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Tube & Pipe

One-stop shop

By Emily Vasquez

Above: The W-604 reduced cylinder and pipe processing jobs from 10 hours to one for Power Service.

Pressure vessel manufacturer cuts process time with help from advanced profile equipment

October 2015 - Customer satisfaction is imperative for any industry. Companies might wonder, “Will this customer be returning?” Bidding negotiations carefully consider various factors, with a keen eye out for cost, quality and timeliness. 

In an environment built on tight deadlines and strict schedules, unexpected downtime can be costly for both parties. A vital part of the metals industry, machinery needs to run efficiently without sacrificing quality and more importantly, time. 

Power Service Inc. cites “drive and passion” for its commitment to providing the best products and services to its customers, according to Steve Jackson, marketing manager for the Casper, Wyoming-based distributor.

Plug and play

Over the last 60 years, Power Service has quietly grown its rotating and process equipment business to be a “one stop solution,” for the oil & gas industry, providing product lines for air compressors and dryers, blowers, filtrations, generators, mechanical seals and pump equipment. 

In the 1980s Power Service began to repair and replace pumps at its facility, a method President and Owner Tony Cercy calls a “plug- and play-type unit.” 

FFJ 1015 tube image1

This technique allowed Power Service to repair and service its process equipment in a controlled environment without risking errors on location. “In other words we wouldn’t have contractors driving back and forth to locations daily to do the electrical, process piping and welding of the instrumentation as well as designing and programming,” says Cercy. “We do all that in our facilities. As our fabrication division grew by using the products that we distribute, we ran into an opportunity to start building ASME vessels.” 

Power Service acquired ASME boiler and pressure vessel accreditation in 2007, verifying their compliance with ASME laws and regulations in the United States and Canada, and granting the manufacturer a unit and repair stamp to build and ASME pressure vessels for the U.S. government. 

Acquiring ASME U and R code vessel stamp certification meant Power Service needed to accommodate new business opportunities with equipment that would keep up with demand for boiler and pressure vessels. Power Service turned to Watts Specialties Inc., Puyallup, Washington, a manufacturer and global industrial pipe cutting equipment supplier, specializing in CNC pipe profiling solutions. 

“In 2014 we visited Fabtech in Atlanta and met Watts Specialties where we bought our first machine to enhance our manufacturing process, a W-604 pipe profiler, capable of cutting 3 in. to 60 in. diameter material. Along with that, we also purchased a smaller model W-124 that gave us the ability to torch holes in pipe and cylinders 1.5 in. up to 12.75 in. in diameter,” says Cercy.

Saving time

The W-604 replaces manual cutting methods at Power Service. “It was at least a 10-hour process doing that. By buying the machine we’ve taken that down to a one-hour process,” says Cercy. 

“We would have to bring a cylinder in and lay it on the floor and locate where the holes would be cut and then call QA/QC down and come verify and check it. [Operators] would have to manually torch the holes and then grind them out. Now all you have to do is bring a cylinder and chuck it up and the CAD file is sent wirelessly to the computer on the profiler and starts cutting the holes. That process is about 80 percent more efficient.”

Watts Specialties PypeServer software programming makes nesting parts easier while seamlessly streamlining job estimating, scheduling, reporting and inventory management.

Looking to increase its capabilities, in 2014, Power Service returned to Watts Specialties, who has recently partnered with Germany-based Müller Opladen. Power Service jumped at the opportunity to acquire a Müller CNC controlled dome profiling machine. Müller patented dome profiling technology has revolutionized this process.

FFJ 1015 tube image2

“We immediately contacted [Watts Specialties] after we found out they [had] a new relationship with Müller Opladen from Germany. And we saw how effective the Watts pipe profiler was—we wanted to work with them to design a dome or head profiler. We worked with them for a design we needed for an up to 160 in. diameter head or dome,” explains Cercy.

The Müller Oplanden is designed for different thermal cutting processes but also workpieces other than round pipe. Its Heavy-Duty dome profiler installed at Power Service handles a maximum diameter of up to 160 in. and workpieces up to 30 tons.

Cercy breaks down savings for Power Service in man-hours, revealing a dramatically lower process time. “We build around 2,000 vessels per year. We’ve cut 20,000 man hours per year to 2,000 man hours, in our facility alone with only one machine.”

With an array of new equipment installed at Power Service, Watts Specialties provided its brigade of service technicians to train operators and employees. Watts specialists spent seven days at Power Service’s Casper facility, making sure operators were familiar with the PypeServer program and its safety standards. “We also flew our people to Washington to [Watts’] facility when it was near completion to see it run,” says Cercy. “So far, so good. I don’t think we’ve had any down time.”

Power Service continues to expand, adding 120,000 sq. ft. fabrication and office space to its current footprint. Cercy says the investment on new machinery has built a more reliable, efficient cutting process. “It saves us money on the initial upfront cutting of equipment and it slaps savings on the backend with cuts so clean and precise there’s very little cleanup when our welders install nozzles in it.” 

Ultimately, Cercy says the equipment has met demands for its time-conscious customers. “It helps us with the oil & gas customers that demand we deliver more equipment at a quicker rate.” FFJ

Sources

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Company Profiles

AIR FILTRATION

HYDRAULIC PRESSES

NESTING SOFTWARE

SERVICE CENTERS

Camfil APC - Equipment Beckwood Press Co. Metamation Inc. Admiral Steel
Camfil APC - Replacement Filters Triform

PLASMA TECHNOLOGY

Alliance Steel
Donaldson Company Inc.

LASER TECHNOLOGY

Messer Cutting Systems Inc.

SOFTWARE

BENDING/FOLDING

AMADA AMERICA, INC.

PLATE

Enmark Systems Inc.
MetalForming Inc. Mazak Optonics Corp. Peddinghaus Lantek Systems Inc.
RAS Systems LLC MC Machinery Systems Inc.

PLATE & ANGLE ROLLS

SigmaTEK Systems LLC

BEVELING

Murata Machinery, USA, Inc. Davi Inc. Striker Systems
Steelmax Tools LLC TRUMPF Inc.

PRESS BRAKE TOOLING

STAMPING/PRESSES

COIL PROCESSING

LINEAR POSITION SENSORS

Mate Precision Tooling AIDA-America Corp.
Bradbury Group MTS Sensors Rolleri USA

STEEL

Burghardt + Schmidt Group

MATERIAL HANDLING

PRESS BRAKES

Alliance Steel
Butech Bliss Fehr Warehouse Solutions Inc. AMADA AMERICA, INC.

TUBE & PIPE

Red Bud Industries UFP Industrial Automec Inc. BLM Group
Tishken

MEASUREMENT & QUALITY CONTROL

MC Machinery Systems Inc. Prudential Stainless & Alloys

CONVEYOR SYSTEMS

Advanced Gauging Technologies SafanDarley

WATERJET

Mayfran International

METAL FABRICATION MACHINERY

PUNCHING

Barton International

DEBURRING/FINISHING

Cincinnati Inc. Hougen Manufacturing Flow International Corporation
ATI Industrial Automation LVD Strippit

SAWING

Jet Edge Waterjet Systems
Lissmac Corp. Scotchman Industries Inc. Behringer Saws Inc.

WELDING

Osborn Trilogy Machinery Inc. DoALL Sawing American Weldquip
SuperMax Tools

METAL FORMING

HE&M Saw Strong Hand Tools
Timesavers FAGOR Arrasate USA Inc. Savage Saws T. J. Snow Company

 

MetalForming Inc.

 

 

 

MICROFINISHING TOOLS

 

 

 

Titan Tool Supply Inc.

 

 


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