Compact Weigh/Measure/Stencil - 8 ft of Table Space
The Compact WMS is a new technology that combines the tasks of real time product data acquisition and compilation, quality control, and all other WMS tasks into one integrated system. With production rates as high as 5 pipe per minute for tubing applications the Compact WMS solves the problem of a production process bottleneck. The Compact WMS can be fit into any roll-down table using less than 8 ft. of table space, greatly reducing the floor space needed for WMS operations.
The Compact WMS can be configured to process tubing and/or casing, and sized to handle any common length product. This provides for production flexibility by allowing a large range of system throughput. Work-In-Process material handling is greatly reduced since product can be processed through one integrated system, versus separate processes. The Compact WMS provides unparalleled flexibility with regard to its location within a tube or casing processing layout.
The Compact WMS works well when placed in a layout as shown in the figure below, with associated coating and pipe handling equipment. Shown are an inbound pipe table allowing pipe to be dropped onto a roll-down section feeding the Compact WMS. A short exit table feeding a coating conveyor, induction heating for preparing the pipe surface to accept the coating, a coating applicator, exit conveyor section, chain drive exit dry down table, and roll down table section where finished pipe are removed for shipment of storage. T&S can supply all or any part of this equipment.
The Compact WMS can also be mounted in line with hydro testing equipment, threading equipment, etc., depending on the upstream processes to be supported. Pipe does not have to be end referenced on the Compact WMS.
The Compact WMS integrates a Roll-Down Scale process for capturing pipe weight in motion. The Roll-Down scale captures the weight of each pipe or tube to API specifications as they roll across a short inclined table section. There are no moving parts (other than the strain sections of the load cells) associated with the weight capture, an operation that can be completed in as little as two seconds. This development has made possible the inclusion of all components of a WMS to fit within eight feet of a conventional pipe accumulation roll down table (See the concept figure below).
PURPOSE of the Compact WMS:
WMS stands for “Weigh, Measure, and Stencil”. For OCTG pipe producers and finishers, this term should also be extended to include the production and storage of individual pipe identity and information. The Compact WMS also includes application extensions to update business and MES databases with complete produced pipe information in real time.
The core technologies involved are as named: weighing, measuring length, and stenciling the pipe identity on the surface of the pipe. The Compact WMS integrates all of these functions into a roll-down table “plug-in” System.
The goal of a properly integrated WMS is to rapidly process each individual pipe introduced with total accuracy, with methods for handling any quality control exceptions, and stenciling the product in a way that satisfies both the producer and its customers. All while taking up as little floor space as possible.
OPERATION of the Compact WMS:
With the Compact WMS, the processing of product within a particular batch is handled automatically. This is accomplished via a WMS Supervisory Computer System (Including Operator HMI and connectivity to other business systems) and a local Programmable Logic Controller (PLC) managing routine pipe handling functions. An overhead beam spans the pipe processing area, with axes supporting Length Capture and Stenciling operations. This beam is sized to allow pipe to pass underneath and over the Roll Down Scale section, with an end mounting arrangement.
A “V” notch with hardened inserts is installed in the table at the Length Capture station. The notch catches incoming pipe, stabilizing the pipe and lining up the longitudinal axis in the notch before measuring.
The Length Measuring System (LMS) is then activated, and the length is quickly determined by moving two pipe end sensors along the longitudinal axis of the pipe until the location of both ends are detected. The motions are encoded for accuracy. Each axis starts from the locations registered for the last pipe in, so motion is limited to the variability in the batch.
Current API requirements require this length to be accurate to +/- 0.1 feet (one tenth of a foot), a requirement that is met handily by the Length Measurement System of the Compact WMS.
The length thus determined is immediately passed to the Compact WMS Supervisory Computer and product data retained for further data processing. Should a problem (length out of range) occur, the System Operator will be notified, and methods for rapid recovery will be invoked.
Assuming the Stencil Station of the Compact WMS is clear, the pipe is then indexed out of the LMS notch and rolls across the Roll Down Scale Station. Here, the weight is captured and immediately sent to the WMS Supervisory Computer, where it can be tested against weight limits set for the batch.
A second set of “V” notches in the Compact WMS Assembly is included at the Stenciling Station. The pipe lands in this notch after crossing the scale. Here, weight per unit length testing is accomplished, per API specifications. Weight per Length is handled for both plain end and upset tubing, with automatic application of weight gain depending on the upset configuration.
Assuming that the weight per unit length check is passed, the pipe is automatically stenciled with its data particulars. Since the LMS has determined the locations for each end of the pipe, the Compact WMS does not need the pipe to be end referenced in order to apply the stencil at the proper location.
The stenciling head is immediately moved to the proper starting point where it is lowered and the stencil applied. This starting point can be at either end of the message to be stenciled, since the Compact WMS is capable of stenciling in either direction, from start to end of the stencil, or from end to start. Also, since the system spans the full length of the pipe, it is capable of double stenciling where this is a requirement. Note that the Compact WMS can operate with Zero-VOC inks and solvents for stenciling.
There are a variety of stencil applicators on the market. The Compact WMS offers the TASKWRITER™, REA-Jet™, and Zanasi® stencilers for air-atomized or DOD applications. There are strong offerings from other competitors in the stenciling market, each having advantages and disadvantages, and customers with experience with any or all have strong feelings about their preferred method.
The WMS Supervisory Computer, in organizing all this activity, has now acquired all the details regarding the pipe just processed. This pipe data, including weight, length and message stenciled, along with any number of other communicated details (Grade, O.D., Wall, Wt/Ft, Customer, Order Numbers, etc.), can then be added to any producers local tally and made available to the business database.
New Technology – but Proven in the Real World:
This equipment is built for years of continuous service, with oversized drive shafts, bearings, and a simplicity of construction that ensures that the Compact WMS will operate long after it’s initial payback. The system shown above is capable of processing pipe from 1.90” O.D. to 11” O.D., handling lengths from 15-48 ft., with a max weight of 3500 lbs. The Compact WMS shown can process pipe at a rate of 5 pipes per minute.
Each element of the system is custom tailored to the needs of the producer or finisher. Limited range finishers would be able to procure the Compact WMS at a discount from multi-range finishers, because the length of the Compact WMS overhead gantry can range from 15 – 63 feet. This is true also for tubing producers over casing or large pipe producers, since the underlying Compact WMS structures could be sized to their particular product mix.