Company Presentation 05/20/2014 Release 06 1

Transcription

1 Company Presentation 05/20/2014 Release 06 1

2 Company Presentation Company Overview Key Figures Production Facilities New Investments Quality Control Certifications Markets & Products 07/19/2013 Company Presentation 2

3 Company Overview Forgiatura Morandini was established in 1970 and is a private company belonging to the Morandini family. Located in Cividate Camuno (Italy) on a 100,000 sqm area, of which 55,000 sqm are under cover. Continuous focus on a technological and qualitative development of the production of forgings made of special steel qualities and alloys. 05/20/2014 Company Presentation 3

4 Forgiatura Morandini at a Glance Forgiatura Morandini Location Production capacity Markets Cividate Camuno (Italy) 75,000 t Nuclear, Thermal, Hydro, Petrochemical, Mechanical, Naval Industry Max. ingot size 125 t / 140 t Melting Processes Forging Presses Ring mill Manipulators Conventional, ESR, VIM, VAR 7,000 3,000 3,000 1,000 t + 15,000 t under construction Ømax 8,000 mm with Hmax 4,000 mm 300 t t t - 80 t - 50 t - 25 t - 20 t - 15 t - 10 t - 3 t Dimensions as forged Ø 4,500 mm / Lmax = 23,000 mm as rolled Ø 8,000 mm / Lmax = 4,000 mm heat treatment Ø 8,000 mm / Lmax = 23,000 mm Heat stability test Automatic UT Certificates ASME III, RINA ISO , NNSA, LLOYD'S REGISTER OF SHIPPING, AMERICAN BUREAU OF SHIPPING, BUREAU VERITAS, DET NORSKE VERITAS, GERMANISCHER LLOYD, EUROPEAN PRESSURE EQUIPMENT DIRECTIVE 97/23/EC, TṺV 05/20/2014 Company Presentation 4

5 Key Figures Forgiatura Morandini Turnover 147,000 k Employees Production 124,000 k ,000 k ,000 k ,000 k 98,000 k 80 80,000 k 93 85,000 k ,000 t 36,000 t 43,000 t 38,000 t 41,000 t 40,000 t 42,000 t 44,000 t /20/2014 Company Presentation 5

6 Production Facilities Raw Material The raw material (blooms and ingots) for the production of the forgings is purchased from qualified steel plants only, which can guarantee vacuum-degassing. Productions capabilities ranges from a minimum of 100 kg to a maximum of 140 t for carbon and alloyed steel, incorporating a minimum diameter of 200 mm, a maximum diameter of 8,000 mm and a maximum length of 23 m. Annual production capacity of 75,000 t 05/20/2014 Company Presentation 6

7 Production Facilities FORGING SHOP 7000 t press 1 oleodynamic press 7000 t maximum ingot weight 140 t 05/20/2014 Company Presentation 7

8 Production Facilities FORGING SHOP 3000 t press 2 oleodynamic presses 3000 t maximum ingot weight 35 t 1000 t press 1 oleodynamic presses 1000 t maximum ingot weight 5 t 05/20/2014 Company Presentation 8

9 Production facilities RING MILL Ring Mill Equipment Ring mill Ø 8,000 mm H 4,000 mm Max. weight of rolled part 150 t status operating Mobile manipulator 150 t operating Heating furnaces Two heating furnaces, loading capacity 300 t/each operating 05/20/2014 Company Presentation 9

10 VIDEO 05/20/2014 Company Presentation 10

11 Production Facilities Heat Treatment Shop Heat Treatment Furnaces 7 car-bottom furnaces 5 stationary hearth furnaces 2 overturning furnace 1 stationary hearth furnace under construction 05/20/2014 Company Presentation 11

12 Production Facilities Heat Treatment Shop Quenching 3 Water tanks up to 700 m³ 1 Oil Tank 1 Polymer Tank 1 Spray Quenching (horizontal rotation) 2 Forced Air Stations 1 Circular Tank Ø 8 m / 600 m 3 05/20/2014 Company Presentation 12

13 Production Facilities Heat Treatment Shop Heat Stability Testing Machines Heat stability 1 load capacity: from 750 mm to 8,250 mm length max. diameter: approx. 2,200 mm max. weight: 150 t Heat stability 2 load capacity: from 500 mm to 4,500 mm length max. diameter: approx. 1,100 mm max. weight: 35 t Automatic readout 05/20/2014 Company Presentation 13

14 Production Facilities Machine Shop 22 band sawing machines 2 oxygen lance cutting machines 1 CNC vertical lathe 1 vertical lathe 5 parallel lathe (4 CNC-machines) 1 CNC milling machine (with movable pillar) 1 milling machine (with movable pillar) 05/20/2014 Company Presentation 14

15 Quality Control Automatic US-Testing System working length: from 1.50 m to 12 m working diameter: from 400 mm to 2,500 mm max. weight: approx. 75 t software UTxx by GE Inspection Technologies 05/20/2014 Company Presentation 15

16 Quality Control Testing Equipment Chemical Analysis optical emission spectrometer ARL 3460 portable spectrometer SPECTROPORT F portable X-Ray spectrometers NITON XLT 898 Leco instruments for determination of C,S,O,N,H-content Micrography Inspections optical microscope with digital image manager apparatus for the polishing of test specimens equipment mod. LSP micrography with repetition portable microscope type SM 500 Non-Destructive Testing magnetic particle examination dye penetrant examination manual ultrasonic examination automated ultrasonic examination for shafts hardness measurers (ERNST/EQUOTIP) HB 10/3000/15 residual stress determination ASTM E 837 radioactivity measurer heat stability testing machine 05/20/2014 Company Presentation 16

17 Quality Control Testing Equipment Mechanical & Technological Properties universal testing machines up to 60 MN (ISO and ASME) impact testing machine testing temperatures from 196 C up to 600 C drop weight test machine machine for stress rupture testing profile measurer hardness tester portable digital tester portable digital gauger simulated heat treatment of test specimens Other Testing Equipment (external) Forgiatura Morandini strives a strong collaboration with external material testing laboratories for specific tests as SEM (Scanning electron microscope) creep tests fracture mechanics K IC,J IC,CTOD (Crack tip opening displacement) 05/20/2014 Company Presentation 17

18 Certifications RINA ISO BS OHSAS : 2007 ASME III, Div.1 and 3, NCA/WA /20/2014 Company Presentation 18

19 NORSOK Qualification Forgiatura Morandini has been successfully qualified in compliance with the requirements of NORSOK M650 ed. 4 for open-die forgings manufactured in the following steel grades ASTM A182 F51 thickness up to T=410 mm NORSOK M630 MDS D44 ASTM A182 F53 thickness up to T=280 mm NORSOK M630 MDS D54 05/20/2014 Company Presentation 19

20 Certifications NNSA RINA RINA EUROPEAN PRESSURE EQUIPMENT DIRECTIVE 97/23/EC TüV BUREAU VERITAS DET NORSKE VERITAS GERMANISCHER LLOYD AMERICAN BUREAU OF SHIPPING LLOYD S REGISTER OF SHIPPING 05/20/2014 Company Presentation 20

21 Latest Recognitions 05/20/2014 Company Presentation 21

22 New Investments FORGING SHOP Laboratories Inspection & shipment RING MILL and t-PRESS Heat treatment Large rings Cutting Large pieces Future Investments 05/20/2014 Company Presentation 22

23 Expo /20/2014 Company Presentation 23

24 New investments Forging Department Equipment Launch Forging press 150-MN-Press, capacity upsetting ingots up to 200 t 1st quarter /20/2014 Company Presentation 24

25 New investments Forging Department Equipment Launch Railbound manipulator 300 t lifting capacity, 600 t*m loading moment operating Furnaces Heating furnaces: - car bottom 5.2 x 3.65 x 13 m [W x H x L] 1st quarter 2015 Furnaces Heating furnaces: -car bottom 6,2 x 4,5 x 13 m [W x H x L] 1st quarter /20/2014 Company Presentation 25

26 New investments Heat Treatment Department Equipment Launch Heat treatment furnace stationary hearth furnaces: 6.3 x 5.5 x 15 m [W x H x L] 250 t load capacity 1st quarter 2016 Polymer quenching tank Circular tank (500 m 3 ) fitted with: 3 dual cooling towers, 6 centrifugal pumps of 30 kw each, temperature control, diameter = 7 m - depth 7 m load capacity from 80 to 100 t 1st quarter /20/2014 Company Presentation 26

27 Markets & Products NUCLEAR 4% REDUCTION GEARS 7% Product mix 2013 GENERAL MACHINES 7% SHIP-DIESEL ENGINE 2% POWER GENERATION 24% OIL & GAS 20% PETROCHEMICAL 36% 05/20/2014 Company Presentation 27

28 Markets & Products Nuclear Power Generation Thermal Power Generation Hydro Power Generation Oil and Gas Petrochemical Equipment Offshore Pipelines Compressors & Pumps Naval industries Mechanical Industries 05/20/2014 Company Presentation 28 end

29 Nuclear Power Generation Pressurizer Shell Upper head Lower head Steam generator Shell Torispherical head Tube sheets Hot legs Nuclear casks Shell, Bottom, Cover Reference Projects: AP TN International - NPCIL 05/20/2014 Company Presentation Menu 29

30 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet SA508GR.3 forging weight 50 t 05/20/2014 Company Presentation Menu 30

31 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet SA508GR.3 forging weight 44 t 05/20/2014 Company Presentation Menu 31

32 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet SA508GR.3 forging weight 48 t 05/20/2014 Company Presentation Menu 32

33 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet SA508GR.3 forging weight 76 t 05/20/2014 Company Presentation Menu 33

34 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet SA508GR.3 forging weight 45 t 05/20/2014 Company Presentation Menu 34

35 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet SA508GR.3 Rough machined weight 20 t 05/20/2014 Company Presentation Menu 35

36 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet Nuclear casks Shell, Bottom, Cover A350LF5 05/20/2014 Company Presentation Menu 36

37 Thermal Power Generation Gas and steam turbines either solid or composite Generator shafts 05/20/2014 Company Presentation Menu 37

38 Thermal Power Generation STEAM TURBINE SHAFT 28NiCrMoV Rough machined weight 18 t STEAM TURBINE SHAFT 28NiCrV8.5 Rough machined weight 15 t 05/20/2014 Company Presentation Menu 38

39 Thermal Power Generation GENERATOR ROTOR SHAFT 28NiCrMoV Rough machined weight 40 t GAS TURBINE SHAFT 28NiCrMo11.5 Rough machined weight 1.5 t 05/20/2014 Company Presentation Menu 39

40 Thermal Power Generation STEAM TURBINE SHAFT 30CrMoNiV4.11 Rough machined weight 50 t GENERATOR SHAFT 28NiCrMoV Rough machined weight 45 t 05/20/2014 Company Presentation Menu 40

41 Hydro Power Generation Generator shafts Hydraulic turbines, generator and coupling shaft Shafts for electrical motors Wind rotors 05/20/2014 Company Presentation Menu 41

42 Hydro Power Generation Forging of shaft Final inspection of shaft TURBINE SHAFT A668 Mcl.D Forging weight 68 t 05/20/2014 Company Presentation Menu 42

43 Hydro Power Generation LOWER SHAFT ST442S-25CrMo4 Forging weight 75 t 05/20/2014 Company Presentation Menu 43

44 Hydro Power Generation BULB TURBINE SHAFT A668 cl.e Rough machined weight 76 t NDE SHAFT A668 cl.e Rough machined weight 47 t 05/20/2014 Company Presentation Menu 44

45 Hydro Power Generation GENERATOR SHAFT 42CrMo4 Rough machined weight 49 t TURBINE SHAFT 30Mn5 Rough machined weight 65 t 05/20/2014 Company Presentation Menu 45

46 Hydro Power Generation TURBINE SHAFT P355QH1 Forging weight 95 t 05/20/2014 Company Presentation Menu 46

47 Hydro Power Generation THRUST COLLAR A668M cl. E Forging weight 60 t 05/20/2014 Company Presentation Menu 47

48 Oil and Gas Valve bodies Pump bodies Spheres Covers Flanges Tubes 05/20/2014 Company Presentation Menu 48

49 Oil and Gas B.O.P A182 F22 Rough machined weight 16.2 t VALVE BODY A182 F22 Rough machined weight 2.7 t 05/20/2014 Company Presentation Menu 49

50 Oil and Gas PINION SHAFT 40NiCrMo7 Rough machined weight 3.1 t VALVE BODY AISI 4130 Rough machined weight 4.8 t 05/20/2014 Company Presentation Menu 50

51 Oil and Gas STRESS JOINT SA 336 F22 Rough machined weight 13.4 t Length 12.8 m 05/20/2014 Company Presentation Menu 51

52 Petrochemical Tube sheets Channel shells Covers Bottoms Bushes Flanges Nozzles Valves Stub-ends Pinions Tubes 05/20/2014 Company Presentation Menu 52

53 Petrochemical SHELL A182 F22V Forging weight 68 t FORGED PIPE A182 F22V Rough machined weight 33 t 05/20/2014 Company Presentation Menu 53

54 Petrochemical SHELL SA336 F11 cl.2 Forging weight 28 t FORGED TEE A182 F91 Rough machined weight 6 t 05/20/2014 Company Presentation Menu 54

55 Petrochemical FORGED EXPANSION NOZZLE SPECIAL LIFTING FLANGE A182 F347 Forging weight 1 t A508 Gr3 Cl.2 Rough machined weight 7 t 05/20/2014 Company Presentation Menu 55

56 Petrochemical PUMP BODY A182 F53 Welded & fully machined 10 t 05/20/2014 Company Presentation Menu 56

57 Petrochemical SEPARATOR ASME SA336M F347 Machined weight 17 t LATERAL NOZZLE ASTM A182 F22 Machined weight 9.5 t 05/20/2014 Company Presentation Menu 57

58 Petrochemical SHELL SA336 F22V Forged weight 68 t Final dimensions: Ø5027/4679x2237mm 05/20/2014 Company Presentation Menu 58

59 Petrochemical HEAT EXCHANGER SA 336 F22 CL3 Rough machined weight 10.3 t HEAT EXCHANGER SA 336 F22 CL3 Rough machined weight 10.9 t 05/20/2014 Company Presentation Menu 59

60 Petrochemical CASING 15NiCrMoVb5 Machined weight 11.3 t 05/20/2014 Company Presentation Menu 60

61 Pipelines Compressors & Pumps Channel shells Covers Bottoms Bushes Flanges Nozzles Valves Stub-ends Pipes 05/20/2014 Company Presentation Menu 61

62 Pipelines Compressors & Pumps VALVE BODY X3CrNiMo13-4 Fully machined weight 5.5 t FORGED TEE A182 F91 Rough machined weight 5 t 05/20/2014 Company Presentation Menu 62

63 Pipelines Compressors & Pumps SPHERICAL BODY SA350 LF2 Machined weight 12 t COMPRESSOR HOUSING SA350 LF6 Forging weight 45 t 05/20/2014 Company Presentation Menu 63

64 Pipelines Compressors & Pumps CASING A350 LF2 Machined weight 14,5 t NOZZLE A350 LF3 forging weight 9 t 05/20/2014 Company Presentation Menu 64

65 Pipelines Compressors & Pumps 05/20/2014 PIPES SA 182 F92 Forged weight 17.2 t Rough machined weight 10 t Length 9.5 m Company Presentation PIPES SA 182 F92 Rough machined weight 4 to 8 t Menu 65

66 Pipelines Compressors & Pumps PIPES SA 182 F91 Forging weight 22 t Rough machined weight 6 t Length 10 m 05/20/2014 Company Presentation Menu 66

67 Naval Industries Propeller shafts Intermediate shafts Thrust-bearings and rudder shafts Components of marine diesel engines such as connecting rods, piston rods, piston heads, cylinder covers, cross heads 05/20/2014 Company Presentation Menu 67

68 Naval Industries CONNECTING RODS PROPELLER SHAFT C25 Machined weight 4 t CK45 Machined weight 28 t 05/20/2014 Company Presentation Menu 68

69 Naval Industries CYLINDER COVERS & CONNECTING RODS 16CrMo4.4 6 t PROPELLER SHAFT Ck45 30 t 05/20/2014 Company Presentation Menu 69

70 Naval Industries PROPELLER SHAFT 12NiCrMo7 Machined weight 19 t 05/20/2014 Company Presentation Menu 70

71 Mechanical Industry Centrifugal casting moulds Pinions Gears wheels Shafts Columns for presses Cylinder covers and piston heads Die blocks Components for extrusion equipment such as casings, cylinder liners, headers, matrixes 05/20/2014 Company Presentation Menu 71

72 Mechanical Industry MOULD C25 machined weight 25 t CYLINDER 42CrMo4 forging weight 90 t 05/20/2014 Company Presentation Menu 72

73 Mechanical Industry CRANK SHAFT 42CRMo4 machined weight 10 t ROLL 42CrMo4 forging weight 61 t 05/20/2014 Company Presentation Menu 73

74 Mechanical Industry CYLINDER 21NiCrMo3 Rough machined weight 64.5 t ANVIL RING 34CrNiMo5 Rough machined weight 110 t 05/20/2014 Company Presentation Menu 74

75 Mechanical Industry GEAR PINION SHAFT 40NiCrMo7 machined weight 15 t CONTAINER ( S+C ETS GmbH ) Container Mantle : X38CrMoV5-1 (1.2343) Intermediate Liner : X38CrMoV5-3 (1.2367) Inner Liner : X38CrMoV5-1 (1.2343) Total weight after assembling 68 t 05/20/2014 Company Presentation Menu 75

76 Thanks for your attention! For further information please visit our homepage or contact us directly. Web site: Contact: Phone: /19/2013 Company Presentation 76