SOLUTIONS - Tube-Tec · 2019-05-17 · 3 TUBE-TEC Rohrverformungstechnik GmbH is one of the...

SOLUTIONSIN TUBE FORMING & WELDING

2www.tube-tec.de 2

INHALT

Company 2-3

Tube Bending Technology 4-5

Quality & Processes 6-7

Petrochemicals 8-9

Power Station Technology 10-11

Foodstuffs Industry 12-13

Chemical Plant Construction 14-15

Pharmaceutical Industry 16-17

Industrial Plant Construction 18-19

Renewable Energy 20-21

Offshore 22-23

Premises

33

TUBE-TEC Rohrverformungstechnik GmbH is one of the world-wide leading companies in tube bending and welding technology.

As high performing and flexible owner-managed family business our clients profit from a flat hierarchy and short decision-making routes and continuous investment in qualified personnel, machine technology and new processes.

Through our expansive depth of production with in-house sheet metal processing facilities and own tool construction, mastery of all bending processes in the cold-forming of tubes, we enjoy a distinguished position with our clients and partners in engineering enterprises, power station service companies and plant construction.

HIGH-QUALITY – MADE IN GERMANY

TUBE-TEC - THE COMPANY

APPROVED MANUFACTURER ACCORDING TO:

• DIN EN ISO 9001:2008

• DIN EN ISO 3834-2

• AD 2000 - W0

• AD 2000 - HP0

• EN 764-5

• DGRL Werkstoffe

• ASME U, U2 + S Stamp

• US National Board Registration

• Germanischer Lloyd

• Bureau Veritas Mode II

• TÜV Austria Kesselgesetz §14

• EAC

Company

4www.tube-tec.de 4

PIPE ELBOWS AND PIPE BENDS

up to max. tube diameter 219.1 mm

TUBE-TEC is one of the leading manufacturers and contract manufacturers of boilers, pressure components, tube coil systems and single coils (bended) in Europe. In this enviable market position we are able to master the spectrum of all tube bending processes in the field of cold-forming.

Our CNC-driven modern bending machines can bend tubes from ø 10 mm up to ø 406.4 mm and in different wall thicknesses of up to 30 mm depending on the material used and the bending radius.

20 years of experience in tube bending technology has presented us with one of the largest and expansive pool of tools, placing us in the position to be extremely flexible and client cost-effective in the production.

• Industrial pipeline construction

• Pneumatic conveyance

• Granulate conveyance

• Pneumatic post systems

• Storage tank facility

• Cement conveyance

• Prefabricated heating surfaces

• Superheaters

• Economizers

• High pressure steam piping

• Waste & slurry incineration

DIFFERENT PROCESSES FOR THE MOST DIFFERENT OF DEMANDS

TUBE BENDING TECHNOLOGY

FLAT COILS AND SPIRAL COILS


APPLICATION EXAMPLES APPLICATION EXAMPLES

55

HELICAL COIL SYSTEMS


• Silo systems

• Compounding plant

• Extruders

• Conveyer plant in general

SPECIAL PIPE BENDS


APPLICATION EXAMPLES

OUT IN FRONT WITH IN-HOUSE TOOLING

• Heat exchangers

• Radiation recuperators

• Waste heat recovery boilers

• Condensers

• Deodorizers

• Crude oil distillation

• Heaters

• Indirect steam generation

• Agitator vessels

• Evaporators


Tube Bending Technology

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Especially in the fabrication of complex tube coil systems we are dealing with not only enormous know-how in bending technology, but also the issue of welding technology expertise.

Here the demands placed on us by technical standards/codes (EN, ASME) for the processing of challenging materials such as fine-grained steels, creep-resistant steels, heat-resistant steels, austenitic CrNi steels, Nickel-based steels or even from mixed bondings of various material groups such as heat treatment required reach levels that only a few specialised companies can master.

TUBE-TEC was one of the first to qualify as welding technology specialist and today possesses in excess of 120 different welding procedure tests in accordance with ISO 15614-1,-2,-6,-8.

• Wolfram inert gas welding process 141/142, with/without filler material, cold wire and hot wire, manual, mechanised, part-automatic

• Plasma welding process 15, manual, mechanised, part-automatic

• Orbital welding process 141/142, with/without filler material

• Metal active gas welding process 135/136 with solid wire electrodes or flux-core wire electrodes

OUR WELDING PROCESSES

TUBE WELDING TECHNOLOGY

QUALITY & PROCESSES

77 Quality and Processes

Continuous further training and securing the high level of welding technology are prioritised by TUBE-TEC with a constant number of more than 20 apprentices in metalworking for on-going replenishment in qualified welding technology personnel. A large number of own welding technicians (EWT) and welding engineers (EWE) compile welding & testing plans and personally monitor fabrication of the complex components up to final acceptance.

A team of up to 8 persons responsible for quality manage-ment secure & safeguard rule-compliant completion of working processes, in line with the usual high quality to be found in TUBE-TEC products. Reliance on an expansive depth of production and the added advantage with in-house certified testing personnel, many testing processes can be performed within the production sequence.

• Computed tomography, radiographic testing, 3d X-ray

• Radiographic testing with own X-ray bunker

• Ultra-sonic testing of wall thickness

• Dye penetrant testing

• Magnetic particle testing

• Hardness testing

• Cold water pressure test

• Leakage test

• Cold water pressure test

• Visual testing

• Endoscopic testing

• Mistake testing (RFA)

• Dimensional inspection with optical 3D measurement process

• DIN EN ISO 9001:2008

• DIN EN ISO 3834-2

• AD 2000 - W0

• AD 2000 - HP0

• EN 764-5

• DGRL Werkstoffe

• ASME U, U2 + S Stamp

• US National Board

• Germanischer Lloyd

• Bureau Veritas Mode II

• TÜV Austria Kesselgesetz §14

• EAC

OUR TESTING PROCEDURES

OUR CERTIFICATIONS

8www.tube-tec.de 8

Ready to Install register for a Refinery

Syngascooler

Ready to Install Helical Coil System Helical Coil System for Fertilizerindustry

Syngascooler

Syngascooler

99

Demands on deployed materials and tube coil systems in the petrochemical industry are extremely high. In waste heat boilers for methanol plant, distillation columns or steam reformers refinery residue such as pitch and tar among others are gasified in accordance with the so-called Shell Process.

In the course of this process, our tube coil systems are exposed to incoming gas temperatures of up to 1400°C with flow speeds of 30 m / sec. as well as a pressure in the coils of 76 bar and more.

In order to withstand the high wall temperatures, generally speaking special steels such as low-alloyed carbon steels 10CrMo9-10 are deployed.

The highest of demands in welding technology are placed on these materials, their fabrication process and their testing systems: Here it is absolutely necessary that all welded seams are fully tested and the complete component is annealed in a tempering oven to reduce internal tension.

TUBE-TEC shoulders the responsibility of such excellence in production through own-welding training with their own specialised welding engineers, continual qualification and further training as specialised welding firm and fabrication specialist acc. to EN and ASME as well as further specific certifications such as CMC or SAUDIARAMCO.

This highest expansive depth of production renders to a large extent the possibility to carry out extremely effort-conscious testing on their premises with in-house personnel- without forgetting the X-ray lab.

Petrochemicals

PETRO-CHEMICALSWORLDWIDE DELIVERY

Pigtails Tube Bends

Helical Coil System for a Refinery

Finned Tubes Vaporizer for a Refinery

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Power stations, whether based on fossil fuels or regenera- tive, safeguard & ensure the energy supply for our society and economy.

In the case of new constructions however, and also in the case of inspections whereby we always talk about the shortest lead times with the most stringent demands on quality, TUBE-TEC with its expansive depth of production is the preferred partner for operators but also service companies.

With their own tooling & fabrication facilities, completed pressurised components such as economizers, air pre-heaters or super-heaters and even components such as pipe elbows, tube coil or protective shells, half-pipes etc. can be fabricated flexibly & rapidly.

Adaptations to the constructed situation on-site are often carried out by TUBE-TEC engineers with so-called Detail- Engineering. Their specialised sales engineers make absolutely sure that the agreed-upon “Milestones” are adhered to, even in project management, which leads to an exceptionally high degree of delivery for TUBE-TEC.

Maintenance work takes advantage of rapid supplies, thereby minimising downtimes and their related costs involved.

PREFABRICATED COMPONENTS

POWER STATION TECHNOLOGY

1111

Heater Manufacturing

Curved Finned Tubes

Weld-cladded Tube Bends Prefabricated Superheater Bundle

Lateral Bending System

Power Station Technology


Whether in the dairy industry, in processes such as pasteurising, in the brewing industry in the thermal treatment of wort, yeast, mash or in the fruit juice & drinks industry, conservation of juices, fruit concentrates, sugar solutions, tea and soft drinks – tube coil systems from TUBE-TEC find use in more ways than you can imagine.

This is where high quality stainless steels come into their own- they are treated in the so-called “white fabricati-on zone“ at TUBE-TEC, where there is strict separation of

carbon steels and stainless steels. Production takes place under highest quality & hygiene standards.

Often welding seams are ground away as well as complete tube coil systems are electrolytically polished, in order to comply with the stringent demands on surface sterility made by the food industry.

Specialist welding technology processes such as automa-ted TIG Plasma welding as well as orbital processes are

HIGHEST QUALITY STANDARDS

FOODSTUFFS INDUSTRY

Elbows

One-Piece Tube Bends Helical Coil

1313 Foodstuffs Industry

deployed for lowest root protrusion in circumferential welds. The foodstuffs industry demand the highest of quality and TUBE-TEC has accompanied its clients for many years now with high precision welding technology and increasingly more with CNC-controlled tube forming technology with tight tolerances.

• Heating coils for chocolate manufacture

• Coaxial evaporators and curved piping for dairies and breweries

• Steam generators for the sugar industry

• Complicated tube coil systems in stainless steel for edible oils & margarine manufacture

• Tube coils and curves for the coffee industry

• Tube elbows for the tobacco industry


EReady to Install Helical Coil System Heat Exchanger


The chemical industry and its affiliates demand tube coils in practically all imaginable geometries and materials. Deployment possibilities are wide-ranging; taking in applications such as cooling registers, residual gas preheaters for nitric acid plant, Chlorine heaters, condensers or even radiation & convection coils. TUBE-TEC even fabricates so-called ”crystalizers“ for its own clients. Here we are talking about plant systems in which plastics are constantly heated until a fixed mass is formed. This is then further processed into granulate.

Special to this type of tube coil system is the extremely smooth outer surface. Firstly, TUBE-TEC starts with a pre-ground tube and then the coils are electrolytically polished after processing.This particular process paves the way for a mirror-like surface, onto which plastic neither adheres nor clogs.

Here, TUBE-TEC thinks along the lines of the client and his need for improvement in production figures: maintenance stoppages are reduced, thereby increasing production runs.

HIGHEST QUALITY FOR LONGER PRODUCTION RUNS

CHEMICAL PLANT CONSTRUCTION

Ready to Install Helical Coil System Helical Coil Sytem with Ground Spiral

1515 Chemical Plant Construction

• Cooling registers, residual gas pre-heaters for nitric acid plant

• Chlorine heaters

• Condensers

• Pipework systems for urea – reactors

• Polymerisation plant for synthetic fibre manufacture

• Pipework systems for process ovens

• Radiation & convection zones

• Superheater for TiO2 manufacturing


One-Piece Tube Bends

Meander Coil

Heat exchanger


Whether pharmaceutically freeze-dried, the so-called Lyophilization in tube baskets from so-called meander coils or the deployment of cylindrical tube coils in sterilisation chambers – expectations in excessive welding, root sag and quality of finish are enormous.

Quite a few clients require ground or electro-polished surfaces, in order to achieve the desired high surface quality of finish in the fabrication process.

TUBE-TEC makes use of the reliable orbital welding sequence of processes as well as the TIG manual/part- automated process.

Specialised handling as well as the bespoke quality of the stainless steels used by TUBE-TEC is more than met by the separate finishing zone for stainless steels.

• Evaporators for freeze-drying plant

• Tube coil systems for process heating

• Heat-exchangers

• Tube elbows and bends for deployment / plant construction

COMPONENTS FOR HIGHEST STANDARDS

PHARMACEUTICAL INDUSTRY


Ready to Install System

Vaporizer


TUBE-TEC fabrication know-how is to be found behind normal day-to-day applications and products of our daily life. Just one example is the production of Titanium dioxide (TiO2), a predominantly white pigment, that finds its use as foodstuffs additive in toothpaste, chewing gum and cough lozenges.

As to the technical applications of Titanium dioxide which account for about 80% of the total usage, are paints in their many & varied forms, plastics and textiles whereby Titanium dioxide creates optimum surface characteristics.

Cylindrical tube coil systems are required in the manufacture of TiO2 pigments; the coils being made from Nickel-based material, which is one of the best extremely heat-resistant materials on the market.

There are very few materials in this world that can perform this job at such high temperatures. TUBE-TEC with its technical welding expertise has already supplied complete systems with this type of technology, thus proving it has the corresponding project management on an international level.

Applications for our heat exchanger systems in industry are many and varied. In most cases our systems are involved in the generation process heat required in fabrication sequences. These can be economizer packages with collectors and waste heat recovery boilers for production machines in the production of chipboard or even with individual bends according to isometrics in high pressure pipework.

• Waste heat recovery boilers for generating power

• Heaters for process heating

• Heat transfer plant using oil for the paper & timber industry

• Turnkey systems for chemical processes


Thermal Oil Heater

INDUSTRIAL PLANT CONSTRUCTIONCOMPLETE SYSTEMS FOR INDUSTRY

1919 Industrial Plant Construction

Ready to Install Station

20

Heat Transfer Oil Plant

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The greenhouse effect and thereby resulting climate change has initiated an on-going debate about how to reduce the emission of CO2. Energy has to be used through either regeneration, alternative and/or renewable methods.

As from the year 2000, power stations had to be climate- friendly bringing on the so-called Energy Revolution and the necessity for new individual and client-specific special constructions but also new processes.

Even when efficiency and economy cannot keep pace with traditional processes from coal to electricity, subsidies and the tightening of the German Federal Emission Control Act have in fact paved the way for a positive situation for the realisation of new technologies and process sequences.

TUBE-TEC cooperates closely along these lines, in which we collaborate with our clients in industry, especially in the areas of research and process development, developing pressurised components, tube coil systems and vessels – often even with new geometries - from prototypes in a pilot plant until they are ready to go into production.

Whether heat exchange processes for Bio-ethanol manu-facture or Bio-diesel production (fermentation, distillation and condensation) or for evaporators, super-heaters and condensers for solar technology – TUBE-TEC fabrication know-how is part & parcel of many of these technologies.

• Bio-ethanol manufacture (heat exchanger processes for fermentation, distillation and condensation)

• Bio-diesel production (heat exchanger processes for esterification, thermal/mechanical separations)

• Evaporators, super-heaters, condensers and further components for solar technology, geo-thermics and co-generation plant (combined heat & power units)

• In general: heat exchangers in the widest sense

• In general: waste heat recovery / cooling processes / process heat supply / thermal oil heaters


Heat Transfer Oil Plant

RENEWABLE ENERGYNEW PROCESSES FOR MORE ENVIRONMENTAL FRIENDLINESS

2121 Renewable Energy

Heat Transfer Oil Plant System for a Biomass Plant

Helical Coil SystemHelical Coil for Solar Industry

Flat Coils


Ever since its foundation, TUBE-TEC has been a partner to the shipbuilding industry with the likes of supplying reserve boilers flexibly and promptly according to client´s specifications for new construction and even through as far as rapid after-sales business in the case of inspections or time spent in-dock.

Thermic oil heaters and thermal heat transfer plant using oil from TUBE-TEC are ideally suited for all heat-exchange processes in exhaust gas streams in marine propulsion

systems. Here, they have an important function in the preheating of heavy oil towards optimised ignition and highest possible residue-free combustion in the main machines.

Further application possibilities lie in the preparation of process heat for the heating of oil bunkers in tankers, thereby enabling pumping out when off-loading heavy oils. And even the generation of steam or process water in on-board networks is possible.

MARINE / SHIPBUILDING INDUSTRY

OFFSHORE

Helical Coil System

Elbows Helical Coil System

2323 Offshore

Equipped with our many certifications, we are in a positi-on to produce according to a wide range of professional & technical codes such as EN, ASME and even client-specific. The complete boiler is built and certified acc. to constructional regulations of all generally accepted national and international shipbuilding classification authorities.

Specially for the OFFSHORE sector, e.g. for the extraction of crude oil from deep-sea installations, TUBE-TEC supplies tube coil systems, elbows and bends manufactured from

seawater-resistant Duplex & Superduplex steels. These components are designed & built with a service life of up to 25 years fulfil the highest of demands on ovality and surface characteristics.

Ship Heat Recovery Boiler

One-piece Tube Bends Helical Coil System

Headquarter NistertalAdministration / Production

TUBE-TEC Rohrverformungstechnik GmbH

Hirtscheider Straße 13-1557647 NistertalGermany

Tel.: +49 2661 9591-0Fax: +49 2661 9591-950www.tube-tec.de

Bending competence center SainscheidProduction

TUBE-TEC Rohrverformungstechnik GmbH

Siemensstraße 1756457 Westerburg-SainscheidGermanywww.rohrbogen-tt.de

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SOLUTIONS - Tube-Tec · 2019-05-17 · 3 TUBE-TEC Rohrverformungstechnik GmbH is one of the...

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