Flyer 2012 20 10 English - TECHNOMAR Unternehmensgruppe · 2013. 12. 6. · DIN 18800 and DIN...

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TECHNOMAR G R O U P TECHNOMAR GmbH & Co. KG Specialized Machinery Engineering Oil-Water Separation Welded Constructions Mega-Yachts Repair Service Lifting and Cargo Handling Gear Cargo Lashing and Sea Fastening Bremer-System-Technik GmbH Fine Mechanics CNC-Processing Device and Apparatus Design Component Group Assembly H. Schroeder GmbH Project Management Development and Construction Calculations Building Supervision Documentation

Transcript of Flyer 2012 20 10 English - TECHNOMAR Unternehmensgruppe · 2013. 12. 6. · DIN 18800 and DIN...

Page 1: Flyer 2012 20 10 English - TECHNOMAR Unternehmensgruppe · 2013. 12. 6. · DIN 18800 and DIN 15018, class E Qualification forwelding military products according to DIN 2303 Q1

TECHNOMAR

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TECHNOMAR GmbH & Co. KG Specialized Machinery Engineering Oil-Water Separation Welded Constructions Mega-Yachts Repair Service Lifting and Cargo Handling Gear Cargo Lashing and Sea Fastening

Bremer-System-Technik GmbH Fine Mechanics CNC-Processing Device and Apparatus Design Component Group Assembly

H. Schroeder GmbH Project Management Development and Construction Calculations Building Supervision Documentation

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Contents

History 3 Departments and Tasks 4 Production / Certificates 5 Production Facilities 6 1. Mega-Yachts 7 2. Building Devices for the Aerospace Industry 12 3. Lifting and Cargo Handling Gear 15 4. Special Systems and Devices 18 5. Oil-Water Separation 20 6. Producing Individual Components 22 7. Repair Service 24 8. Alterations and Conversions 25 9. Engineering 26 Appendix (Machinery) 31 1. Milling Machines 31 2. Lathing Machine 32 3. Drilling Machines 32 4. Cutting Equipment 33 5. Presses 33 6. Specialised Processing Machinery 33 7. Metal and Steelwork Processing Machinery 33 8. Welding Machines 34 9. Paint Coating System 35 Contact Information 36

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History TECHNOMAR was founded in 1974. In the early years, the company's activities were focused on the areas of marine technology and repairs, with assignments carried out both in Germany and abroad. Over the years, more and more jobs were carried out in our own workshops, so that eventually the workshop capacities had to be increased. Thus, in 1991 our modern and expandable company headquarters and production facilities were built in Bremen-Woltmershausen. Since 2001, TECHNOMAR GmbH. is under new management. Since then, our fields of activity have expanded from classic metal work to the manufacture of complex units and systems for various industries, such as ship building, aerospace engineering, environmental protection, conveyance and material handling technology. Since 2003, the engineering company H. Schroeder GmbH has been part of the TECHNOMAR group. H. Schroeder GmbH has been active for more than 30 years now and specializes in designing specialized vessel constructions, cargo handling gear and various other apparatuses and devices. Since the merger, we increased and improved the cooperation between the development/design and production facilities and successfully concluded a variety of projects. Finally, in October 2005, the company Bremer System Technik GmbH (BST) was integrated into the TECHNOMAR group. BST Bremer-System-Technik GmbH was founded in 1997 by former employees of the defunct company DST (Deutsche-System-Technik GmbH). What is more, we expanded our approx. 1800 m² of workshop and production facilities in Bremen-Woltmershausen. Our highly efficient workshops have production facilities for the following fields:

• Mechanical production facilities using CNC cutting and machining tools • Sheet metal processing • MAG/WIG welding as well as spot welding • Damp paint coating, including preparatory works and annealing stove • Electro-mechanical installations and testing • Component group assembly

All administrative tasks of the different companies have been bundled in a single central administration. At the beginning of 2007, a new large-scale production hall was built on the TECHNOMAR premises, which enables us to build and assemble large-scale components with unit weights of up to 20 tons. In July 2007, the production facilities of Bremer-System-Technik were moved onto the existing TECHNOMAR premises. Nowadays, we view ourselves as the TECHNOMAR Group, which enables us to offer to our partners the complete production process from project management via design and calculations to manufacture, assembly, documentation and after-sales-services, all carried out by a single hand.

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The following organigram illustrates the distributi on of tasks and responsibilities within the TECHNOMAR Group:

TECHNOMAR

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TECHNOMAR Verwaltungsgesellschaft mbH

Tasks :

• Central administration • Human resources • Management • Accounting • Finances

TECHNOMAR GmbH & Co. KG

Specializations :

• Welding technology • Building specialized machinery • Lifting and cargo handling gear • Mega-yacht equipment and refits • Building special devices • Vessel conversions and repairs • Steel and aluminum constructions

Special qualifications and certificates:

• Specialized company according to § 19 l WHG

• DIN EN ISO 9001 : 2008 • Welding certificates : o German Lloyd and Lloyd's Register : � Welding of marine constructions /

piping, aluminum, steel, CrNi, Duplex stainless stee, fine grained steel S 690.

� Manufacturer qualification according to

DIN 18800 and DIN 15018, class E

� Qualification forwelding military products according to DIN 2303 Q1 / Q2

H.Schroeder GmbH

Specializations :

• Project development and management

• Design / Calculations • Devices and fixtures • Specialized vessel designs • Cargo fastening • CE-documentation • Consulting • Building supervision

Special qualifications and

certificates: • DIN EN ISO 9001 : 2008

BST Bremer-System-Technik GmbH

Specializations :

• Fine mechanics • Building fixtures • Building special devices • Building apparatuses • CNC- milling / lathing • Paint coating

Special qualifications and certificates :

• EN 9001:2008

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Production All in all, the TECHMOMAR Group has 45 employees: • Tool smiths • Engine fitters and mechanics • Airplane mechanics • Lathe operators • Pipe fitters • Metal workers • Welders • Specialized personnel (welding engineers, technicians, foremen) • Apprentices for the professions industrial mechanic and construction mechanic

Certificates • Grand certificate of ability according to DIN 18 800 T7 / DIN 15 018 • Welding certificates issued by German Lloyd and Lloyd's Register • Welding techniques used : E-manual, MIG, MAG and WIG • Materials used : steel, CrNi-steel, Duplex, CuNiFe, aluminum • Restamping permit issued by the German Lloyd • (BST): Certified QM-system according to EN 9100 (aerospace engineering norm) • (H. Schroeder): Certified QM-system according to DIN EN ISO 9001 • Approved as a specialist company according to § 19 l WHG • Permit for lending out personnel

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Production capacities • 1600 m² production area, divided into steel building and mechanical processing • Hall cranes 2.5 t; 5 t and 2 x 10 t • Hall for preparatory steelwork • 5000 m² of paved open surface • 400 m² offices • Fork lifts 2.5 – 8 t • Various transport vehicles • Maschinery: see appendix (pages 31 – 35)

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1. Mega-yachts We have many years of experience in refitting, converting and newly building components for mega-yachts. In addition to proper functioning, we place special emphasis on the design and on corrosion protection to guarantee a long life for the components. Our products and services include: • Pipe fitting in steel, CuNiFe, CrNi-steel, thermoplastics and aluminum • Side gangways • Vessel portals • Overhaul and modification of machinery systems • Deck machinery • Outer doors • Bulwark ports • Handrails • Hatches • Shift systems for tender boats • Masts • Tender boat storage • Overhaul of stern flaps and platforms • Integration of adjustable staircases into existing platforms • Building and integration of foldable Security Steps in order to prevent unauthorized

entering of the vessel's deck.

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Deinstalling a diesel generator from a mega-yacht

Installing a diesel engine into a mega-yacht including foundation and piping

Overhauling the outer doors of a yacht 3-D analysis carried out in order to determine the optimal lever function

Checking a gear wheel for surfaces fissures

Exchanging the turbines of a mega-yacht including piping

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Modifying the two originally fixed jut-outs of the stern platform of a mega-yacht. After the modification, the jut-outs may be stagelessly swiveled by 90°, enabling them to reach vertically into the water. A staircase was integrated into the platform, whose steps adjust themselves to the swivel angle of the jut-outs. Thus, the staircase may be accessed in every position.

The handrail has a twistable bearing, which allows for adjusting the distances between the handrails. Moreover, an extendable fender system was integrated into the stern platform, where tender boats with weights of up to approx. 10 tons may be moored. The system was designed with a 3D program, which allows for simulating the complex movement sequences and geometric shapes in the computer.

Special requirements: • The system must move silently. • Absolutely seawater resistant • Near perfect fit for optical reasons • Safe and simple operation

Scope of the project: • Various alternative designs • Development • Calculation • Production • GL approvals • Commissioning

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The photo above shows the stern platform of a mega-yacht, which incorporates an automatically adjustable staircase. This stern platform was completely overhauled and modified.

The photo above shows a fender system for a mega-yacht which was developed by us. After determining the static and construction data, we developed several design suggestions in close cooperation with the owner's representatives.

The result was a fender system, made entirely from stainless steel. The most notable feature is the simple handling via a special step-up gear..

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Subsequent installation of a staircase system at the foldable bathing platform of a mega-yacht. The scope of the project included design, development and calculation as well as refurbishing the stern flap, installing the hydraulic system and the PLC control system as well as manufacturing new handrails..

Building an exhaust gas system from CrNi-steel for a mega-yacht

Tender boat cradle on board of a mega-yacht

Electrically powered boat shifting system inside the tender boat hangar of a mega-yacht.

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2. Building Devices for the Aerospace Industry The Technomar Group produces individual testing and transport systems for various projects of the aerospace industry. The highly sensitive components such as titanium tanks require precise and exact manufacturing. In order to meet the clean room requirements of our customers, orders from the aerospace industry are carried out in a separate workspace apart from the general steel workshop.

Testing container for testing the fuel sieves of satellite drives. Scope of the project: • Project management • Design and development • Production

Substructure of a transport container for satellites with a pneumatic dampening system. Scope of the project: • Production

Multi-rotation system for welding satellite fuel pipes (electron beam welding) Scope of the project: • Design and development • Production

Testing container for testing the filter sieves in the fuel systems of satellite drives. Scope of the project: • Design and development • Production

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Universal device for handling satellite tanks (cleaning, welding and measuring) Scope of the project: • Production • Modifications

Testing device for satellite tanks: A satellite tank is clamped into this device and subjected to vibration tests at a testing institute. The cage is a welded aluminum construction, the table is a steel construction.

This photo shows the test stand inside the institute with the testing device manufactured by us Scope of the project: • Design and development (partially) • Production

Welding system for welding the perimeter seams of satellite tanks (electron beam welding) Scope of the project: • Design and development • Production

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For the SAR-LUPE project we developed this container for transporting satellites by truck, train and plane.

The transport container is equipped with a generator, air conditioning system and filter system for ventilating the container during transport by air. The satellite and its integration stand are protected by a dampening system, which reduces shocks of +/- 3 G from all directions to under 1 G.

The container may be used at temperatures of -30°C to +30° C. The interior of the container is completely lined with stainless steel sheets in order to reach the required purity class 100.000.

The scope of the project included the complete engineering including static calculations, dimensioning of the dampening elements and the insulation as well as the ready-to-use production and delivery of the container. In addition to the applicable norms the container also had to adhere to the IATA regulations.

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Transport container for a small satellite Container for the safe transport of satellite tanks made from titanium.

3. Lifting and cargo handling gear We offer the design, dimensioning, calculation and production of individual lifting and cargo handling gear for various goods up to a weight of 1000 t. If the customer desires it, the lifting and cargo handling gear are tested by the TÜV or any classification society. Our standard products are: • Container spreaders, operated manually or automatically • Special cargo handling gear for cotton, paper, cellulose and similar goods, also

available with pneumatically operated hooks • Pipe hooks, forged or welded, with carrying capacities of up to 16 tons • Modifying the hatch covers of vessels to enable them to carry additional heavy

cargoes. The main employment areas for our products and services are: - Cargo handling in ports - Installing off-shore windparks - Dimensioning the sea fastenings of collies with high weights per unit

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Spreader SWL 350 t in action Two board cranes Loading a 600 t – collie in tandem operation, using a 660 t-traverse and the respective spreaders

This photo shows the 660 t traverse while under construction.

Traverse for lifting the turbine compartment of an off-shore windmill

10 m³ - grapple after a general overhaul Load test of 2100 t traverses prior to coating

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Frame and pendants for loading cellulose bales. The hooks are pneumatically opened via a radio signal.

Load test of a traverse intended for lifting the entire turbine compartments of off-shore windmills

Frame for loading big bags. The pneumatic hooks open via a radio signal.

120 t traverse for handling the rotor hub casing of a windmill

Cargo handling plant for runway pallets, which protects the pallets against cold and wet weather.

20“ low temperature container spreader during the load test

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4. Special Systems and Devices A further part of the scope of services offered by our company group is designing and manufacturing special systems and devices. After consulting with the customer, we develop those one-of-a-kind devices in close cooperation with and suited to the specific requirements of the customer. Afterwards, those special systems are produced in out own workshop.

Hatchway beam for launching the core collection carrier of the near polar research vessel Maria S. Merian

Model of the Ariane 5 rocket, scale 1 : 4, created in honour of the 30th anniversary of the European carrier rocket.

Development, production and installation of more than 100 foldable multi-purpose masts for the Old Harbour/New Harbour district in Bremerhaven. The masts are illuminated by night.

The multi-purpose masts by day

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Mobile washing system Dockboy for the environmentally sound cleaning of the bottom of a docked vessel. The system is remote controlled.

Dockboy in action

Sample collection tubes developed for the German border and customs authority. The tubes allow for taking diesel samples from vessels or agricultural machinery up to a depth of 8 meters. The samples are then subjected to a quick test by adding a reagent.

One-person lifting platform employed in the clean room of the company manufacturing the drives for the Ariane 5 rocket. The lifting platform can reach a maximum height of approx. 7 m and is also employed inside the ATV-module for integration purposes.

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5. Oil-water separation Technomar offers oil collection systems and oil-water separation equipment. Our oil-water separation systems are individually tailored for the specific needs of our customer. The units are available either firmly installed aboard an oil spill combating vessel or as mobile SEPCON units in standard ISO 20' containers. These units are also employed for industrial purposes.

Oil spill combating vessel Eversand Multi-purpose vessel Neuwerk in action

Skimmer pump unit 320 m³/h Skimmer being launched into the water

High sea skimmer during a trial run on the North Sea.

Inland water skimmer 40 m³/h during a trial run

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Delivering an oil separation container to the German government disaster relief organisation THW

Two SEPCONs after completion on the Technomar premises

External pump 40 m³/h for a SEPCON unit

SEPCON during a training session at the THW

SEPCON being unloaded Final filter system Degree of purity <5 ppm oil in water

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6. Producing individual components Our mechanical production team is highly qualified, versatile and flexible. Our mechanical production division includes the areas lathing and milling, both conventional as well as by CNC technology. The entire execution of an order from production to the post-production tests is carried out in accordance with the quality management system EN 9100-2003. The manufactured components are subjected to a final test at digitally equipped measuring stations. Test and measurement protocols are drafted depending upon the wishes of the customer. We offer:

• Components for medical equipment such as X-ray machines or X-ray tables • Mechanically processed components for scientific lab equipment • Components for the aerospace industry • Military equipment, e.g. sensors for detecting radioactivity underwater employed

aboard submarines, frigates, etc…. • Components for mega-yachts

Gear body made from solid metal Aluminum main component for telescopes attached to helmets

Underwater loudspeaker for military vessels

Processing a casing component

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Cams for the control units of drone aircraft, milled plastic component

Locking system for the hull portals of a mega-yacht; welded construction made from Duplex stainless steel

Bearing pedestals for the hull portals of a mega-yacht

Device for assembling small components in medical technology

Producing a manually operated deflector gear

Building a helicopter simulator

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7. Repair Services Our service team specialises in carrying out all sorts of metal repair work. The repair work is carried out either in our own workshop or on site, depending upon the circumstances and type of work.

Before

After

Repairing a gangway, which was damaged by a mooring vessel.

The supports have been replaced and the steel construction was aligned anew.

Bronze valve prior to refurbishing

The same valve after refurbishing

Repairing the cast iron casing of a steam turbine via repair welding

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8. Alterations / Conversions We carry out alterations and conversions of special machinery and for vessel components according to our customer's wishes. The necessary static calculations are carried out in close cooperation with our design subsidiary.

Converting a transport frame for windmills into a test stand

Subsequent addition of a device for transport frames

Conversion of a horizontal lifting clamp with one grip and a smooth clamp area

Repair of a skimmer for the vessel MV Neuwerk

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9. Engineering For more than 35 years, we have been providing engineering and design services for the fields of shipbuilding and maritime technology, port and cargo handling technology, hydraulic engineering and systems for the aerospace industry. We employ 3-D software and various FEM calculation programs. In addition to classic engineering services, we offer the entire range of project management services to our customers, from project development via construction, calculation, building supervision and documentation to the final approval. We support our customers from the very beginning of the project, helping them to find solutions to their problems. We develop possible solutions, suited to our customers' individual requirements. Promising ideas are then pursued further. The fact that Technomar is involved in the project from the very beginning on enables us to achieve the best possible solutions for our customers with regard function, production costs and delivery dates. Preferably, we use 3D programs to design our projects. This has several advantages, such as simplifying the generation of workshop drawings and automatizing the generation of parts lists. Motion sequences can be simulated, which provides the assurance that the final product will function as planned. Interfaces allow for uploading the 3D-models into die FEM calculation programs. Due to the close connection between engineering and production, Technomar has a lot of practical experience in developing designs suited for production, allowing for cost-effective manufacturing. On request, we also support our customers during external production processes by offering building supervision services. Hereby, the production status is continuously documented. We also support our customers during the licensing and approval process with government authorities, classification societies and the TÜV. We develop cargo securing and seafastening measures for project cargoes on high sea vessels such as container gantry cranes or pre-assembled industrial plants and coordinate the measures with both shipowners and insurance companies. Furthermore, we supervise and document all loading and security measures.

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Production hall plans for the transport of windmills

Development, design and calculation of off-shore lifting gears for windmills.

Complete model in theory II order, including dynamic stresses and wind loads.

Separate proof calculation of lashing points generated with FEM according to FKM regulations.

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Loading cable drums for the off-shore industry on top of a vessel's hatch covers. Weight per unit 380 t, Ø 12m, width approx. 6 m. The forces exerted upon the vessel at sea, including sailing round Cape Horn, were calculated. A mixed FEM shell/beam model was used to prove that the bearing capacity of the hatch structure and the necessary stiffeners were sufficient.

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Developing a timing table for serial production. In addition to the design, a mind map including all points necessary for developing the project can be seen as well.

For the ATV, a supply platform for the International Space Station ISS, we developed, designed, calculated and documented (in accordance with the CE norms) an ATV Lifting Pad. Technomar won the bid against 5 competitors all over Europe. Our design was chosen, because it was ideally suited to the requirements (takes up little space, high stiffness), and was successfully produced by us.

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Development, design, calculation und production of various traverses for heavy cargoes.

The image above shows a traverse designed for operation with two coupled vessel cranes with a lifting capacity of 450 t each. The traverse shown has a bearing capacity SWL of 850 tons as an average load. In addition to the situation shown, the spreaders may also be attached to cranes separately.

Distance pipes allow for suiting the length to the size of the cargo. SWL 450 t Class : LR

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Appendix Maschinery 1. Milling Machines Machine type Table size (mm) Movement range (mm) x y x y z Cincinnati Arrow 2 (CNC) 950 x 550 750 x 500 x 500 Deckel FP2A (CNC) 620 x 390 300 x 300 x 400 Deckel FP3A (CNC) 700 x 460 400 x 400 x 400 Schaublin 32 (CNC) 630 x 320 520 x 320 x 320 MAHO MH600 (NC) 800 x 400 500 x 400 x 400 Drilling machine 1000 x 1000 1200 x 1000 x 800

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2. Lathing Machines Machine type Height (mm) Lathing length (mm) Leinen / DLZ 140 500 Leinen / DLZ 140 500 Heidenreich / VDF 210 1000 Heidenreich / VDF 470 2600 Index Model GE42 (CNC) 175 360 (42 mm breakthrough)

3. Drilling Machines Machine type Table size (mm) Remarks Table drill 1700 x 355 D13 with coordinate indicator Radial drill 1200 x 500 D32; GG max. 45mm Upright drill 1700 x 700 x 1700 D65 in steel

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4. Cutting Equipment Sawing machine Kaltenbach RK Rods up to 6000 mm Plate saw Martin T83 For aluminium profiles and plates Length of cut 2300 mm Length of cut 110 mm Hacksaw Kasto for diameters up to 350 mm Mitre box saw Berg + Schmidt up to 230 mm Belt saw Mosser, type SSF for aluminium and plastic plates Eisele circular pendulum saw, type 762773/001 for pipes up to 100 mm Mobile assembly saw FEMI 783 for external pip laying operations 5. Presses Manual screw press W+N max. 40 t, table size 650 x 500 Eccentric press Ebu SK25 max. 25 t, table size 600 x 410 Edging press Fasti (manual) max. component width 1000 6. Specialised processing maschinery Engraving machine GmI/2 300 x 200 x 200 Eroding machine ER-1500 TG at 20 mm; electrode 12 mm Trovalier glide grinding machine 230 litres; 1100x500x500 Trovalier glide grinding machine Diameter 400 x 500 Sand and glass blasting cabin 1200 x 750 x 700 Threading machine Microtap M 0.8 to M6 Tool grinding machine WU2m S Tool processing 7. Metal and steelwork processing machinery Punching machine Peddinghaus Model 210 Super 11 up to 30 mm, diameter 25 mm EMB pipe bending machine type Tubomat for pipe diameters up to 42 mm Roller leveller Tenge-Rietberg, type H-E Diameter 250 x 1000 mm Roller leveller Hahn & Kolb 5 x 230 mm diameter Sander machine Metabo, type 7831 P 80 mm pad width Sander machine Simon, type M2 Face grinding area 200 x 500 mm Sander machine Flott 75 mm pad width Rotating welding machine for diameters up to m 900 mm Photo-electric burner 3000 x 2500

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8. Welding machines

1 ESAB-LAN-400 380V 400A 1994

1 ESAB-LAN-400 380V 400A 1995

1 ESAB-LAN-400 380V 400A 1995

1 Jäckle-WIG-201 iAC/DC Inventory 230V 160A 2000

1 Jäckle-WIG-201 i DC Inventory 230V 160A 2001

2 Transformer + rectifier 380V 400A 1990

1 Transformer Pfister 230V 130A 1998

1 Märtens Inventory Fronius-RC 230V 150A 2002

1 ESAB DTB 375 AC/DC 380V 375A 1990

1 ESS Thyromig 400 MIG/MAG. 380V 400A 1 Kjellberg KH 400 380V 400A 1996 1 Oerlikon Optipuls 350i 380V 350A 2003 3 Jäckle MIG 500 Ts 380V 500A 2007 1 ESAB LHF 400 380V 400A 1 ESS MIG MAG 302 M 380V 300A 1 Pego MAG 356 LK 380V 350A 1 Eurotronic MAK K 4500 W 380V 450A 1 Jäckle WIG 301i AC/DC 400V 300A 2008

1 Circulating air oven N500/750° 380V 27 KW 1987

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9. Paint coating system Damp coating any kind of paint coating work including structural paint L = 1000, W = 1000, H = 400, up to 40 kg Drying stove max. 200°C W = 1300, H = 2000, D = 1500

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Contact Data TECHNOMAR GmbH & Co. KG Carl-Stockhinger-Straße 6 D-28197 Bremen, Germany Telefon: +49 (0) 421- 54 90 9 - 0 Telefax: +49 (0) 421- 54 90 9 - 50 E-mail: [email protected] Internet: www.technomar-group.de

BST Bremer -System -Technik GmbH Carl-Stockhinger-Straße 6 D-28197 Bremen, Germany Telefon: +49 (0) 421- 54 90 9 - 70 Telefax: +49 (0) 421- 54 90 9 - 79 E-mail: [email protected] Internet: www.technomar-group.de

H.Schroeder GmbH Carl-Stockhinger-Straße 6 D-28197 Bremen, Germany Telefon: +49 (0) 421- 54 90 9 - 60 Telefax: +49 (0) 421- 54 90 9 - 69 E-mail: [email protected] Internet: www.technomar-group.de

Our representative for South-East Europe : Daube Rainbow SRL 27 Alexandru Cernat Str. 800087 Galati Romania Managing Director: Mr Victor Ionitza Tel/Fax: +40-236-463958 Mobile: +40-722-640797 [email protected]