THE KOLHAPUR STEEL LIMITED A Kirloskar Group Company The Kolhapur Steel Limited . Welcomes 1
THE KOLHAPUR STEEL LIMITED A Kirloskar Group Company On World Map 2 Pune - 230 Km
Vision Mission & Quality Policy 3
Environmental and Energy Policy 4
Core Competency Manufacturer of Steel Castings Plain Carbon Steel Alloy Steel Stainless Steel Duplex Steel Super Duplex Steel Weight range: Plain Carbon & Alloy Steel – 300 kg to 14 MT Single Piece Stainless Steel – 300 kg to 6 MT Single Piece 5
ISO Certifications ISO 14001:2004 ISO 9001:2008
Certifications IRS NORSOK
Certifications PED Well Known Foundry
Customer Recognition NTPC Foundry Approval Best Vendor Award from BHEL KEPL , IndiTech Valves & KBL- Certificate of Appreciation
Pattern Making Good infrastructure for in house repair, rectification of all types of pattern by dedicated skilled work force. New pattern manufacturing work outsourced from local reputed pattern manufacturers equipped with CNC & VMC setup. 10
Methoding Magma 5.3 and 10 Core processor Simulation software predicts the complete casting process including filling, solidification, cooling and allows the quantitative predication of various properties. Simulation accurately describes a cast component quality up-front before pattern manufactured and the Casting Methoding can be designed to meet required quality invariably reducing casting development time. 11
Methoding SPD Pump 12
Methoding 42” -150 Body Casting 24” -600 Valve Body Casting 13
Moulding Equipment & Infrastructure The Moulding shop is equipped with 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 14
Moulding Infrastructure 3D Mould & Core by 3D print Moulding at KBL-Kirloskarvadi 15
Melting Furnaces & related Infrastructure Induction Furnace with five crucibles, One - 2 MT, Two - 5 MT, One - 8 MT & One - 12 MT capacity. Ladle Refining Furnace - 14 MT capacity. Argon oxygen decarburization - 7 MT capacity. Wire Injection machine for deoxidization. 16 Induction Furnace
Core Wire Injection for Deoxidation An essential feature in steel refining is the injection of calcium in the steel ladle in the form of a cored wire for de-oxidation and inclusion modification. A cored wire is a continuous steel tube filled with calcium bearing powder. The melting behavior of these cored wires has an important bearing on the efficiency of the injection process, castability of steel and the product quality. The recovery of calcium in this process is relatively higher than in the conventional lumpy 17 Core Wire Injection
Secondary Refining Facilities LRF under Operation AOD under Operation 18
Heat treatment Facility The Heat treatment shop is equipped with two HT furnaces well calibrated as per API 6A standard. To achieve good hardenability quenching tank is fitted with 60HP pump system. Furnace dimension 3.5 M X 4M X 2M ( Capacity 10 Ton) Furnace dimension 4 M X 5M X 2M 19 ( Capacity 13 Ton)
Fettling & Finishing Shot Blasting Grit Blasting Apart from various pneumatic, electric grinders fettling shop is equipped with Grit blasting facility and 3MT shot blasting machine. 20
Inspection Facility Image Analyzer Baird(USA) make Spectrometer 21 Spectromax (Germany) Spectrometer with with 18 Elements 31 Elements including Nitrogen facility
Mechanical Testing Facility Extensometer Impact Testing machine Universal Testing Machine 100 Tons with cryogenic testing capacity with Extensometer calibrated Specimens facility up-to -46 0 C under Lloyds, TUV, IRS and IBR.
Sand and Mould Testing Scratch Hardness Permeability Meter Tester Compression Strength Tester Tester Baume Meter Moisture Tester Sieve Analyzer 23
Process Control Facility Radioactive Contamination Using RADCHECK Meter 1500 & 2000 mm 24 King Brinell 1000 mm Vernier Caliper Vernier Height Gauge Hardness Tester
Ultrasonic Testing Ultrasonic Testing machine Standard Reference Blocks 25
Magnetic Particle Inspection Prod with Wet Fluorescent Demagnetization is Prod with Wet Fluorescent Method Method with 5 gauss Accepted Pie Field Indicator
Radiography Apart from support from parent company dedicated vendor viz. Quality Inspection Services, Hyderabad and Industrial NDT and Inspection services, Pune perform RT with help of qualified personal using Co-60 and Ir-192 source and reference radiography films. Reference ASTM E446 Standard 27
Welder Qualification Welding qualification tests are used to establish and ensure that the welder can weld up to the company’s standards. TKSL has 14 qualified welder as per ASME section IX for various position and grade. 28
Machining Vertical Turning Center Ø 4m Apart from In-house machining TKSL is supported by dedicated machining vendors in and around Kolhapur. Vertical Turning Center Ø 2m 29
Product Gallery (Latest manufactured products) Impeller 6.6 MT (CF8M ) Guide Vane (CA6NM ) Diaghpharam 13.5 MT (WCB ) FRANCIS RUNNER 3.6 MT (CA6NM ) Stay Ring with diffuser vanes (WCB ) BOWL (CF8M ) TILLER (WCB ) 1800 mm Inlet Body 13.5 MT (WCB )
Product Gallery (Products manufactured using 3D Print Mould & Core) Pelton Runner 3 MT (CA6NM) Francis Runner Dia 600 mm (CA6NM) Impeller 2 MT (CA6NM) Suction Casing (CA6NM) Top Half Casing (WCB)
PUMPS BOTTOM HALF CASING PUMP CASING PUMP BOWL BOTTOM HALF CASING ENCLOSED IMPELLER OPEN IMPELLER
PUMPS PUMP BOWL TOP HALF CASING OPEN IMPELLER TOP BOTTOM CASING
STEAM TURBINES OUTER CASING UPPER HALF OUTER CASING BOTTOM HALF SWVELL HOUSING UPPER & LOWER HALF CASING
HYDRO TURBINE FRANCIS RUNNER GUIDE VANE CARRIER GUIDE PIECE FRANCIS RUNNER
VALVES VALVE BODY VALVE BODY VALVE BODY VALVE BODY VALVE BODY BONNET
MINING SPROCKET MEMBER CENTER CASE
GENERAL ENGINEERING CRANK GEAR TOGGLE HEAD STOCK BELL MOUTH SPINDLE CROWN PINION LINER
Global Customer Visit Outotec, Finland
Global Customer Visit MHPS – Japan & India
Global Customer Visit Voith Hydro Pvt. Ltd.
Global Customer Visit AL-Hassan, UAE
Global Customer Visit GE Power (Gas Power System) Mr. Laurent Veronese - GE Belfort, France Mr. Varadaraju - GE India
Global Customer Visit Metso - Global Team Mr. Juho Sopanen - Global Category Manager ( from Metso Tampere Plant, Finland ) Mr. Marcelo Mazuchi - Global Manager, Supplier Prod Proc Development ( from Metso Sorocaba Plant, Brazil ) Mr. Olivier Flet - Global Quality Assurance Manager ( from Metso Macon Plant, France) Mr. Anjan Sen – Head Supply Chain (India) Mr. Puneet Goyal – Manager Quality (India)
Global Customer Visit Doosan Škoda Power Mr. Ladislav Zahalka - (Head of Global Sourcing) Mr. Tomas Glusa - (Head of Materials Engineering) Mr. Jaromir Fiala - (Senior Purchaser) Mr. Martin Polak - (Welding Specialist) Mr. Rajesh Kumar Singh – (Senior Manager)
Valuables Customers Pump : Hydro Turbine : 1) Kirloskar Brothers Limited 1) Kirloskar Brothers Limited 2) Kirloskar Ebara Pumps Limited 2) GE Power India Limited 3) TM.P . S.P .A Termomeccanica Pompe 3) Voith hydro Private Limited 4) BHEL, Hyderabad 4) B Fouress Private Limited 5) Jyoti Ltd., Vadodara 5) Chintamani Industries 6) Jyoti Limited Valves : General Engg. /Marine / Defence : 1) Kirloskar Brothers Limited, Kondhapuri 2) Ghatge Patil Industries Limited 1) L&T KOBELCO Machinery Private Limited 3) L&T Valves Limited 2) L&T Rubber Processing Machinery 4) BHEL, Trichy 3) KLEEMANN GmbH (Wirtgen Group) 5) Inditech Valves. 4) Goa Shipyard Limited 6) Dembla Valves Limited 5) Disa India Limited 6) L&T, Powai Steam Turbine : 7) Vulcan Industrial Engineering Co. Limited 1) Kirloskar Ebara Pumps Limited 8) BEML, Mysore & KGF 2) Triveni Turbines Limited 3) BHEL, Hyderabad 4) Siemens Limited 5) Turtle Turbines Private Limited
Turnover Strategy LONG TERM STRATEGY (MASTER PLAN – II) In-house Machining Infrastructure (Proof / Finished) Value Addition by Supply of finished castings to customer
Turnover Strategy Steps towards Business Excellence Supply of Qualitative Income Finished from other Products Sources 100% Utilization of burnt sand by Strategic Cost Thermal Reclamation Reduction in all Focus on functional Value areas Added Products
Human Resource Management Human Resource Management
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