Company Presentation 03/18/2015 Release 07 - morandini.it presentation R.07... · Company Overview...
Transcript of Company Presentation 03/18/2015 Release 07 - morandini.it presentation R.07... · Company Overview...
07/19/2013 Company Presentation 2
Company Presentation
Company Overview
Key Figures
Production Facilities
New Investments
Quality Control
Certifications
Markets & Products
Company Overview
03/18/2015 Company Presentation 3
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.
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Forgiatura Morandini at a Glance
Forgiatura Morandini
Location Cividate Camuno (Italy)
Production capacity 75,000 t
Markets Nuclear, Thermal, Hydro, Petrochemical, Mechanical, Naval Industry
Max. ingot size 125 t / 140 t
Melting Processes Conventional, ESR , VIM , VAR
Forging Presses 7,000 – 3,000 – 3,000 – 1,000 t + 15,000 t under construction
Ring mill Ømax 8,000 mm with Hmax 4,000 mm
Manipulators 300 t - 150 t - 100 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 9001-2008, 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
Key Figures
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109,000 k€
96,000k€ 94,000 k€
98,000 k€
124,000 k€
85,000 k€
116
124 126
137 142
147
38.000 t 41.000 t 40.000 t 42.000 t 44.000 t 41.000 t
0
20
40
60
80
100
120
140
160
2009 2010 2011 2012 2013 2014
Turnover Employees Production
Forgiatura Morandini 2009 ÷ 2014
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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
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Production Facilities – FORGING SHOP
7000 t press 1 oleodynamic press 7000 t
maximum ingot weight 140 t
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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
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Production facilities – RING MILL Ring Mill Equipment status
Ring mill Ø 8,000 mm H 4,000 mm Max. weight of rolled part 150 t
operating
Mobile manipulator 150 t operating
Heating furnaces Two heating furnaces, loading capacity 300 t/each
operating
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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
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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 m3
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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
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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)
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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
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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) HB10/3000/15 residual stress determination ASTM E 837 radioactivity measurer heat stability testing machine
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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 KIC ,JIC,CTOD (Crack tip opening displacement)
Quality Control – Testing Equipment
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Certifications
RINA ISO 9001-2008 ASME III, Div.1 and 3, NCA/WA-3800
BS OHSAS 18001 : 2007
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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
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Certifications
RINA
AMERICAN BUREAU OF SHIPPING
LLOYD’S REGISTER OF SHIPPING
DET NORSKE VERITAS GERMANISCHER LLOYD
EUROPEAN PRESSURE EQUIPMENT DIRECTIVE
97/23/EC
TüV NNSA RINA
BUREAU VERITAS
New Investments
FORGING SHOP RING MILL and 15000-t-PRESS
Inspection & shipment
Laboratories Heat treatment – Large rings
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Cutting – Large pieces
Future Investments
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New investments Forging Department
Equipment
Forging press 150-MN-Press, capacity upsetting ingots up to 200 t
Launch
1st quarter 2016
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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 2016
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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 m3) 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 2016
Markets & Products Product mix 2014
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POWER GENERATION
28%
PETROCHEMICAL 26%
OIL & GAS 23%
NUCLEAR 6%
REDUCTION GEARS
4%
GENERAL MACHINES
11%
SHIP-DIESEL ENGINE
2%
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Markets & Products
Hydro Power Generation
Thermal Power Generation
Nuclear Power Generation
Petrochemical Equipment Offshore
Pipelines Compressors & Pumps
Naval industries Mechanical Industries
end
Oil and Gas
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: AP1000 - TN International - NPCIL
Company Presentation 03/18/2015 29 Menu
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
Company Presentation 03/18/2015 30 Menu
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
Company Presentation 03/18/2015 31 Menu
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
Company Presentation 03/18/2015 32 Menu
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
Company Presentation 03/18/2015 33 Menu
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
Company Presentation 03/18/2015 34 Menu
Pressurizer - Shell Pressurizer - Upper head Pressurizer - Lower head Steam generator - Shell Steam generator - Torispherical head Steam generator - Tube sheet
Nuclear Power Generation
SA508GR.3
Rough machined weight 20 t
Company Presentation 03/18/2015 35 Menu
SA182 F316L
Rough machined weight 6.5 t
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
Company Presentation 03/18/2015 36 Menu
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Thermal Power Generation
Gas and steam turbines either solid or composite Generator shafts
Menu
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Thermal Power Generation
STEAM TURBINE SHAFT 28NiCrMoV12.6.5
Rough machined weight 18 t
STEAM TURBINE SHAFT 28NiCrV8.5
Rough machined weight 15 t
Menu
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Thermal Power Generation
GENERATOR ROTOR SHAFT
28NiCrMoV13.7.4
Rough machined weight 40 t
GAS TURBINE SHAFT 28NiCrMo11.5
Rough machined weight 1.5 t
Menu
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Thermal Power Generation
STEAM TURBINE SHAFT 30CrMoNiV4.11
Rough machined weight 50 t
Menu
STEAM TURBINE SHAFT 30CrMoNiV4.11
Rough machined weight 33 t
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Thermal Power Generation
GENERATOR SHAFT 28NiCrMoV13.7.4
Rough machined weight 45 t
Menu
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Hydro Power Generation
Generator shafts Hydraulic turbines, generator and coupling shaft Shafts for electrical motors Wind rotors
Menu
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Hydro Power Generation
Forging of shaft Final inspection of shaft
TURBINE SHAFT A668 Mcl.D
Forging weight 68 t
Menu
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Hydro Power Generation
LOWER SHAFT ST442S-25CrMo4
Forging weight 75 t
Menu
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Hydro Power Generation
BULB TURBINE SHAFT A668 cl.E
Rough machined weight 76 t
NDE SHAFT A668 cl.E
Rough machined weight 47 t
Menu
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Hydro Power Generation
GENERATOR SHAFT 42CrMo4
Rough machined weight 49 t
TURBINE SHAFT 30Mn5
Rough machined weight 65 t
Menu
Hydro Power Generation
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TURBINE SHAFT P355QH1
Forging weight 95 t
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COMPLETE ROTOR 34CrNiMo6
Forging weight 64 t
Hydro Power Generation
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THRUST COLLAR A668M cl. E
Forging weight 60 t
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Oil and Gas
Valve bodies Pump bodies Spheres Covers Flanges Tubes
Menu
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Oil and Gas
RISER F22 MOD
Forging weight 30 t
Menu
RISER F22 MOD
Forging weight 32 t
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Oil and Gas
PINION SHAFT 40NiCrMo7
Rough machined weight 3.1 t
Menu
VALVE BODY A182 F22
Rough machined weight 2.7 t
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Oil and Gas
STRESS JOINT SA 336 F22
Rough machined weight 13.4 t
Length 12.8 m
Menu
LIFT CAP 2-1/4Cr1Mo
Rough machined weight 1.8 t
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Petrochemical
Tube sheets Channel shells Covers Bottoms Bushes Flanges Nozzles Valves Stub-ends Pinions Tubes
Menu
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Petrochemical
SHELL SA350M LF5 CL.2
Forging weight 42 t
FORGED PIPE A182 F22V
Rough machined weight 33 t
Menu
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Petrochemical
SHELL SA336 F11 cl.2
Forging weight 28 t
FORGED TEE A182 F91
Rough machined weight 6 t
Menu
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Petrochemical
FORGED EXPANSION NOZZLE
A182 F347
Forging weight 1 t
SPECIAL LIFTING FLANGE
A508 Gr3 Cl.2
Rough machined weight 7 t
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PUMP BODY A182 F53
Welded & fully machined 10 t
Petrochemical
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SEPARATOR ASME SA336M F347
Machined weight 17 t
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Petrochemical
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LATERAL NOZZLE ASTM A182 F22
Machined weight 9.5 t
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SHELL SA336 F22V
Forged weight 68 t Final dimensions: Ø5027/4679x2237mm
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Petrochemical
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Petrochemical
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HEAT EXCHANGER SA 336 F22 CL3
Rough machined weight 10.3 t
HEAT EXCHANGER SA 336 F22 CL3
Rough machined weight 10.9 t
CASING 15NiCrMoVb5
Machined weight 11.3 t
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Petrochemical
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Pipelines Compressors & Pumps
Channel shells Covers Bottoms Bushes Flanges Nozzles Valves Stub-ends Pipes
Menu
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Pipelines Compressors & Pumps
VALVE BODY X3CrNiMo13-4
Fully machined weight 5.5 t
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CONNECTING ROD 42CrMo4
Rough machined weight 2 t
Company Presentation
Pipelines Compressors & Pumps
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SPHERICAL BODY SA350 LF2
Machined weight 12 t
COMPRESSOR HOUSING
SA350 LF6
Forging weight 45 t
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Pipelines Compressors & Pumps
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CASING A350 LF2
Machined weight 14,5 t
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NOZZLE A350 LF3
forging weight 9 t
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Company Presentation
Pipelines Compressors & Pumps
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PIPES SA 182 F92
Forged weight 17.2 t Rough machined weight 10 t
Length 9.5 m
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PIPES SA 182 F92
Rough machined weight 4 to 8 t
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Company Presentation
Pipelines Compressors & Pumps
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ELBOWS SA336 F22V
Rough machined weight 1.5 t
FORGED TEES A182 F91
Rough machined weight 5 t
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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
Menu
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Naval Industries
CONNECTING RODS
C25
Machined weight 4 t
PROPELLER SHAFT
CK45
Machined weight 28 t
Menu
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Naval Industries
INTERMEDIATE C45
Forging weight 65 t
PROPELLER SHAFT Ck45
Machined weight 30 t
Menu
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Naval Industries
Menu
ANVIL RING 34CrNiMo5
Rough machined weight 126 t
PROPELLER SHAFT C35
Forging weight 77 t
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Naval Industries
PROPELLER SHAFT
12NiCrMo7
Machined weight 19 t
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RUDDER TRUNK Carbon steel
Forging weight 88 t
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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
Menu
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Mechanical Industry
MOULD C25
machined weight 25 t
CYLINDER 42CrMo4
forging weight 90 t
Menu
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Mechanical Industry
CRANK SHAFT 42CRMo4
machined weight 10 t
ROLL 42CrMo4
forging weight 61 t
Menu
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Mechanical Industry
CYLINDER 21NiCrMo3
Rough machined weight 64.5 t
CONNECTING RING S355 J2G3
Rough machined weight 36 t
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Mechanical Industry
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
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GEAR PINION SHAFT 40NiCrMo7
machined weight 15 t
Menu
Mechanical Industry
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BOTTOM COVER PLATE SA266 CL.2
machined weight 0.2 t
FREMM S355 J2G3
machined weight 3.5 t
Mechanical Industry
Company Presentation 81 81 Company Presentation 03/18/2015 Menu
CYLINDER CROSSHEAD S355 J2G3
machined weight 35 t
TOP COVER EXTENSION PLATE SA266 CL.2
machined weight 0.2 t
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Thanks for your attention!
For further information please visit our homepage or contact us directly.
Web site: www.morandini.it Contact: [email protected]
Phone: +39 0364 347 0