QUALIFIED SOLUTIONS FOR THE TRANSMISSION INDUSTRY

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Erin Perry
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1 QUALIFIED SOLUTIONS FOR THE TRANSMISSION INDUSTRY

3 INDEX OUR HISTORY 4 HEAD OFFICE AND PLANT 5 TECHNICAL ACCURACY 6 PRODUCTS 7 PTMb horizontal parallel gears step-up and reduction gear boxes for centrifugal, 8 turbo generator or compressor application Auxiliaries for turbines and compressors 12 GR right-angle gears 14 HS parallel shaft gears step-up gear boxes for high speeds 18 High speed parallel reducing gear boxes for turbo expander applications 20 Multistage, vertical offset and packages 21

4 OUR HISTORY 1921 Gusti Alfredo SpA The group was established by Mr. Alfredo Gusti with the name of Gusti Alfredo SpA. Since the very beginning the core business was both the manufacturing and engineering of mechanical components with a special focus on gears and transmissions. A strong relationship with the Navy and the Railway industry was immediatley established for the production of gears and gearboxes. Gusti Alfredo developed in the last thirty years three major lines of products: mass production gears for automotive, tractors, sport cars and textile machines (This branch has been sold in 1989); gears and gear units for industrial application, high speed step-up units, railway gears, test bench; machines for Glass Industry (vials, ampules and glasses) OCMI was established: the company main business was and still is the engineering and manufacturing of glass machines. Gusti Alfredo SpA spin-off all its assets into a Newco named OTG (ORGANI TRASMISSIONE GUSTI) and also moved to a new premise. OCMI purchased from Schott Moderne Mecanique, its main competitor in the ampoule line manufacturing business. OTG bought METI srl and all people and machines tool related to the core business production, together with Engineering Department. Meti srl have been working on the market since 15 years by designing and buildings skid-mounted plants far the petrochemical field. OCMI and OTG merged into OCMI-OTG SpA. The idea behind the OCMI India project is to supply the market with products made especially for the need of the Indian producer and realised with the quality and the aftersale service of a top European manufacturer.

5 HEAD OFFICE AND PLANT Land Area m 2 Building Area m 2 Via Venezia Giulia, Milano - ITALY EMPLOYEES 13 Workshop 4 Engineering Dpt 2 Quality assurance 2 Administration and marketing 21 TOTAL

TECHNICAL ACCURACY OTG core business has always been the manufacturing of gears for many different applications.

time they have been engaged with the high speed (i.e. Ferrari Cars 308, 328 and Testarossa, Piaggio, Fiat Avio and gear units coupled with turbines for

The development of the unit is completely followed inside the factory by highly qualified engineers connected with the Politecnico University of Milano

For this reason they are in the position to follow under tight quality control any new project which could involve special gear units construction or

OTG can shortly resume the method of work as follows: Design aimed to obtain best functional performance (torsional strenght and resistance to bending

6 TECHNICAL ACCURACY OTG core business has always been the manufacturing of gears for many different applications. In the time they have been engaged with the high speed (i.e. Ferrari Cars 308, 328 and Testarossa, Piaggio, Fiat Avio and gear units coupled with turbines for industrial purposes) and also with high power and heavy duty services. The development of the unit is completely followed inside the factory by highly qualified engineers connected with the Politecnico University of Milano from design to manufacturing and assembling of all inside components and final tests. For this reason they are in the position to follow under tight quality control any new project which could involve special gear units construction or their standard units. OTG can shortly resume the method of work as follows: Design aimed to obtain best functional performance (torsional strenght and resistance to bending stress, efficiency, etc.) through finite element programming and integrated computer aided design Procurement oriented just at qualified suppliers periodically checked by Quality Assurance Production organized by complying with manufacturing cycles as to match design and requested standards. Middling test directed towards respect of Quality Control Plan for every single gear unit and specially adressed to verify the requested standard during manufacturing plan Final test executed according to test procedures for speed increasers and reducers, and particularly with possibility of load test until CV

7 PRODUCTS PTMb horizontal parallel gears for centrifugal pump, turbo generator or compressor applications Auxiliaries for turbines and compressors GR right-angle gears HS parallel shaft gears step-up and reduction for high speeds High speed parallel reducing gear boxes for turbo expander applications Multistage, vertical offset and packages

PTMb horizontal parallel gears step-up and reduction gear boxes for centrifugal pump, turbo generator or

06, AGMA 6011 calculation codes Casing in cast iron or welded and annealed carbon steel Double/single helical

shaft in forged alloy steel Both rotors dynamically balanced in accordance with API 613 or ISO 1940 rules.

shaft end The gearbox is completed with a main lubrication pump, directly driven by low spead shaft and with an

8 PTMb horizontal parallel gears step-up and reduction gear boxes for centrifugal pump, turbo generator or compressor application Main construction characteristics: API 613, 677, AGMA , AGMA 6011 calculation codes Casing in cast iron or welded and annealed carbon steel Double/single helical gears in forged alloy steel, carburized and hardened, teeth finished by grinding after heat treatment Low speed shaft in forged alloy steel Both rotors dynamically balanced in accordance with API 613 or ISO 1940 rules. Radial bearings fix profile type Thrust bearning taperland/tilting pad type Oil seals, labirynth type on both shaft end The gearbox is completed with a main lubrication pump, directly driven by low spead shaft and with an oil inlet header, in welded stainless steel Gearbox Instrumentation: Temperature elements on bearings Provision for mounting of Bently Nevada vibration probes or full probes supply

Dimensions of P.T.Mb series - standard sizes and intermediate versions (all size are indica ve) Size I A B C D E F G H (H 10) L M N O P Q Approx. weight Kg Average oil lt.

9 Dimensions of P.T.Mb series - standard sizes and intermediate versions (all size are indica ve) Size I A B C D E F G H (H 10) L M N O P Q Approx. weight Kg Average oil lt

indicator 1 Main Lubrica on pump 2 Auxiliary and prelubrica on pump 3

10 Example of layout Example of lube oil system References to the symbols PI Pressure gauge PS Pressure switch PSV Safety valve TI Temperature indicator 1 Main Lubrica on pump 2 Auxiliary and prelubrica on pump 3 Heat exchanger 4 Double filter (delivery) 5 Filter (suc on) 6 Flow regulator

EXTRACT OF P.T.Mb REFERENCE LIST Customer Driv. Mach Model Kw Ra o gabbioneta pump P.T. Mb 15 3180 2960/1500 wor ngton pump P.

pump P.T. Mb 30 3400 2980/4950 pantochim compressor P.T. Mb 36 4000 1500/5000 nuovo pignone test bench P.

T. Mb 560 14000 4170/1500 ansaldo generator P.T. Mb 60 22600 4200/1500 ellio pump P.T. Mb 60 3350 5000/600

11 EXTRACT OF P.T.Mb REFERENCE LIST Customer Driv. Mach Model Kw Ra o gabbioneta pump P.T. Mb /1500 wor ngton pump P.T. Mb /3950 fsm/ferrari engine test P.T. Mb /16000 nuovo pignone centr. pump P.T. Mb /4950 pantochim compressor P.T. Mb /5000 nuovo pignone test bench P.T. Mb /1800 fincan eri generator P.T. Mb /1500 ansaldo generator P.T. Mb 50S /1500 cei generator P.T. Mb /1500 ansaldo generator P.T. Mb /1500 ellio pump P.T. Mb /600

12 Auxiliaries for turbines and compressors Special purpose auxiliary gearboxes for step-up and lubrication of GE-NP gas turbines (PGT 10, GE 10, M55002E series) and lubrication of GE-NP compressor (PCL series).

GR right-angle gears step-up and reduction gear boxes Main construction characteristics: Casing in grey cast iron or welded and annealed

teeth lapped or finished grinding after heat treatment Both rotors dynamically balanced in accordance with API 613 or ISO 1940 rules Bevel

Anti-rotation device fitted on the low speed shaft (free wheel) if required Forced feed lubrification by means of separate lube oil system

14 GR right-angle gears step-up and reduction gear boxes Main construction characteristics: Casing in grey cast iron or welded and annealed carbon steel, complete with inspection window and breather pipe One pair of bevel gears in forged alloy steel, carburized and hardened, teeth lapped or finished grinding after heat treatment Both rotors dynamically balanced in accordance with API 613 or ISO 1940 rules Bevel roller or sleeve type bearings Oil seal labirynth or retaining ring on high speed shaft Oil seal retaining ring on low speed shaft Anti-rotation device fitted on the low speed shaft (free wheel) if required Forced feed lubrification by means of separate lube oil system Special models with hollow shaft for fire fighting application as per NFPA-20 notes Gearbox Instrumentation: Temperature elements on heat exchanger

15 Sizes DIMENSIONS (all dimensions are indica ve) A B C D E F H (h 10) Approx. weight Kg Average oil quan es lt

16 KEY TO DIAGRAM FG Visual flow indicator LI Visual level gauge PI Pressure gauge PSV Safety valve TI Temperature gauge 1 Lubricator pump 2 Heat exchanger 3 Self cleaning filter on delivery side 4 Suc on side filter

EXTRACT OF GR REFERENCE LIST Customer Applica on Model Kw Ra o termomeccanica italiana pump GR 6 520 1840/1485 dresser pump GR 6 545

17 EXTRACT OF GR REFERENCE LIST Customer Applica on Model Kw Ra o termomeccanica italiana pump GR /1485 dresser pump GR /1500 ellio pump GR /1710 dresser pump GR /1500 wor ngton pump GR /1800 ellio pump GR /445

HS parallel shaft gears step-up gear boxes for high speeds Main

pre-fabricated steel, welded and heat-treated after welding

hardened, finished by grinding after heat treatments, teeth

Each rotor dynamically balanced in accordance with API 613 or

Thrust collars in 3 pieces on high speed pinion Forced feed

Instrumentation: Resistance temperature detectors for bearing

18 HS parallel shaft gears step-up gear boxes for high speeds Main construction characteristics: API or Agma calculations Carter in pre-fabricated steel, welded and heat-treated after welding Single helical gears in forged alloy steel carburized and hardened, finished by grinding after heat treatments, teeth quality as per DIN 5 class Low speed shaft in forged alloy steel Each rotor dynamically balanced in accordance with API 613 or ISO 1940 specifications Low speed shaft radial bearing fixed profile type High speed shaft radial bearings tilting pad type Axial bearing taper land/tilting pad type on low speed shaft Thrust collars in 3 pieces on high speed pinion Forced feed lubrification by means of separate lube oil system Gearbox Instrumentation: Resistance temperature detectors for bearing temperature monitoring Provision for mounting Bently-Nevada vibration probes or full probes supply

EXTRACT OF HS REFERENCE LIST Customer Loca on Model Kw Ra o nuovo pignone Solvay - Rosignano HS 150 70 2980/11925 nuovo pignone CTIP - Milazzo HS 250 180 2980/9500 sulzer escher wyss - HS 300 785

19 EXTRACT OF HS REFERENCE LIST Customer Loca on Model Kw Ra o nuovo pignone Solvay - Rosignano HS /11925 nuovo pignone CTIP - Milazzo HS /9500 sulzer escher wyss - HS /28015 nuovo pignone Test Bench HS /15000 sulzer escher wyss - HS /13021 nuovo pignone - HS /34545 dresser rand UIOM - Pau HS /1500 nuovo pignone Test Bench HS /18000 nuovo pignone T.P.L. - Iraq THS /21221 sulzer escher-wyss Kalusk THS /21622 nuovo pignone Fenco - Francia THS /27658 nuovo pignone A.K.Z. - Brazil THS /22546 sulzer escher-wyss Kelsterbach THS /34114 nuovo pignone Fenco - Canada THS /7716 nuovo pignone Enichem - Ravenna TH2S /35262 sulzer escher-wyss Seadri - USA TH2S /22016 nuovo pignone Enichem-Anic - Porto Torres 2THS /16895/25680 nuovo pignone Skikda - Algeria 2THS /15898/19714 nuovo pignone Enichem - Priolo 2TH3S /26510/36068 nuovo pignone Sonatrach-Bir Rebaa - North Algeria 2TH3S /22401/22401 nuovo pignone Italsider - Taranto 2TH3S /12321/15583 nuovo pignone Danieli - Iraq 2TH3S /15850/18198 nuovo pignone IGI - Manfredonia 2TH4S /29715/38520 nuovo pignone Enichem-Anic - Porto Torres 2TH4S /28000/49468 nuovo pignone Metalka - Yugoslavia 2TH4S /21174/30946 THR THS TH2S 2THS 2TH3S 2TH4S

High Speed parallel reducing gear boxes for turbo expander applications EXTRACT OF HS TURBO EXPANDER REFERENCE LIST Customer Model Kw

API or Agma calculations Carter in pre-fabricated steel, welded and heat-treated after welding Single helical gears in forged alloy

alloy steel Each rotor dynamically balanced in accordance with API 613 or ISO 1940 specifications Low speed shaft radial bearing

Thrust collars in 3 pieces on high speed pinion Forced feed lubrification by means of separate lube oil system Gearbox

20 High Speed parallel reducing gear boxes for turbo expander applications EXTRACT OF HS TURBO EXPANDER REFERENCE LIST Customer Model Kw Ra o nuovo pignone HS /3058 nuovo pignone 5HS /23030/17022/10581/1500 Main construction characteristics: API or Agma calculations Carter in pre-fabricated steel, welded and heat-treated after welding Single helical gears in forged alloy steel carburized and hardened, finished by grinding after heat treatments, teeth quality as per DIN 5 class Low speed shaft in forged alloy steel Each rotor dynamically balanced in accordance with API 613 or ISO 1940 specifications Low speed shaft radial bearing fixed profile type High speed shaft radial bearings tilting pad type Axial bearing taper land/tilting pad type on low speed shaft Thrust collars in 3 pieces on high speed pinion Forced feed lubrification by means of separate lube oil system Gearbox Instrumentation: Resistance temperature detectors for bearing temperature monitoring Provision for mounting Bently-Nevada vibration probes or full probes supply

21 Multistage, vertical offset and packages Special purpose gearboxes enginereed and built for customer specifications, multi axes, vertical type, coaxial, test bench also with complete lube oil system (API 614 or standard manufacturer) and assembly on skid of customer parts.

EXPORT WORLDWIDE OTG references include the most important manufacturers of turbines, compressors

The company is engaged in manufacturing different type of gearboxes starting from sport car units,

Tightly linked with gear units manufacturing is the realisation of medium and small lots of gears

Horizontal or vertical offset Right-angle gears SUB CONTRACTING Every customer can make use of OTG

OTG also specialises in: Railway gears Textile gears Compressor gear trains Turbo auxiliary gear

22 EXPORT WORLDWIDE OTG references include the most important manufacturers of turbines, compressors and pumps and the top engineering companies. The company is engaged in manufacturing different type of gearboxes starting from sport car units, such as Ferrari and Porsche, ending with marine and heavy duty services gear boxes. Tightly linked with gear units manufacturing is the realisation of medium and small lots of gears on customer drawings for different industrial applications, but mostly for railway transmission, printing machines and steel plants. REDUCTION AND STEP-UP GEARS Single and double helical with or without collars Single or multistage Horizontal or vertical offset Right-angle gears SUB CONTRACTING Every customer can make use of OTG know-how and equipment. OTG also specialises in: Railway gears Textile gears Compressor gear trains Turbo auxiliary gear trains Complete packages ACCESSORIES Together with its step-up and reduction gear boxes, OTG offers: Bearings Oil filters Complete lube oil systems OCMI-OTG S.P.A. Via Venezia Giulia, Milano (Italy) Phone Fax info@ocmigroup.com

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