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Design and production of a large Edger drive

Galbiati has recently built a large Edger drive for an existing hot rolling mill at Mariupol, Ukraine.

The engineering process was undertaken by the Galbiati Group in collaboration with Primetals Linz, whilst the large Edger drive was purchased directly by Metinvest Engineering LLC, Dnipropetrovsk, Ukraine.

Galbiati Group’ supply covered the engineering and manufacturing of a large Edger drive for a hot rolling mill, with three reduction ratios, double motorization in vertical auto supported. Two twin and specular reduction units, with high rigidity union flange. The Edger control gear is parallel axis vertically mounted with double inlet and double outlet. The gears consist of shafts and toothed wheels with helical pinions made of 18CrNiMo7-6 steel, hardened, hardened and ground in DIN 6 quality. Lens shafts made of 42CrMo4 steel.

Galbiati Group has extensive experience in the design, manufacturing and revamping of: mechanical transmissions for steel industry (hot and cold rolling mill), large Edger drives, pinion stands and twin drives for mill stands, main drives for shears, tilting converters drives, coilers and uncoilers.

Third party mechanical machining on a flame tube for a gas turbine

Third party mechanical machining

Galbiati Group has carried out mechanical machining on behalf of a third party customer on a gas turbine component for an important international client.

This is a flame tube for gas turbine made of stainless steel with high chrome content.

The main difficulty occurred during the drilling of the flame tube for creating holes with a diameter of 1.8 mm, for a total of 1,200 holes.

The photo below shows the flame tube for turbine during the drilling operations.

The Mechanical Machining and Construction Division at Galbiati Group is the ideal partner qualified for custom construction of mid and large-sized components that require high quality standards.

Galbiati Group and its activity of reconditioning of gear reducers

gear reducers

The Galbiati Group recently undertook a project to recondition two gear reducers for screw down drives installed in an old plant operating at Mariupol in the Ukraine.

The engineering was entrusted to renowned industry leader Primetals Linz, whilst the machines themselves are the property of end customer Metinvest Engineering LLC, also located in the Ukraine at Dnipropetrovsk.
The reconditioning operation concerns a pair of gear reducers coupled to screw down drives 2X, 100 KW at 670/42 rpm, in an assembly weighing 18 tons overall, which includes the support frame, auxiliaries, brakes, auxiliary geared motors, etc. The gear reducers consist in two symmetrical components of around 9000 kg each.
Once completed, a full-speed running test is performed. Temperatures, noise levels, and vibrations are continuously measured and properly recorded.
A “Certification File” is issued for each drive, which contains the materials and inspection certificates as well as all intermediate and final inspection drive report.
For more details click here or visit the company website.

Galbiati Group built a large pinion stand drive

The Galbiati Group recently built a large pinion stand drive as part of a revamp carried out on an existing hot rolling mill at Mariupol, Ukraine.

The engineering process was undertaken by the Galbiati Group in collaboration with Primetals Linz, whilst the pinion stand drive was purchased directly by Metinvest Engineering LLC, Dnipropetrovsk, Ukraine.

Galbiati Group’s supply contract covered the engineering and manufaturing of a large pinion stand drive for a hot rolling millequipped with 1 x 7000 kW motor, a single horizontal input shaft and twin output shafts. The gears and shafts consist of double helical pinions made of 18CrNiMo7-6 steel, hardened, casehardened and ground to meet the standards of DIN 3961 grade 6. Gear teeth undergo profile correction to optimize power transmission and contact between mating surfaces of the gear pair. In addition, the pinion shafts are fitted with ring seals designed to prevent wear.

The housing of the pinion stand drive is an electrically welded and stress-relieved structure made of S355J2 carbon steel. It also incorporates generously proportioned inspection windows and an air breather for the levelling of machined surfaces.

The pinion stand drive is fitted with high quality roller bearings mounted in metal cages ideally suited to the specified speeds of rotation.

All machined parts of the pinion stand drive are treated with Tectyl to guard against corrosion, and guaranteed fully waterproof. The unit is suitably protected and packed in a wooden crate ready for shipment by sea.

Individual components of pinion stand drive are inspected to determine wear and deformation. Non-destructive tests, are conducted by skilled and experienced technicians, using high-precision instruments and a ZEISS MMZ-G 30 60 25 three dimension measuring machine.

Once completed the pinion stand drive, a full-speed running test is performed. Temperatures, noise levels, and vibrations are continuously measured and properly recorded.

A “Certification File” is issued for each drive, which contains the materials and inspection certificates as well as all intermediate and final inspection drive report.

Galbiati Group has extensive experience in the design, manufacturing and revamping of: mechanical transmissions for steel industry (hot and cold rolling mill), large Edger drives, pinion stands and twin drives for mill stands, main drives for shears, tilting converters drives, coilers and uncoilers.

Indian Steel Industry

India is the second largest producer in global crude steel production after China and the UE.

Trade remedial measures have contributed towards enhancing domestic production. These measures have encouraged “Make in India” steel production, increasing production capacity by 25.6% from 2014-15 with 75% capacity utilisation during 2017-18.

According to Joint Plant Committee (JPC) data, India reached 106 MT production during 2018, a 5% increase year-on-year. This strong performance has been driven by private steel companies. Unlike the globally adopted trend, India is making most of its steel (57%) through the electric route, the rest being via the usual oxygen one. This trend id mindful of reducing carbon footprint.

Besides its durability, steel also offers saving over the life cycle of products, particularly in terms of energy and iron ore required to produce them. Moreover, with 100% recyclability, steel scraps as an input is environment-friendly.

India overtook Japan in January- December 2018 to become the world’s third-largest crude steel producer.

Galbiati Group is a Company leader in the steel field: the Mechanical Machining and Construction Division and the Gear Reducers Division make Galbiati Group the ideal partner qualified for mechanical transmissions for steel industry and for customized construction of mid and large-sized components that require high quality standards. http://www.galbiatigroup.it.

Kenya: the first nuclear power plant

Kenya is going to have its first power plant, commissioned by 2027.

One of the most difficult challenge for the project’s realization is the lack of skilled personnel in this field: it seems that through Kenya Nuclear Energy Board, the Energy Ministery has been training some of its personnel in Korea.

Also the University of Nairobi is working to train local professionals in order to cut down the the cost of Korean training. The Ministry has sponsored 15 students to pursue Masters degree in nuclear power and related studies at UoN.

In the last six years a team of experts has conducted researchs in 26 countries to establish the most appropriate location for the inaugural nuclear power plant.

The deadline for the first plant is 2017, Kenya joins other African countries such as Ghana, Nigeria, Algeria, and Uganda in the quest for nuclear energy. Last year Sudan entered into an agreement with Russia to build a nuclear plant for peaceful purposes starting mid of this year.

Galbiati Group, company specialized in the Engineering and Construction of mechanical machines, produces machined components for steam, gas, and nuclear power plants characterized by a high-level of quality.  All the details are available at the website www.galbiatigroup.it.

The ASTRI radio telescope starts its activity!

ASTRI radio telescope

Galbiati Group has completely realized the mechanical construction of the ASTRI radio telescope (Mirror Astrophysics and Italian Replicating Technology) ASTRI SST-2M at the Catania Astronomical Observatory. ASTRI is the new prototype of a new type of telescope that will built the project called Cherenkov Telescope Array (CTA) and will be used for functional tests and scientific calibrations.

During the construction phase were used mobile precision measuring instruments and all the production capacities of the Oggiono mechanical workshops equipment the company has availed of. The raw materials, in particular steel, were used for the construction of the parabolic antenna rails, from which the bending operations and the subsequent mechanical processing to achieve the required high precision were followed. The azimuthal rotation wheels and axis of the antenna were made in the Galbiati workshops, using the most modern steels to increase the surface hardness, and to guarantee greater durability and reduced wear over time. Galbiati Group has entirely realized the rails, the carts and all the mechanical details of which the radio telescope structure is composed.

The ASTRI radio telescope, the first prototype of the 70’s line of the CTA project, will provide three-dimensional images with higher resolution. The CTA project, led by a Consortium of scientific institutions belonging to more than 20 countries and funded by the European Commission, will be the most powerful and flexible gamma ray observatory with E> 30 GeV energy, never built before. It provides for the construction of two observatories, placed one in the northern hemisphere and one in the southern hemisphere, made in turn by a group of telescopes. At the center there will be some large telescopes with a diameter of 23 meters, surrounded by dozens of medium telescopes (diameter 12 meters). The observatory in the southern hemisphere will also have many dozens of small telescopes with a diameter of 4 meters each.

Galbiati Group, leader in the construction of large sized precision machines and plants, works successfully in the astronomy sector manufacturing mechanical components for satellite dishes and radio telescopes. Discover more about the company!

Tunnel Boring Machine – Hiroshima Project

Galbiati Group has designed and built the largest segment erector, it has a maximum capacity of 9,7 tons, intended for a Tunnel Boring Machine that will be used for an important project called “Hiroshima Project” in Japan.

The TBM for which the erector has been built, with a 13,2 meter diameter cutter head, will have the task for creating a tunnel for the construction of lane 5 of the Hiroshima expressway in Japan.

Galbiati Group started with the mechanical machining of 4 sector that, assembled, make up the rotating ring of the erector with a diameter of 13.5 meters. Given the size and weight, the rotating ring of the erector made assembly operations difficult, so that is has not been possible to position the erector vertically.

The erector in question is equipped with a mechanical segment pick-up unit.

Erector technical data:

  • Translating speed = 100 mm/sec
  • Rotational speed = 1.5 rpm
  • Maximum load capacity = 9,700 kg (segment)
  • Total weight = 75,900 Kg
  • Intrados diameter = 12,200 mm

Watch the video of erector assembling:

Galbiati Group builds TBM components such as planetary gearboxes, bearing supports, erectors. The company has recently realized 4 ton-segment erector for a Tunnel Boring Machine designed for an excavation project. For more information visit the website www.galbiatigroup.it.

Galbiati Group and its activity in proton therapy equipment

Galbiati Group has collaborating with international leading company in the medical field, in particularly in the filed of radiology and proton therapy.

Proton therapy is an important technological advance in cancer treatment, in this therapy are used proton beam to irradiate the patient’s diseased tissue.
The main advantage is the ability to more accurately localize the proton radiation dosage through a cyclotron, a particle accelerator, i.e. a machine whose purpose is to accelerate proton beams with high kinetic energy.

Galbiati Group has developed a high quality in the machining of cyclotrons, in fact, the precision and quality required are very high, the tolerances required are very strict (micron).

Example of a mechanical machining cycle performed on a cyclotron:

• mechanical processing of the full iron block;
• boring;
• milling;
• drilling;
• dimensional check in our three-dimensional measuring machine ZEISS MMZ-G 30 60 25, which, placed in an air-conditioned chamber, is able to perform dimensional checks for applications requiring millesimal tolerances.

Galbiati Group is an Italian company, internationally-recognized for the quality of its machining, mechanical engineering and construction. Is active also in the medical sector with its high standard in quality.

Galbiati Group is an Italian company, internationally-recognized for the quality of its machining, mechanical engineering and construction. Is active also in the medical sector with its high standard in quality.

Galbiati Group will partecipate at Hannover Messe Exhibition 2019

Galbiati Group will partecipate as an exhibitor at the next Hannover Messe 2019 fair, which will take place from the 1st to the 5th April in 2019, into IAMD-Motion, Drive & Automation Hall.

The IAMD Motion, Drive & Automation is one of the most important fairs in the world for our areas of expertise, in particular for: mechanical transmissions, gearboxes, gears. It is considered a fundamental appointment to present innovative products, solutions and new applications to an audience coming from all over the world.

Hannover Messe 2018 once again has been confirmed to be a global reference point for the digital transformation of industries. The main theme was once again the global transition to Industry 4.0. Extensive value creation networks, new forms of human-machine collaboration and the growing integration of artificial intelligence into production, digitization and connectivity operations were the main topics that were once again disclosed in Hannover.

Galbiati Group will attend this event, as a company recognized internationally for the quality of its machining and construction, for the engineering and manufacturing of medium and large gearboxes and innovative metal working machines. These machines are custom built according to customer designs and projects or are fully designed at Galbiati based on the customer’s specifications.

Galbiati will wait for you at pavilion F13, stand 25!

Click here to download Hannover Messe 2019 visitors’ guide!

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GALBIATI GROUP
Via Cà Bianca Pascolo, 26
23848 Oggiono (Lc)
Italy

 

+39 034126331

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