Izhorsky Trubny Zavod (ITZ), part of the Severstal Group based in Kolpino near St. Petersburg, Russia, has placed an order with SMS Meer for the supply of a new gap closing press with a press force of 25 MN. The machine will be integrated into the existing 18m JCOE® large-diameter pipe mill, which SMS Meer supplied in 2006.

With the gap closing press, recently developed by SMS Meer, and related process technology tubes with small diameters and higher wall thickness can be produced more cost-effectively. This means that the growing market for typical offshore dimensions can be served with a wide range of products and above all cost-efficiently. Compared to a single JCO® long-stroke press, productivity can be tripled when combined with the new gap closing press.

Precise, rapid forming of the heavy plates is performed first in an adapted process in the JCO® pipe forming press. The remaining gap is then reduced to a minimum in just a few steps using the new gap closing press - ensuring the tack welding process can be safely carried out. The forming process itself is controlled here using the SHAPE software developed by SMS Meer. The result is high-quality pipes with very low tolerances for sophisticated applications.

As project manager Berthold Genser from SMS Meer explains: "The crucial factor for the placement of this order by ITZ was that we were able to demonstrate the high productivity and precision of our gap closing press. We had previously tested the new technology successfully in production trials. ITZ were also impressed by the results." This is already the second order for this type of closing press.

Moreover, the VSP (variable speed pump) control system is being used on the new gap closing press for the first time. This modern and efficient hydraulic drive system significantly reduces energy and maintenance costs. With hydraulic systems featuring this type of control system there is no need for proportional valve technology, a cooling system or central hydraulic power pack. All components are mounted directly on the machine. In addition, the hydraulic pumps run only when the system requires pressure, i.e. no longer continuously. This allows significant energy savings to be made.

This is already the second order for a gap closing press of this type.

The gap closing press is scheduled to go into operation in the 1st quarter of 2013.