Technical process of forging and steel industry


Charge preparation
Manufacturing Feedstock is scrap metal. Scrap metal that arrives at the plant undergoes thorough incoming inspection and also has supporting documentation proving compliance with GOST 4121-2002 Recyclable Ferrous Metals. General Technical Requirements.
Ferro agents preparation
All purchased ferrous materials undergo thorough incoming inspection, that is, are subjected to check-up of chemical composition and compliance with explosion and radiation safety.
 
Melting in electric arc furnace
The steelmaking unit is fitted out with 2 steelmaking furnaces UHP (ultra-high power) where scrap metal is melted and liquid steel is making. The rated capacity of each furnace makes up 18 ton of liquid steel.
Finishing of steel using ladle metallurgy facility
This unit consists of 3 stations. Metal is cleaned and refined from slag on the first station. Metal is heated and ferrous alloys are added into the metal on the second station. The third station consists of a chamber into which a degassing steel-ladle is placed for vacuum processing steel is degassed and stirred. All this makes it possible to obtain steel of high cleanliness and quality. In the process of finishing sampling is performed constantly in order to determine chemical composition and measure temperature. On receiving from the laboratory confirmation of specified chemical composition steel is passed to casting.
Steel casting
Casting of steel is performed on steel continuous casting machine or steel is casted into moulds by means of bottom-poured (siphon) casting.
Continuous casting steel
Continuous casting of steel is performed on two-lane plant of vertical type for square blooms of 250-650 mm with the length up to 6000 mm obtaining. Cross-section and length depends on the geometric parameters of finished product
Siphon casting
The enterprise has opportunity to cast steel by means of bottom-poured (siphon) casting into ingots of 6,5, 9, 10,5 ton weighing . There is possibility to produce ingots of other configurations depending on availability of moulds. The weight of ingots can amount to 18 ton.
 
Forging heating
Two furnaces are given for heating of ingots and blooms to be forged: two zone through-pass type furnace with moving longerons and furnace with roll-out backstone (bogie hearth furnace).
Longerone furnace
Two zone through-pass type furnace with moving longerons is used for heating of continuously-casted bars (max 6 ton) before forging.
Furnace with draw plate
Bogie hearth furnace).is used for heating before forging and for heat treatment of continuously-casted bars and siphon casting ingots max 12 ton.
 
Forging
Forging of ingots and blooms is performed on a fast-acting press UFP-15 or on a -630 radial-forging machine.
Forging on fast-acting press
Maximum weight of a treated bar is 12 ton.
Radial forging machine
Hydraulic radial forging machine stress strain 630 tons. Designed to produce forging type of smooth and stepped rods with a diameter of from 127 to 300 mm long and from 4000 to 16500 mm Max. weight of workpiece 6 tons.
 
Ultrasonic control
Forged bars are inspected ultrasonically by means of ultrasonic detector UD 4-76.
Heat treatment
Thermal equipment helps to provide material with required mechanical properties (hardness).
roller bottom furnace Olivotto;
Forging thermal sector has two thermal through-type furnaces with screw conveyor design to move and rotate the bars white heating them: max dimensions of furnaces are: 10 x 18 m, max temperature 900 ˚C. Temperature zones: 10 zones of temperature control. Hardening tank of spray type is designed for hardening of forged bars.
Furnace with roll-out backstone
Bogie furnace is designed for heating before forging and also for heat treatment of continuously casted bars and siphon casting ingots max weight of 12 ton.
 
Dressing
After heat treatment all bars are tested for straightness. Equipment for straightening: straightening machine of 700 ton load equipped with a system of bending control.
Ultrasonic inspection
After straightening all the bars are 100% ultrasonically inspected. Equipment automatic ultrasonic device KISS-400.
Machining
Machining workshop represents conveyer equipped with highly productive special equipment for production of drill collars, kellys, HWDP, etc. and also for metal production rough-working.
Storage facilities
Shipping to the storage facilities.


Finished product storage of SE "Drill Collars and Kellys Plant" is a railroad mechanized warehouse of closed type that represents a separate 10 m high building and is designed for storage and shipment of finished products of own production. Placement of products in the openings fully ensures their safe storage.

Loading and unloading of products is performed by the instrumentality of overhead traveling cranes with lifting capacity of 20 tons.

Finished product storage building gives the opportunity to carry out shipment by rail and trucking that allows shipment by small and large lots of products.