HAANE welding systems - ENERGY INDUSTRY (english, web)

ENERGY INDUSTRY
FOSSIL | NUCLEAR | WIND | HYDRO | OIL & GAS | ONSHORE & OFFSHORE
ENERGY INDUSTRY
FOSSIL | NUCLEAR | WIND | HYDRO | OIL & GAS | ONSHORE & OFFSHORE
INNOVATIVE & CUSTOMIZED
SOLUTIONS
ENERGY INDUSTRY
FOSSIL | NUCLEAR | WIND | HYDRO | OIL & GAS | ONSHORE & OFFSHORE
6HIGH PRODUCTIVITY SOLUTIONS
22EFFICIENT LONG SEAM WELDING
8CHALLENGING OFF-SHORE PROJECT
24YOU REQUIRE HIGH PRODUCTIVITY?
THEN EACH COMPONENT HAS TO MATCH
PERFECTLY!
12AFTER SALES SERVICE – WORLDWIDE - RELY
ON US!
26CUSTOMIZED PLC WELDING CONTROLLER &
WELD DOCUMENTATION SYSTEM
16A SUCCESSFUL STORY - A PIPELINE FROM
ISRAEL TO BRAZIL
30TURBINE MANUFACTURING
18SOLUTIONS FOR OIL-PLATFORMSTRUCTURE
ELEMENTS AND OFF-SHORE WIND TOWERS
36GOOD ACCESS FOR THE
OPERATOR – GOOD WELDING
50AN INTELLIGENT FLUX FEEDING AND
RECOVERY SYSTEM
38WELD OVERLAY SOLUTIONS
HARD-SURFACING & CRA
52
PRODUCTION LINES
56
PROCESS DEVELOPMENT
58
REFERENCE LIST
42OVERLAY WELDING OF TURBINE SHAFTS
44
PIPE MILL SOLUTIONS
48TWO-STEP PRODUCTION PROCESS:
FORMING AND TACK WELDING
HIGH PRODUCTIVITY SOLUTIONS
HAANE welding systems is a company active in mechanical engineering for the welding
industry with many years of experience, but nevertheless a young and very flexible team
of designers, welding specialists and a professional production workforce.
Our products? Solutions! We handle different kinds of welding processes, special
cutting applications and a very wide range of work piece handling systems.
We not only ensure high deposit rates, but also seek to minimize the non-arc-time
which quite often accounts for more than half of the welding time.
Thanks to our own in-house facilities, 3D-designing (SolidWorks) and manufacturing,
we are able to realize customized solutions very quickly.
Being future-oriented and open to new challenges, we will identify the best way how to
contribute to the success of your projects.
We deliver consultant studies, equipment and turn-key units.
Our assembly, start-up and after-sales crew with a great deal of international
experience operates worldwide. They do their job on land, on water and, if necessary,
even in the air.
This broschure offers you a journey through the exciting industry we work in to discover
our core values and our contribution to the advancement of welding technology.
6
CHALLENGING OFF-SHORE PROJECT
HAANE welding systems also delivered a welding station, suitable for joining two pipes
each 13,500 mm in length, welding inside and outside. The double-pipe of 27,000 mm
length thus created was fed into the fire line of a pipe-laying vessel sinking off-shore
subsea pipelines.
But there was one tricky point: Circular welding of 10” ID pipes was not yet state-ofthe-art technology at this time. However, HAANE welding systems took this job: Finding
a solution including design, manufacturing, testing, installing, start-up and production
supervision within a few months. And we did it with success.
8
CHALLENGING OFF-SHORE PROJECT
Additionally, we also took care of non-arc times, because time is money,
especially valid for jobs on a very expensive vessel.
Some technical features: • Pipe length 13,500 mm each
• Pipe diameter 10” ID
• Circumferential inside and outside welding
• Inside welding with SAW single wire technology
• Outside welding with SAW tandem technology DC/AC
• Welding head positioning speed: 40,000 mm/min
• Laser tracking system
• Equipped with Siemens PLC-System and
HAANE welding controller
• Remote-Service-Facility via satellite
10
AFTER SALES SERVICE – WORLDWIDE
RELY ON US!
12
AFTER SALES SERVICE – WORLDWIDE
RELY ON US!
Of course, there was also a need for assembly, start-up and after sales service on the
vessel. But that was no problem for the highly motivated and experienced HAANE team.
All trainings needed like the Norwegian Offshore Survival Training (OLF), Netherlands
Emergency Response Training (NOGEPA), also Helicopter Underwater Escape Training
(HUET) plus Emergency Breathing System were carried out in order to acquire the
necessary professional off-shore licenses.
14
(image source: Allseas Engineering bv, NL-Delft)
A SUCCESSFUL STORY
A PIPELINE FROM ISRAEL TO BRAZIL
Vessel layers are hurrying from job to job somewhere in the world and it was our
challenging task to install our complete welding equipment ready for use between two
of those jobs during the crossing from Israel to Brazil – and only 4 weeks were left for
this ambitious target…
Finally, everything went according to plan and the job was successfully finished in time.
Certificate HMTS 2009
Certificate
Falck Nutec Rotterdam
Participant place and/or date of birth: 23.05.1968
In recognition of successful completion of the following course of instruction
Basic Offshore Safety Introduction and
Emergency Response Training (NOGEPA 0.5A),
including HUET plus Emergency Breathing
System
Approved by NOGEPA for 48 months
3927592
______________________________
16
Authorised Signature
______________________________
Certificate Number
03.11.2015
______________________________
Falck Nutec Rotterdam 02.11.2011
______________________________
Valid Until
Course Location and Date
BORKEN
Samstag, 24. Dezember 2011
Borkener Zeitung / Nr. 299
1. Lokalseite
BORKEN
HEIDEN
SPORT
Konferenz zur
Schulschließung.
Margret Schweppe-Ebber über das
Diplomatenleben in Rom.
Drei Schwestern
sorgen für Schwung.
5. Lokalseite
8. Lokalseite
12. Lokalseite
Borken
Weihnacht bei Wind und Wellen
Fachleute aus Borken und Umgebung installieren Schweiß-Technik auf 300 Meter langem Schiff
MELDUNGEN
Einbrecher ohne Beute
BORKEN. Ohne Beute
sind Einbrecher geblieben,
die am Donnerstag in ein
Haus an der Königsberger
Straße eingedrungen sind.
Wie die Polizei mitteilt,
hebelten die bislang unbekanten Täter eine Balkontür auf, um in das Haus zu
gelangen. Als die Hausbewohnerin gegen 17.45 Uhr
nach Hause kam, flüchteten die Einbrecher durch
den Garten. Gestohlen
wurde nichts. Hinweise
nimmt die Polizei unter
der Telefonnummer
02861/9000 entgegen.
Mit Kabarett das Jahr beginnen
BORKEN. Die Kabarettistin Frieda Braun ist am
Sonntag, 8. Januar 2012,
zu Gast in Borken. Auf
Einladung der Kolpingsfamilie Borken wird sie ab
17 Uhr im Jugendhaus ihr
Programm „Sammelfieber“
präsentieren, heißt es in
einer Ankündigung. Die
Kabarettistin wurde für ihre hervorragende Mimik
und Sprachwitz mit dem
Dattelner Kleinkunstpreis
ausgezeichnet. Eintrittskarten zum Preis von 10
Euro gibt es bei Ingrid
Kuth unter der Telefonnummer 02861/61687 und
bei Monika Ebbing unter
der Telefonnummer
02861/1037. An der
Abendkasse kosten sie
zwölf Euro.
| www.kolping
-borken.de
Raser tappen in Radarfalle
BORKEN/KREIS. 85 Kilometer pro Stunde bei erlaubtem Tempo 50: Der
Autofahrer, der auf der Raesfelder Straße geblitzt
wurde, hatte deutlich zu
viel auf dem Tacho. Für die
Polizei war das eine der
gravierendsten TempoÜberschreitungen der Vorweihnachtswoche. 12.901
Fahrezuge seien an 38
Messstellen im Kreis geprüft worden, heißt es in
einer Pressemitteilung.
Mehr als sechs Prozent der
Fahrer seien zu schnell
unterwegs gewesen. Acht
Männer und Frauen über-
schritten die zulässige
Höchstgeschwindigkeit
derart, dass sie mit einem
Fahrverbot rechnen müssen. 130 Bußgeldverfahren
wurden eingeleitet. In 685
Fällen wurden vor Ort Verwarnungsgelder fällig beziehungsweise Zahlscheine ausgehändigt. „Überhöhte Geschwindigkeit
und Raserei zählen nach
wie vor zu den Hauptunfallursachen und führen
immer wieder – auch bei
unbeteiligten Verkehrsteilnehmern – zu schweren
Unfallfolgen“, heißt es
vonseiten der Polizei.
Von Markus Schönherr
WESEKE. Während es sich
die Verwandten in der Heimat heute vor dem Weihnachtsbaum gemütlich machen, passieren 15 Männer
aus dem Raum Borken die
Meerenge von Gibraltar. Auf
der einen Seite Europa, auf
der anderen Afrika. Der 300
Meter lange Ozeanriese Solitaire ist bis Ende Januar ihr
Zuhause.
„Eine Weihnachtsfeier haben wir nicht vorbereitet“,
sagt
Ulrich
Kleine-Boes
durch ein knisterndes Satelitentelefon. „Aber es gibt einen kleinen Weihnachtsbaum.“ Kleine-Boes ist Konstruktionsleiter der Firma
Haane Welding Systems. Das
Weseker Unternehmen entwickelt und fertigt Schweißautomaten. Und genau dieses Know-how ist jetzt auf
der Solitaire gefragt. Die
420-köpfige Stamm-Besatzung verlegt Tiefsee-Pipelines. Die Männer des Weseker Unternehmens und ihres
Zulieferers Lanfer Automation
sorgen
mit
ihrer
Schweißtechnik für mehr Effizienz.
Dass Weihnachten auf
Die Solitaire in Aktion. Mit Schweißtechnik aus Weseke verlegt die Besatzung Tiefsee-Pipelines.
dem Schiff eine eher untergeordnete Rolle spielt, liegt
auch an dem engen Schichtplan: Zwölf Stunden wird
immer am Stück gearbeitet.
„Wir
installieren
neue
Schweißköpfe“, erklärt Kleine-Boes den Job der Seeleute auf Zeit. Damit sollen die
zwölf Meter langen Einzelteile des Endlosrohres zusammengefügt werden, das
Heute aktuell:
Konferenz zur Auflösung der Duesberg-Hauptschule.
Umfrage: Was kommt
unter den Weihnachtsbaum?
Redaktion Borken
Peter Berger (pet) Tel. 02861/944-163
Marita Rinke (mr) Tel. 02861/944-164
Markus Schönherr (kus) Tel. 02861/944-168
Fax 02861/944-179, [email protected]
15 Seeleute auf Zeit: Bis Ende Januar sind die Experten in Sachen Schweißtechnik an
Bord der Solitaire.
die Solitaire beim nächsten
Auftrag hinter sich herziehen wird. Das wird in brasilianischen Gewässern der
Fall sein. Im Moment befindet sich die Solitaire auf der
Überfahrt. Die Tage auf dem
Atlantik werden genutzt, um
das Schiff mit der neuer
Technik aus Weseke auszustatten.
Die wenige Freizeit, die
den Männern an Bord bleibt,
wird hauptsächlich zur Entspannung genutzt. „Es gibt
eine Sauna, einen Fitnessraum und Fernseher“, sagt
Kleine-Boes. Nachdem das
Schiff Anfang der Woche auf
Zypern ausgelaufen war,
hatten die waschechten
Landratten noch mit der Gewöhnung an das Schiffsleben und mit der Zeitumstellung zu tun. „Da haben wir
in der Freizeit viel geschlafen“, berichtet Kleine Boes.
Anspruchsvoll ist nicht
nur die Arbeit an Bord.
Fotos: pd
Schon im Vorfeld wurde den
Schweiß-Experten
einiges
abverlangt. Nachdem die
Weseker Firma den Zuschlag
für den Vier-Millionen-Euro-Auftrag bekam, mussten
die Teilnehmer erst mal ein
Sicherheitstraining absolvieren – inklusive eines simulierten
Hubschrauber-Absturzes in einem Wasserbecken.
In punkto Sicherheit sind
die Männer also bestens vorbereitet. Jetzt kann ihnen eigentlich nur noch eins das
Leben schwer machen: der
Trennungsschmerz, speziell
an den Weihnachtstagen.
„Ich arbeite ja viel, da werde
ich kaum Zeit für Heimweh
haben“, sagt Crew-Mitglied
Marc Stemmermann. Und
wenn die Sehnsucht doch
mal zu groß wird, muss das
eigens für diesen Zweck angeschaffte Satellitentelefon
her. Auch, wenn es knistert
in der Leitung.
Anzeige
Thema der Woche
Weihnachtliche Gedanken zum gelben Sack
Auf dem Wunschzettel: Bürgerfreundlichkeit
uch das gehört zu
die Planwirtschaft Einzug in
Zweckentfremdung der gel-
den Stadtrand dackeln muss,
Versammlung der
Vogelschützer
SOLUTIONS FOR OIL-PLATFORMSTRUCTURE
ELEMENTS AND OFF-SHORE WIND TOWERS
18
SOLUTIONS FOR OIL-PLATFORMSTRUCTURE
ELEMENTS AND OFF-SHORE WIND TOWERS
Off-Shore structure elements like monopoles or chords and braces for tri- or
quattro-pods, as well as off-shore wind towers possess mostly large diameters
and/ or high wall thickness solutions having many meters of weld joint length.
Anyhow, HAANE welding systems is able to supply solutions for all this kind of
applications.Huge welding platforms equipped with 2, 3 or 4 welding heads, even
multi-wire, operating at the same time, also tandem-twin solutions, that’s our business.
A high degree of automation, narrow gap solutions,
multi-wire applications - that’s what we handle.
20
EFFICIENT LONG SEAM WELDING
Those of you who have ever assessed the arc-time, the main time of production if
it comes to welding, might have been disappointed recognizing the low duty cycle
percentage whilst long seam production.
The non-arc-time is one of the essential figures in this game.
Many efforts are made to increase the deposit rate,
but this means only trying to be more efficient during
the 25 % of arc time.
But the non-arc-time is killing your profit,
accounting for about 75 %.
In this context, it is difficult to understand why
the non-arc-time is usually not in the focus of the
welding equipment suppliers.
HAANE welding equipment takes care of this, e.g. by
installing automatic wire cutters.
We kill your non-profit non-arc-time,
whenever possible.
22
YOU REQUIRE HIGH PRODUCTIVITY? THEN EACH
COMPONENT HAS TO MATCH PERFECTLY!
In order to achieve the highest possible increase in efficiency and productivity, a perfect
combination of all components is a must in the manufacturing system:
• High deposit welding process
• Low joint volume concept
• Disturbance-free wire feeding system and bulk wire spools
• Never ending flux supply system, also able to provide pre-heated
flux at the welding torch
• A flexible workpiece positioning unit
• A quick and rigid weld head positioning unit
incl. tracking system
24
CUSTOMIZED PLC WELDING CONTROLLER &
WELD DOCUMENTATION SYSTEM
Having an excellent MMI (Man Mashine Interface) is one of the challenges of today.
Being informed about the actual status of all welding system components involved,
ensures you to recognize upcoming problems at a very early stage.
Thus you will be able to react in time and to avoid possible damages to your workpiece
and/or to your machine.
Therefore, Haane welding systems provides solutions based on Siemens S7 technology.
26
CUSTOMIZED PLC WELDING CONTROLLER &
WELD DOCUMENTATION SYSTEM
Product quality, product safety and product
liability are good arguments for installing a
weld data documentation system. It is possible
to get a separate documentation sheet for
each workpiece which makes this system
an important part of a higher-level quality
management system.
28
TURBINE MANUFACTURING
30
TURBINE MANUFACTURING
Manufacturing gas or steam turbines requires a high level of
interdisciplinary know-how.
(image source: Siemens AG, Berlin)
To save valuable resources and lower the CO2 emission any increase
of turbine efficiency is of great importance. That’s why new steel alloys
for the forged rotor and the casted housing are developed in order
to achieve process temperatures of up to 600° C providing a higher
efficiency. Welding this kind of heat and creep resistance steels is a
very huge challenge.
32
TURBINE MANUFACTURING
For welding and handling such heavy
workpieces HAANE welding systems
delivers equipment at top quality level,
e.g. a turn- and tilting positioner cradle
type for workpieces with a weight of up
to 200t securing highest accuracy and
minimized distortion, or SAW tandem
twin technology.
34
(image source: Siemens AG, Berlin)
(image source: Siemens AG, Berlin)
GOOD ACCESS FOR THE OPERATOR –
GOOD WELDING
Usually, the welding head is mounted on the same boom as the operator seat. But then
operator’s access to the weld is quite poor, because the welding happens under his feet.
Good access to the weld means a good control of the weld and this means good chances
for a good weld result. HAANE welding systems offers operator seats mounted on a
second, independent and separately adjustable boom. Thus the operator is able to
define his best possible access to the weld without influencing the weld head position.
The result: Excellent quality.
HAANE welding systems also integrates workpiece
heating facilities, e.g. gas heaters, inductive or
resistance heaters.
36
WELD OVERLAY
SOLUTIONS/HARD-SURFACING & CRA
38
WELD OVERLAY
SOLUTIONS/HARD-SURFACING & CRA
There are many reasons for doing a weld overlay on work pieces.
It can be hard-surfacing against abrasion or cavitation performed by using wearresistant manganese steel or cobalt –based consumables (e.g. stellite); it can also be
CRA (corrosion resistant alloys) in order to protect your construction against chemical
attack eg. by CrNi (stainless steel) – or Ni-alloyed overlays (e.g. Inconel).
HAANE welding system delivers welding and handling equipment for almost
all of these applications.
Welding procedures supplied by us:
SAW, TIG (GTAW) hot wire cladding, MIG/MAG
(GMAW), Open Arc welding, SAW cladding,
ES-Cladding (strip cladding), PTA (Plasma
Transferred Arc) thermat spray cladding.
And of course we are always open for
implementing new procedures!
40
OVERLAY WELDING OF TURBINE SHAFTS
One special application is the weld overlaying of turbine shafts for
gas and steam turbines.
On the one hand the rotor itself needs the best possible heat-resistant steel grade and,
on the other hand, the bearing areas need a different chemical composition.
A weld overlay in the bearing area is therefore the best solution to meet
both requirements.
HAANE welding systems has developed a weld overlay system setting the welding
torch to the right position fully automatically during the welding process. The current
weld height and temperature are controlled by the PLC welding controller, and also the
preheating unit and the PWHT system are integrated here.
42
PIPE MILL SOLUTIONS
“We don’t do things by halves“ – Which means we provide turnkey
solutions for helical on-/ offline pipe mills and for longitudinal pipe mills.
This includes:
• Pipe forming, preparation and welding
• Pipe handling
• Pipe testing
Our customers produce pipes in conformity with the API (American
Petroleum Industry) standards for oil, gas and water transmission for
the on-shore and off-shore sector. Many innovations for the welding
technology bear our signature, e.g. an adjustable flux temperature,
an optimal wire transport and wire straightening. All these special
applications reflect our high production quality and stability.
Whether you wish to build a new pipe mill or modernize an existing one,
we are the dependable partner for you.
44
PIPE MILL - DETAILS
For SAW multi-wire welding with inside and outside welding heads detailed solutions
are available which allow high deposition rates.
Also for small pipe diameters there exists a 14” solution with a 90° straightener and
contact jaws having a lifetime of up to one week in a 3-shift operation, successfully
implemented by the engineering experience in this field.
As so often, it is the small details which are the key to success.
Therefore, together with our customers, we have developed solutions round the
handling of the welding head approved for applications under great operation stress.
Optionally using an intelligent cassette system, any adjustment of the torches is
coupled with a safe flux provision of flux to every wire.
Furthermore, the user-friendly equipment greatly reduces maintenance time.
46
TWO-STEP PRODUCTION PROCESS:
FORMING AND TACK WELDING
The tack welding head is a success story:
• Welding speed in ongoing operations of 10m/min up to 15 m/min
• Minimum pipe diameter
› 14”
Due to a specially designed wire-feed system in
combination with a „proven-in-use” gas protection the
weld spatters are considerably reduced and less stops
will be necessary for cleaning during operation especially
in a flying cross joint machine.
Besides, all these systems are completed by a laser
tracking system inside or outside for an automatic
welding head guidance.
48
AN INTELLIGENT FLUX FEEDING AND
RECOVERY SYSTEM
The flux recycling admixing rate has to be controlled and complied with the
requirements of the API and oil company regulations.
For this purpose, HAANE welding systems has developed a flux
recovery system which fulfills these requirements. Some of the
special features are: • Due to a controlled temperature level of › 100 °C the flux is
safe during operation
• Providing pre-heated and insulated tanks
• Including heated flux funnels
The systems are typically equipped with magnet separators. The
design follows a soft and smooth flux transport which reduces the
stress for the components and also for the flux itself.
We only use first class components for the operation stations from
carefully selected and well-known suppliers, e.g. FESTO, SIEMENS,
who ensure fast and future availability by high value stability.
50
PRODUCTION LINES
52
PRODUCTION LINES
HAANE welding systems is able to supply design
studies for nearly planned or reorganized production
lines and factory layouts.
Therefore, it will always be an advantage to take
a look beyond the basics of existing stand-alone
solutions, even and especially if they have existed for
a long time.
Many argue - „Never change a running system“.
But fact is that productivity is the fuel of our
technical progress.
So don‘t be too late!
54
PROCESS DEVELOPMENT
If you want to optimize a process of your production apart from the mainstream,
but in any event you want to keep it confidential: Please contact us.
We are the right partner to help you face your individual challenges.
We are competent and discreet, and we know how to handle
a confidentiality agreement.
We can help you to optimize everything around your production process.
If you need a specific solution, let us know – our experts will find it!
56
REFERENCE LIST
We proudly present some of our renowned customers:
• Aker Solutions AS, Norway
• Jindal SAW Ltd., India
• Allseas Engineering bv, The Netherlands
• OSX Construção Naval S.A., Brazil
• Arcelor Projects Spiral Mill Bv, The Netherlands
• PSL Ltd., India
• Berg Steel Pipe Corporation, USA
• PSL North America, USA
• Bharat Heavy Electricals Ltd., India
• Salzgitter Mannesmann Großrohr GmbH, Germany
• Böhler Schweißtechnik Deutschland GmbH,
Germany
• Maschinenbau Scholz GmbH & Co. KG, Germany
• Caterpillar Global Mining HMS GmbH, Germany
• Corinth Pipeworks s.A., Greece
• Essar - Hazira Pipe Mill Limited, India
• Europipe GmbH, Germany
• Federal Institute for Materials Research and
Testing, Germany
• FST Industrie GmbH, Germany
58
• Siemens AG, Germany
• Sempell AG, Germany
• SIF Group b.v., The Netherlands
• Sulzer Metco AG, Switzerland
• Ümran, Turkey
• VandeGrijp Bv, The Netherlands
• Welspun Gujarat Steel Pipe Ltd., India
INNOVATIVE & CUSTOMIZED
SOLUTIONS
IMPRINT
ENERGY INDUSTRY
printed 2013 in Germany
information booklet | english edition
All trademarks and registered trademarks belong
to their respective owners. Reproduction only
with explicit permission.
HAANE welding systems GmbH & Co. KG
Subject to technical modifications and other changes.
HAANE welding systems GmbH & Co. KG
Kotten Büsken 37
D-46325 Borken-Weseke
Germany
[P]
[F]
+49 (0) 28 62 / 58 98-0
+49 (0) 28 62 / 58 98-164
[E][email protected]
[I]www.haane.de