Magnum Presentation English Version

8/19/2019 Magnum Presentation English Version

1/120


2/120

Welcome to the

Magnum CompaniesTampa, FL USA


3/120

The Magnum Companies arecommitted to:

! Safety

! environmental conservation

!The community

! Reducing our customer’s unit cost per ton

! Rapid response and service


4/120

are dedicated to supply parts and servicesin the following sectors:

! Mining

! Sugar Mills

! Paper Mills

!Cement

! Electric Generation

! Industries that require special materials and partsin their operations with better designs, moreeffective and better prices

Magnum Companies:


5/120

• Magnum Steel

• Magnum Slurry

• Magnum Engineered Products

• RBT Industrial & Electrical Services

• Magnum Star Latin America

• Unimag S.A.

Magnum Companies:


6/120

MINING SECTOR


7/120

Parts for Mining Equipment


8/120

Track Pads


9/120

The Challenge Produce Track pads for bucket wheelexcavators that willlast longer than theOEM KRUPP and cost

much less. Some other parts produced: corner bits,cone liners, 2 wheelbogies, upper bogies,tumblers and cams,

take up tensioner,drive shafts, bucketwheel shafts andmuch more.


10/120

Krupp- Magnum

9 months of life 24 months of life

@ 53% avail. = 3434 hrs. @ 53% avail. = 9158 hrs.

Cost per set: $616,000 Cost per set: $178,000

Delivery time: 17 months FOB Colon, Germany

Delivery time: 5 months FOB Tampa, Florida

raw your own conclusion

From 1991 until 2010 Magnum constructed more than 625 different parts for the KRUPP Bucket Wheel Excavator system, supporting 3 bucketwheels, 6 MTC’s, and more than 10,00 0 ft. of 54” and 72” conveyorssaving PCS Phosphate, Inc. in Aurora millions of dollars in parts costand many more millions in down time that was not lost due to improveddesign and construction, working with PC’S personal.


11/120

Mobile Transfer Conveyors at

PCS Aurora


12/120

P&H 4100 C Boss

Shovel working in wetsoil conditions. Helpstabilize machine

The best solution willbe to redesign Track

Pads putting 54%more steel on theground, reducing theground pressure by

33%

P&H MAGNUM

$2.1 million per set of 90 Pads

$1.3 million per set of 90 Pads

New Challenge

* Since this is a new project this is Magnums best estimate of cost


13/120

P&H Design of Track

Pad

51,104 Sq.In in contactwith the ground


14/120

MAGNUM Design ofTrack Pad

79,104 Sq. In In contact with the groun

Improved design of Track Pad


15/120

Existing Track Pads &

Undercarriage


16/120

Cast and machined pads ready forshipment

4100 C P&H Boss excavator Pads cast onalloy steel by P&H

4100Track Pads cast inmanganese steel by

Magnum


17/120

Underground mining chain withtungsten carbide inserts in potash

Feeder breaker picks with tungstencarbide inserts

Stamler MAGNUM

Pic $205.00 Holder $590.00

Pic $107.00 Holder $238.00

Chain /Sprockets


18/120

The Challenge


19/120

Bucyrus Erie MAGNUM

Cam Housing Cam Housing

$605,000 $299,000

Bucyrus Erie 2550 DraglineConstruct a universal walkingcam housing that will not breakin at the foot and can be used onboth sides of the machine byredesigning lower half ofhousing.


20/120

The Challenge

Design a shoe slide that has largerCross sectional thicknesses usingT-1 Alloy steel plate to double thestrength

Larger opening in the shoe box

Reinforcing with T-1 gussets


21/120

The Challenge

Mesco shoe slide shown in

Grey.B.E. slide in black.

Installing new shoe slide


22/120

Some parts designed by Magnum forthe draglines and shovels


23/120 Marion 8200 Dragline

Construct a tub for

the 8200 that willnot crack under thesoft groundconditions at PCS

Aurora

The Challenge


24/120

The solution was to construct an octagonal center section toreduce inward point loading stress by half from high

strength low alloy steel


25/120

The tub was completely constructed on site atthe mine – PCS Aurora


26/120 Robotic Welding


27/120

Machining with laser the upper roller path

after installing 6” thick alloy plate.

Marion 8200 Dragline


28/120

Machining one of the two new forged swing

bosses installed

Marion 8200 Dragline


29/120

Photo from top of 8200 looking at completed tub in Magnum work zone


30/120

This was the first

tub built with anoctagonal centersection and highstrength low alloysteel. As of lastinspection report

2010, no crackingwas found


31/120

Machining the base with the laser


32/120

Separating the machine from old tub


33/120

Removing the old tub


34/120

Preparing tolower the boom

The boomlowered


35/120


36/120

Rebuilt machine in operation


37/120

Marion (minserco) MAGNUM base tub cost only base tub cost only

$ 4,900,000tub only

$3,319,000tub only

mild steel alloy steel

Magnum’s bid to PCS in mild steel was$2,650,000


38/120

Zero time lost, zero incidents, zeroaccidents


39/120

Bucyrus Erie 1260 Relocalizacion

The Challenge


40/120

I

• Dismantle, move and repair Bucyrus Erie 1260 from Big

Sky Montana to West Beach Florida

• Upgrade electrical system from analog to digital using SIEMENS


41/120

Drives and controls installed


42/120

C ll ll


43/120

Conveyors, Pulleys, Rollers

Th Ch ll


44/120

Construct rollers and pulleys that would last in a 72” beltconveyor carrying 3600 TPH moving with a belt speed of

over 1100 fpm

The solution was to bolster the structuralmodules of the KRUPP design with heavier crosssectional materials and changing the rollers toCEMA F with vulcanized rubber covers thatwould except one of the most severe conditionsworking in the U.S.

The Challenge

Th Ch ll


45/120

Caterpillar D10 track links were used in the great Canadian tar sands

projects carrying oil and sand to the separation plants. The problemwas they were unable to accept the extreme forces of this application.In this case when the plant broke a link in the chain it caused morethan $500,000 in damaged equipment and more than $1,000,000 ofdown time. (Based on oil being $65 a barrel

The Challenge


46/120

The solution was the design a new side link increasing thecross-sectional thickness across the link and still haveinterchangeability with Caterpillar components i.e. rollers,guides, sprockets and tumblers. Also, Magnum wouldchange the metallurgical composition of the link fromCaterpillars 1070 carbon steel to AISI 4340 ultra highstrength alloy steel after hardening links to 400 Brinell, thelinks would go through a process of nitrating to close the

grain structure on the surface to help prevent stresscorrosion cracking.


47/120

Caterpillar D-10 link forgedin 1070 carbon steel

MAGNUM D-10 forged in 4340 ultrahigh strength steel.


48/120

The final Solution


49/120

Slurry Pumps


50/120

• Magnum manufactures itsown brand of pumps

(Magnum SPP) and is analternative source fordimensionallyinterchangeable partswith:

• WARMAN • GIW

Magnum’s pump parts are completely


51/120

g p p p p yinterchangeable with GIW pumps

Magnum’s pump parts are completely


52/120

interchangeable with Warman pumps

-Large Inventory -Immediate Shipment-Perfect Fit

-Completely Interchangeability -Bellenite High-Chrome WhiteIron-Bearing Housings Available inmost sizes

Magnum SPP 20 x 20 working with Magnum suction


53/120

plate. GIW frame plate and pedestal

M h illi f


54/120

Magnum has millions ofdollars of pup parts in ourinventory ready for shipment


55/120

Dredge pumpwhich uses a

103”diameterimpeller


56/120

Magnum 8 x 6 being installed inan Alumina Plant (retro fits withGoulds)


57/120

Magnum wet in parts for GIW interchange

• chrome whiteiron ASTM-A532

III• manganese A128-

grade-A

• Ni-hard 4

Gate Valves


58/120

Gate Valves


59/120

CEMENT

PLANTS

The Challenge


60/120

A kiln ring that can be

changed withoutcutting the kiln in halfeliminating over$1,000,000 in laborand 3-4 weeks ofdown time.

The Challenge

Shown above, a 2 piece kiln ring228” OD with a 34” face that canbe changed without cutting the

kiln in half


61/120

Machining ring and completed tyre shown

C l t t f


62/120

Complete parts for Ball mills


63/120

HK Stainless Steel Kiln Nose


64/120

HK Stainless Steel Kiln Nose Ring for 2100 degrees F.

HK Stainlees Steel Tipping


65/120

HK Stainlees Steel Tipping Seat Vortex

HH or HK regular or


66/120

g pocket style cooler grates

A few of the critical parts that Magnum manufactures for the


67/120

cement industry.

Undercarriage and digging equipment for theconstruction and mining sectors for most


68/120

construction and mining sectors for mostmakes and models


69/120

Teeth and adapters for backhoes, loaders, excavatorsand dragline buckets for most makes and models

(Caterpillar, Komatsu, John Deer, and many others)

Sugar Mills


70/120

Sugar Mills& Co-generation Plants


71/120

71

-Complete Sugar Mills

-Refinery

-Ethanol

-Cogeneration

-Parts & Services

Turnkey Projects


72/120

72

Turnkey ProjectsDesign, Manufacture, Erection & Commissioning


73/120

73

MEPCO & HI-TECH are suppliers of complete engineeringsolutions for Sugar, Power & Cogeneration Industries.


74/120

74

Cogeneration


75/120

75

-Turbines-Generators

-BoilersDesignEngineeringConstruction

-Switchgear-Control Panels

-Automation-Electrical Maintenance& Services-Inspections-Complete Mills/ Drives-Mechanical & Civil

Engineering

Cogeneration


76/120

76


77/120

77

We have gained vast experience from previous turn-key co-generation projects as well as ourongoing research and development program. MEPCO and HI-TECH have joined together to offercomplete services of design, engineering and constructions of projects involving turn-key sugar millsand co-generation facilities. We have the expertise to take you from the fuel, to the boiler, to the

power grid and every step in between.

Facilities for electrical work:

-In-house capability of MCC panel building.

-In-house capability of VFD panel building.

-In-house capability of panel fabrication.

-In-house capability of electrical project execution.


78/120


79/120


80/120

Turn plates with replacable alloytips

450-500 brinel


81/120

Pinion shafts

Cane carrier sprockets

Mill shell flanges

Forged shafts


82/120

Forged shafts

finished machined in 1040, 4140 & 4340

Offset


83/120

Offset

square forging


84/120


85/120


86/120

Shredder hammers fabricated from MTA 500 plate with Shark-Bite tungsten carbide tips

The Shark-Bite tipsare easily replacedusing a grade 8 boltsystem


87/120

Shredder rotors for hammer millsand swing back knivesconstructed at Magnum using

alloy steel and Magna- Cladd plate for greater wear life


88/120

Shredder rotors fabricated from T-1 alloy steel with 4340 highstrength alloy shafts


89/120

MAGNUM WEAR TECHNOLOGY

• Shark-Bite tungsten carbide

• Magna-Cladd overlay plate• MTA 500 alloy wear plate

Materials commonly cast by


90/120

!Work-hardening had \field manganese! Alloy steel! High chrome white iron!Gray iron! Ductile iron

!Cast steel! High temperature & corrosion resistant Stainless Steel!bronze

Materials commonly cast by Magnum:

Protect you body


91/120

Protect you body

MAGNUM MTA 500 For the best resistance to impact and

abrasion Magnum MTA 500 allows the

reduction of thickness to allow greater

loading capacity of transported cargos

Magnum can cut the plates exactlyto the size you require(installation kits for excavators,front end loaders, drag line

buckets and articulating trucks

Tensile strength: 250 ksi Yield strength: 185 ksiEllongation: 11.0% in 8” Brunell Hardness: 475 min / 500

nominal


92/120

MTA - 500 is an alloy steel quench and

tempered with high pressure water. It is

utilized in applications where severe impact

and abrasion is the principal cause of materialfatigue

Principal Characteristics:

MTA - 500 Can be used in the most sever

abrasion and high impact conditions.

MTA - 500 Can be machined or drilled using

high speed tungsten carbide tooling

MTA – 500 Can be easily welded with

electrodes, low carbon E-70XX or E-110XX

MAGNA-CLADD


93/120

MAGNA CLADD

• Easy to install with welding. Magna-

Cladd is applied to a structural steel A-36.

• Plate of Magna-Cladd hard coating

with an implementation with three passes and a counter sunk hole

• We can cut or form Magna-Claddaccording to any of your plans orspecifications


94/120


95/120

Chemistry Composition:Crome - 26-35%Carbon - 4.0%Manganese - 2.0%Silicon - 0.50%

Stock Sizes:1/8” en 1/4” X 60” x 120”1/4” en 1/4” X 60” x 120”3/8” en 3/8” X 60” x 120”Other sizes and thicknessesavailable upon request

Magnum Shark-Bite


96/120

g

• The wear side of the Shark-Bite

insert is 91 Rockwell A. The alloysteel around the carbide is 52-55

Rockwell C.

• Protect your expensive mining

consumables such as buckets,teeth adapters, lips, cornershrouds, shouts, crushers, andhigh impact areas with Shark-

Bite tungsten carbide inserts.


97/120

• Lip shroud lasted 10 timeslonger, protected by Shark-

Bite

Shark-Bite welded to bucket

adapters and corner shroud

• Mechanical lip shroud with morethan 5,000,000 tons ofoverburdened mined


98/120

soldar facilmente


99/120

Eletrical Division &

Automation


100/120

RBT INDUSTRIAL ELECTRICAL SERVICES


101/120

•OVER 27 YEARS EXPERIENCE IN PHOSPHATE

• FOOD GRADE JUICE PLANTS

• POWER GENERATION AND CO-GENERATION

• SUGAR MILLS AND REFINERIES

•CHEMICAL PLANTS

• PHOSPHORIC AND SULPHURIC AUTOMATION


102/120

INSTALL POWER ANDCONTROL FORFLORIDA PHOSPHATE


103/120

13,000 volt feeder tie between 45megawatt turbine generator andmain sub station feeding chemical

plant


104/120

PumpingstationControl panels

Install mediumvotage starters


105/120


106/120

• BUILD• AUTOMATION

• PROGRAM• POWER• DISTRIBUTION•UPGRADE

• MAINTAIN•TROUBLESHOOT


107/120

•MOTOR CONTROL CENTER

•POWER AND CONTROL SIDE


108/120


109/120


110/120

500 mcm cablebeing pulled


111/120


112/120


113/120


114/120

Automating animal feed plant – Allen Bradley controls logixsystem.


115/120

CT wiring going into terminal box from the mcc (motor control center)displaying motor amps


116/120

Automating MCC and control panel with starks stop andauxiliary contacts


117/120

Allen Bradley MCC


118/120

start-stop relays, powersupplies and circuit breaker(Allen Bradley)

Allen Bradley Controllogix processor and I/Oracks

Magnum offers:


119/120

•Complete design engineering and construction•The best materials to fight against wear•Capacity to cast & finish machine pieces up to 82,000 lbs.

• Forgings finish machined up to 33,000 lbs.• 15 different licensed foundries and forging houses in the globalmarket• All foundries have ISO 9001 certification• Engineers readily available to help assist your engineeringdepartment to asses solutions and available designs to prolong

your equipment• More than 150 years of combined experience• Assistance in hydraulic pumping systems• Assistance in electrical design & installation

A few of our clients:


120/120

Alcoa CEMEX

Albian Southern Peru Copper

Suncor Xtrada

Syncrude BHP Billiton

PCS Phosphate Titan

PCS Potash Lafarge

Mosaic Phelps Dodge

Texas Utilities Argos Cement

Tampa Electric Orlando Utilities

Barrick Arch MineralsConsolidated Coal C.F. Industries

U.S. Sugar Corp. Okeelanta

Documents

Magnum Presentation English Version