Untitled Document

In recent years we have completed the following projects:

OAO "SEVERSTAL" ( Cherepovets).

Mixers for transportation of liquid cast-iron of 600 tons capacity.

- calculation of mixers strain state;

- evaluation of mixers body temperature field;

-measurement of stresses in fall-scale structure under weight of liquid cast-iron and by dynamic effects when moving along the rails;

- ultrasonic control of weld seams;

- measurement of metal thickness with ultrasonic method;

- definition of the material mechanical characteristics including an impact strength;

- fractographic analysis of the material structure.

The work carried out by us resulted in extending the mixers life by 5 years with the possibility of extending it again by repeating the procedure.

Rotary stand of steel concasting machine.

- calculation of the metal frameworks strain state;

- evaluation of the body temperatures field;

-measurement of stresses in fall-scale structure depending on a ladle weight and dynamic effects when rotating during acceleration and braking;

- ultrasonic control of weld seams;

- measurement of metal thickness by ultrasonic method;

- definition of the material mechanical characteristics including an impact strength.

Based on this research we carried out the following procedures:

- Recommendations to strengthen the connections in the rotating unit were implemented.

- structure and composition(chemistry) changes of the material in comparison with certificate data and the results of previous researches have been revealed;

Since there was no data regarding extreme values of the material properties, specifying its critical condition , one year prolongation for the unit operation has been given..

Blast furnaces.

Finding the cause of the cracks appearing in the blast furnace casing and working out the technology for crack welding.

The converter.

Analysis of the converter body strain state.

The Chelyabinsk pipe rolling plant ( Chelyabinsk)

Hydraulic moulding presses for 1020-1200mm diameter oil and gas pipes, in operation since 1971.

In 2005- 2006 a complex operation to increase the strength capacity of base parts of the press was completed, after which the molding operation force was increased from 200 MN to 360 MN (after press modification). We were the first company in the world to introduce this pioneering operation for increasing the axial force of a hydraulic press by 1.8 times whilst still retaining it’s original dimensions and main base parts.

A system for controlling strength and technological parameters was designed and installed. The system provides optimum conditions for the base parts operation by restricting the stresses exceeding the material strength value and controlling the parameters of technological process.

In 2006 the works on press 20 MN base recovery and its column thermo-tightening have been done.

The Stupinsky metallurgical company (Stupino)

VSMPO-AVISMA (Verkhnyaya Salda )

A press of 300 М N, in operation- since 1961.

In 2003 the system controlling the strength and technological parameters of the press were developed and installed. The system provides optimum conditions for the columns operation by criteria restricting the stresses exceeding the material strength value, as well as controlling the column tightening force and parameters of technological process.

A press of 750 М N, in operation- since 1961.

Institute of Light Alloys ( Moscow)

Technical solutions were implemented to prevent the dismantling and destruction of a 60MN forging press moving cross-beam (manufactured by UZTM) . The i nner ribs of the cross-beam were damaged by diagonal cracks spacing from the top horizontal plate to the bottom horizontal plate. The cross-beam was equipped with the tightening device in 1985 is still in operation now without any restriction of the press axial force.

Kamensk-Uralsky metallurgical plant (Kamensk-Uralsky)

In 2006 the condition of the base parts of 60 MN press (manufactured by UZTM) were examined and technical solutions for trouble-free press operation were developed.

Nizhnetagilsky metallurgical complex (Nizhny Tagil)

Railway-wheel presses of 20, 35, 50 and 70 MN (UZTM) were inspected and the design conditions for base parts operation have been provided .

OOO "OMZ-SPETSSTAL" (Kolpino)

The process solutions to recover the 32 MN press base have been worked out and implemented .

Ufaleysky metallurgical engineering plant (Verkhny Ufaley)

The condition of the columns, cylinders and cross-beams of a 20MN press were checked. The press column tightening parameters were calculated and thermo-tightening done . Methods for repairing the sheave pin of a steel casting ladle have been developed.

Pervouralsky novotrubny plant (Pervouralsk)

In 2006 the work - «Examination of the actual condition of automatic mill TPU - 220 stand» was carried out. Based on it’s results the conclusion of the residual life of the mill stand have been given, the reasons for the cracking in the supporting leg determined and technical solutions for overhauling the stand were proposed.

2006- « Investigation into the condition of press 170». As a result of an investigation carried out, t echnical improvements to ensure trouble-free operation of the press were introduced.

ALCOA The Samara metallurgical plant (Samara)

2006- « Investigation into the actual state of the press 300 MN base parts ». As a result of the investigation carried out, technical solutions were proposed to ensure trouble free operation of the press.

The technical specification enabling a reduction in the time and cost to overhaul a 100 М N press was calculated and drawn up.

The column of 800 mm diameter with completely destroyed thread has been restored.

Vyksunsky metallurgical plant (Vyksa)

Hydraulic presses of 20, 35, 50 and 100 М N producing railway wheels, in operation since 1971.

Complex work to increase the strength and reliability of the press base parts was carried out, increasing production line output from 450 000 wheels/years (1971 -2002 ) to 850 000 wheels/years (2003-2006). 850 000 full load cycles per year is a productivity world record for a production line comprising powerful hydraulic presses.

In 2004 the mounting surface of lower will-mill edger has been reconditioned without frame dismantling (diameter 960mm, depth 1500mm).

The fillet of a 35 MN press cylinder bottom the circle crack has been revealed by ultrasonic method . The cylinder was restored by welding without
preh eating and heat treatment.

The reasons of cylinders’ failure have been determined and a new cylinder design and manufacture technology proposed to ensure unlimited cylinder life.

In 2007 the works on reconditioning the internal surfaces of pilger mill have been executed .