Siemens Subsea Products Adopts All-Electric Tube Bending

Press Release
Tuesday, January 22, 2013

Siemens Subsea Products has chosen an all-electric tube bender from Unison to improve the quality and speed the production of the small-bore hydraulic tubes it uses on subsea hydraulic flying leads with Multiple Quick Connections (MQC), Cobra Heads and associated offshore oil and gas recovery equipment.

 

The tubes feature complex bends of extremely high accuracy, and until now the company has either fabricated them manually or bought them in as pre-formed sub-assemblies.



Siemens Subsea Products produces a wide range of subsea electric, fiber optic and hydraulic power and control systems for offshore oil and gas subsea applications. Its hydraulic workshop at Kongsberg in Norway operates world-class fabrication and assembly processes, producing systems for direct sales and third-party suppliers. As part of its strategy to expand manufacturing capabilities in this specialist field, the company recently reviewed tube bending automation, starting by comparing the performance of a number of leading hydraulic and all-electric tube bending machines.



According to Terje Barth Andersen, Technical Advisor for Subsea Products in Siemens, “It was quickly apparent that electric tube benders offer a number of advantages over hydraulic machines; including more accurate and repeatable results, lower energy consumption and lower noise. In the all-electric sector, Unison’s machines stand out from the competition because they allow much faster tool changeover – which is important for us because we produce many of our tubes in very small batch sizes. Another key factor behind our choice was Unison’s willingness to develop a machine configuration specifically for our needs.”
 


The tube bender supplied to Siemens Subsea is a 25 mm model based on Unison’s popular Breeze platform of all-electric machines, and incorporates a ‘rise and fall’ pressure die which enables it to perform right- and left-handed bending; this increases manufacturing flexibility and throughput by allowing long and complex parts to be produced from a single length of tubing in one continuous cycle. Installed at Siemens’ Kongsberg facility at the end of last year, the machine is currently undergoing commissioning and due to commence operation during January 2013.



The subsea equipment produced by Siemens Subsea is designed for long term deployment – many of the systems have a design life of 30 years and are intended for operation at depths up to and beyond 3,000 meters. As a consequence, the tubes used within the equipment that convey hydraulic fluid for power and control purposes are subject to extremely high internal and external pressures and need to be manufactured to exceptionally high standards. A key requirement is to minimize stressing of the tubes at their bend points – which could lead to in-service failure – by avoiding use of small bend radii. Whereas many conventional tube bending machines are incapable of handling large bend radii, the Unison machine supplied to Siemens features ‘full stroke’ programmable positioning of the pressure dies and clamps, enabling it to create bends with a CLR (centre-line radius) up to five times the diameter of the tube, with fully automatic set up.



All critical movement axes on the Unison tube bender are controlled by precision servomotors, enabling fast and repeatable fabrication of parts with accuracies to within fractions of a millimeter. The machine is also capable of generating the high torque needed for bending tubes fabricated from exotic alloys such as Inconel, Duplex and Super Duplex, which are used extensively for subsea applications to improve corrosion resistance.



Siemens Subsea’s first project involving the Unison machine will be the South Belut Project production of 800 tubes, all made from 316 and requiring complex bends and orbital welding in both ends, for use on umbilical termination units known as MQCs. These are used on various subsea structures, including Christmas trees, and Siemens’ versions can accommodate up to 13 hydraulic lines, demanding extremely tight manufacturing tolerances. Each tube is designed on a Inventor 3D CAD system, and the company generally then produces a prototype to verify its accuracy and feed any necessary corrections back into the production process to ensure the quality of subsequent parts. Automating the tube bending process is set to accelerate this procedure – the CAD system and bending machine are linked by a production computer network – and will help Siemens Subsea Products maintain the fully traceable manufacturing records needed for this industry.
 


Terje Barth Andersen points out that the accuracy and throughput capabilities of Unison’s tube bender offer major economic benefits to companies working with expensive materials. “We calculate that the machine will pay for itself in less than two years, based solely on the number of tubes that we can now process in-house instead of purchasing as ready-made parts. Furthermore, the machine’s automated set-up capabilities and control software flexibility will help us significantly reduce scrap material by ‘right first time’ manufacturing. We also envisage selling excess tube bending capacity to the market, making this an even more cost-effective investment.”



Steve Haddrell of Unison adds, “This order from Siemens Subsea Products demonstrates a growing awareness of the benefits of all-electric tube bending. The traditional market for high-performance machines of this type is in the aerospace industry, where precision bending of exotic alloy materials is a common requirement. But companies serving the offshore oil and gas industries also face similar demands, as their products are used in ever more hostile environments.”

 

Maritime Reporter May 2015 Digital Edition
FREE Maritime Reporter Subscription
Latest Maritime News    rss feeds

Technology

Torqeedo Introduces New Deep Blue Inboard

Torqeedo now offers a shaft drive version of its 40 and 80 horsepower Deep Blue motor. An electric drive designed for marine use from the ground up, the Deep Blue inboard shares the safety,

Protea to Launch Heavy-Lift Cranes at Nor-Shipping

Protea, a global manufacturer of offshore handling equipment, will launch two types of heavy lift cranes at Nor-Shipping 2015 in Oslo, June 2-5. Tomasz Paszkiewicz,

Inmarsat 3rd Global Xpress Satellite's Launch Delayed

Inmarsat has provided an initial update on the launch schedule for Inmarsat-5 F3 (I-5 F3) following the failure of the preceding Proton Breeze M launch from

New Products

DMW Marine Takes the Lead in Military Cranes

DMW Marine Group, LLC. has completed a number of projects for the U.S. Navy and foreign Navies in recent years, claiming a place as a go-to supplier for Navy departments globally.

Torqeedo Introduces New Deep Blue Inboard

Torqeedo now offers a shaft drive version of its 40 and 80 horsepower Deep Blue motor. An electric drive designed for marine use from the ground up, the Deep Blue inboard shares the safety,

Protea to Launch Heavy-Lift Cranes at Nor-Shipping

Protea, a global manufacturer of offshore handling equipment, will launch two types of heavy lift cranes at Nor-Shipping 2015 in Oslo, June 2-5. Tomasz Paszkiewicz,

Offshore

US Oil Platform on Fire in Gulf Of Mexico

An oil platform caught fire and was evacuated in the U.S. Gulf of Mexico offshore Louisiana in the early hours of Friday, though no injuries were reported, the U.

IMO Adopts Polar Code Environmental Provisions

United Nations' International Maritime Organization (IMO) has adopted the environmental part of the Polar Code. Hereby, internationally binding regulations on

Two Hurt in Petrobras Platform Accident; Output Halted

Brazil's state-led oil company Petrobras was forced to stop output at its P-56 offshore oil production ship on Wednesday in the Marlim Sul field after an explosion

Environmental

US Funding for Air Emissions/Alternative Energy Projects

The U.S. Maritime Administration (MARAD) announced that up to $1.3 million in Federal funding is now available through cooperative agreements for projects supporting

Torqeedo Introduces New Deep Blue Inboard

Torqeedo now offers a shaft drive version of its 40 and 80 horsepower Deep Blue motor. An electric drive designed for marine use from the ground up, the Deep Blue inboard shares the safety,

SoCal Beach Cleanup Could Take Months

The U.S. Coast Guard captain overseeing cleanup of oil spilled from a pipeline rupture that closed two California state beaches and fouled offshore waters near

Marine Equipment

DMW Marine Takes the Lead in Military Cranes

DMW Marine Group, LLC. has completed a number of projects for the U.S. Navy and foreign Navies in recent years, claiming a place as a go-to supplier for Navy departments globally.

Protea to Launch Heavy-Lift Cranes at Nor-Shipping

Protea, a global manufacturer of offshore handling equipment, will launch two types of heavy lift cranes at Nor-Shipping 2015 in Oslo, June 2-5. Tomasz Paszkiewicz,

Long Beach Port to Set-up Peak Relief Chassis Fleet

The Port of Long Beach will seek bids on the creation of a new fleet of truck chassis for peak periods of the year, complementing the existing equipment used

Offshore Energy

US Oil Platform on Fire in Gulf Of Mexico

An oil platform caught fire and was evacuated in the U.S. Gulf of Mexico offshore Louisiana in the early hours of Friday, though no injuries were reported, the U.

Protea to Launch Heavy-Lift Cranes at Nor-Shipping

Protea, a global manufacturer of offshore handling equipment, will launch two types of heavy lift cranes at Nor-Shipping 2015 in Oslo, June 2-5. Tomasz Paszkiewicz,

Two Hurt in Petrobras Platform Accident; Output Halted

Brazil's state-led oil company Petrobras was forced to stop output at its P-56 offshore oil production ship on Wednesday in the Marlim Sul field after an explosion

 
 
Maritime Careers / Shipboard Positions Maritime Security Maritime Standards Navigation Offshore Oil Pod Propulsion Salvage Ship Electronics Ship Repair Ship Simulators
rss | archive | history | articles | privacy | contributors | top maritime news | about us | copyright | maritime magazines
maritime security news | shipbuilding news | maritime industry | shipping news | maritime reporting | workboats news | ship design | maritime business

Time taken: 0.2117 sec (5 req/sec)