Company Presentation 07/01/2016 Release 09 1
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1 Company Presentation 07/01/2016 Release 09 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. 07/01/2016 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 200 t / 250 t Melting Processes Forging Presses Ring mill Manipulators Conventional, ESR, VIM, VAR 16,000-7,000 3,000 3,000 1,000 t 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 6,500 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 , UNI EN ISO 14001:2004, BS OHSAS 18001:2007, EnergyMS-59 ISO 50001:2011, LLOYD'S REGISTER OF SHIPPING, AMERICAN BUREAU OF SHIPPING, BUREAU VERITAS, DET NORSKE VERITAS, GERMANISCHER LLOYD, TṺV 07/01/2016 Company Presentation 4
5 Key Figures Turnover Employees Production Forgiatura Morandini ,000 k ,000 k 98,000 k 96,000k 95,000 k t t t t t /01/2016 Company Presentation 5
6 Forgiatura Morandini 07/19/2013 Company Presentation 6
7 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 250 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 07/01/2016 Company Presentation 7
8 Production Facilities Forging Shop t press 1 oleodynamic press t maximum ingot weight 250 t Railbound manipulator 300 t lifting capacity, 600 t*m loading moment Mobile manipulator 150 t 07/01/2016 Company Presentation 8
9 Production Facilities Forging Shop 7000 t press 1 oleodynamic press 7000 t maximum ingot weight 140 t 07/01/2016 Company Presentation 9
10 Production Facilities Forging Shop 3000 t press 2 oleodynamic presses 3000 t maximum ingot weight 35 t 1000 t press 1 oleodynamic press 1000 t maximum ingot weight 5 t 07/01/2016 Company Presentation 10
11 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 07/01/2016 Company Presentation 11
12 Production Facilities Heat Treatment Shop Heat Treatment Furnaces 7 car-bottom furnaces 5 stationary hearth furnaces 2 overturning furnaces 1 stationary hearth furnace under construction 07/01/2016 Company Presentation 14
13 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 07/01/2016 Company Presentation 15
14 Production Facilities Heat Treatment Shop Heat Stability Testing Machines Heat stability 1 load capacity: 12,000 mm length max max. diameter: approx. 2,200 mm max. weight: 150 t Heat stability 2 load capacity: 7,000 mm length max max. diameter: approx. 1,200 mm max. weight: 35 t Automatic readout 07/01/2016 Company Presentation 16
15 Production Facilities Machine Shop 22 band sawing machines 2 oxygen lance cutting machines 1 CNC vertical lathe 1 vertical lathe 5 parallel lathes (4 CNC-machines) 1 CNC milling machine (with movable pillar) 1 milling machine (with movable pillar) 07/01/2016 Company Presentation 17
16 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 07/01/2016 Company Presentation 18
17 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 visual and dimensional inspection hardness measurers (ERNST/EQUOTIP) HB 10/3000/15 residual stress determination ASTM E 837 radioactivity measurer heat stability testing machine 07/01/2016 Company Presentation 19
18 Quality Control Testing Equipment Mechanical & Technological Properties universal testing machines GALDABINI 40 MN INSTRON 60 MN (ISO and ASME) impact testing machines up to -196 C testing temperatures 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) 07/01/2016 Company Presentation 20
19 Certifications RINA ISO ASME III, Div.1 and 3, NCA/WA /01/2016 Company Presentation 21
20 Certifications BS OHSAS : 2007 UNI EN ISO : 2004 EnergyMS-59 ISO : /01/2016 Company Presentation 22
21 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 07/01/2016 Company Presentation 23
22 Certifications LLOYD S REGISTER OF SHIPPING RINA RINA TüV BUREAU VERITAS DET NORSKE VERITAS GERMANISCHER LLOYD AMERICAN BUREAU OF SHIPPING 07/01/2016 Company Presentation 24
23 Latest Recognitions 07/01/2016 Company Presentation 25
24 Latest Recognitions 07/01/2016 Company Presentation 26
25 Customs authorisation FORGIATURA MORANDINI srl is authorised exporter for: Algeria Norway South Africa South Korea Switzerland (cfr. customs authorisation no. IT/026/BS/15) Presentazione aziendale 27
26 New Investments FORGING SHOP Laboratories Inspection & shipment RING MILL and t-PRESS Heat treatment Large rings Cutting Large pieces Future Investments 07/01/2016 Company Presentation 28
27 New investments Forging Department Equipment Launch Furnaces Heating furnaces: -car bottom 6.2 x 4.5 x 13 m [W x H x L] 4th quarter /01/2016 Company Presentation 29
28 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 4th quarter 2017 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 4th quarter /01/2016 Company Presentation 30
29 Markets & Products REDUCTION GEARS 5% NUCLEAR 6% Product mix 2015 SHIP-DIESEL GENERAL ENGINE MACHINES 3% 13% POWER GENERATION 27% OIL & GAS 19% PETROCHEMICAL 27% 07/01/2016 Company Presentation 31
30 Markets & Products Nuclear Power Generation Thermal Power Generation Hydro Power Generation Oil and Gas Petrochemical Equipment Offshore Compressors & Pumps Naval industries Mechanical Industries 07/01/2016 Company Presentation 32 end
31 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 07/01/2016 Company Presentation Menu 33
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 50 t 07/01/2016 Company Presentation Menu 34
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 44 t 07/01/2016 Company Presentation Menu 35
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 48 t 07/01/2016 Company Presentation Menu 36
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 forging weight 76 t 07/01/2016 Company Presentation Menu 37
36 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 07/01/2016 Company Presentation Menu 38
37 Nuclear Power Generation Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet SA508GR.3 SA508GR.3 SA508GR.3 07/01/2016 Company Presentation Menu 39
38 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 A350LF5 SA182 F316L 07/01/2016 Company Presentation Menu 40
39 Thermal Power Generation Gas and steam turbines either solid or composite Generator shafts 07/01/2016 Company Presentation Menu 41
40 Thermal Power Generation STEAM TURBINE SHAFT 28NiCrMoV Rough machined weight 18 t STEAM TURBINE SHAFT 28NiCrV8.5 Rough machined weight 15 t 07/01/2016 Company Presentation Menu 42
41 Thermal Power Generation GENERATOR SHAFT 28NiCrMoV Rough machined weight 45 t GENERATOR ROTOR SHAFT 28NiCrMoV Rough machined weight 40 t 07/01/2016 Company Presentation Menu 43
42 Thermal Power Generation STEAM TURBINE SHAFT 30CrMoNiV4.11 Rough machined weight 50 t STEAM TURBINE SHAFT 30CrMoNiV4.11 Rough machined weight 33 t 07/01/2016 Company Presentation Menu 44
43 Thermal Power Generation GAS TURBINE END SHAFT B50 A420 B10 Rough machined weight 2 t TURBINE SHAFT 30CrMoNiV4.11 Rough machined weight 3.3 t 07/01/2016 Company Presentation Menu 45
44 Thermal Power Generation GAS ROTOR TURBINE SHAFT ASTM A471 Type 10 Rough machined weight 1.5 t GAS ROTOR TURBINE SHAFT ASTM A471 Type 2 Rough machined weight 1.5 t 07/01/2016 Company Presentation Menu 46
45 Thermal Power Generation GAS TURBINE DISK B50 A633 D10 Rough machined weight 1 t GAS TURBINE DISK B50 A420 B12 Rough machined weight 1.3 t 07/01/2016 Company Presentation Menu 47
46 Thermal Power Generation GAS TURBINE SHAFT ASTM A471 Type 2 Rough machined weight 2.3 t TURBINE SHAFT ASTM A471 Type 10 Rough machined weight 3.5 t 07/01/2016 Company Presentation Menu 48
47 Thermal Power Generation FORGED TEE A182 F92 FORGED Y-PIECE A182 F91 07/01/2016 Company Presentation Menu 49
48 Thermal Power Generation PIPES SA 182 F92 Forged weight 17.2 t Rough machined weight 10 t Length 9.5 m PIPES 14MoV6-3 07/01/2016 Company Presentation Menu 50
49 Hydro Power Generation Generator shafts Hydraulic turbines, generator and coupling shaft Shafts for electrical motors Wind rotors 07/01/2016 Company Presentation Menu 51
50 Hydro Power Generation TURBINE SHAFT 24CrMo5 Rough machined weight 54 t TURBINE SHAFT 24CrMo5 Rough machined weight 54 t 07/01/2016 Company Presentation Menu 52
51 Hydro Power Generation TURBINE SHAFT 34CrNiMo6 Forging weight 92 t TURBINE SHAFT 34CrNiMo6 Rough machined weight 64 t 07/01/2016 Company Presentation Menu 53
52 Hydro Power Generation Forging of shaft Final inspection of shaft TURBINE SHAFT A668 Mcl.D Forging weight 68 t 07/01/2016 Company Presentation Menu 54
53 Hydro Power Generation LOWER SHAFT ST442S-25CrMo4 Forging weight 75 t 07/01/2016 Company Presentation Menu 55
54 Hydro Power Generation BULB TURBINE SHAFT A668 cl.e Rough machined weight 76 t NDE SHAFT A668 cl.e Rough machined weight 47 t 07/01/2016 Company Presentation Menu 56
55 Hydro Power Generation ROTOR BODY 25CrMo4 Rough machined weight 30 t SHAFT SR 42CrMo4 Rough machined weight 22 t 07/01/2016 Company Presentation Menu 57
56 Hydro Power Generation TURBINE SHAFT P355QH1 Forging weight 95 t TURBINE SHAFT A668 cl.d Rough machined weight 60 t 07/01/2016 Company Presentation Menu 58
57 Hydro Power Generation THRUST COLLAR A668M cl. E Forging weight 60 t 07/01/2016 Company Presentation Menu 59
58 Oil and Gas Valve bodies Pump bodies Spheres Covers Flanges Tubes 07/01/2016 Company Presentation Menu 60
59 Oil and Gas 24 Grip Lock Connector A105 Rough machined weight 10.3 t 30 QualiTee Tap Connector A694 F65 Rough machined weight 7.8 t 07/01/2016 Company Presentation Menu 61
60 Oil and Gas RISER 2¼ Cr 1 Mo Forging weight 30 t RISER 2¼ Cr 1 Mo Forging weight 32 t 07/01/2016 Company Presentation Menu 62
61 Oil and Gas B.O.P 2¼ Cr 1 Mo Rough machined weight 16.5 t B.O.P 2¼ Cr 1 Mo Rough machined weight 12.3 t 07/01/2016 Company Presentation Menu 63
62 Oil and Gas BLOCK MASTER VALVE 2¼ Cr 1 Mo Forged weight 23.6 t BLOCK MASTER VALVE 2¼ Cr 1 Mo Rough machined weight 13.5 t 07/01/2016 Company Presentation Menu 64
63 Oil and Gas PINION SHAFT AISI 4330 mod Rough machined weight 3.1 t VALVE BODY 2¼ Cr 1 Mo Rough machined weight 2.7 t 07/01/2016 Company Presentation Menu 65
64 Oil and Gas STRESS JOINT 2¼ Cr 1 Mo Forging weight 20 t STRESS JOINT SA 336 2¼ Cr 1 Mo Rough machined weight 13.4 t Length 12.8 m 07/01/2016 Company Presentation Menu 66
65 Oil and Gas LOWER BODY AISI 8630 Rough machined weight 4.6 t UPPER BODY AISI 8630 Rough machined weight 3.1 t 07/01/2016 Company Presentation Menu 67
66 Oil and Gas CYLINDER AISI 4140 Rough machined weight 2.6 t LIFT CAP 2¼ Cr 1 Mo Rough machined weight 1.8 t 07/01/2016 Company Presentation Menu 68
67 Petrochemical Tube sheets Channel shells Covers Bottoms Bushes Flanges Nozzles Valves Stub-ends Pinions Tubes 07/01/2016 Company Presentation Menu 69
68 Petrochemical SHELL SA336 F22V Forged weight 68 t Final dimensions: Ø5027/4679x2237mm 07/01/2016 Company Presentation Menu 70
69 Petrochemical SHELL SA336 F22V fully machined 81 t SHELL SA336 F11 Cl.3 fully machined 53 t 07/01/2016 Company Presentation Menu 71
70 Petrochemical NOZZLE 68 SA508 Gr.3 Cl.1 Forging weight 10 t INLET-FLANGE SA508 Gr.3 Rough machined weight 12.5 t 07/01/2016 Company Presentation Menu 72
71 Petrochemical SEPARATOR ASME SA336M F347 Machined weight 17 t LATERAL NOZZLE ASTM A182 F22 Machined weight 9.5 t 07/01/2016 Company Presentation Menu 73
72 Petrochemical FORGED EXPANSION NOZZLE SPECIAL LIFTING FLANGE A182 F347 Forging weight 1 t A508 Gr3 Cl.2 Rough machined weight 7 t 07/01/2016 Company Presentation Menu 74
73 Petrochemical HEAT EXCHANGER SA 336 F22 CL3 Rough machined weight 10.3 t HEAT EXCHANGER SA 336 F22 CL3 Rough machined weight 15 t 07/01/2016 Company Presentation Menu 75
74 Petrochemical CASING 15NiCrMoVb5 Machined weight 11.3 t SHELL SA336 F11 cl.2 Forging weight 28 t 07/01/2016 Company Presentation Menu 76
75 Petrochemical TUBESHEET SA182 F60 Machined weight 5.8 t TUBESHEET SA182 F60 Machined weight 4.6 t 07/01/2016 Company Presentation Menu 77
76 Petrochemical TUBESHEET SA965 F304H Machined weight 15.9 t 07/01/2016 Company Presentation Menu 78
77 Compressors & Pumps Channel shells Covers Bottoms Bushes Flanges Nozzles Valves Stub-ends Pipes 07/01/2016 Company Presentation Menu 79
78 Compressors & Pumps VALVE BODY X3CrNiMo13-4 Fully machined weight 5.5 t CONNECTING ROD 42CrMo4 Rough machined weight 2 t 07/01/2016 Company Presentation Menu 80
79 Compressors & Pumps SPHERICAL BODY SA350 LF2 Machined weight 12 t COMPRESSOR HOUSING SA350 LF6 Forging weight 45 t 07/01/2016 Company Presentation Menu 81
80 Compressors & Pumps CASING A350 LF2 Machined weight 14,5 t NOZZLE A350 LF3 forging weight 9 t 07/01/2016 Company Presentation Menu 82
81 Compressors & Pumps ELBOWS SA336 F22V Rough machined weight 1.5 t HIGH-PRESSURE COMPRESSOR 42CrMo4 Rough machined weight 12.5 t 07/01/2016 Company Presentation Menu 83
82 Compressors & Pumps PUMP BODY A182 F53 Welded & fully machined 10 t 07/01/2016 Company Presentation Menu 84
83 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 07/01/2016 Company Presentation Menu 85
84 Naval Industries CONNECTING RODS PROPELLER SHAFT C25 Machined weight 4 t CK45 Machined weight 28 t 07/01/2016 Company Presentation Menu 86
85 Naval Industries INTERMEDIATE SHAFT 30Mn5 Forging weight 65 t INTERMEDIATE SHAFT 30Mn5 Rough machined weight 51 t 07/01/2016 Company Presentation Menu 87
86 Naval Industries RUDDER TRUNK Carbon steel Machined weight 40 t PROPELLER SHAFT 12NiCrMo7 Machined weight 19 t 07/01/2016 Company Presentation Menu 88
87 Naval Industries PROPELLER SHAFT C45 Forging weight 30 t PROPELLER SHAFT C45 Machined weight 22 t 07/01/2016 Company Presentation Menu 89
88 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 07/01/2016 Company Presentation Menu 90
89 Mechanical Industry MOULD C25 machined weight 25 t FLANGE SHAFT 42CrMo4 machined weight 11.5 t 07/01/2016 Company Presentation Menu 91
90 Mechanical Industry CRANK SHAFT 42CRMo4 machined weight 10 t ROLL 42CrMo4 forging weight 61 t 07/01/2016 Company Presentation Menu 92
91 Mechanical Industry CYLINDER 21NiCrMo3 Rough machined weight 64.5 t FLANGE YOKE 34CrNiMo6 Rough machined weight 4 t 07/01/2016 Company Presentation Menu 93
92 Mechanical Industry GEAR PINION SHAFT 40NiCrMo7 machined weight 15 t CONTAINER Container Mantle : X38CrMoV5-1 (1.2343) Intermediate Liner : X38CrMoV5-3 (1.2367) Inner Liner : X38CrMoV5-1 (1.2343) Total weight after assembling 68 t 07/01/2016 Company Presentation Menu 94
93 Mechanical Industry BOTTOM COVER PLATE SA266 CL.2 machined weight 0.2 t FREMM S355 J2G3 machined weight 3.5 t 07/01/2016 Company Presentation Menu 95
94 Mechanical Industry CYLINDER CROSSHEAD S355 J2G3 machined weight 35 t TOP COVER EXTENSION PLATE SA266 CL.2 machined weight 0.2 t 07/01/2016 Company Presentation Menu 96
95 Mechanical Industry ANVIL RING 34CrNiMo5 Rough machined weight 126 t CONNECTING RING S355 J2G3 Rough machined weight 36 t 07/01/2016 Company Presentation Menu 97
96 Tradefairs and exhibitions 07/01/2016 Company Presentation 98
97 Thanks for your attention! For further information please visit our homepage or contact us directly. Web site: Contact: Phone: /19/2013 Company Presentation 99
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