PEMA Flange Fitting Station enables fast, safe and accurate fitting and welding of flanges to the wind tower and tower foundation sections. Compared to the traditional way where shells must be flipped to horizontal fitting table for flange fitting and then flipped back to the original position for welding, Pemamek's new innovation allows fit-up process without this complicated crane operation, which results in savings in time and increased safety.
PEMA Flange Fitting Station is an ideal solution for both onshore and offshore tower production. Continuously growing size of wind turbines requires larger diameters and heavier weights in flanges and tower sections, which makes handling of these components with overhead crane more challenging and requires special skills and tools from the crane operator.
With PEMA FF Station, flange fitting is possible without turning the shell, and cranes can be released to other tasks. Also, the amount of repairing is minimized as there is no need for lifting clamps.
"It is amazing how many different flange designs there is currently on the market. Pemamek has worked together with both onshore and offshore customers to make PEMA FF Station flexible for all different variations.
Our FF Station can handle tubular and conical shells, it has a wide range for different diameters and lengths of the shells and changeable tools to help adjusting the fit-up tool for different L- and T-type flanges", explains Teemu Tolonen, Pemamek's Application Manager of Wind Energy.
"Pemamek is also further developing the station with measuring tools, helping operators to perform perfect fittings."
With PEMA FF station, the production time for flange fitting and welding is reduced while the quality of fit-up only increases. The station can be integrated with PEMA Column&Boom, which enables welding to be done in the same place. The integration significantly increases the easiness and efficiency of manufacturing, and its been proven successful also in offshore wind tower foundation production.
"This new innovative process was firstly tested in Offshore transition-piece flange fitting where our client was able to reduce the fitting time down to 2 hours, keeping the flatness in required tolerance without milling operation", Tolonen mentions.
One of the companies that has invested in PEMA Flange Fitting Station is a Brazilian company TEN, Torres Eólicas do Nordeste. TEN specializes in the manufacturing of metal towers for wind power production.
"Pemamek's solution for handling flange fitting helped us to achieve significant reduction in the process times and with this, our return on investment will be fast", Mr. Carlos Konopatzki, General Director of TEN explains and continues:
"With FF Station, we are able to simplify our production and optimise the use of floor space. The need for overhead cranes is minimized and moreover, the safety of the overall process improves - benefit that we cannot put a price on."