Solid quality. Absolute safety.

PEMA welding and production automation for power generation

Boiler manufacturing. Pressure vessel manufacturing. Pipe manufacturing. Process equipment manufacturing.

Deep understanding and knowledge of the industry, turn-key solutions

Working for decades in this highly advanced sector has made us the leading manufacturer of automated welding systems in the power generation industry.

Understanding the needs of our customers, reliable equipment, modern processes, and the constant development of our products is key when it comes to serving our clients across the globe.

PEMA wide production range covers water tube panel welding lines, solutions for tube shops, robotized applications for complex constructions, and general steel constructions. 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. 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

PEMA welding and production automation systems

Flexible panel lines for various production needs

Boiler manufacturing: panel production

Pemamek offers a wide range of boiler panel machines for various needs. Our panel lines enable the high level of flexibility that is needed in batch-type panel manufacturing. 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.

PANEL PRODUCTION

  • Tube and fin-bar feeding
  • Material handling
  • Panel welding with stationary machines
  • Panel bending systems

FIN-BAR PROCESSING

  • Uncoiling and cleaning
  • Straightening and calibrating
  • Cutting to length
tube fabrication

PEMA welding automation for tube and coil processing

Boiler manufacturing: tube fabrication

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.

Efficiency and quality guaranteed throughout the production line

Pressure vessel production

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

Highest safety

Heavy vessel production automation requires rigid roller beds and
large size welding Column & Booms or welding platforms. Efficient material transportation without unnecessary crane activities is ensured with transfer cars. We have everything you need for modern pressure vessel manufacturing. 

The semi-narrow gap SAW technique is used on welding exceptionally thick plates, 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 roller beds come with an automatic hydraulic anti-creep function to prevent axial movement.

Integrated circular milling

PEMA welding platform

C&B and assembly station integration

koonti- ja hitsauslinja

PEMA shell fabrication solutions boost production

Pressure vessel manufacturing: shell fabrication and assembly

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

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

PEMA Nozzle Welding Station

Pressure vessel manufacturing: nozzle welding

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

Boost your pipe production

Pipe manufacturing: special pipe fabrication

Your pipe production gets a boost in productivity
when PEMA’s rollerbeds, welding C&B, welding automation systems and engineering solutions are utilized.

Longitudinal pipe sections can be welded outside by our Multi-Arc SAW portals and inside by our long reach welding booms.

Longitudinal and circumferential welding

We have dedicated welding automation solutions for longitudinal
welding of tubular pipes, pipe-to-pipe, elbow-to-pipe and flange
to pipe connections. Our positioners and welding column & boom
solutions combined with special welding automation can be selected from our wide range of standard modular product families.

Various welding processes such as GMAW or GTAW for root pass
welding and Multi-Arc SAW welding for filling up are integrated in
our pipe fabrication equipment.

Efficient welding head and motorized slide modules have been
developed to fulfill the technological needs that are required to
automate the welding of different size geometries and designs.

You can choose from a wide range of PEMA positioners and the
appropriate model and machine can be equipped with custom-made clamping devices.

External and longitudinal pipe welding

Large and small diameters

Combined welding processes

Automating the demanding pipe manufacturing phases

Pipe manufacturing: pipe component fabrication

Fast process, immediate results

The offering of automated PEMA welding and production solutions cover welding heavy and thick walls in pipe elbows and assemblies, such as valve frame welding.

Our experts optimize the right handling equipment and welding Column & Boom from our extensive selection of modular product families.

Various welding processes such as GMAW or GTAW for root pass
welding and Multi-Arc SAW welding for filling up are integrated inour pipe fabrication equipment.

A specific range of Column & Booms are designed for internal
welding of pipe elbow segments as well for external welding
operating in integration with PEMA Positioners.

In synchrony with PEMA material handling

Internal pipe elbow welding

Valve welding

Automated solutions for process equipment manufacturing

Process equipment manufacturing: robotic welding

  • 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

 

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.

Other modular solutions for process equipment manufacturing

Pemamek offers a wide range of other modular solutions to make your manufacturing processes more efficient.

  • Welding positioners
  • Welding roller beds
  • Welding Column & booms

Click HERE to find out more about PEMA solutions.

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PEMA Robotic welding solution

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