PIPE CUTTING MACHINES

YOUR PARTNER IN SUCCESS THROUGH INNOVATION

Table of Contents

Performance Engineered Products . . . . . .4-5

Common Applications . . . . . . . . . . . . . . .6-7

Machine Configuration . . . . . . . . . . . . . . .8-9

Pipe Handling Equipment . . . . . . . . . . .10-11Turning Roll & Conveyor Assembly . . . . . . . . . . . . . .10

Entrance Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Discharge Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . .11

Mechanized Cutting Assemblies . . . . .12-13Two-Torch Straight Cut-off Assembly . . . . . . . . . . . . .12

Mechanical Pantograph Assembly . . . . . . . . . . . . . . .13

Computerized Profiling Assemblies . . . . . . . . . . . . . .13

Multi-Axes Controls . . . . . . . . . . . . . . . . . . . . . . . . . .14

Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . .15

Dedicated Software . . . . . . . . . . . . . . . .15-16On-line Operating Software . . . . . . . . . . . . . . . . . . . .15

Optional Off-line Software . . . . . . . . . . . . . . . . . . . . .16

Internet-based Factory Service . . . . . . . . . . . . . . . . . .16

Pipe cutting technology has advanced rapidlysince the days of hand-held torches andwraparound paper templates. A single cuttingmachine can now supply enough pipe to satisfy 5 to 10 fit-up and welding stations.Knowledgeable business owners recognize that a centralized, efficient cutting operation governsall downstream operations. Speed, safety, andquality have become the benchmarks ofprofitable pipe fabrication, the same qualities that describe Vernon pipe cutting machines.

In 1948, Vernon Tool Company acquired therights to manufacture the Douglas cuttingmachine, a simple mechanical pantograph forburning straight cuts, simple miters and saddles.The acquisition of the Douglas patents wasVernon’s introduction to pipe fabrication. It haslead to a 60-year history spanning threegenerations and culminating in today’s reputationfor reliability, longevity, and dedicated customer support.

Investment in design engineering, advancedtechnology, and experienced staff constituteVernon’s commitment to the fabrication market.Alignment of interests and continuous exchangeof information between Vernon and itscustomers have forged relationships that haveexisted for more than forty years. Loyalty andrespect have bred a common goal of improvingproductivity and fostering innovation.

While many of the basic cutting and materialhandling concepts are still valid today, Vernoncontinues to incorporate the newest technologyin its machines. Innovations like machine-mounted microprocessors, programmable logiccontrols, and network-compatible operatingsystems have reduced costs, improved cutaccuracy, and decreased redundant data entry.Vernon recognizes that the key to its future iscontinuous product improvement and satisfiedcustomers.

Vernon Tool is committed to improving your pipefabrication operations. Eight hundred installationsworldwide since 1948 attest to Vernon’s successtoward this goal. We offer the most advancedequipment and a professional staff of engineersand technicians with over 100 years of combinedpipe fabrication experience. Vernon looksforward to sharing its vision, resources, andknowledge to improve your cutting operations.

Overview

Vernon’s Commitment to Pipe Fabrication

Performance Engineered Products

Simple Set-up & Accurate Pipe ProfilesMechanization of cutting improves the speed andrepeatability of each contour. A rigidly welded machinebed supports turning rolls that rotate pipe as the cuttingtorch travels over the pipe. The pipe’s weight is evenlydistributed over the entire length of the machine bed.Cutting can be performed anywhere on the machine.The pipe is self-centering in the turning rolls. Only thetorch needs to be raised and lowered to accommodatedifferent diameters. With excellent operator visibility, acutting carriage travels on precision machined andhardened ways under a solid rack and pinion gear drive.

All cutting operations are controlled by one person fromthe operator’s console. For making common pipeconnections and holes, cut data is entered at theoperator’s console in response to simple questions on theconsole display. Computer numerical control (CNC) withclosed loop encoder feedback insures exact repeatability.No special programming or operating skill is required toobtain precise, repeatable cuts.

Precision components and simpleoperation allow Vernon machines toproduce fabricated fittings, nozzles,and saddles in minutes.

Integrated conveyors improvespeed and safety of all cuttingoperations. No overhead cranes orextra personnel are required.

Safe, Efficient Pipe HandlingIn 1965, Vernon Tool integrated powered pipeconveyors into the turning roll machine bed. Pipe ispower fed into the cutting area, hydraulically loweredonto the powered turning rolls, cut, hydraulicallyraised from the turning rolls, then discharged out ofthe cutting area ... all from the operator’s console.Machine setup and material handling times arereduced by up to 80 percent. The operator canconcentrate on cutting activities instead of pipehandling. Both the finished piece and the remnantare fully supported, rotated, and moved without theneed for additional labor and lifting devices.

Streamlined Data FlowWindows-based operating software collects andconverts cut data into machine instructions to ensuresimple start-up and user-friendly interaction betweenthe operator and the machine. Part programs may becreated at the machine console, from a remote PC, ordownloaded directly from most popular 3D modelingprograms.

Seamless CAD-CAM communication eliminatesredundant data entry with its concurrent human errorsand time-consuming conversions. Important data iscaptured from isometric spool drawings, structuraldesign and analysis models, and pressure vesselfabrication drawings. Operators can verify accuracy ofend profiles and midsection holes using customizedshop packets and 2D and 3D graphic illustrations on theoperator’s console.

Management may delegate part-programming responsi-bilities to remote engineering centers or to the shopfloor. Machine performance ensures customersatisfaction, so every last detail is engineered to improveproduction and decrease costs.

Common Applications

Industrial piping features straight runswith simple connections, easy work forVernon pipe cutting machines.

Structural support piping requires proper fit-up of brace members. Weld preparationangles made to stringent AWS specificationsenhance structural integrity and reducegrinding and filling labor.

The name “Vernon”has becomesynonymous with

pipe cuttingmachines in a wide

variety of industries. Fabricatorsspecializing in process piping,power generation, mechanicalcontracting, pressure vesselmanufacturing, and structuralframes rely on Vernon for highproduction and precise fit-up. Pressure vessel shells with multiple off-

centerline hole penetrations, as well as thecorresponding inlet and outlet nozzles, canbe programmed and burned with minimalmanual intervention.

Structural Support PipingFabricators of offshore jackets, bridges,architectural space frames, and lifting cranesemploy pipe as load-bearing framework ofwelded structures. Compound, overlappingjoints with centerline and axial offsets arecommon yet complex. The cost of field erectionand rework dictates that clean, tight fit-ups arethe rule not the exception.

Vernon computerized machines eliminatevirtually all manual lofting, measuring, andmarking operations. By producing accurate, highquality cuts, Vernon machines convert pipefitters into pipe welders who can concentrate onproducing high quality connections instead of“dressing” unsatisfactory profiles. Complex cutsare computer precise, while the materialhandling system loads pipe quickly and safely.

Pressure Vessel FabricationWhere pipe serves for containment, pressurevessel fabricators employ Vernon machines tomanufacture heat exchangers, compressors,separators, pumps, boilers, and turbines. Manualmeasuring, marking, and grinding are virtuallyeliminated using Vernon computerized cuttingmachines.

On-line or off-line software generates andtransfers part programs to the machine control.Relieved of programming responsibility, theoperator concentrates on maximizingproduction. Part programs produce vessel shellsand nozzles with precise distance and axiallocation between each cut.

Industrial PipingProcess piping applications include tubularsections through which gas, fluid, or solids pass.Common users include mechanical contractors,petrochemical, paper and pulp mills, powergeneration plant constructors, HVAC fabricators,shipbuilders, and oil and gas pipeline companies.

Typically this type of fabrication requires smallerdiameters and simple connections. Pipe spoolsconsists of small diameter pipe and welded orforged fittings. Contours are relatively simple andrepetitive. Straight lengths of pipe areconsecutively processed using the integrated pipeconveyor system and two-torch straight cut-offcarriage. Where multiple spools are needed,cutting and beveling operations move in aproduction line manner from raw storage tofinished spool.

End profiles and holes are produced bycoordinating several axes of motion. Mechanicalpantograph models employ adjustable cams andlevers, while CNC models rely on closed-loopencoder drives.

Machine Configuration

Shop Layout RecommendationsCutting pipe is a critical operation in any fabrication shop. Efficient cutting operations set the pace for all downstream operations. Speed, quality and dimensional accuracy contribute tolower project labor costs. The cutting operation should be the focal point of a productivityanalysis. A well-conceived cutting system will incorporate the following concepts:

• Organize raw material by diameter andmaterial to minimize set-up changes.

• Centralize cutting operations in a single areafor improved organization, cleanliness, andsupervision.

• Consolidate “cutting to length” and“contouring” into a single operation toeliminate redundant handling and setup.

• Material flows in both directions to improvesystem flexibility.

• Conveyors and automatic feed systems movematerials instead of overhead lifting devices forspeed and safety.

• Buffer areas and storage racks accommodatedifferent cycle times, production runinterruptions, downstream bottlenecks andscheduling changes.

• Non-cutting operations located where they donot interfere with burning and conveyingoperations.

1. Pipe is loaded on to storage racks locatedon each side of the entrance conveyor.

2. Selector gates on the entrance conveyorare raised flush with the storage rack level.Raw pipe is rolled from either side of the rackuntil the desired piece is positioned on theconveyor.

3. The work piece is hydraulically lowered ontothe powered, hour-glass conveyor rolls

4. The conveyor system transfers the pieceinto the cutting area and hydraulically lowersthe pipe onto the turning rolls.

5. The desired cuts are produced by the profilingassembly . Straight cuts are made using thetwo-torch straight cut-off assembly located onthe operator’s side of the machine.

6. The lifter-conveyor assembly raises the pipefrom the turning rolls and moves it onto thedischarge conveyor.

7. Finished pipe is raised by the selector gatesand discharged left or right onto adjoiningpipe racks . The remnant piece is eitherpositioned in the cutting area for repeat cutsor returned to the raw storage racks.

Custom is Standard at VernonOver 60 years and 800 installations have taught us that no two customers are alike. Eachinstallation is designed for specific pipe sizes and lengths. Multi-axis computer controls matchthe intended application. Construction begins only after material flow and footprint have beenapproved by you, the customer. Each installation processes pipe in the following sequence.

Pipe Handling Equipment

Turning Roll & Conveyor AssemblyVernon machines consist of a rigid structural steelframe on which two parallel shafts with turningrolls are mounted. The shafts are driven by avariable-speed DC motor through two minimumbacklash worm gearboxes. Heavy-duty roller andthrust bearings ensure smooth rotation of the mainshafts and pipe. The pipe is self-centering and fullysupported by turning rolls located along the entirelength of the machine bed. Various modelsaccommodate a wide range of pipe diameters, soonly the cutting torch is raised or lowered toaccommodate different diameters.

The standard machine is capable of conveying androtating a single random (20-22 foot) length ofpipe. An optional machine extension provides fullrotation and support for double random lengths upto 44’ long. Extensions are identical in constructionto the standard machine bed and connect to themain drive shafts, lifter-conveyor frame, andstraight cut-off carriage track of the base machine.

The lifter-conveyor assembly, consisting of hour-glass shaped rollers on a welded frame, useshydraulic power to lower and raise pipe out of the rotation rollers. Sealed ballbearing flanged units on the roller shafts and DC drives ensure smooth, trouble-free lateral movement of the pipe.

Controlled from the operator’s console, pipe is fedsmoothly and safely into the machine. End loadingand unloading eliminates the need for overheadlifting and extra personnel, thereby improving thesafety and speed of the cutting process.

For superior visibility the profiling assembly moveson a carriage track mounted on the machineopposite the operator. The operator console andthe two-torch straight cutoff assembly movealong a track running the entire length of thecutting machine.

The entrance conveyor permits the operatorto select pipe from raw storage racks andload it safely and smoothly into the cuttingarea. Remnant pieces can be returned toraw storage.

With gates UP, raw pipe canbe rolled side to side.

With gates DOWN, pipe is cradledin conveyor rolls for transport intothe cutting machine.

With gates UP and either tiltcylinder extended, pipe isdischarged to finished pipe racks.

Entrance ConveyorSimilar in design to the machine’s lifter-conveyorassembly, entrance conveyors load pipe into and outof the cutting machine bed. Structural steel framessecure a series of hour-glass rollers on shafts inflanged ball bearings. Linked together by chain &sprocket assemblies, the conveyor rollers arecontrolled by a variable speed, reversible DC drive motor.

Hydraulically-actuated selector gates raise and lowerpipe onto and out of the rollers to the height of theadjacent pipe racks. In the full UP position, theselector gates are flush with the pipe storage rack sothat pipe can be rolled from side to side. When thecorrect pipe is located over the conveyor, the selectorgates are lowered and the pipe is cradled by theconveyor rollers.

Discharge ConveyorAfter all cutting operations are completed, finishedpipe is power fed onto the discharge conveyorwhere it is raised out of the hourglass rollers byhydraulic selector gates. Hydraulic cylinders tilt theconveyor in either direction to roll the finished pipeonto storage racks. All conveyor functions, likepower feed direction and speed, selector gateUP/DOWN, and hydraulic discharge tilt are controlledfrom the operator’s console.

Fast, smooth, and safe material handling relies on automated pipe conveyorsintegrated with rugged pipe rotating beds. Rigid structural steel frames containprecision components to ensure predictable operation and unmatched longevitydating back to the early 1950s.

Discharge conveyors of various lengthstransport pipe to the respective fit-uparea. All operations are controlledfrom the operator’s console.

Mechanized Cutting Assemblies

Two-Torch Straight Cut-off AssemblyThe 2-torch straight cut-off assembly produces pipespools to length with straight and beveled end cuts.Two torches make cuts simultaneously, one on thetrailing end of the first piece and one on the leadingedge of the second piece. The operator moves therolling torch carriage to the proper distance on themachine, locks it into positions according to a tapemeasure mounted on the machine frame, andconveys the pipes against a retractable pipe stop.While cutting is performed, steel wheels mountednext to the torches maintain a constant tip-to-pipedistance.

Mechanical PantographAssemblyFirst developed in the late 1940’s, the semi-automatic pantograph attachment synchronizeslongitudinal torch movement with pipe rotation.Most common saddle and miter cuts may be cutwith a maximum of three simple settings usingadjustable gears and levers.

ComputerizedProfilingAssembliesMicroprocessor technology putsproduction-line productivity at yourfingertips to quickly and accuratelyprocess all types of pipe profiles andholes. Computer-controlssynchronize torch movement,burning and pipe handling functions,and maintenance diagnostics. PLCtechnology coordinates auxiliarymachines functions like torch on-off andautomatic out-of-round compensation.

Rugged construction using minimum-backlashworm drives, machined & hardened ways andprecision rack & pinion drives ensure repeatability andlongevity. Mechanized movement is controlled by DC servomotors with encoder feedback.

A state-of-the-art, industrial computer offers tachless multi-axismotion controls, rapid processing speeds, large data storagememory, and internal software specifically designed for pipeprofiling operations. Windows-based programming ensuresnetwork compatibility to generate, transfer, and archive pipeprograms. Programs may be created at the machine console ordownloaded from remote file servers. Microprocessor machinesare ideal for both one-off and long run production jobs.

Mechanizing the cutting operation results in repeatable, high quality cuts free from humanerror. Moveable torch carriages allow all diameters to be cut to length without interferenceanywhere along the machine bed and in full view of the operator.

The 4-axis control, Model MPM-4, incorporates four axes of motion toorient the torch to the proper weld preparationangle and to maintain the proper torch-tip-to-pipe distance. This produces a constantincluded weld prep angle between theadjoining pieces. The computer controlcompensates length measurement regardlessof weld prep angle. Automatic out-of-roundcompensation is accomplished by analogproximity sensors on an independent closed-loop servo circuit. The cutting carriage andoperator’s console travel the full length of the machine.

The 2-axis control, Model MPM-2, employs a simple processor tocoordinate pipe rotation with longitudinal torchmovement. The torch remains at a fixed bevelangle so the included weld preparation anglebetween members varies throughout theconnection.

Profile cutting is performed on the front end ofthe machine bed. Height adjustment iscontrolled from the operator’s console.

The 5-axis control, Model MPM-5, adds an additional axis of motion torotate the torch bevel angle so that it remainsnormal to the contour cut path. To produce aconstant weld prep angle, the machine canburn any desired bevel angle at any location onthe pipe.

The principal benefits of this assembly areslightly faster cutting speeds and very accurateweld preparation angles common in offshoreconstruction and pressure vessel fabrication.

MPM-2

MPM-4

MPM-5

Controls to MatchDifferent Needs

PlasmaCutting &RotatingGroundsAll Vernon machinesare readily adaptable

to plasma powersupplies for cutting

carbon and stainless steel,alloy materials and

aluminum. Plasma cutting yields asmaller heat-affected zone with less materialdistortion. Three to five times faster cutting speedsand no preheat delay reduce cutting times and clean-up labor.

When using plasma arc withthe Vernon machine, the

rotating ground directsthe plasma current backto the power source toavoid damage to themachine’s movingparts and electricalcomponents. Therotating ground is

attached to a collapsiblespider clamp, which is

inserted into the pipe andtravels with the pipe as it is

conveyed on the machine.

Optional Accessories

Preheat Torch5-axis computerized models can be fitted with apreheat torch to improve the speed and quality of thecut on large wall thickness. Traveling ahead of thecutting torch, the preheat torch operates underprogram or manual control. Automatic ignition,solenoids, valves, regulators, and hoses are includedwith this option.

Dedicated Software

On-line Operating SystemThe Windows-based operating software ensuressimple start-up and maintenance. Synchronizingsimple graphical user interface with complexgeometric algorithms, a series of simplequestions leads the operator to enter cut data.Each part program contains front and rear endprofiles and almost unlimited numbers ofcircular and rectangular holes with exactdistances and axial angles. All layout andburning operations are consolidated into asingle operation.

To simplify operation and maintenance, theconsole includes a touch-screen monitor,. TheWindows-based program provides interactiveerror messages, labeled illustrations, brilliantcolor graphics, and an on-line instructionmanual. Compatible with imperial and metricdimensions, all data is easily entered. Consolegraphics display the finished piece with verifiabledimensions in 3D and 2D format.

The WinMPM operating system is common toall Vernon machines and ensures reliability, userfamiliarity, and maintenance continuity. Withinthe limits of computer memory and speed, allusers can be upgraded to a standard, provenversion of software.

Off-line SoftwareNetwork compatibility gives management the ability todelegate part-programming responsibilities to the shopfloor, to remote engineering centers, or direct CAD-CAMdownloads from most popular 3D modeling programs.Isometric, structural, and pressure vessel design programsgenerate data files easily received and converted intomachine-readable formats. Redundant data entry andhuman errors are eliminated.

Customized cut sheets containing intersection data, 3Dand 2D dimensioned images, materials, quantities andcustomer or project identification may be generated fordistribution to the shop floor. The operator simply recallsthe file name and begins to cut.

Internet-based Factory ServiceThe Vernon on-line diagnostic service, Ve-Assist, connectsfactory technicians to your machine by secure, dedicatedhigh speed internet link. On-site operators andtechnicians communicate in real-time with factoryexperts who supervise, demonstrate, and troubleshootsoftware and hardware problems. Data files review,machine set-up parameters, and operating systemupgrades are performed in seconds. The on-linedialogue and “whiteboard” illustrator facilitatestep-by-step instruction. Internet technologyputs factory technicians virtually side-by-side your staff to perform and monitor themachine operations.

End profile shapes include standard straight cutswith bevels, multiple intersection T-, K-, and Y-type saddles, centerline offsets, I.D.-O.D.transitionsaddles, elbow supports, gusset slots, and pipe-to-cone shapes. Hole shapes include circular andrectangular shapes, reinforcing rings, andoverlapping “boat bumper” holes. All centerlineand axial offset dimensions are computercontrolled. Layout and burning operations areconsolidated into a single operation. All cutsconform to applicable AWS Welding Codes fortubular structures.

Complimentary Products

Vernon MastertubePlasma ProfilerPlasma cut tube products like handrails, structuralframes, and nozzles with production line speed.

User-friendly control generates straight cuts, T, K, & Y shapes, centerline offsets, slots

and holes in round and rectangular shapes.

Vernon Abrasive SawCut, bevel and groove all diametersand material with extraordinary speedand uncontaminated, machine-like quality.Abrasive wheels cut materials ranging fromcarbon and stainless steel, alloy, ductile iron,ceramic, plastic, and cement-lined pipe.

Vernon machines provide the lowest total cost of ownership through a comprehensive program that begins when you place the order and extends decades beyond delivery. We sell solutions to the most difficultfabrication challenges. Your success is our reward.

A Lincoln Electric Company.Specifications subject to change without notice.© 2000 Vernon Tool Company. Printed in U.S.A.Catalog: P2009-09.02

503 Jones Road, Oceanside, CA 92058

Phone: 760.433.5860 • Fax: 760.757.2233

Web: www.vernnontool.com • E.mail: www.sales@vernontool.com