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Production Savings in Oil and Gas Manufacturing

With the Dörries VTL, complete processing in one set-up is possible for many typical pump components (housings).

The Dörries CONTUMAT VC 2400 MC-V vertical lathe provides high-precision machining of rotary components.

The Dörries Contumat VCE 2000 VTL is fitted with a pallet table with a separate straightening table and motor-driven alignment stand.

"Top tier suppliers to the oil and gas and power generation industries are no different than companies involved in any other supply chain-they need to constantly work smarter, quicker and more cost-effectively to not only meet their customers' demands, but also to ensure that their own bottom-line margins are not only maintained but, ideally, also improved," said a Starrag spokesperson. "Nowadays, this means investing in best-in-class manufacturing technologies. And as global oil and gas markets become ever-more competitive, an increasing number of suppliers (and OEMs) are gaining production savings by harnessing Starrag's `Engineering precisely what you value' strategy."

As part of Starrag's comprehensive product range, machines from Dörries and Scharmann in particular are reportedly benefitting users in oil and gas industries. In each case, Starrag can modify and supply each machine specifically to suit each user's unique machining needs.

A manufacturer of piston compressors that operate up to 3,600 bar, Burckhardt Compression uses a quartet of Starrag machines-a Scharmann Alpha 1250 M machining center, a Scharmann Heavyspeed 2 ram-type boring mill, a Dörries Contumat VC 2400/200 vertical turning lathe (VTL) and a Scharmann Ecoforce 2 HT4 machining center-to machine cylinders, cylinder blocks, frames, valve heads and steering rods. Producing components up to 236" long and weighing 66,139 lbs., the production routines are demanding, including finish machining to 20 microns and H7 holes up to 51.2" deep. "The Starrag machines consistently meet all requirements while also generating time and production savings compared to former methods," said the spokesperson.

According to August Dünki, Burckhardt Compression Director of Large Part Manufacturing, "We especially gain extra benefits from the use of the Dörries VTL's additional moveable work table axis (for set-up and/or in-situ workpiece inspection) and reduced unproductive time via the 72.4 HP Ecoforce 2 HT 4, which utilizes head attachments (with automatic pick-up) and robot tool handling. Starrag's machine pre-approval software package is particularly beneficial. It details workpiece processing, including all machining parameters, tools and targeted processing times, and is an important part of machine selection."

In another example, Mokveld is using a 80.5 HP Dörries Contumat VCE 2000 VTL to machine high-pressure axial flow control and stop valves measuring up to 94.5" long by 78.7" diameter and weighing up to 26,455 lbs. These are produced from materials such as cast and chrome steels, duplex, super duplex Inconel and titanium. Eighty percent of the machining-to finishes of 30 microns-is focused on turning. Again, the use of a second work table is proving beneficial by enabling a workpiece to be set up while another is being machined, for example. Additionally, because boring can also be undertaken on the VTL, Mokveld is reducing formerly long machining times, re-location errors and costs by machining the components complete in a single set-up.

KSB also utilizes a Dörries Contumat VTL-in this case a VCE 2800/220 MC model-on which it is machining machine pump housings weighing up to 6,614 lbs. to exacting IT6 tolerance standards. Replacing a process that involved turning the housings' front and rear sides and then re-locating on a different machine for drilling, the Contumat performs all required tasks in a single clamping. The machine not only reduced throughput times, but it has also replaced two to three conventional machines, allowing KSB to gain further financial capital investment rewards and improved operator utilization.

For more information contact:

Starrag USA Inc.

North American Headquarters

Skyport Business Park

2379 Progress Drive

Hebron, KY 41048


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