TPT March 2008

T echnology U pdate

Latest generation spiral pipe mills and related equipment

The VGP3D software checks for ‘real part feasibility’ by creating an environment on screen that takes account of the ‘actual’ conditions on the nominated CNC tube bender to calculate a cycle time based on the use of virtual tooling. This feasibility check gives an immediate cost and time saving, because there is no need to design, produce and adjust prototype tooling. It also provides the necessary reassurance without physically running the machine, with the pre-production calculation of the real time cycle time ensuring accurate component costing for quotation purposes. Even when different tube bending machines are used, there is no need for bend trials, because the software takes account of the allocated machine’s 3D dimensions and characteristics when compiling the most efficient bending cycle. Completed bend programs can be saved according to specific search keys, while production- related data can be used to monitor machine performance in terms of downtime, set-up time and maintenance requirements. The VGP3D software caters for all the main tube sections – round, square, rectangular, oval, elliptic and flat-oval – with automatic calculation of tube length. For example, it enables complex tube components to be completed in one cycle on the 12 axes of the E-Turn. This allows the multi-tool stack tube machine to perform, in automatic cycle, a combination of left and right hand bends, conventional (drawn) and variable radius (push) bends, multi-radius bends, tight radius bends, and compound bends (ie with little or no straight between bend). With all the axis movements set automatically, job changeover can be completed in two to three minutes, which means that short batch work can be managed as efficiently as high volume work. As a further safety check, when a new bend program is selected the E-Turn automatically runs its ‘safeguard’ cycle. This reduces all speeds and pressures to 20 per cent, to eliminate possible collision damage that might result from inadvertent setting or tooling errors.

PRD-Cagil, USA, has commissioned a state-of-the-art offline upgradeable spiral pipe manufacturing facility for Gregorian International, Venezuela. The mill is set for API rated pipe manufacturing and equipped with a PRD-Cagil FRS 5001 series new generation forming unit. The system will start in an online production capacity but will be upgraded to offline in the future. In addition to the SWP mill, the company has also supplied a hydrostatic pipe tester, end beveling machines, X-ray units and a material handling system. PRD-Cagil has also supplied a new generation mill to Ameron International, a leading US pipe manufacturer. This SWP machine has PRD-Cagil’s latest (3 rd generation) metal joiner, which is equipped with an edge milling machine that reduces coil end joining time to 15 minutes. The SWP machine is equipped with aFRS 5001 series new generation forming unit that will produce pipe 24-144" in diameter, 6-18m in length and wall thickness up to 25mm. Ameron also ordered an edge milling machine and a new forming unit under their upgrade plan. The EMM will be integrated into one of Ameron’s previously ordered PRD SWP mills. The new forming unit will replace the forming unit of an old SWP mill. PRD-Cagil has also supplied an offline upgradeable SWP machine (with double

› PRD supply state-of-the-art spiral pipe mills and other machinery

main drive) to Erciyas Pipe, Turkey. This SWP machine – which uses 360t of forming force at the new generation forming unit – is designed to serve products with an X100 grade of steel. The SWP machine has an uncoiler with pre-tensioning system that eliminates springback for coils with X80 grade or more. Trinity, USA, has also taken delivery of a new SWP mill. This mill will produce pipe from 16-120" in diameter, 6-16m in length and up to 25mm wall thickness. PRD-Cagil now supplies new process reporting software for its SWP mills. This software enables the users to monitor online process data as well as the actual process for a certain period. Pacific Roller Die Company Inc – USA Fax : +1 510 887 5639 Email : prdsales@prdcompany.com Website : www.prdcompany.com

State-of-the-art 25" ERW tube mill line A complete 25" ERW tube mill line is currently being manufactured by Nakata Mfg Co Ltd, Japan, and is due for delivery to a leading pipe manufacturer in Russia. Nakata, as the sole creator of this facility, is devoted to reaching its targeted start-up date of 2009, from the entry section to finishing/testing section. The facility is designed for a manufacturing tube mill for API application (API 5L X80) which requires the highest quality. In addition, this facility has an FFX mill system as its core element in combination with a roll box system (common-use roll shaping machine for hollow sections), and an RFS cutter (a tip saw type flying cut-off machine). It will be a state-of-the-art tube mill facility for both round and square pipes utilizing cutting-edge technologies. Both the FFX mill for a tube/pipe mill and the RFS flying cut-off machine are highly- valued due to their stable performance, which results in a quick start-up. This leads to a rapid increase of mill line projects – not only for the introduction of new facilities but replacing existing ones as well.

BLM Group UK Ltd – UK Fax : +44 1525 402 312

Email : sales@blmgroup.uk.com Website : www.blmgroup.uk.com

BLM SpA – Italy Fax : +39 031 715911 Email : export@blm.it Website : www.blmgroup.com

Nakata Mfg Co Ltd – Japan Fax : +81 6 6303 1905 Email : t-naka@nakata-mfg.co.jp • Website : www.nakata-mfg.co.jp

›

37

www.read-tpt.com

M arch 2008