Questions and Answers
When you look at our industry and the companies involved in modernization in sectors like mechanical engineering, metallurgy, and the oil and gas industry, you’ll notice that the most success is linked to production-focused companies. Metallurgical companies that produce steel and rolled products are naturally focused on manufacturing, and that’s how it should be—production is the foundation of our economy. Our company, however, was initially tied to engineering. In the past, our country had a network of institutes—some university-based, others industry-focused—that were closer to production, and they drove modernization efforts. But with the restructuring and events of the 1990s, these institutes were closed, and the need for them diminished. Most companies began purchasing equipment and technologies from foreign firms. When we entered the market, we realized we were practically alone, with only foreign players besides us. I’d like to say that from the beginning, we envisioned our company as an engineering firm, first and foremost. Yes, we have production capabilities, but we primarily manufacture custom or small-batch products, continually striving to improve with each modernization project. We are an engineering company, and our production is driven by engineering—by new ideas and new designs.
- I would say that we meet the modern demands of the market by continuing to collaborate with leading, active specialists from industry-specific universities.
In today’s fast-paced world, we need to be just as agile, efficiently implementing our ideas and design developments. Even better if we can offer a complete technical solution, delivered "turnkey." We need to move away from the stereotype that the best projects and equipment can only be bought in the West or ordered from China. Our experience working with medium and large businesses shows that we implement the best, most reliable, and appropriate solutions for production needs. And most importantly, these solutions are tailored to each specific production.
- We participate in tenders. Often, the client specifically wants our Engineering Center to handle the work. Nowadays, all company leaders understand that going for the lowest prices can lead to nothing but trouble—delays, missed deadlines, and disrupted plans. Yet, we still have to operate under such conditions. As experience shows, it's not always about money; it's the specialists and companies that have proven themselves in the market and earned a reputation as reliable partners who make the real difference.
Since 1995, our company has been engaged in equipment modernization. In all major projects we have completed, we create high-precision drives with full integration of mechanics, electrical machines, power electronics, microprocessor technology, and software. One of our first projects in mechatronics and robotic systems was the comprehensive modernization of electric arc furnaces and forging complexes at the Bummash plant in Izhevsk in 2001. We rebuilt a 25-ton electric arc furnace and automated it, while also upgrading a 2000-ton forging complex with a manipulator. Even at that time, the blacksmith could set the profile of the future workpiece on a monitor, and the forging complex would shape the part to the required dimensions. Another notable project is the modernization of a robotic wheel press-rolling line at EVRAZ-NTMK in 2011. We carried out a comprehensive upgrade to address the manufacturer's deficiencies. A centering device was developed, the robot-manipulator control algorithm was changed, the cooling and lubrication manipulators were upgraded, and new drives and control systems were created. This enabled us to achieve stable positioning accuracy of the workpiece within ± 1 mm, reducing workpiece weight and lowering the labor intensity of subsequent mechanical processing.
When it comes to water hydraulics for press and rolling production, our company has been manufacturing hydraulic devices for press equipment that operates on water and water emulsion for many years. The replacement of these hydraulic devices during repairs or modernization is complicated by two factors. First, the hydraulic devices of powerful press equipment operating on water emulsion or water are usually unique products, and second, there are currently very few organizations in our country capable of designing, let alone manufacturing, such devices that meet modern requirements for their characteristics and quality. We develop and manufacture shut-off control valves, two-valve distributors with hydraulic and electromagnetic control, overflow valves for filling tanks, safety valves, and check valves. All our developments are patented and are unique.
As for water hydraulics for scale removal systems, we also work in this direction—we develop and manufacture scale removal collectors and valves.
We provide full engineering, supply, and commissioning of press systems that operate on water. For rolling and pipe-rolling production, we develop scale removal systems. We also have a separate direction—test stands. Since 2014, our company has been working with Transneft. In 2014, we completed the design, manufacturing, supply, installation, and commissioning of the main equipment for the testing center, which is a multifunctional stand for conducting automated tests of mainline horizontal pumps, support vertical pumps, and high-pressure pumps. This stand is part of the plant for localizing the production of horizontal and vertical pumps and units in Russia. The tests on the stand are conducted using water. The testing center allows not only acceptance testing of a wide range of pumps but also advanced scientific research and engineering refinement in the development of new industrial pump prototypes. Currently, we are preparing to launch two more new stands for Transneft. Additionally, for water-operated testing equipment, we have developed or upgraded test stands for pipes. Our company stands out by offering a turnkey solution, including project design, equipment manufacturing, installation, commissioning, and personnel training.
In some cases, we can claim that our project work belongs to the 6th level of complexity, which requires conducting exploratory research and development. A notable example is our modernization of the control systems for the unique NP-130 forging press for the VSMPO-AVISMA Corporation.
After modernization, our presses provide forging accuracy of ±2 mm, so corking a bottle of wine would be easy for us. This kind of trick is not a problem for us—we’ve already done it.
For our projects during press modernization, we produce valves ranging from DN 10 to DN 250 mm with pressures up to 320 atm. For descaling systems, we produce valves ranging from DN 6 to DN 250 with pressures up to 250 bar.
For press production, demand is not increasing due to the shift towards oil-based drives.
For rolling mills and pipe mills in descaling systems, it remains at the same level. Demand could only increase with the introduction of new mills. The same applies to test stand equipment.
Since our company is focused on industrial hydraulics (we don't have experience in fields like the food industry or medicine), I haven't noticed any significant new areas of application so far.
In our drives, we incorporate the latest advancements of "Industry 4.0." We equip the control system with modern automation solutions, including controllers, computers, operator panels, software, and industrial equipment.
In our field (metallurgy, heavy machinery, oil transportation), water hydraulics is only used where there are large flow requirements. Therefore, it's safe to say that where large fluid flows are needed, it's only water. Perhaps another argument is the lower cost and simplicity of use.
Currently, many Russian enterprises are undertaking modernization of the hydraulic and control systems of powerful stamping and forging presses, where water is used as the working fluid in the hydraulic systems. The goal of modernizing these systems is often to improve the reliability and precision of their operation, increase convenience and safety in maintenance, and ultimately enhance the quality of products produced on the presses, improve press productivity, and reduce downtime due to repairs.
An example of such modernization can be seen in the foundry shop of JSC "Corporation VSMPO-AVISMA" for the hydraulic and control systems of the unique NP-130 stamping press with a force of 300 MN. In this case, only the working and lifting hydraulic cylinders and the valve body components of the hydraulic distributors were retained from the original system. The valve body components, made of carbon structural steel, were upgraded by welding corrosion-resistant steel onto all sealing surfaces.
Numerous design solutions were implemented in the control system of the press. During the design phase of the modernized electro-hydraulic control system for the NP-130 press's traverse, mathematical modeling of the press's operation with this system was carried out. The modeling made it possible to: first, gain insight (within the limits of the assumptions and simplifications made during the modeling) into the operability of the designed system and its ability to ensure movement of the moving traverse with misalignments relative to the horizontal plane within the limits specified by the technical requirements under varying eccentric loads, and second, determine the initial value of the feedback coefficient vector, which helped reduce the labor intensity of commissioning work.
In press equipment, I don’t see much potential for this. However, in cooling systems and descaling systems, water hydraulics will continue to be used and improved.
3D printing is a relatively new and experimental approach in the field of hydraulics. For our latest project, we needed to create a prototype of a centrifugal pump for testing, and we turned to 3D printing technology. The printed model is currently undergoing tests on a new test stand. While the focus here is not on reducing the cost of hydraulic components, it opens up the possibility of producing and testing a single prototype.
