Grade - Stahlguss Saar
Grade - Stahlguss Saar
Grade - Stahlguss Saar
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Da<br />
•Profile<br />
•Facilities<br />
•Products<br />
•Contact<br />
•References<br />
Company Profile<br />
<strong>Stahlguss</strong> <strong>Saar</strong> GmbH<br />
Germany, St. Ingbert<br />
Status: August 2012<br />
1
Profile: Introduction<br />
•<strong>Stahlguss</strong> <strong>Saar</strong><br />
•<strong>Stahlguss</strong> <strong>Saar</strong><br />
<strong>Stahlguss</strong> <strong>Saar</strong><br />
•<strong>Stahlguss</strong> <strong>Saar</strong><br />
• manufactures high-quality steel castings<br />
• is a established and reliable supplier for the sectors energy, pumps,<br />
compressors and mining.<br />
• performs as a strategic partner of our customers, e.g. for Siemens<br />
or Alstom in the energy sector, multifarious requirements<br />
• is - like <strong>Saar</strong>schmiede GmbH - a member of the <strong>Saar</strong>stahl Group<br />
2
Profile: Management Ratios<br />
Turnover 2011<br />
Employess<br />
Shipping Weight<br />
• Ca. 12 Mio. €<br />
• 106 employees<br />
• Max. 15 t per component, including allowance for machining<br />
(max. 25 t liquid weight)<br />
3
Profile: Range of Delivery<br />
Valve Casing „Elbistan“<br />
Valve Casing „Eshkol“<br />
• Maximum shipping weight according to the steel grade<br />
- app. 15 t for none and low alloyed grades<br />
- app. 12 t for high alloyed grades<br />
• Maximum dimensions: 4500 mm x 2500 mm x 3000 mm<br />
• Cast steel qualities:<br />
- Hot solid and high temperature cast steel<br />
- Corrosion and acid restistant cast steel<br />
- Cast steel for low temperatures<br />
- Quenched and tempered cast steel<br />
- Wear-resistant cast steel<br />
• Composite designs by construction welding of forged<br />
components to steel casting parts<br />
• Production according to national and international standards,<br />
as well as client specifications with the highest requirements.<br />
Valve Casing „RDK“ 4
Profile: Steel grades<br />
Front lid<br />
Gear segment<br />
Ring exhauster<br />
• Common used steel and alloy steel grades<br />
Identification: ID No.:<br />
GE300 1.0558<br />
GP240GH 1.0619<br />
G32NiCrMo14-5 1.6746 (without casting specification)<br />
G20Mn5 1.6220<br />
G20Mo5 1.5419<br />
G17CrMo5-5 1.7357<br />
G17CrMoV5-10 1.7706<br />
G17CrMo9-10 1.7379<br />
GS12CrMo19-5 1.7363 (as per SEW 595)<br />
GX12CrMoVNbN9-1 P91 (similar)<br />
GX4CrNi13-4 1.4317<br />
GX13CrMoCoVNbNB9-2-1<br />
GX12CrMoWVNbN10-1-1<br />
CB2<br />
1.4906<br />
GX25CrNiSi20-14 1.4832<br />
5
Facilities: Production<br />
Pouring<br />
Heat Treatment<br />
Welding<br />
• Pattern shop<br />
• Moulding shop<br />
• Melting shop and casting department<br />
– 2 electric arc furnaces (up to 9 t, up to 15 t)<br />
– 1 Argon Oxygen Decarburazion (AOD) Converter (15 t)<br />
• Shaking out, fettling, gas burning, arc air burning,<br />
• Heat treatment department<br />
– 5 furnaces, max. dimensions 7,5 m x 3,7 m x 2,2 m<br />
– All kind of heat treatment possible, max. 1150°C<br />
– Water-hardening-basin with re-cooling function<br />
– Oil-hardening in cooperation with <strong>Saar</strong>schmiede GmbH<br />
• Welding department<br />
– Fabrication and construction welding<br />
– Prozesses: manual metal arc welding (111), metal active gas<br />
welding (135, 136, 138), Tungsten inert gas welding (141)<br />
6
Facilities: Process Engineering<br />
Simulation of<br />
Solidification<br />
Simulation of<br />
Feeding<br />
Time Scheduling<br />
• Optimized feeding and casting technique, before beginning of<br />
the production<br />
• Castingsimulation (Magma Soft, version 4.4 und 5.0)<br />
• MPP (Manufacturing and testing plan of manufacturing and test<br />
steps, milestones and all documented process parameters<br />
• Work instructions to arrange the production processes and test<br />
instructions, particulary for NDT<br />
• Time scheduling and monitoring for the production and for all<br />
traded components, with continously information to our customers<br />
7
Facility: Quality Assurance<br />
Spectrometer<br />
Radiographic Equipment<br />
UT<br />
• Destructive Testing:<br />
− Equipment for analyzing of chemical elements and gas content<br />
− Equipment for testing of mechanical properties<br />
− Metallographic equipment and microsection<br />
• Non-Destructive Testing:<br />
− Ultrasonic Testing (UT)<br />
− Magnetic Particle Testing (MT)<br />
− Dye Penetration Testing (PT)<br />
− Radiographic Testing (RT)<br />
− Visual Testing (VT)<br />
− Dimension Control<br />
8
Facility: Quality Assurance<br />
DIN EN ISO 9001: 2008<br />
DGRL 97/23EC<br />
HP0<br />
DIN EN ISO 3834-2<br />
• DIN EN ISO 9001: 2008<br />
• EU Guidline Pressure Equipment Directive (PED) 97/23/EC<br />
• AW 2000-Form HP 0 and DIN EN ISO 3834-2<br />
• Certified NDT-operators Level 2+3 as per EN 473<br />
• Qualified welding operators as per EN 287 and certified welding<br />
supervisor welding personal SFI/SF and SAP as per guideline<br />
DVS-EWF 1171 to 1173<br />
• Approved welding procedure qualification records (WPQR) and<br />
welding procedure specification (WPS)<br />
• Inspection certificate as per EN 10204 3.1 und 3.2<br />
9
Products: Power Generation Machinery<br />
Valve Casing<br />
Valve Casing<br />
Valve Casing<br />
• Component: Valve Casing<br />
• <strong>Grade</strong>: GX13CrMoCoVNbNB9-2-1 (CB2)<br />
• Weight:11 mt<br />
• Component: Valve Casing<br />
• <strong>Grade</strong>: GX12CrMoVNbN9-1<br />
• Weight: 10 mt<br />
• Component: Valve Casing<br />
• <strong>Grade</strong>: G17CrMoV5-10<br />
• Weight:14 mt<br />
Seite 10
Products: Power Generation Machinery<br />
Vane Carrier<br />
Inlet Pipe<br />
Intermediate Pieces<br />
Shaft Seal<br />
• Components: Vane Carrier<br />
• <strong>Grade</strong>: GX13CrMoCoVNbNB9-2-1 (CB2)<br />
• Weight: Up to 5 mt<br />
• Components: Inlet Pipe<br />
• <strong>Grade</strong>: GX12CrMoVNbN9-1, also in CB2<br />
• Weight: Up to 10 mt<br />
• Components: Intermediate Pieces and Shaft Seal for Steam<br />
Turbine<br />
• <strong>Grade</strong>: G17CrMoV5-10, G20Mo, GP240GH; G17CrMo5-5<br />
• Weight: Up to 5 mt<br />
Seite 11
Products: Renewable Energy Sector<br />
Rotor<br />
Pelton Rotor<br />
Planet Carrier<br />
• Component: Turbine Rotor for Hydro-Electric Power Station<br />
• <strong>Grade</strong>: GX4CrNi13-4 (1.4317)<br />
• Weight: Up to 10 mt<br />
• Component: Pelton Rotor for Hydro-Electric Power Station<br />
• <strong>Grade</strong>: GX3CrNi13-4 (1.6982)<br />
• Weight: 10 mt<br />
• Component: Planet Carrier for Gear Boxes for Wind Power<br />
Turbines and Mining Equipment<br />
• <strong>Grade</strong>: G42CrMo4<br />
• Weight: 2 mt<br />
Seite 12
Products: General Machinery<br />
Rotor<br />
Bearing Case<br />
Hand Gear<br />
• Component: Rotor for Flue Gas Desulfurization Plant<br />
• <strong>Grade</strong>: GX2CrNiMoCuN25-6-3-3<br />
• Weight: 10 mt<br />
• Component: Bearing Case<br />
• <strong>Grade</strong>: G20Mn5<br />
• Weight: 2 mt<br />
• Component: Roller Hand Gear<br />
• <strong>Grade</strong>: GE300<br />
• Weight: 1 mt<br />
Seite 13
Products: Pump Sector<br />
Pump Casing<br />
Pump Casing<br />
Pump Casing<br />
• Component: Pump Casing for Polymer Production<br />
• <strong>Grade</strong>: GX4CrNi13-4<br />
• Weight: 1 mt<br />
• Component: Pump Casing for Polymer Production<br />
• <strong>Grade</strong>: GX4CrNi13-4<br />
• Weight: 5 mt<br />
• Component: Pump Casing for Polymer Production<br />
• <strong>Grade</strong>: GX4CrNi13-4<br />
• Weight: 12 mt<br />
Seite 14
Products: Compressor Sector<br />
Compressor Casing<br />
PRT-Casing<br />
• Component: Compressor Casing for Offshore<br />
• <strong>Grade</strong>: GX12CrMoWVNbN10-1-1<br />
• Weight: 8 mt<br />
• Component: PRT-Casing for Chemical Industry<br />
• <strong>Grade</strong>: GX5CrNiMoNb19-11-2<br />
• Weight: 9 mt<br />
• Component: Compressor Casing Upper + Lower Part for Offshore<br />
• <strong>Grade</strong>: GX4CrNiMo16-5-1<br />
• Weight: 8 mt + 12 mt<br />
Compressor Casing Seite 15
Products: Mining Sector<br />
Bearing for a Hinge<br />
Bearing for a Hinge<br />
Panel Band<br />
• Component: Bearing for a Hinge of Earth-Moving-Machinery<br />
• <strong>Grade</strong>: G20Mn5<br />
• Weight: 5 mt<br />
• Component: Bearing for a Hinge of Earth-Moving-Machinery<br />
• <strong>Grade</strong>: G20Mn5<br />
• Weight: 7 mt<br />
• Component: Panel Band for Excavated Material<br />
• <strong>Grade</strong>: GX120MnCr12-2<br />
• Weight: 200 kg<br />
Seite 16
Products: Wear Resistant Cast<br />
Blow Bar<br />
Hammerhead, Hammer<br />
Crusher Ball, -ring<br />
• Component: Blow Bar<br />
• <strong>Grade</strong>: GX300CrMo27-1<br />
• Weight: 340 kg<br />
• Component: Hammer Head, Hammer<br />
• <strong>Grade</strong>: GX300CrMo27-1<br />
• Weight: 30 kg<br />
• Component: Crusher Ball, Crusher Ring<br />
• <strong>Grade</strong>: GX260CrMo18-1<br />
• Weight: 350 – 600 kg<br />
Seite 17
Products: Services<br />
Heat Treatment<br />
Dimension Control<br />
Ultrasonic Testing<br />
• Heat Treatment (Normalizing, QT, Stress-Relieving)<br />
• Blasting (Steel Shot)<br />
• Mechanical Properties Testing (Tensile / Bending / Hardness<br />
Testing etc.)<br />
• Chemical Analysis (Spectrometer Analysis)<br />
• Metallographic Testing (Macro / Micro)<br />
• Preparation of Test Pieces<br />
• Non Destructive Testing (Dye Penetration / Magnetic Particle /<br />
Ultrassonic / Radiographic Testing)<br />
• Demagnetization<br />
• Dimension Control with Three-Axle-Measurement Equipment /<br />
FARO Arm<br />
• Casting Simulation ( Magma Soft 4.4 und 5.0 )<br />
Seite 18
Contact<br />
General Manager<br />
Helmut von Maurice<br />
Phone +49 (0) 6894 598 16<br />
Fax +49 (0) 6894 598 10<br />
Mobil +49 (0) 171 223 4200<br />
E-Mail helmut.v.maurice@stahlguss-saar.com<br />
<strong>Stahlguss</strong> <strong>Saar</strong> GmbH<br />
Kahlenbergstraße 5<br />
66386 St. Ingbert<br />
Germany<br />
19
Contact<br />
Sales Department<br />
Sales Department<br />
Gerd Braun<br />
Phone +49 (0) 6894 598 45<br />
Fax +49 (0) 6894 598 10<br />
E-Mail gerd.braun@stahlguss-saar.com<br />
Frank Kiefer<br />
Phone +49 (0) 6894 598 93<br />
Fax +49 (0) 6894 598 10<br />
Mobil +49 (0) 160 718 3510<br />
E-Mail frank.kiefer@stahlguss-saar.com<br />
<strong>Stahlguss</strong> <strong>Saar</strong> GmbH<br />
Kahlenbergstraße 5<br />
66386 St. Ingbert<br />
Germany<br />
20
Contact<br />
Sales Department Wear<br />
Resistant Steel and Trade<br />
Sales Department Wear<br />
Resistant Steel and Trade<br />
Dirk Konrad<br />
Phone +49 (0) 6894 598 46<br />
Fax +49 (0) 6894 598 51<br />
E-Mail dirk.konrad@stahlguss-saar.com<br />
Markus Böhm<br />
Phone +49 (0) 6894 598 39<br />
Fax +49 (0) 6894 598 51<br />
E-Mail markus.boehm@stahlguss-saar.com<br />
<strong>Stahlguss</strong> <strong>Saar</strong> GmbH<br />
Kahlenbergstraße 5<br />
66386 St. Ingbert<br />
Germany<br />
21
Contakt<br />
Quality Department<br />
Quality Department<br />
Dr. Bernd Engels<br />
Phone +49 (0) 6894 598 42<br />
Fax +49 (0) 6894 598 58<br />
Mobil +49 (0) 160 718 3537<br />
E-Mail bernd.Engels@stahlguss-saar.com<br />
Berthold Schneider<br />
Phone +49 (0) 6894 598 28<br />
Fax +49 (0) 6894 598 58<br />
E-Mail berthold.schneider@stahlguss-saar.com<br />
<strong>Stahlguss</strong> <strong>Saar</strong> GmbH<br />
Kahlenbergstraße 5<br />
66386 St. Ingbert<br />
Germany<br />
22
Contact<br />
Production und<br />
Time Scheduling<br />
Giovanni Raimondo<br />
Phone +49 (0) 6894 598 18<br />
Fax +49 (0) 6894 598 58<br />
E-Mail giovanni.raimondo@stahlguss-saar.com<br />
<strong>Stahlguss</strong> <strong>Saar</strong> GmbH<br />
Kahlenbergstraße 5<br />
66386 St. Ingbert<br />
Germany<br />
23
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