Wind Mill Tower Production Equipment Guide

Wind Mill Tower Production
Table of Content
Company Profile
Wind Mill Tower Production Procedure
Our Equipment Proposals
Alternative Production Equipment
Welding Processes: Our recommendations / Alternatives

Our Customers / Reference List
Kistler GmbH
www.kistler-machine.de

Company profile
The KISTLER Machine Company, founded in 1966 by Roland Kistler,

is a long established family business engaged in engineering and manufacturing of
welding positioning and cutting systems for the welding industry, especially for pipe
welding and cutting.
It is the intent of KISTLER to provide quality welding positioning equipment to the
welding trade at a reasonable price to a mutually acceptable schedule.
Service after the sale insures that our customers will realize full value from the
equipment procured from KISTLER
Kistler GmbH

Company profile
The location of the KISTLER factory and engineering facility is in Bad Saulgau, in the
south of Germany, near the Lake of Constance. New workshop facilities have been
completed in 2007.
Kistler GmbH

Company profile
Kistler Cutting and Welding currently employs a team of 34.

The main customers of the KISTLER products are doing business in the following sectors
of industry:
Shipyards
Oil exploration and oil refineries
Chemical industry
Mechanical contractors
Wind mill tower manufacturing
Pipe mills
Steel construction
Kistler GmbH

Company profile
Since 2001, F.Bode & Sons Ltd, Preston UK, being Europes largest manufacturer of
welding positioning equipment is a sister company of Kistler and since 2008, UP Helfert,
Kreuztal Germany, a company specialized in submerged arc welding is also part of the
Kistler group.
The Kistler group nowadays is the only supplier being able to offer complete solutions for
cutting and welding automation from a single source.
The Kistler group in 2012 includes the following companies:
Kistler Maschinen- und Anlagenbau GmbH, Bad Saulgau, Germany
F. Bode & Sons Ltd., Preston, UK
UP Helfert GmbH, Kreuztal, Germany
Kistler Middle East FZ LLC, Ras-al-Khaimah, UAE
Kistler GmbH

Production Procedure: Plate Cutting
Kistler GmbH

Production Procedure: Welding of Plates
Kistler GmbH

Production Procedure: Bending
Kistler GmbH

Production Procedure: Longitudinal Welding
Kistler GmbH

Production Procedure: Longitudinal Welding
Kistler GmbH

Production Procedure: Additional Bending
Kistler GmbH

Production Procedure: Tack Welding / Assy.
Kistler GmbH

Production Procedure: Flange Assembly
Kistler GmbH

Production Procedure: Internal
Circumferential
Kistler GmbH

Production Procedure: Flange Welding
Kistler GmbH

Production Procedure: External
Circumferential
Kistler GmbH

Production Procedure: External
Circumferential
Kistler GmbH

Production Procedure: Welding of Built-in Parts
Kistler GmbH

Production Procedure: Cutting/Welding of Door
Kistler GmbH

Production Procedure: Cutting/Welding of Door
Kistler GmbH

Production Procedure: Shotblasting
Kistler GmbH

Production Procedure: Painting
Kistler GmbH

Production Procedure: Final Assembly (Ladders
etc.)
Kistler GmbH

Production Procedure: Dispatch
Kistler GmbH

Production Procedure: Dispatch
Kistler GmbH

Our proposal for Welding of Plates: PJU
Kistler GmbH

Our proposal: Complete Layout for Customer
Kistler GmbH

Our proposal: Longitudinal Welding C&B
Kistler GmbH

Our proposal: Longitudinal Welding C&B
Kistler GmbH

Our proposal: Rotators for Tacking
Sections
Kistler GmbH

Sections
Kistler GmbH

Sections
Kistler GmbH

Our proposal: Internal Boom for Circumferential
Kistler GmbH

Kistler GmbH

Kistler GmbH

Our proposal: Flange Welding Unit
Kistler GmbH

Our proposal: Platform for external
circumferential
Kistler GmbH

Our proposal: Rotators for Built-ins,
Brackets
Kistler GmbH

Our proposal: Rotators for door cutting and
Welding
Kistler GmbH

Our proposal: Explosionproof Rotators for Blasting
Kistler GmbH

Our proposal: Explosionproof Rotators for Painting
Kistler GmbH

Our proposal: Rotators for Assembly
Kistler GmbH

Alt. Approach for Longitudinal Welding
Kistler GmbH

Kistler GmbH

Kistler GmbH

Kistler GmbH

Kistler GmbH

Kistler GmbH

Alt. Approaches for Tacking: Jackup
Rollers
Kistler GmbH

Alt. approach for internal circumferential:
Tractor
Kistler GmbH

Alt. approach for flange welding: Tractor
Kistler GmbH

Alt. approach for external circumferential: C&B
Kistler GmbH

Alt. approach for external circumferential:
Special
Kistler GmbH

Special
Kistler GmbH

Special
Kistler GmbH

Welding process (our proposal /
alternatives)
Process
Proposal
Alternatives
Internal and external longitudinal

seamwelding
Three wire SAW
Single wire, twin wire SAW
Tack Welding of Cans to

achieve sections
Manual CO2
Assembly of flanges to sections
Manual CO2
Internal circumferential welding,

(and flange welding)
Four wire SAW
Kistler GmbH
Single wire SAW (tractor)

Twin wire SAW (tractor)
Four wire SAW

Welding process (our proposal /
alternatives)
Process
Proposal
Alternatives
Flange welding
Tandem SAW
Single wire SAW (Tractor)

Twin wire (Tractor)
Tandem SAW (C&B)
External circumferential welding
Three wire SAW
Single wire, Twin wire
Welding of Built-in parts, brackets

for ladders...
Manual CO2
Cutting Welding of door architrave
Manual CO2
Kistler GmbH

Our customers / References:
Customer
Year
Type
Qty.
Method
Max Bgl, Neumarkt

Germany
2011
Column & Boom for

External/Internal/
Circumferential/Longitudinal
Single wire
Max Bgl, Neumarkt
2012
Conversion Column & Boom
Tandem
Max Bgl, Neumarkt

Germany
2013
Column & Boom for

External/Internal Circumferential
Tandem
PBS Industry a.s.

Czech Republic
2009
Column & Boom for

External/Internal/
Tandem
CSC
Germany
2008
Special installation for

Horizontal welding of
tripod central pipe
Single wire
CSC
Germany
2010
Special installation for

Horizontal welding of
Single wire
Kistler GmbH

Customer
Year
Type
Qty.
Method
Weserwind
Germany
2005
Column & Boom for

External/Internal/
Single wire
SIAG
France
2004
Column & Boom for

External / Circumferential/
Longitudinal
Tandem
SIAG
France
2004
Internal Boom for Internal/

Circumferential
Tandem
2004
Column & Boom for

External/Internal/
Longitudinal
Single wire
SIAG
Czech Republic
2004

Tandem
SIAG
Czech Republic
2004
Column & Boom for

Internal/Circumferential
Single wire
Kistler GmbH

Customer
Year
Type
Qty.
Method
SIAG
CZ Chrudim
2004
Column & Boom for

External / Circumferential/
Longitudinal
Single wire
2005
Tandem
2001

Tandem
2008

Circumferential
Three wires
2002
Column & Boom for

Tandem
2005
Tandem
2007
Tandem
SIAG Finsterwalde
Germany
SIAG Leipzig
Germany
Kistler GmbH

Customer
Year
Type
Qty.
Method
EEW Rostock
Germany
2007
Column & Boom for

External/Internal/
Three wires
2008
Column & Boom for

Internal/Longitudinal
Three wires
2008
Column & Boom for

2
Tack Welding Internal/Longitudinal
MIG
2008

Three wires
2008
Ext. Longitudinal welding station
Two welding heads

each with three wires
2008
Ext. Circumferential welding station 1
Three welding heads

each with three wires
Kistler GmbH

Customer
Year
Type
Qty.
Method
EEW Rostock
2008
Welding tractor for Internal/

Circumferential
Tandem
AMBAU Grfenhainichen
Germany
2002
Column & Boom for

External/Internal/
Tandem
2011
Column & Boom for

External/Internal/
Tandem
2011
Column & Boom for

External/Circumferential
Tandem
2011
Column & Boom

Internal/External/Circumf.
Tandem
2012
Column & Boom for

Tandem
Kistler GmbH

Customer
Year
Type
Qty.
Method
AMBAU Grfenhainichen
2012
Column & Boom

Internal Circumferential
Tandem
AMBAU Dessau
Germany
2011
Column & Boom for

Tandem
AMBAU Cuxhaven
Germany
2008
Column & Boom for

Internal/Longitudinal
Three wires
2008
Column & Boom for

External/Longitudinal
Three wires
2008
Plate Joining Station
Three wires
2008
Internal Boom for Internal

Circumferential
Four wires
2008
Column & Boom for

Three wires
Kistler GmbH

Customer
Year
Type
Qty.
Method
AMBAU Cuxhaven
Germany
2010
Internal boom for

internal circumferential
Two heads with four wires each
2010
Column & Boom for

Three wires
2012
Plate Joining Station
Four wires
2011
Column & Boom for

External/Longitudinal
Three wires
2012
Column & Boom for

Three wires
2012
Welding tractor
Tandem
2006
Installation of subarc
equipment (existing Esab boom)
Tandem
AMBAU Bremen
Germany
Kistler GmbH

Customer
Year
Type
Qty.
Method
AMBAU Bremen
Germany
2006
Internal boom for internal circumf.
Three wires
2006
Column & Boom for

Three wires
2006
Column & Boom for

Foundation parts
Tandem
2007
Column & Boom for

Three wires
2007
Column & Boom for

External/Internal/Longitudinal
Tandem
2010
Internal Boom for Internal circumf.
Three wires
2010
Column & Boom for

External/Internal/Longitudinal
Tandem
Kistler GmbH

Customer
Year
Type
Qty.
Method
AMBAU Bremen
Germany
2011
Plate joining station
Three wires
2011
Column & Boom for

External & Internal circumf.
Three wires
2011
Column & Boom for

External&Internal longitudinal
Tandem
2011
Column & Boom for

Four wires
2011
Welding Station for External

Circumferential
Four wires
2013/14
Internal Longitudinal
welding station
Four wires
2013/14
External Longitudinal
welding station for
Cylindrical Workpieces
Four wires
CRIST Gdansk
Poland
Steelwind
Germany
Kistler GmbH

Customer
Year
Type
Qty.
Method
Steelwind
Germany
2013/14
External Longitudinal
welding station for
cyl. & conical work pieces
Four wires
2013/14
External Circumferential
welding station for flanges
Four wires
2013/14
welding station with assembly
Unit varanus
Two heads four wires

each
2013/14
External Circumferential
welding station
15
Four wires
2013/14
welding station with long boom
Four wires
Kistler GmbH

Wind Mill Tower Production Equipment Guide

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Wind Mill Tower Production

Welding Processes: Our recommendations / Alternatives