ArcelorMittal Engineering Products Ostrava · ArcelorMittal Engineering Products Ostrava Structure...

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


CCM moulds Scrap buckets


LadlePort crane girder length of 26 m


Crank shaftStands


Coke oven doorsFrames for coke oven doors


Fan housing Pelletizing drum


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


Automotive line renovation Wagon tilter


Ladle cleanerPortal loader


Decoiler Cast bay - bridge, Q=1504025t, L=22m; A7N P


Annealing furnace heating hood Ladle car

36


Transfer Car for slab Discharging and charging rolls

36


Crane Trunion ring

36


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.

46

Production parameters

49

References

Super heavy ingot moulds up to 150 tons Large ingot moulds 20 - 70 tons

50

References

Small ingot moulds 1 - 20 tons Roll castings

51

References

Rolling mill scraper Gear case

52

References

Ladles Reeler plug s for production of tubes

53

References

Alloy wheels for railway, sidings, trolleys, cranes and gear wheels

Frames for coke oven doors

54

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

71

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

88

References

Wheel sets for metalurgical vagons Driving wheel sets

89

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


• 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


• 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.


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


• 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


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).


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


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


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.


Roll Turning Shop

69


• 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


Heat Treatment

76

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


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


Railway wheel sets

83

• 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

82

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


• 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


• 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

85

Rolled and cast solid wheels, composite (tyred) wheels


• External diameter: max. 1 250 mm


• 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


• 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..

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