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

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

Production capacity required by the shipyard: 3 panels per day (24 hours)

Type of machine:         production line for panel, Shipbuilding and Offshore – Panel Fabrication Line
Make:                             Pema
Type:                              Pemamek
Year of Manufacture: 2010 (never used, still packet)
Location:                       Brazil
Country of origin:        Finland
Delivery time:              To be agreed upon
Freight basis:               Ex Location
Price:                              US$ As request
Payment:                       Before Delivery

** Included: Layouts, Spare parts, Complete Technical Specifications

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

 

1 – PEMA OSW-M 18000/2 one-side welding station (with in- and out-feeding conveyors)

2 – PEMA OSW-M 18000/2 One side welding station

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

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

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 production line for panel
–  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

3 – PEMA Flip-over arms for panel turning

4 – PEMA PBW-18000/2 Plate butt welding portal

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

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 10×12 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

5 – Cutting and marking station

6 – PEMA SMP-18000/2-600 stiffener mounting and tack welding

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 production line for panel

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

6.1 – 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)

7 – PEMA SWP 18000/6 stiffener welding station

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

8 – Floor & transportation equipment

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

9 – PEMA WMP-18000/2 web mounting portal

10 – PEMA SP-18000/8 Service Gantry

Transportation trains, Load-out station, Ultrasonic testing equipment

Capacity calculations
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

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
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 max 710 mm for 2

profiles

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 max 710 mm for 2

profiles

WEBS Min. mm Max.
Height 500 mm 4.000 mm
Length 3.000 mm 18.000 mm
Weight 10.000 kg
Distance 1000 mm

 

PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
PEMA Flat and double bottom production line for panel (16) PEMA Flat and double bottom production line for panel (16)
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