Project # 10
Problem: Lack of accurate drawings for ordering spare parts, leading to risks and downtime.
Solution: DRT GROUP performed 3D scanning, reverse engineering, and equipment delivery, correcting errors in the old documentation.
Key results: • Errors in the previous supplier's incorrect drawings were corrected. • The structural cause of frequent bearing failures was identified and eliminated. • Modifications were implemented to simplify operation and reduce the number of spare parts. • The project's payback period was 2 months.
Methodology: The service includes on-site visits, 3D scanning (including high-precision measurements), material analysis, and the creation of a complete set of accurate 3D models and working drawings.
Solution: DRT GROUP performed 3D scanning, reverse engineering, and equipment delivery, correcting errors in the old documentation.
Key results: • Errors in the previous supplier's incorrect drawings were corrected. • The structural cause of frequent bearing failures was identified and eliminated. • Modifications were implemented to simplify operation and reduce the number of spare parts. • The project's payback period was 2 months.
Methodology: The service includes on-site visits, 3D scanning (including high-precision measurements), material analysis, and the creation of a complete set of accurate 3D models and working drawings.
Project # 9
Customer: JSC PNTZ (TMK Group)
Summary: Delivery and commissioning of a ladle drying stand with a system for capturing and afterburning harmful emissions for an electric steel mill.
Key result: Reduction of formaldehyde and carbon monoxide emissions into the workshop atmosphere by a factor of 100, resulting in compliance with the permissible exposure limits.
Main functions of the stand:
• Drying and heating the fire-resistant lining of the bucket to 1200 °C.
• Automatic control and regulation of the process.
• Capture and afterburning of harmful gases.
Composition and features:
• Includes a drying box, a ventilation system, a hydraulic station, and control and safety automation.
• The equipment complies with the technical regulations of the Customs Union.
• All necessary documentation has been developed and approved, including a positive conclusion from the industrial safety examination (ISE).
Implementation conditions: Installation and launch were carried out in a short timeframe without stopping the existing production.
Summary: Delivery and commissioning of a ladle drying stand with a system for capturing and afterburning harmful emissions for an electric steel mill.
Key result: Reduction of formaldehyde and carbon monoxide emissions into the workshop atmosphere by a factor of 100, resulting in compliance with the permissible exposure limits.
Main functions of the stand:
• Drying and heating the fire-resistant lining of the bucket to 1200 °C.
• Automatic control and regulation of the process.
• Capture and afterburning of harmful gases.
Composition and features:
• Includes a drying box, a ventilation system, a hydraulic station, and control and safety automation.
• The equipment complies with the technical regulations of the Customs Union.
• All necessary documentation has been developed and approved, including a positive conclusion from the industrial safety examination (ISE).
Implementation conditions: Installation and launch were carried out in a short timeframe without stopping the existing production.
Project # 8
Customer: PJSC MMK (LPC No. 4)
Summary: Replacing the outdated SIGNODE strapping machine with a new automated machine for the 2500 hot rolling mill.
Scope of work: Design, supply, шеф-монтаж, commissioning, and integration of the system into the existing shop floor automation system.
Result: A fully automated single-head strapping machine for steel coils weighing up to 40 tons has been put into operation. The work was completed in a short time.
Summary: Replacing the outdated SIGNODE strapping machine with a new automated machine for the 2500 hot rolling mill.
Scope of work: Design, supply, шеф-монтаж, commissioning, and integration of the system into the existing shop floor automation system.
Result: A fully automated single-head strapping machine for steel coils weighing up to 40 tons has been put into operation. The work was completed in a short time.
Project # 7
Customer: JSC PNTZ (TMK Group)
Summary: Creating an accurate 3D model of the DSP-120 operating steel-making furnace for its modernization project.
Objective: Obtaining a digital model for the design of new equipment from an Italian supplier.
The work was carried out in collaboration with a Russian partner.
• Field stage: Laser scanning of a furnace in a working production facility (LEICA RTC360 system).
• Camera stage: Construction of a detailed 3D model of structures, equipment, and communications.
Result: The Italian manufacturer received an up-to-date, high-precision 3D model of the entire installation
Summary: Creating an accurate 3D model of the DSP-120 operating steel-making furnace for its modernization project.
Objective: Obtaining a digital model for the design of new equipment from an Italian supplier.
The work was carried out in collaboration with a Russian partner.
• Field stage: Laser scanning of a furnace in a working production facility (LEICA RTC360 system).
• Camera stage: Construction of a detailed 3D model of structures, equipment, and communications.
Result: The Italian manufacturer received an up-to-date, high-precision 3D model of the entire installation
Project # 6
Customer: JSC PNTZ (TMK Group)
Summary: Creating an accurate 3D model of the DSP-120 operating steel-making furnace for its modernization project.
Objective: Obtaining a digital model for the design of new equipment from an Italian supplier.
The work was carried out in collaboration with a Russian partner.
• Field stage: Laser scanning of a furnace in a working production facility (LEICA RTC360 system).
• Camera stage: Construction of a detailed 3D model of structures, equipment, and communications.
Result: The Italian manufacturer received an up-to-date, high-precision 3D model of the entire installation
Summary: Creating an accurate 3D model of the DSP-120 operating steel-making furnace for its modernization project.
Objective: Obtaining a digital model for the design of new equipment from an Italian supplier.
The work was carried out in collaboration with a Russian partner.
• Field stage: Laser scanning of a furnace in a working production facility (LEICA RTC360 system).
• Camera stage: Construction of a detailed 3D model of structures, equipment, and communications.
Result: The Italian manufacturer received an up-to-date, high-precision 3D model of the entire installation
Project #5
Customer: Balakovo Metallurgical Plant JSC
Summary: Replacement of two outdated knitting machines with modern ones with advanced functionality for steel tape binding.
Scope of delivery: Two new knitting machines with correct devices and Japanese strapping heads (KOHAN KOGYO), as well as spare parts kits.
Key feature: The equipment is assembled using components from leading European and Japanese manufacturers (Siemens, SEW, Kohan Kogyo).
Summary: Replacement of two outdated knitting machines with modern ones with advanced functionality for steel tape binding.
Scope of delivery: Two new knitting machines with correct devices and Japanese strapping heads (KOHAN KOGYO), as well as spare parts kits.
Key feature: The equipment is assembled using components from leading European and Japanese manufacturers (Siemens, SEW, Kohan Kogyo).
Project #4
Customer: Balakovo Metallurgical Plant JSC
Summary: Replacing an outdated knitting machine with a modern model with advanced functionality.
Scope of work: Delivery and commissioning of a set of equipment that includes a new knitting machine, a package formatter, and a unwinder.
Key feature: The machine is assembled using components from leading European brands (Rexroth, Siemens, Schneider Electric, etc.).
Summary: Replacing an outdated knitting machine with a modern model with advanced functionality.
Scope of work: Delivery and commissioning of a set of equipment that includes a new knitting machine, a package formatter, and a unwinder.
Key feature: The machine is assembled using components from leading European brands (Rexroth, Siemens, Schneider Electric, etc.).
Project #3
Customer: JSC PNTZ (TMK Group)
Summary: Comprehensive modernization of the slab marking system on the continuous casting machine (CCM). The project involved the repair of existing equipment, the design of new equipment, and the delivery, installation, and commissioning of new equipment.
Objective: Replace outdated equipment with modern equipment to reduce downtime and improve reliability.
Result: A system of three marking heads (2 repaired, 1 new) operating in automatic mode has been put into operation. The equipment applies impact marking with information about the smelting process to the end of the workpiece.
Key Features:
• The project was implemented jointly with an Italian partner.
• The control system is based on Siemens (Step7) components and is integrated into the existing automated process control system.
• All work was completed during the scheduled overhaul of the workshop.
Summary: Comprehensive modernization of the slab marking system on the continuous casting machine (CCM). The project involved the repair of existing equipment, the design of new equipment, and the delivery, installation, and commissioning of new equipment.
Objective: Replace outdated equipment with modern equipment to reduce downtime and improve reliability.
Result: A system of three marking heads (2 repaired, 1 new) operating in automatic mode has been put into operation. The equipment applies impact marking with information about the smelting process to the end of the workpiece.
Key Features:
• The project was implemented jointly with an Italian partner.
• The control system is based on Siemens (Step7) components and is integrated into the existing automated process control system.
• All work was completed during the scheduled overhaul of the workshop.
Project #2
Customer: PAO "Ashinsky Metallurgical Plant" (AMET)
Project Description: Comprehensive diagnostics of a large-sized bearing of a continuous casting machine (CCM).
The work performed included:
• Visual inspection for defects.
• Measurement of wear under load.
• Monitoring of the lubrication system and seals.
• Analysis of gear wear and operating noise.
Result: Based on a detailed technical report with recommendations, the customer received a clear justification for continuing the safe operation of the existing unit. This allowed them to avoid immediate replacement and save money on purchasing a new expensive ROTHE ERDE bearing.
Project Description: Comprehensive diagnostics of a large-sized bearing of a continuous casting machine (CCM).
The work performed included:
• Visual inspection for defects.
• Measurement of wear under load.
• Monitoring of the lubrication system and seals.
• Analysis of gear wear and operating noise.
Result: Based on a detailed technical report with recommendations, the customer received a clear justification for continuing the safe operation of the existing unit. This allowed them to avoid immediate replacement and save money on purchasing a new expensive ROTHE ERDE bearing.
Project # 1
Customer: JSC PNTZ (TMK Group)
Summary: Delivery, installation, and commissioning of two four-line tribes (wire injection machines) for the Furnace-Bucket Unit.
Purpose: Introduction of aluminum and steel alloying wires into liquid metal for steel processing.
Objective: To reduce metal processing time and increase the productivity of the "Bucket-Furnace" unit in the electric steel plant.
Key Features:
• The project was implemented jointly with an Italian partner.
• The control system is based on Siemens components.
• The installation was carried out during a scheduled major repair of the workshop.
Summary: Delivery, installation, and commissioning of two four-line tribes (wire injection machines) for the Furnace-Bucket Unit.
Purpose: Introduction of aluminum and steel alloying wires into liquid metal for steel processing.
Objective: To reduce metal processing time and increase the productivity of the "Bucket-Furnace" unit in the electric steel plant.
Key Features:
• The project was implemented jointly with an Italian partner.
• The control system is based on Siemens components.
• The installation was carried out during a scheduled major repair of the workshop.
