Large turning centre machines in 'one hit'

Before an oil and gas sector products supplier invested in a large turning centre its productivity was being affected by production bottle-necks arising from multi-machine set-ups.

Itasco Precision in Fife, Scotland, has invested in a Doosan Puma 700LM 3.2m bed CNC turning centre improve productivity in the machining of complex oil and gas sector components.

Supplied by Mills Manufacturing Technology of Leamington Spa, UK, the the Puma 700LM machines 'end fittings' made from low alloy carbon steel.

These components are large, heavy and asymmetric.

They have difficult-to-machine features, such as flanges, threads, angled bores and so on.

They are machined to high precision and tight tolerances, with surface finishes typically 0.4/0.8 micron Ra.

Parts are machined and supplied to customers in small batches - typically one- to four-off.

Itasco Precision designs, manufactures and supplies end-fittings, which are critical components that make the connections for thermoplastics hoses and/or steel tube 'umbilicals'.

These are used in the oil/gas sector for a variety of purposes (production, gas lift, gas injection, water injection and so on) in sub-sea installations.

Before purchasing the Puma 700LM the end-fittings were machined on a number of Itasco's existing CNC machines.

* Multi-machine setting - one of Itasco's directors, Jim Mullen, said: "Before the Puma 700LM was installed we had to transfer parts between machines (lathes and machining centres) for pre-weld machining and finishing operations.

This presented a number of problems".

He explained: "Because we didn't have the capability (at that time) to take advantage of 'one-hit' machining we were spending too much time on job set-ups (with parts being moved from one machine to another), and our productivity was also being affected by production bottle-necks (i.e, waiting for machines to become free)".

* 'One hit' machining - Mullen said: "The Puma 700LM means that machining operations can be completed in a single set-up." He said that the Puma can perform heavy-duty machining operations (45kW 1,500 rev/min spindle) quickly and reliably and it gives the company a high-accuracy and high-volumetric removal facility.

Mullen added: "Furthermore, owing to the Puma's driven tool capability (12 tools/ 11kW 3,000 rev/min) we can mill, drill and tap complex features (bores, threads and so on), via the same one set-up".

He said: "The productivity improvements we have experienced since installing the Puma have been tremendous.

We've been able to reduce our lead times (dramatically), we require less operator involvement, we've improved part accuracies (due to less work handling) - and we're more competitive".

In addition to the performance and capability of the machine - there were other reasons why the Puma 700LM was selected.

Itasco has previously invested Doosan turning capability, which was a detrmining factor as were operator familiarity with Fanuc control systems and program compatibility between machines.

Another key decision was machine availability.

* Availability - availability is important as Itasco has to cope with dynamic and competitive industry sectors.

Mullen added: "We have to be able to respond and react quickly to market trends and customer requirements".

"Some machine tool manufacturers aren't geared up to meet these demands and quote machine delivery times that are months and months down the line".

About Mills, Mullen said that the opposite is true: "We were able to order and install the machine quickly with the minimum of fuss or disruption.

This, plus Mills' first-class after-sales services, were important factors in the decision making process".

* About Itasco - Itasco was established in 1976 and said it had experienced something of a 'renaissance' during the last three to four years.

The company previously was a general engineering subcontractor manufacturing high-volume (low profit margin) precision parts.

Whilst still being profitable, Itasco found that it increasingly had to 'chase' work and, that competing against the emerging, low wage economies of Eastern Europe and the Far East was unsustainable.

Following a management buy-out in 2005, the company re-positioned itself to become a market-leader in the oil/gas, marine and nuclear sectors.

Mullen said: "Companies that have a 'jack of all trades' approach usually are the masters of none.

We were determined that this wouldn't be the case for Itasco and so all of our efforts and resources have gone into growing the business, and making it more profitable".

As well as investing in advanced machine tool technologies (the Puma 700LM being a case in point), Itasco has made significant investment in developing its in-house CNC welding rig capability.

Set up in 2005, Itasco claims its welding facility is now amongst the best in the business.

Equipped with two Fronius and a Polysoude GTAW hot-wire cladding machines, Itasco provides its customers with an optimum weld overlay service.

To withstand the harsh conditions experienced in oil/gas exploration and production environments - machined parts (such as the end-fittings machined by Itasco) undergo weld cladding operation.

The cladding material used is Inconel 625 welded onto the parts to produce a hard, durable skin over critical features.

Similar strategic investment in quality and inspection equipment and two heat treatment furnaces, and advanced CAD/CAM software means that Itasco can provide its customers with complete turnkey solutions, including design, precision machining, weld-cladding, ND Testing and Heat Treatment.

All these services are supported by the company's expert project management and quality control processes and systems.

Since 2005 the company has experienced significant year-on-year growth, and is looking to develop its capabilities and capacity through further investment in advanced technologies.

With sub-sea installation activities thriving as operators, backed by high commodity prices, seek to bring more deep water oil and gas reserves on-stream...it is clear that demand for Itasco's products and services will continue to grow.

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