The new PEMA Flange Fitting Station aims to provide fast, safe and accurate flange fitting and welding to wind tower and tower foundation sections.

Flange fitting is possible without flipping shells to a horizontal fitting table for flange fitting and then back to the original position for welding, which can be challenging for crane operators when lifting these heavy pieces. The PEMA FF station either minimizes or eliminates the need for a crane depending on part size.

As wind turbines continue to grow larger, and their tower sections and flanges grow in weight and diameter, handling an overhead crane becomes more challenging and requiring special skills and tools from the crane operator. The FF station is flexible enough to handle many different variations of flange designs and can be integrated with PEMA Column & Boom, which enables welding to be done in the same place, reducing weld time and increasing welding efficiency. Additionally, there is no need for lifting clamps.

“Our FF Station can handle tubular and conical shells with different diameters and lengths and has changeable tools to help to adjust the fit-up tool for different L- and T-type flanges,” said 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.”

Pemamek tested the FF welding process using an offshore transition-piece flange fitting. Fitting time was reduced from eight hours to two hours, keeping flatness and tolerances without the need for a milling operation.

The company provides welding automation technology and integrated manufacturing solutions to a range of industries including shipbuilding, alternative energies, heavy fabrication, oil and gas, wind energy and boiler manufacturing. The company offers welding positioners, column and boom units, roller beds and robotic solutions as well as the proprietary PEMA WeldControl programming and control software, among other technologies.

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