netherlands, Belgium, Austria, Switzerland, Spain, Romania, Russia, China, India, Brazil, South Africa and USA. More information on Rosler Oberflachentechnik GmbH tel: +49 9533 9240 fax: +49 9533 924300 info@rosler.com www.rosler.com See us at Tube Duesseldorf – Hall 6 Stand B03 6 IMT February/March 2010 www.internationalmetaltube.com ‘Remesh’, the new function in COPRA® FEA RF R F - the Finite Element Simulation of the Roll Forming Process. In recent years it has become apparent that the use of Finite Element Simulations will be more and more important in the roll forming industry. Due to the growing popularity of light weight construction, sheet thickness is constantly being reduced, and to compensate the loss in stability; more and higher strength materials are being used. More and more profiles are also being rolled with pre-punched material, where the quality of the holes in the final section in terms of correct position and shape are also an important issue. For all cases, only limited experience and trial and error methods are available within the roll forming industry. Therefore, the only way to avoid expensive and time wasting experiments is to virtually simulate the process with FEA. This is the reason why data M Sheet Metal Solutions GmbH has on the one hand, focused upon making the roll design faster, and on the other, taken away the time wasting modification of the FEA mesh when using pre-punched material with COPRA® FEA RF. The target being to significantly reduce the time required for preparing an FEA simulation. Alongside the possibility to “automatically mesh pre-punched material”, a new function was added to COPRA® FEA RF. The “remesh­functionality” has been on the data M Sheet Metal Solutions' development wish list for a long time now. A technical solution has been now realised in which the Mesh can be redefined as needed during the simulation. The current results are interpreted and assigned to the new mesh. The remesh can be performed both locally and globally. The elements must not be refined equally in all directions, but can also be refined in cross sectional direction only, for example, when a nebend will be formed in the following station. With this opportunity, the number of • Fig. 2 and 3: Remesh of the simulated tube: refinement of elements in one direction at specific positions in the cross section. Results will be mapped to the new mesh. Fig. 4 and 5: Further forming: round to shaped profile with adequate mesh. • elements correspond with the element refinements to describe Solutions GmbH will also or data M Sheet Metal Solutions present bends that are in the specific bends will be adapted demonstrate at the Tube GmbH at the exhibition Tube 2010 cross section and must not be according to the truly occurring exhibition the new features of the in Düsseldorf / Germany allocated from the beginning of deformations (i.e. caused by latest and very successful roll Booth F19, Hall 4 the simulation. necking). An optimal description form software called “COPRA® More information on dataM Besides the significant gain in of the bends can be guaranteed RF”. If you like to download the Sheet Metal Solutions GmbH simulation time (about 30-40% through the complete simulation original pictures in high Contact:­ for typical roll forming of all roll forming stations with a resolution quality (300 dpi), www.datum.de applications) also a clear minimal number of elements and please go to our website at: tel: +49 8024 6400 improvement in quality can be without intervention of the user. www.datam.de/en/shows-fax: +49 8024 640300 faced: The position of existing Of course data M Sheet Metal press/press/tube2010 datam@datam.de Easy tool change with minimum downtime T he Oto 40616 ETC tube mill includes a Flexible Forming (FFX) as conceived by Nakata. Forming rolls need not be changed, but simply adjusted according to recipes as a function of tube diameter. Finishing and sizing sections are designed with interchangeable 4-roll stands. The tooling change has been created to minimize change­over time and operator involvement throughout the tube mill. Using existing forming concepts, we have automated the tooling pick and set-up operations. In the finishing and sizing, the quick change-over does not occur by replacing the entire stand (as typically executed on smaller mills), but by swapping the assembly including rolls, shafts, bearing blocks, and side rolls from the top of the stand. All driven stands are mounted to the mill base, and universal joints are provided with an automated engagement/ disengagement hydraulic system from the mill shafts. Thus allowing for the roll, bearing block, shaft, and side rolls (if provided) to be moved in and out of the stands which are designed with an opening at the top to enable the change-over operation via crane. Jacks and absolute encoder for top shaft adjustment are part of the removable assembly. Adjustments on the roll, shaft, and bearing block assembly are performed through electric gear motors and absolute encoders. The entire change-over operation is automatic, so that operators are simply involved in the lifting of the roll assembly in one motion. The Oto 40616 ETC tube mill comes with a second set of shaft, bearing block and side roll assemblies to enable off­line roll change-over. Customer may select to purchase extra shafts and bearing blocks which can be permanently assembled to the rolls for even faster roll replacement. Also, a special tool designed to help the off-line roll change­over is offered. More information from Oto Mills at: tel: +39 (0)522 481211 fax +39 (0)522 964188 otoinfo@otomills.com www.otomills.com 8 IMT February/March 2010 www.internationalmetaltube.com Maximise your production with Green Automation Maximmise your producttion with Green Auutomation An all-electric, fully automated tube-forming cell. An all-eleectric, fully automated tube-foorming cell. Developed by Herber together with selected partners. Developeed by Herber together with seelected partners. Using a r robot feed system, full-length tubes are fed inobot feed system, full-lengthh tubes are fed in and then, completely automatically, they are formed, and thenn, completely automaticallyy,, thhey are formed, cut, burred and end-formed into a .nished pred and ended and end-formed into a .nnished product. cut, burr formed into a .nnished product. cut, burr It is even possible to check the product automatically It is evenn possible to check the producct automatically with the aid of an optical measurement system. with the aid of an optical measurement system. The tube-forming cell can be programmed to manu- The tubee-forming cell can be programmmed to manu e several different products at the same time. In factur e several different products at tthe same time. In doing so optimal use can be made of both machinery doing soo optimal use can be made off both machinery and materials. and matterials. As the system runs entirely on electricity, energy As the system runs entirely on elecctricityy,, energy savings of at least 80% can be achieved. Overall, this savingssavings of at least 80% can be achieved. Overall, this of at least 80% can be achieved. Overall, this fers signi.cant time and cost savings. of fers signi.cant time and cost savinggs. Not to mention the environment. Not tto mention the environment. our no1 choice in advanced Tube forming solutions Y our no1Yo 1 Tu choice in advanced Tube formming solutions Herber Engineering manufactures all-electric cold tube forming machinery. With a total Herber Enngineering manufactures all-electtric cold tube forming machineryy.With a total undertaking we offer customised, fully automated production equipment. From the idea undertaking we offer customised, fully automated production equipment.. From the idea stage through to prototypes, training, zero series, commissioning and maintenance. stage throough to prototypes, training, zeroo series, commissioning and maintenance. Accuracy, quality and the environment are our watchworAccuracy, quality and the environment aree our watchwords. www .herber.se .herber.se New concept tube finishing equipment from Danieli D anieli Centro Maskin has supplied 156 carbide-tipped circular saw plants for various applications in the steel industry since the mid-fifties, with 37 machines/systems awarded in the last five years. The carbide tipped saws can be used for cutting bars upstream of the re-heating furnace, for cutting off layers of pipes into length downstream of the cooling bed, and finally also for cutting of blank couplings in the finishing shop. In case of single piece cutting the maximum diameter processed is 810mm, with maximum layer width of 1,500mm. With no vibration and measures taken to increase the blade life, plus the stable movement of the cutting head and the fast/ precise cutting control, allow for a very high productivity ratio (50 seconds to cut a 300mm round bar of C45, HB 200) and an excellent operational factor of the cutting equipment. Danieli Centro Maskin has recently completed the design of a range of innovative CNC threading machines for both tubes and couplings. The finished threaded products fully comply with API and GOST standards, with the capability also to produce Premium Threads. The thread diameters currently range from 1.9” to 20” according to the machine model. State of the art technical solutions and the innovative design of thread cutting head and tool holders, guarantees an excellent deployment factor - even with the most varied product mix. The tube threading machine carries out facing and chamfering on internal and external diameters, taper turning and threading on both internal and external diameters, plus thread deburring. Up to now, most production of Premium Joints was only possible by using lathes with the pipe rotating. Lathes permit the creation of all thread profiles, but have a major disadvantage in that they have low production rates. This is due to the handling of the tube and to the reduced cutting speed which is limited by the rotation speed of the tube itself. The innovative Danieli Centro Maskin design of the thread cutting head and of the tool holders guarantees the same flexibility as a lathe, but ensures a considerably higher production rate (up to 185 pieces per hour). The coupling threading plants consist of two twin thread cutting heads, each one performing the complete production cycle on one half of the coupling. Such machines can work independently, or can be supplied together with Non Destructive Testing, marking, phosphatising and painting equipment, all fully integrated into a completely automatic line, without the need of intermediate storage areas. An excellent thread quality is obtained since the work piece is held rigidly in position during the entire working cycle, through the loading to the unloading operation. As with the tube threading machines, the innovative design of the tool holders allows the production of Premium Joints with a very high output, compared to the alternative lathe technology (up to 130 pieces per hour). As an integral part of the • 10 IMT February/March 2010 www.internationalmetaltube.com . production process of seamless and welded tubes and pipes, Danieli Centro Maskin is able to supply a wide variety of equipment, both in the hot rolling and finishing areas. Danieli Centro Maskin also offers the following auxiliary tube finishing equipment: . facing and bevelling machines, . coupling starter, screw-on and full stroke drifting units, . rotating tools / rotating pipe cut-off machines, . O.D. and I.D. protector applier units. The above machines can be integrated into complete tube manufacturing plants supplied by Danieli, or also as stand alone units in existing plants. More information on Danieli & C. SpA tel: +39 0432 1951716 fax: +39 0432 1958082 dcmk@danieli.it www.danieli.com New development: EVO Turbine S ingle disc blast wheels are characterised by their ease of maintenance, and the quick change of their throwing blades. These characteristics make them the ideal blast wheels for applications where pre-blast and post-blast manufacturing steps. For example, robotic parts loading, or the capacity of a painting system, or a burn table, pose a limit to the overall part’s transport speed. However, organizations like steel trading companies or steel fabricators require a very high parts throughput. For these companies the newly designed twin disk turbine from Rösler offers the required high speed for their shot blast operations. The new twin disc direct drive turbines, named EVO 38, are available with drive motor powers from 11 up to 37kW (15 to 50HP), and throwing up to 530kg (1,172lbs) of blast media per minute. Our second twin disc turbine range, EVO 50, this time with indirect drive, offers a maximum drive power of 110kW (150HP) and up to 1,300kg/min (2,866 lb/min) media troughput. This new generation of Rösler turbines have been completely researched, designed, prototyped, tested, and manufactured in-house at Rösler. The use of highly wear resistant materials like manganese, or hardened tool steel, and the very precise fit of the laser-cut wheel housing components, guarantees a robust design with a very long life. The new turbine design, incorporates a self locking slide-in system for the throwing blades, thus eliminating the need for fast wearing screws and clips, making the exchange of the throwing blades easy and quick. The EVO 38 is avaiable in three different diameters: 340mm, 380mm and 400mm. The blast pattern of the new turbine is more concentrated, especially with regard to the “Hot Spot”. This makes these powerful turbines ideal for shot blast applications that require highly abrasive and aggressive blasting. As an all-round supplier, Rösler GmbH is an international market leader in the production of surface finishing, shot blasting machines, painting systems and preservation lines as well as process technology for the rational surface finishing (deburring, descaling, sand removal, polishing, grinding…) of metals and other components. Besides the German plants in Untermerzbach and Bad Staffelstein, the Rösler Group has branches in Great Britain, France, Italy, The Netherlands, Belgium, Austria, Switzerland, Spain, Romania, Russia, China, India, Brazil, South Africa and USA. More information on Rosler Oberflachentechnik GmbH tel: +49 9533 9240 fax: +49 9533 924300 info@rosler.com www.rosler.com See us at Tube Duesseldorf – Hall 6 Stand B03 Reliable & leak-tight S wagelok Company has released a larger size of its popular FKB series medium-pressure ball valve. Designed for improved cycle life in the field, the trunnion-style ball valves provide a leak-tight seal for applications up to 15 000 psig (1034 bar) and feature Swagelok’s patent-pending direct load design, which delivers a more consistent seal across a full range of pressures. Innovative stem and end connection seals prevent shell leakage and provide robust cycle life even in severe conditions. The two-way 8FKB ball valve complements the original 6FKB ball valve introduced in May 2009. The 8FKB ball valve, with a 0.375 in. (9.52 mm) orifice, offers 1/2 in. gaugeable Swagelok® medium-pressure tube fitting end connections or 1/2 in. female NPT. The 6FKB ball valve is available with 0.209 in. (5.31 mm) orifice and 1/4, 3/8, or 1/2 in. Swagelok medium-pressure tube fitting end connections, or female NPT end connections. All valves feature 316 stainless steel body construction, and reinforced PEEK seat seals. The valves are rated for temperatures from 0° to 250°F (-17° to 121°C) and maintain a full pressure rating throughout the entire operating temperature range. Multiple O-ring materials are available, including nitrile, fluoroelastomer, and perfluoroelastomer. Swagelok medium-pressure ball valves deliver reliable and repeatable operation to meet the performance requirements of common off-shore applications, such as topside wellhead control panels, chemical injection panels, well workover panels and control systems. Maintaining the integrity of the valve seal is critical for applications where positive shut off is required. A bottom-loaded stem design eliminates stem blowout for enhanced operator safety. The FKB series features low-torque actuation, eliminating the need for assist methods and accessories in manual actuation. If pneumatic actuation is required, the valves are available with ISO-5211 compliant actuators. A positionable handle provides flexibility in panel layout by reducing clearance issues with other components. Swagelok medium-pressure tube fitting end connections provide single turn makeup, or configurations for use with medium pressure stainless steel tubing, both heavy wall annealed and cold-drawn 1/8 hard, and SAF 2507™ super duplex tubing. Headquartered in Solon, Ohio, U.S.A., Swagelok Company is a major developer and provider of fluid system solutions, including products, assemblies, and services for the research, instrumentation, pharmaceutical, oil and gas, power, petrochemical, alternative fuels, and semiconductor industries. More information on swagelok at: tel: +1 440-349-5934 www.swagelok.com ID Scarfing and bead rolling systems scarfing heads are now available manufactures’ ID mandrels. This using the Kent Corporation ID sales@kenttesgo.com to work with almost any allows you to save money by inserts and gives you the www.kenttesgo.com 12 IMT February/March 2010 www.internationalmetaltube.com K ent Corporation has introduced a new Tube Scrap Chopper. Initial designs are for 2” and 3” maximum diameter tube. The heavy duty robust flywheel design has a separate material feed and multi-sided blades for longer life. By chopping your scrap tube, you can save valuable floor space. One dumpster can take up to three times the space of chopped scrap. You will also reduce transportation and handling costs, and some scrap dealers will pay an extra 30% or more for your scrap - making it very easy to justify. More information on Kent Corporation please contact: tel: (001) 440-582-3400 sales@kenttesgo.com www.kenttesgo.com Keeping hydraulic .uid clean can be challenging under the best of circumstances. That’s why one of the world’s leading makers of hydraulic pumps chooses Sandvik hydraulic tubing, always packaged in a manner that protects the interior surface of the tubing from contamination during transportation and storing. When you receive our tubes, you can install them immediately, saving time on inspection and cleaning. All Sandvik tubes undergo a proprietary cleansing process to ensure the highest degree of cleanliness. Clean hydraulic tubes are especially important on remote sites such as oil platforms, or in the construction of a new ship, where your engineers want absolute assurance that nothing compromises a multimillion-dollar project. CHALLENGE Y OUR EXPECT A TIONS The first of Its kind from the global market leader I t has been said before: Only the best will make history. And, that is exactly what Ernst Blissenbach GmbH has been doing from its inception. Today the company is the worldwide leader in innovative systems for high quality inside tube scarfing. Ernst Blissenbach GmbH are highly focused on their customer’s individual needs and success. Based on our competence, reliability and ideas, each new requirement is seen as an opportunity for new developments. Our engineer’s profound knowledge and skills make the critical difference when it comes to solving and exceeding our customer’s expectations. So, it is no coincidence that the innovative custom tools produced by Ernst Blissenbach GmbH – designed for the removal of the inside welding flash from HF longitudinal weld tubes – can effectively increase your production output, while at the same time, demonstrating a high level of technical know-how. In doing so, the Blissenbach systems fulfill all requirements regarding precision, quality and durability necessary to create safe production processes. Would you like to know what tomorrow’s inside tube scarfing systems look like today? Interested in the opportunities they create for tube producers and plant construction companies? Curious to know what imaginative innovation can significantly optimize your workflow? Market leader Ernst Blissenbach GmbH would be happy to answer all your questions at the TUBE 2010. It also where you can see the company’s latest product that is setting new benchmarks and revolutionizing process engineering. Ernst Blissenbach GmbH Hall 6, Booth 6A 41 More information 0n Ernst Blissenbach GmbH contact: tel: +49 2191 9982-0 fax: +49 2191-9982-24 info@blissenbach.de A new generation of all-electric pipe bending machines at Tube 2010 The all electric drive of the Tubotron Vario guarantees maximum bending precision, and Booth E 21 Tracto-Technik presents the new Tubotron 40 Vario which is designed for bending pipes up to 42mm OD. In addition TT presents a new optical measuring cell and the current version 4.0 of its Pipefab production management software for the pipe workshop. Pipefab combines the generation of isometric drawings, work preparation and production control for the pipe pre­production. It not only organizes the material and time management, but also supplies all the required production documents for the pipe workshop. In order to simplify the handling, a special Pipefab Explorer with plug-in-technique has been developed. This tool allows the user to add individ-ual applications without having to reinstall the whole system. Indeed, all the extensive basic functions of the previous Pipefab version 2.9.4 are included in the new version 4.0 too. Moreover each isomet-ric drawing provides 3D views of the pipes. It's possible for the user to parametrically define the ele­ments of the 3D models by means of a new symbol editor application. More information on TRACTO­TECHNIK GmbH & Co. KG contact tel: +49 (0) 2725 / 9540-0 tubomat@tracto-technik.de www.tracto-technik.com 16 IMT February/March 2010 www.internationalmetaltube.com Chlorine-free tube production R eliable and efficient processes require the integral consideration of the entire value creation chain. Hence, within the production of tubes and deep drawn pressed components for automotive exhaust systems, high-quality forming lubricants are in demand. Such lubricants have to fulfill a variety of complex requirements. The German Boysen Group (www.boysen­online.de), one of the world’s leading suppliers in exhaust technology, relies on a strategic alliance with German lubricant expert Georg Oest Mineralölwerk GmbH & Co. KG (www.oestgroup.com). For more than two decades, the Boysen subsidiary BAK Abgaskomponenten GmbH has successfully utilised several OEST products for different tasks. The focus, however, lies on specifically additivated, chlorine-free oils for pressing and punching processes. The requirements placed on lubricants used in tube production are rising continuously. The trend is towards long-term quality and reliability rather than of short-term quantity. Even though years ago almost all defined metal forming tasks where solved by virtually no product discrimination, today different rules apply: “The demands on precise and reliable lubricant distribution within forming processes are increasing continuously. Exhaust technology’s future lies in materials of constantly decreasing sheet thickness as well as more cost-efficient, more precise, tailor-made blanks. At the same time, international markets are asking for components with even more elaborate contours and complex geometries“ Volker Talmon, production manager of BAK Boysen’s press shop, explains. “Preliminary to the selection of lubricants, their implications on each following production step have to be considered thoroughly. This also includes the question when and how the oil has to be removed from the components.” Against this background, it is evident that an efficient metering of OEST forming lubricants requires a variety of application techniques – depending on the considered process. Whereas bending and expanding of tube ends require rather large amounts of lubricant, the method of choice for pressing and punching of blanks is mainly sectoral lubrication with precisely calculated spray quantities. Best possible • Reaching the Top! Inside tube scarfing Are you ready for inside tube scarfing of the highest quality? Achieve peak performance with our state-of-the-art high precision tools. Superior functionality, ultimate precision and durability reduce tool-related machinery down-time, avoid avalanche-like cost explosions and increase I.D.-scarfing quality – noticeably! Please visit us at the TUBE 2010, Hall 6, Booth 6 A 41 and benefit from choosing the worldwide leader in I.D.-scarfing tools. Together we can reach the pinnacle of innovation and progress. contact: +49 (0)2191 9982-0. info@blissenbach.de www. blissenbach.com Hall 6 | Booth 6 A 41 12 -16 April 2010 Düsseldorf · Germany 20 IMT February/March 2010 www.internationalmetaltube.com products. Harmful impacts for humans and adverse environmental effects are thereby eliminated. By intense research in its in-house laboratory, OEST succeeded in the development of special formulations for enhanced process safety and reproducibility – without using chlorinated paraffines at all. Dr. Martin Wünsch, OEST’s business development manager for forming lubricants, summarizes: „A large number of applications have already incorporated a complete substitute chlorinated product – consistently maintaining high process quality.” Individual solution in demand Facing the diversity of forming processes at BAK Boysen, OEST’s experts focus on application guidance in specific tasks. By doing this, the entire process peripherals are considered to achieve optimal solutions, especially with regard to downstream processes. Giving an example, Volker Talmon mentions the workflow punching and laser welding within tube production: “To secure a stable lubrication film on the punching tool, the oil is continuously applied. Furthermore, for several punching processes we are using a vanishing oil to• • minimise residues on the operations, e.g. laser welding of surfaces and to avoid these components. interference with subsequent OEST has developed a special lubricant for this punching operation according to a detailed specification. Product manager Sinn explains: “Boysen submits the individual requirements, for example degreasing behaviour and coking tendency of lubricating and drawing oils. We document all essential process parameters in a standard form. Our extensive know-how regarding the entire value chain including the particular design requirements for automotive exhaust systems contributes to our research efforts efficiently. Our new formulations then will be tested at BAK Boysen according to defined quality criteria. Each new lubricant undergoes these tests before it gets the approval for serial production. Depending on the respective application, new and further developments are to be implemented under high time pressure. In this context, the physical proximity between the companies’ sites pays off: there are less than 30 minutes to travel by car between the two partners. Concluding, production manager Volker Talmon emphasizes: “Our customers rightly expect zero-defect results – with ever-increasing contour requirements and tighter tolerances. Therefore, absolute process reliability and definite reproducibility are the measure of all things. With OEST we have the perfect partner offering expertise, flexibility and an outstanding service speed. Georg Oest Mineralölwerk GmbH & Co. KG Bahnhofstr. 5 72250 Freudenstadt Telefon 0 74 41/ 539 - 124 Telefax 0 74 41/ 539 - 219 www.oestgroup.com Manufacturer of Seamless and Welded But-weld Fitngs in EN, DIN and ASTM norms • Seamless Elbows, Equal TEEs, Reducing TEEs, Reducers, Caps • Welded Elbows, Welded TEEs • Forged Carbon Steel Flanges TMOSB Mermerciler Cad. No:59 Tuzla-Istanbul / Turkey TEL: +90 216 581 81 00 FAX: +90 216 593 04 09 Info@uni.t.com.tr wire 2010 and Tube 2010 Industry looks to Düsseldorf ful wire 2010 and Tube 2010 – stron 1 6 March 2010: Just under four weeks to go until doors open. wire 2010 and Tube 2010, the two No.1 trade fairs for the wire, cable and tube processing industries will be presenting forward-looking technologies, current techniques and latest services in the exhibition halls on the Rhine from 12 to 16 April. For the twelfth time now, the International Wire and Cable Trade Fair (wire) and the International Tube and Pipe Trade Fair (Tube) are to be held concurrently at Düsseldorf fairgrounds. The sector has moved out of the trough of 2009 and now looks to Düsseldorf expectantly. Being leaders in their respective fields, both trade fairs have succeeded in increasing their exhibitor numbers over the record year 2008! wire 2010: For wire 1,216 companies have registered over 52,000 square metres of exhibition space so far! This corresponds to a 7.1% increase in exhibitors. In terms of area occupied, however, wire loses just under 1,400 square metres and hence 2.8 % compared to 2008. The exhibits on display at wire 2010 range from wire manufacturing and finishing machinery, to process engineering tools and auxiliaries, not forgetting raw materials and special wires. Furthermore, innovations from the areas of cable, measuring and control technology as well as test engineering are presented. Specialist areas such as logistics, conveying systems and packaging round off the ranges that occupy the exhibition Halls 9 to 12 and 15 to 17. New is the segmentation in Halls 15 to 17: Fastener Technology will be featured with latest technologies in Hall 15. In parts of Hall 16 the latest processes in Spring Making will be on show. All applications related to wire and cable, wire and cable machinery as well as fibreglass machines can be found in Halls 9 to 12 and 16 to 17. Tube 2010: Tube will be held in Halls 1 to 7 and Hall 7a. 1,167 exhibitors will be displaying their innovations on a total exhibition area of 44,575 square metres. This means that compared to the previous event in 2008 Tube has grown by 12% in terms of the number of exhibiting companies and by 7% (just above 3,000 square metres) in terms of area occupied. On show will be the entire spectrum from tube and pipe making and finishing to processing. The ranges include raw materials, tubes and accessories, tube manufacturing machinery and rebuilt and reconditioned machinery, process engineering tools and auxiliaries plus measuring and control technology. Test engineering and special segments such as warehouse automation and control and monitoring systems round off the extensive product portfolio. Tube trading and stockists also occupy a prominent place. After the successful premiere in 2008 the segments Pipelines and OCTG Technology (oil country tubular goods) will also be featured again. Debut: A special show focusing on profiles/sections and section engineering! Both plants and machinery for manufacturing sections and finished products in a variety of materials and cross-sections will be exhibited. Constantly updated information on both trade fairs can be found at the two trade fair portals: www.wire.de and www.Tube.de 24 IMT F e bruar y/Mar c h 2010 w w w .int ernationalme taltube.c om l of expectations: nger than ever! Hallen/Halls 9–12, 15 –17 Draht-, Kabel- und Glasfaser-maschinen, Draht- und Kabelproduktion und -handel Wire, Cable and Fibre Optic Machinery, Wire and Cable Production and Trade Federfertigungstechnik Spring Making Umformtechnik Fastener Technology Hallen/Halls 1– 7.0 Internationale Rohr-Fachmesse International Tube join the best and Pipe Trade Fair 12 – 16 April 2010 Düsseldorf, Germany www.tube.de H erber Engineering AB are a leading edge Swedish company, with over sixty five years experience in the design and manufacture of tube bending machines. In 1945 there was a growing demand for quality tube bending in the aircraft industry. During this period the late Swedish aircraft engineer Herbert Bragd developed a range of machines to meet these demands. Knowing the weakness and shortcomings of some manufacturers, Herbert Bragd quickly formed a team of professional engineers to develop a range of advanced, innovative machines. The Herber logo was later designed as a tribute to this exceptional aircraft engineer. Today, we continue to build on this vast wealth of experience and are still leading the way with an all new, enviromentally friendly All Electric range of twenty mandrel tube bending machines. Capable of bending tube sizes from 4mm/od up to 168mm/od, this state of the art family of machines also includes two models for dual, right and left hand bending, plus two five axis twinhead benders all built using the latest globally sourced components. Hassel Free Production: The Herber Group's robotic production cells are once again revolutioning the way forward. Cells that include award winning All Electric production processes such as -Herber tube store and bending machines - KUKA advanced robotic handling - Bors state of the art deburring, cutting and endforming machinery, and Automatic vision technology. Herbers Group partnership with Green Automation combine to build programmes with the latest flexible software packages, and offer you options which are loaded with benefits designed to help maximise your production out-put dramatically. These include, loading of full-length tubes, sequential bending, cutting, deburring and endforming. Measuring and stacking of several different shaped components one after the other, and at the same time making the production area a safer, noise free, efficient environment. 3D bending simulation,and an anti-collision test programme are also available, to determine the most efficient, and cost-effective cost savings of up to 80%. With no oil disposal required, as we use Irmco petroleum free mandrel lubrication technology. No noise, no heat generation, and up to 40% less machine build components compared with alternative hydraulic machines. We see ourselves as 21st century problem solvers. The tougher the task, the more we relish the challenge, since this gives us the opportunity to demonstrate the outstanding qualities of our machines. We deliver on our promise and continually invest in the quality of our products. We try to tick all the right boxes -why not visit us and take a closer look. You will be made very welcome. To arrange a demonstration please do not hesitate to contact me direct. Visit us at Tube Dusseldorf 12 - 16 April Hall 5:B09 and take a closer look. You will be made very welcome when you visit our purpose built factory, showroom and offices. Further information: Lennart Claesson Tel: +46 (0)370 69 95 73. T he Messe Duesseldorf premiere is nine months away, and oil pipelines are being pipelines, will present the valve GmbH will be holding the 420 companies from 35 different planned and built worldwide to industry with big economic Valve World Expo with an nations have already registered meet the increasing demand for opportunities. European accompanying conference and will participate. An area of energy. Yet, it is already open to manufactures in particular expect for the first time from 30. more than 12.000 square metres discussion whether every pipeline to benefit significantly from the November to 2. December 2010. has been reserved for the event. can be supplied with sufficient gas major Nord Stream, South Stream Innovative industrial valve and The race for the fossil energy and oil. One thing is for certain, and Nabucco projects. fittings solutions will be on display resources, natural gas and crude namely that the ever increasing The calculation is simple. during the fair. Even though the oil, is in full swing. Numerous gas construction of transport Improved living standards the 28 IMT February/March 2010 www.internationalmetaltube.com billion cubic metres will be transported before capacity is doubled one year later. Gazprom, the Russian energy company, is the project’s biggest stakeholder with 51 per cent. Twenty per cent stakes are held by the two German companies BASF/Wintershall and E.ON Ruhrgas whilst the Dutch Gasunie has a 9 per cent holding. South Stream is being planned by Gazprom and the Italian energy group Eni. It will go from Beregovaya on the Black Sea coast, through the Black Sea all the way to Bulgaria, Greece and Italy. Construction is expected to start in 2010 and it will begin pumping gas from 2013 onwards. The intention is for the yearly gas capacity to start off at 31 billion cubic metres. Later this figure will be raised to 47 billion. Nabucco is an EU-supported pipeline. Russia, in contrast to the Nord and South Stream projects, is not involved. The Nabucco consortium is made up of companies from Germany, Austria, Hungary, Romania, Bulgaria and Turkey. The pipeline, for which ´construction is projected to start in 2011, will supply natural gas from the Caspian region to West Europe. Thirty-one billion cubic metres should be flowing through the 3,300 kilometre long pipeline from 2014. Approximately 7.9 billion euro will be invested in the• • project – 250 million euro is being financed by the EU. Ecological issues Originally, the Nabucco consortium wanted to start detailed planning in as soon as the first half of 2010. Now the investment decision will probably only be made towards the end of 2010. Technological and ecological aspects have to be resolved first of all. The Nabucco consortium is also currently negotiating with potential lenders. In contrast, the Scandinavian countries, along with Russia and Germany, have already given Nord Stream the go-ahead. Many nations have already approved South Stream. Nabucco is therefore a “maybe” but the valve industry can already look forward After the tenders were evaluated as to their commercial ‘ ’ Nabucco has its eyes on, flows on the other hand to Russia and, only recently, via the Trans-Asian pipeline to China. Should Nabucco not be able to meet its capacities, the EU will be unable to fulfil its objective of becoming less dependent on Russian gas. Russia on the other hand has nothing against remaining the EU’s main supplier. In pursuing its South Stream project, it means Nabucco is facing powerful competition from the former super power. Nord Stream and South Stream will additionally enable Russia to achieve its aim of bypassing the Ukraine which acts as a transit country. The two have been involved in an ongoing conflict in recent years over gas prices and transit fees. Nord Stream is already rk on Nord Stream see-Pipeline­Anbindungs-Leitung” (OPAL – the Baltic Sea Pipeline Link). OPAL al gas from am in Lubmin, near eifswald, and then transport it es south to the tive contracts ve industry. equire a total of es with a nominal een DN 150 and es will be used alled ound with a tap extension plained Olaf er, the Divisional Head at the AL NEL TRANSPORT GmbH. lded and allations ery 12 to 18 al gas pipelines,” elucidated Olaf Müller. ations are AL and they ed round the ol room. The sary, be tele­ sor plants are r the OPAL. e’ll be a further need for ound – mainly in of up to 1200.” Valves ion stages valves of up to 36“ in the compression stage 220 bar will be fitted. “Fully welded valves in this compression stage and diameter have, as far as we know, never or rarely been fitted.” New pipelines worldwide Europe however is not the only place where pipelines are springing up like mushrooms. Asia and South America are also currently forging ahead with the construction of transport pipelines and are therefore cranking up the valve business to an even greater extent, but only basically in pipes with a diameter of 40“. China especially is meeting the needs of its emergent economy by building numerous new pipelines. One recently completed project is the ww.internationalmetaltube.com India In India, the National Gas Grid will be built to supply the country’s large cities with gas. It will be fitted with valves of up to 36“ ANSI 600. Major contracts, on the other hand, cannot be expected to come out of Iran over the next two years. This is down to the economic embargo. Energy companies still include Iran on their lists. The Hungarian energy group, Mol, is looking to fill the planned Nabucco pipeline with gas from Iran. According to the group, sooner or later gas will have to be drawn from the country. Mol is therefore already building up its contacts in the technological sector. Another member of the Nabucco • Pipelines & Valve Economics • consortium, the German RWE energy group, has, up to now, stressed that gas from Iran will not be needed. But the dim chances of receiving fossil energy resources for Nabucco from Turkmenistan may well have led to Mol changing its mind. Australia The Australian market is also turning out to be an interesting one for the valve industry. Some projects have been completed Down Under using valves of up to 36“. Competition here comes, in the main, from Asia. Oil storage and export facilities are in the process of being built for a pipeline project in the United Arab Emirates. The Abu Dhabi Crude Oil Pipeline wants to offer an export alternative to the Strait of Hormuz “bottle neck” for the Habsham oilfield, which is the collection centre for a large proportion of Abu Dhabi’s onshore oil production. The British Rotork group is supplying electrical valve controls for the 370 kilometre pipeline which will transport crude oil to Fujairah on the east coast of the Emirate. Rotork Fluid Systems has additionally won a contract for gas-oil valves for a new strategic 180 kilometre gas pipeline which is intended to help develop the economy in the Kurdish region in Iraq. The Swiss based ABB has won a contract worth 223 million US dollars from the Algerian oil and gas company Sonatrach for three gas refineries in Algeria. The project, which is expected to be finished in the first quarter of 2012, includes compressor trains, new measuring technologies for the old gas treatment plant and an integrated control system for the new and old facilities. The compressor trains will serve to increase the gas flow rate in the pipelines. And what is Russia offering the valve industry? The former super power is, after all, by far the world’s biggest gas producer with a market share of 20 per cent. “The Russian market has, is in our estimation, collapsed,” said Birgit Schuck from the Schuck Group. Hardly any projects are being realised at the moment, “and when they are, they use Russian produced valves.” But how long will the pipeline euphoria last? Oil reserves are coming to an end. The German “Bundesamt für Geowissenschaften und Rohstoffe” (BGR – Federal Institute for Geosciences and Natural Resources) predict that half the earth’s extractable oil will have been used up in as soon as 10 to 15 years time. “A successive reduction in oil production can be expected from that time onwards.” Philip Watts, the head of the world market leader Royal Dutch/Shell, reckons the world will be using more natural gas than oil from about 2025. Assuming the production of gas remains at a constant level then one can also assume there will be sufficient oil reserves up until the 2070s. Therefore, the valve boom within the oil and gas production industries will continue for a few decades. But a stagnation of the boom will occur sooner or later. Regenerative energies are already knocking on the door and it is here that the valve and seals industries will have to look for their long term opportunities. More information on this article contact: Petra Hartmann-Bresgen Kathrin Kleophas ( +49 (0)211/4560-541 ( +49 (0)211/4560-544 2 +49 (0)211/4560-87 541 2 +49 (0)211/4560-87 544 7 HartmannP@messe­duesseldorf.de In-Line Diameter and Shape Contr ol STEELMASTER Gauges for Hot and Cold Rolled Products STEELMASTER Gauges Hi-speed laser scanning. Measurement of diameter, ovality, height, width and diagonals. s Possible measuring modes s Standard measuring ranges up to 500mm s 1 up to 6 measuring axes s Measuring frequency: 1000 / s for each axis New! Measuring solutions for round and non-round products. Captures also asymmetrical shape deviations of round, oval and polygonal products. PROFILEMASTER® Gauges Advanced vision technology (light-section). s Any shape sStandard measuring ranges up to 300mm s1 up to 6 laser/camera modules Visit us at: 12-16 April 2010 Booth5 C27 Ask us for additional information: askme@zumbach.ch SwitzerlandArgentinaBeneluxBrazilChinaFranceGermanyIndiaItaliaSpainTaiwanUKUSA www. zumbach.com Tubes do have a life of their own W ith many phases to pass through from concept to completion - tube runs the gauntlet of temperature, damage during transportation, mishandling in storage, prototyping, the welding process and many other stages before it becomes the finished article or component. The single exception to this is in the CAD department. Even there, gremlins are waiting to pounce, such as unpredictable handling changes that make it difficult to predict the dimensions and place them in the various 3D functions of CAD programmes. Tubes by their nature, have to conform to very tight bends and tolerances, and, have to meet exacting and complex design requirements with 100% accuracy in very restricted areas. At the same time, these high end CAD ‘constructions’ might not match the realities of the bending department. They can create radii without having the required tooling, or cylinder lengths which are not consistent. Tubes hydrostatically formed are easier to pass, as the CAD programme sees them as planes, with the tube not being generated out of a centreline, but in two half shells as it were. However this presents one with a dilemma – acquisition. It also offered the opportunity to insert either bends into a 2D or 3D level, or to delete bends with disturbing shape. Many exciting breakthroughs in accurate tube measurement have added to the impressive portfolio offered by TeZet over the years The need to prove the tube is still round after the bending process and the welding of any add-on features is important The menu guided software pinpoints the measuring probe in the exact position of the ovality and shows it graphically and the accompanying data on a separate table. There are many more easy to use functions i.e – the measurement of a radius, its a serious issue, because if changes occur to the radius, both straights, before and behind the bend either extend or shorten. TeZet understands the huge raft of complexities when it comes to tube measurement. Our specialists are constantly are exploring new solutions to meet changing industrial demands, and we look forward to talking to you at Tube 2010 Dusseldorf – Hall A21 - Stand More information on TeZet Technik at tel: +44 56 249 3760 fax: +44 56 249 2878 www.tezet.com bending data cannot be generated out of these planes. Happily there is a solution for these day to day Tube problems – TezetCad, the flexible, tube specific software from TeZet. In the early nineties, our design module allowed the user to manipulate the tubes with fixed A and B bends with real time data WAFIOS and MEWAG present two world firsts at the TUBE in Düsseldorf For the second time running WAFIOS and MEWAG will appear together at TUBE in Düsseldorf. These two experts in tube bending, will present the tube processing industry with new solutions in tool technology, as well as complete production cells. In the tube diameter range up to 21mm, WAFIOS will display for the first time the BMZ 52, a new product which can be modularly configured to suit many different profiles according to the needs of the user. MEWAG will present the Ecolus 15: a completely new compact machine concept for small tube diameter ranges, setting new standards with regard to the cost versus output relationship. The first synergy effects of the co­development are in the new programming software installed on both machines, which offers future users higher operator comfort. More information on WAFIOS AG please contact Andreas Hoster tel: +49 7121 146 309 a.hoster@wafios.de www.wafios.com 12” x .500” SFM HF Welding Pipe Mill with Cage Forming *API Option Available* Year 2008, Brand New Mill Already Built and Ready for Immediate Shipment, Tube Diameter: 4” – 12”, Thickness Range: .158” - .500”, Shaft Diameter: 7.8”, Sizes: 100mm x 100mm through 250mm x 250mm, 60mm x 100mm through 200mm x 300mm, Entry Coil Car, Dual Head Mandrel Uncoiler, 7 Roll Straightener, Shear/End Welder, Horizontal Accumulator, 8 Stand Forming Mill with Cage Forming, 800 Kw Solid State Welder, 5 Stand Sizing Mill, (2) 4-Roll Turkheads, Milling Type Cut-Off, Electrics, Galaxie Corporation For Sale Tooling Tube Mills 76mm DMS-Loire W2.5 Tube Mill Line Year 1981, Diameter Range: 20mm – 76mm, Shaft Diameter: 90mm, Solid State Welder 250Kw, Tooling 2.5” x .125” T & H WU-25 Tube Mill .5” – 2.5” Tube Diameter, .125” - .028” Wall Thickness, 2.5” Spindle Diameter, Thermatool 200 Kw Welder, Alpha Double Cut Cut-Off, #SR-41 Series III, Tooling 2.5” Back Chun Stainless Tube Mill Line Year 1992, 2mm – 4mm Thickness, 15.8mm – 60.5mm Tube OD, 68mm Spindle Size, 7 Stand Forming Mill, 3 Stand Sizing Mill 2.5” x .120” Abbey Etna 2K Rafted Tube Mill Line Mechanically Rebuilt in 1999, 3” - .500” Tube OD, .120” ­.018” Wall Thickness, 300 FPM Line Speed, Kent Floop, 2K Forming Mill with Rafted Forming Stands, 250 Kw Thermatool Welder, Praxair Coating System (New 2003), Eddy Current Tester, Beta Ram Double Cut Cut-Off, 2 Double Cut Dies, Tooling and Spare Parts 3000mm x 16mm PRD Spiral Pipe Mill Year: 1980 Updated: 2000, 2006, 2007, Dia Range: 508mm–3200mm, Thickness: 4.4mm – 16mm, Strip Width: 1250mm, Coil Weight: 50,000 Lbs, 2 Coil Storage Ramp, Coil Lift, Mandrel Uncoiler, Peeler Table, Pinch Rolls, Edge Guides, 5 Roll Back-Up Flattener, Traversing Coil Joining Station, Crop Shear, Plasma & Welding Torch, Lincoln NA-3N Controls Automatic Wire Feed, PRD/Cagel Edge Milling Machine (New 2002), ID & OD Welding Heads, Metavision Laser Guidance System (New 2006), X & Y Cross Slides, ID & OD Laser Tracking, Allen Bradley PLC, Siemens Controls, Kraut Kramer Ultrasonic Tester Tube Equipment 4” Sutton 6 Roll Pipe Straightener Model 618, Wall Thickness Range: .050” - .300” @ 75,000 PSI Yield, 80 – 250 FPM Line Speed, 30’ Entry & Exit Tables, Spare Rolls 3.5” Alpha Cut-Off with Double Cut Die Double Cut Die, Die Accelerator, Tallyrand Length Control Kent Floop Model R323 LE, Year 1990 10” Strip Width, .025” - .135” Thickness Capacity, Left to Right Direction, Floop Fill Speed 800 FPM, DC Driven Mair Packaging Line, Model 002/1, Year 1990 14mm – 90mm Dia, 4m – 10, Lengths, Rounds, Squares and Rectangles, Hexagonal, Square and Rectangular Bundles, Entry Feed Table, Lift Table, Bundling Section, PLC Controls Slitting Lines 72” x .5” x 60,000 Lbs Cincinnati Slitting Line (PM Heads) .030” - .500” Thickness Range, Mandrel Uncoiler, 2 Slitting Heads, 11” Arbor Diameter, Recoiler, 225 HP DC Drive 72” x .375” x 50,000 Lbs Paxson Dual Head Loop Slitting Line .037” - .375” Thickness Range, Coil Car, Mandrel Uncoiler, 2 Slitter Heads, 12” and 9” Diameter Arbors, 150 HP DC Slitter Drive, 5/8” Butech Scrap Choppers 60” x .250 x 50,000 Lbs Dahlstrom Loop Slitting Line Thickness Capacity: .020” - .250”, Coil Car, Peeler Table, Crop Shear, 2 Slitting Heads, 9” Dia. Arbors, 150 HP DC Drive, Shimless Tooling, Scrap Winder, Rotary Tension Stand, Crop Shear, Recoiler, 150 HP DC Drive, 2 Speed Gear Box, Exit Coil Car, Digital Drives 60” x 40,000 Lbs Stamco Loop Slitting Line Year 1981, .010” - .115” Thickness, 4 Arm Entry Turnstile, 2 Slitter Heads, 6.5” Diameter Arbors, Rotary & Drag Board Tension Stand, Recoiler, 100 HP DC Motor, 2 Speed Gear Box 40” x 20,000 Lbs Cauffiel Slitting Line Mandrel Uncoiler, Peeler Hold Down Roll, Slitter Head, 8” Arbors, Recoiler, 100 HP Drive 36”x .250” x 30,000 Lb Loopco Heavy Gauge Slitting Line .025” -.250” Thickness Range, L-Type Coil Car, Mandrel Uncoiler, Crop Shear, Shimless Tooling, Recoiler, 100 HP DC Drive Slitter Heads 62” Bronx Slitter Head 62” Arbor Face, 6.5” Diameter Arbors, 60 Kw Motor, Tooling (2) 60” x 8” Seco Slitter Heads 62” Arbor Face, 8” Diameter Arbors 60” Braner Turret Slitter Head with Shimless Tooling 64” Arbor Face, 7” Diameter Arbor, 125 HP DC Motor 72”x 11” Dia Arbors Production Machinery Slitter Heads 4 Cuts of .500” Capacity, Tooling