Download - Kranendonk Offshore

Improve your quality and fl exibilityBuilding off shore structures with roboti c precision

�� is the robot technology centre

for non-repeti ti ve producti on.

Stay competi ti ve in a risky businessConstructi on companies have to cope with the volati lity of the off shore business. Sudden changes in oil demand or price drops can have a big impact. Also, operati on risks and legal regulati ons can endanger constructi on companies in their daily business. It emphasizes the need for fl exible producti on soluti ons and innovati on in surrounding processes. Effi ciency and fl exibility are the major issues to compete in a risky business.

Innovati on is key to compete in a tough industry

Investments in off shore wind farmsThe global demand for renewable energy is rapidly increasing. Governments are setti ng ambiti ous goals to embed renewable energy into their country's demand. Wind energy appears as a clean soluti on to cope with a great part of these ambiti ons. In Denmark for example, more than 20% of electricity is already produced from wind. Onshore space for the installati on of wind turbines is becoming scarcer. Off shore wind farms are seen as a good alternati ve, and are planned at a growing pace.

Ambiti ous goals for off shore renewable energy

Ongoing growth in energy consumpti on puts pressure on existi ng

oil and gas fi elds. It leads to developments in (ultra-)deep water and

arcti c explorati ons, but also to major off shore renewable energy

projects. Constructi on companies have to cope with these new

demands. It drives the need for reliable producti on systems and

technological innovati ons.

Facing our global challenges together

Potenti al oil and gas reserves

Known oil and gas reserves

Potenti al locati ons for off shore wind energy

2 �� Smart roboti cs

20101980 2035

Deepwater demands innovati ons There is a strong growth in deepwater regions. Companies are purchasing deepwater pipelay and constructi on equipment. Deeper and deeper water brings specifi c challenges that have to be overcome. ‘The current (aged) vessels are unable to meet the requirements of today’s off shore industry’, according to Off shore Constructi on Market. It drives the need for sophisti cated producti on systems and technology innovati ons.

Ultra-deep explorati on leadsto new concepts

Energy consumpti on on the riseAs there are sti ll limited scalable alternati ves to oil, the pressure on existi ng fi elds remains high. It results in high competi ti on in the industry, which fl ows downwards to contractors and constructi on companies. It puts pressure on manufacturers to deliver challenging projects of high quality, within budget and planning.

Ever growing energy consumpti on

Arcti c conditi ons give new challengesEnormous potenti al lies in arcti c regions. These are esti mated to hold 25% of the world’s undiscovered reserves. The arcti c conditi ons are much diff erent to what the industry is used to. It gives new requirements to materials, components and constructi ons. Robustness to meet impact toughness is the key. The search to meet the arcti c demands conti nues.

Arcti c conditi onschallengeconstructi ons

Primary sources of energy consumpti on

10% Renewable

21% Coal

24% Natural gas

3% Liquid biofuels

33% Oil & other liquids

8% Nuclear

7%

21%

25%

1%

37%

9%

3 Off shore automati on by ��

Smart roboti csTraditi onally, industrial robots are used for repeti ti ve tasks. We develop sensors and soft ware that make our robots smarter. It means we can automate non-repeti ti ve producti on processes. This unique competence opens a world of opportuniti es for manufacturers. We use our skills to build fully automated producti on shops, where all processes are integrated and aligned.

Cutti ng edge technologyOur wide knowledge on roboti c automati on makes us excellent problem solvers. We assist you from an early stage, to create an opti mal producti on fl ow for your facility. This way, we jointly create a tailored automati on plan that raises producti vity and saves costs. The culture for innovati on within �� makes sure we always deliver cutti ng edge technology at the highest level.

�� and off shore constructi onOver the years, �� has developed off -shore automati on at the highest level. We were among the fi rst companies to use robots for beam and tube cutti ng. In 1987, we supplied the fi rst roboti c H-beam cutti ng line, and improved the con-cept ever since. Currently, we are supplying the 3rd

generati on of our robot beam cutti ng line: the most advanced system available for off shore.

Welding in off shoreWelding in off shore is incredibly diverse and the quality demands are high. With our extensive robot welding experience, we have conducted many heavy welding projects. As a result, our engineers know the challenges in off shore welding. It gives us the positi on to develop customized robot welding soluti ons for off shore constructi on. These will make the diff erence in your facility.

Supplier

Engineer

TechnologyCentre

Supporter

Partner

Cutti ng edge innovati onThe Robot Technology Centre

�� is the robot technology centre for non-

repeti ti ve producti on. We make robot systems suitable

for non-repeti ti ve tasks, by developing smart sensors and

soft ware. �� can maintain a Technology Centre

positi on by simultaneously being an engineer, supplier,

supporter and partner, and connecti ng to all stakeholders.


‘Being fanati c in robot engineering’‘At ��, we use clear methods when designing new robot applicati ons. Whether it's a specialized welding tool or a soft ware interface, our way of work-ing is characterized by an approach we call Triple C. The fi rst C is for Constructi on. Creati ng a rigid constructi on that handles a harsh producti on environment is the main requirement. Secondly, Calibrati on makes sure our systems are extremely accurate. By applying soft ware correcti ons, we make a robot more accurate that it can physically be. Lastly, Controls are being developed. We use smart soft ware to enable easy opera-ti on of the machines. In any new develop-ment process, we pay att enti on to every detail. You can call us fanati cal about this.’

Evert GeurtsenTechnical [email protected]

Getti ng a ti ght grip on Getti ng a ti ght grip on Getti ng a ti ght grip on Getti ng a ti ght grip on the producti on processthe producti on processthe producti on processThe versati lity of off shore constructi on

Every facility is unique Every off shore constructi on company has a unique set of skills to compete on the global market. Jackets, tripods, top-sides and all kinds of specialized constructi ons are built within ti ght quality restricti ons. The diversity of the structures that are build at an off shore yard is refl ected in the producti on processes and the equipment. It requires fl exible machines that deliver the quality to build safe and reliable off shore structures.

Your demand for quality No producti on step stands on its own. Every acti on infl uences the following steps, and ulti mately the quality of the end product. And in off shore con-structi on, these quality demand are high. Building safe off shore structures requires a ti ght grip on the complete producti on processes. ��'s soluti ons are tailored to the demanding off shore constructi on processes. We have proven this for over 25 years.

The producti on of off shore structures is incredibly diverse. Jackets, modules and many special structures are constructed with extreme precision. All producti on units need to deliver excellent quality, while remaining fl exible. �� off ers soluti ons to automate key parts of this process.

Sub-assemblies Heavy welding (page 14)

Plates and profi les Plates and profi les Plates and profi les Profi le cutti ng (page 10) Edge Preparati on System (page 11) Plate beveling (page 13)

Beams and tubes Beam cutti ng (page 10) Tube cutti ng (page 12)

Input raw materials Steel plates, profi les and tubes

Pipe shop Roboti c pipe shop (page 15)


Cutti ng tubes and beamswith one machine

Robot welding in the pipe shop

Smarter cutti ng methods tolower your total producti on costs

Roboti c pipe shop (page 15)

‘Keeping your fl ow running’‘As customer support manager, it is my goal to maintain the highest possible producti vity of your �� equip-ment. We off er a full pack of services to do so. Our support engineers regularly visit your yard for inspecti ons and performance tests. This way, we keep you producti vity high and reduce downti me to a minimum. Also, we train your operators and mainte-nance crew. In this way, we improve your fl ow and keep it running.’

Werner Smeiti nkManager Customer Support

HelpdeskHolland +31 344 655 443Japan +81 832 425 [email protected]


Building for extreme conditi onsIncreasingly, oil and gas companies are working in areas that recently would have been considered impossible to explore. This includes operati ng in deep waters and moving into more remote and hosti le envi-ronments, such as the Arcti c. Constructi on companies are expected to meet the chal-lenging off shore demands. Over the past decades, off shore acti viti es have been stretching the limits of technology, and so have the producti on methods.

Photo: Creati ve Commons license (CC)


High precision oxy-fuel cutti ngfor all typical off shore shapes

Save costs by cutti ng extremely accurate Any off shore constructi on starts with the cutti ng of plates, profi les and tubes. Because of the high demands on welding quality, the cutti ng has to be done very accurately. A wrong cut will take up valuable welding ti me in a later stage. Thus, more accurate cutti ng saves ti me and money in the total producti on process. �� has the technology and the experience to excel in this fi eld. Our �� cutti ng system features high-tech components that result in unmatched accuracy.

Achieving perfectly fi tti ng partsThe �� cutti ng system has three unique features. First, smart soft ware is used that adapts the cutti ng path to deviati ons in the steel beams. It reduces the gaps when assembling and welding the parts. Secondly, an in-fl ow positi oning system eliminates the need for a length measuring trolley or gripper. This speeds up the process and signifi cantly reduces maintenance. Finally, the �� cutti ng system is designed for reliability: all components, wiring and controls are integrated in a single base frame.

Over the past 25 years, we have built a strong reputati on in off shore beam processing. ��'s cutti ng systems are known for their high accuracy and reliability. Our machines have proven to be a secure investment for off shore faciliti es.

Roboti c beam cutti ng line CCS 1250

Raising quality with smarter cutti ng methodsAccurate cutti ng improves your welding


‘Delivering a 3rd generati on cutti ng line’‘The success of our off shore cutti ng lines is based on our strong connecti on with the industry. Our current beam cutti ng line – �� 1250 – is already our 3rd generati on machine. It holds all the experience we have gained over the past decades. Smart features, like in-fl ow profi le positi on-ing, give you bett er cutti ng results in the demanding off shore constructi on busi-ness. The rigid design makes it a machine you can rely on.’

Jelle JanssenSales [email protected]

Accurate milling of plate edges

Automati cally preparing plates edgesTo improve the quality of coati ngs, plate edges have to be prepared (rounded). Automati on of this process requires an adapti ve machine that per-fectly follows plate contours. The Edge Preparati on System combines proven �� technology with a state-of-the-art force controlled milling system. The system machines both sides without turning of the plate. Advanced soft ware with a touch interface makes sure that operati on is easy.

Fitti ng starts with smart measuring methodsYou can save hours on assembly and welding ti me by cutti ng fi rst-ti me-right. We off er a proven way to create perfectly fi tti ng parts. By applying measur-ing methods, we take all profi le deviati ons (toler-ances) into account. On top of that, our cutti ng lines ances) into account. On top of that, our cutti ng lines can take the deviati ons in connecti ng profi les into can take the deviati ons in connecti ng profi les into account. This means that your beams will fi t well account. This means that your beams will fi t well into the connecti ng parts, reducing the required assembly and welding ti me.

Edge Preparati on System

Perfect fi ts are realized by measuring both profi les

Tight fi tsTight fi tsTight fi ts


Cutti ng large tubes with roboti c precision

Cutti ng tubes and beams with one machineA combined Tube and Beam cutti ng system is the soluti on for fl exible off shore constructi on. The fl oati ng chuck rotates small tubes, but also large ones up to 2.3 meters in diameter. Beams, profi les and even plates can be processed on the cutti ng bed, without any additi onal setup ti me. ��'s sophisti cated soft ware gives easy operati on with touch controls. Tube and beam deviati ons are taken into account.

The Tube and Beam cutti ng system processes beams as well as tubes with roboti c precision. Complex bevels and end cuts are made with ease: no need for manual programming of the system. This machine off ers real off shore fl exibility.

Tube and Beam cutti ng system

Increasing the fl exibility of your cutti ng shop One machine for tubes and beams

Achieving perfectly fi tti ng parts


Adapti ve beveling of plates

Adapti ng to the material Adapti ng to the material with Dual Laser Height Control with Dual Laser Height Control

Sensor: Dual Laser Height Control (��) Two laser beams close to the cutti ng torch conti nuously measure deformati ons (tolerances) in the material and adapt the cutti ng path in real ti me. The robot movements are changed within milliseconds. Our �� technology creates the perfect bevel every ti me, which means that your products will fi t exactly. It saves cost in welding and improves your producti on fl ow.

Plate Beveling Cell

Creati ng perfect weld preparati onsTo create a perfect bevel, a high precision robot is not enough. Heat input from the fl ame will deform the material during the cutti ng process. �� solved this problem by developing a smart sensor: �� (Dual Laser Height Control).

Following curved platesFollowing curved plates

Razor-sharp weld preparati ons to all plates contours


Securing your qualitywith robot welding Off shore welding soluti ons

Roboti c subarc welding with integrated fl ux recovery

Robot welding of large structuresWe have over 25 years of experience in heavy welding applicati ons for all types of products in the off shore industry. With the fl exibility of roboti cs we deliver customized welding soluti ons to automati cally weld large structures. Our soluti ons are gantry or track supported robots and mobile robot welding systems.

Mobile robot welding soluti onsA mobile robot can be positi oned anywhere at the shopfl oor, making it a very fl exible producti on tool. Perfect for off shore welding. The mobile robot delivers a consistent quality, also with multi -layer welds. On top of this we off er the subarc welding process (SAW), which provides high quality heavy welding.

Submerged arc welding stati on

The versati lity of off shore constructi ons is well refl ected in the welding of assemblies. The quality demands are high, but all products are diff erent and very large. This is where �� has a large experience: robot welding of non-repeti ti ve products of all dimensions.

Mobile robot performing heavy welding of parts

Smart sensors systems for multi -passand multi -session welding


Roboti cs for heavy off shore welding‘Robot welding and off shore is a challeng-ing combinati on. Welding in off shore is incredibly diverse. Full penetrati on welds, high quality demands and no repeti ti on make it a tough job, but also a job where �� excels. We have a lot of expe-rience with heavy welding automati on, and have done various projects for welding in off shore. We conti nue to explore robot welding in off shore with new innovati ons and partnerships.’

Kevin JongkindArea sales [email protected]

Flange assembly line

Increasing producti vity with the roboti c pipe shop

The world's fi rst roboti c pipe shopThe producti on of pipe spools for outf itti ng of off shore modules is a true craft sman's job. Flanges have to be welded to the tubes within strict toler-ances to cope with the high demands in off shore constructi on. The process is hard to automate, but we have developed a unique soluti on that does the job. All processes are integrated and centrally controlled, to create fi rst roboti c pipe shop in the world.

From 4 hours to 8 minutes producti on ti meA roboti c pipe shop is the result of a thorough analy-sis of the producti on of pipe spools. The roboti c pipe shop brings the producti on ti me for a pipe spool back from 4 hours to 8 minutes. The central control system takes care of the producti on fl ow and monitors each tube individually.

Automati c assembly and weldingand weldingandof fl anges to tubes


www.kranendonk.com

�� is the robot technology centre for non-repeti ti ve producti on. By implementi ng intelli-gent robot technology, we enable manufacturers to produce more effi ciently and eff ecti vely. We supply custom build soluti ons that are cleverly integrated into material and data fl ows.

�� was founded in 1983. We started our company as a supplier of custom automati on systems for industrial applicati ons. Over the years we have specialized in advanced roboti cs for heavy steel applicati ons. Today we off er an innovati ve approach that creates a range of automati on oppor-tuniti es for manufacturing companies.

In the near future we see technological and macro-economical developments putti ng pressure on the producti on process. Advanced automati on is spreading into new areas. Integrated process and centralised operati ons are decisive factors in choos-ing the right equipment. �� will keep assisti ng companies in transforming their produc-ti on processes to make them more effi cient, fl exible and ready for the future.

Contact informati on

Kranendonk Producti on Systems ��(headquarters)

Phone +31 344 623 944Fax +31 344 623 388

P.O. Box 6147��-4000 �� TielThe Netherlands

[email protected]

��

Sir Rowland Hillstraat 10��-4004 �� TielThe Netherlands

v 07 2013