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International Metal Tube Volume 1 Issue 5

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NEWS ROUND-UP • GLOBAL NEWS ROUND-UP • GLOBAL NEWS ROUND-UP • GLOBAL NEWS R Precise handling for your paper reels. Cranes and components by Demag offer optimum speed, precision and ef. ciency for the manufacture and storage of paper and reels. Solutions tailored to meet your needs and comprehensive service provide for economical and reliable handling for a wide range of applications. SUCCESS FACTORS Comment Over the coming months the next major trade shows – Tube Southeast Asia (Bangkok) and Fabtech (Chicago) – will start to gain momentum. These shows are a solid investment, both for companies that exhibit and visitors who simply want to stay abreast of latest industry developments. It’s heartening to see that so many companies have continued to develop new solutions for metal tube and pipe producers, while processors have had the foresight to look beyond the current economic woes and plan for the upturn. While some companies have chosen to drop trade shows and magazine marketing, the resulting lack of market visibility can only further bring into question their image in the eyes of potential clients. We’ve all been at trade shows and heard comments such as “No they are not exhibiting” followed by “Are they in trouble?” It is just this scenario that fuels rumours and could delay the much needed recovery. With this in mind we strongly urge our readers to support those forward looking companies who contribute to IMT magazine. IMT magazine is planning special issues for both of the trade shows mentioned above when we will be putting the spotlight on some of the exhibitors. We will also include direct links to the organisers’ sites where more general information can be found on venues, travel, times and so on. Looking forward to 2010 we have Tube Düsseldorf in April. Let’s hope that this showcase event will reflect the global recovery predicted for many companies and further enhance the efforts they have made over these past and coming months. • In the next issue of IMT (August/September) we will be focusing on tube and pipe bending; endforming and swaging technology; and oil, gas and water pipes. That’s in addition to our Tube Southeast Asia highlights – IMT will be on booth R15. So remember, if you have an developments in these topics, as well as general product, industry and personnel news, we’ll be pleased to hear from you. Vince Maynard IMT Contact Information PUBLICATION MANAGER DIGITAL CONVERSION BY & EDITORIAL CONTROLLER Print to Digital Vince Maynard PRINTED BY+44 (0) 1732 505724 Holbrooks Printers Ltd,Mobile +44 (0) 7747 002286 Norway Road, Hilsea, Portsmouth, Fax +44 (0) 1732 860052 Hampshire, imtmagazine@btopenworld.com PO3 5HX. EDITORIAL ADVISOR Tel: 02392 661485 Dave Richmond PUBLISHED BYeditorial@internationalmetaltube.com Hartswood Media TRANSPORT & LOGISTICS EDITOR Hallmark House David Young 25 Downham Road editorial@internationalmetaltube.com Ramsden Heath CIRCULATION Essex CM11 1PU June Bray United Kingdom Fax 01268 711567 T- + 44 (0) 1268 711560 F- + 44 (0)1268 711567PUBLISHER - PAUL BARRETT www.internationalmetaltube.com hartswoodmedia@aol.com REPRO BY Anton Print Solutions antonprint1@btconnect.com www.antonprintsolutions.co.uk The cutting head construction of the TS72 guarantees optimum cut quality. avoiding scratching or marking of material by lifting it away from the lengths from the same stock washing, drying and collecting vice bed and vice jaws during the length and to unload these cut operations. automated feed operation. lengths in four different The new machine can process locations. More information on BLM Group material up to 102mm OD and, The TS72 is designed to UK at: depending on the machine operate either as a stand-alone Tel: 01525 402 555 specification, up to 4.5m in unit – as at Paramount – or fully Fax: 01525 402 312 length. It can be programmed to integrated into an automated sales@blmgroup.uk.com process up to four different cut system with additional deburring, www.blmgroup.uk.com 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. BLM laser technology beams into Caparo C aparo Tube Components (CTC) secured two major orders during 2007 because BLM Group UK was able to supply the necessary production equipment within extremely tight delivery targets. The total investment amounted to £1.4m, with 90% of the equipment and tooling being supplied by BLM. CTC, part of the £1bn­turnover Caparo Group, manufactures a range of tubular components and assemblies, predominantly for the European automotive sector. As a first- and second-tier supplier CTC offers customers what sales manager Simon Baxter describes as “full support throughout the product design and development cycles and on to the delivery of the finished component”. To hit its stringent quality and traceability targets, the ISO 9001/ISO 14001-accredited company has set up a manufacturing sequence that extends from the supply of steel strip and steel tube production in the adjacent Caparo Precision Tubes to tube bending, forming, laser profiling, welding, press work, machining, finishing and assembly within CTC. Accreditation to the TS16949 automotive industry standard means that components can be delivered straight to line. Dean Newey, CTC’s operations and engineering manager, believes the all-electric drive technology featured in BLM’s E-Turn and E-Bend CNC tube benders has revolutionised the tube bending process: “The accuracy and repeatability that we can achieve using BLM’s technology in our tubular components is far superior to anything else we have seen before and changeovers take just a few minutes.” CTC quotes for new business on the premise that, according to Simon Baxter, “if we don’t have the capacity now, we will make sure that it is in place before the project is ready to run”. While the choice of machine tool is inevitably influenced by price he points out that CTC also takes account of the performance of existing machines and the service and support provided to keep them running: “We cannot afford for a machine to be down; not least because there may be penalty clauses involved. It is better to have some over­capacity, although we don’t want machines standing idle for long periods of time.” CTC currently has 17 BLM machine tools, including a BLM LT 712D CNC tube laser. More information on BLM Group UK at: tel: +44 (01525) 402 555 fax: +44 (01525) 402 312 sales@blmgroup.uk.com www.blmgroup.uk.com Meta Vision launches 3D laser scanner F ollowing an extensive R&D programme combining optics, electronics, firmware and mechanical sensor design, Meta Vision Systems, based near Oxford, UK, has launched a 3D digital laser scanner for use in automated welding equipment. Designated DLS300, it can also be used in other manufacturing applications, such as profile measurement and scanning for reverse engineering. Conventional laser vision systems based on the triangulation principle use a laser stripe projected onto the target. This is processed by a 2D area camera to produce a 3D profile of the target. Use of a laser stripe has practical limitations, however. Because constant laser power is used for the whole stripe it is not possible to vary the intensity to increase the light reflected from dark areas and decrease the light received from lighter areas. The camera images the complete scene including either side of the stripe, which can lead to further problems with dynamic range and unwanted reflections. Meta’s new sensor uses triangulation, but is based on a scanning spot rather than a stripe, solving the two main problems of stripe-based triangulation. First, it is easy to implement effective automatic gain control to compensate for reflectivity changes. Second, imaging is via a linear charge coupled device, which only looks at the region of interest and is not affected by reflections. Additional benefits of the scanning technology include a programmable field of view and independence of the sensor’s depth of field from the width of field. According to Bob Beattie, Meta’s managing director: “We are very pleased with the performance of the DLS300, which has exceeded our expectations and the initial design specification. “Trials in various welding applications, including adaptive submerged arc welding of nuclear vessels and wind tower production, have been extremely successful.” More information on Meta Vision Systems at: tel: +44 1865 887900 fax: +441865 887901 sales@meta-mvs.com www.meta-mvs.com Düsseldorf launch enhances Unilux’s service U nilux has boosted its stroboscopic surface inspection activities in Europe, the Middle East and Africa by opening a marketing research centre in Düsseldorf, Germany. The new facility will enable Unilux to increase its inventory of strobe lights, spare parts and accessories. "Our new office in Europe is all about maximising customer service," says Unilux president Michael Simonis. "With the space to eventually inventory products and parts we can ship orders faster, especially to customers in European Union countries, and speed and simplify the procedures for receiving, servicing and sending back units we service." The EMEA office covers Europe and Africa as well as countries in the Middle East. It also works with Unilux representatives in 20 countries. "Our stroboscopic inspection systems help people do a better job of meeting their customers’ strict quality standards," says Volker Schlevoigt, marketing director of Unilux EMEA. "We now have the ability to add more people who can help our customers eliminate costly waste and improve their customers' productivity and, hopefully, their profitability." Unilux products are built around stroboscopic surface inspection lighting that enables operators to spot defects at production speeds which can exceed 750m/min (2,200 ft/min). Operators can use their knowledge of products and production systems to determine the severity of a defect and take steps to find and eliminate its cause. The company has combined its high-speed inspection lighting with high-speed video and photography systems to provide engineering departments with visual data to develop long-term solutions to repetitive production problems. Unilux designs and manufactures stroboscopic and pulsed LED inspection lights ranging from handheld, battery-powered units for spot or narrow-web inspection, maintenance or troubleshooting applications to fixed-mounted units capable of inspecting surfaces up to 36ft (12m) wide, either individually or in combination. More information on Unilux at: tel: 201 712 1266 fax: 201 712 1366 www.unilux.com Company profile Unilux Inc, based in Saddle Brook, New Jersey, USA, is in its 47th year of designing and manufacturing industrial surface inspection lighting systems. The company has sales representatives in 42 countries in North America, Latin America, Europe, Asia, Australia and Africa. Haven teams up with SOCO Haven Manufacturing Corporation of Brunswick, Georgia, USA has formed a strategic alliance with SOCO Machinery Company of Taiwan to sell and service their respective lines of tube cutting equipment. Company President Dave Erickson says the partnership provides Haven with an outstanding opportunity to grow within the Asian markets, while SOCO’s growth in the US market will be enhanced by Haven’s extensive market knowledge and reputation. Haven will have exclusive US rights to sell SOCO’s line of automated-tube saws, solid-bar saws and tube and bar machining centres. SOCO will represent Haven in China and South-East Asia, marketing Haven’s range of tube processing machines including the dual-blade shear cutoff, supported-shear cutoff, secondary finishing machines and the new Haventrak flying-shear cutoff. More information on Haven Manufacturing Corporation at: tel: 912-265-7536 fax: 912-264-9001 www.havencut.com More information on SOCO Machinery Company at: tel: +886-4-2359-1888 fax: +886-4-2359-2386 www.soco.com.tw Universal coating for Michigan Seamless Tube line M ichigan Seamless Tube, for over 80 years the producer of the widest range of carbon and alloy seamless cold-drawn pipe and tube in US industry, has added a UV coating line to its South Lyon, MI facility, offering 100% solid UV coatings with increased corrosion resistance and enhanced product appearance. Using a unique vacuum system to achieve consistent film thickness all around the tubular product, MSTube is now able to offer an added six months or more of corrosion resistance to its customers in distribution, transportation, energy, heavy equipment and original equipment manufactures. The new coating line has been built using a system installed by UK coating equipment manufacturer Universal Finishing Systems. Universal has been manufacturing integrated modular pre-treatment, coating and drying systems for the world tube industry for 15 years, with exports accounting for up to 80% of sales. MSTube’s new 100% solid UV coating joins existing services including supplying a full line of mechanical and pressure products to ASTM ASME and API, including heat exchanger, condenser, boiler, IPS pressure pipe, and oil production tubes. “The new line was up and running on schedule”, says MSTube’s engineering and maintenance manager David T Wellhofer. “Universal was very helpful in the start-up and in the training of our personnel.” More information on Michigan Seamless Tube at: www.mstube.com tel: 239 821 1710 fax: 248 437 2779 info@mstube.com More information on Universal Finishing Systems at: www.universalfinishing.com tel: +44 (0) 1244 280654 fax: +44 (0)1244 288102 info@universalfinishing.co.uk B&K spins revamped website B&K has updated its website to case studies indicating how B&K structural products and automatic include detailed information on its systems can improve your changeover between sizes. metal framing production production capabilities. The website also features systems, including: B&K Supermill systems extra information on B&K coil • The high-speed Supermill include: processing and handling patented stud and track roll • The 2DWR Drywall production equipment: precision levelers forming system; system – said to be the fastest and uncoilers. Further • The master bundler packaging production roll former in the information on the coil processing system; industry at 500fpm (150mpm); equipment can be found at • The dynamic capability • The expanded capability www.bklevelers.com. accessory system; of the 2DWR Plus, offering • The Versamill stud and track roll variable leg height drywall stud More information on Formtek at: forming system; and track with 500fpm www.formtekgroup.com, • Patented cam rotary punch and production capability; More information on B&K at: shear technology. • The 3TSR Supermill system, said tel: 216-292-4460 or The website now features to be the ultimate in metal framing 800-631-0520 detailed pictures and videos of the production with 12-25 gauge fax: 216-292-2898 equipment and products, with product range for drywall and www.bkformtek.com Company profile B&K is a member of the Formtek Group of long-established companies, each with a well-known name and a history of providing innovative, reliable equipment to the metal forming and metal processing industries. As a single source provider Formtek continues to supply its customers with the highest quality equipment, parts and service available in the industries it serves. K ent Corporation, the world leader in strip accumulators, has received an order for two large horizontal accumulators. They are of the roller style design for heavier, wider materials. The two machines range in size from 3-16mm (0.118-0.629in) thickness and from 127-813mm (5-32in) strip width. The customer chose Kent because of its long list of satisfied accumulator customers and in-depth knowledge of what it takes to make an accumulator work in a wide variety of applications. These accumulators will be used in line with Kent’s complete entry system on API pipe mills. Kent has been providing strip accumulator systems to the tube and pipe mill industry since 1971; it now has over 2,000 machines running successfully in applications varying from 0.012­750in (0.3-19mm) thick and from strip widths of 0.9-80in and above (23-2,032). More information on Kent Corporation at: tel: 1-440-237-9286 fax: 1-440-237-5368 email: Lens@kenttesgo.com www.kenttesgo.com A question from Plymouth Plymouth Tube Company believes there is a great deal of confusion in the aerospace tubing industry regarding testing requirements for some aerospace and military tubing material specifications. As a leading tubing manufacturer Plymouth is fully aware of its responsibilities when manufacturing for the aerospace industry as well as ensuring all protocols are followed in the strictest manner. With this in mind Plymouth self-disclosed its own discrepancies and fully co-operated with audits performed by Honeywell, Boeing, GE, FAA, NASA and the US Department of Defence. In working with these organisations, Plymouth made changes to conform to the appropriate aerospace tubing standards. Plymouth believes it is the only tubing mill to self disclose issues; it will continue to lead by example and build customer relationships while providing superior quality solutions and premium service. Specifying PTCA tubing, ensures Integrity When purchasing steel tubing for the aerospace industry Plymouth advises manufacturers to ask the following questions: • Do you possess all testing documentation for your aerospace tubing? • Does it meet the criteria of AMS or MIL-T specifications? • Are you aware that mechanical properties (tensile, yield, elongation), specifications also cover other raw material testing requirements including chemical composition, grain size, heat treating, passivation, pressure testing, formability testing, non­destructive testing, sampling frequency and conformance inspection requirements? • Have you been offered a mill tour at the tube producing mill in order to audit processes and procedures? • Are you confident you had all the required tests done for your aerospace tubing purchase? • Were your embrittlement and chemical tests performed and applicable to MIL-T and AMS specifications? If you answered 'no' to any or all of these questions, Plymouth says its technical team will be happy to address your concerns and guide you through any other problems you may encounter. More information on Plymouth Tube Co at: tel: 630-393-3550 fax: 630-393-3551 ptca@plymouth.com www.plymouth.com Co-Sponsors Industry Partners Aircraft component maker takes tube bending to new level G KN Aerospace has radically improved the efficiency and speed of tube bending operations at its wing component operation in Filton, UK, despite using some of the most demanding tubing materials and fabricating extremely complex part shapes. Successive installations of all-electric tube bending machinery from Unison, culminating in the recent installation of novel combined left- and right-hand bending machines, underpin a fabrication process that now includes ultra-precise parts in very small batches – typically without generating any scrap. Among the extreme challenges the tube bending team faces every day are tubular parts with as many as 19 bends, complex shapes with multi-radius coils, and titanium tubing with wall thicknesses up to 2.6mm (to cope with the high-pressure systems on its customer Airbus's latest double-deck A380). GKN Aerospace's tube bending facility fabricates up to 4,000 parts per week, using tubing ranging from a few millimetres in diameter to over 100mm. Aircraft applications are its main market, and the materials used, such as titanium, aircraft-grade aluminium and corrosion-resistant steels, are expensive. The company's interest in all-electric tube benders was rooted in the need to cope more efficiently with small batch sizes (typically less than 20 parts). Until about seven years ago the workshop used hydraulic bending machines, and the skilled attention required to reconfigure a machine for a new batch meant that scrap was almost invariably produced at each batch 10 IMT June/July 2009 changeover - sometimes several pieces. For materials such as titanium this was extremely expensive, so GKN initiated a search for machines offering higher levels of accuracy and repeatability. More than 15 tube bending machinery manufacturers competed for the business; Unison won the contract with a 65mm-diameter version of its all-electric tube bender. The precision and repeatability of set-up provided by the company's servomotor-controlled architecture proved the key factor. Scrap on regular production runs was virtually eliminated and productivity increased to the extent that the machine paid for itself within three months. GKN quickly acquired two more machines to handle smaller sized tubular parts, then a 115mm­diameter bender to handle the largest parts it bends, and most recently two custom-made combined left- and right-handed machines to improve productivity on the most complex tubing shapes it has to fabricate. GKN has exploited the capability of the all-electric machines to continually improve the workshop's tube bending processes and productivity. Bends are typically made to 1mm 3D envelope accuracy – sometimes as tight as 0.3mm for the workshop's military aircraft output – and the machines' ability to meet this specification reliably has allowed the workshop to eliminate a lot of its jig-based inspection processes. This process improvement helped achieve cost reductions on the component parts. Instead of inspection jigs, a co-ordinate measuring machine is now usually employed for post-bending inspection; Unison also wrote an interface utility for this to speed the development of new bending programs by automatically compensating for tolerance variations in the first prototype component. The precision and repeatability of bending also allowed GKN to eliminate any need for sawing operations following bending to meet the target length, yielding yet more savings. The workshop capitalised on this by purchasing many of its steel tubes pre-sawn to the exact lengths required. The intrinsic quality of the bend is another area where all-electric operation has supported significant improvements. The ductility characteristics of titanium in particular mean that slowing the bending process improves forming. This can be a particular issue with some of the material that GKN has to process, Unison apprentice leads WorldSkills finalists Tom Adams, an apprentice designer with Scarborough, England- based tube bending machine manufacturer Unison, has become the nation's highest scoring finalist in the WorldSkills Engineering CADD Competition. Now he and four other finalists – two of whom are also from the North-East – will go forward to the national final in London. The winner will represent the UK in the 41st international WorldSkills Competition, also in London, in October 2011. The northern heat of the WorldSkills Engineering CADD Competition was organised by TDR Training and held at the Newcastle offices of NDI, of which Unison is a member. The 10 competitors were judged on their skills in using CAD systems to produce 2D technical drawings, 3D models and 3D assemblies. Higher level competitors were also required to produce animations, including GDT (geometrical dimensioning and tolerancing) in technical drawings. Alan Pickering, Unison's managing director, says: "Tom has worked for Unison for more than two years now in a variety of design roles. We are extremely pleased that he has made the national final for the WorldSkills 2011 competition, especially with the highest score of any entrant, and wish him every success." Robin Fox, managing director of NDI, says: "We were delighted to host the regional final in the North-East and the skill shown by all such as thin-wall titanium tubing. devised in the form of combined The servomotor-controlled left- and right-hand bending bending axes on the Unison machines – the first all-electric machines allow GKN to create version of this unusual bending programs that exercise automation. precise control over all aspects of Workpieces can now be the tooling's speed and force transferred automatically from applied during fabrication left- to right-hand tool heads as (including at very low speeds, many times as needed to bend which is impossible with hydraulic the required shape in a single technology) to achieve optimum stage. As a result batch material flow and shaping. fabrication times have fallen from The latest machinery three days to just one-and-a-half installations – the two combined hours for one of the coiled parts, left- and right-hand bending and from two-and-a-half hours to machines – were acquired by GKN 30 minutes for a batch of the to overcome a long-standing multi-bend part that used to problem with some component involve switching machines. shapes. These include tubular "Aerospace is undoubtedly parts with lots of closely spaced among the most demanding bends, and tubes with coil applications for tube bending out structures that provide the there, and over time the mechanical flexibility to manufacturing tolerances are accommodate flexing movement tending to become much tighter,” during the operation of wing flaps. says Unison’s Alan Pickering. “Yet One part has so many bends it's still commonplace to see that GKN used to make it on two older-style hydraulically actuated machines, to avoid collisions. The benders in use – machinery that is operator skill required was very much more suited to large-batch high. Other coiled parts posed production of run-of-the-mill their own problems, in that the components. All-electric bending need for variable radii demaned an automation has helped GKN individual hand-crafted approach. Aerospace to evolve a component GKN approached Unison with production process that is at the the problem, and a solution was vanguard of what is technically those taking part was of the highest order. It is little surprise to us that Tom did so well, as Unison is a top quality company which we are delighted to have as a member of NDI." • In 2011 the UK will host the WorldSkills competition in London. More than 1,000 competitors from 50 countries are expected to take part in the four-day event, which is designed to encourage young participants, tutors, trainers and employers to stretch their aspirations, and to improve the public perception of vocational skills. For more information see www.worldskillslondon2011.com possible, in terms of precision, shape creation, and cost effectiveness." Peter Tiley, process unit manager at GKN Aerospace, says: "We provide commercial tube bending services targeted at precision and high performance applications. Traditionally, the very high level of operator skills required for this kind of fabrication leaves little scope to improve throughput. But with the catalyst of all-electric tube bending automation we have managed to multiply productivity without compromising quality, while simultaneously eliminating almost all scrap on regular batch production. “From the time we first invested in new-generation bending automation we have increased our overall productivity while additionally tightening manufacturing tolerances – and the Unison tube benders have played a key role in this achievement." More information on Unison at: tel: +44 (0)1723 582868 fax: +44 (0)1723 582379 enquiries@unisonltd.com www.unisonltd.com Company profile 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; today the company produces a wide range of servo-controlled machines, spanning tube diameters from 6-170mm. Applications involving small batch sizes, expensive materials, and high bending precision are key markets for its machines. Based at Scarborough, North Yorkshire, the company is the UK's only manufacturer of CNC tube bending equipment. Over the past decade it has consistently pushed the boundaries of this technology: among its latest advances are a laser measurement system that dynamically measures the accuracy of bend angles and automatically compensates for any errors. Kocks rolls into India for BP&S B hushan Power & Steel (BP&S) has completed the final stage of its phase II expansion programme. The company, which is based in New Delhi, was established in 1970 and has grown to become of India’s leading steel producers with seven world-class plants and an annual turnover of more than $750m. Now one of the world’s most modern combined wire rod and bar mills is to be installed next to BP&S’s new integrated steel plant in Jharsuguda in the state of Orissa. The core technology of this 500,000tpy rolling mill is a three-roll reducing and sizing block (RSB) which is being supplied by Friedrich Kocks & Co of Hilden, Germany. The order includes the design, supply, erection and commissioning of a four­stand/three-roll RSB with a nominal roll diameter of 370mm. The RSB is prepared for a possible future extension to five stand positions; it will be implemented after stand No 18 of the two-high roughing and intermediate mill. As a finishing block the RSB rolls finished straight bar lengths ranging from 16-80mm and hexagons from 18.25-50.0mm onto the cooling bed as well as bar in coils of 16-60.0mm. As a pre-finishing block the RSB produces all necessary pre-sections for the downstream wire rod finishing block. An extended ‘free-size’ range of up to ±1.5mm from the nominal size allows rolling of a variety of sizes with tightest tolerances by simply adjusting stands and guides via remote control. The optimum adjusting values for motor speed, rolls and guides as well as gear steps are calculated by the bar mill configuration system (BAMICON). The adjustment is done automatically within 60 seconds, facilitating the trouble-free, economic production of high quality bar. Whenever the finished dimensions exceed the ‘free-size’ range the quick stand changing system allows changes of stands in less than five minutes. This means any size can be rolled without any restrictions by using a minimum number of roll sets and stand changes. More information on Friedrich Kocks & Co at: tel: +49 2103 79 0151 fax: +49 2103 54028 v.d.Heiden@kocks.de www.kocks.de SMS Siemag gets back to its roots SMS Demag, a leading supplier of metallurgical plant and rolling mill technology for the steel and aluminum industry, is now trading as SMS Siemag. This is the largest company in the SMS group in terms of order intake and sales. Its range of products and services will remain the same but the new name recalls the roots of the company, which was founded more than 130 years ago by the Weiss family of entrepreneurs. All shares in the SMS group are once again under the control of the Weiss family. SMS group chairman Heinrich Weiss, says: “By taking this step my family is continuing the tradition of our family-owned company.” That tradition dates back to 1871 when the company was founded in Siegen Germany as a forging business. By 1918 it had evolved into Siegener Maschinenbau AG (Siemag); it started producing rolling mills in 1927. SMS Group is internationally active in plant construction and mechanical engineering for the steel and nonferrous metals industry. It comprises two divisions, SMS Siemag (metallurgical plant and rolling mill technology) and SMS Meer (tube, long product, press and forging technology). In 2008 some 8,400 employees worldwide generated a turnover of more than E3.5bn. More information on SMS Demag at: tel: +49 (0) 211 881-4127 fax: +49 (0) 211 881-774127 thomas.isajiw@sms-group.com www.sms-group.com TüV approval for wide range of valve types F ollowing a recent audit by approvals agency TüV Mannheim Süd, Parker Hannifin’s instrumentation products division has won TA-Luft approval for a wide range of its manifolds, valves and flanged products. This approval, which largely mirrors the new ISO 15848 standard, helps designers meet the most stringent rules governing fugitive emission limitations to maximise the integrity of processing systems. According to Parker’s project manager, Walter Kummer: “Companies are under growing pressure to limit the environmental impact of their industrial processes. Many of the world’s leading chemical and petrochemical processing companies are based in Germany and are already specifying the use of TA-Luft-approved components in their installations, to help implement ‘zero emissions’ and safety design goals. “The availability of these products from Parker will provide process system designers with a key competitive advantage in both domestic and world export markets.” Parker’s flanged manifold valve products and manifolds for instrument hook-ups are already available in ISO 15848-compliant versions. Independent third-party verification of the products’ design and performance testing phases – an obligatory part of the approval process – was provided by Lloyd’s Register. Following the audit by TüV Mannheim Süd, which looked at Parker’s design, test equipment and production test procedures, the company is now in the unique position of being able to demonstrate both ISO 15848 class A and TA-Luft approval. To meet these extremely rigorous, environmental standards Parker has taken its high-quality monoflange and Pro-Bloc flange-ended double block and bleed manifolds, which were already designed for minimal leakage paths, and effectively re-engineered their integral needle and ball valves. The new valves feature a combination of complementary sealing methods, using high-performance elastomeric O-rings to provide enduring resistance to leaks over repeated actuations, combined with traditional graphite packaging rings for fire-safe performance. The first products to be made available in TA-Luft versions are Parker’s Pro-Bloc, Monoflange and Hi-Pro double-block and bleed manifolds, and H-Series valves and manifolds. All products are supplied as standard with integral Parker A­LOK compression-tube fitting ends for high-integrity connections to process tubing. Highest standards The TA-Luft (Technische Anleitung zur Reinhaltung der Luft, or Technical Instructions on Air Quality) sets limits for emissions when processing, conveying or transferring dusty, liquid or gaseous materials, taking into account the specific risk potential. For ball valves, initial maximum leakage rates of 0.03g/h are permitted for high-risk materials; this value takes into account the normal limits for leakage from static seals (eg flange connections). This figure means that the maximum emission rate of helium (He) is 4.99x10­2cm3/s. This is seen as equivalent to sealing a valve stem by means of a bellows with safety gland seals in series. ISO 15848 defines three leakage classifications, specifying maximum leakage rates from less than or equal to 1x10-2mg/s/m, to a figure four orders of magnitude less. Meeting any of these low levels is challenging: Parker’s valves are designed to meet the highest ‘A’ classification level of 1x10-6 mg/s/m, over the temperature range -29 to +180°C at standard instrumentation manifold working pressures. New name reflects wider focus The company data M Software has accurately reflects the market in solutions it offers wide-ranging reflects this expanded focus. changed its name to data M Sheet which it works. consulting and engineering services. Metal Solutions. The new name has In the past few years the company These include design, analysis More information on data M Sheet no effect on its legal corporate has extended its business activities of reforming processes and Metal Solutions at: structure or its business dealings. from those of a pure developer of custom research and tel: +49 (0) 8024/6400 The new name is said to be a state-of-the-art software for sheet development in the field of roll fax: +49 (0) 8024/640300 logical consequence of the metal working. In addition to forming; notably innovative ‘flexible datam@datam.de company’s growth and more CAD/CAM and CAE software roll forming’. The change in name www.datam.de Tube and fitting alliance aims to boost quality and cut costs T housands of fluid instrumentation users will be able to cut their costs following the introduction of a supply service from Parker Hannifin, a global leader in motion and control technologies. Complete packages of tube fittings and tubing can now be purchased via a single order, thanks to an alliance with Sandwich Materials Technology. The agreement brings together two of the world's best-known players in the fluid instrumentation market. In addition to simplifying purchasing, the sheer volume of Parker's business means that it has been able to secure Sandvik tubing at rates that are highly competitive with no compromise on quality. A further advantage of the new service relates to the underlying product quality control. In today’s cost-conscious climate users might be tempted by vendors that focus purely on lowest price, running the risk of compromising quality. Choosing Parker/Sandvik packages locks users into an all-embracing quality system that is cost-competitive but also ensures fluid instrumentation tubing components have genuine integrity and perform to specification. This is vital for plants processing harsh media, or in corrosive environments. This quality control begins with an audit trail for the raw materials. Sandvik melts its own steel to ensure quality control from the outset and right through to the finished product. This attention to detail extends throughout the design and manufacturing chain up to and the world. Working with Sandvik including verification of allows our customers to benefit performance by independent from a level of quality and total third-party test houses. cost-competitiveness that we "Tube quality is critical for the feel gives us the edge". correct performance of our "We believe that this supply product," says Parker Hannifin's initiative demonstrates what can Sheldon Banks. "Our aim is to be achieved when like minded provide a high integrity organisations work together to connection every time with our maximise the potential for their range of connectors anywhere in products,” says Peter Rose of Company profile With annual sales exceeding $12bn, Parker Hannifin is the world's leading diversified manufacturer of motion and control technologies and systems, providing precision-engineered solutions for a wide variety of mobile, industrial and aerospace markets. The company employs some 62,000 people in 48 countries around the world. It has increased its annual shareholder dividends for 52 consecutive years; this is among the top five longest-running dividend-increase records in the S&P 500 index. Sandvik Materials Technology. “We are reserving mill capacity in order to meet the expected demand that this agreement will bring.: Parker Hannifin's alliance with Sandvik covers seamless instrumentation tubing in 316/316L stainless steel, as well as a range of the most commonly used exotic alloys including 304/304L, 6Mo, 321, SAF 2507, 625, 825 and Hastelloy C276. In addition to serving the mainstream market for stainless-steel tubing, Sandvik is well known as a pioneer of engineered materials for dealing with the exceptionally harsh pressure and corrosion-prone conditions faced by users in the offshore oil and gas industry. Parker Hannifin is renowned for its tube fitting range and has earned a reputation worldwide over many decades for reliability and innovation. Its range of threadless tube fittings range from industry standard twin-ferrule compression types featuring the unique corrosion-resistant Suparcase ferrule technology to three further fitting innovations designed to allow users to make tubing connections faster, cleaner and safer. The company's latest innovation, Phastite, delivers friendly compression-style assembly to high-pressure connections up to 20,000psi providing a cost-saving alternative to welded and cone­and-thread connections. More information on Parker Hannifin at: tel: +44 (0)1271 313131 ipd@parker.com www.parker.com RSA mourns Rainer Schmidt Rainer Schmidt, the founder, managing director and co-partner of the RSA group, died suddenly on 5 May, aged 65. Mr Schmidt founded an engineering company in his home town of Altena, Germany in 1971 with the aim of developing industrial applications for the use of high-performance brushes. He rapidly identified deburring as a market need and became a pioneer of this technology, developing numerous automated solutions. The company achieved Top appointment at MSA Nikolai Ovchinnikov is the new executive committee chairman at Russian valve manufacturer MSA, which is part of the trunk pipeline equipment business unit at oilfield services specialist Rimera (the OFS division of ChTPZ Group). Before joining Rimera Mr Ovchinnikov spent 28 years in Uralmash, one of Russia’s largest heavy machinery companies. During that time he was promoted from foreman to head of engineering. Mr Ovchinnikov says his main goal will be developing and executing long-term strategy for MSA to make it a key asset in Rimera’s trunk pipeline equipment division. More information on MSA at: tel: +420 553 881 111 fax: +420 553 651 236 sales@msa.cz www.chtpz-group.ru rapid growth, leading to the foundation of companies in France, England and Turkey. Mr Schmidt also made a name for himself as an author, communications trainer and marketing strategist. In 1997 RSA launched a new sawing concept for the mass production of steel tubes and sections; Mr Schmidt participated in the development of many other sawing machines and processing modules – RSA now offers solutions for all forms of pre-fabrication. More information on RSA Group at: tel: +49 (0)2351 995-5 fax: +49 (0)2351 995-300 rsa.d@rsa.de Thailand Iron and Steel Industry Club Messe Düsseldorf, THAI STAINLESS STEEL Malaysian Iron & Steel organizer of DEVELOPMENT ASSOCIATION Industry Federation CNC endworking enhances flexibility T he flexible endworking of pipes and tubes is crucial for the production process. Arla Maschinentechnik of Wipperfurth, Germany builds CNC-controlled endworking machines which are available for both single- and double-sided machining. They are based on a solid frame with one or two precise machining units including a unique concentric workholding technology. This means the machine can replace two CNC lathes. The Arla design comprises a fixed workpiece with revolving tools. All machining units are directly driven by servomotors; they are extremely rigid, powerful, and designed for high torques. The units, which feature integrated motor spindles, can be supplied with tool changing systems. Typical applications include turning, facing, planing, tapping, threading, chamfering, boring, drilling, milling and deburring. The new series of Arla spindle units can be used with the HSK interface or integrated facing heads. The machining of complex contours with a single tool system normally demands the use of facing heads with dedicated machining ranges from 5-410mm. The but also held in a special release units to meet various requirements. mechanically synchronous, high- position for radial and axial The clamping systems on Arla's speed clamping technology allows adjustment purposes. endworking machinery are a clamping force of 10-175kN. available as independent units, A range of jaw sets are used to More information on Arla at: either pneumatically or reduce the diameter without tel: +49 2267 6585-0 hydraulically actuated. According readjusting the center. And Arla fax: +49 2267 6585-70 to the model size the maximum has developed an option that info@arla.de outer diameter that can be handled allows workpieces to be clamped www.arla.de Hart extends piping stocks Last year Dutch stockist Hart extended its line-up of seamless pipe in 200/201, 400, 600, 625 and 825 alloy and grade two titanium. Now it is further increasing its range with more sizes and wall thicknesses. Services include 24-hour deliveries and cutting to length. For the past 40 years Hart has supplied a full range of piping packages, plate and bar; the ISO-approved company dispatches materials worldwide. • The company will be displaying its stock and services at the Stainless Steel World Exhibition in Maastricht on 10­12 November. More information on Hart at: www.hartbv.nl, tel. +31-33-2453848, email: central@hartbv.nl, fax. +31-33-2459875. DWT launches another Babcock beveller I t’s no secret that effective preparation of tube ends has a direct bearing on the quality of the welding junction. This is particularly important when welding thick walled tubes and with orbital welding technology. For many years DWT has been a licensed manufacturer of Babcock portable pipe bevelling machines. DWT offers a range of special applications for on-site operations with flexible, lightweight machines which are ideally suited to boiler walls and heavy-duty pipes. Additionally, their high working speed and fast preparation time reduce manufacturing costs. The latest MF6i-50 can machine pipes with a inside diameter up to 711mm on-site. It is driven by pneumatic motors and controllable by a single operator. Other features include a high metal removal rate, ease of handling and rugged, compact construction. • DWT will be exhibiting its range at a number of shows in the coming months including: October; Maintain, Munich, Welding & Cutting, Essen, Germany, 13-15 October; and Germany, 14-19 September; Tube India, Mumbai, India, 10-12 Tubotec, Sao Paulo, Brazil, 6-10 February 2010. Company profile DWT is a family-owned company based in Essen in the industrial heart of Germany. It was set up in 1987 as a major supplier of German mining companies. It delivers pneumatic products all over the world for a wide range applications. Following re-unification in 1990 DWT set up a company in eastern Germany, followed by a branch office in south­ west Germany. Activities include: • Sales and servicing of industrial production equipment; • Production and sales of nitrogen generators; • Production and sales of Babcock pipe bevelling equipment. More information on DWT at; www.dwt-gmbh.de, tel: +49 201 45099 0 fax +49 201 45099 99 info@dwt-gmbh.de On shore and off shore Protem’s latest OHSB-C 6-14 The tube clamping range is 6­machine is designed to produce 14in with a maximum tool holder bevels and compound bevels by plate speed of 170rpm. The copying. beveller weighs 1,980kg . It A carriage with hydraulic measures 1,560mm high by radial movement mounted on 1,450mm wide and 1,920mm long the tool holder plate while the hydraulic actuating incorporates a copying cam to cylinder has an axial stroke of match bevels. The tool holder is 150mm and a radial stroke equipped with carbide plates; of 80mm tube wall thickness of up to 60mm can be accommodated More information on Proem at: with a bevel height lower than tel: +49 (0) 7247-9393-0 30 mm and a maximum angle fax: +49 (0) 7247-9393-33 of 37°. protem-gmbh.de CNC platform provides economic solution for twin-head steel cutter O xyser has dramatically increased the throughput of its oxy­acetylene steel cutting machinery and has automated the process by developing a twin-head machine controlled by NUM's Axium CNC platform. This powerful CNC unit controls 16 motor axes to manage the motion of a gantry with two positioning heads, each fitted with mobile oxy-acetylene cutting torches. The machine has just been commissioned at Grupo Ros Casares' plant in Aviles, Spain, where it is being used to produce steel plate sections required to construct wind turbine generator towers. The shaped plates are typically cut with bevelled edges so that they can be welded together easily on site. Believed to be the first of its kind, the machine introduces automatic programmed control of shape cutting in a sector used to much simpler machines: traditionally, only three CNC-controlled axes are employed and the initial positioning of the oxy­acetylene tool for linear cuts is performed manually. The gantry runs over long worktables. This allows raw steel plate to be loaded on one side of the gantry while cutting operations are in progress on the other side. Combined with dual cutting heads (which can be used individually or simultaneously in a master-slave configuration) the machine has more than doubled throughput. Oxyser developed the new-generation cutting machine to improve productivity for Grupo Ros Casares, a major supplier of structural steelwork in Spain and the rest of Europe which provides a wide range of steelwork processing services including complex shape cutting. The cutting capability of the machine's oxy-acetylene torch heads was conceived with the versatility needed to produce bevelled edges for the cladding of wind turbine structures; it will cut virtually any complex shape defined by a CAD program. Oxyser specialise in producing plasma and oxy cutting machines, but up to now it has concentrated on smaller systems with up to five control axes. This project marks the company's entry into the high-end cutting market. The key technical requirement to meet the demands of this application was a much more powerful CNC kernel. NUM provided a solution in the form of its Axium platform, which offered continued on next page Company profile At the start of the 1960s, more than 10 years before the CNC control was starting to become widely accepted, NUM's first CNC controller was being developed. The company focuses on a number of high-end CNC applications. Based in Switzerland, with R&D facilities in Switzerland, France and Italy, NUM currently has more than 35 sales and service locations worldwide. In addition to CNC hardware and software, NUM develops and manufactures core products having impact on the overall performance of the system including drives and motors. The company will also integrate and take responsibility for third-party products in close co-operation with partners and customers to provide a one-stop shop for CNC solutions. Company profile Since 1982 Oxyser SL (www.oxyser.com) has specialised in the construction of plasma and flame cutting machines. Its products incorporate the latest advances in mechanics and electronics, including linear guides with recirculating skate – a technology pioneered by Oxyser. The company has also taken the lead in the use of numerical control based on PCs and open architecture components, providing almost limitless possibility for the future control of the machine tool. TS 4.20 2D is an innovative operation the sheet metal with cutter and welder from the new final sizes is ready to be Tube Tech Machinery of moved to the next work station. San Martino, Italy. It is Like the rest of the Tube Tech equipped with a single head to Machinery range, the TS 4.20 has cut and weld sheets ranging from 2,000x1,000mm up to 4,100x2,050mm in thicknesses from 1-8mm. The production run comprises the following steps: • Automatic loading; • Alignment and spot-drilling via a centering station; • Sheet metal translation by NC- controlled multi-process; Auto loading on cutter/welder continued from previous page the computational power to control the required 16 axes of motion. NUM was also able to provide all necessary ancillary automation components including drives, motors, I/O and HMI panel. The machine is enormous – the parallel worktables (one for each tool head) are 26m long and 8m wide. The gantry supports two cutting tool heads with one slave tool following the motion of the master tool. The 42mm-thick steel plates being cut for the wind turbine application weigh about eight tonnes each, measure some 10x2m and have bevelled edges. To meet the end user's production requirements the machine currently operates for 16 hours a day during which time it cuts up to 32 steel plates. Thanks to its high degree of automation only one operator is needed, both to run the machine and remove offcuts. The 16 axes control the X-Y movement of the gantry as well as the vertical and rotational movement axes of the two cutting heads. Inside each cutting head, three acetylene torches are positioned in a line. The middle torch is fixed but the outer torches have two axes of linear and rotational movement to provide the flexibility of positioning required for cutting complex shapes and bevel edges. The torches can be used singly or in combinations. All axes are powered by servo motors designed by NUM exclusively for high-performance CNC applications. NUM also helped Oxyser to develop a custom operator control panel based on the company's standard NUMpass HMI. The program allows the operator to easily enter the required cut characteristics including speed, acceleration, angle of cut and torch power. To help Oxyser develop the machine, NUM write a utility to provide the analog signals required to control the acetylene torches. Unai Gonzalez of Oxyser says: "NUM's controller proved a cost-effective platform for this project as all the axes can be managed from one CNC kernel, together with all of the I/O. The software environment simplified the CNC programming by making it easy to set up groups of axes to break down the complexity of this large machine.” More information at: www.num.com tel: +44 871 750 4020 sales.uk@num.com Company profile Ros Casares Group (www.froscasares.es) is the Spanish leader in industrial distribution and logistics, steel service centres and structural steelwork. The group has become a basic link in the supply chain of many companies. • Sheet metal blocking using a sheet pressing system; • Trimming by 2d laser cutting head; • Sheet edge adjustment for perfect alignment; • Laser welding through the same laser head and control by Precitec LWN system; • Opening sheet pressing systems; • Welded sheet metal translation. At the end of the welding been designed using FEM (Finite Elements Method) structural calculation programs. • Tube Tech Machinery will be exhibiting at a number of shows this year: Essen, 14-19 September; Milan, 5-10 October; Piacenza, 19-21 November; Stuttgart, 1-4 December. Overall machine dimensions: 32,000x10,500mm Maximum sheet size: 4,100x2,050mm Minimum sheet size: 2,000x1,000mm Maximum thickness: 8mm Minimum thickness: 1mm Vertical stroke: 500mm maximum Horizontal stroke: 5,000mm Fixed table maximum load: 15,000kg More information on Tube Tech Machinery at: tel. +39 030 7256 311 fax +39 030 7256 333 info@tubetechmachinery.com www.tubetechmachinery.com Tekla and HGG launch software for tubular profiles I n 2007 Tekla and HGG teamed up to develop standardised software for the steel tube industry; now that project has borne fruit. Tekla Structures 15 introduces producing required control data for NC (numerically controlled) machinery in standard open XML format. It is said to be the only software on the market to cover all 3D tubular structures, from design and detailing to automatic fabrication. Until now data transfer with tubular sections has required several manual operations and editing of data. By completing the 3D building information model (BIM) with a wide range of tubular connections it is now possible to export information to tube profiling machines by using open XML as the new Tekla Corporation’s model-based software products make customers’ core processes more effective in terms of building and construction and infrastructure management. Tekla has area offices and partner organisations worldwide. International operations account for nearly 85% of net sales. industry standard. The Tekla and HGG integrated solution for modelling and manufacturing tubular steel structures includes: • A full range of components in Tekla Structures to cover the needs for modelling tubular structures: offshore saddle (AWS) and offshore chamfer, saddle and hole, mitre and hole, chamfer and slotted hole; • Integrated export of complete manufacturing information from the model directly to 3D tube profiling production; • XML format-based industry standard for transferring data that is open to any tube profiling machine company or design software supplier; • Visualisation module for 3D representations of cutting shapes on tubular structures. Company profile Company profile Founded in 1966, Tekla is one of the longest established software companies in Finland. Tekla Structures BIM (Building Information Modelling) software encompasses specialised configurations for structural engineers; steel detailers and fabricators; concrete detailers and manufacturers and construction companies. Founded in 1984, HGG specialises in steel profile cutting; it is said to be the only company exclusively devoted to this technology. Machines developed and produced by HGG combine plasma cutting with ox fuel cutting; they are supplied to companies worldwide. HGG provides engineering and production of pipe and profile All information about tubular sections can now be managed and kept up-to-date in the structural building information model so all data for fabrication can be extracted from one source. This does not require any manual input or editing, and even complex tubular connections can be handled automatically. The objective has been to enable input of required parameters, such as root opening, shrinkage, bevel, and profile type, into Tekla Structures. The new NC application creates the required control data file in XML format More information on Tekla at: tel: +358 40 7071622 saku.jarvinen@tekla.com www.tekla.com cutting solutions. The HGG Management Information System (MIS) ProCAM offers added functionality such as industry-specific tools (eg can rotation for the offshore industry); integral production management (eg return signals confirming processing); and project planning (eg estimated production times). from these parameters; the HGG calculation module generates contour information from this file to be used as input when visualising weld preparations in the Tekla Structures 3D environment. The NC application will be distributed as part of the standard installation of Tekla Structures 15 Steel Detailing configuration. More information on HGG at: www.hgg.nl, tel. +31 227 504030 fax: +31 227 501903 ig@hgg.nl TeZetCAD software checks for perfection It’s a fact of life that when tubes the cylinders before and after the that the bent radius and centre which are not perfectly round and leave the bender they are not always bend will differ, which can lead to points in flange holes might not leads the user with the straight and not always round. It them being rejected at the quality be accurate. measuring probe exactly to these could be that the straight has a control stage. TeZetCAD aims to simplify the points. slight bend or that the bend picked Tube bending specialists have necessary measurements of all up a certain ovality while being known this since they started these factors with software that More information on formed in the bender. bending tubes; they also know automates the whole process. Its TeZetCAD at: There is also a possibility that that when measuring tubing the specialised tube software, is tel: +41 56 2493760 the radius no longer conforms to most important criteria are the continuously updated to remain fax: +41 56 2492878 the predefined radius of the measuring points. state of the art; the program leistritz@tezet.com tooling. In this case the lengths of Another potential problem is automatically finds the points www.tezet.com 20 IMT June/July 2009 www.internationalmetaltube.com Swagelock launches medium-presure ball valve D esigned for improved cycle life in the field, the Swagelok FKB Series medium-pressure ball valve provides a leak-tight seal for applications up to 15,000psi (1,034 bar). The trunnion-style ball valve features 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 introduction of this ball valve extends the company’s range of medium-pressure valve delivers a consistent leak-tight, live-loaded seat seal across a full range of pressures,” says Swagelok market manager Bill Menz. “Even when depressurisation of the system occurs, the direct-load design ensures a leak-tight seal upon repressurisation of the system." 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. A bottom-loaded stem design eliminates system blowout for enhanced operator safety. Maintaining the integrity of the valve seal is critical for applications where positive shut­off is required. The valve 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 ball valves feature a 0.209in (5.3mm) orifice, 316 stainless-steel body construction and temperature range. O-ring materials include nitrile, fluoroelastomer and perfluoroelastomer; all wetted materials are compatible with most hydrocarbons. Offered in a two-way configuration, the valves are available with Swagelok medium-pressure tube fitting end connections which provide single turn makeup, or can be made up by torque, for reduced installation time and labour costs. Like traditional Swagelok tube fittings, the end connections use a two-ferrule design to deliver robust tube grip, leak-tight gas seal and vibration resistance. Female NPT end connections are also available. End connections sizes are 0.25in 0.375in and 0.50in. The FKB Series valve is the company’s first release of three sizes for its medium-pressure product line. The Swagelok line of medium-pressure products currently includes medium-pressure fittings and seamless tubing. The 316 stainless-steel fittings are available in a variety of configurations for use with medium-pressure stainless-steel tubing, both heavy-wall annealed and cold-drawn 0.125 hard, and heavy-wall SAF 2507 super duplex tubing. • SAF 2507 is a registered trademark of Sandvik AB. More information on swagelok at: tel: +1 440-349-5934 www.swagelok.com Company profile Headquartered in Solon, Ohio, USA, 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. Its manufacturing, research, technical support and distribution facilities support a global network of more than 200 authorised sales and service centres in 57 countries. South America and the Far East. A comprehensive repair and Büker Rohrtechnik maintenance service is available. • Büker Rohrtechnik was established in 1963; under the leadership of managing director Emil Büker it is active in sectors T he latest addition to the Heinz Strempel. and the company’s other including pipeline construction, extensive range of pipe The company will be products and services power plants, chemical plants manufacturing and promoting the Jettester on its These include machinery for and boiler production. testing equipment from stand at the Schweissen & pipe end preparation, bevelling, Büker Rohrtechnik of Schneiden show in Essen on 14-pre-heating, cutting and looks for leaks More information on Büker Meerbusch, Germany is the 19 September. A film detailing bending; a rental service is Rohrtechnik at: Jettester, which find leaks in the Jettester’s benefits will be available. The company also Tel: +49 (2150) 2500 tubes quickly and easily. It was shown on the stand, which will exports machinery throughout Fax: +49 (2150) 6010 developed in-house by the be manned by technical staff the EU and beyond, with clients company’s chief technician, who will brief show goers on this as far afield as South Africa, www.Bueker-Rohrtechnik.de TeZetCAD software checks for perfection It’s a fact of life that when tubes leave the bender they are not always straight and not always round. It could be that the straight has a slight bend or that the bend picked up a certain ovality while being formed in the bender. There is also a possibility that the radius no longer conforms to the predefined radius of the tooling. In this case the lengths of the cylinders before and after the bend will differ, which can lead to them being rejected at the quality control stage. Tube bending specialists have known this since they started TeZetCAD aims to simplify the necessary measurements of all these factors with software that automates the whole process. Its specialised tube software, is continuously updated to remain state of the art; the program automatically finds the points which are not perfectly round and leads the user with the measuring probe exactly to these points. More information on TeZetCAD at: tel: +41 56 2493760 fax: +41 56 2492878 leistritz@tezet.com www.tezet.com Meta Vision launches 3D scanner F ollowing an extensive R&D programme combining optics, electronics, firmware and mechanical sensor design, Meta Vision Systems has launched a 3D digital laser scanner for use in automated welding equipment. The DLS300 can also be used in other manufacturing applications, such as profile measurement and scanning for reverse engineering. Conventional laser vision systems based on the triangulation principle use a laser stripe projected onto the target. This is processed by a 2D area camera to produce a 3D profile of the target. However, the use of a laser stripe has practical limitations because constant laser power is used for the whole stripe. This means it is not possible to vary the intensity to increase the light reflected from dark areas and decrease the light received from lighter areas. The camera images the complete scene including either side of the stripe, which can lead to further problems with dynamic range and unwanted reflections. Meta’s new sensor uses triangulation, but is based on a scanning spot rather than a stripe, solving the two main problems of stripe-based triangulation. First, it is easy to implement effective automatic gain control to compensate for reflectivity changes. Second, imaging is via a linear charge coupled device, which only looks at the region of interest and is not affected by reflections. Additional benefits of the scanning technology include a programmable field of view and independence of the sensor’s depth of field from the width of field. Jonathan Moore, Meta’s technical director, says: “By exploiting the latest developments in programmable electronics we have been able to integrate a lot of intelligent signal processing inside the sensor head. “The connection from the sensor to the outside world is by Ethernet, providing digital control of the sensor from any external device over a UDP link and enabling rapid digital reporting of the sensor data.” Managing director Bob Beattie adds: “We are very pleased with the performance of the DLS300, which has exceeded our expectations and the initial design specification. Trials in various welding applications, including adaptive submerged arc welding of nuclear vessels and wind tower production, have been extremely successful.” More information on: Meta Vision Systems at: tel: +44 1865 887900 sales@meta-mvs.com www.meta-mvs.com S ub Sea Services was established in Stavanger, Norway in 1990 as a small family firm. Today its services and specialised products have won international acceptance in the offshore industry. To meet increased demand, as well as its own stringent quality and productivity standards, the company has invested in high-tech manufacturing technology – it is now finishing pipe assemblies and components using highly efficient TIG hot-wire technology from international market leader Polysoude of France. Otto Henning Sulen, weld-shop manager at Sub Sea Services, says: “Pipes and systems used to convey crude oil or natural gas energy sources at high speed and at high pressure demand high levels of investment. The sand and other abrasive minerals, as well as corrosive media which are also conveyed during exploration, necessitate pipe materials of the highest possible quality. “To control costs and preserve resources we finish the internal walls of our components using deposition welding. In this process, the extremely hard and tough material Inconel is melted on to the cost-effective and easy-to-process carbon steel parent metal [Inconel is a trademark of Special Metals Corporation]. “To achieve this we found an especially efficient and effective system in the shape of the automated TIG hot wire and deposition welding system from Polysoude. The new system with its six computer-controlled axes welds and coats reliably and efficiently.” This helps enable the 50­person company to manufacture its unique niche products, such as the remote-controlled, interchangeable, modular slip joint for pipes on drilling platforms around the globe, at the same high quality levels and to schedule. Mr Sulen explains: “Quality and delivery times are given the highest priority in our organisation. For manufacturing, this means that the availability of the production equipment used must be extremely high. For my particular area of responsibility the equation is really very simple – if the welding system breaks down, there is no product!” The decision to invest millions in manufacturing equipment was not an easy one for the Stavanger-based company. A variety of equipment manufacturers were invited to display their technology before locally based consultancy TEMA made contact with Polysoude’s Dutch representative Kees Meurs. From that point Six computer controlled axes for welding and coating deliver a high degree of reliability and efficiency. everything progressed quickly. Mr Sulen says: “At Polysoude we found the automated welding solution that we had in mind. High-tech equipment, not exactly cheap but of the highest quality, and both robust and appealing in design. “It was not least the people there, competent and reliable, that tipped the scales in their favour. Outstanding technology and quality has always cost more and we have decided to invest in the best.” Thanks to much shorter production cycles the new system has greatly increased productivity for both joint and deposition welding. This has enabled the company to boost Inconel application levels by up to 80%, with a quality increase of some to 40%: “This also enables us to meet the specifications more closely. For example, the melt level of the carbon steel parent metal is consistently below 3%, which is what makes it so hard-wearing. More information on Polysoude at: tel: (33) 2 4068 1100 fax: (33) 2 4068 1188 info@polysoude.com www.polysoude.com More information on Sub Sea Services at: tel: +47 5183 9530 fax: +47 5183 9541 post@subseaservices.no www.subseaservices.no Product range The range of materials processed by Sub Sea Services extends from X60, X65 and X70 via AISI 4150, 4140 and 8630 through to low-carbon steel F22. Pipe components are made from 1,000-1,500mm in length with diameters of 150-1,000mm. The company meets every required standard and specification, including the DNV (Det Norske Veritas); IPE (Implementation of design-related requirements in Production and Erection); and ASME (American Society of Mechanical Engineers). The quality procedures are certified to ISO 9000 following in-depth hardness and flexion tests as well as material grinding. The welders in Stavanger have all the requisite qualifications and undertake ongoing training as a matter of course for the personnel. With a smile, Mr Sulen recalls that his welders and machine supervisors were initially sceptical of the new technology: “It was of course a natural human reaction in the face of the new and of changes. Once they had thoroughly familiarised themselves with the machines, automated welding and deposition process, they are now hugely enthusiastic. “They are also proud to be given responsibility for the new technology. This is because they have witnessed their own high levels of productivity and the consistently high quality. They also see the value they then bring to the company – and that fills them with pride.” • Inconel is a registered trademark of Special Metals Corporation. systems, machines, components mobile TIG welding system for construction. Schneiden trade fair in and technology for orbital and tube assembly using automated Intuitive operation has been Essen on 14-19 mechanised joining and cladding. orbital welding opens up continued on p.26 continued from p.25 combined with the modular system concept established with Polysoude’s smaller P4 version. A large touch screen provides the human-machine interface (HMI); all interactions with the system take place via this interface. It issues commands to the internal electronics via the software and transmits the status of the joining process to the operator. The P6 also features autonomous system configuration and auto-programming; as well as real-time welding data recording for a welding result that is guaranteed to be reproducible. The machine not only detects the type of tool connected (open or enclosed weld heads, etc); it also knows the tool’s limit values. Auto-programming takes over the adjustment of the welding parameters down to the last detail. Along with the precision power source, the weld heads are the most important factor in the Polysoude has developed the P6 TIG power source with CNC control for orbital and mechanised welding. The engineers from Nantes have developed automated joining technology for boiler construction in power plants known as TIG narrow-gap welding. This process is especially suitable for joining thick-walled, concentric circular work pieces. It is favoured for wall This is the TS weld head for tube/tubesheet applications thicknesses from 25-300mm. Following a favourable reception from power plant construction companies, Polysoude is presenting it for the first time to a wider audience. Welding Autoprogramming for pipe welding systems M agnatech’s Pipemaster is widely used for multipass orbital pipe and boiler tube welding. The Pipemaster has an autoranging input of 220-480V AC with a 200A output; it will operate weld head models incorporating controls for torch rotation, wire feed, torch oscillation and arc voltage control functions. Orbital multi-pass pipe welding systems can provide significant productivity improvements. However, many potential users are concerned by the need to program the equipment for each pipe size and material and the training needed for their welders to program a CNC tool. inexperienced user simply enters Now, the new autoprogramming pipe OD, wall thickness and mode allows operation without material; a weld program will programming training. An automatically be generated. The resulting weld program can then be run and, if not perfect, can be modified in two ways: • In ‘edit’ mode any parameter can be changed at any point during the weld; • In ‘scaling’ mode parameters such as rotation spread or amperage can be changed by a percentage for the entire program. The power source stores up to 100 weld programs. More information on Magnatech at: www.MagnatechLLC.com tel: (860) 653-2573 info@MagnatechLLC.com fax: (860) 653-0486 In-Line Diameter and Shape Contr ol For Hot and Cold Processes – For Any Pipe, Tube, Profile STEELMASTER Gauges Hi-speed laser scanning. Measurement of diameter, ovality, height, width and diagonals. s Possible measuring modes sStandard measuring ranges up to 500 mm s1 up to 6 measuring axes sMeasuring 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 300 mm s1 up to 6 laser /camera modules Visit us at: Moscow, Russia May 12-15, 2009 Booth FOB02 Worldwide Customer Service and Sales Offices: Pittsburgh, PA, USA Zumbach Electronic AG – SWITZERLAND (H.Q.) Zumbach Electrónica Argentina S.R.L. – ARGENTINA Zumbach Electronic S.A. – BELGIUM Zumbach do Brasil Ltda – BRAZIL Zumbach Electronic Co., Ltd. – CHINA P.R. Zumbach Bureau France – FRANCE Zumbach Electronic GmbH – GERMANY Zumbach Electronic India Pvt. Ltd. – INDIA Zumbach Electronic Srl – ITALY Zumbach Electrónica S.L. – SPAIN Zumbach Electronics Far East – TAIWAN Zumbach Electronics Ltd. – UK Zumbach Electronics Corp. – USA Plus more than 40 agencies www.zumbach.com May 04-06, 2009 Booth # 1211 ZUMB.707.0092.E_Feb.09 Measurement and control from Zumbach Z umbach offers a comprehensive line of non-contact measuring and control systems for hot and cold applications. They offer accurate measurement and real-time control of tubes, pipe, profiles etc. Systems are designed to cope with demanding environments in the metals industry. The Zumbach line-up includes: • Steelmaster measurement systems for hot and cold applications; • ODAC laser diameter gauges and USYS data acquisition, processing and display systems; • Profilemaster systems using ‘light section’ technology and machine vision for accurate in-line measurement of the complete cross-section. Steelmaster Steelmaster measurement systems are based on cutting-edge technology. The hardware architecture and software have been designed for operation under the severe conditions encountered in the steel industry. Steelmaster systems offer flexible and application-specific configurations. The measuring gauges are available in two designs, SMO and SMS models; and in two measuring ranges, 60 and 100mm (2.4 and 4.0in). SMO oscillating models suit round and non-round products such as wire, rod, squares, hexagons and flats. They are designed for up to six measuring axes and an oscillation angle of up to 180°, allowing them to capturing the full 360° profile very quickly. SMO models need practically no maintenance. SMS static models are extremely compact and easy to www.internationalmetaltube.com install. They are ideally suited to round products, need no maintenance and are designed for shortest measuring distances in the longitudinal axis. Benefits include: • A high measuring rate of 1,000 measurements per second/axis (up to 6,000 measurements per second); • Exceptional accuracy; • Industrial PC operation without a hard disc, making it absolutely stable and reliable; • Easy installation with only one fibre-optic cable between the measuring gauge and the data processing unit; • Extremely compact design with practically no maintenance; • The Multigauge concept, which allows the connection of up to four measuring gauges; • A wide range of additional software packages. Steelmaster is the overall system name for these packages as well as the user interface. A number of modules control the many functions and tasks, facilitating flexible expansion and upgrades. • Steelgauge controls the configuration of the measuring unit(s), interface with the ODAC laser heads, temperatures and shrink values. • Steelfiner (for internal or external installation) controls product configuration, tables and administration. • Steeldata filters and processes measurement values for configurations, parameter definition, statistics, printout and host protocol. • Steeldatabase (for external installation) facilitates storage of the measurement values in a My SQL server on the hard disk. • Steeldbviewer (SDB Viewer) recalls and reviews the measurement data and sections screens according to selectable search criteria. • Steelmaster Remote allows communication with up to 10 work stations (PCs) over the ethernet for independent tasks such as recipe preparation, statistics and remote display. • Steelhost is the standard communication protocol for downloading nominal values and set points and for retrieval of measurement data statistics. ODAC Zumbach offers a comprehensive line-up of modular, single-, dual-and triple-axis ODAC laser gauges and USYS data acquisition, processing and display units. Zumbach Electronics is among the leading manufacturers in this field with more than 60,000 ODAC scanners or systems operating worldwide for in-line measurement of diameter, ovality and other dimensions in industrial processes. The gauges are based on the latest laser scanning technology, backed up by Zumbach's long experience in this field. They can be used in almost all manufacturing processes, including: • Extrusion of cables, hoses, profiles etc; • Drawing, grinding, cold and hot rolling of metal rods, tubes etc; • NDT lines for any product; • Packaging sausage skins and other food products; • Tubing, pipe and conduit extrusions. USYS systems for data acquisition, processing, display, statistics, process control and networking are available for any specification and budget. All USYS processors are built to industrial standards. They are stable, easy to operate and extendable. They can process up to six ODAC gauges plus other sensors, speed and event inputs. Sensors and processors must be able to communicate with other computers and networks; Zumbach offers a range of ODAC versions, interface units and USYS software to satisfy almost any need and concept. This technology brings a number of benefits. In the case of ODAC laser scanners these include: • High resolution and accuracy; • High measuring rate of up to 2,400/sec; • Integrated fault detection; • Permanent calibration; • Robust construction to ensure a long service life; • Insensitivity to dirt; • Optical immunity; • No problems with safety. Zumbach’s USYS processors also offer clear benefits: • A model to suit every application and budget; • Extremely fast and powerful performance thanks to Zumbach’s hardware and real-time software; • Industrial quality technology which is easy to operate; • A rugged and stable evaluation and processing system; • Programs on flash disc with no hard disc; • Process-specific configuration and software packages; • A flexible design which is suitable for extension. Profilemaster Profilemaster systems use the ‘light section’ principle and machine vision for accurate in-line measurement of cross-sections. The dimensions, or even the complete cross-section of tubes and profiles must be continuously measured and monitored in the manufacturing process. Standard samples are measured on a profile projector or similar apparatus and the results are registered. But this is a complex operation and does not offer continuous quality control. In addition to this it can be inaccurate, simply because there are many steps in the procedure during which exact and careful handling is necessary. And optical in-line measuring All relevant dimensions such as width, height, angle and radii are added ‘ together to form the full cross-sectional picture. ’ technology using standard laser diameter gauges or CCD cameras cannot measure indented or concave parts of the profiles, such as connecting rails, grooves etc. However, Zumbach’s Profilemaster systems offer an accurate, economical and practical solution to the problem. One or up to four laser/camera modules measure the cross-section of the moving profile on-line and continuously. One or multiple lasers (depending on the number of modules) project a visible laser contour around the profile and this is registered by a similar number of CCD cameras. A powerful PC-based processor combines the partial pictures from the cameras, which comprise straight lines and radii. All relevant dimensions such as width, height, angle and radii are added together to form the full cross-sectional picture. The nominal values for this profile can be directly imported from the CAD construction which allows easy and problem free programming; changes in speed and twist within normal limits have no affect on the measurement. Nearly all geometrical data from a profile can be collected. An operator-friendly graphic display of this data allows the product to be monitored during the production process. When designing the Profilemaster system Zumbach focused on the most suitable solution in terms of the price/performance ratio for the application. The combination of 1-6 laser/camera modules allows the measurement of virtually all shapes, providing the best possible measurement result with the smallest possible number of laser/camera modules. Thanks to the numerous models available, with or without protective housings, the Profilemaster system can be used in a wide range of applications. This extends from laboratory applications to the harsh environments that are encountered in the production of steel and metal profiles. More information on Zumbach at: tel: +41 (0)32 356 04 00 fax: +41 (0)32 356 04 30 www.zumbach.com 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. 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