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 October 2014 Digital Edition
FREE Maritime Reporter Subscription
Latest Maritime News    rss feeds

Technology

Woodside to Pick up Moroccan Acreage

Woodside advises that it has entered into a contract for an exclusive Reconnaissance Licence (RL) with the Office National des Hydrocarbures et des Mines, the

Zargon Oil & Gas Sells Hamilton Lake Assets

Zargon Oil & Gas Ltd. announces that it has entered into a definitive purchase and sale agreement to sell its Hamilton Lake property for $25 million. Property

Strategy Can Maximize UKCS potential

Companies operating in the North Sea require a cultural shift to make the most of the its potential, according to a new report from Deloitte, the business advisory firm.

New Products

Dometic to Debut New Product Line at Workboat

New products on display will include the Dometic Cup Cooler, the Smart Touch Integrated Intelligence Control system and the Dometic Sea Xchange watermakers; attendees

New Training for Man Overboard Response

Falling overboard is a life-threatening emergency, not only for the person in question but also for those involved in their rescue. Every step in the rescue process

Terex Scoops 2 IBJ Awards

Terex® Quaymate M50 mobile harbour crane is Crane of the Year – Dr. Mathias Dobner honored Rotterdam/Düsseldorf, 24 November 2014 – Terex Port Solutions (TPS)

Offshore

Woodside to Pick up Moroccan Acreage

Woodside advises that it has entered into a contract for an exclusive Reconnaissance Licence (RL) with the Office National des Hydrocarbures et des Mines, the

Strategy Can Maximize UKCS potential

Companies operating in the North Sea require a cultural shift to make the most of the its potential, according to a new report from Deloitte, the business advisory firm.

Pile Testing for Wikinger Wind Farm Launched

In October 2014 the first phase of the pile testing campaign for the Wikinger offshore wind farm project was launched after the site’s geotechnical investigation on the Baltic Sea had been completed.

Environmental

What’s All the Noise at IMO?

Shipping may think they hear the sound of new regulations as they are slammed onto their desks.  What is all the noise concerning noise at IMO?  This may very well be the question from ship owners,

Will Congress Pass Any Maritime Legislation in 2014?

Following its usual summer break over August 2014, Congress came back from its five-week summer recess and spent a whopping eight days or so back in session before recessing once again,

ICS Addresses OECD Shipbuilding Working Party

The OECD should be cautious about becoming involved in the question of what constitutes an ‘eco-ship’, the International Chamber of Shipping (ICS) said to governments

Marine Equipment

Rolls-Royce Wins US Marine Corps Contract

Rolls-Royce has been awarded a new, two-year contract to provide aftermarket engine support for the US Marine Corps and Air Force V-22 fleets, which provides

MacGregor's Deck Equipment For Chinese Shipyard

MacGregor, part of Cargotec, has secured a comprehensive deck equipment contract from New Times Shipyard, in China, for Intership Navigation Co Ltd's three new 36,500 dwt Laker-class bulk carriers.

US Navy Evaluating SEWIP for LCS

The U.S. Navy is evaluating a scaled-down version of the Surface Electronic Warfare Improvement Program (SEWIP) system for potential incorporation on future Littoral Combat Ships (LCS),

Offshore Energy

Woodside to Pick up Moroccan Acreage

Woodside advises that it has entered into a contract for an exclusive Reconnaissance Licence (RL) with the Office National des Hydrocarbures et des Mines, the

UniMarine Opens Office in Pireaus

UniMarine announced the opening of its new office UniMarine South Europe & Mediterranean. Located in Piraeus (Greece), the office will be servicing the Southern

Strategy Can Maximize UKCS potential

Companies operating in the North Sea require a cultural shift to make the most of the its potential, according to a new report from Deloitte, the business advisory firm.

 
 
Maritime Careers / Shipboard Positions Maritime Contracts Offshore Oil Pipelines Port Authority Ship Electronics Ship Repair Ship Simulators Shipbuilding / Vessel Construction Winch
rss | archive | history | articles | privacy | terms and conditions | 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: 0.3017 sec (3 req/sec)