Large Cylindrical Iron Castings for Paper Drying and other Applications

Transcription

1 PMT Group PMT Industries Ltd Large Cylindrical Iron Castings for Paper Drying and other Applications By David Moore Quality & Technical Manager David Moore - Quality & Technical Manager with PMT Industries Ltd gave a presentation about the company, which is part of the PMT Group, owned by Italian company, the Nugo Group. The group has two main divisions, power generation and paper machinery. PMT Industries is part of the paper machinery division. As one of only a few foundries in the world with deep pits, the company is capable of casting very large cast iron components, not only for the paper industry but also for other industries. It is recognised for its excellence in quality castings. PMT Yankee, MG and Paper Dryers are designed and manufactured at the company s 12,000 m 2 factory in Bolton, UK. Where state of the art computerised design, engineering, foundry and machining resources combine with traditional skills and craftsmanship in a unique single location. Around 500 Yankee and MG dryers have been designed and manufactured since 1884 and thousands of paper dryers, continually developing the designs and production techniques and building up a vast experience and know-how in this specialised area of papermaking technology. The castings manufactured range in size from 1 Tonne to 150 Tonnes in grey and ductile cast iron, and the presentation describes the various stages in production that the company uses, particularly some of the unusual moulding techniques that are necessary in order to produce the very large castings. It is one of very few foundries to use loam (a mixture of red sand, clay, water and horse manure) applied by hand to a refractory brick lining. The company also uses cement sand for some of the large diameter castings, again a process that is unusual. The foundry has one of the largest melting capacity medium frequency electric furnace installations in Europe. The twin 9 MW inverter powered and computer controlled furnaces melt 38 Tonnes of iron per hour, with each 12 Tonnes charge being melted to 1450 C in just 38 minutes. The presentation also describes some of the process control techniques that are used by the company and the quality standards to which the company is certified.

2 Large Cylindrical Iron Castings for Paper Drying and other Applications By David Moore Quality & Technical Manager PMT Industries Ltd

3 BOLTON FACILITIES PMT Industries Limited Kentfield Drive Bolton Lancashire BL1 8UL Telephone: +44 (0) Fax: +44 (0)

4 BOLTON SITE HISTORY Cylindrical castings have been produced at our Foundry in Bolton since 1961 Cylindrical castings have been produced by associated companies since 1860 In 1961 the Bolton foundry opened and four foundries from Bury & Wigan were consolidated on the one site The site has had various names including Walmsleys (Bury) Ltd, Beloit Walmsley, Beloit Bolton & Sandusky Walmsley In October 2006 the site closed and 3 months later the foundry and Yankee Dryer machining & assembly area was re-opened as PMT Industries. Retaining the skills & experience of many of the former employees of the previous company

5 PMT SouthAfrica Pty Ltd PMT GROUP PROFILE Lidia Srl Holding Company PMT Italia SpA Nugo Romano SpA PMT Industries Ltd PMT Winding

6 PMT GROUP Romano Nugo - Milan Site PMT Italia Pinerolo, Turin Site

7 OTHER PMT GROUP SITES PMT SOUTH AFRICA SITE

8 . PMT GROUP LOCATIONS. Pinerolo (Turin, Italy) Mainly Paper Machinery business Piedimulera (Milan, Italy) Mainly Power Generation business Bolton (U.K.) Established 2006 Castings and Yankee Dryers Group companies Contact offices Johannesburg (South Africa) Established 2007 Paper Machinery Services Valkeakoski (Finland) Established 2010 Windings

9 CYLINDRICAL CASTINGS Cylindrical castings at PMT are made to various configurations Parallel Stepped Profile With Protrusions

10 PARALLEL

11 STEPPED PROFILE

12 STEPPED PROFILE

13 PROTRUSION - LIFTING LUG

14 MOULD BOSS PROTRUSIONS

15 PADS AND BOSSES PROTRUSIONS CASTING AS REMOVED FROM MOULD

16 CASTING- EXTERNAL PROTRUSIONS FINISHED MACHINED CASTING

17 CYLINDRICAL CASTINGS VARIOUS SIZES & WEIGHTS Sizes 0.25 m to 6.70 m Diameter (10 inches to 22 feet) 1.00 m to 11 m long (36 inches to 36 feet) Weights 1 tonne to 150 tonnes

18 VARIOUS SIZES

19 VARIOUS THICKNESES

20 VARIOUS LENGTHS

21 PMT CYLINDRICAL CASTINGS FOR VARIOUS INDUSTRIES Paper Making Oil & Gas Construction Food Processing Street Furniture

22 PMT CYLINDRICAL CASTINGS IN VARIOUS GRADES OF CAST IRON GREY CAST IRON EN GJL 150 to 350 ASTM A278 CLASS 25 to 60 S.G. (DUCTILE) CAST IRON EN GJS to 800-2

23 PMT CYLINDRICAL CASTINGS PMT Cylindrical castings are made by various moulding methods Core Assembly Section Moulds & Cores - Small Diameter castings Full pattern & corebox - Small Diameter castings Strickle Moulds - Large Diameter castings PMT Industries Ltd PMT Group

24 CORE ASSEMBLY DRAG CORE

25 CORE ASSEMBLY COPE CORE

26 CORE ASSEMBLY ASSEMBLING MOULD

27 CORE ASSEMBLY MOULD AWAITING WEIGHTING

28 SMALL DIAMETER CYLINDERS SMALLER DIAMETER CYLINDERS The mould and cores are made in furan (resin bonded) sand for sizes up to 8 ft (2.5m) diameter and 420 inch (10.7m) long There are four main components to any smaller diameter cylinder mould Base seating Mould casings Core & barrel Runner bush

29 Refractory Tile Steel or cast iron plate BASE SEATING Furan sand

30 FURANE MOULD SECTION Furan sand Steel casing (moulding box)

31 CENTERING PATTERN TO CASING

32 ASSEMBLED CASINGS

33 FULL PATTERN WITHDRAWING PATTERN

34 FURANE CORE

35 CASING

36 CORE SET WITH CHAPLETS

37 POURING BUSH

38 TYPICAL POURING BUSH

39 PREPARING FOR POUR DESLAGGING LADLE & TAKING TEST SAMPLES

40 SETTING UP TO POUR

41 POURING

42 POURING

43 STRIPPED CASTING Casting as removed from mould

44 FOUNDRY MAIN BAY

45 LARGE DIAMETER CYLINDERS LARGER DIAMETER CYLINDERS sizes 10 ft to 22ft (3m to 6.7m ) Diameter x 300 inch (7.7m) long Moulds are made in brick and loam sand Cores are made by the Randupson (cement sand) process There are four main components to this type of mould Base seating Mould and casing Cores Runner bush & ring

46 PREPARING SEATING

47 LOWERING CASING

48 LOAM & BRICK

49 APPLYING LOAM

50 APPLYING LOAM

51 STRICKLE BOARD

52 BLACKED MOULD

53 PATTERN MAKING

54 CORE MAKING

55 REMOVING CORE

56 FINISHED CORE

57 PLACING CORE IN MOULD

58 TYPICAL POURING BUSH

59 ASSEMBLED MOULD

60 ELECTRIC INDUCTION MELTING 2 x 9 MW - 12 Tonne capacity Inductotherm Furnaces melt time to 1450C = 38mins SIGNIFICANT CASTING QUALITY IMPROVEMENTS WERE MADE WHEN WE CHANGED FROM CUPOLA TO ELECTRIC MELTING

61 MELTING & TREATMENT FURNACES BACK-TILT FOR SAMPLING & DE-SLAGGING SIGNIFICANT S.G IRON CASTING QUALITY IMPROVEMENTS WERE MADE WHEN Mg CORED WIRE INJECTION EQUIPMENT INSTALLED

62 READY TO POUR

63 POURING 144 Tonnes

64 HANDLING CASTING

65 HANDLING CASTING

66 HANDLING CASTING Yankee Dryer Shell Casting as Received from Foundry

67 MACHINING & NDT YANKEE DRYER SHELL CASTING 100% MACHINED

68 PRODUCT TESTING UT, RT, MT, HYDRO-STATIC PRESSURE UP TO 280 PSI

69 PROCESS CONTROL QUALITY CONTROL ROUTINES Moulders complete QCRs includes: Moulding Coremaking Refractory Coatings Pouring Bush Mould Assembly CONTRACT ORDER: CASTING No. PAGE OF CUSTOMER: SIZE: ALL CORES MUST BE MEASURED AFTER PAINTING & PRIOR TO DRYING No. 43 BLACKING Core BAUME BAUME BAUME BAUME BAUME COMMENTS CLOCK DATE No. COAT 1 COAT 2 COAT 3 COAT 4 No TERRAPAINT QUALITY CONTROL ROUTINE SUBJECT: YANKEE & M.G DRYER SHELL CORE COATING RECORD 1 COAT OF TERRAPAINT MUST BE APPLIED TO THE TOP & BOTTOM CORE JOINT - 1 BRUSH WIDTH TERRAPAINT - 1st COAT BAUME = 60 OTHER COATS BAUME = 90 No. 43 BLACKING BAUME = 50 TOP FLANGE CORE No. 43 BLACKING QCR YD0100 PAGE 1 OF 1 Issue: B Approved: DFM Dated: 21/01/09

70 SAND TESTING SAND TESTING Smaller Diameter Cylinders Sand quality is critical to mould & casting integrity Reclaimed Furan sand from continuous mixers Dust & Fines Content LOI Grain size & distribution Moisture Content Linear Contraction Spot checks on % reclaim PMT Industries Ltd PMT Group Mixer calibration Calibration tubes Physical volumes & weights

71 SAND TESTING SAND TESTING Large Diameter Cylinders Sand mix is critical to casting surface finish The result of extensive trials & further developed Each mix of Loam sand is tested for Clay Content LOI Grain size & distribution Moisture Content PMT Industries Ltd PMT Group Cement Sand tested Moisture Compression Strength WT. % RETAINED 5 0 TYPICAL LOAM SAND DISTRIBUTION <63 CLAY SIEVE TEST SIZES

72 FOUNDRY TECHNICAL C & S DETERMINATOR FOUNDRY METHODS TENSILE TESTING SPECTROGRAPHIC ANALYSIS

73 SIMULATION SOFTWARE MAGMASOFT All large diameter castings and ancillary parts are modelled using Magmasoft casting simulation software under a continuous improvement programme. A mould is modelled in all its constituent parts The metallurgical conditions are input The predicted results of the mould fill, casting cooling & mechanical properties can then be reviewed Changes can then made to any of the input conditions and the simulation re-run

74 MOULD & CASTING MODELLING

75 CASTING PREDICTION

76 METALLURGICAL CONTROL What is the problem? Casting 1: C = 3.30% Si = 1.85% Pouring temp. = 1320 o C No Casting defects All Measured Data correct Casting 2: C = 3.30% Si = 1.85% Pouring temp. = 1320 o C Casting defects found All Measured Data correct The problem is that not all essential data is measured and knowledge is lacking. The metallurgist cannot see what he needs to see in order to control quality. ATAS (Adaptive Thermal Analysis System) allows him to see other parameters

77 METALLURGICAL CONTROL Spectrometer & ATAS Thermal Analysis The spectrometer only shows the amount of each element. ATAS shows the effect of all elements and compounds. It is the effect that is important to know for process control

78 METALLURGICAL CONTROL Screen Shots from ATAS Software Used for process development and daily quality control

79 TRANSPORT 1905 STYLE OF TRANSPORT

80 TRANSPORT 1950 STYLE OF TRANSPORT

81 TRANSPORT 2010 TRANSPORT

82 LOADING A YANKEE DRYER

83 DELIVERY OF FINISHED DRYER DRYER TRANSPORTATION LIFTING FINISHED DRYER

84 ON THE ROAD

85 AT THE DOCKS

86 ANY QUESTIONS