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PEMAMEK CUSTOMER MAGAZINE 2012

Robotised submerged arc welding PEMA WeldControl Heavy-duty robot welding stations for the marine industry


PEMANEWS

Competitiveness from partnership Dear Reader, Pemamek was established in Loimaa in 1970. We continue to operate there. Over 40 years, our operating environment has undergone great upheaval. Through this process of change, we have constantly increased and developed our business. Today, our company is the world’s leading supplier of heavy-duty welding automation solutions. We intend to maintain that position. But in a changing world, this cannot be achieved by continuing with the old ways. The future belongs to those companies that can best meet the individual needs of their customers. We are applying the latest robot- and automation technology to our products. Automation solutions tailored to customer needs are our core field of expertise. Our strategic partners are also the best in the world in their own fields. But in the future, you won’t get very far with just a palette of products even if the quality of that palette is top-class. In recent years, we have single-mindedly moved from equipment sales to long-term partnerships with our customers, from individual devices to turnkey deliveries. We are the guarantors of usability and availability.

The customer is always the expert in its own field. We know about automation. Without exception, the end-results are excellent when we combine these skills and develop the required solutions together. We call this ‘partnership’.

For us, this means adopting new operating practices and the constant development of activities. Service does not remain static but should keep reproducing, time after time. Right from the start. Always with the same high quality.

Partnership requires flexibility and persistence. It is a product of work carried out together over the years and of the deep trust that has evolved as a result. Partnership involves not only the development of solutions but also life-cycle maintenance and other life-cycle-related services.

I am sure that, through co-operative development, our services can get even better. With best wishes, Pekka Heikonen President and CEO

Contents Editorial..................................................................................................................................................... 2 Robotised submerged arc welding.......................................................................................................... 3 PEMA WeldContr ...................................................................................................................................... 6 Perspectives on the future....................................................................................................................... 8 Heavy-duty robot welding stations for the marine industry.................................................................10 Manufacturing automation for power station boilers............................................................................12 Panel lines and welding stations............................................................................................................14 Newsflash................................................................................................................................................16

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Robotised submerged arc welding can improve the productivity of the welding of heavy work pieces, even if the work pieces have so-called double curvature saddle surfaces, corners or short welds.

Robotised submerged arc welding – quality and productivity for the production of more complex work pieces

As a method, submerged arc welding is not among the newer ones: it was first introduced back in the 1930s. Some claim that the Soviets developed it for the manufacture of their T-34 tanks, others that it was developed around the same time by Union Carbide Company of the USA. Whoever is right, it is an effective and highly productive method for heavy-duty welding. Submerged arc welding is renowned as a method whose deposition rate, welding speed and metallurgical weld quality are high. It is arc welding in which the arc flame burns between the constantly feeding welding wire and the work piece, hidden under granular flux. The flux protects the weld pool from air contamination, removes impurities, forms the weld bead and provides the weld pool with alloying elements. Some of

the flux melts forming a layer, which later solidifies into the slag over the weld. Inert shielding gas is not needed. Up until recently, the submerged arc was considered an effective way to weld mainly long and straight or circumferential joints, not really a method for robotised welding and more complex shapes. The devices have been bulky, clumsy and labo-

rious to focus on the welds. Typical welding positions have been flat and horizontal-fillet welds. PEMA has, however, been able to show that robotised submerged arc welding can improve the productivity of the welding of heavy work pieces, even if the work pieces have double curvature saddle surfaces, corners or short welds. Robotisation significantly increases the flexibility

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PEMANEWS

The submerged arc welding of a saddle surface in a robotised PEMA welding station.

of the welding station in relation to the shape of the pieces to be manufactured. Equipment configuration A robotised submerged arc welding station is always configured based on the requirements of the application in question. A heavy-duty gantry-type station or a robot column & boom significantly extends the field of movement of the robot. The wire feeding device can be located in the robot’s wrist flange, upper arm or base. Typical wire diameters are up to 4mm. Twin-wire welding is also possible. Flux handling The central dropping of the flux leaves available all six of the robot’s degrees of freedom. Dropping in front of the welding torch removes one degree of freedom. The use of a fixed powder vacuum is limited to straight welds with open ends. Thanks to a spring- or compressed air mechanism, it is also possible to weld curved surfaces. The collection of the flux and slag in a bin under the welding station enables the full utilisation of all the robot’s degrees of freedom, and even the welding of corners, for example, is easy. The loose flux and the slag from the welds are recovered, the slag is separated from the flux which is then reused.

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Seam searching and tracking Seam searching can be carried out in the same way as in the MIG/MAG welding process, using the voltage at the tip of the welding wire. An alternative is optical seam searching and tracking, a fast and precise (±0,2 mm) method, which enables seam tracking and the adjustment of the welding process during welding, based on a possible change of gap geometry. Without seam tracking, the robot cannot detect possible deformations or unknown variations in gap geometry that take place during the weld. Optical tracking limits the trajectories of the robot and the monitoring device requires a little room in the equipment set-up. Power source The power source is an important component in all welding stations. The Lincoln PowerWave AC/DC 1000 SD is an optimal solution for heavyduty welding. One feature of the equipment is the easy change of polarity in direct-current welding (DC+ - DC-), alternating-current welding either in square-wave or sinewave form, controlled adjustment of root penetration and deposition rate through frequency and phase shift, and efficient prevention of magnetic arc blow. The control software for the power source is easily updatable, so the

Also complex geometry work-pieces can have top-quality welding seams by means of robotised SAW.

equipment can start to use the latest features as soon as they become available. For the PowerWave power source, typically good arc ignition is an important feature in robotised submerged arc welding. The future of submerged arc welding looks good. The method and its utilisation are constantly being developed, although the process itself has remained the same in principle for decades. At present there is no more effective process for welding thick scantling. A deficiency has been, however, that the use of this highly productive method has been restricted mainly to long and straight welds. Through robotisation, the good productivity of submerged arc welding can also be efficiently utilised with more complex work-piece geom-


PEMANEWS PEMANEWS

Benefits of robotised SAW • Increase in overall productivity • Operator free to carry out other tasks while the robot is welding, for example to prepare the next work-piece • Welding of more complex work-piece geometries compared with conventional welding mechanization solutions • Elimination of time-consuming realignments, for example in multi-layer welding, leads to increase of arc ratio • Simultaneous, syncronised movements of the robot and the work-piece handling device during welding • Excellent repeatability – good for multi-layer welding • Increase in safety-at-work

Lincoln Electric Power Wave AC/DC SAW Using AC/DC SAW

The challenges of robotised SAW

Positive Current Level = Penetration

Waveform Control Technology • control penetration • control bead shape • eliminate arc interactions which can cause arc blow.

Waveform Control Technology capability provides precise control over: • AC Frequency • Balance (Percentage of time in the positive polarity portion of one Cycle)

Current, Voltage, or Power

The waveform may be varied to: Cycle Balance = Penetration/Deposition

• Flux recycling and slag handling Negative Current Level = Deposition

• Offset (Negative Amplitude)

Effect on Penetration from Balance

Effect on Penetration from DC Offset

Current, Voltage, or Power

Current, Voltage, or Power

+ 840

(+) Offset = More Penetration

0

(-) Offset = Less Penetration

50% DC+ Penetration 8,8 mm

30% DC+ Penetration 6,1 mm

etry. Robotisation is, however, just one of the directions of development for submerged arc welding, and certainly not the only solution for the effective automation of welding. In

• Finding the right solution to each application (work-piece geometry – corners or straight welds, i.e. a bin or suction solution) • Seam searching and tracking • Optical tracking stands for higher investment cost

• Without tracking, the robot is blind and PEMA boiler manufacturing - 840

70% DC+ Penetration 9,8 mm

• Robotic welding requires accurate prefabrication

automation

840 DC+ 500 DCPenetration 9,3 mm

500 DC+ 840 DCPenetration 7,1 mm

can not react to changes in gap geometry range: taking place during the welding process

• stationary welding machines Bending of hoses and cables may cause • gantry-type welding • machines • panel conveyor lines wire/work spot displacement favourable applications, • fin-barrobotisaprefabrication • Keeping flux on the welding spot and large tion can achieve very good results, • tube prefabrication weld pool restricts welding but of course there• automatic is still reason to material feeding use other methods too.

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PEMA WeldControl

- new control devices and user interfaces PEMI control devices and user interfaces have been renewed. The state-of-the-art controls based on touch-screens help users to exploit the features of the column and booms as extensively as possible, and significantly boost the efficiency of both the welding process and the handling of work pieces. WeldControl 100 PEMA WeldControl 100 is a modern and efficient user interface for welding column & booms. It collects together the controls of the column & boom, the welding power source, the work piece positioning equipment and the management of welding values into one clear and easy-to-use package. WeldControl 100 has a touch-screen on which welding values can be illustratively monitored in graphic form. Control of PEMA column & booms can also be connected to the factory’s local area network (LAN). Basic settings The basic settings for the welding column & boom and its related equipment can be easily configured by the user based on the configuration of the work station. The settings and the selection of functions for the work piece-positioning equipment connected to the column & boom are done by means of indicative icons. Seam tracking and powder processing done with submerged arc welding are also easy to control. WPS editor The built-in WPS editor (WPS = welding parameter settings) controls the parameters of all the most common welding processes and stores information about work pieces and welding consumables. Fast selection of the stored parameters from the WPS memory is done by means of a table. The same initial and final parameters can easily by utilised. The WPS editor can control all modern welding power sources. Welding values WeldControl 100 offers many ways

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Graphic user interface of the PEMA WeldControl 100 on a 12” touch-screen. Separate remote control for the main movements and cross-slide of the column & boom, visible on the right side of the screen.

to display measured welding values, such as real-time and averaged displays, heat input and weld metal output, and a graphic display of welding values using a trend curve. Production data and diagnostics Data gathering is a standard feature of the control of WeldControl 100. It stores general information about the utility ratio of the machine, such as up- and down-time, and metres and times welded by each welding head. The control gathers and stores welding setting values for each work piece as well as the averages of measured welding values. The information can easily be examined graphically and numerically using a computer’s internet browser. The computer can be

WeldControl 100 Control equipment and connections • Graphic user interface, 12” touch-screen to control the movements and functions of the column & boom • Separate remote control for the main movements and cross-slide of the column & boom • Fieldbus connection for PEMA rollerbeds and positioners • Ethernet connection for production data and remote diagnostics

connected either directly to the column and boom or an Ethernet connection can be created. The gathered data can be stored in the browser for later use if needed. Back-up copies of the WPS tables can also be made using the browser. User levels There are three levels of user rights


PEMANEWS for the creation and maintenance of welding parameters: operator, welding engineer and maintenance. At the work station, the operator selects the WPS and work piece-specific settings he will use, and he can change the values only within limits set in the WPS editor. The operator can fine-tune the welding values using the touch buttons. The welding engineer creates new WPS tables for the device. A user with service codes also has the user codes and, if necessary, carries out the equipment settings. PEMA WeldControl 500 Premium PEMA WeldControl 500 Premium is the most advanced control system for welding column & booms on the market. It can be used to manage the welding parameters and movements of the column & boom and work piece positioning equipment using the same user interface. The system also enables diverse data gathering and graphical and numerical displays of the information. The PEMA 500 Premium control system includes ready connections to accessories such as a monitoring camera or laser seam-tracking device. Its basic features and functions are similar to the WeldControl 100, and additional features such as multi-layer functionality and adaptive welding elevate it to a class of its own. 500 Premium meets even the most demanding requirements for productivity and quality. Additional features The multi-layer function of the PEMA 500 Premium user interface is based on the measurement of the shape and volume of the welding joint. Alternatives are a fixed adjustable layer chart, automatic filling based on the gap width and height, and simultaneous use of a fixed and automatic layer chart. In simultaneous use, the base layers have a fixed share, the seam filling stage is adaptive and surface layers are welded based on the fixed chart. A fixed chart is used

The user interface and control system of the PEMA WeldControl 500 Premium is a PC-based 19” touch-screen, which controls the movements and functions of the column & boom and its related workpiece positioning equipment.

when welding the underside of a metal plate. In adaptive welding, the welding values are automatically adapted to the changes taking place in the gap, such as manufacturing inaccuracies. This feature can also be utilised in multilayer welding. The user interface’s WPS editor has its own view of the forming and display of welding parameters. In multi-layer use, for instance, one WPS page contains all the parameters required to weld the piece. Management of the configuration of the welding heads also takes place using the WPS editor. Many auxiliary devices of welding such as a seam tracking devices, monitoring camera and auxiliary software can be directly controlled from the PEMA 500 Premium user interface. A system formed in this way is easy for users to operate and visualise. Through job rotation management, it is easy to automate tasks that occur repeatedly. WeldControl 500 Premium control gathers both general information about the utility ratio of the machine and production information about

WeldControl 500 Premium Control equipment and connections • PC-based user interface and control system, 19” touch-screen to control the movements and functions of the column & boom • Separate remote control for the main move ments and cross-slide of the column & boom • Adaptive welding and multi-layer functionality • Automatic management of job rotation • Can be combined as a welding cell with PEMA rollerbeds and positioners • Management of the integration of welding power sources • Can be positioned either on a base or at the end of a jib • Ethernet connection for production data and remote diagnostics

each work-piece. The functions are harmonised with the control of WeldControl 100, but in addition to the connected computer, it can also be checked from the control user interface. The control systems for the PEMA WeldControl range of products are also used in other PEMA welding solutions, such as manufacturing automation for shipyards and industrial boilers. The default languages for the user interfaces are Finnish, English and also the local language.

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PEMANEWS

Perspectives on the future Pemamek and Lincoln Electric arranged a joint welding automation seminar on 21st-22nd September, 2011 in Loimaa, Finland. The occasion also celebrated PEMA’s 40 years in heavy welding automation business.

Opened by Pekka Heikonen, CEO of Pemamek Oy Ltd. and Steve Sumner, Lincoln Electric’s global marketing and product development director, the two-day technologyfocused seminar discussed future trends, solutions and opportunities to increase productivity by means of modern welding technology, and enjoyed demonstrations of latest welding machinery and automation stations. Over 120 attendees around the world participated presentations, demonstrations and the evening programme of the event. Long history gives wide perspectives to look into the future The seminar started with a talk about the future challenges in the welding industry in the global operating environment by professor Reijo Tuokko from the Department of Production Engineering in Tampere University of Technology. Jukka Rantala, Pemamek’s sales and marketing director, told PEMA’s 40-year-long story from the back of a rural garage to the world’s leading heavy welding automation manufacturer. Jukka also described how the company is able to increase customer productivity now and in the coming years. Solutions for shipbuilding and offshore, mobile machinery, and civil construction industries The rest of the presentations focussed on welding technology and automation. Harri Kartano from PEMA talked about plate joining and stiffening automation for shipbuilding and offshore as well as civil construction industries. Mike Flagg described Lincoln Electric’s latest engineering solutions in seaming welding applied

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The seminar presentations brought up ideas about how leading-edge welding and automation technology applications can help to improve productivity. Pictured professor Reijo Tuokko talking about the future challenges in the welding industry.

to improve the productivity of panel lines. PEMA’s heavy-duty robotised welding automation design philosophy and real world solutions were presented by Mikko Savolainen, and Lincoln’s welding processes and productivity enhancements for automation by Steve Sumner. Volvo’s Krister Ericson talked about experiences and development outlook in heavy welding automation of Volvo construction machinery, and set-up and benefits of Lincoln’s production monitoring as well as Weld Score systems were presented by Keith Sheffer. In late afternoon, the seminar moved to tour PEMA’s modern factory shop floor for presentations and demonstrations of utilization of work-piece handling equipment, a robot station for SAW and MIG welding, use of

heavy robotised welding station with a positioner, a flat panel and block production line, and use of Lincoln’s Weld Score in MIG welding. The day was concluded with a renaissance dinner in the King’s hall of the historical Castle of Turku. As guests of Duke John of Finland and his wife, duchess Katarina Jagellonica, the participants not only got a taste of a typical mid-16th century evening meal but also some court ways and manners. Industrial boiler manufacturing, wind energy, and process and nuclear industries The second seminar day was launched with a talk about complete manufacturing systems, i.e. PEMA’s automation solutions for boiler and mobile machinery manufacturing by Harri Kartano. Next, Mike Flagg pre-


PEMANEWS sented how productivity and speed can be increased by means of single wire sub-arc using Lincoln Power Wave AC/DC, the next generation of welding for membrane wall panel systems. PEMA’s Anssi Mäkelä told about PEMA’s latest welding automation solutions for heavy tubular workpieces common in the wind energy sector as well as process and nuclear industries. Harm Meelker talked about Lincoln’s Multiple Arc Welding system, its operation and consumables for tubular work-pieces like towers and vessels. In the afternoon, Teemu Tolonen presented PEMA’s latest advanced welding automation control systems, operator-friendly interfaces and ease of programming. Steve Sumner explained waveform control and the benefits of Lincoln’s control technology, how it impacts the arc and how optimised waveform has contributed to real-world applications. The seminar presentations were completed by Dr Alan Thompson from TATA Steel Europe, a tier one industrial member of the UK Nuclear Advanced Manufacturing Research Centre (NAMRC). He described how welding research is carried out in the NAMRC, and how they are going to utilise their heavy PEMA multi-wire column & boom to benefit the research programs.

The seminar participants were invited to have a mid-16th century dinner with Duke John of Finland and his wife, duchess Katarina Jagellonica in the historical castle of Turku.

Demonstration of a PEMA robot station and Lincoln’s Weld Score monitoring system.

After the talks, the participants joined in another factory tour demonstrating a PEMA welding column & boom station, utilisation of a PEMA advanced welding automation control system, a wind tower manufacturing line with Lincoln’s Tandem PowerWave AC/DC, a membrane wall panel welding machine, and a tube prefabrication line for membrane wall panels. Finally, the seminar was closed with a programmatic barbecue dinner on the factory shop floor to celebrate PEMA’s 40th anniversary. Summary The objective of the seminar was to present ideas about how lead-

PEMA’s 40th anniversary barbecue dinner was held on the factory shop floor.

ing-edge welding and automation technology applications can help to improve productivity. In conclusion, there’s no need to wait for the future

to bring better or completely new technical solutions. The technology is already here. It is just a question of deciding to make the most of it.

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PEMANEWS

I.P Huse AS uses Europe’s largest robot welding station to manufacture the winch drums for the anchor-handling vessels of oil-drilling platforms.

Heavy-duty robot welding stations for the marine industry As recently as a few years ago, robot welding stations on the market were meant only for thin plate thicknesses. PEMA has now brought the benefits of robotics to heavy production too. I.P. Huse I.P Huse AS, a company located on the island of Harøy off the coast of Norway, halfway between Bergen and Trondheim, is the world’s leading designer and manufacturer of large winches for anchor-handling vessels. From its state-of-the-art workshops, the company, which is specialised in heavy equipment, delivers winches and deck machinery for oil production vessels and platforms, and other similarly demanding offshore industry applications. The main customers are shipbuilders, shipping companies and oil companies. The company works in close co-operation with Rolls-Royce Marine, and employs about 130 people. Europe’s largest robot welding station In early spring 2011, PEMA and I.P.

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Huse concluded a contract for the design, manufacture and delivery of a heavy robot welding station. The station was delivered and commissioned on November 2011. The largest robot welding station in Europe is being used to manufacture winch drums for the anchor-handling vessels of oil-drilling platforms. This was a question of the turnkey delivery of a robot welding station. The delivery included two YaskawaMotoman welding robots on PEMA X-Y-Z-type three-axis robot positioners, a heavy two-axis PEMA workpiece positioner for handling winch drums and two sets of Lincoln Electric PowerWave MAG welding equipment. The greatest diameter of work pieces to be welded is 6 metres and they can weigh up to 35,000 kg. The method used is multi-layer welding

in which the size of the welds varies between a5 and a13. The station is controlled by means of a parametrised offline programming/ control system and user interface belonging to the PEMA WeldControl 300-series. The delivery also included a safety system, operator training and the commissioning and start-up of the station. Jiangsu Rainbow Heavy Industries Jiangsu Rainbow Heavy Industries Co., Ltd (RHI), which was established in Nantong, China in 2003 employs more than 1,500 people. The company is specialised in the design, manufacture, sales and maintenance of cranes, marine equipment, offshore structures, parking halls and other steel structures. For a long time, RHI has worked as


PEMANEWS

Simulation helps in the development of more effective solutions

RHI welds the end- and side plates of MacGregor hatch covers used on cargo ships with a heavy portal-type PEMA Vision robot welding station.

With the parametrised PEMA Vision System, RHI’s robot operator can generate a five-hour unmanned robot welding programme from his user interface in just 15 minutes.

A Yaskawa-Motoman robot on two XY-Z-type three-axis robot positioners efficiently multi-layer welds a winch drum work-piece on a PEMA work-piece positioner.

a key partner in Asia for the Finnish company, Cargotec, and its subsidiaries MacGregor and Kalmar. RHI has also developed its own branded products for the crane and parking technology market.

nal robot axis, 6-axis welding robot and a patented PEMA WeldControl 200-series Vision2D software system. The delivery also included a PEMA fume extraction system, rails and gear tracks, the required welding programmes, as well as installation, commissioning, training and a full service package.

PEMA Vision robot welding station The first heavy portal-type PEMA Vision robot welding station was delivered to RHI in autumn 2011. The station is being used to weld the endand side plates of MacGregor hatch covers used on cargo ships. The delivery included a complete PEMA VRWP-5500/1 robot welding portal, including a Yaskawa Motoman MH6 welding robot with a DX100 controller. The power source is a Lincoln Electric PowerWave 455M for MAG welding. The portal comprises a welding gantry with three exter-

’For us this a significant breakthrough into the Chinese heavy metal industry market,’ says Jukka Rantala, Pemamek’s Sales and Marketing Director. ’An increase in cost efficiency often requires raising the level of automation. Thanks to its high arc time and good utility ratio, our user-friendly PEMA VRWP robot portal significantly improves the productivity of the production of steel structures.

For its customers, PEMA carries our weldability analyses in virtual welding systems as part of its development work for customer-specific welding automation solutions. These analyses use 3D models of actual work-pieces of the customers. A simulation model of production equipment or an entire production line is made, in which the customer can see the manufacturing process for its product. This top-class robot software makes use of simulations of individual welding station throughput times, reach and weldability. Simulations can also be successfully exploited at the product development stage, in the optimisation and certification of robot weldability before production test runs done on actual work pieces. PEMA uses software particularly developed for production simulation and layout design in wider factory-level simulations, such as in production throughput time checks and in the optimisation of overall layout plans for production lines. A virtual factory is built for the flow and analysis simulations of the manufacturing process. Special production events can be combined to simulate the operations of an actual production line by feeding workstation sub-process data into the system process. The impact of equipment shut-downs, possible interruptions in logistics and production bottlenecks can thus be indentified and eliminated as early as the design stage.

A 3D simulation model of a heavy PEMA robot welding station used in welding the chassis and platforms of Multiva tractor trailers. The model has two work stations.

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PEMANEWS

Manufacturing automation for power station boilers - quality built into the production process

PEMA is the world’s leading supplier of production lines for membrane wall-panels. Indian TBWES and Brazilian HPB SIMISA decided on PEMA lines, because productivity and quality produced were important foundations of key decision-making. Improved productivity for megaprojects in India’s energy production Founded in March 2010, TBWES is a joint venture company between Thermax Ltd and Babcock & Wilcox Power Generation Group Inc. (B&W PGG). Thermax is an Indian supplier of energy and environmental solutions and B&W PGG, an operating unit of Babcock & Wilcox Company (B&W) from the USA, is the world’s leading manufacturer of the power generation industry. TBWES designs, manufactures and delivers super- and subcritical power station boilers of more than 300 MW to the growing Indian power generation market. The company combines Thermax’s expertise in the integration of energy and environmental solutions and B&W’s renowned experience as a supplier of state-of-the-art power generation technology and a world-class project management specialist. Five production lines to India In spring 2011, PEMA concluded a contract for the design, manufacture and delivery to TBWES of a membrane wall-panel production line and four tube prefabrication lines. The lines will be used for the manufacture of components for supercritical power boilers in a new production plant in Pune, India. At present, the plant’s annual boiler production covers the needs of about 3,000 MW of power generation capacity. The lines were delivered at the end of 2011. - In the production of supercritical boilers, there is absolutely no room to compromise on quality, says Rajeev Sondur of TBWES. ‘It must there-

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Representatives of TBWES at factory tests at PEMA in November 2012 in front of the second welding station of the panel line. Rajeev Sondur is second from the left.

fore be built into the production process. In PEMA panel lines, this is how things are: the need for operator training is small, and the process controls all operations from the integrated handling of material flows to the dispatch of the completed panels. The entire process needs only one operator at a time. The line includes two PEMA 3000/6 membrane wall panel welding stations, which can weld 25m-long and up to 3m-wide membrane wall panels with 12 sets of Lincoln Electric PowerWave AC/DC 1000 A SD submerged arc welding equipment. The line includes complete panel transportation tracks, a fin-bar calibrating line, an automatic tube and fin-bar feeding system

for feeding bars to the panel line for welding between the tubes, and the required buffer stores for sub-panels. The panel transportation track is able to perform all panel-handling tasks: it includes in- and out-feeding roller conveyors for two welding machines, cross-transport conveyors for panel sideways movement and buffer storage, and hydraulic flip-over arms for the panels for welding on the other side. Thermax already have three PEMA panel lines in other production plants. The first of these was commissioned in 2004. - In tests that we have just concluded, we achieved 30% greater speed


PEMANEWS than our previous production lines, says Sondur. - The productivity of the new line is better than a two-sided MIG/MAG panel line with a total of 20 welding heads. This is achieved by Lincoln Electric PowerWave technology and PEMA’s advanced control system. The investment costs for the submerged arc welding line are a little higher than for the MIG/MAG line, but because the quality produced is impeccable, the investment payback period is shorter. The challenges involved with production lines are always the same – the use of space must be reduced whilst productivity must be improved. The prefabrication lines included in the overall delivery consist of three PEMA automatic tube cutting, endbevelling and end-buffing (ATCEP) lines with integrated conveyors. The delivery also includes a PEMA automatic end-bevelling and end-buffing line (ATEP).

HPB SIMISA’s PEMA 2700/6 welding station with six Lincoln Electric PowerWave AC/DC 1000 A SD submerged arc welding power units.

- In my opinion, PEMA’s way of taking account of the customer’s ideas in product design is good. In machinebuilding, feedback from end-users should never be underestimated, says Rajeev Sondur. Breakthrough on the South American industrial boiler market HPB-Simisa Sistemas de Energia LTDA was established in January 2010 to provide technology solutions to the Brazilian thermal power industry. The joint venture company owned halfand-half by the major Brazilian sugar and ethanol producers, HPB Engenharia e Equipamentos Ltda:n and SIMISA – Simioni Metalúrgica Ltda, built a state-of-the-art industrial boiler plant at Sertãozinho in the state of São Paulo in 2011. HPB SIMISA decided to safeguard sufficient production capacity for its high-quality membrane wall-panels by ordering a PEMA 2700/6 welding station with six sets of Lincoln Electric PowerWave AC/DC 1000 A SD submerged arc welding power units. Conveyor systems were constructed by HPB-Simisa to PEMA designs. The equipment was delivered to Sertãozinho in spring 2011.

The PEMA membrane wall-panel line is controlled by the PC-based PEMA WeldControl 100-series control system. HPB SIMISA.

On the left, the tube cutting, end-bevelling and end-buffing ATCE for the TBWES delivery, on the right the welding stations for the membrane wall-panel line.

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PEMANEWS

Jiangnan Changxing Shipbuilding’s two PEMA PBW two-sided welding stations with magnetic beds.

Panel lines and welding stations:

state-of-the-art turnkey deliveries to China and Brazil Each PEMA panel line and welding station is designed and built to boost the competitiveness of customers’ steel production. Both production volumes and quality increase when production line deliveries are tailored and tuned to meet all requirements, all the way from basic design to commissioning. PEMA’s close co-operation with shipbuilders and offshore yards all over the world has enabled the development of products and their delivery reliability to reach world-class levels. Yangfan/Zhejiang East Coast Shipbuilding Co. Zhejiang East Coast Shipbuilding is located in Zhoushan, in the middle of May Island in the Yangtze River delta. This super-modern shipyard covers an area of 74.5 km². Its annual production exceeds 1 million DWT: typical products include car transportation vessels, container ships, chemical tankers, multipurpose vessels and special vessels. PEMA delivered to the yard a panel line almost 400m long, which con-

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sists of two PEMA OSW-M one-sided welding stations for the extension of plates. The stations can weld two seams at once. The line also includes, among other things, a PEMA SWP stiffener welding portal, whose 24 welding power sources can simultaneously weld six stiffener profiles to metal plate on both sides with four wires. The shipyard built the welding-floor type conveyor, side-shifting conveyors, steel structures for the block transportation trains and the panel rotating station based on PEMA’s designs: PEMA’s delivery also

included key components and the supervision of installation. The largest panels to be welded are 16 x 30 m. Jiangnan Changxing Shipbuilding Jiangnan Shipyard was established in 1865 in Shanghai, and was located just south of the city centre until the near the end of the first decade of the 21st century. In 2009, the yard was moved to Changxing Island in the Yangtze River delta to the north of Shanghai. It is said that this stateof-the-art, still growing shipyard will be the world’s largest when it is completed. It builds, repairs and refurbishes both merchant and military vessels: the size of the dry docks is enough to build an aircraft carrier. PEMA delivered to the yard two PEMA PBW two-sided welding stations with moving magnetic beds and a PEMA SWP stiffener welding portal, in which 16 welding power sources can simultaneously weld four stiffener profiles on both sides with four wires.


PEMANEWS Qingdao Wuchuan Heavy Industry Qingdao Wuchuan Heavy Industry based in Shandong Province builds merchant, military and offshore vessels and steel structures at a yard opened in 2009, the surface area of which is 72.5 km². The company is part of the China Shipbuilding Industry Corporation. The yard has now installed a PEMA SMP stiffener profile mounting and tack-welding portal, in which eight welding heads simultaneously tackwelds 20m-long profiles to metal plate. The line also includes a PEMA SWP stiffener welding portal, whose 24 welding power sources can simultaneously weld six stiffener profiles to metal plate on both sides. The first panel line delivery for the Brazilian offshore industry In autumn 2011, PEMA delivered its first panel line to Brazil. This line delivered to an as yet unannounced offshore customer consists of a PEMA OSW-M plate extension station with a magnetic bed, a PEMA flip-over station for turning panels measuring 18 x 18m, a PEMA PBW portal for welding the other side of metal plate, a PEMA Ultrasonic testing portal for inspect-

A PEMA OSW-M one-sided plate extension station in operation.

ing welds with ultrasonic technology, a plasma cutting and marking portal for the plasma cutting and marking of metal plate, a PEMA downdraft cutting table, a PEMA SMP stiffener profile mounting and tack-welding portal, two PEMA WMP longitudinal stiffener mounting portals and a PEMA SP portal for the manual welding of longitudinal stiffeners. The de-

livery also included a load-out station for lifting blocks for transportation, all necessary conveyors, and transportation trains for moving completed blocks on to the end of the line. This state-of-the-art and flexibly operating line will manufacture block structures for the needs of Brazil’s constantly growing offshore industry.

The PEMA SWP stiffener welding portal delivered to Qingdao Wuchuan Heavy Industry, whose 24 welding power sources can simultaneously weld six stiffener profiles on both sides.

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Newsflash PEMA fit-up stations for the wind energy industry

Appointments A series of positioners for the production of railway carriages

Rauno Takala, Area Sales Manager Rauno has long experience of the welding industry, having moved to Pemamek from Esab Oy. At PEMA he is in charge of domestic sales. Sakari Kojo, Project Engineer Sakari previously worked at Jukova Oy in such roles as work supervisor, project engineer, site manager and project manager. At PEMA, he is working as a project engineer focusing on installation supervision.

The first new-generation PEMA fit-up stations developed for the manufacture of foundation and tower structures for wind farms have been delivered to Belgium and Turkey. The stations comprising fit-up rollerbed lines equipped with hydraulic aligning and the PEMA A-series standard rollerbeds significantly improve the efficiency and quality of the production of heavy towers and foundation components.

The Tikhvin Freight Car Building Plant (TVSZ) in the Leningrad region of Russia is one of Europe’s largest ongoing investments in the machine building industry. The production of freight cars began in January 2012. The factory ordered nine PEMA APS 3500 Skymaster positioners to streamline its welding process and ensure the quality of the manufacture of car components.

A submerged arc welding station for offshore production

Edison Chouest Offshore and PEMA conclude a service support agreement Edison Chouest Offshore (ECO) of the USA is one of the world’s most diverse and dynamic marine transportation companies and also owns six shipyards. In spring 2011, PEMA and ECO signed a service support agreement, which will guarantee the constant availability of PEMA panel lines, robot welding stations and welding portals at four shipyards. The agreement covers software support, line and station maintenance and servicing and spare parts services.

AS E-Profil of Estonia manufactures anchorhandling winch and crane components for the offshore industry. The company decided to automate its manual welding process and switch to submerged arc welding. In future, the work will be done by a PEMA 5 x 5 MD special welding column & boom equipped with a set of Lincoln Electric PowerWave AC/ DC 1000 A SD submerged arc welding equipment, and four PEMA APS 3500 Skymaster positioners.

PEMANEWS is the customer magazine of Pemamek Oy Ltd. P.O. Box 50, 32201 Loimaa, Finland, tel. +358 (0)2 760 771 fax +358 (0)2 762 8660, www.pemamek.com

Jussi Suominen, Area Sales Manager As well as having been an entrepreneur, Jussi also has work experience from Metso Automation Oy and Kone Corporation, where we worked as a project engineer and project marketing manager. At PEMA, Jussi is working as an Area Sales Manager focusing on international sales of project applications. Tommi Reponen, Application Manager, Production Automation Tommi has solid work experience in the shipbuilding industry and especially in robotics and control systems, gained from his time at STX Finland. At PEMA, he is working in the Technology Department, handling development and sales support functions for production systems. Dmitrij Trofimov, Area Export Manager Having graduated from university in the UK, Dmitrij is a citizen of both Finland and Russia. He has previously worked at Canon and Hilti, among other companies. At PEMA, he is in charge of sales to Russia and the CIS. Matti Lahtinen, Application Manager, Robot Automation Matti previously worked with industrial robots and automation solutions at Yaskawa Finland Oy. At PEMA, Matti works in the Technology Department in tasks related to the sales support, development and implementation of robotics projects. Kari Ahonen, Sales Manager Kari has a Masters degree in Engineering as well as an IWE (International Welding Institute) degree and a special vocational qualification in foreign trade. He has previously worked at Nokian Tyres, Konecranes and Kojair. At PEMA, Kari is working in global project sales.


PEMA News 2012 (english edition)