Solid quality. Absolute safety.

PEMA welding and production automation for power generation

In the production of critical components, there is absolutely no room to compromise in quality

Therefore, quality must be built into the production process.

In PEMA production lines, solid and robust quality comes as standard. With several decades of experience behind us, Pemamek understands that safety and quality are critical factors in the boiler industry.

PEMA welding and production automation systems

Pemamek is a leading manufacturer of automated welding systems for the power generation industry.

Get the most out of your production

Working for a long time in this highly advanced sector has made us the leading manufacturer of automated welding systems for the boiler industry. Understanding the needs of our customers, reliable equipment, modern processes and the constant development of our products is key when it comes to securing business. With PEMA welding equipment for membrane wall panels, tube welding, and cutting, tube prefabrication, etc. you get the most of your production.

Pemamek is recognized for its long-term cooperation and key-customer thinking. This concept includes full lifetime support services and retrofit projects. The fact that some of our very satisfied customers have included PEMA products in their production lines for over twenty years is a testament to this.

Production plant layout design

Production flow and capacity studies

Welding process support services

“Welding automation is the only solution for a successful boiler production.”

Mr. Klein
CEO, Meeraner Dampfkesselbau GmbH
Hitachi Power Europe
tube fabrication

BOILER MANUFACTURING:

Tube Fabrication

PEMA welding automation for tube and coil processing

Pemamek has a wide product range available for tube shops. Complete lines are highly automated and can even be controlled by one operator. The combination of efficient cells and fully integrated conveyor systems creates ultimate productivity with solid and constant quality.

Modern welding techniques include conventional TIG as well as multi-hotwire TIG and plasma hybrid processes. Efficient storage and material handling solutions are a prerequisite for coiled production systems. One line can be equipped with several welding stations depending on the required capacity.

Tube shot blasting

Tube shot blasting with steel grit is a prerequisite for high-quality SAW welding. It reduces welding defects and the need for manual repairs after the panel welding.

Tube end beveling and buffing

The tube end beveling unit includes specific tools designed for each groove type. End buffing unit integrated into the end beveling line.

Cutting to length

Tube length measuring and cutting saw is integrated to the PEMA tube line.

Tube to tube welding and seam grinding

Tube to tube welding with hot wire TIG and seam grinding after the welding process is integrated into the PEMA line. Seam grinding is required for panel welding.

BOILER MANUFACTURING:

Panel Production

Flexible panel lines for various production needs

If you require various sizes of tubes and fins with varying production batches, we can offer flexible panel lines. The fast changeover time for tools makes the line flexible for different tube and fin bar sizes.

Flexible PEMA panel production makes it possible to have a first-step investment to meet various production expansion needs. PEMA stationary panel welding line with a one-panel welding machine is usually designed for small or medium-scale batch production and can have 2-6 SAW power sources. The typical panel width is up to 2000 mm.

“Welding automation is the only solution for a successful boiler production.”

Mr. Klein
CEO, Meeraner Dampfkesselbau GmbH
Hitachi Power Europe

PRESSURE VESSELS OF POWER PLANTS:

Shell Fabrication and Assembly

With PEMA shell fabrication solutions, you can dramatically decrease the welding time during your production

Special functions have been designed to make the work flow even more easily. Pema Assembly station can decrease fit-up and tacking time up to 50%: it is a unique concept based on self-aligning rollers, fixed jig unit and a growing line fuction.

Special functions to increase efficiency

  • Multi-arc SAW welding with automated functions
  • Conical shell tilting
  • Fully auto-adjustable special PU rollers
  • Fast rotation from internal to external welding in long
    seam welding
  • Integrated grounding
  • Wireless control
  • Extremely fast fit-up with assembly line developed
    specifically for wind tower assembly

Milling of longitudinal seams

Longitudinal seam welding station

PEMA Assembly station

PRESSURE VESSELS OF POWER PLANTS:

Pressure Vessel Production

Specially designed solutions for vessel manufacturing ensures efficiency and quality throughout the production line

PEMA solutions cover all welding and material handling needs during these phases.

Highest safety

Heavy vessel production automation requires rigid rollerbeds and
large size welding Column & Booms or welding platforms. The
semi-narrow gap SAW technique is used on welding exceptionally
thick plate, typically 50-150 mm.

A narrow, preformed welding groove reduces the seam volume and decreases the amount of fillet material needed. On the other hand, producing a quality seam is a process that places extraordinary demands on a production facility.

PEMA’s 100- 1200-ton rollerbeds are designed to meet the special
needs of semi-narrow gap welding. In semi-narrow gap welding,
the vessel must be rotated with extreme precision, with no axial
movement, even over the longest period of time. For this reason,
PEMA’s large rollerbeds come with an automatic hydraulic anti-creep function to prevent axial movement.

Integrated circular milling

PEMA welding platform

C&B and assembly station integration

PEMA Nozzle Welding

PRESSURE VESSELS OF POWER PLANTS:

Nozzle Welding Station

Solution for pressure vessels.

PEMA Nozzle welding station for pressure vessels automates the nozzle welding process. The station is an optimal solution for heavy-duty workpieces.

Thanks to its hi-tech features, the system allows the automatic creation of robotic welding programs, based on laser-scanned groove geometry.

PEMA Nozzle welding station is an optimal solution for heavy-duty workpieces. The solution allows the automatic creation of robotic welding programs, based on laser-scanned groove geometry. PEMA Nozzle welding station has a quick ramp-up period.

Automated multi-layer welding results in visibly improved welding quality and reduced defect rate. Furthermore, automation reduces defect rates and saves manual welding hours typically required for a time-consuming and demanding multi-layer welding procedure.

Automated programming

Adaptive welding

Reduced defect rate

ROBOTIC WELDING:

Power plant equipment manufacturing with PEMA Robotic solutions

  • Solutions for process equipment
  • Complete deliveries including material handling and conveying systems
  • Effective programming solutions such as PEMA Vision System and off-line
  • Profitability for small-scale production
  • Commissioning, training, and modernization services
  • Yaskawa Motoman System Partner

 

PEMA robotic welding systems are designed to meet even the highest demands

The modular PEMA robotic solution range allows building the production system of numerous components with a large variety of robot tracks and material handling solutions.

Play Video

PEMA Robotic welding solution

Get the Power Generation Brochure

Sign up to our email list and get access to our brochure downloads as well as the latest news about PEMA!

Power Generation - Pemamek

Get Our Power Generation Brochure

Contact Us

The PEMA Team is at your service. Contact us and we will help you with any questions you may have.