AWS Schäfer Pipe Forming Machines

From 1959 – 2013 WORLDWIDE more than 2800 Machines

1959 - 60 Startup by Mr. Schäfer‘s Grand Father with Han drivenMachines for Plate Rolling

1980 First Plate Rolling Machine up to wall 120 mm in t he world

1987 First JCO Presses 6500 t

1988 Induction bending machines

1984 Fist T- Fitting Press

1989 First Cladding and Calibration press in the world

1970 – 1990 Plate Pre Forming, Welding and Cutting Machi nes

History of Schäfer Technologie

From 1959 – 2013 WORLDWIDE more than 2800 Machines

1980 Profile bending machines, Rollbending machines

1991 First Hydroforming machine for Automtive1994 First worldwide complete Hydroforming Line for Auto motive OPEL 2003 New Hydro-Mechanical Hydroforming Machine HFC 120

2006 Biggest Hydroforming Machine in the World HFC 380 ( 380,000 kN) forBi Metal Pipes and Calibration

2013 Induction Bending Machine SRBMI 1600

History of Schäfer Technologie

Induction Bending Machines

• Variable bending radius. The proposed technology enables manufacturing of elbows with different radiuses within the length of the pipe, including radii less than 1.5 x D, using only one set of tooling for the same diameter pipes. Bending radius can be anything from 1.5 to 40 DN

• Bending can be performed with preservation of some straight sectionslength both before bending area and behind, as well as in between. Itreduces the number of welds in the system and prevents welding oncritical points (tangential), which can not be avoided in the manufacture of assemblywelding units

• High quality of elbow, low wall thinning and ovality, high performance

• Minimal required set of tools does not require large amounts of the expensive stamping equipment as in the manufacture of stamped elbows.

• CNC system based on an industrial PC in combination with Hydraulic power and thanks to a special algorithm of coordinated movements of the inductor and the pipes for great quality with minimal human intervention

The advantage of the induction bending

Induction bents with large radius for oil & gas pipelines

Induction bents with tight radiusfor gas pump station

Induction bents made of heat resistant steelfor nuklear power plants and oil refineries

Induction bents for steel bridges

Induction bents for steel construction

Bending of reqtangual pipies

Bending of beams

Induction bents for steel construction

Unit bent

Unit welded

Induction bents without welding joints

Stamped elbow of two pieces Ø 1020 x 32 mm R= 1,5 X D, 90°

Induction bent Ø 1020 x 32 mm R= 1,5 X D, 90°

At least 17 different manufactoring processes

Costs intensive manufactoring process

High amount of specialist is required

Pressure keeping 2,0 of nominal

Delivery time 1 pc. approx. 7-10 days.

Only 5 different manufactoring processes

Low costs manufactoring process

Low amount of specialist is required

Pressure keeping 3,0 of nominal

Delivery time 1 pc.approx. 0,5 day. ( at least 6,5 days faster than stamped technology)

Induction bents vs stamped technology

Pipe diameter Ø 57 mm – 1660 mm

Pushing force up to 5000 kN

Bending moment up to 10.000 kNm

Wall thickness 4 mm till 120 mm

Radius from 1,0 x D till 10 m

Bending speed 3-150 mm/min

S355 - P92,

austenitic steel

ferrititc steel

Technical Specifications

One Machine = Three Functions:

1. Pipe Clading

2. Pipe Calibration

3. Hydro Static Testing

AWS Bi-Metal/Clad Pipe Technologies

0 1

2 3

ToolCalibration Inner Pipe To Outer Pipe

Outer Pipe

Inner Pipe

Cladding Process

Bi-Metal/Clad Pipe Forming Process

Examples: Pipe Calibration

Bi-Metal/Clad Pipe Calibrationmachine

Examples: Pipe Calibration

Bi-Metal/Clad Pipe Calibrationmachine

Examples: Pipe Calibration for Drill Pipes

Bi-Metal/Clad Pipe Calibrationmachine

Sizes: 90 240 320 380 480 520Pipe Ø: - 200 mm - 355 mm - 457 mm - 508 mm - 610mm - 650 mm

Wall-thickness:- 5 mm - 17 mm - 20 mm - 20 mm - 22 mm - 25 mm

Pipe Length: Any Length / Standard: 6 m – 12 m

Machine Range

Bi-Metal/Clad Pipe Calibrationmachine

SHFC 320 Pipe Length 12 m SHFC 380 Pipe Length 12 m

Bi-Metal/Clad Pipe Calibrationmachine

Outer Diameter Wallthickness

4" 8.56 mm

6" 10.97 mm

8" 17.7 mm

10" 15.09 mm

12" 17.48 mm

14" 19.5 mm

16" 20.0 mm

20" 20.0 mm

Pipe Diameter Wall Thickness Ratio

Outer Pipe Material Inner Pipe MaterialType Yield

(MPa)Norm

X42 290 API 5L

X52 359 API 5L

X60 414 API 5L

X65 448 API 5L

X70 483 API 5L

X80 552 API 5L

L 360QB 360 DIN EN 10208-2

L 415QB 415 DIN EN 10208-2

L 450QB 450 DIN EN 10208-2

L 485QB 485 DIN EN 10208-2

UNS Type Cr M o N i N PRE

S41000 410 12 — 0,5 — 12

S32100 321 18 — 9,0 — 18

S31603 316L 17 2,5 11,0 — 24

S31703 317L 18 3,0 11,0 0,05 29

N08904 904L 21 5,0 25,0 0,10 39

N08825 Alloy 825 22 3,0 40,0 — 32

N06625 Alloy 625 22 9,0 60,0 — 52

N06059 Alloy 59 23 16,0 59,0 — 75

C70600 CuNi10Fe — 10,0 — —

C71500 CuNi30Fe — — 30,0 —

N08926 Alloy 926 20 6,5 25,0 0,20 45

N08367 Alloy 367 20 6,5 24,0 0,22 45

PRE: Value for pre resistance corossion, (0 - Protection for Steel)

Pipe Material Combinations

High Quality In Repeatability, In Roundness, In Tolerances

Cost Effective And Flexible Production

Corrosion Protection

Abrasive Protection

Life Time 10 x Higher Then Carbon Steel Pipes

Advantages of AWS Cladding Machines

T – Forming Machines

Steel T-fittings with diameter from 114 mm till 1067 mmmade of austenitic and ferritic grades of steel

Elbows with small radius with diameterfrom 114 till 630 mm made of austenitic and ferriticgrades of steel

Reducers with diameter from 114 mm till 1220 mm made of austenitic and ferritic grades of steel

AWS Machines For Tees

Machine Closing Filling with water

Horizontal cylinder advance

Control water pressureHolding cylinder controlled

Pressure releasePress open part removal

T – Forming Process

SHFC 40 - 2014

New Generation Type: SHFC

1. Pipe stock 2. Pipe cutting 3. Sand blasting/Cleaning/Brushing

4. Lubrication 5. Hydroforming 6. Heat treatment

7. Cutting off the cap 8. End preparing 9. Marking

T-Fitting Line

Advantages of Hydroforming

Proposal for creation of high-efficiency, highly effective and flexible production of pipeline fittings which guaranties:

Reduction of a work cycle of manufacture of a product - cost price advantage

Increasing mechanical characteristics of a tee at the expense of a cold hardening and the subsequent heat treatment

High efficiency,

Manufacturing of products according to all standards like DIN, ANSI, Gost

Minimal production time, in comparison with other technologies

100 % repeatability of the sizes and properties of dimensions

Less influence of the human factor on the basic processes, as a consequence of the high quality output

The minimum requirement of the highly skilled personnel

Pipe End Manufacturing MachinesPipe End Expander Type: SRE 1200

Pipe End Milling MachinesWelding - Requirement For Pipe End Shapes

Pipe End Milling MachinesPipe End Milling Machine Type: SRF

Pipe End Milling MachinesPipe End Milling Machine Type: SRF

AWS Schäfer Technologie GmbH

Oberhausenerstr. 8

57234 Wilnsdorf, GermanyKonstantin ZimmerTel.: 0049 2739 87003-28Fax.: 0049 2739 87003-10E-Mail: k.zimmer@aws-schaefer.de Internet: www.aws-schaefer.de

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