power of process quality of service - steeltube€¦ · • skiving and roller - burnishing of...
TRANSCRIPT
POWER OF PROCESS QUALITY OF SERVICE
Železiarne Podbrezová a.s. belongs to the oldest metallurgical companies
in Central Europe. Its history dates back to 1840.
Železiarne Podbrezová GROUP,
geographic location of members
2
Železiarne Podbrezová GROUP, members
3
4
Notes:
- Slovak market is 4 % of total sales and 6 % of tube sales.
- Export Sales department of Podbrezova sales to territories: Hungary, former Yugoslavia and Soviet Union, its share of total sales is 28 % and of tubes 18 %.
- Transmesa, its share of total sales is 3 % and of tubes 4 %.
Železiarne Podbrezová GROUP, members
Sales and Marketing companies
PIPEX International, Nidau Switzerland • the company sales and distribution channel through which are sold
ŽP production in European and wolrd markets. Its share of total sales is 12 %, tubes 20 %.
PIPEX Italia, Arona, Italy
• the company is ŽP sales and distribution channel, which accounts for 18 % of total sales.
It operates on European and Middle East markets. Its share of tube sales is 23 %.
ŽP Trade Bohemia, Praha, Czech republic
• company is the distributor marketing ŽP and Transmesa products in Czech Republic.
Its share of total sales is around 22 % and tube sales is 12 %.
Slovrur, Stalowa wola, Poland
• company is the important distributor marketing the ŽP and transmesa products in Poland.
Its share of total sales is around 13 % and tube sales is 17%.
TS Steel pipe & Fittings, Bagnatica, Italy • Tube stock company that is operating products in Italian market.
ŽĎAS SGS,, Düsseldorf, Germany • company is the important distributor marketing ŽĎAS products in Germany.
Sales of core products, in year 2012
5
ESTIMATE OF CONTRIBUTION TO THE PRODUCTION OF SELECTED
PRODUCTS IN THE EU, in 1st half of 2012
Contribution to production, hot rolled seamless steel tubes 7,1 % total
production in the segment was 1 286 kt. (pipe lines and OCTG tubes excluded)
Production in EU ŽP production
6
Contribution to production, precision cold drawn
seamless tubes is 9,2 %, total production in the segment was 257 kt.
Production in EU ŽP production
source ESTA, PRODCOM statistics
Market share
Geographical sales, 2012
7
Chart shows the company sale by countries in tons, (excluded con-cast bloom)
- 5 000 10 000 15 000 20 000 25 000 30 000 35 000
Poland
Italy
Czech Rep.
Germany
Slovakia
Hungary
Spain
USA
Serbia
Austria
Croatia
Holland
Turkey
France
Romania
South Korea
Great Britain
Belgium
Bulgaria
Slovenia
Others
Strengths
8
1 Closed production cycle begins with the purchase and processing of steel scrap, continues with steel
and steel tubes production and it follows with finalization and transportation to the customer. All
activities are performed by companies associated under the name ZP Group.
2 Research and Development center belonging to the ZP Group and cooperation with the Faculty of
Metallurgy of the Technical University are the guarantors of progress and development of products,
services and technologies.
3 Developed global sales and distribution network, technical support, quick response to customer
demands and short delivery times.
4 Private Secondary Technical School and private High School of the company annually prepares more
than fifty graduates of the metallurgical profession.
5 Continuous modernization and optimization of technologies in the annual financial statements by an
average of 22 million. EUR.
9
Planned activities for investment development for year 2013:
• Dedusting of electric arc furnace and ladle furnace
• Total reconstruction of equipment for continuous casting of steel (september 2013).
Continuously cast steel billets
10
Steel scrap processing
Electric Arc Furnace (EAF)
Ladle Furnace (LF)
Continuously Casting Machine
Continuously cast steel billets
square cross-section
125, 150, 160, 180, 200, 225, 280 mm
circular cross-section
150, 180, 210, 240, 260, 280 mm
11
Steel blooms applications :
Hot rolled tubes, steel flanges, steel forgings, steel rolled bars and profiles
Continuously cast steel billets
4 000 –10 000 mm
12
billet → heating → sizing mill → piercing press →
elongating mill → push bench → withdrawal mill →
reheating → reducing mill → finalization
(cutting, straightening, testing, marking, packaging)
Seamless hot rolled steel tubes
OD: 21,3 – 139,7 mm
WT: 2,3 – 12,5 mm
production in 2010 → 169 941 t
production in 2011 → 183 099 t
production in 2012 → 193 886 t
Hot rolled seamless tubes
Production in acc: EN, ASTM, ASME, API, GOST,
JIS, DIN, BS, NF A, UNI, STN, ČSN, PN – H,
Tubes for mechanical and general engineering - 52,9 %
Tubes for power industry - 27,2 %
Line pipes - 15,4 %
Tubes for buildings - 4,4 %
Casing and tubing - less than 0,01 %
Power engineering
13
We pay a great deal of attention to the production of quality
products designed for the energy-engineering sector as well as
the subsequent production of tubes and final heat processing.
Tubes are checked by the latest technology of non-destructive testing. Our tubes are heat resistant up to 600 °C / 1 110 °F
and withstand pressures of 16 MPa / 2 320 psi - X10CrMoVNb9-1 (P/T91).
Tubes intended for use in the energy industry are supplied as:
seamless ranging from 10 to 139 mm with a wall thickness from 1.6 to 12.5 mm
STEEL TUBES for high output, reliable and environmentally safe power plants …
14
Železiarne Podbrezová is approved supplier:
Steel tube for pressure appliances
for room temperature pressure use
tubes for low temperature pressure use
boiler tubes for high-pressure use
fine grain steel tubes for pressure equipment
Steel tubes for heat exchangers
Boiler and exchanger tubes with internal riffling
Power engineering
The laboratory to verify the tube quality, including creep tests.
STEEL TUBES for high output, reliable and environmentally safe power plants.
15
Power engineering
Jaworzno II
EVI Abfallverwertung B.V.
PKN Orlen
16
Production in
2008 → 46 879 t
2009 → 25 124 t
2010 → 40 390 t
2011 → 47 389 t
Precision cold drawn seamless tubes
Tubes for machining and machine parts - 52,8 %
Tubes for hydraulics and pneumatics - 18,1 %
Tubes for automotive industry - 16,1 %
Tubes for heat exchangers - 11,7 %
Pipe lines - 0,9 %
Tubes for ball bearing - 0,3 %
Tubes for buildings - 0,1 %
Number of drawing benches: 23
Number of annealing furnaces: 7
Precision seamless
cold drawn steel tubes
OD: 4,0 – 120,0 mm
WT: 0,5 – 10,0 mm
Provided Heat treatment (acc. DIN and EN)
BKW (+LC) - cold finished / soft
BKS (+SR) - stress relieve annealing
GBK (+A) - annealed
NBK (+N) - normalized
BK (+C) - no heat treatment
Annealing atmosphere:
N2, N2+H2(2% or 3,5%), N2+H2(40%)+CO+CO2,
17
• cutting off tubes
• internal and external end beveling
• skiving and roller - burnishing of inner surface of tubes
• bending of tubes
Zinc plated seamless precision steel tubes
OD: 4,0 – 42,0 mm
WT: 0,5 – 5,0 mm
• coating thickness 8 – 30 micrometers
• the second layer Cr (Cr6+ Free)
• after agreement it is possible to seal Zn/Cr coating
• additional PVC or polyester coating possible
• transparent passivation (An), iridescent passivation (Cn)
• marking Fe/Zn8/An/T0 (example)
Final treatment of precision tubes
18
Machine
OD (mm) Wall thickness
WT ( mm )
Length
L ( mm )
Length tolerancies
( mm ) min. max.
Brehm 6 – Cutting 25 152 * 25 – 610 0,2-0,5
Píĺa ADIGE – Sewing 12 100 1 - 5 20 – 3 250 0,3-2
Wrt 8 – 500 - Brushing 8 60 od 1 30 – 500
ST 661 – Brushing 12 102 od 1 150 – 3 000
WM 612 – Washing 12 102 od 1 150 – 3 000
ECONOMY M – Beveling 10 70 1 – 4 20 – 190 0,15
ECONOMY V – Beveling 10 70 1 – 4 190 – 690 0,15
REIKA – Rotary cutting off 20 90 1 – 12 150 – 2 000 0,15
SIN-O- Matic 1,2 – Sewing 12 81 1 – 6 20 – 340 0,05
ADIGE CM 502 - Sewing 12 76 1 – 7 (20)35 – 600 0,05
Cutting off and beveling
Machine
OD (mm) Wall
thickness
Length L (mm) max. Rm bend (mm) max. angle
of bent arm
Tolerancies of
bend angle ( ) min. max. with mandrel without mandrel with a contact strip with rollers
BM42IMC 16 42 up to 3 3 000 3 700 130 260 187° 1
Machine diameter ( mm ) Wall
( mm )
Length
( m ) Inside diameter tolerancies
ID OD
TBSR 6500 – skiving and burnishing 40 - 110 50 - 130 5 - 10 3 - 6 H 8, H 9
Bending
Tubes for hydraulics cylinders
Final treatment of precision tubes
19
Tubes are produced using several technologies and supplied as:
precision seamless cold drawn steel tubes, within the range: from 4 to 120 mm with wall thickness from 0.5 to 10 mm
Automotive
20
Hydraulics a pneumatics
Tubes for manufacture of cylinder barrels: precision seamless tubes for mechanical treatment – HPZ, ID 40-115 mm (after agreement up to 160 mm), WT 4-10 mm,
precision seamless tubes "ready to use" – HP, ID 40-110 mm WT 4-10 mm ((after agreement welded tubes)
Tubes for manufacture of pistons and telescopic cylinders: precision seamless tubes – HPK, ID 40 -120 mm WT 5 - 10 mm Tubes for hydraulics pressure lines tubes for pressure hydraulic and pneumatic lines – HPL, OD 6-80 mm ID 4-55 mm galvanized tubes for pressure hydraulic and pneumatic lines – HPL, OD 4-42 mm WT 0,5-5 mm
OUR PRODUCTION IS PRECISE not only in term of dimensions – but also in terms of deadlines ...
21
Examples of use of tubes and tube semi-finished products as the input semi-finished products are as follows: hydraulic cylinders high-pressure hydraulic distributions pressure vessels ball bearings parts and axles of engineering units construction units of processing machines bases and support of machines construction parts of cartridges and containers preparations for tools parts of agricultural machinery conveyor belts parts of ships
Machinery
OUR PRODUCTION IS PRECISE not only in term of dimensions – but also in terms of deadlines ...
22
Total sales in years 2008 - 2011: 1 190 tons
Steel cylinders are manufactured in accordance with
applicable EN / ISO regulations and technical
specifications. Raw material is chrome-molybdenum
steel 34CrMo4.
- Seamless steel cylinders for industry gases
- Seamless steel cylinders for compressed natural gas
- Seamless steel cylinders for fire equipment
- Seamless steel cylinders for beverage and drinking devices
- Seamless steel cylinders for acetylene
Machinery
STEEL TUBES for high output, reliable and environmentally safe power plants.
23
Gea Batignolles Technologies Termiques, France
- process air cooled heat exchangers
Doosan Mecatec, South Korea
- shell & tube heat exchangers
FBM – KNM Group, Italy
- heat exchangers, air coolers, boilers
Ravagnan, Italy
- heat exchangers, pressure vessels
Power engineering
24
Butt welding Reducers
OD1: 21,3 – 88,9 mm
OD2: 26,9 – 114,3 mm
WT1: 2,0 – 3,2 mm
WT2: 2,3 – 3,6 mm
Butt welding
Elbows
OD: 21,3 – 610,0 mm
WT: 2,0 – 12,5 mm
Large diameter welded
steel tubes
D: 323,9 – 2235,0 mm
t: 5,0 – 25,4 mm
Other products
Civil engineering - 78,7 %
Power industry 21,3 %
Surface treated by
sand blasting
25
Predaj výrobkov iných výrobcov
Seamless tubes:
OD: 273,0 – 610,0 mm
WT: 9,5 – 72,0 mm
Welded tubes:
OD: 26,9 – 219,1 mm
WT: 1,8 – 8,0 mm
* Possible zinc plating
Cold drawn steel tubes,
delivered in coils
OD: 4,0 – 18,0 mm
WT: 0,45 – 2,5 mm
For injection devices of combustion (Diesel) engines
sizes 6x1,8; 6x2,1; 6x2,125; 6x2,2; 6x2,25 mm, made
from steel grade St 30Al, are delivered.
Depending on tube size there is tube of 60 - 400 m
length in coil.
PIPEX Italia, S.p.A.
Via Paleocapa 10
28041 Arona, Italy
phone: +39 0322 235511
fax: +39 0322 44659
www.pipex.it
ŽP TRADE Bohemia, a.s.
Ztracená 272
16100 Praha, Czech republic
phone: +420 235302307
fax: +420 235300760
www.zptrade.cz
SLOVRUR, Sp. z o.o.
Brandwicka 138
37464 Stalowa Wola, Poland
phone: +48 15 8448045
Fax: +48 15 8420234
www.slovrur.pl
TRANSMESA, S.A.
Calle de la industria, 10
08330 Premia de Mar, Spain
phone: +34 93 7549200
Fax: +34 93 7523847
www.transmesa.com
TS Steel Pipe and Fittings, S.r.l.
Via F. Ili Kenedy, snc
24060 Bagnatica (BG), Italy
phone: +39 035 687560
Fax: +39 035 676278
www.tssteel.it