PEMA - Panel Welding Automation 2009

II Boiler Manufacturing
seminar
Turku 25 June, 2009
PEMAMEK Oy Ltd
Productive membrane wall panel welding line
Harri Kartano, Sales Manager
Membrane wall panel production H. Kartano © 2009 Pemamek Ltd
PEMA MEMBRANE WALL PANEL PRODUCTION
• Basic panel lines
• Productivity improvement with efficient material handling
• Two machines panel line – doubled productivity
• Panel welding machine construction & welding flexibility
WORLD CLASS WELDING AUTOMATION Page 2/32

BASIC PANEL LINES:

PEMA 900/2 panel welding machine
• Max panel width 950 mm, typically only two welding torches
• Mainly for boiler service purposes, not typically for mass production
• Faster to change tooling for different tube / fin size (c. 2 – 3 hours)
• Less automation in material feeding, typically only in- /out-feeding & feed-back
conveyors
• Lower investment cost
PEMA 900/2 panel welding lines in Aalborg, Danmark and in FW, Finland

BASIC PANEL LINES:

PEMA standard wide panel welding machines
• Standard panel widths 2000, 2500 and 2700 mm
• Typically 4 – 6 welding torches
• Panel length maximum up to 30 m
• Line includes basic conveyors for panel handling
• Automatic tube & fin bar in-feeding for increasing the productivity
PEMA 2000/6 welding line in Babcock Borsig Service in Germany and in SES, in Slovakia

BASIC PANEL LINES:

PEMA 2500/6 welding line in Babcock Borsig Service in South Africa

BASIC PANEL LINES:

PEMA 2700/6 welding line in Thermax Ltd, India

BASIC PANEL LINES:

SPECIAL WIDTH: PEMA 4500/6 panel welding machine
PEMA 4500/6 welding line in Alstom, USA

The production capacity of the panel welding line depends on:

• Number of welding torches / welding machines
• Material handling automation
• Material quality, cleanness of materials and correct size (fin bar)
• Panel welding sequence / torch set-up in full panel welding
• High quality of the weld and the panel … means less afterwards reparation
• Arc time:
• Typically in sub-panel welding 80 – 90 %
• Welding sub-panels together 40 – 50 %

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

Basic panel conveyor line has following features:
• Staging table with manual fin bar & tube feeding
• Panel in-and out-feeding roller conveyors
• Cross transport conveyor for sideways panel movement (both sides of welding
machine)
• Flip-over arms for panel turning
• Feed-back roller conveyor


• Roller conveyor are supplied in standard modules and transported with “loose
legs” –> transportation space savings & fast installation
• Cross transport conveyor is equipped with hydraulic reel – no more cable
chains
• Customer supplies foundation & base plates


• Flip-over arms for panel turning – safe and fast – not damaging the panel

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING.

Integrated tube and fin bar PEMA welding Fin bar prefabrication Fin bar shot
in-feed line: machine line: blasting machine
- Tube storage with hydraulic 2 - 6 pcs - Calibrating machine
tube lifting units submerged arc
- Butt welding bench
torches
- Fin bar pulling device and
- Uncoiler
fin bar feeding system
In and out feed track:
- Roller conveyors
Buffer storage: Cross transport Flip-over arms Feed-back

conveyors, 2 sets conveyor
- Hydraulic buffer
racks for sub-panels

Side view of the complete panel line conveyors with automatic tube and fin bar
in-feeding to the panel line.
Integrated tube and fin bar Buffer storage:

in-feed line:
- Hydraulic buffer
- Tube storage with hydraulic racks for sub-panels
tube lifting units
Staging table Cross transport conveyor


Automated tube & fin bar in-feeding system
• Material in-feed system is integrated to panel in- and out-feed roller track with
staging table and cross transport conveyors.
• Complete material feeding system for tube and fin bar in-feeding to the panel
line.
Tack-welding Integrated tube and fin bar

in-feed line:
bench
- Tube storage with hydraulic
tube lifting units


Fin bar pulling device takes the fin bar on the chain conveyor

Tubes are lifted from buffer store to in-feeding system


Tubes and fin bars feeding to staging table


Sub-panel buffer store
• Buffer store for sub-panels with 4 hydraulically up/down moving levels
• Own special in-out feeding conveyor
Sub-panels pick-up from buffer store to welding machine

Two machines line for higher production capacity

• Second machine doubles the production capacity without adding conveyors
• Typically 4 – 6 welding torches per machine
• First machine for first side welding with heavy duty hydraulic guiding
• Another side welding with second machine, tooling can be “lighter”
2 x PEMA 2000/6 line in Rafako, Poland

..… Two machines line for higher production capacity

• Arc time can be very high in sub-panel welding (80-90 %)
• Line includes same basic conveyors for panel handling (feed-back conveyor
changed to in- / out-feeding conveyor)
2 x PEMA 2700/4 in Thermax,Ltd, India


• More flexibility can be achieved with additional feed-back conveyor between
two machines, then each machine can be used also individually if necessary
• Automatic tube & fin bar in-feeding for increasing the productivity (must !)
2 x PEMA 2700/6 welding line in DB Thermal, South Africa

H. Kartano © 2009 Pemamek Ltd

• Additional feed-back track makes it possible to use each single welding
machine as own line
• Also during service of second machine production can be ran with one
machine

PEMA panel welding machine

• Welding machine is used for sub-panel welding and welding sub-panels
together; or for economiser tube welding
• Number of welding equipment typically 2 – 6 units / machine
• Complete package including vacuum unit for flux & slag suction, hydraulic
system and integration to conveyor line
• Flux cyclone with multiple input , heating elements and low level alarm unit
Main control unit (left) and hydraulic Flux cyclone and support wire feeders
control unit (right)

• With new partially fixed / floating tooling there is no need to adjust the form
roller tooling different for first compared to second side.
• Basic welding machine tooling (one form roller set) is designed according to
customer’s need for one tube diameter / pitch size, tooling for another tube &
pitch size can be made by the customer according to Pema drawings
• Change over time for tooling is approx. 4 - 8 hours (6 torches machine).
8 pairs of form roller shafts, six torches machine requires 6 pcs form rollers for each shaft


• Panel is strongly guided with hydraulically operated form roller shafts, fin bar
pressing unit, fin bar support and side pressing rollers
Flux recovery Side pressing roller Fin bar pressing roller
Form roller shaft Welding heads Flux feeding nozzles

Sub-panels
• The panel welding sequence can be made according to
customers requirements
• Torch set-up can be easily changed = suitability for
both mass production or flexible small panel welding
Here are some examples of welding sub-panels and

sub-panels together:
Heat input can

cause distortion

PEMA panel welding machine / welding of example panel

- 31 tubes panel (tube outermost)
- Length 24 m, tube Ø 63,5 mm, fin bar width 48 mm (pitch 80 mm), ready welded panel 2432 mm
wide. It is estimated that in sub-panel production the arc time is approx. 80 % and in welding
sub-panels together it is approx. 40 %. Welding speed in panel production is 1100 mm/min.
sub-panels: No. torches welding time / min

8 pcs o-o-o 4 182
- second side 182
4 pcs o-o-o - o - o-o-o 4 182
- second side 182
2 pcs 7 tubes - o - 7 tubes 4 91
- second side 91
1 pc 15 tubes - o - 15 tubes 4 45
- second side 45
- No torches set-up changing time -
Total welding time: 1000 min

Total welding length: 2400 m
Referring to above calculation for above type panel the total weld amount is approx. 1150 m
per 8 hours. Note: welding amount is different if it is welded only sub-panels during 8 h shift
(approx. 1600 m). With two machines line the panel is welded in half of the time.


Submerged arc welding process in the panel welding :
• The only welding process accepted by European the boiler customers
• High welding speed 1.1 – 1.2 m/min in production
• Operator friendly process: no arc radiation, no fumes
• No spatters as is possible in MIG welding (spatters cause markings to
tubes, when panel is going through form rollers)
• Correct penetration, shape and high quality weld
• Panel distortion minimised with correct sub-panel welding


Latest SAW technology in panel welding available now:
• Inverter based Lincoln Powerwave AC/DC 1000 power sources
• Using the AC square wave output and waveform control features
• Higher welding speed c. 20 % more speed compared to DC welding
• Less magnetism


The panel welding line production / process monitoring:
• Production management requires up to date production information
• On-line information through internet; machine’s PLC is sending to office PC
• Production data: arc time, welded meters per hour or shift
• Process data: welding parameters, date & time
• Info fed by operator: project number, flux & wire type etc.
• PLC system can optionally have net

control board and I/O ports for data
collection.
• Operator control / input is done via
touch screen in the main control
panel.
• Ethernet link for SW back-up &
diagnosing

Fin bar calibrating machine:

• Fin bar calibrating line consists of uncoiler, butt welding bench, fin bar cleaning with
shot blasting and the calibrating machine itself
• Calibrating machine calibrates the width and cuts to the correct length and the amount
programmed; also bevelling option can be added to calibrator (forming or milling)
• By adjusting the width of the fin bar the final width of welded panel can be controlled
Calibrating machine with uncoiler and butt Max width calibration is 3 mm,
welding bench below example of calibrated fin

“Let us use our know-how to increase also your production

capacity and quality – and profit ! ”
More information:
• harri.kartano@pemamek.com
• Internet: www.pemamek.com
Smile !!!

PEMA - Panel Welding Automation 2009

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

PEMA - Panel Welding Automation 2009

Hochgeladen von

Copyright:

Verfügbare Formate

II Boiler Manufacturing

PEMA MEMBRANE WALL PANEL PRODUCTION

• Basic panel lines

• Productivity improvement with efficient material handling

• Two machines panel line – doubled productivity

• Panel welding machine construction & welding flexibility

WORLD CLASS WELDING AUTOMATION Page 2/32

BASIC PANEL LINES:

WORLD CLASS WELDING AUTOMATION Page 3/32

BASIC PANEL LINES:

WORLD CLASS WELDING AUTOMATION Page 4/32

BASIC PANEL LINES:

PEMA 2500/6 welding line in Babcock Borsig Service in South Africa

WORLD CLASS WELDING AUTOMATION Page 5/32

BASIC PANEL LINES:

PEMA 2700/6 welding line in Thermax Ltd, India

WORLD CLASS WELDING AUTOMATION Page 6/32

BASIC PANEL LINES:

PEMA 4500/6 welding line in Alstom, USA

WORLD CLASS WELDING AUTOMATION Page 7/32

The production capacity of the panel welding line depends on:

WORLD CLASS WELDING AUTOMATION Page 8/32

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

WORLD CLASS WELDING AUTOMATION Page 9/32

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

WORLD CLASS WELDING AUTOMATION Page 10/32

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

WORLD CLASS WELDING AUTOMATION Page 11/32

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING.

Buffer storage: Cross transport Flip-over arms Feed-back

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

Integrated tube and fin bar Buffer storage:

Staging table Cross transport conveyor

WORLD CLASS WELDING AUTOMATION Page 13/32

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

Tack-welding Integrated tube and fin bar

WORLD CLASS WELDING AUTOMATION Page 14/32

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

Tubes are lifted from buffer store to in-feeding system

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

Tubes and fin bars feeding to staging table

MORE PRODUCTIVITY WITH EFFICIENT MATERIAL HANDLING

Sub-panels pick-up from buffer store to welding machine

WORLD CLASS WELDING AUTOMATION Page 18/32

Two machines line for higher production capacity

2 x PEMA 2000/6 line in Rafako, Poland

WORLD CLASS WELDING AUTOMATION Page 19/32

..… Two machines line for higher production capacity

2 x PEMA 2700/4 in Thermax,Ltd, India

WORLD CLASS WELDING AUTOMATION Page 20/32

..… Two machines line for higher production capacity

2 x PEMA 2700/6 welding line in DB Thermal, South Africa

WORLD CLASS WELDING AUTOMATION Page 21/32

..… Two machines line for higher production capacity

WORLD CLASS WELDING AUTOMATION Page 22/32

PEMA panel welding machine

PEMA panel welding machine

WORLD CLASS WELDING AUTOMATION Page 24/32

PEMA panel welding machine

Flux recovery Side pressing roller Fin bar pressing roller

Form roller shaft Welding heads Flux feeding nozzles

WORLD CLASS WELDING AUTOMATION Page 25/32

Here are some examples of welding sub-panels and