D15387-2 PEMA panel line - technical specs 30.09.2010 · 2016-09-23 · POS. 3.1 PEMA OSW-M 18000/2...

Author: Harri Kartano Date: 30.09.2010 Page: 1/45

Copy: File-Rev: D15387-2

Customer: Usiminas Mecanica S.A.

Subject: Technical specification for offer D14855-7 / PEMA Flat and double bottom production line

Copyright 2010 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

Technical specification D15387-2 for offer D14855-7

for

PEMA Flat and double bottom production line for panel size 18 m x 18 m

for

Usiminas Mecanica S.A.






POS. 1. GENERAL DATA

This is the technical specification D15387-2 for the commercial offer: D14855-7.

Customer: USIMINAS Mecânica S/A Av. do Café, 277, Torre A - 8º andar, Ed. Centro Empresarial do Aco – Jabaquara, 04331 000 – Vila Guarani Sao Paolo BRAZIL Attn. Mr. Fábio Yukio Miyabara Mr. Athiel Pires Júnior

Subj: Technical specification for offer D14855-7 for PEMA Flat and double bottom production line for panel size 18 m x 18 m






TABLE OF CONTENT

POS. 1. GENERAL DATA 2

POS. 2. MAIN DATA 4

POS. 2.1 PANEL LINE DIMENSIONS 4

POS. 2.2 MATERIAL DIMENSIONS / SPECIFICATION 4

POS. 3. TECHNICAL DESCRIPTION & SPECIFICATION 8

POS. 3.1 PEMA OSW-M 18000/2 one-side welding station 8

POS. 3.2 Flip-over arms for panel turning 14

POS. 3.3 PEMA PBW-18000/2 Plate butt welding portal 15

POS. 3.4 Cutting and marking station 16

POS. 3.4.1 Vacuum draft cutting table 16

POS. 3.5 PEMA SMP-18000/2-600 stiffener mounting and tack welding station 19

POS. 3.5.1 Option: PEMA SMP-18000/2-800 stiffener mounting and tack welding station 23

POS. 3.6 PEMA SWP 18000/6 stiffener welding station 24

POS. 3.7 Floor & transportation equipment 26

POS. 3.8 PEMA WMP-18000/2 web mounting portal 28

POS. 3.8.1 Option: The sideways cassette feeding conveyors 30

POS. 3.9 Option: PEMA VWS-18000/4-4000 vertical welding machine 30

POS. 3.10 PEMA SP-18000/8 Service Gantry 33

POS. 3.11 Transportation trains 35

POS. 3.12 Load-out station 36

POS. 3.13 Ultrasonic testing equipment 37

Pos. 4.1 Capacity calculations 38

Pos. 4.2 Working tolerances 43

Pos. 4.3 Number of operators 45






POS. 2. MAIN DATA

POS. 2.1 PANEL LINE DIMENSIONS

Panel Line’s main dimensions according to preliminary layout drawing M21039-4:

- Length total c. 220 m (preliminary) - panel width 18 m - span 23,5 m - height of the floor equipment from floor level 550 mm

POS. 2.2 MATERIAL DIMENSIONS / SPECIFICATION

POS. 2.2.1 Plate / panel sizes

- steel to be welded is shipbuilding steel grade A – (AH36) – DH36 - recommended plate edge straightness for butt welding: max ± 0,75 mm

difference / 18 m plate length - fairness requirement of the plates: max 4 mm difference / 1 m panel length /

width - surface quality of plate edges: recommended machine grind / milled surface

(after cutting) - recommended primer removed from the bottom edge of profile and from the

plate on the positions of stiffeners, in any case maximum allowed primer thickness is 20 µm

- different thickness of plates, the thicker plate edge needs to be tapered to a = 3 x b, when b = 1-10 mm (b= difference of plate thickness), at OSW station the difference can be on top side only

- Seam preparation (recommended, depends also is there one or two sided welding): - I-groove up to 12 mm material thickness - Y-seam (50°-70° with 4-7 mm nose) for 12-22 mm material thickness - X–seam (two sided welding) for 12-35 mm material thickness

- Standards: plates EN 10029 – EN5817, profiles DIN 1017 for flats and DIN 1019 for flat bulbs and angle bars






PLATES

Min.

Max.

Length

12.000 mm

18.000 mm

Width

2.440 mm

3.000 mm

Thickness

9 mm

25 mm

Weight

11.000 kg

PANELS

Min.

Max.

Length

12.000 mm

18.000 mm

Width

4.900 mm

18.000 mm

Thickness

9,0 mm

25 mm

Weight

64.000 kg

To be installed by SMP (note options for 600 mm and 800 mm high profiles) and welded by SWP:

STIFFENERS / Bulb & flat bar

Min. mm

Max.

Size

76 x 6 mm

370 x 15 mm

Length

3.000 mm

18.000 mm

Distance

406 mm for one profile, 610 mm for 2 profiles

max 710 mm for 2 profiles

STIFFENERS / L (angle iron)

Min. mm

Max. Mm

Size

100 x 50 mm

360 x 100 mm

Length

3.000 mm

18.000 mm

Distance

600 mm







STIFFENERS / T – profiles

Min. mm

Max. Mm

Size

360 x 100 mm

800 x 300 mm

Length

3.000 mm

18.000 mm

Distance

610 mm


The stiffener flange sizes have to be checked. Sizes, which are not suitable for SMP or SWP will be installed manually with WMP web mounting portal.

WEBS

Min. mm

Max.

Height

500 mm

4.000 mm

Length

3.000 mm

18.000 mm

Weight

10.000 kg

Distance

1000 mm

-

POS. 2.2.2 Energy supplies

Voltage: 440 VAC, -10 … +5 %, 60 Hz (± 1 %) Air: 7 bars Co2 : 1,2 bars Oxygen: 10 bars

Preliminary required power connections to each station:

OSW-18000/2 190 kVA Flip-over arms 60 kVA

PBW-18000/2 180 kVA SMP-18000/2 90 kVA

STT-18000 carriage 10 kVA SWP-18000/6 190 kVA

Conveyor line: c. 100 kVA WMP-18000/2 80 kVA VWS-18000/4-4000 130 kVA






SP-18000/8 255 kVA Transportation trains c. 100 kVA (each train) Load out station 80 kVA

POS. 2.2.3 Environment

Temperature: - Minimum temperature: 0 degrees C - Maximum temperature: + 45 degrees C Relative humidity: - Minimum 1 % - Maximum 90 %

POS. 2.2.4 Painting of the machines

Color of equipment: according to Usiminas specification

POS. 2.2.5 Enclosed documents

Layout drawing: M21039-4






POS. 3. TECHNICAL DESCRIPTION & SPECIFICATION

POS. 3.1 PEMA OSW-M 18000/2 one-side welding station

Photo: OSW with in- and out-feeding conveyors

Description

Ready prepared plates are brought to the beginning of the line by means of an existing overhead crane and they are lowered on the in-feeding conveyor, which consists of up/down moving chain conveyors and sideways alignment movement. Panel is fed on the other side of OSW and reversed back against the stoppers with chain conveyors and clamped with magnetic bed. The second plate is transported into the OSW station by the in-feeding chain conveyor and positioned against first plate or against the tools for air cap. Working cycle: - The first plate is conveyed through the station and then reversed against the

stoppers (manually movable) in the OSW station. - The magnet clamping system on the reverse side of the station is activated

and the plate is clamped tightly - The second plate is lifted on chain conveyor and transported onto the OSW

station and positioned against the first plate. If air cap has to be used, the operator uses manual air cap setting tools for it.






- The magnet clamping system on the front side of the station is activated and the second plate is clamped tightly.

- The start and stop plates are ready welded or they can be welded on each panel side on OSW station

- The plates are tack-welded together - The welding trolley is prepared for butt-welding and welds the plate joint by

means of one-side welding technology against backing flux on the copper backing

After finished the welding, magnets are deactivated, the chains on the OSW are lifted up and the panel is moved one plate length further. Old backing flux is removed and new backing flux is laid automatically on the backing with the welding carriage.

Plate transportation system

Transport of plates on the OSW station is based on up/down moving conveying chains. The sideways movement of chain conveyor module is used in the in-feeding side of the station for easy plate aligning. The conveying chain arrangement consists of an endless chain running in fabricated steel channels, and a gear motor package. The out-feed conveying arrangement consists of up/down moving chain conveyors for full panel size.

In-feeding transportation conveyor Conveying the panel on the chain conveyors - Number of tracks ………………………… 20 pcs in-feed - Each track module is synchronised electrically together - hydraulic up/down movement ………….… 50 mm - area between chains is covered with steel plate - Conveying length ………………………….. 7000 mm - hydraulic sideways movement …………... ± 200 mm - Conveying speed …………………………. 0 – 6 m/min continuously

adjustable by means of inverter controlled AC-drive

Out-feeding conveyor - similar to in-feeding conveyor without the sideways movement - conveyor length is 3 m + 18 m (for one full panel size)






PEMA OSW-M 18000/2 One side welding station

The OSW station works as a push through system. The station is very open and the operator can walk on panel, so no extra platform is needed. The station has a magnet clamping system for fixing the plates to the right position and one welding carriage for the one-side welding. The welding carriage is mounted to the gantry. The one side welding process is submerged arc-welding (SAW) with a height adjustable floating flux backing. When welding, there are pressing rollers running before the welding head, in order to assure, that the plates are aligned correctly for welding. When the welding is completed, the magnets are switched off, backing bar lowered and the chains are lifted up for the transportation of the panel.

The welding trolley on the heavy duty gantry has two (2) SAW-welding heads, which are adjustable in angle, height and distance. It includes also flux laying nozzles, a suction system for flux and manual hand wheel for torch set-up adjustment. The slag breaking & suction and refilling of new root flux is set automatically during the welding carriage home return drive.

Photo: The operator has good open environment






Stationary welding gantry Type ............................................................. Portal Width ............................................................. c. 23500 mm Welding carriage ........................................... servo motors / gear rack Lights …………................................................ Spotlights on the gantry Plate stoppers ..........................................….. Manually movable stoppers, 4 pcs Plate tack welding equipment ………………... ESAB OrigoMIG 408, 2 pcs

Magnet clamping equipment No of magnets.................................................... 38 x 2 pcs Size of magnets…………………………………… 250 x 450 mm Clamping force……………………………………. 3000 kg / magnet

Photo: Magnet clamping system of OSW Backing Type................................................................. Copper, flux filled, water cooled

Size of groove ………………………………….. 3 x 35 mm Length of backing bar....................................... 18500 mm

Height adjustment............................................ 15 mm, pneumatic






Flux filling ………………………………………. Automatically by welding carriage

Miscellaneous ………………………………….. Plate thickness difference on the top of plates

SA Welding equipment Manufacturer ................................................... ESAB Power sources ................................................. 1 pc LAF 1250 DC

1 pc TAF 1250 AC Wire feeding ..................................................... A6, 2 pcs Control system ................................................ ESAB PEK, 2 pcs Flux recovery ................................................... ESAB / PEMA Torch adjustment ………………………………. Manual hand wheel

Torch positioning ……………………………….. By means of laser pointer Miscellaneous .................................................. Automatic backing flux feeding

and slag breaking & suction Flux containers.................................................. 1 pc 75 litre for top flux, separate

container for backing flux (25 l) Flux heating system in flux container ………….. Thermostatically controlled,

50 - 110 °C Wire reels.......................................................... 2 x 30 kg

Photo: OSW’s control panel






Pressing rollers - Installed to the welding carriage - Hydraulically operated, max pressing force 20 kN - Pressing rollers are to ensure that the plate is properly against the flux backing Control system The main control panel is suspended from the welding carriage: - PLC-control Siemens S7 - LCD -colour display - Programming of:

- Welding length - Welding speed - on line adjustment with ± push-buttons - Number of SAW-torches - Start / stop of flux feed, backing flux laying

- Welding current and voltage are adjusted from Esab PEK process controller

Photo: Inspection pit under the panel line. Inspection pit

Inspection pit is recommended to the foundation for the checking of root weld, if floor construction allows it.






POS. 3.2 Flip-over arms for panel turning

Flip-over arms are used for turning the panel around for the second side welding. - The panel is transported into correct position against the back stoppers on top

of flip-over system - The operator starts automatic turning cycle and the panel is turned over by

means of hydraulically operated arms, which operate in synchrony mode, operation controlled by an operator

- 7 pcs of flip-over units consisting of 14 pcs arms - arms are integrated into the floor equipment and installed between rollers - own hydraulic aggregate - max loading capacity 70 metric tonnes

Photo: An example of panel flip-over unit






POS. 3.3 PEMA PBW-18000/2 Plate butt welding portal

The moving gantry has one (1) welding carriage which has two (2) SAW-welding heads, which are adjustable in angle, height and distance. The trolley has also a welding flux laying head and the suction system for flux recycling.

Gantry Type.......................................................……. portal Span............................................................... 23.500 mm Rail type.......................................................... E60 Machinery...................................................... Electric Travelling distance......................................... ca. 20 m Travelling speed............................................. 0,5 -12 m/ min, friction drive Control system................................................ PLC-control Miscellaneous................................................. Travelling speed and distance

controllers on control panel

Photo: Plate butt welding portal & flip-over arms (in low position)






SA Welding equipment Manufacturer ................................................... ESAB Power sources ................................................. 1 pc LAF 1250 DC

1 pc TAF 1250 AC Wire feeding ..................................................... A6, 2 pcs Control system ................................................ ESAB PEK, 2 pcs Flux recovery ................................................... ESAB / PEMA Torch adjustment ………………………………. Manual hand wheel

Torch positioning ……………………………….. By means of laser pointer Miscellaneous .................................................. flux feeding & recovery Flux containers.................................................. 1 pc 75 litre for top flux, separate

container for backing flux (25 l) Flux heating system in flux container ………….. Thermostatically controlled,

50 - 110 °C Wire reels.......................................................... 2 x 30 kg

Control system The main control panel is suspended from the welding carriage. - PLC-control Siemens S7 - OP 27 LCD -colour display 10x12 cm - programming of:

- welding length and speed - number of SAW-torches - start / stop of flux feed

- welding current and voltage are adjusted from welding process controller

POS. 3.4 Cutting and marking station

ESAB Telerex TXB 22500 cutting & marking machine is for plate cutting, marking and primer removing. The specification is according to attached file 999-201000128-5 (dated 30.09.2010).

POS. 3.4.1 Vacuum draft cutting table

Pemamek offer the vacuum draft cutting table, which has own protected transportation equipment for moving the panel to / out from cutting station.

As the cutting causes a lot of fume, dust and waste, a customised furnace bed underneath the cutting area is there to collect a big part of them.






The furnace bed is consisting of - for plate / panel transport there are four (4) chain conveyors with a length of c.

20 m to pull the panel through the cutting area - five (5) movable vacuum suction carriages with slag boxes The carriages are automatically following the cutting torch, but are not mechanically connected to it. The construction of cutting table is designed so, that there are only longitudinal supports. When carriage is driven to the end of the cutting table the waste box of carriage can be changed to empty one. At the bottom of carriage is a scraper, which keeps the floor clean under cutting area.

Furnace bed:

- working size 18000 x 18000 mm - furnace bed size 18500 x 18500 mm - furnace bed consists of grate elements, which can be changed with each other

to have even wearing - the max loading on the furnace bed is 500 kg/m², however so, that max loading

on furnace bed is totally 64.000 kg - furnace bed is not allowed to lift when the work piece is on the bed

Vacuum carriage:

Below the furnace bed and steel net is a motorized vacuum carriage, which is supported by side beams (no rails on the floor) Vacuum carriage: - movement by inverter controlled AC-drive - carriage is chain driven from both sides - max speed 20 m/min, speed is adjustable - drive is automated: carriage is following the cutting machine; the control is done

with sensors and own control system, so that it is not connected to the control of the cutting machine

- also manual control is possible - the offer includes two waste boxes/element, totally 10 slag waste boxes; a

waste box is positioned in the vacuum carriage and can be lifted away by crane to change to empty one

- on the bottom of the vacuum carriage there is a scraper, which keeps the floor clean from slag

- the vacuum carriage has a special common frame with waste box, so that they together build up a rectangular suction nozzle

- both ends of the vacuum carriage are equipped with suction channels, which are connected to the longitudinal suction channels






- the control panel for vacuum carriage and vacuum suction unit will be placed nearby the cutting machine

Fume extraction system – Supplied by Usiminas For example: Vacuum unit..................................................… Nederman, 2 pcs - capacity ………………………………………... 11000 m³/h / each - motor power …………………………………... 15 kW - filters …………………………………………... Filtermax DF120, 2 pcs

Photo: Vacuum draft table with ESAB cutting & marking station Cutting area - Chain conveyors, 4 sets

The chain conveyor is the most common and reliable transportation system for panels on a welding line. It consists of an endless chain running in fabricated steel channels, manual gripping tool, a gear motor and an adjustable turning wheel. It is operated from a remote controller. There are four chain conveyors in order to enable a flexible transportation of the panel through cutting area. Number of tracks ……………………………… 4 pcs, track modules are






synchronised electrically together Conveying length ……………………………… approx. 20 m

Cutting area - disc rollers

In the cutting area it is necessary to use steel blade rollers instead of standard steel rollers, because cutting is damaging the rollers and they need to be heat tolerant and easy to change. Roller diameter ................................................ 350 mm Material .......................................................... Steel blade Height from floor................................................. 500 mm

POS. 3.5 PEMA SMP-18000/2-600 stiffener mounting and tack welding station

Description

This station can do the mounting and automatic tack-welding of stiffeners. The station works as stationary system, ie the panel is not moved during the mounting and tack-welding. The station includes motorised stiffener trolley (STT) with a stiffener cassette and a stiffener mounting gantry (SMP). The SMP has a non-rotating lifting beam with magnetic clamping arms for stiffener pick up, pulling magnet carriages and hydraulic pressing system to push profile down against the panel. For tack welding there is one (1) motorised welding carriage equipped with two MIG welding equipment for automatic tack welding of the stiffener.

Stiffener mounting and tack-welding station

The panel is transported to this station by means of the chain conveyor: - the panel is transported to the right position on the conveying line - the stiffeners are loaded to the stiffener cassettes in correct order elsewhere in

fabrication line and brought in cassettes to this station by main crane - the stiffener cassette is loaded by main crane or by sideways cassette feeding

conveyor (option) on the STT stiffener transportation trolley, which is feeding the stiffeners to the assembly gantry

- the stiffener mounting and tack-welding portal (SMP) picks up the stiffeners one by one from the cassette with magnet arms

- the stiffener is positioned by the operator and lowered on the panel to the pre-marked position and pressed against the panel by hydraulic pressing cylinders

- the panel is pressed down and at the same time pulled up with the magnets of the welding carriage to minimize the air gap between panel and stiffener






- the tack welding of stiffeners is done automatically from both sides with MIG-welding equipment, which are running on motorised carriages on the both sides of the beam

- after the stiffener is completely tack-welded, the pressing cylinders are deactivated, the SMP portal is driven above the stiffener cassette and back to the next stiffener marking and same process continue

Photo: SMP with magnet arms Gantry

Type............................................................... portal Span............................................................... 23.500 mm Machinery...................................................... Electric Travelling distance......................................... c. 20 m Travelling speed............................................. 0,5 -12 m/ min, friction drive Max lifting capacity …………………………… 2.5 tons

Max height of the stiffener ………………….. 600 mm






Magnetic clamping fingers Number of clamping fingers.......................... 18 pcs

Clamping force of the magnet ……………… 250 kg / magnet Lifting height................................................. approx. 1500 mm Parallel alignment ........................................ ± 150 mm, hydraulic function Sideways adjustment.................................... ± 150 mm, hydraulic function

Tack welding equipment Number of welding carriage1 ………………… 1 pc Number of welding sets .................................. 2 x MAG, CO2 Manufacturer .................................................. ESAB OrigoMIG 408 Power source.................................................. 400 A Wire feeding.................................................... 2 pcs Wire packs...................................................... 15 kg Travelling speed.............................................. 0,5-12 m/min

Length of tacks …….. ………………………… 70 – 100 mm Pressing cylinders Number of cylinders ……………………………. 18 pcs Locking force …………………………………….. 5000 kg, ie force, which holds

the profile when pulling magnets are used

Pulling magnet carriage, 1 pc Number of magnets......................................... totally 4 pcs / carriage Pulling force...................................................... 5000 kg / carriage

Stiffener transportation trolley STT STT trolley is for moving the cassette always beside the SPM portal. Number of trolleys............................................ 1 pc

Max loading capacity ………………………….. 20.000 kg Span …………………………………………….. c. 22.000 mm Travelling distance …………........................... approx. 20 meters Travelling speed............................................... 0,5 - 10 m/min Number of stiffener cassettes .......................... 1 pc (+ production drawings) The stiffener cassettes are loaded elsewhere and brought to this station by main crane.

OPTION: STT with sideways cassette feeding conveyor

The motorised transversal cassette feeding conveyor is for feeding one profile cassette to STT (integrated construction) sideways from beside bay to panel line. Length of the conveyor is approx. 40m.






Photo: STT stiffener cassette trolley

Control system

Main Control station

Located on one side of gantry bottom beam, with following functions:

- control of gantry movement - control of stiffener clamping magnets - control of stiffener mounting beam up & down - control of parallel alignment - control of sideways adjustment - emergency stop button - emergency stop Reset (notice, Reset can be done only at the main control

station) - tack-welding length - tack-welding ON / OFF / each carriage Remote control box, Radio control

- control of angular alignment - control of sideways adjustment - control of parallel alignment - control of pressing cylinders - control of pulling magnets






- emergency stop button - travelling speed from potentiometer - travelling distance manually run / stop

Remote control box at each carriage

- control of pulling magnets - emergency stop button - travelling speed from potentiometer - travelling distance manually run / stop

POS. 3.5.1 Option: PEMA SMP-18000/2-800 stiffener mounting and tack welding station

Stiffener mounting portal similar to Pos. 3.5 except: - max weight of the stiffener is 3.600 kg - max height of the profile is 800 mm - stiffener clamping arms include upper and lower magnets for better clamping

force for big profiles - reason for offering to options for SMP is that typically stiffeners higher than 600

mm is assembled with WMP. If there are lot of stiffeners over 600 mm, then it is better to select option 3.5.1

Photo: SMP-18000/2-800 has upper and lower magnets for big stiffeners






POS. 3.6 PEMA SWP 18000/6 stiffener welding station

Description

This station welds of the assembled and tack-welded stiffeners. The mobile SWP-gantry is positioned above the stiffeners and the fillet welding is carried out on both sides of three stiffeners at a time with six MAG welding equipment. For the transportation of the panels the existing conveyor line is used. The welding is done only for longitudinal profiles (ie. transversal to panel line flow). The profiles to be welded have to be checked (reach ability study).

Photo: Stiffener welding portal with six MIG welding equipment

Stiffener welding station

The mobile gantry has one welding carriage, supporting three torch holder sets, each having two MAG welding head with mechanical joint tracking system. The welding heads are adjustable in height, tilt and angle and they get the guidance from the stiffeners. The operation is PLC- controlled.






- the welding portal is driven manually to the first three (1-3) stiffeners group,

positioned manually by the operator. - the stop of the welding of each torch set will be automatically controlled with

sensor - the welding is carried out automatically according to PLC-programming and the

welding carriage is running from one side of the plate to the other side - welding heads are running on each side of the stiffener non-symmetrically, ie

first torch ahead of the other to minimise the heat input to the panel - With PLC control it is possible to program welds: different type of intermittent

welds - start / stop of each welding head set can be controlled individually (enables

starts/ends of the profiles in different locations) Gantry Type.......................................................……. portal Span............................................................... c. 23.000 mm Rail type.......................................................... E60 Machinery...................................................... Electric Travelling distance......................................... c. 20 m Travelling speed............................................. 0,5 -12 m/ min, friction drive Control system................................................ PLC-control - adjustable welding length and speed Miscellaneous................................................. Travelling speed and distance

controllers on control panel Welding carriage

- welding carriage is attached on the portal’s horizontal beam - the welding carriage has three welding sets (each set has two torches) - each welding set has own pneumatic vertical slide 900 mm so that in case the

welding set is not used, it can be in top position - each welding set has floating welding heads for ±50 mm - welding sets can be manually adjusted for stiffener distance 610 – 711 mm - each torch set has one sensor installed before tracking roller for automatic start

and stop of welding - at the end of the profile it is possible to lock the floating slide according to the

sensor’s signal. Also the welding length after sensor’s ending signal up to end of profile will be settable parameter

MAG welding equipment, 6 sets Number of welding sets .................................. 6 Manufacturer .................................................. Esab






Power source.................................................. AristoMIG 500 Wire feeding.................................................... Aristo Feed 48 Welding gun.................................................... Binzel Robo 650 (water cooled) Seam tracking................................................. pneumatic-mechanical

Wire packs ……………………………………… 100 kg Marathon packs Wire size ……………………………………….. Ø 1,6 mm

Gas feeding …………………………………… Gas flow meters for each torch

POS. 3.7 Floor & transportation equipment

Roller conveyors with pulling chains

Transportation of plates and panels in the OSW station is based on OSW’s own special conveyors included to the OSW station. The transport of panels along the welding line after OSW and flip-over stations up to SWP station is based on rollers and two conveying chains. The conveyor consists of rails with fixed rollers and two chain driven conveyor. Plates / panels are engaged to the chain by means of manual plate gripping tools. The plate gripping tools are guided by the wagon to ensure straight and parallel movement. The two chain conveyors can be operated synchronised or individually. Through this flexible operation, it is possible also to straighten the panel prior to stiffener assembly if needed. Rollers

Fixed rollers are used for conveying the plates with the chain conveyors. They are installed in parallel rows and inside cover-profiles to avoid plates jamming during transportation. The alignment of the plates is easily done parallel to the panel line axis. Fixed / conveying rollers Roller diameter............................................... 160 mm Material .................................................... Steel Height from the floor....................................... 550 mm Number of rows.............................................. 24 pcs Distance between rollers................................ 750 / 1500 mm

Chain conveyors, 2 sets

The chain conveyor is the most common and reliable transportation system for panels on a welding line. It consists of an endless chain running in fabricated steel channels, wagon with wheels, manual gripping tool, a gear motor and an






adjustable turning wheel. It is operated from a remote controller. The chain conveyor is divided into two sections in order to enable a flexible transportation of the panel.

Number of tracks ……………………………… 2 pcs, each track module is

synchronised electrically together (can be driven also separately)

Conveying speed ……………………………… 0 - 6 m/min continuously adjustable by means of inverter controlled AC-drive

Mechanical grippers ………………………….. 6 pcs loose grippers

Photo: roller conveyor line with pulling chains Sideways transportation After SWP station the line have sideways conveyors for moving the flat panel to another bay. The conveyor consists of several rows of motorized fixed chain conveyors. - transportations length is approximately 30 m - rows of fixed chain conveyors are supported by floor mounted U-beams - sideways transportation conveyor will be manufactured by the customer

according to Pemamek’s instructions and manufacturing drawings.






POS. 3.8 PEMA WMP-18000/2 web mounting portal

With this station can be lifted, mounted and tack-welded the transversal & longitudinal webs. The station works as stationary system, ie the panel is not moved during the mounting and tack-welding. The station consists of a mobile service gantry for web mounting. The WMP has a motorised lifting & mounting beam with manual plate clamps for web pick up and semiautomatic MIG welding-equipment supported from the gantry for manual tack welding of profiles. - the panel is transported to the correct position on the conveying line - the webs are loaded to their racks / cassettes elsewhere in fabrication line and

brought on the panel with the existing crane - the webs are picked up one by one from the racks / cassettes with manual

clamps - the webs are lowered on the panel to the pre-marked position - the tack-welding is carried out with semi-automatic welding equipment (2 pcs)

supported by the gantry. - after the profile is completely tack-welded, the next web is picked up,

positioned and tacked

Photo: example of WMP web mounting portal






Gantry Type................................................................ portal Span................................................................ 23.500 mm Machinery......................................................... Electric Travelling distance........................................... 20 m Travelling speed............................................... 0,5 -12 m/ min, friction drive Control…………………………………………… Radio controller + distance

controllers on control panel.

Plate lifting boom Number of plate clamps .......................……… 4 + 4 pcs Lifting height................................................... for 4000 mm high webs Lifting capacity ………………………………… 10.000 kg Rotation…………………………………………. ±180 degrees

Photo: WMP lifting hoists, hydraulic pressing unit in the middle is only for assembling profiles with max height 1000 mm).

Profile lifting hoist and pressing beam (photo above) Number of plate clamps .......................……… 2 pcs Lifting height................................................... 4000 mm max height of the profile …………………….. 1000 mm






Lifting capacity ………………………………… 3.600 kg Rotation…………………………………………. ±180 degrees Stiffener cassette rack is not included (customer’s supply) Tack welding equipment Number of welding sets................................... 4 x MAG Manufacturer .................................................. Esab Power source.................................................. Esab OrigoMig 408 Wire packs...................................................... 15 kg

POS. 3.8.1 Option: The sideways cassette feeding conveyors

The motorised transversal cassette feeding conveyor is for feeding one profile cassette to STT (integrated construction) sideways from beside bay to panel line. Length of the conveyor is approx. 40m. Stiffener cassette rack is not included (customer’s supply)

POS. 3.9 Option: PEMA VWS-18000/4-4000 vertical welding machine

Description

This machine is assembled on a movable portal and it is capable of welding 4 (four) vertical welds of a tack-welded webs’ and double bottom plates’ cross-section at the same time. It has four independent MIG/MAG-welding heads, which can be programmed to jump over the horizontal stiffeners on the webs. The platform is height adjustable by means of electric motor and the positioning of the machine to the cross-section centre is done by means of laser light-beams.

Vertical Welding machine

The machine has four MIG-welding power sources and water cooled torches and also an extraction system for the welding fume. The torches are positioned against the vertical fillet automatically and the guidance for the torches comes from crossings of the webs.






Photo: Vertical welding station for double bottom’s vertical welds Description of operation: - the operator drives the platform of the VWS to a correct position above a

cross-section to be welded - the machine is positioned to the centre of a cross-section by means of two

crossing laser beam lights - the machine is lowered to the right height and supported on the plates by four

pneumatic support arms - the number of welding heads is chosen (1-4 pcs) and they are lowered to the

bottom - the welding length, height of horizontal stiffeners, oscillations & welding

parameters are chosen and fed in to the PLC/ NC-control system in clear text - the welding is started from start button - the welding heads are working in stepwise operation and fully automatic

according to programmed values - the welding equipment are hanging from a turning ring, and it is possible to

change the welding heads position by turning the ring with a motor (± 90 ° ) Vertical Welding Machine Platform size.................................................…. 2500x3500 mm






Number of control units..................................… one fixed and one remote Working width.................................................... 18000 mm Working height................................................... 4500 mm Welding height …………………………………… 4000 mm Max horizontal stiffener size…………………… 250 mm / 30°/ 80 mm Height adjustment............................................... hydraulic Travelling speed................................................. 0,5-12 m/min Welding equipment Number of welding sets...................................... 4 Manufacturer ..................................................... ESAB Power source..................................................... 500 A Wire feeding...................................................... 4 pcs Wire packs......................................................... 15 kg Cooling system................................................. Bernard ( 4 pcs) Guidance system............................................. mechanic-pneumatic Welding gun....................................................... Binzel Robo 455, 450 A,

water cooled Fume extraction equipment …………………… 2 pcs Kemper Mini, hoses to four welding heads, changeable

filters PLC control: - Jetter Base E, PLC/NC-control - easy operator friendly clear text display - operator needs only to choose the right welding program from memory and

change some parameter values - control of welding parameters; voltage, wire feeding speed, welding speed;

values can be altered during welding with ± -push buttons - adjustable welding length, speed, intermittent and staggered intermittent weld

functions, adjustable oscillation length, delay time at the sides, the height of the horizontal

- profiles to be jumped over, height distance between welding heads

Welding gantry The vertical welding machine is supported by a movable gantry. The VWS’s platform is running on the gantry on rail, which are located on top of portal. The gantry is a welded construction with a drive motor on each end of the portal. Type............................................................... portal Span.............................................................. 23.500 mm Travelling speed……………………………… 0,5-12 m/min Drive…………………………………………… Electro motor / friction drive






Control…………………………………………. PLC-controlled movement Travel distance ………………………………... c. 20 m

POS. 3.10 PEMA SP-18000/8 Service Gantry

This station consists of web welding and finalising equipment mounted to movable gantry. The panel is positioned beneath this station and the welding of web profiles is done manually with eight (8) pcs semi-automatic MIG/ MAG hand welding equipment hanging from jib arms on the portal. The welding equipment can be lifted up/down by means of motor driven hoists. In addition the portal has 250 kg electrical hoist for lifting purposes. The hoist runs on a C-profile under the gantry support beams. Gantry Type............................................................... portal Span............................................................... 23.500 mm Machinery......................................................... Electric Travelling distance........................................... 20 meters Portal travelling speed..................................... 0,5- 12 m/ min, friction drive Jib arms Reach ……………… …………………………… 3000 mm Max load ………………………………………… 150 kg Lifting height ……………………………………. 5500 mm Number of arms ……………………………….. 8 pcs






Photo: Service portal

Manual welding equipment Number of welding sets.................................... 8 x MAG Manufacturer ................................................... Esab Power source................................................... Esab OrigoMig 408 Welding torch .................................................. 400 A

Accessories Electrical hoists .............................................. 8 x 125 kg

Electrical hoist in the gantry …………………… 2 x 250 kg Compressed air ………………………………… 4 x 15 m reel Gas outlets ……………………………………… 4 x 15 m reel Energy outlets ………………………………….. 4 x 240 V (220 ? to be checked)

Lightning ………………………………………… Spot lights on the gantry






POS. 3.11 Transportation trains

Transportation after sideways conveyor up to the end of the lines is done with transportation train lines. Transportation equipment for blocks includes low construction transportation trains (2 pcs), each train having 3 wagons. The steel support construction between the trains is made by the shipyard. The transport system is built to be flexible for different size and shape of panels. It is controlled from two main operation panels, one of which can be active at a time. PEMA TS transportation trains

Through the block fabrication line the panels are moved by means of panel transportation trains. There are two (2) pcs height adjustable trains, each consisting of three (3) wagons. These heavy duty trains can lift up and convey the stiffened panel through the panel production line. They are operated from a radio transmitter and they run synchronized or individually. - each train is running on two rails, which are installed on the foundation - each train consists of three (3) wagons, which are mechanically connected to

each other - each train has its own hydraulic system - at the both ends are the scrapers to keep the rail clean - all trains are running side by side, run parallel & synchronized. At the end of

the track there is a home station. Each train has its own drive-mechanism and controllers

- the energy feeding track is installed on the side of the floor frame construction and it is well covered (energy track is included in the delivery)

- number of rail tracks 2 x 2 pcs (supplied by the customer) - number of wagons 2 x 3 pcs - total length of trains 18 meters - conveying speed 0,2 - 6,0 m/min continuously adjustable - Inverter controlled AC-drive - height adjustment hydraulic - lifting height 150 mm (450-600 mm) - lifting capacity 50.000 kg / wagon - total lifting capacity of trains 250.000 kg - lifting time max 30 s - operation remote control from radio transmitter - safety valves in the case of pipe breaking






Photo: example of transportation train (note: this is with high lift-up, offered train is equipped with low lift-up)

POS. 3.12 Load-out station

The load out station consists of two parallel rows hydraulic cylinders, which are connected to each other from the top end by a steel profile beam. The cylinders are sunk in the foundation and they are secured sideways by a strong scissors guiding-system. Station has an own hydraulic aggregate and the operation control is manual from a remote controller. One load-out station is required for each bay. Off-load station number of lifting beams........................................ 2 pcs number of cylinders ............................................. will be specified later distance of beams……………....…………………. 12000 mm lifting height........................................................... 500 - 1800 mm loading capacity.................................................... totally 250 tons lifting time …………………………....…………… 10 - 15 min

The off-load station is delivered complete with hydraulic pipes, valves and control system.






Photo: load out station

POS. 3.13 Ultrasonic testing equipment

The quality of plate butt welding is checked with ultrasonic testing equipment. The system includes scanner with sensors and carriage with magnet wheels. The equipment can be Force Technology AGS-2 or comparable.






POS. 4. MISCALLENEOUS

Pos. 4.1 Capacity calculations

Assuming, that the logistics of plate supply and stiffener supply is taken care of by the shipyard, we can give the following estimation for the capacity of panel welding line. The production capacity is so called machine capacity and there is not counted operators lunch or coffee breaks or other human breaks. STANDARD FLAT PANEL SIZE ………… 18000 x 18000 mm (AH32)

PLATE SIZE ………………………………... max 3000 x 18000 mm NUMBER OF PLATES …………………….. 6 pcs (5 joints) NUMBER OF STIFFENERS (T-profiles)… 18 pcs (longitudinal L-profiles) THROAT THICKNESS …………………….. a4 mm (in capacity estimation) PLATE THICKNESS ……………………….. 20 mm

NUMBER OF WEBS ……………………..… 4 pcs 2,5 m high transversal webs

In capacity estimation the plates have ready welded start & stop plates before feeding to OSW station (where thick plates are welded the first side, and in PBW station the second side).

Production capacity required by the shipyard: 3 panels per day (24 hours). The plate butt welding is done two sided, first weld with OSW, turning with flip-over arms and second side with PBW.

SMP assembly time is estimated with the STT stiffener trolley, if the stiffeners are ready on panel on jig (vertical position), assembly time per stiffener is approx. 4 minutes faster. In SWP station it is assumed that the distance between stiffeners is constant. .






4.1.1. OSW one-side welding station:

Welding of 20 mm thick plate first side (x groove with 4 – 5 mm nose), plates have ready welded start & stop plates.

Action

Time

h, min

speed m/min

distance

Removal of old flux & new flux laying

0.00.00 (two sided)

2,50

18,300

Plate 1 positioning & clamping

0.04.00

Plate 2 positioning & clamping

0.04.00

Weld head positioning

0.01.00

0,50

0,50

Welding

0.31.00

0,6

18,50

Open clamping, move backing

0.01.00*

Move the plate/panel

0.02.00

3,0

3,50

Total / one seam

0.43.00

Duty cycle

80 %

Total manufacturing Time/ seam

0.54.00

NET WELDING TIME (5 x seam)

4.30.00

* In “open clamping” position there is not calculated cooling time.






4.1.2 Plate turning with flip-over arms

18 m x 18 m plate turning time with the flip-over arms is approx. 20 minutes.

4.1.3 PBW welding station:

Welding the second side after plate turning

Action

Time (ave)

h, min

Speed m/min

Distance

M

Portal movement to welding position

0.01,00

6,00

5,0

Portal positioning

(welding carriage return at the same time)

0.02,00

0,5

1,00

Weld head positioning

0.02,00

0,50

1,0

Welding

0.31,00

0,60

18,5

Total / one seam

0.36,00

Duty cycle

80 %

Total manufacturing Time/ seam

0.45,00

NET WELDING TIME

(5 x seams)

3.45,00






4.1.2 Stiffener assembly and tack welding with SMP-18000/2

Action

Time (ave)

h, min

Speed

M/min

Distance

M

Plate driving (only one drive)

0.04,00

6,00

20,0

Plate positioning (only once )

0.02,00

0,10

0,20

Panel moving time, total

0.06,00

Panel is stationary during stiffener assembly

Stiffener assembly:

Portal driving (stiffener pick-up from STT)

0.01,00

3,00

3,0

Lower the magnetic heads, stiffener pick-up

0.01,50

Portal return

0.01,00

3,00

3,0

Positioning the stiffener

0.01,50

Pressing the stiffener on the panel

0.01,00

Automatic tack-welding

0.10,00

1,9

18

Lifting up clamping beam

0.01,00

Time per one stiffener

0.17,00

18 x stiffeners

5.06,00

Duty cycle

80 %

Net manufacturing time per 18 x stiffener

6.23,00

Time/ stiffener / min

c. 21,5

SMP assembly time is estimated with the STT stiffener trolley, if the stiffeners are ready on panel on jig (vertical position), assembly time per stiffener is approx. 4 minutes faster.






4.1.3 Stiffener welding with SWP-18000/6

Action

Time

H, min

Speed

Distance

Plate driving (only once)

0.04,00

6,00

20,00

Plate positioning (once)

0.02,00

0,10

0,20

Panel moving time, total

0.06,00

Panel is stationary during stiffener assembly

Stiffener welding:

Portal driving / positioning

0.02,00

c. 0,2 - 3

3,0

Welding head return – at the same time as portal driving

0.00,00

20,00

18,0

Welding head pairs positioning

0.01,00

Welding start & stop, welding heads up

0.02.00

Welding continuous

0.30,00

c. 0,6

18

Total welding

0.35,00

18 / 3 x stiffeners = 6 runs

3.30,00

Duty cycle

80 %

Net manufacturing time: 18 stiffeners 3 at a time (6 runs)

4.23.00

Time / stiffener, when 3 welded at the same time

c. 15 min

Welding method: single wire MIG/MAG, throat thickness 4 mm in normal production.






4.1.4 Web assembly with WMP-18000/2

The web assembly is done manually with the help of the service portal with lifting hoists and manual installation tools. The assembly time depends on the stations and operators amount. 4.1.5 SP-18000/6 service portal for finishing the panel

For finalising the panel is used service portal for manual welding with 8 welders. The welding is done manually and productivity is totally depending on welders’ activity. SUMMARIZE of production capacity: According to above estimation we can say that flat panel line is able to weld one panel in one shift. We are not able to give estimation on the block construction production due to totally manual work.

Pos. 4.2 Working tolerances

Working tolerances are depending mainly on two things: - functional tolerance of the equipment - operational tolerance of the operator

4.2.1 OSW & PBW - plate tolerances according to Pos.2.2, ie ± 0,75 mm straightness - positioning tolerance the same (can be reached with PEMA-OSW-equipment) - sideways positioning, if cut afterwards, ± 5 mm

4.2.2 SMP - positioning tolerance is up to operator, as the positioning is done manually - to the pre-marked line, with help of a laser light beam. - optimal tolerance here ± 1 mm 4.2.3 SWP - positioning tolerance is up to operator, as the positioning is done manually - to the pre-tacked stiffener, with help of a laser light beam. - the guidance of the welding heads is a floating one, ie it accepts variations of

stiffener position ± 50 mm






4.2.4 VWS (option) Required assembly tolerances: - Webs’ positions: ± 50 mm - the tolerance of webs angles is ± 1 degree - air cap 0 – 3 mm - minimum spacing according to the drawing below:






Pos. 4.3 Number of operators

For the panel line described in Pos. 3. We recommend following amount of operators / machine: Station: Number of operators or welders / station: OSW butt welding 1 PBW butt welding &flipping over 1 SMP stiffener assembly 1 SWP stiffener welding 1 WMP Web assembly 2-3 / station VWS 1 / station SP panel finishing 8 / station overall material handling 2 – 3 / line

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D15387-2 PEMA panel line - technical specs 30.09.2010 · 2016-09-23 · POS. 3.1 PEMA OSW-M 18000/2...

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Transcript of D15387-2 PEMA panel line - technical specs 30.09.2010 · 2016-09-23 · POS. 3.1 PEMA OSW-M 18000/2...