Cleaning, Casting Defects and Die Castings. CleaningFettling of Castings
Pioneers in Steel Castings for over 50 Years · 2020. 8. 11. · manufacturer & exporter providing...
Transcript of Pioneers in Steel Castings for over 50 Years · 2020. 8. 11. · manufacturer & exporter providing...
The Kolhapur Steel LimitedA Kirloskar Group Company
Pioneers in Steel Castings
for over 50 Years
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1. Who we are
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2. Our Location
3. Our Capabilities
4. Our Certifications
5. Our Manufacturing Facilities
6. Our esteemed customers
7. Product Showcase
About Kolhapur Steel Limited
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Kolhapur Steel Limited (TKSL) is a
wholly owned subsidiary company of
Kirloskar Brothers Limited (KBL).
KBL is a flagship company of $ 2.1
billion Kirloskar Group
Established in the year 1965 Kolhapur
steel is a premier steel casting
manufacturer & exporter providing
high quality castings across industries
like Pumps & Valves, Power, Earth
Moving Equipment, Shipping and
Heavy Engineering Applications and
many more…
With a Installed capacity of 3600 MT
per annum Kolhapur Steel produces
Steel castings in the weight range of
300 Kg to 10 T per piece with
governing dimensions up to 4m x 4m.
Carbon Steel Castings | Stainless Steel Castings | Alloy Steel Castings
1. Who we are
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2. Our Location
3. Our Capabilities
4. Our Certifications
5. Our Manufacturing Facilities
6. Our esteemed customers
7. Product Showcase
Kolhapur : The Foundry and Engineering Cluster
Kolhapur Steel is situated in Kolhapuron the Pune – Bangalore highwayproviding excellent accessibility.
It‟s location in Kolhapur, one of themost prominent foundry and
engineering clusters in India offersmany strategic advantages
• Skilled and Qualified Manpower
• Excellent Connectivity to major
industrial hubs like Bangalore, Pune
and Mumbai (Mumbai port is one of
the busiest ports for import/ export in
the country)
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1. Who we are
2. Our Location
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3. Our Capabilities
4. Our Certifications
5. Our Manufacturing Facilities
6. Our esteemed customers
7. Product Showcase
Product Grades
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Kolhapur Steel specializes in manufacturing Carbon steel, Stainless steel, Duplex Steel, Super
Duplex and Alloy steel castings in as cast, proof machined and finish machined conditions meeting
highest quality standards for customers across industries.
Type of Casting Material Specification Capability
Carbon Steel Castings for
General Engineering purpose
IS-1030, ASTM A 27, IS-2707, IS-2644,
DIN-1681
300 kg to 10 MT Single
Piece
Corrosion Resistant Stainless
Steel Castings
ASTM A 351, Gr. CF-8M, CF-8, CA
6NM, CF3M
300 kg to 6.5 MT Single
Piece
Duplex Stainless Steel Castings
for high pressure and corrosion
resistant application
ASTM A 890 & ASTM A 995 Gr. 1A,
3A, 4A, 1B
300 kg to 6.5 MT Single
Piece
Super Duplex Stainless Steel
Castings for high pressure and
corrosion resistant applicationASTM A 890 & ASTM A 995 Gr. 5A
300 kg to 3.5 MT Single
Piece
High Alloy Castings resistant
to abrasion and cavitation
corrosion
ASTM A 743, Gr. CA6NM, CA15 and
CF8M
300 kg to 10 MT Single
Piece
1. Who we are
2. Our Location
3. Our Capabilities
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4. Our Certifications
5. Our Manufacturing Facilities
6. Our esteemed customers
7. Product Showcase
Certification & Approvals
Kolhapur Steel is committed to providing
high quality castings and has been
approved by various certifying authorities
ISO 9001:2015 ISO 14001:2015 IRS
PED Well Known FoundryNORSOK
ISO 9001: 2008 by TUV-NORD
ISO 14001:2004 by TUV-NORD
NORSOK M630 Ed.6, MDS D56 Rev. 05
ASTM A995 GR.5A
Pressure Equipment Directive
2014/68/EU (PED)
Indian Register of Shipping (IRS)
National Thermal Power Corporation
(NTPC)
Well Known Foundry (IBR)
We are committed to obtain America
Bureau of Shipping (ABS)
certification.
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1. Who we are
2. Our Location
3. Our Capabilities
4. Our Certifications
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5. Our Manufacturing Facilities
6. Our esteemed customers
7. Product Showcase
Pattern Services
Kolhapur Steel‟s In-house Pattern Shop is
adequately equipped to maintain rectify and
repair existing customer patterns serviced by a
dedicated and skilled team.
While new patterns and core boxes are prepared
by reputed third party suppliers located nearby
equipped with CNC & VMC setup
Kolhapur Steel offers basic pattern services to
it‟s customers. These services include
• Design
• Layout
• Manufacturing of new patterns
• Maintenance of existing patterns.
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Methoding
Kolhapur Steel uses state of the art
Magma 5.3 and 10 Core processor
Simulation software to predict the
complete casting process including filling,
solidification and cooling which allows the
quantitative predication of various
properties.
Such simulation accurately describes a cast
component‟s quality up-front before
pattern manufactured and the Casting
methoding can be designed to meet
required quality invariably reducing casting
development time.
SPD Pump
24”-600 Plug Valve Body Casting42”-150 GTV Body Casting
SPD Pump
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Moulding
Omega Continuous Sand Mixer – 20 MT
3D Printed Moulds & Cores
The Moulding Shop of Kolhapur Steel
Limited is equipped with the latest
moulding facilities
20 MT Omega make continuous sand
mixer.
3 MT Omega make continuous sand mixer
10 MT/hr. Omega make sand reclamation
unit
Gas fired mould heating oven
Four E.O.T cranes (30 MT, 25 MT , 10
MT , 5 MT)
At Kolhapur Steel we also have access to
WORLD‟s LARGEST 3D printing
machine of Kirloskar Brothers Limited.
The Moulds created by 3D printing
provide superior casting quality specially
for castings having weights upto 10T13
Melting
Ladle Refining Furnace (LRF) - 14 MT capacity.
Argon oxygen decarburization (AOD) - 7 MT
capacity with pollution control equipment
Wire Injection machine for deoxidization.
of a well equippedKolhapur Steel boasts
Melting shop
5 Induction Furnaces
One - 2 MT
Two - 5 MTOne - 8 MTOne - 12 MT
LRF – 14 MT
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AOD – 7 MT with Pollution ControlInduction Furnace - 12 MT
Benefits of AOD
Argon Oxygen Decarburization “AOD”, is
an advanced technology at TKSL which
gives it unparalleled capability to make any
grade of stainless steel casting
In AOD process, through the
management of an additional high oxygen
partial pressure gas mix and argon, the
metal is refined and can reduce carbon
levels to 0.01% or lower which is critical
for production of modern duplex, super-
duplex, and super-austenitic grades
AOD process provides significant quality
improvements thru pinpoint accuracy in
chemistry (surface and internal cleanliness)
associated with low levels of sulphur,
dissolved gases (oxygen, nitrogen, and
hydrogen), carbon and volatile tramp
element (Zn, Pb, and Bi) contents
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Argon oxygen decarburization (AOD)
Heat Treatment
Kolhapur Steel‟s Heat treatment shop is
equipped with two HT furnaces well
calibrated as per API 6A standard.
CBG Fired Furnaces
• 5 m x 4.5 m x 2 m – 13 MT
• 3.5 m x 3.5 m x 2 m – 10 MT
Water Quenching Tank – 6.1 m x 5.2 m x
3.8 m – 1,20,000 Ltrs.
Adequately supported with a 60 HP
pumping system to achieve good
hardenability.CBG Fired Furnace – 10 T with Automated water Quenching
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Fettling
Apart from various pneumatic and electric
grinders, Kolhapur Steel‟s fettling shop is
equipped with
Grit blasting facility
Shot blasting machine – 3MT
TKSL has qualified welders as per ASME
section IX for various grades equipped
with suitable welding machines and ovens
Grit Blasting Shot Blasting – 3MT
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Machining
Additionally TKSL has a well established
vendor base for outsourcing finished machining
activities. These Vendors are equipped with
advanced CNC machines and CMM.
TKSL Offers castings in machined condition.
The company has in-house machining facilities
viz.
Vertical Turning Lathe – 4 m dia, 2.2 m height
Vertical Turning Lathe – 2 m dia
Heavy Duty Lathe – 2 m Swing dia
Vertical Turning Center Ø 2m
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Vertical Turning Center Ø 4m
Quality
Sand Testing
• Universal Strength Machine – 60 Kg/cm2• Sand Muller - 5 Kg capacity• Rapid Moisture Tester• Sieve Shaker• Permeability Meter
• Code Permeability Tube
Kolhapur Steel has a well equipped Laboratory
for testing all requirements of product quality
Chemical Testing
• Spectrometer – 31 Elements including
Nitrogen Facility
• Storlines Apparatus for Wet Analysis
Image Analyser for micro structure study Spectrometer – 31 Elements including Nitrogen Facility
• Standard Samples • Mould Permeability Tester19
Quality
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Non Destructive Testing
Ultrasonic Inspection - Einstein II DGS Ultrasonic Inspection - da. Vinci. DeltaIIW – Magnaflux Probe for magnetic particle inspection
Radiography Testing
TKSL has access to KBL Radioactive testing labs at Kirloskarwadi which can provide Cobalt,Iridium and also X-Ray
TKSL‟s testing Laboratory is also equipped with Mechanical & NDT testing equipment
Mechanical Testing
• Universal Testing Machine – 100 MT• Impact Testing withCryogenictesting upto460C
• Machine Profile Projector for „V‟ Notch Insp.• Broaching Machine for Charpy „V‟ Notch• 0.2% Proof Test Facility with Extensometer
Calibrated ASTM B2
Ultrasonic Tester Universal Testing MachineImpact Testing machine with
Cryogenic testing up to 460C
1. Who we are
2. Our Location
3. Our Capabilities
4. Our Certifications
5. Our Manufacturing Facilities
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6. Our esteemed customers
7. Product Showcase
Our Major Customers
Pumps
Valves
General
Engineering
International ClientsDomestic Clients
International ClientsDomestic Clients
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Our Major Customers
Steam
Turbines
Hydro
Turbines
Shipping &
Marine
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Customer Recognition
Kolhapur Steel‟s commitment to quality
and has been appreciated by our
customers over the years
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1. Who we are
2. Our Location
3. Our Capabilities
4. Our Certifications
5. Our Manufacturing Facilities
6. Our esteemed customers
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7. Product Showcase
Pumps
Valves
Pump BowlPump Casing Casing
Sample of our products made
Diaghpharam
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Valve BodyValve Body
Hydro
Turbines
Steam
Turbines
SWVELL HOUSINGUPPER & LOWER HALF CASING OUTER CASING BOTTOM HALF
Francis Runner Guide Vane Pelton Runner (Using 3D Mould)Runner Blade
Sample of our products made
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Crushers &
Earth Moving
Shipping &
Marine
Sample of our products made
End Frame Jaw CastingJaw Casting
Stern Tube Boss AFT Naval PipeTIller
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General
Engineering
Sample of our products made
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Gear Wheel Lower Bell Cylinder
Kolhapur Steel’s Castings have been pivotal in
executing Marquee projects across the globe
TKSL‟s Castings were used in the 2x1.5 MW Kalpan Hydro
Turbine generator Set in the Kayyakam SHEP project
commissioned by Kerala State Electricity Board (KSEB)
TKSL‟s supplied castings for the Auxiliary, Cooling and Raw water
pumps for the 400 MW Combine Cycle Power Plant Bibiyana III
in Bangladesh commissioned by Larsen & Toubro Limited
Hydro
Turbines
Pumps
TKSL‟s manufactured castings CV CW Pumps and the
VT Pumps for the Circulating water System in the
Darlipalli Super Thermal Power project by NTPCPumps
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The Kolhapur Steel Limited(Subsidiary company of Kirloskar Brothers Limited)
31
Pune Bangalore Highway,
Shiroli (Pulanchi), Hatkanangale,
Kolhapur, Maharashtra, 416122, INDIA
Tel: +91 - 0230 - 2468061/62/63 Fax: +91 - 0230 – 2468761
Email: [email protected] Website: www.kolhapursteel.com