arcelormittal engineering products ostrava -...
TRANSCRIPT
ArcelorMittal Engineering Products Ostrava
Structure in AM Czech
• Engineering Production
• Foundry
• Electric Motor Repairs
• Roll-Turning Shop
• Heat Treatment
• Railway Wheel-Sets
The company is divided into units:
Subsidiary company of ArcelorMittal Ostrava
(established 1. 1. 2011) as a manufacturing and
repair unit company.
ArcelorMittal Service Group
Structure in AM Poland
• Engineering Production + Saw blades
• Design Office
The company is divided into units:
ArcelorMittal Service Group Sp. z o.o. based in Dabrowa Górnicza belongs to ArcelorMittal Poland S.A.
The company has been operating since 2006 and has 40 years of tradition and experience
Engineering production
1. Strategic spare parts
2. Regeneration
3. Projects
CORE business for Mechanical and welding shop
Basic portfolio
• saw blades for cold and hot cutting
• moulds for CCM machines
• tundishes
• dummy bars
• segments for CCM machines
• cylinders for CCM
• machine parts and gears
• columns for buildings, beams, joists and girders of bridge cranes
• components of profiled sections
• steel bodies of machines and large gearboxes
• fan impellers and hoods
1. Strategic spare parts
• toothed gears and cable drums
• rulers, connectors, solid and hollowcylinders
• steel roller tables, coated (metals, synthetic paints)
• vibrators, sliders, flaps and compensators
• pipelines and pipeline structures
• roller transfer systems
• stepping walking beam coolers
• recycling press bodies
• technological equipment for cement plants:cyclones, silos, pouring equipment, etc.
References – spare parts
CCM moulds Sinter cars
References – spare parts
CCM moulds Scrap buckets
References – spare parts
LadlePort crane girder length of 26 m
References – spare parts
Crank shaftStands
References – spare parts
Coke oven doorsFrames for coke oven doors
References – spare parts
Fan housing Pelletizing drum
References – spare parts
Saw blade disksDummy Bar
Basic portfolio
2. Regenerations
• providing complex servicing of machines and equipment for metallurgy, copper industry,etc.
• lifting equipment
• pressure devices
• systems of power hydraulics and pneumatics
• CCM rolls
• CCM segments
• gearboxes
• axles/shafts
• Other spare parts suitable for renovation
References – regeneration
CCM rollsCCM rolls
References – regeneration
Shafts of rolls Gearbox
Design Office
3. Projects
The Design Office consists of the following departments:
• devices for mechanization and lifting equipment
• building department
• department of electrics
The departments in charge of designing prepare documentation in the following fields:
• technical
• modernization, repair and restoration
• registration dossier of devices subject to technical supervision
• electrical and power distribution substations
• design measurement of control automation and signalling
Basic portfolio
Projects
• steel structures for heating and metallurgical furnaces
• cooling boxes
• retention tanks
• BOF vessels
• wagon tilter
• transfer cars and vagons
• extension of rolling mill
• upper part of tandem furnace
• automotive line renovation
• drum for laying of submarine cables
• ladle cleaner
• decolier
• cast bay - bridge
References - projects
Upper part of tandem furnaceExtension of rolling mill
References - projects
Automotive line renovation Wagon tilter
References - projects
Ladle cleanerPortal loader
References - projects
Decoiler Cast bay - bridge, Q=1504025t, L=22m; A7N P
References - projects
Annealing furnace heating hood Ladle car
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References - projects
Transfer Car for slab Discharging and charging rolls
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References - projects
Crane Trunion ring
36
References - projects
Ladle transfer car Fan housing
40
Foundry
• tradition since 1951
• long term experience
• production of demanding castings of:
steel
grey iron and nodular iron castings
• the operation unit includes also a pattern shop and scales treatment center
About unit
41
Grey iron and nodular iron castings
About unit
• moulds and accessories
• stands
• beds of machine tools
• tables
• base plates
• fixing plates
• pressing tools
• gearbox housings
• flywheels
• gears and chain wheels etc.
Steel castings
• fluid motor boxes
• pulleys
• belt pulleys
• grates and grate bars
• chain, gears and travel wheels
• railway discs
• slag ladles
• funnels
• castings for mining machines
• rolls etc.
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Production parameters
49
References
Super heavy ingot moulds up to 150 tons Large ingot moulds 20 - 70 tons
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References
Small ingot moulds 1 - 20 tons Roll castings
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References
Rolling mill scraper Gear case
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References
Ladles Reeler plug s for production of tubes
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References
Alloy wheels for railway, sidings, trolleys, cranes and gear wheels
Frames for coke oven doors
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References
Large ingot mould machining Sinter cars
Electric motor repairs
Repairs and servicing of electric machines:
• AC and DC
• rotating synchronous and asynchronous
• with squirrel cage and slip ring rotors
• DC motors and high-voltage motors
• stationary electrical devices
reactors
lifting magnets
About unit
• special burning press MP-303 MICAMATION for high-voltage coils up to 7m
• SCHENCK dynamic balancer
• BAKER high-voltage winding tester
• ALTMAN mobile filtration station
• STRUNZ ecological burning furnace etc.
Production equipment
Output range: 1 kW – 10 000 kW, AC machines up to 6 kV
Output range: 1 kW – 5 000 kW, DC machines up to 6 kV
Insulation system: REMICA – temperature class "F" ("H" is possible on agreement)
Impregnation: VPI (vacuum-pressure)
References
Rotor winding repair Stator winding repair
References
Generator rotor balancing
68
Roll-turning shop
• long tradition and experience
• producing of new rolls
• renovation of rolls for hot rolled steel sections and strips
• machining:
alloyed forgings
iron and steel castings (hardness up to 90 HSh)
tungsten carbide rolls
• production of gauge or copy templates
• production of templates on a spark cutting machine
About unit
70
References
Roll for Medium-Section Rolling Mill production line – longitudinal cutting
Roll for Medium-Section Rolling Mill production line - reinforcing bars
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References
Rolls for Heavy-Section Rolling production line – section L140
Rolls for wire rod mills
75
Heat treatment
• performed in gas and electric furnaces
Types:
• annealing:
normalizing
soft annealing
stress relief annealing
stabilization annealing
dissolvent annealing
sferoidization annealing
About unit
81
Railway wheel-sets
• production of axles
• production of solid and tyred wheels
• assembly and repair of wheel–sets
• installation of bearing boxes on axle journals
• static balancing of solid and tyred wheels
• replacement:
tyres
disc and gearing wheels
brake discs
About unit
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References
Wheel sets for metalurgical vagons Driving wheel sets
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References
Tyred wheels Axles for locomotives, wagons and trams
Technical Back Up and Machinery
Engineering
Machining with cutting tools
Production parameters (AMSG)
• Lathes - Ømax = 500, Lmax = 2000 Ømax = 1050, Lmax = 8000 Ømax = 1600,
Lmax = 5500 Ømax = 2500, Lmax = 10000
• CNC Lathes - Ømax = 700, Lmax = 3000, Qmax = 1600kg.
• Carousel lathes - Ømax = 4200, Hmax = 2500
• Universal milling machines - Xmax = 1400, Ymax = 440, Zmax = 475
• Gantry milling machines - Xmax = 9000, Ymax = 2600, Zmax = 3000
• CNC Milling machines - Xmax = 1800, Ymax = 800, Zmax = 710
• Machine tools - Ømax = 1000/360°, Hmax = 1200
• Boring machines - Xmax = 1800, Ymax = 5000, Zmax = 3000, Ømax = 1500
Machining with cutting tools
Production parameters (AMSG)
• CNC boring machine - Xmax = 3000, Ymax = 2500, W = 800, Zmax = 900
• CNC machining center - Xmax = 850, Ymax = 700, Zmax = 650
• Grinding machines for cylindrical surface - Ømax = 800
• Spherical grinder - Ømax = 600
• Surface grinding machine - Xmax = 2000, Ymax = 400, Zmax = 500, Ømax = 1000
• Milling machines for gears - Ø = 250 – 1600, m = 3-20
• Hobbing machines - Ømax = 3200, m = 3 -36
Steel structures
Production parameters (AMSG)
• Shot blasting - Smax = 5000, Hmax = 5000, Lmax = 12000
• Mechanical cutting - gmax = 25, Lmax = 3150, Ømax = 510 (amax = 500 x bmax = 710)
• Thermal cutting - gmax = 300, Smax = 3000, Lmax = 14000
• Sheet coiling - gmax = 12, Smax = 2000 Ømin = 440 gmax = 60, Smax = 3500 Ømin = 600
Saw blade discs
• produced in sizes Ø (600 - 2100) mm with a pitch of (8-22) mm
and disc thickness (6-12) mm.
Production parameters (AMSG)
Services
• machining with cutting tools on CNC machines,
• blasting and painting of steel structures,
• mechanical and thermal cutting (plasma)
• welding of steel and non-ferrous metals,
• non-destructive testing of materials and welds
• testing of mechanical properties of welded joints,
• inspection and repairs of welding equipment,
• welding courses.
Machining
Production parameters (AMEPO)
• Center lathes – range of machined diameters up to 1 250 mm and the maximum turning length 12 000 mm (CNC: SPU 40 CNC, SUI 63 CNC)
• Vertical turret lathes – maximum machined diameter 5 000 mm, with the maximum height 2 990 mm,(CNC: SKJ 12 CNC, SKQ 20 CNC)
• Milling machines – longitudinal travel up to 1 400 mm, cross shift of the table up to 450 mm(CNC: FGS 63 CNC)
• Horizontal boring machines – spindle diameter 80, 100, 130, 160, 200, 250 and travel up 9 000 mm, (CNC: WH 10 CNC, WHN 13 CNC, W160 CNC)
• Round grinding machines – up to the outer workpiece diameter 630 mm and length 3 000 mm
• Flat grinding machines – maximum table area 600 x 3 000 mm with a longitudinal travel 3 000 mm
• FRÖMAG vertical pull type broaching machines and tool sharpening grinder SAACKE
Millwright activities and fabrication of steel structures
Production parameters (AMEPO)
• roll bending of plates/sheets, tubes, and sections
• plates/sheets deburring up to the length 9 000 mm
• material cutting (shears, saws, flame cutting machines), straightening
• fabrication of steel structures and pressure vessels of stable group A, B category IV
• fabrication of steel structures for road and railway bridges
• fabrication of lifting equipment and crane runways
• fabrication of pipelines
• manufacturing of complete gearboxes, including run tests
• manufacturing of complete hydraulic cylinders and simple hydraulic components
• electric arc welding by method 111, gas shielded arc welding by method 135, submerged arc
welding with a wire electrode by method 121
• surfacing of rolls and shafts
Millwright activities and fabrication of steel structures
Production parameters (AMEPO)
Manufacturing of all types of structures:
• up to the weight of 50 000 kg
• length of 20 000 mm (unique case length of 27 m)
• other dimensions are limited by the width (6 300 mm) and height (5 800 mm).
Technical Back Up and Machinery
Motor repairs
Welding school
About unit
• courses for welding process111(E), 135(M), 141(T) and 311(G)
• courses as per DIN (RW TÜV), API
• preparation courses for hard soldering as per ČSN EN 13 133
• additional training and testing of welders from safety provisions as per ČSN 05 0610, ČSN 05 0630, ČSN 05 0650
• welding courses as per ČSN EN 287-1, ČSN EN ISO 9606 – 2, ČSN EN 1418
• courses for higher welding personnel – European Welding Practitioner (EWP) in cooperation with the Czech Welding Institute (in Czech Český svářečský ústav s.r.o.)
• courses for the “welding worker”qualification take one week
• basic courses take four weeks, additional courses take three weeks
• preparation courses for achieving the welder’s test as per ČSN EN 287-1 take three weeks and in case of extending the validity of the test (or expanding) the course takes one week
Production parameters
Repairs and servicing of rotating electric machines:
• rewinding
• mechanical repairs
• winding revision (even on site)
• measuring on electric machines (including rotation tests – loading tests up to 300kW)
• dynamic balancing of electric machines rotors, flywheels, fans, turbines, etc. (up to the
weight of 7 500 kg, maximum span of 5 600 mm, maximum balancing diameter of
2 700 m, maximum balancing speed of 3 600 rpm).
• installations of electric machines in process plants (using laser technology for positioning
of foundation frames and couplings of electric motors)
• process diagnostic measuring
• we ensure also transport in case of complex requirements
Production parameters
Repairs and servicing of non-rotating electric machines:
• reactors
• lifting magnets
• static and rotation welding machines
The unit provides repairs and servicing of all types and versions of electric machines made
by domestic and foreign manufacturers – mainly SIEMENS, ABB, ANSALDO, SCHORCH.
Technical Back Up and Machinery
Roll Turning Shop
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Production parameters
• Centre lathes – machining diameter range up to 1 250 mm at the max. turning length 7 000 mm
• Vertical turret lathes – machining diameter range: 1 000 and 1 200 mm at the max. height 1 150 mm
• Multispindle portal milling machines – longitudinal travel up to 3 500 mm, cross shift of the table up
to 900 mm
• Horizontal boring machines – spindle diameter: 130 mm, fixing plate size up to 3 775 x 4 550 mm
and travel 3 000 mm, equipped with the Heidenhain iTNC 530 CNC control system
• Roll grinders – up to the workpiece external diameter 1 000 mm and length 5 000 mm, including
conical journals
• Flat grinding machine – maximum dimensions of fixing plate 1 000 x 320 mm with longitudinal feed
of 1 000 mm
• Special milling machines for production of rolls for reinforcing steel bars - up to the roll diameter of
500 mm and max. length 2 500 mm, including electric spark marking of the rolls
Technical Back Up and Machinery
Heat Treatment
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Types:
• refining of carbon and alloyed steels
• controlled carbon potential cementation
• hardening of tooling steels up to the austenitization temperature of 1 200 °C
• hardening of special and ledeburitic steels
• hardening in the atmospheres
• tempering in a salt bath
About unit
77
Production parameters
Maximum sizes of processing furnaces
Max. internal dimensions of chamber furnaces: width = 3 100 mm; length = 8 200 mm; height = 1 600 mm
Max. internal dimensions of cementation furnaces: diameter = 750 mm; height = 1 300 mm
Maximum sizes of cooling bath
Max. internal dimensions of the water bath:width = 2 900 mm; length = 9 000 mm; depth = 6 000 mm
Max. internal dimensions of the salt bath: width = 2 400 mm; length = 6 400 mm; depth = 800 mm
Product limits
Depending on the internal dimensions of the furnaces and weight up to 20 000 kg
Technical Back Up and Machinery
Railway wheel sets
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• Railway wheel–sets
production of new wheel–sets
repairs of wheel–sets (tyres, discs, brake discs, gear wheels)
• Railway wheels
solid rolled wheels
solid cast wheels
composite wheels (tyred wheels)
• Axles (for railway vehicles and tramways)
driving axles
common axles
disc-wheel axles
• Tramway monoblock wheels
• Tyres
Portfolio of products and services
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Tests
Tests of material and mechanical parts for identification of surface and internal defectsby the following methods:
• ultrasound method
• capillary method
• magnetic powder method
• visual method
All tests are documented by the corresponding protocols in accordance with EN, ČSN.
About unit
84
Wheel-set parameters
Production parameters
• Wheel diameter: 360 mm - 1 250 mm
• Wheel track: max. 1 680 mm
• Weight: max. 3 000 kg
Axles–driving, common and axles for trams
• Length: max. 2 400 mm
• Diameter: max. 450 mm
• Weight: max. 1 000 kg
• Material: ČSN 11 558.1, ČSN 15 230.9, Os.L
as per GOST 4728-79, EA1N, EA4T
as per EN 13261; hot rolled round bar
grade 15 230.9
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Rolled and cast solid wheels, composite (tyred) wheels
Production parameters
• External diameter: max. 1 250 mm
• Weight: max. 1 000 kg
• Rolled wheels: profile as per UIC – ORE, or based on agreement, material: as per EN 13
262 (UIC 812-3)
• Cast wheels: material as per ČSN 42 2711, 42 2712, 42 2650, 42 2660, or based on
agreement, any shape of the wheel (depending on the customer)
• Tyred wheels: disc castings, material 20L, 25L as per GOST 977-75, 4491-86 up to a
diameter of 900 mm, or based on agreement. Castings of material ČSN 42
2650, ČSN 42 2660, external diameter 710 mm - 900 mm, any shape of the
wheel (depending on the customer)
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Tyres
Production parameters
• External diameter: max. 1 250 mm
• Material: rolled piece of quality grade as per
UIC 810-1 or GOST 398-2010
Monoblock wheels for trams
• External diameter : 650 mm - 710 mm
• Rim width: 85 mm - 120 mm
• Material: rolled piece of quality grade as per
TM1 (12 063.7), or based on agreement.
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Certificates
Certificate of technical eligibility no. 343,Certification center ČD České dráhy, a.s., Prague
Confirmation of vocational-technical eligibility no. 143/12, Železničná spoločnosť Slovensko a.s.
Confirmation of vocational-technical eligibility registration no. 143, Železničná spoločnosť Cargo Slovakia, a.s..