INDUSTRIAL BOILERSWELDING AND PRODUCTION AUTOMATION SOLUTIONS FOR

WELDING AND PRODUCTION AUTOMATION FOR

BOILER MANUFACTURING

Several decades’ experience in the highly advanced sector has made Pemamek the leading provider of automated welding systems for boiler industry. Customer-oriented solutions, reliable equipment, modern processes and constant development of PEMA products have been the key factors to global success.

When manufacturing critical components, there is simply no room for compromising in quality. Thus, quality needs to be built right into the production process. In PEMA production lines, solid and precise quality comes as standard.

MORE PRODUCTIVITYFUTURE COMPETITIVENESSFAST RETURN ON INVESTMENT

The efficiency of PEMA machines has been proven in continuous three-shift production. The panel production line capacity is difficult to achieve by manual welding, and thus we have focused on both high availability rate and reliability of complete systems.

TUBE AND COIL PROCESSING

We know that in tube, panel and coil production quality and capacity are extremely important. Pemamek is committed to provide you the right solutions to raise competitiveness and achieve business goals.

WHEN CAPACITY AND QUALITY GO HAND IN HAND

PEMA SOLUTIONS FOR EACH STAGE OF MANUFACTURING PROCESS

FIN-BAR PROCESSING PANEL PRODUCTION – A CRITICAL PROCESS

PEMA tube line product range includes all sub-process machinery you need from raw material storage to finishedlong straight tube for coil shop or panel production.

The straightness and accuracy of calibrated fin bar can be achieved with PEMA fin bar calibrating line.

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THE ADVANCED SAW PANEL WELDING PROCESSFlexible Lincoln PowerWave system brings several possibilities to optimize the welding process. When the process is combined with efficient material handling and control systems, together they will help you to meet the ever-growing demands.

Thanks to our expertise and know-how, each solution is designed by listening customer’s needs. Solutions, such as bending systems can also be provided when needed.

Tube shot blasting with steel grit is a prerequisite for high-quality SAW welding. It reduces welding defects and the need for manual repairs after panel welding.

The tube end beveling unit includes specific tools designed for each groove type. End buffing unit integrated into the end beveling line.

Tube lenght measuring and cutting saw is integrated to PEMA tube line.

Tube to tube welding with hot wire TIG and seam grinding after the welding process is integrated into PEMA line. Seam grinding is required for panel welding.

The PEMA heavy-duty fin-bar calibrating machine is designed for constant production and best possible quality in panel welding.

The complete PEMA delivery will ensure productivity, quality and good geometrical tolerance of the finished panel.

ALL PROCESSES FROM ONE SUPPLIER• Production plant layout design• Production flow and capacity studies• Welding process support services

TUBE PROCESSING• Blasting for material cleaning• Cutting to length• Tube end beveling and buffing• Tube to tube welding • NDT integrated into tube lines• Integration into tube bending

systems

FIN-BAR PROCESSING• Uncoiling and cleaning • Straightening and

calibrating

• Cutting to length

PANEL PRODUCTION• Tube and fin-bar feeding• Material handling• Panel welding with

stationary machines• Panel bending systems

Pemamek is experienced in all major processes of panel and tube production. The earlier you involve us in your project, the more you can benefit from your investment.

SOLUTIONS FOR THE ENTIRE PRODUCTION CHAIN

6. PANEL WELDING1. TUBE SHOT BLASTING 2. TUBE END BEVELING AND END BUFFING

3. CUTTING TO LENGTH

4. TUBE TO TUBE WELDING AND SEAM GRINDING

5. FIN BAR CALIBRATING

PEMA SOLUTIONS FOR MANUFACTURING PROCESS

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INDUSTRIAL BOILERSMORE PRODUCTIVITY WITH PEMA TUBE SHOP

PRECISE CUSTOMIZATION OF LINE ACCORDING TO THE AVAILABLE SPACE

• Tube shot blasting • Tube cutting and measuring• Tube end beveling • Tube end buffing• Tube to tube welding machine with grinding• Tube inspection• Storage systems• Conveyor line and control system• Tube bending machine with integration to coil line

Pemamek has a wide product range availbale for tube shops. Complete lines are highly automated and can even be controlled by one operator. The combination of efficient cells and fully integrated conveyor systems creates an ultimate productivity with a solid and constant quality. Modern welding techniques include conventional TIG as well as multi-hotwire TIG and plasma hybrid processes. Efficient storage and material handling solutions are a prerequisite for coiled production systems. One line can be equipped with several welding stations depending on the required capacity.

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INDUSTRIAL BOILERS

PRODUCTIVE TUBE SHOP

A productive tube shop demands a high degree of automation. With PEMA's tube shop, one operator is capable of handling the whole system in one shift.

Capacity can be defined according to the customer’s needs. Preset parameters ensure a reliable process without the possibility of human errors during the welding and cutting process. Repeatable functions without interruptions guarantee solid and reliable quality of the tubes.

Double welding machine panel lines and coil shops require efficient tube lines. Typically, raw tubes are a maximum of 12 meters long and can be extended up to 30 meters by tube panels or over 100 meters with coil welding. This means several joints to the tube and often a 100% inspection rate.

The tube line can be fully integrated with blasting, grinding, cutting, measuring, beveling and buffing processes. Defect-free welding combined with a high inspection rate demands reliable processes and system control.

All PEMA tube line machines are designed to meet these requirements without any compromises. The joint preparation is carried out with special tools, designed specifically for certain types of joint. Welding is performed with a hot wire TIG, enabling high deposit rates. The welding control system has a wide range of parameters which can be adjusted to achieve the best possible result. One welding lap can be divided into several smaller sectors to fine-tune the parameters for even the most challenging materials.

The x-ray system can be fully integrated to the tube line. The automatic selection of tubes, depending on the inspection results or production requirements, can be included in the system.

TUBE TO TUBE WELDINGTube to tube welding station with hot wire TIG process ensures high quality and good deposition rate.

TUBE END BEVELLING AND BUFFINGWith PEMA tube processing lines you will get consistent quality and reliable capacity.

PEMA TUBE PROCESSING LINE PEMA tube processing line with integrated tube conveyors.

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INDUSTRIAL BOILERSPANEL PRODUCTION

PEMA stationary panel welding line with one panel welding machine is usually designed for small or medium-scale batch production and can have 2-6 SAW power sources. The typical panel width is up to 2000 mm.

TOOLS FOR SERVICE BUSINESSCompact PEMA lines are a perfect choise for a smaller batch size production, with the same reliable PEMA technology and controls as in mass production lines.

VARIABLE LAYOUTS - SCALABLE CAPACITYModular PEMA panel production line can be build according to fabricators capacity needs by picking up certain elements from the complete system. Line can be upgraded in case the production capacity needs to be raised. A production line can also be designed to be extended from one to two machine lines, if required later on. The same can be done with welding heads; e.g. 4 heads can be extended to 6 heads.

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INDUSTRIAL BOILERS

PANEL PRODUCTION

An efficient control system makes it possible to use minimal production staff when batch sizes are small. Custom-made design enables enlargement of equipment from service station to mass production. The number of welding heads can be increased for more capacity.

PEMA flexible panel production makes it possible to have a first-step investment to meet various production expansion needs.

COMPACT PANEL WELDING LINEFlexible production line in repair business with two SAW welding heads. Production can be started by one operator.

EASE OF USE AND ERGONOMICSThe heart of the line is equipped with the most advanced SAW welding technology enabling top quality for membrane wall panels.

If you require various sizes of tubes and fins with varying production batches, we can offer flexible panel lines. The fast changeover time for tools makes the line flexible for different tube and fin bar sizes.

PANEL WELDINGA panel welding line with a possibility of extending to two welding lines to double your production.

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PANEL PRODUCTION LINES - TWO MAIN TYPESHigh capacity production lines with two welding machines are integrated with tube and finbar prefabrication systems. In high capacity production machines there are typically six Lincoln PowerWave power sources for SAW welding. SAW is a user-friendly process with no spatter, fumes or arc reflection and PEMA WeldControl 100 system with various options for production and quality data collection.

PEMA stationary panel welding lines are designed with solid quality for high a capacity production.

PANEL PRODUCTION LINES

PANEL WELDING LINE• Integrated tube and fin bar in-feed system

• Two stationary panel welding machines

• Roller conveyors

• Flip-over system

• Cross transport conveyors

• Buffer storage for sub-panels

• Inspection table

FIN-BAR PREFABRICATION LINE• Fin-bar uncoiler

• Fin-bar cleaning with blasting

• Fin-bar straightening

• Fin-bar calibration

• Fin-bar cutting to length

• In-feed system to panel welding line

TUBE PREFABRICATION LINE• Tube cleaning with shot blasting

• Tube end beveling

• Tube end buffing

• Tube-to-tube welding machine with weld bead grinding

• Tube cutting to length

• Tube inspection

• Tube Conveyor line and control system

INDUSTRIAL BOILERSHIGH CAPACITY

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INDUSTRIAL BOILERS

The panel welding line with two welding machines and an integrated tube and fin bar prefabrication systems is a complete package for high-productivity requirements. Efficient automated tools for combining tubes and fin bars to sub-panel beside the welding line, while the previous sub-panel is welded, ensures a high arc on time. Additional feed back conveyors and buffer storages for sub-panels minimize the crane operations.

The line can be utilized with all necessary components for water tube wall panel production from raw material handling to ready-welded panels. Standard panel widths are 2000 and 3000 mm. The length of the modular panel line is set according to the customer needs, typically in range of 12 m -30 m.

EFFICIENT PANEL PRODUCTIONPEMA mass production line with an additional conveyor track.

The PEMA panel welding line with two stationary panel welding machines are designed for mass production of water tube panels. The modular design of the line means that it can be built according to panel width and length requirements. A line with a double stationary welding machine system produces up to over 3000 meters of weld in one shift.

HIGH CAPACITY PANEL LINEPEMA panel welding line with two stationary welding machines.

PANEL PRODUCTIONHIGH CAPACITY

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INDUSTRIAL BOILERSMORE PRODUCTIVITY. FUTURE COMPETITIVENESS.

IN-HOUSE INTELLIGENCETake your production into the modern age by acquiring innovative welding processes and increasing the level of technology. All automated PEMA solutions are designed by Pemamek’s trained professionals and use advanced PEMA WeldControl management systems.

MATERIAL HANDLINGPowerful and stable material handling is the key to efficient manufacturing. Integrate automated PEMA handling equipment solution into a larger production line or use them in perfect synchrony with automated PEMA welding solutions.

USER FRIENDLINESS

PRODUCTIVITY

TURNKEYSOLUTION

QUALITY

FROM PRE-DESIGN TO LIFE-CYCLE MANAGEMENTAt Pemamek, our key philosophy is to provide carefree investments for our customers. That is why each PEMA solution can be delivered as a turnkey including everything from pre-design to life-cycle management.

WORLD-CLASS WELDING AUTOMATIONReliable and high performance machinery has direct positive effects on weld quality. Pemamek has extended its expertise to quality adding solutions, such as integrated edge preparation, in order to supply extensive world leading welding automation for its customers.

PROCESS & PRODUCTION SUPPORT SERVICESThanks to our strong experience in the industry, we are able to help you to choose the most suitable welding process according to your production requirements. Our main goal is always to maximize your productivity as well as ensure fast ramp-up period at all times.

QUALITY MANAGEMENTConsistent quality is an integral portion of providing the best end-product to your customers. We have developed PEMA WeldControl management system which, in addition to production monitoring and process control, provides valuable information from the weld work. PEMA WeldControl provides analytical details about the quality, such as weld specific stream power and average values of the process.

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LET'S MAKE MORE – TOGETHERINDUSTRIAL BOILERS

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Caldema, Brazil

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We had a very positive experience in dealing with Pemamek. Pemamek provided quick responses throughout the project.

PEMA is the most qualified and technically advanced solution for our purposes. This has been proven to be true in practice.

Welding automation is the only solution for a successful boiler production.

Mr. KleinCEO

Meeraner Dampfkesselbau GmbHMitsubishi Hitachi Power System Europe,Germany

Babcock & Wilcox, Mexico

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Your industry, PEMA's solution.

WWW.PEMAMEK.COM

Pemamek is a global leader in welding and production automation. Specialized in designing and manufacturing automated welding and production systems, as well as work-piece handling equipment, our competence has been recognized worldwide.

• SHIPBUILDING• INDUSTRIAL BOILERS

• WIND ENERGY• HEAVY FABRICATION

• OIL&GAS AND PROCESS

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experience

50Countries with

PEMA deliveries

15,000Number of

customer solutions

Stand out from competitors with

PEMA SOLUTIONS

PEMA Headquarters in Loimaa, Finland

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