In 2016, Spanish onshore wind tower manufacturer GRI Renewable Industries decided to move towards offshore tower production.
As a new operator in the offshore market, there were some new production related aspects to consider. As material thicknesses grow, tower heights can rise up to 120 m and section weights can be over 200 tons. GRI needed a partner that could meet the company's production standards, support its future business goals and provide high-quality manufacturing solutions.
GRI selected Pemamek as its partner, and the two teams worked closely to tackle the production challenges and meet the strict safety requirements that were set for the production line. Only 10 months later, the automated PEMA production line for offshore towers was deployed.
The line includes overall seven PEMA extra heavy duty column and booms, one PEMA double head welding platform, 32 pairs of heavy PEMA roller beds (max. weight 350,000 kg, max. diameter 10 m), four PEMA assembly lines, plate joining station and milling machines for longitudinal and circular joints.
The core of the PEMA production line is that all crucial processes, such as welding, milling and material handling, are integrated in order to constitute efficient workflow and high-end quality.
The line is equipped with PEMA WeldControl. The interface provides easy use of welding and material handling. It includes the management and production control system and integrates all the controls needed for successful welding. The interface provides maintenance and service alarms and diagnostics, as well as automatic quality analytics and reports while providing instant information from production. All heavy roller beds can be fully controlled by welding manipulators and are equipped with wireless controls.
"Production is going well with low welding rejection rates and with a spectacular learning curve in terms of processing hours, which is great for a start-up factory," said Juan Jose Porras Borrego, Plant General Manager, GRI Towers.
Pemamek carries out scheduled maintenance and supports GRI's production with remote access as well as local partner network whenever needed.
For more information contact:
Pemamek LLC
20333 State Highway 249, Suite 200
Houston, TX 77070
228-238-0881
info.us@pemamek.com
www.pemamek.com