SEMI-FINISHED PRODUCTS AND MATERIALS

The JSC «SMNPO – Engineering» manufactures the castings of grey cast iron, steels and non-ferrous metals.

The following grades of cast iron are used for castings:Sch 10, Sch 35 (GOST 1412-85), ChH1, ChH2, ChH3, ChH28D2 (GOST 7769-82).

These castings are intended for parts manufacture of pumps for nuclear power stations, heavy-duty compressors and chemical equipment, which are operated in conditions of aggressive, toxic, explosion and fire dangerous media, high pressure and wide temperature ranges. The finished castings meet the strict requirements for mechanical properties, microstructure, chemical composition and density. Castings weight: from 50 g to 20,000 kg at maximum dimensions of 6,000×4,000×900 mm.
For steel castings the following steel grades are used: 20L, 25L, 35L, 20H13L, H18H9TL, 20H20N 17S2L, 110G13L (GOST 977-88).

For steel castings the following steel grades are used: 20L, 25L, 35L, 20H13L, H18H9TL, 20H20N 17S2L, 110G13L (GOST 977-88). The steel castings are intended for parts manufacture of pumps for NPP, centrifuges and heavy-duty compressors, which are operated in conditions of radioactive media and high pressure.

Steel melting is carried out in DSP-1.5, DSP-3 electric arc and IST – 0.4 induction furnaces. Castings weight: from 10 kg to 2500 kg at maximum dimensions of 1,500×1,000×1,000 mm.

For investment casting the following steel grades are used: 20H13L, 12H18N9TL, 12H18N12M3TL. The main nomenclature list includes impellers and guide vanes for centrifugal pumps. Steel melting is carried out in IST – 0.4 induction furnaces. Castings weight: to 20 kg at maximum dimensions of 300x300x200mm.

For copper alloys casting the following grades are used: BrO5C5S5, BrO10F1, BrA9G3L, BrO7S13N3, BrO12S2, L63. Melting is carried out in IST-0.16 and IST-0.4 induction furnaces. Pouring is carried out into chill molds, moulds of centrifugal machines and partially into sandy-clayey forms.

Castings weight: to 200 kg at maximum dimensions of 500x500x300 mm.
For aluminium alloys casting the following grades are used: АК12, АК5M2, АК5М7. Casting is carried out in IAT – 0.4 induction and crucible gas furnaces.
Castings weight: to 150 kg at maximum dimensions of 800x800x300mm. 

For  forgings  manufacturing  up-to-date  unique  equipment  produced  by  domestic  and  foreign  Companies  is used.Forgings are made of structural carbon, low-alloy, alloy, tool, corrosion-resistant, high-temperature and wear-resisting steels and non-ferrous metals.

Billets:

Initial billets are ingots of 6, 9, 12 tons weighing out, which are manufactured by the Company, purchased ingots of weight up to 18 tons, rolled steel of round and square section with the dimension up to 360 mm. Steel billets are heated in batch-type furnaces and gas furnaces with walking beam. Non-ferrous and alloy billets are heated in electric furnaces.

Equipment

Forging is carried out at air and steam-driven hammers with drop parts weight of 150 … 3000 kg as well as at hydraulic press with force of 2000 t. Rolling of rings is carried out at specialized flange rolling machine.
Heat treatment of forgings is carried out in gas batch-type and shaft electric furnaces.

Forgings:

JSW (Japan) hydraulic forging press of 2000 t force. It is served through forging manipulator with load-lifting capacity of 18 tons.

The press makes possible to manufacture the following forgings:

– solid discs and discs with a hole of diameter up to 1500 mm and weight up to 5000 kg;

– shafts with barrels diameter to 550 mm, length to 5000 mm and weight up to 6000 kg;

– rolled rings with external diameter up to 1800 mm and weight up to 6000 kg;

– cylinders with external diameter up to 900 mm and length up to 1800 mm, weight up to 5000 kg;

– bars and plates of length up to 5000 mm, weight up to 10000 kg.

«Wagner Dorthmund» the ring-rolling machine RAW 160/125 of 160 t radial force and 125 t axial force.

It makes possible to manufacture:

• seamless rolled rings with external diameter  up to 2500 mm, height from 70 mm to 500 mm and weight up to 3500 kg.

Pneumatic and steam-driven free forging hammer of arch and bridge type with drop parts weight from 150 kg to 3000 kg.

It makes possible to manufacture the following forgings:

• discs and rolled rings of diameter from 100 mm up to 600 mm, weight up to 320 kg;
• shafts of barrel diameter up to 400 mm, length up to 400 mm, weight up to 2000 kg;
• bars and plates of section up to 350 mm, length 3500 mm, weight up to 2000 kg;
• shaped forgings.

JSC “SMNPO – Engineering” has a great experience in tubulars manufacture and currently manufactures tubes by cold rolling; by welding of carbon steels, stainless steels and non-ferrous metals and bimetallic finned tubes, which are used for heatexchangers.

Cold-finished seamless tubes:

Tube diameter, mm – from 8 to 76

Wall thickness, mm – from 1 to 10

Tube length, m – to 23

Material – different grades of steel, non-ferrous metals and alloys of normal, high and precision accuracy, in particular according to GOST:: 8733; 9567; 21729; 9941; 550; 617; 17217; 21646; 494; 22897. API 5L. ТУ – 14-3-460; 14-3-251; 14-3-501-76

Electric-welded cold-finished  corrosion-resistant steel tubes :

ube diameter, mm – from 8 to 76/102

Wall thickness, mm – from 1 to 3

Tube length, m – to 23

Accuracy of manufacturing – normal, high and precision accuracy as to ТУ 27.2-8-66-2003

Finned bimetallic pipes :

ube diameter, mm – 25

Wall thickness, mm – 2.5

Tube length, m – to 12

JSC “SMNPO-Engineering” has experience in the manufacture of bottoms for vessels and apparatus by stamping, flanging.

1. Stamped elliptic bottoms as to GOST 6533-78

Equipment:

– hydraulic press Q = 800t/f – 2 articles;

– hydraulic press Q = 400t/f – 1 article

Bottoms maximum dimensions:  ∅1800х50 mm

Materials:

– steel 3 SG, 09G2S, ST20, 12H18N10Т;

– titanium VТ1-0;

– titanium-base alloys PТ3V, АТ3, ОТ4-0.

2. Hemispherical welded steel bottoms

Bottoms maximum dimensions ∅3000х80 mm, over ∅ 3000 mm with rework when mounting.

3. Flanged elliptic bottoms as to GOST 6533-78

Bottoms maximum dimensions ∅3400х30 mm

Oversized stamping-welded articles designed for high pressure are widely used as connection parts of pipelines of gas main, booster and gas lift compressor stations, in gas refining production, during gas mains construction.

The experts of the company has designed optimum series covered the diameters of connected pipes from 57 to 1220 mm (for pipe bends from 57 up to 1220 mm).

High quality low-alloy cold-resistant steels of 10A2OA type and strength grade K60 as well as steels of 09A2N and Co.20 type are used as the main structural material..

To produce oversized stamping-welded shaped articles the company has available a large fleet of various process equipment: heating furnaces for sheets, manipulators for billets supply to the furnace and stamping zone, hydraulic presses, welding and metal-cutting equipment.

The manufacture of stamping-welded pipe bends, T-pieces and passages is made by method of two identical parts stamping and their subsequent welding in vertical plane. This method guarantees the minimum thinning in a zone of maximum deformation.

The welding process is maximum mechanized and automated. Automatic and semiautomatic electroslag and gas shielded welding is widely used. Welded joints are 100% tested when manufacturing by nondestructive inspection (ultrasonic inspection, radiography) in compliance with standardized documents.

The required grooving geometry of welded joints is made by machining with the help of vertical turning lathes and boring machines using special accessories