BMC Formaco BV Cuijkseweg 4 5443 PA Haps The Netherlands T + 31 (0)88 700 1200 F + 31 (0)88 700 1250 E info@formaco.nl I www.formaco.nl
Cooperation w ith specialized factories From the year 1995 onwards Formaco has supplied customers with: • Pre-machined and final machined forgings and castings. • Till today there is a cooperation with international factories, each of which is specialized in certain types of forgings or castings. • All materials, testing and control of machining steps can be executed under a large range of third party companies.
Production capabilities and m aterials Solutions: • Sand and lost wax castings • Centrifugal castings • Open die forgings • Closed die forgings • Seamless rolled rings • Forged Lifting components • Machining & Assembling • Surface treatment Material specifications & grades: - Carbon steel - Grey iron - Stainless steel - Ductile iron - High alloy steel - Non Ferro alloys - Tool steel - Non standard alloys Dim ensions + w eights: - From < 250 kg till 100 ton unit weight
Market & I ndustries • Ship building • Ship yards • Dredging • Ship propulsion • Ship applications as lifting • Project engineering • Steel mills • Machine shops • Tools shops • Food Industry • Hydraulic cylinders • Gear industry • Bridge building • Heavy duty gear applications • Energy sector • Pump manufacturers • Off shore applications • Turbine industry • Wind mill industry • Petro chemical industry
Quality is the m ost im portant added value ! Our competences and customer advantages (added value): • New tender phase, work in progress, communications, visits • Qualification costs and risks • Preparation ITP & MP (Inspection Test Plan & Manufacturing Plan) • Visiting customer for the commercial and technical reviews • Visiting suppliers for monitoring of the process • Quality assurance of supplier and action plan for improvement • Idem for sub-contractors of the supplier • Preparation of contractual obligation vice-versa • Preparation of financial structure including assurances • Contract award • Project management during production • Progress reporting • Inspection notifications follow up • Third party inspection (double) follow up • Certification tracking / document control and building Material Record Books • Release of goods with final inspections • After care, vice versa • Warranty issues • Culture issues to be absorbed, communications languages and travel distances to be managed
Exam ples – Ship building Production of: • Propeller shafts • Intermediate shafts • Thrust bearing stub pipes • Rudder shafts • Cylinder and piston heads • Connection rods • Turbine shafts • Piston rods • Pinion and gears for reduction units Steel grades: • 42CrMo4 (1.7225) • C35 (1.0501) • C22 (1.0402) • S355J2G3 (1.0570) • 34CrNiMo6 (1.6582) • 16MnCr5 (1.7131) • S460QL1 (1.8916)
Exam ples – Project engineering - Mechanical Production of: • Pistons, cylinders, mandrels, columns and crosspieces for presses • Coupling boxes, extensions, gaskets and cylinders for rolling mills • Segments, mandrels and rolls for coiler tape train of rolling mills • Mandrels and cylinders for the production of tubes • Rolls and axles for cement factories • Bushes and yokes for paper mills • Shafts, pinions and wheels for gearboxes • Crankshafts Steel grades: • 30CrMoV9 (1.7707) • 18CrNiMo7-6 (1.6587) • 35NiCrMo16 (1.2766) • 40NiCrMo7 (1.6565) • 42CrMo4 (1.7225) • 30CrNiMo8 (1.6580) • 39NiCrMo3 (1.6510) • S355J2G3 (1.0570)
Exam ples – Steel m ills Production of: • Rolling mill screw • Milling roll chock • Mandrel with expansion segments • Coiler mandrel • Milling rolls Steel grades: • S355 • 42CrMo4 QT • 30CrNiMo8 QT • GX300CrNiSi 9.5.2 • GX260CrMoNi 20.2.1 • GX260CrNi 25.2 • GX260Cr27 • GX300CrMo 15.3
Exam ples – Energy sector Production of: • Valve bodies for subsea and surface trees • Build up propellers • Wellheads • Stress joints for riser system • Structural parts for tension legs platforms • Tube sheets, shells, flanges, gates and other forged equipment for refineries and chemical plants (heat exchangers) Steel grades: • Carbon Steel • AISI 4130 • AISI 8630 • ASTM A182 F22 • ASTM A182 F91/ 92 • ASTM A182 F6 NM
Exam ples – Sand Castings Process: • Simulation of the casting process (solidification) using software from Magma • Patternshop / toolmaker • Moulding with model forms and cores • Pouring of the casting • Heat treatment • Pre Machining • Quality control - NDT • Repair by welding operations & procedures • Final machining • Quality control – Dimension check Materials: - Carbon steel - Grey iron - Stainless steel - Ductile iron - High alloy steel - White iron - Duplex steel - White temper (soft) iron
Exam ples – Closed die forging Production of: • Subsea Systems • Surface Systems • Drilling Systems • Flow Control Steel grades: • Carbon Steel • Stainless Steel • Duplex • Super Duplex
Exam ples – Seam less rolled forged rings / tubes
Exam ples – Centrifugal Castings ( horizontal & vertical) m inim um m axim um Dim ensions: outside Ø Length outside Ø Length Short horizontal castings - bushes 80 150 850 1000 Long horizontal castings - bushes 200 1000 1000 4500 Vertical castings - rings 300 200 6000 2500 Stainless steel: - CF3M, CF8M, CB7Cu1, CA6NM: - GX2CrNiMo19-11-2 , GX5CrNiNb19-11 , GXCrNiMo13-4 , . . . - (super) Duplex steel f.e.: - GX2CrNiMoN22-5-3 , GX3CrNiMoCu26-6-3 , . . . - Inconel 625: - NiCr22Mo9Nb - Uranus B6: - GX1NiCrMoCuN25-20-5 - Hastelloy C: - CW12MW (NiMo18Cr16Fe6W4V) - Nickel based - Monel 400 (NiCu30Fe3) , CU5MCuC (GX5NiCrMoCuNb42-22) Copper alloys: - Bronze f.e.: - CuSn12 , . . . - Copper Aluminium f.e.: - CuAl10Ni , . . .
Exam ples – Lifting com ponents Crane hooks, Hook assem blies, Sheaves, Hook Blocks & types: • Nuclear • Laminated • Offshore • Ramshorn • Eye hooks • Single hooks Dim ensions: • Heavy lifting hooks and anchors to 4000 tons SWL (Safe Working Load) • Forged weight of 20.000 kg
Exam ples – Machined & assem bled parts Turning Milling Grinding Drilling Honing
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