Well prepared for all eventualities

Although the oil and gas industry has always been volatile, there used to be a familiar predictability to the boom and bust cycles.

But recently things have become even more challenging: dramatic and erratic commodity price fluctuations, ambiguities concerning the future of fossil fuels and contentious global trade negotiations – let alone the impact and effects of the pandemic – have created further uncertainties and anxieties. For UK-based precision manufacturing companies operating in the oil and gas sector the situation remains challenging.

But some companies are rising to that challenge. Tyne and Wear-based precision subcontract specialist Washington Components for example has recently invested in two new, high-performance Doosan machine tools from Mills CNC which have dramatically increased the company’s machining capacity and capabilities.

The new acquisitions comprise a Doosan Puma TT 2100 SYY twin-turret, twin-spindle turning centre with dual Y-axis capabilities; and a Doosan Mynx 7500/50 powerful, large-capacity box guideway vertical machining centre. Both machines are equipped with Fanuc controls.

Washington Components is focused on the machining and manufacture of high-quality, high-precision performance critical components – often in difficult materials – and assemblies for a range of UK-based customers operating in the oil and gas (subsea), wind energy (subsea) and energy transfer (pipeline transportation) industries.

In addition to machining, Washington Components provides customers with in-house coded welding (approved to ISO 3834) and project management services, as well as a range of integrated ancillary services such as non-destructive testing (NDT), positive material identification (PMI), painting, plating and load testing.

Specialisms

Operating in and serving the subsea and offshore markets from the outset has helped position the company as specialists in the machining of hard and difficult-to-machine materials. The majority of its machines are Doosans supplied by Mills CNC.

Tony Sutherland, Washington Components’ managing director says: “We operate in tough and challenging markets. The offshore sector is volatile and, even before the outbreak of the pandemic, there were cost down pressures being experienced throughout the supply chain.

“In order to maintain our competitive edge we have focused our efforts and resources on differentiation and on gaining share in a depressed market by being the best we can possibly be. This has meant developing and refining the range of services we provide, making them more flexible, more effective and better able to meet our customers’ quality requirements, stringent lead-times and reducing budgets.”

Five year plan

To ensure the company is able to successfully navigate its way through these turbulent times a comprehensive, ambitious five year business plan was created, with implementation commencing in 2020.

It aims to put the company on track to achieve 100% growth over the five year period (2020 -2025), and included in it is a strategic capital equipment investment programme, part of which, is focused on the acquisition of advanced machine tool technologies.

“The Plan is important,” Mr Sutherland explains. “It directs all of our efforts and makes sure we are all pulling in the same direction. Running through it, from start to finish, is our commitment to continuous improvement and the ways that, through investing in our people, our plant and equipment, and our processes and systems we can become leaner, more agile and achieve our business growth targets.”

In terms of machining, specific areas highlighted for immediate attention involved the company’s small turned parts and its large milling capabilities.

“Our bar-feed section, comprising eight lathes, needed an overhaul,” Mr Sutherland affirms. “Some of the machines in the section, although still performing well, were not effective at producing parts at the lower costs now expected from customers. We believed that investing in a new multi-tasking turning centre equipped with Y-axis and driven tooling would significantly increase the performance of the whole section.”

He continues: “A similar situation existed with our milling capabilities. We knew that an investment in a new, large-capacity, heavy-duty machining centre would not only help us improve our ability to fulfil machining contracts with our existing customers but could also be leveraged to win new work.”

The Doosan: Mills CNC partnership

Washington Components is no stranger to Mills and Doosan. In fact, 13 of the company’s 14 CNC machines are Doosans supplied by Mills CNC.

Nevertheless, for the latest purchases the company spent time researching the market and drew up detailed specifications for a new multi-tasking turning centre and a new large-capacity vertical machine.

“We did our research, but in both cases Mills CNC came out on top,” explains Tony Sutherland. “We have a great relationship with Mills and believe that Doosan machines are difficult to beat on performance and price. The fact that the machines are backed by Mills’ aftersales service is also a real positive.

“Mills CNC is a proactive company that takes the time to understand our needs and requirements. From talking to their sales and technical staff we made the decision to invest in a new TT 2100SYY turning centre and a Mynx 7500/50 vertical machining centre. We also like the fact that Mills holds many machines in stock or on very short lead-times of typically two to six weeks.

“Installation was seamless. The delivery and installation of our new machines involved the movement of 12 others. The whole exercise was completed in three days.”

New technology

TT 2100SYY

The TT 2100SYY is a 8 inch chuck/65mm bar diameter twin-turret/twin spindle turning centre with dual Y-axis capabilities on its upper and lower turrets. The machine is fast, powerful, highly-productive and versatile and enables small precision parts to be machined to completion in a single set-up.

The TT 2100SYY at Washington Components was installed with an integrated bar-feeder to optimise production and to help exploit the machine’s full productivity potential. Since installation it has been used to machine, in relatively high volumes, a range of small, complex precision parts up to 30mm in diameter.

“The new TT 2100SYY is the centrepiece of the Bar-feed Section and, such is its speed, reliability and flexibility, that it has enabled us reduce the number of machines in the section from eight down to five,” Mr Sutherland advises.

“The machine’s purchase was facilitated by funding assistance from ERDF (European Regional Development Fund), SAM (Sustainable Advanced Manufacturing), Sunderland University and Northern Powerhouse.”

Mynx 7500/50

The Mynx 7500/50 is a powerful, large capacity vertical machining centre that has a rigid box guideway construction and a high-torque spindle with a BT50 (Big Plus) spindle/tooling interface.

The machine is designed for heavy-duty machining applications and is renowned for its high material removal rates and for its ability to machine tough and difficult materials. The Mynx 7500/50 at Washington Components is being used to machine large offshore components in small volumes and batches. These parts are characterised by their tight tolerances, superior surface finish requirements and intricate and complex features.

“The Mynx 7500/50 is a true workhorse that delivers consistent, high material removal rates day in day out. It’s been a great acquisition,” Mr Sutherland concludes.

Mills CNC www.millscnc.co.uk

Washington Components www.washingtoncomponents.co.uk