OEM April 2014 by I-Tech Media Pvt Ltd

MAHENG/2009/33944

Vol 5 Issue 11 • Pages 72 • Mumbai

April 1, 2014 • `100 • www.oemupdate.com

For Efficient Manufacturing

Speak Out 10 Siemens Ltd. 18 IIW-India 50 NNG LLC. An I-Tech Media Publication

Expert Column 28 EWAC flux core arc welding for construction equipment industry

Pumps & Valves Die & Mould

SIRIUS Innovations. Click ‘n’ Go! www.siemens.com/industry

The permanent advancement and continuous innovation of SIRIUS optimally prepare our customers for current and future requirements and provide them with efficient solutions. All components of the SIRIUS modular system are characterized by their space-saving design and high degree of flexibility. Configuration, installation, wiring and maintenance can be realized easily and in minimum time. SIRIUS system has global acceptability with UL/CSA and CE marking. SIRIUS components are suitable for 60°C without de-ration. Thanks to the latest innovations of sizes S00 and S0 up to 40 A, the SIRIUS modular system now offers even more functional diversity:

• Very high termination reliability, shock and vibration proof terminals thanks to Spring loaded terminals • Application monitoring integrated in the feeder due to direct mounting of current monitoring relays on the contactor • Innovative function modules for the easy assembly of star delta starters that replace the control wiring. • Ease of data communication to PLC with communication capable contactors with open communication protocols like AS-i and IO link For more details and enquiries mail to: lvsgr-mktg.india@siemens.com or SMS CP9 to 9223 011 000

Answers for industry.

CMYK

CONTENTS Cover Story Green Welding, eco-friendly, cost-effective ��14 Quick Update Red Lion introduces PXU series of PID controllers ��8

B&R reduces cycle times in peripheral devices to 1 µs ��8

Speak Out Siemens Drive Technologies: one-stop shopping for drive train ��10 IIW-India adding skills to welding technology ��18 NNG: flexible, experienced navigation software for any hardware ��50

Technology

Sandvik innovation: achieve required chemistry in single layer ��24

Welding EASEWELD: welding with ease ��27 SigmaWeld: saving energy, increasing productivity ��34

Expert Column EWAC flux core arc welding for construction equipment industry ��28

Pumps & Valves Grundfos S-tube impeller: ready for the future ��38 KHD Valves: four-decade companion for industrial valves ��38 Alfa Laval’s new tantalum range to minimise lifecycle costs for heat exchangers ��40 ABEL compact membrane pumps ��40 Caliber’s appreciated butterfly and wafer check valves ��41

Die & Mould Special refractory materials to withstand at high temperature ��42 Fibro gas springs for mould making ��44

Case Study Pump maker extends life of its machine tools, reduces downtime by 10% ��46

Brand Report Klinweld welding wires ��52 Cybernetik’s robotic weld lines ��52 igus CFRIP: cutting stripping cables time by 50% ��54 Abhijeet offers world-class injection and blow mould ��54

46 April 2014 n OEM Update n 4

Han-Fast Lock in action ��56

New Projects ��68 Tenders ��69

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April 2014 n OEM Update n 6

All eyes on elections On February 17, in his interim budget speech while talking about economy, Finance Minister P. Chidambaram mentioned, “Manufacturing is the Achilles’ heel of the Indian economy. The deceleration in investment in manufacturing is particularly worrying. Consequently, there is no uptick yet in manufacturing.” However, after a year-high growth in February, the manufacturing operating conditions continue to improve in March, albeit slightly. As the weaker domestic demand dragged on output growth, the manufacturing activity grew at a slower pace during the last one month. The HSBC India Manufacturing Purchasing Managers’ Index (PMI), a measure of factory production, stood at 51.3 in March, down from 52.5 in the previous month, signalling a “slight and weaker” improvement of business conditions across the country’s goods producing sector. “The momentum in the manufacturing sector eased on the back of a slowdown in order flows and raw material shortages,” Leif Eskesen, Chief Economist for India and ASEAN at HSBC said. According to the survey, Indian manufacturers reported higher new export orders in March, stretching the current period of growth to six months. Also, employment in manufacturing sector is increased marking a six-month sequence of expansion. Meanwhile, inflation also moderated. HSBC predicts that the growth is likely to remain moderate in coming months as fiscal tightening, relatively high corporate leverage, and rising non-performing loans in the banking system pose headwinds to growth. Though, the present government has proposed a few steps to boost manufacturing in its interim budget, but experts do not see a revival until the new government comes into the action. “While we might see traction on economic reform and execution of investment projects after the upcoming elections, the recovery in growth is likely to prove protracted,” HSBC PMI indicated. Please do send me your comments at editor@oemupdate.com

Quick Update

Red Lion introduces PXU series of PID controllers Compact design and universal input options provide PID control for a wide range of temperature and process signals

ed Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced the launch of its new PXU series of proportional-integral-derivative (PID) controllers. The PXU series, which is the latest addition to Red Lion’s portfolio of industrial automation solutions, is designed for machine builders, systems integrators and commercial equipment manufacturers. The PXU series enables tighter, more reliable control over a wide range of processes, including temperature, flow and pressure, from a single model. Capable of being deployed in precision process applications within the food and beverage, plastics, packaging, energy, gas, heat-treating, commercial and medical industries, the PXU series offers 1/16, 1/8 and 1/4 DIN size models to provide a range of space-saving options. Features and benefits include: • Enhanced bezel design with larger, easyto-read displays for better visibility from long distances

• Optional RS-485 communications allows integration with PCs, PLCs and HMIs • One inch shorter in depth to save space • Programmable via front panel push buttons and/or Red Lion’s Crimson configuration software • On demand auto-tuning for easy set-up • Universal input supports thermocouple, RTD, 0 - 10 VDC and 4 - 20 mA (0 - 50) • UL listed, 61010-1, process control equipment meets industry standards. “The PXU series of PID controllers gives

customers compact PID controllers with large, easy to read displays,” said Jeff Thornton, Director - Product Management, Red Lion Controls. “The range of sizes and universal input coupled with our awardwinning Crimson software make these controllers a must have for OEM machine builders and commercial equipment manufacturers.” n For more information, visit www.redlion.net/PXU

B&R reduces cycle times in peripheral devices to 1 µs W

times to be reduced to as low as 1 µs. B&R takes advantage of the Automation Studio 4 development environment’s ability to allocate software modules to distributed hardware and utilise the surplus capacity of logic components in the modules. This allows function block libraries to be stored there through the use of dynamic updates.

ith reACTION technology, B&R is able to reduce cycle times in industrial automation down to 1 µs. This new approach allows extremely time-critical sub-processes to be managed using standard hardware – all within the requirements of IEC 61131 – while cutting costs by reducing the load on the controller and optimising performance to match demands. The result is an immense increase in performance without added costs. The fastest response times achieved in the field, from receiving the input signal to sending the output signal, have seldom been under 100 µs until now.

B&R’s reACTION technology: Groundbreaking 1 µs cycle times, using standard X67 series components

Increased performance without added cost With reACTION technology, programs created in the function block editor are

executed directly on I/O modules from the X20 and X67 series, eliminating internal data transmission and allowing response

April 2014 n OEM Update n 8

These libraries can then be executed locally on the I/O module like the command set for a microcontroller, allowing timecritical sub-processes to be implemented, using standard hardware and eliminating the need for specialised modules – all while reducing the load on network and controller. n

Speak Out

Siemens Drive Technologies: one-stop shopping for drive train

“With our integrated drive systems, we have what the market is looking for,” Wolfgang Weissler, Vice President, Drive Technologies, Siemens Ltd.

iemens has been present in India for more than a century and manufacturing motors for the market since 1966. Today, the company is able to provide innovative and integrated products and systems for the manufacturing and process industries as well as the energy and infrastructure segments. In an exclusive interview with OEM Update, Wolfgang Weissler shares why there is hardly any other company that has the same complete portfolio as Siemens Drive Technologies (DT) Division.

Drive Technologies is a major business division of Siemens. How is the recent demand-supply scenario? The current economic situation in India does not show GDP growth what we all would like to see. The pre-election phase slows down government investments, and the private sector will wait for the election result before launching new projects. There is certainly significant money waiting to be invested into India. We will see the results not before the last quarter of 2014. To bridge the time, India’s industry is focusing on productivity improvements to be ready when business picks up again. We are happy to offer solutions which would help our customers improve their productivity. We also expect a growth beyond the general April 2014 n OEM Update n 10

GDP for the foreseeable future. As India catches up with China and the other Asian markets, improving ‘productivity’ will be one of the key drivers for the years to come. With our integrated drive systems, we have what the market is looking for — an offering that allows for higher productivity, shorter time to profit and lower energy consumption.

What is your market share in this business? Being a listed company, we cannot reveal sector- or division-specific market shares. Siemens has been present in India for more than a century and manufacturing motors for the market since 1966. Given this lineage and our in-depth understanding of the local needs, we are able to provide innovative and integrated products and systems for the manufacturing and process industries as well as the energy and infrastructure segments. We address key industry priorities to help our customers reduce costs and strengthen their competitiveness in productivity, energy efficiency and reliability. There is hardly any other company that has the same complete portfolio as Siemens Drive Technologies (DT) Division. DT caters to an extensive range of verticals, including metal and metal products, capital goods, chemical, textile, cement, oil and gas and power generation.

You launched the integrated drive systems initiative in 2012; how is the concept catching up in India? We made the official launch of IDS in the Hannover Fair in April 2013. It is a new approach to drive technology and the world’s first true one-stop solution for entire drive trains. The concept is being well received and appreciated by our customers, especially from sectors where power ratings are high. This is because savings through IDS will be substantial therein. We also foresee demand coming from material handling and cement and from OEMs who see the benefits in engineering time when shifting to Siemens IDS. Equally, we see more and more small machines coming into the market, which would be built based on IDS because of the “one-stop shop” and the single point of contact. I would say the range of potential applications is virtually endless.

What were your prime objectives behind launching this initiative? General practice in the industry is to purchase individual components or sub-systems from multiple vendors and assemble these into a complete drive train. This results in excessive project management as well as increases the Continued to 12

Sandvik welding products - when performance really matters

Pune Mumbai Road, Dapodi, Pune 411012 wire.india@sandvik.com 020-27104563/ 4604 www.smt.sandvik.com

Sandvik Asia Pvt Ltd

Speak Out Continued from 10 f

operational cost throughout the entire life of the machinery. Also, manufacturers need to embrace cutting-edge technology that would increase productivity and efficiency and reduce time-to-market. A completely assembled drive train package designed and integrated to work together is referred to as Integrated Drive System. It employs system engineering principles that benefit from the initial specifications through the installed operational life. Siemens offers a one-stop shopping for drive train that are cost effective (initial and lifecycle) and easy to install. Our robust portfolio is fully integrated and offers a seamless combination of products, systems and applications that are ideal for harsh industrial conditions. Additionally, we have a strong service portfolio to provide preventive and value-added services

Could you highlight the advantages of integrated drive systems? The core element of IDS is the three-way integration of the drive train: horizontal, vertical and lifecycle integration. Horizontal integration essentially helps improve machine productivity, production quality and machine efficiency. It also increases the plant availability up to 99 per cent. Vertical integration increases plant productivity as well as production flexibility and transparency. With Totally Integrated Automation (TIA) portal, engineering time

can be cut up to 30 per cent. Lifecycle integration offers consistent integration over the entire lifecycle of a product and the associated production system and can cut the maintenance cost up to 15 per cent. The three-level integration of IDS leads to increased efficiency, reliability and productivity and enable noticeably shorter time to market and profit.

will be improving our focus on the MSME segment.

Finally, to conclude, what are your long- and short-term objectives for manufacturing sector in India?

Drive technology applications and energyefficient motors to increase energy efficiency and productivity will help MSMEs save huge costs. For example, large variable speed drives such as perfect harmony offers possibilities for substantial energy savings where customers can recover the price of the drive within 19 months of its commissioning. Our IE2 and IE3 range of motors offer efficiency up to 10 per cent higher than the conventional motors. Further the usage of application specific drives also can enable MSMEs to increase energy efficiency and productivity. Our newly launched optimised servo drive system, SINAMICS V90, is not only a costeffective solution but also shortens timeto-market with easy commissioning, thus improving customers’ competitiveness.

The National Manufacturing Policy of the government aiming to increase contribution of manufacturing sector to GDP from 16 to 25 per cent by 2025 is one of the key fundamentals for increasing manufacturing potential in India. However, the 26 million Indian manufacturing Micro Small & Medium Enterprise (MSME) units will play a key role in realising this ambitious goal. They need to adopt technologies that would help them reap higher ROIs and make them competitive on a global scale. There is huge potential and hence in the coming years, we

We will also focus on upgrading technology of our factories along with capacity expansion. Siemens has maintained its position using topnotch technology with cutting-edge R&D. We also have entry level- and mid-level products as well as customised solutions for a wide range of vertical markets. We are ensuring that with our entry level product strategy there is an optimum balance between features and cost. The products are high in performance as well as cost-competitive, and we intend to maintain this momentum. n

IDS enable the users to employ system engineering principles that benefit from the initial specifications through the installed operational life. It mitigates many indirect costs associated with drive train projects. It also reduces time to market and profits while ensuring higher productivity, reliability and efficiency.

Shriram Automall ties up with John Deere India Pvt. Ltd. (John Deere), one of leading manufacturers of agricultural tractors and farm equipment. In this tie-up, SAMIL will provide specialised services to John Deere’s authorised dealerships for disposal of preowned tractors and farm equipment.

hriram Automall India Ltd. (SAMIL), a wholly owned subsidiary of Shriram Transport Finance Company (STFC), has entered into a tie-up with John Deere

April 2014 n OEM Update n 12

Gujarat, Madhya Pradesh, Chhattisgarh, Punjab and Haryana.

The event saw the presence of Ravi Menon, Director - Sales and Marketing, John Deere and Sameer Malhotra, Chief Executive Officer, SAMIL.

“Through this alliance, we would be reaching the unaddressed segment using farm equipment in India. Many challenges faced by India farmers in possessing a tractor for their agricultural activities can be simplified by providing easy, absolute transparent platform for trading pre-owned tractors,” commented Mr Malhotra.

SAMIL would provide the services of disposal of pre-owned tractors and farm equipment to John Deere’s authorised dealers in various states of India including Andhra Pradesh, Tamil Nadu, Karnataka, Kerala, Maharashtra,

The two companies have joined hands to work together for understanding the dynamics of used tractor market and refine the methods for quick, efficient disposal of used tractors and farm equipment. n

Cover Story

Green Welding

eco-friendly, cost-effective The Centre for Materials Joining and Research of Annamalai University has indigenously developed an eco-friendly and cost-efficient welding technology that offers benefits in terms of welding of difficult to weld alloys, better retention of baseline material properties, fewer weld defects, low residual stresses, and better dimensional stability of the welded structure

co-friendly welding (EFW) was invented at The Welding Institute (TWI), UK, which is popularly known as Friction Stir Welding (FSW) process. Compared to many of the fusion welding processes that are routinely used for joining structural alloys, FSW is an emerging solid state joining process in which the material that is being welded does not melt and recast. Due to the absence of parent metal melting, the new FSW process is observed to offer several advantages over fusion welding. The benefits that stand out most are welding of difficult to weld alloys, better retention of baseline material properties, fewer weld defects, low residual stresses, and better dimensional stability of the welded structure. Above all, EFW is an environmentally cleaner process, due to the absence of a need for the various gases that normally accompany fusion welding.

material. Fig 1 explains the working principle of EFW process. When alloys are friction stir welded, phase transformations that occur during the cool down of the weld are of a solid-state type. Due to the absence of parent metal melting, the new EFW process is observed to offer several advantages over fusion welding. The benefits that stand out most are welding of difficult to weld, better retention of baseline material properties, fewer weld defects, low residual stresses, and better dimensional stability of the welded structure. 1.Start Spindle 2. Plunge into Material

Principle EFW is a continuous, hot shear, autogenous process involving non-consumable rotating tool of harder material than the substrate April 2014 n OEM Update n 14

3. Preheat

4. Traverse

Fig 1: Schematic representation of EFW working principle

Work piece Tool shoulder cing

an Adv

Backing bar

Side

tre

ide

n ati

Profiled pin

Fig 2: Different regions of EFW joint

EFW joints usually consist of four different regions as shown in Fig 2. They are: • Unaffected base metal • Heat affected zone (HAZ) • Thermo-mechanically affected zone (TMAZ) • Friction stir processed (FSP) zone or dynamically recrystallised zone (DRX). The formation of above regions is affected by the material flow behaviour under the action of rotating non-consumable tool. However, the material flow behaviour is predominantly influenced by the FSW tool profiles and FSW process parameters.

Cover Story

Fig 3: Computer Numerical Controlled EFW machine

Applications EFW gives rise to softening in the joints of the AA7075, a heat-treatable aluminium alloy, because the dissolution or growth of strengthening precipitates during the welding thermal cycle, thus resulting in the degradation of the mechanical properties of the joints. EFW creates the weld joint without bulk melting. In addition, the extensive thermo mechanical deformation induces dynamic recrystallisation and recovery that refine the microstructure of the stir region. Therefore, welds made by EFW are shown to have much improved mechanical properties than the corresponding fusion welds. EFW is capable of joining magnesium alloys without melting and thus it can eliminate problems related to the solidification. As EFW does not require any filler material, the metallurgical problems associated with it can also be reduced and good quality weld can be obtained. Higher thermal conductivity and thermal expansion of copper result in greater weld distortion than in comparable steel welds. On the other hand, EFW would alleviate most of the problems caused by the fusion welding processes because it does not result in the melting and resolidification of the material to be welded. EFW efforts to date have involved joining of aluminium alloys there is considerable interest in extending the technology to other materials, including steels. EFW appears to offer several advantages over arc welding of steels. The lower apparent energy inputs of EFW are expected to minimise grain growth in the HAZ, limit distortion and residual stress in steels, eliminate welding fumes and hydrogen induced cracking etc.

Environmental benefits Welding is an important occupational activity, in part because from 0.2 to 2.0 per cent of the working population in industrialised countries has been reported to be engaged in welding. Although there are number

Fig 4: Close-up view of EFW during welding steel plates

of processes, it has been estimated that shielded metal arc welding (SMAW) and gas metal arc welding (GMAW) applied to carbon steels, stainless steels and aluminium alloys account for combinations practiced by 70% of welders. The welding environment is very complex, with the presence of numerous gaseous and particulate components. The extremely high temperatures (>4,000 C) of arc welding processes heat both the base metal pieces to be joined and a consumable electrode fed into the weld. Fumes are formed by vaporisation of the elements & oxides from the arc area (near the electrode tip) and rapid condensation of the vapours to form solid particles. The composition of these particles is dependent on the type of material being welded, the type of filler metal being used and the type of flux or shielding gas. In welding processes that use no flux, such as GMAW and GTAW the solid particles produced comprise almost entirely of metal and metal oxides. The metal vapours are oxidised on contact with the air and form small particulates of different complexes of metal oxides. The chemical properties of welding fumes can be quite complex. Most welding materials are alloy mixtures of metals characterised by different steels that may contain Fe, Mn, Cr, Ni, and others. Fumes generated from mild steel welding processes are predominantly Fe and Mn with negligence amount of Cr or Ni. The inhalation of welding fume can produce a number of short and long term health complications. The impact of welding fume is represented in two ways that is acute and chronic. Acute effects are generally exhibited quickly and are often caused by significant doses of inhaled fume. Usually acute illnesses involve the respiratory system and a reduction in pulmonary function. In many cases acute symptoms are the precursor to future chronic effects. One of the most

serious though rare chronic respiratory effects is that of asphyxiation caused by working in confined poorly ventilated work areas. The lack of ventilation allows fume and shielding gasses to build up to a point where they displace the available oxygen. Chronic respiratory diseases include bronchitis, emphysema and asthma. However, the technology developed in this project, eco-friendly welding process (using friction stir welding principle) produces no smoke, no fumes, no arc glare and no infrared and ultra-violet rays. The eco-friendly welding process developed in this project work completely eliminates air pollution (absence of smoke), water pollution (absence of fumes) and soil pollution (absences of fluxes). Hence, the eco-friendly welding process developed in this project is a viable method for green manufacturing.

Economical benefits No need of filler materials: Generally, the traditional welding processes such as SMAW, FCAW, GMAW processes require filler materials (known as electrodes/filler rods/filler wire) to join two metal pieces to fill the profile edge preparation. Here in eco-friendly welding process, there is no necessity of filler materials since there is no profiled edge preparation to fill up. Square butt joint configuration is sufficient and hence filler materials are not required and it reduces the expensive filler material requirements. No need of shielding gases: The traditional welding processes such as GMAW, GTAW, FCAW processes required the supply of shielding gases to protect the molten weld metal during welding. Usually, inert gases like argon and helium will be used to protect the weld pool and these gases are very expensive. But in eco-friendly welding process, there is no necessity to supply shielding gases since this process works under solid state welding condition and there is no melting takes place 15 n OEM Update n April 2014

Cover Story here. Hence, this process does not require shielding gas addition and thus reduces the costly shielding gas requirements. Lower labour cost: Conventional welding processes such as SMAW, GTAW, FCAW, GMAW processes require skilled welders to produce good quality welds. Because these processes are manual controlled or semiautomatic controlled processes. However, the eco-friendly welding process can be easily automated and controlled by a computer and hence there is no necessity of skilled welders to operate this machine. Skilled welders are very scarce in our country and this process minimises labour cost greatly. Less power consumption: The conventional welding processes consumes large amount of power since they work under generators, transformers, inverters and rectifiers technology. But this eco-friendly welding process works under electric motors (stepper motors, servo motors) technology and his power consumption is very less compared to conventional welding processes. High productivity: The eco-friendly welding process is a fast process and it can be very easily automated (all the operations sequence can be programmed). Hence, the production rate is very high compared to all other welding process. Due to higher production rate, the cost of each component will be greatly reduced. Cost comparison: By considering all the

above factors, the actual cost estimation was carried out to weld 100 metres length of aluminium plates of 6-mm thickness for various welding processes and they are: GMAW (` 50,000), GTAW (` 75,000), LBW (` 1,00,000), EBW (` 2,00,000) and EFW (` 25,000). From this cost estimation, it could be inferred that the eco-friendly welding process is less expensive compared to all other conventional and advanced welding processes.

Critical application areas EFW process has lot of potential applications in fabrication industries. Some of the potential industrial sectors are given below: Automobile: Medium strength aluminium panels, sheets and plates are widely used now-a-days in passenger cars, multi-utility vehicles as door frames. These aluminium alloys can be effectively joined by EFW process for higher load carrying capacity. Ship-building: Corrosion resistance aluminium panels, sheets and plates are widely used in cargo ships, war ships and passenger ships. These aluminium alloys can be joined by EFW process for improved corrosion resistance. Power: Low strength, pure aluminium and Electrolytic tough pitch copper are widely used in bus bar applications. These aluminium and copper metals can be efficiently joined by EFW process for better performance. Aviation: Passenger aircrafts are made with

high strength aluminium alloys and these alloys are joined by steel rivets. The rivets can be replaced by this process by spot welding which will reduce the weight of the aircraft and eliminate corrosion problems. Space applications: Cryogenic fuel tanks used in launch vehicles are made by high strength aluminium alloys. These alloys are now joined by GTAW and EBW processes. These cryogenic fuel tanks can be welded effectively by EFW process for enhanced low temperature strength.

Conclusion It is found from many investigations that the FSW process didn’t produce gaseous emission, particulate emission and radiation during welding of aluminium alloys, magnesium alloys, copper alloys, carbon steels and stainless steels and hence it could be very much called as EFW process. Moreover, the joints fabricated by EFW process exhibited superior mechanical and metallurgical properties compared to other joints fabricated by conventional welding processes. n Author:

Dr. V. Balasubramanian, Professor, Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University

Orbital welding power source: Orbitron 5000

niversal Welding Systems introduces the first indigenous orbital welding power source for tube-to-tube sheet welding.

Why orbital welding? • Productivity: An orbital welding system will drastically outperform manual welders, many times paying for the cost of the orbital equipment in a single job. • Quality: The quality of a weld created by an orbital welding system with the correct weld program will be superior to that of April 2014 n OEM Update n 16

manual welding. In applications such as semiconductor or pharmaceutical tube welding, orbital welding is the only way to reach the weld quality requirements. • Consistency: Once a weld program has been established an orbital welding system can repeatedly perform the same weld hundreds of times, eliminating the normal variability, inconsistencies, errors and defects of manual welding. • Skill level: Certified welders are increasingly hard to find. With orbital welding equipment no one needs a certified-welding operator. All it takes is a skilled mechanic with some weld training.

• Segment wise programming with positional reference • In-built weld data logger with USB port either pen drive or printer can be connected • Password protected preset tables for different • Sizes of tubes, can be modified afterwards simple, user-friendly rugged and noiseproof design can run on generators • Specially tuned pulsed GTAW power source for orbital welding • Highly stable currents suitable for orbital welding • Auto tacking facility • Built-in water cooling for tong cooling.

There are other reasons too for the use of orbital equipment over manual welding. For example, inspection of the internal weld is not practical for each weld created.

Applications

Features • Compact design • New touch screen HMI

• • • • • • •

Biotechnology and pharmaceutical Food, dairy and beverage Brewery Nuclear Aerospace Semiconductor Tube/pipe fittings, valves and regulators. n

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Speak Out

IIW-India adding skills to welding technology

“The issue of skilled and semiskilled manpower availability has been always accorded top priority by IIW-India,” says Viay Agwan, Regioal Director (West), IIW-India

IIW-India was established in 1966. How is the journey being so far, and what are the innovative programs you have come up with? IIW-India has started as an association of welding professionals with the aim to share the knowledge and technical data resources. As the welding activities grew in India, both quantitatively and qualitatively, IIW India started providing solutions to the arising situations related to the technology and the expertise in welding. IIW-India, recognising the needs within India, has started addressing these issues at national level through its AM-IIW and NWCTS programmes for the personnel. The membership criteria were streamlined, and the examinations route was opened in mid-90s. The AM-IIW qualification was approved by the Government of India, being equivalent to the engineering degree through the gazette notification. IIW-India has been a member of the International Institute of Welding (IIW/IIS) as well as the American Welding Society. When ISO body entrusted the responsibility of implementation of welding-related standards globally, IIW/IIS chose IIW-India as the only institution, having credibility to help achieve these goals in India. Today it is the only authorised national body for awarding international qualifications to the welding user industries and the personnel working therein as per ISO:3834 and ISO:14731, respectively. These qualifications, though voluntary at present, are becoming an order of the April 2014 n OEM Update n 18

day as we go on to the inevitable next growth phase in India. They are considered almost a necessity in the days of rapid globalisation.

availability has been always accorded top priority by IIW-India. The members of IIWIndia are fully aware of this.

Like every technology, welding also depends on three main factors: applications, equipment and expertise. IIW-India provides opportunities with annual national welding seminars as well as national welding meets to the manufacturers of the equipment to showcase, display and demonstrate the latest developments made available by them to the users, who gather there to deliberate on the technical issues being faced by them, individually and collectively.

To streamline and specify the minimum requirements all over India, IIW-India had come out with its national welding training and certification scheme. It prescribes a syllabus for the training of manpower — mainly this unskilled manpower willing to undertake the welding as a profession — to all the vocational training associations and institutes all over India. Though it was not mandatory, it had a substantial following. With the government’s focus shifting to shortage of skilled manpower and the establishment of National Skill Development Council (NSDC) reporting to PMO, welding skill is topping the list. To identify the needs and implement the scheme in welding technology, IIW-India was chosen and specially invited by the PMO and NSDC together to be its main arm.

The branches of IIW, spread all over India, also contribute by providing a platform to the practicing welding fraternity for technical deliberations, through their monthly technical lectures as well as annual branch seminars, meets and specially organised workshops and conferences.

The said NWCTS programme is now being recognised as the prescribed by NSDC. In turn, the Sector Skill-Development Councils (SSCs) are partnering with IIW-India for sector-wise welding skills development. It is a process of evolution and will take its time to show the results.

These interactions always have snowballing effect, leading to setting up directions for continual multi-pronged growth.

What are the steps taken for technical up gradation and implementation of new process in welding?

What are the initiatives taken by IIW to reduce the rate of unskilled labour in welding industry?

The said programmes of IIW-India help in informing the fraternity of the latest trends in equipment, processes and applications. So the needy users can undertake the technocommercial feasibility studies for adapting

Homogenisation of the welding standards worldwide is very desirable and happening in every nation, and IIW-India is fully shouldering this responsibility.

How is it contributing to the growth of welding industry in India?

The issue of skilled and semiskilled manpower

Continued to 23

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Continued from 18 f

the new technology in their operations. When needed, IIW- India provides technical training for the manpower.

What is the current scenario of welding automation in India, and how automation is going to contribute in the growth of welding industry? When we talk about the automation in welding operation, it necessarily implies mass-production industries, using welding processes. Auto sector and white goods sector manufacturing consumer durable are the two industries where automation is a genuine need, and techno-commercial viability is already established from the point of view of repeat accuracies demanded in mass-manufacturing. Using non-destructive techniques for quality assurance and post-weld corrections are simply not feasible in these industries. Here the automation levels are matching with the latest in industry, tool for tool and transfer-lines for transferlines. Robotic welding is very regularly done here in the main assembly plants.

Distributed by

However, the component manufacturing industry--which feeds these large industries--is yet to rise to that level of automation as the scales of manufacturing has not reached the critical level to justify the investments in automation. People who want it are deprived of the latest automation technology, not even by the earlier government policies. The issues are related to the affordability as the present volumes do not justify adoption of automation.

India consumes about 50 million tonnes of steel every year. What is the effect on steel industry? This aspect is really easy to understand by anyone. Whatever we have today around us is mostly made using steel — all infrastructure-related construction and manufactured goods. The annual steel consumption is taken as a leading economic indicator for the progress of a country for this reason. The statistics shows that a developed nation requires about 50 kg steel per capita to sustain the level of living standards for its population. To build the infrastructure — government spending on large scale — this demand has gone up three folds for short periods before it gets stabilised at sustainable level. We are at about 40-50 kg per capita consumption level only, and this demand will go up as soon as we switch to infrastructure development mode, which is obvious, at least to 150 kg per capita. For every tonne of steel consumed, there is a requirement of 5 kg of welding filler material, which in turn requires two welder shifts. At the current level, we are short of at least 1,00,000 skilled welders. This will go up to at least 3,00,000 welders at 150 kg/ capita consumption rate. That means manpower is going to be a major bottleneck for the growth. No wonder that the Government of India has accorded a top priority for welding skill development under the NSDC programme.

Being the organiser of Weld India Expo, what are your expectations? We expect about 250 organisations taking part in this event. A large number of exhibitors are coming outside of India. Hence, the users of welding technology--attending and deliberating on technical issues in the International Conference--can witness the present status of technology in action. A great and unique opportunity indeed! n

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Technology

Sandvik innovation: achieve required chemistry in single layer Sandvik has done extensive research and developed welding wires to get the chemistry in single layer which reduces product time and problems associated with welding like distortion

eld overlay is normally used in the context of adding filler metal on a substrate to either provide corrosion protection, build-up base material for dimensions or provide wear resistance. All known arc welding processes like GMAW, GTAW, ESW, SAW and SMAW are being used to do weld overlay. While talking about corrosion-resistance weld deposit, the most popular chemistries are 304/304L, 316/316L and 347. Today for getting the above mentioned chemistry, we have to apply two or three layers to take care of dilution effect from the base material. Sandvik Materials Technology, a product area within the global Sandvik Group, has been in the forefront of developing new alloys for the industry in-line with the growing demands of the customers for enhanced corrosion resistance and superior product life cycles. Sandvik has done extensive research and developed welding wires to achieve the required chemistry in single layer. The major benefit in getting the chemistry in single layer are huge reduction in production time, less consumption of welding consumables and reduced problems associated with welding like distortion. The paper will cover the details about the welding wire Sandvik 24.13.LHF, Sandvik 24.16.3.L and Sandvik 24.13.LNb grade chemistry, mechanical properties and actual trial result of Sandvik 24.16.3.L grade.

Today’s way of wire cladding • To get chemical comp. 304/304L or 308/308L overlay: 1st layer 309L, 2nd and 3rd layer 308L • To get chemical comp. 347 overlay: 1st layer 309L, 2nd and 3rd layer 347 • To get chemical comp. 316/316L overlay: 1st layer 309L, 2nd and 3rd layer 316L. April 2014 n OEM Update n 24

Advantages of single-layer surfacing • Saving time: less welding time, shorter lead time • Increasing productivity: higher output, faster in production, less weld cleaning and distortion • Cutting costs: less inventory, lower transportation cost.

Suitable processes for weld surfacing • • • •

TIG Plasma-arc MIG Submerged-arc welding.

• Sandvik 24.13.LNb (ER 309LNb): for single layer 347 • Sandvik 24.16.3.L (ER 309LMo): for single layer 316/316L.

Sandvik 24.13.LHF • Used for TIG, MIG, plasma-arc and submerged-arc welding • Particularly suitable for overlay welding and joining dissimilar steels • Excellent resistance to hot cracking due to its enhanced ferrite content • Suitable for overlay welding of carbon and low alloy steels, where a type 304/304L,

Filler metal Chemical composition WT% C

Max 0.015

0.3

1.8

Max

0.015

Influence of parameters • Surfacing has to be done in such a way that the dilution always is kept low. • The arc should always “rest” on the weld pool and on the previous bead welded. • Position of torch is therefore very important. • Lower amps, higher voltage and lower

Max

0.3

0.05

0.10

0.05

308/308L overlay is required. Ferrite content The ferrite number according to the DeLong diagram, based on the aim composition = 16FN. All weld metal Chemical composition C

Mn P

Max 0.015

High dilution Low dilution Fig. 14: A larg overlap gives low dilution

0.4

1.6

Max

0.015

The data is typical for non-heat treated all weld metal made by MIG welding with a shielding gas of Ar + 2 per cent O and TIG or plasma arc welding with argon as shielding gas. All-weld metal Microstructure – mechanical properties

Low dilution High dilution Fig. 13: Effect of Lateral torch angle on dilution

speed are generalrecommendations to keep dilution low

Three innovative welding wire grades • Sandvik 24.13.LHF (ER 309L high ferrite): for single layer 304/304L or 308/308L

Temperature

Yield strength, RPO.2

Mpa

410

Tensile strength, Rm

Mpa

600

Elongation, A

Reduction in area, Z

Impact strength, Charpy V

140

Hardness, Vickers

160

Technology Microstructure – Physical properties

Microstructure – Mechanical properties SAW, FLUX 15 W

Temperature C

100

300

500

Temperature

Thermal conductivity W/m

Yield strength, RPO.2

Mpa

400

Tensile strength, Rm

Mpa

600

Elongation, A

Impact strength, Charpy V

110

Thermal expansion per C, from 20 C to 400 C 18 x 10-6. Density, gm/ cubic cm, at 20 C 7.9.

Sandvik 24.13.LNb • A niobium stabilised over alloyed filler metal • Suitable for overlay welding of carbon and low alloy steels, where a type 347 overlay is required • Used for TIG, MIG, plasma-arc and submerged-arc welding. Filler metal Chemical composition, WT% C

0.3

2.0

Max 0.020

Max

0.020

0.015

12.5

0.8

All-weld metal Microstructure – Mechanical properties MIG and TIG Temperature

Yield strength, RPO.2

Mpa

400

Tensile strength, Rm

Mpa

600

Elongation, A

Impact strength, Charpy V

110

Hardness, Vickers

180

Austenitic matrix with a ferrite content of about 13 FN according to DeLong.

Sandvik 24.16.3.L • Sandvik 24.16.3.L is unique • Particularly suitable for overlay welding on carbon and low alloy steels • The corrosion resistance of the weld overlays are at the same level as the 316/316L base metal • Pitting resistance is very good due to high Cr, Mo and N-content • Used for TIG, plasma-arc, MIG and submerged-arc welding • SANDVIK 24.16.3.L overlays fulfill requirements in NACE MR0175 or MR0175/ISO15156 • Corrosion resistance of SANDVIK 24.16.3.L similar as/better than that of 316/316L base metal • Overlays made with SANDVIK 24.16.3.L are fully austenitic • High Ni-content increase resistance to H2S induced stress corrosion (SSC) • High Cr and N-content increase resistance of 316/316L to mixed corrosion with carbon dioxide (CO2) and water containing chlorides (pitting and crevice corrosion). Filler metal Chemical composition, WT% C

Max 0.020

0.4

1.5

Max

0.025 0.015 24.5

3.2/(2.8)

0.13

Technology All weld metal Microstructure - mechanical properties Temperature

Yield strength, RPO.2

Mpa

450

-60

Tensile strength, Rm

Mpa

650

Elongation, A

Reduction in area, Z

Impact strength, Charpy V

Austenitic matrix with a ferrite content of about 11 FN according to DeLong Material properties 24.16.3.L Welding process

Arc type

Typical dilution

Base metal C-content

MIG / MAG

Spray

30%

0.15

Spray

30%

Pulsed

15%

Cr %

NI %

Mo %

0.05 17.2

12.1

2.5

0.25*

0.08 17.2

12.1

2.5

0.15

0.03 20.8

14.7

2.8

Pulsed

15%

0.25*

0.05 20.8

14.7

2.8

TIG

20%

0.15

0.04 19.6

13.8

2.7

TIG

20%

0.25*

0.06 19.6

13.8

2.7

A516 gr 70:C-content about 0.25 per cent

Material properties 24.16.3.L Chemical composition 1.6 mm down from the top surface of overlay C%

Si %

Mn %

Cr %

Ni %

Mo %

0.012

0.37

0.89

0.018

0.005

17.32

12.7

2.04

SAW tests in India Wire: 24.16.3.L, Flux: 15W

Ferrite measurement Ferrite number was measured using ferritoscope in the machined component at 1.6 mm down from top surface and the results are: Sample 1

0.29

0.28

0.31

0.35 0.33

Average 0.31

Application Some of the applications where single layer weld overlay is being used are valve and valve components, cladding on pipe and pipe fittings. other defects could be seen at the micro study. The ferrite content of <5 per cent, tells that the solidification mode of the weld metal is primarily ferritic, which is rather safe concerning hot cracking. It is possible to achieve 304/304 L, 316/316L and 347 chemistries in single layer using welding wire. The carbon content in the base material decides the final chemistry (316/316L). Dilution control is a key to get desired result in single layer weld overlay technique. The savings in terms of welding time and consumable is quite significant with single layer weld overlay. n Authored by-

Conclusion The overlay weld tested has a chemical composition that is substantially higher than that of 316L. This means that the composition gives margin for variation in dilution with the base metal. No fissures or April 2014 n OEM Update n 26

Mitul Shah, Technical Marketing Manager, Wire & Heating Technology India, Sandvik Asia Pvt. Ltd.

Technology Welding

EASEWELD: welding with ease • • • • •

MMA

SAW

ASEWELD has started its journey in 1987 by setting up design, production and quality management facilities in Mumbai. With an experience of over three decades in welding and cutting technology, the promoters have greatly helped EASEWELD to establish itself in the Indian welding and cutting equipment market. Its technologically sound manufacturing unit features all requisite facilities to develop products in compliance with clients’ specific requirements. There is an integrated R&D to achieve design excellence throughout its product range.

The latest arrival is complete range of IGBT inverter MMA/TIG/MIG/SAW welders and plasma cutters.

EASEWELD products • • • • • • • • • • •

ARC welding rectifiers AC DC pulse TIG welding set MIG welding machine Submerged ARC welding machine Plasma cutting machine Pug cutting machine Profile cutting machine Hydraulic pre-pinching machine Column and boom Rotators Electric winches

Plate rolling machine Electrode/flux oven Welding cable Electrode Holder Cable couplers and SPMs.

EASEWELD exports its products to countries in Africa, Middle East and SouthEast Asia. The company is hoping to capitalise on the technology shift in terms of automatic and semi-automatic welding which sets to replace manual welding.

Application Automotive, chemical plants, construction, food processing and pharmaceutical industry, gas processing plants, metal fabrication workshops, oil refineries, power plants, steel plants, shipbuilding and offshore. n Contact: Easeweld Equipments India Pvt. Ltd. (An ISO 9001:2008 Certified Company) Tele: +91-22-2852 0692 Telefax: +91-22-2852 2571 E-mail: easeweld@gmail.com Website: www.easeweld.com

Welding solutions from the Industry Leader A comprehensive range of welding products with on job support. The benefits of advanced technology, expert application assistance, robotised solutions, and gas manifolding system for uninterrupted stable gas requirements with total safety. For 5 decades you have come to expect nothing less than this from the welding products business of L & T.

Expert Column

EWAC flux core arc welding for construction equipment industry There is a new wave of demand for more cost-effective application in welding through increased deposition rate and automation thin diameter wire. Minimum thickness of sheet material weldable with this process is 1.6 mm. Considering the mentioned features, FCAW process is one of the most cost-effective methods for a large segment of fabrication applications. The high productivity is one of the key features which make this process suitable not only for welding of joints but also for weld surfacing. Low dilution with the parent metal can be achieved by the selection of suitable welding parameters and flux core wire. Concrete industry (cement mixtures liners and blades)

he immediate concern of the industrial user is production cost and productivity. New technologies, material and other changes are following one another in an ever faster rhythm to address competitiveness. As a result, there is a demand for more cost-effective application in welding through increased deposition rate and automation. A continuing race is ongoing among different welding processes and their modifications or adaptations in search for increasing weld deposition rate and productivity. Traditionally due to its simplicity & easy of operation Shielded Metal Arc Welding (SMAW) has been in use for several years though it has its own dis advantages like low productivity & recoveries, need for re backing, dependency on operator skill & automation not possible etc. It would be nice, it was thought, to feed a long wire trough the torch like it is done with Gas Metal Arc Welding (GMAW) but without the additional complexity of shielding gas supply. Along these lines probably the concept flux core arc welding (FCAW) was evolved. As adequate protection of the weld bead in outdoor applications, where wind interferes with shielding gases, is more achievable using either Shielded Metal Arc Welding (SMAW), or Flux Cored Arc Welding (FCAW). The Self-shielded processes cut down on the April 2014 n OEM Update n 28

amount of equipment needed, i.e. no need to haul in a gas cylinder, hose and regulator. These two are most common processes for construction welding. FCAW-S, where S stands for self-shielded (without additional gas), produces more productive joints, using automatic process â&#x20AC;&#x201D; an advantage when performing welding on joints with poor fitup, i.e. outdoor construction joints.

Needs of FCAW process in construction industries On-site construction of boiler, pressure vessels, offshore platforms for oil prospecting and extracting, and process piping are some of the hot areas requiring skilled welding labour which weighs much in the overall production costs. Any small increase of productivity in these areas can have significant impact on the economy of fabrication. Recognising the superior productivity achievable by flux cored wires as opposed to shielded metal arc electrodes, special attention was devoted to all positions welding, fast freeze slag, controlled amount of diffusible hydrogen levels to reduce crack susceptibility. This welding method is applicable to manual, semi-automatic and automatic welding procedures, in all positions, especially with

Its high deposition rate, application flexibility and good surface quality make it attractive to manufacture and are developed high-quality corrosion-resistant, temperature-resistant and wear-resistant components.

FCAW process Flux-Cored Arc Welding (FCAW) uses a continuously fed tubular electrode, electrical power to melt the electrode, and may or may not use shielding gas from an externally supplied source when depositing material in the weld joint. The resulting weld bead is covered by a residual slag (melted and solidified flux) which helps protect and shape the finished weld and is easily removed upon completion of the weld. Flux Cored Welding combines the high productivity of MIG welding, using a solid electrode with the ability to weld on more contaminated base material. When compared with MIG welding, higher deposition rates are possible, especially when welding out of position. The FCAW uses semiautomatic, mechanised and fully automatic welding systems. The basic equipment includes a power supply, wire feed system and welding gun. The required auxiliary equipment, such as shielding gas, depends on the process variant used and the degree of automation. Fumeremoval equipment must also be considered in most applications of the FCAW process.

Expert Column Power source and wire feed system The recommended power supply for the semi-automatic FCAW process is a constantvoltage direct current (DC) machine. Most power supplies used for semiautomatic FCAW have output ratings of 600 A or less. A power supply rated at 60 per cent or more duty cycle is the best choice for most industrial applications, whereas a duty-cycle rating as low as 20 per cent may be sufficient for maintenance and repair applications. Constant current power supplies are used in certain situations, such as field welding applications, where portable constant current SMAW power supplies are readily available. The addition of a contactor and a voltage-sensing wire feeder makes this an adequate welding system. However, such a system is only recommended when the use of a constant voltage system is not feasible, because constant current systems produce an inherently less stable welding arc than constant voltage systems. Wire feeders for constant voltage FCAW systems are generally simple and provide a constant wire feed speed. The power supply provides sufficient current to maintain an arc at the voltage that is preset at the power supply. A change in wire feed speed results in a change in the welding current.

In a constant current system, the wire feeder is more complex. The welding current is preset at the power supply. The wire feeder has a voltage-sensing feedback loop that allows it to adjust the wire feed speed to maintain the desired welding voltage. The wire feeder generally contains systems to close the contactor and open the shielding gas solenoid valve (gas-shielded FCAW process only) when welding is started. Because fluxcored wires are easily deformed by excessive feed roll pressure, knurled feed rolls are generally used in the FCAW process. Some wire feeders use a single-drive roll paired with an un driven pressure roll. Others

have one or two pairs of drive rolls. It is generally believed that systems having two pairs of drive rolls require the least drive roll pressure to provide dependable feeding.

Manufacturing of continuous electrode for FCAW In general flux-cored electrodes are manufactured using the process shown in Fig 1. A flat sheath material is first formed into a “U” shape. The core ingredients are poured into this “U” at the desired rate. The sheath is then closed around the core materials to form a round tube. The diameter of this tube is then reduced, generally by Strip reel

Flux hopper

Flux poured at this point

“U” forming rolls

Draw die

“U” closing rolls

Reel with formed electrode

Fig 1: Flux core electrodes manufacturing process

Expert Column drawing or rolling operations, to compress the core materials and bring the electrodes to a size that is usable for welding. The finished wire is then wound on spools, coils, or other packages.

Application area Flux-cored arc welding enjoys widespread use in many construction industries. Both process variants are used for shop fabrication, but the self-shielded FCAW process is preferred for field use. Hard facing by flux core arc welding is a surfacing operation to extend the service life of industrial components, pre-emptively on new components, or as part of a maintenance program. The result of significant savings in machine down time and production costs has meant that this process has been adopted across many industries such as steel, cement, mining, petro chemical, power, construction etc. This category of flux core wire include alloy systems like work-hardening manganese alloys, low and medium alloyed steel, antiabrasion which contains very hard metal carbides, martensitic steel alloys, nickel-base and cobalt-base alloy systems etc.

Advantages of FCAW process • High-quality weld deposit with excellent appearance • Can be used to join many types of metals over a wide thickness range • Relatively high electrode efficiency and process duty cycle • Excellent weld penetration simplifies joint design • The arc is visible and easy to use • Because of its greater tolerance for base plate contamination, flux cored welding requires less pre-cleaning than MIG • Deposition rate is up to four times greater than stick welding • The use of self-shielded electrodes eliminates the need for flux handling or gas apparatus and is more tolerant of windy conditions present in outdoor construction than gas-shielded processes.

Limitations of FCAW process • Presently limited to welding ferrous metals and nickel-based alloys • Process produces a slag covering that must be removed • Flux-cored welding electrode wire is more expensive on a weight basis than solid electrode wires, except for some high alloy steels • Equipment is more expensive and complex than required for stick welding; April 2014 n OEM Update n 30

however, increased productivity usually compensates for this • In general, more fume is generated than with MIG welding.

Acceptance of FCAW in construction industries Advancements in technology have played an important role in evolving FCAW into a viable, relevant process option for structural steel fabricators. At one time lugging around a power source with a wire feeder was not portable or practical. But today they are more portable and easier to use than ever. Using the right equipment for FCAW is critical to ensure that the process is successful. Years ago when FCAW started taking a foothold in structural applications, contractors did not have equipment designed for that process, so they would simply hook up a wire feeder to the power source they had—mainly constant current (CC) machines set up for SMAW. That was OK and it did the job, but if you want high strength joint with more emphasis on the toughness of the weld, using the right equipment is a major factor. There’s a big difference if you use a true wire feed power source like a CV (constant voltage) machine. Even with a voltage-sensing wire feeder, a CC power source does not yield consistent results. Technology advancements have gone beyond power sources. Lightweight guns for selfshielded FCAW help prevent user fatigue. Some guns also are designed specifically to extract smoke and fume, while others come equipped with a trigger-hold capability so welders don’t have to continuously press down the trigger while making a weld pass. Volt-sense wire feeders employ a single weld cable to connect to the power source and can accommodate a variety of cored-wire diameters. On average, only 10 per cent of a welder’s time is spent actually welding when using SMAW. FCAW, on the other hand, boasts a 60 per cent welder arc on time. Flux-cored wire is being developed and manufactured to achieve mechanical and weld properties required by a particular industry, such as structural steel. Both gas-shielded and self-shielded wires are engineered to provide weld stability, which helps the welder meet requirements. If a weld has to meet a seismic code or a critical weld code, manufacturers are developing wire specifically for that industry.

Honestly, that’s not happening as much with SMAW electrodes. The development of flux-cored wires — both gas-shielded and self-shielded — has been driven by industry wanting to use those wires. That’s been pulling ahead of SMAW for a while now. Hard facing by flux core arc welding is a surfacing operation to extend the service life of industrial components, preventively on new components or as a part of maintenance program. Productivity, performance and quality criteria are becoming more and more stringent and require newly developed complex materials to meet service requirement during maintenance program as part of surfacing of construction machineries. Shortages of raw materials, economy of man, machine and material etc. are leading causes for development of sophisticated alloy system using non-conventional advance material technology like composite materials, nano crystal materials etc. in hard facing welding. These alloys are processed as filler metal in form of flux core wire consumables and welded with FCAW process to meet extra ordinary service requirements in field.

Trends in hard facing Hard facing is applied in cases where the surface of part is being subject to wear (abrasion, erosion, gouging), corrosion or heat. For example crushing, conveying, mixing and separating in mining, steel and iron industry, cement industry, power plants, chemical industry, over ground and underground working etc. The objective of hard facing is to surface a layer on to the base body which is most beneficially resisting to the wear causing mineral. Layers of 2 mm to 200 mm thickness can be produced using different welding processes to develop surfacing layer over base body. For this purpose, SMAW using stick electrode or tubular electrode is quite popular for small job for repair or if welding position is difficult to access. Low productivity is the major disadvantage of this process. FCAW with self-shielded wire type is popular choice for surfacing on the job or to produce prefabricated hard faced plate called as wear plate. These plates are made of brittle metal carbides surrounded by ductile matrix on mild steel base plate using controlled automatic FCAW process followed by plasma cutting and forming to required

Expert Column shape and size. These plates can be used in construction parts such as hoppers, chutes, screens, tubes, fans, separators etc.

EWAC contributions EWAC Alloys Ltd. is a wholly owned subsidiary of Larsen & Toubro Ltd. For more than 50 years, EWAC Alloys is in field of preventive maintenance and repair of machinery, using own developed welding consumables which are used in construction industries, i.e. flux-cored continuous wires and wire feeders, gas brazing rods etc.

Type of Components

Type of Wear

Product Features

Bucket, shovels

Abrasion and erosion

Chrome carbide system, hardness above 55 HRc

Hammers, wobblers, excavators, sprockets

Metal to metal adhesive, Work harden alloys, i.e. Mn steel with impact and abrasion good wear resistance

Impellers, feed screw

Abrasion and erosion

Cr-C-Nb system with crack free deposits and low co-efficient of friction

Sinter star breaker, tip casting, augers and clinker grinders

High temp erosion and impact

Presence of refractory carbides of CrMo-V in FE-Cr-C eutectic matrix

Track rollers, crusher hammer, sprocket wheel, conveyor rolls

Impact and abrasion

Products with excellent resistance to impact, galling and scoring. High work hardening rate without deformation

Under carriage parts

Abrasion and impact

Product with high resistance to impact and having capability of multi pass built-up

Shovel teeth, crusher roll hammers, agitator shaft

High impact and compression

Excellent work hardening properties with high impact resistance, corrosion and thermal shock

EWAC products

Fig 2: Straight bead wear plate and E-wave bead wear plate

EWAC alloys manufactures widest range of electrodes, flux core wire and wear plates in terms of coating alloys, wear factor, hardness etc. From simple chromium carbide rich overlay to sophisticated refractory complex carbides the products are manufactured to meet application demands with reference to temperatures and other service conditions. Unique features of these products include cutting-edge manufacturing technology, precise control on raw material, ensuring consistent quality, uniform microstructure

with optimised matrix to carbides ratio, special alloys to meet cost to performance requirements etc. EWAC manufactures wear plates with several types of weld-bead patterns like straight bead, E-wave beads etc. (Refer Fig 2) depending on application requirements. The wave type of weld-bead patterns offer several benefits with reference to wear properties and service life. For example, conventional straight bead wear plates when exposed to extra fine erodent can suffer from

Expert Column New technologies EWAC’s endure has been to introduce new technologies so as to offer cost-economic solutions. Some of the technology-based products and services which are under considerations are. Iron ore feeding chute for sinter preparation

Nano technology-based products Vibrating chute of shot blasting unit

Loader bucket

Nano-based technology is rapidly emerging almost in all fields of science and technology. Application of Nano technology in welding has its own challenges. New types of alloy system are being designed and develop to form Nano size structure as especially for hard facing services which demonstrate extra ordinary properties. Other developments include an advance surface engineering technique, using laser cladding, high performance W-C coated plates, components with tungsten carbide tipping.

Conclusions

Down corner Bucket

Though the SMAW using conventional fluxcoated electrode enjoy its own benefits of convenience of operation and capital cost effectiveness. In the recent past, both flux core and metal cored wires are gaining more popularity in view of large increase in productivity, good weldability and high-weld quality.

Wear cover

The recent study shows that labour study is biggest cost in welding. Due to the possibility of automation, high deposition rate and efficiency, use of flux core wires greatly eliminate much of the direct labour cost associated with SMAW. Loader bucket

Impeller

major linear wear that cause pre mature failure. In case of E-wave plates, overlay weld beads are in a weld pattern with specified directional changes. This ensures superior wear resistance.

EWAC product and services to construction industries

and tear of components due to abrasion, erosion, temperature, corrosion etc. These consumables are available in form of stick electrodes or FCAW wires were the deposition requirements are high. Following table highlights some of the components used in this equipment and type of wear taking place.

Construction industry employs different types of earth-moving equipment for faster execution of projects. Due to their continuous usage, there is heavy wear and tear taking place on several parts which will end up with frequent breakdowns and repairs if not attended at regular intervals. Based on service requirements, special applications engineering welding consumable are introduce to combat such a sever wear

These are some of the examples where in the service life of these components is increased by specially developed surfacing alloys. The consumables are in form of stick electrodes or continue wires or value-added “ready to use” products like wear plate and wear parts. EWAC R&D centre keeps track of customer requirements and introduces innovative value-engineered products.

April 2014 n OEM Update n 32

The ever-increasing demand for highperformance, cost-effective solutions has led to introduction of new consumables based on Nano technology, advanced surfacing technique like LASER, HVOF etc. These emerging technologies not only provide improved service life but can give overall cost-effective solutions in reducing down time increase productivity etc. n

Authored by—

Dr P Siva, AGM R&D, EWAC Alloys, Ankleshwar

V.G. Hippargi, Head R&D, EWAC Alloys, Ankleshwar

Welding

SigmaWeld: saving energy, increasing productivity Today more and more states are looking for ways and means to increase their energy availability by saving energy regulates the DC to give excellent welding characteristics along with an efficiency of over 85 per cent. Performance tests by independent consultants consistently confirm that replacing an old power source with an energy-efficient inverter provides a proven return on investment.

Quality of power: power factor Efficiency is only part of the savings equation. Equipment’s power factor also affects one’s energy usage. Power factor is defined as the ratio of real (working) power to apparent (total) power. In a purely resistive circuit, voltage and current waveforms are in phase, and the ratio of real power to apparent power is near to, or equal to one. In circuits with inductors and capacitors, the amp and voltage waveforms are out of phase, and not all of the power is available to do useful work; some of it is returned to the source. Although the power company charges for the apparent power, people are only receiving the benefits of the real power.

f India’s per capita (presently 40 kg) steel consumption is at par with Japan (944 kg), China (400 kg) or USA (330 kg), India would consume nearly 4,500 MW (3 per cent of Indian grid) from national grid for arcwelding process.

rates, decrease training time, and reduce weld defects and rework time. The inverterbased power sources can payback their costs within a year or so based on utility only by virtue of saving through energy and reduced rework.

“Chalta hai, chalne do” is a common practice. Unfortunately, it can lead anyone losing his or her money today. The good old rugged welding transformers and rectifiers may have stood the test of time. However, with the rising energy costs, these equipment can be termed as energy guzzlers when compared to today’s inverter-based welding equipment and the advantages it offers.

Why does the inverter consume less power than traditional equipment?

Inverter-based power sources provide many benefits that can help increase deposition

However, the welding inverter technology converts the incoming AC to DC and then

April 2014 n OEM Update n 34

A high (close to unity) power factor will not only decrease energy usage, but increase you system capacity. Today’s leading inverters, such as SigmaWeld Welding power sources, offer power factors of 0.95.

Traditional welding equipment were based on transformer/rectifier technology which reduces the incoming AC voltage to weldable voltage levels via a transformer. This cannot operate at more than 65 to 70 per cent efficiency. Also, the efficiency varies across different current levels.

Continued to 36

K Series

Base 601

FOR COMPLETE RANGE KINDLY CONTACT US OR VISIT OUR WEBSITE ALL PRODUCTS ABOVE ARE CERTIFIED

499 Haveli Haider Kuli, Chandni Chowk, Delhi 110 006 Ph: 011-6528 8045 / 4308 0688 | Fax: 011-2394 4588 | Mobile: 098101 00911 E-mail: sales@metalarc.in | URL: http://www.metalarc.in

Welding Continued from 34 f

Today state electricity boards have bonus clauses for power factors of over 0.92 and penalties for poor power factors (typically below 0.9)

More for less For standard arc-welding process, the following equipment and connected loads are mentioned below:

Inverters, on the other hand, are much better suited to managing primary power fluctuations and better suited to handling a variety of power input. SigmaWeld welding inverters can keep welding output constant even if input power varies by +/- 15 per cent. This helps ensure that weld output remains consistent, improving weld quality.

Type of equipment

Transformer 400 amps

Rectifier 400 amps

SigmaWeld inverter 400 amps

KVA rating

27 KVA

18 KVA

13 KVA

Weight/machine

115 Kg

122 Kg

35 Kg

So in the same facility where 20 Welding transformers or rectifiers are being used, more than 40 welding inverters can be safely installed without changing the incoming load wiring or applying for additional connected load (power). This helps grow faster at lower costs. When working on project sites mobility of equipment does not require additional facilities like hydra, cranes etc., welding inverters can be easily portable from one location to another. Also on the same genset, more number of welding inverters can be used as compared to transformers or rectifiers.

Consistent performance fluctuations

under

power

Traditional power sources are tied directly to the input power, which means that a spike or dip in the power supply (such as when a large motor starts) can directly affect weld quality. This can lead to costly weld defects, which may need to be reworked, or cause the part to be scrapped costing time and money, which could better be spent elsewhere.

Better quality SigmaWeld inverters also provide other advantages. Welders enjoy welding with them. The consistent arc starts, smooth and stable arc and improved puddle control make welding easier and often lead to better bead quality. With micro controlled-based systems, it is easily possible to incorporate better control features which help reduce dependency on skilled manpower. This allows the operator to concentrate on welding technique. With a welder shortage that is only expected to grow in coming years, features such as anti-stick and in-built hot start have shown to make it easier to train non-welders to produce quality welds.

Energy audits at works SigmaWeld has conducted energy audits at various plants across India. It is found that an average of 30-60 per cent energy savings is possible by converting to SigmaWeld welding inverters from traditional thyristors or transformers.

As per the trials, it was shown that if the arcing time per day is assumed at 10 hours and 2 hours of idle time, SigmaWeld welding inverters save almost 35 units of energy per machine per day. This results in an average of 300 (working days) x 35 (units saved) = 10,500 units of energy annually. At the current energy cost per unit, this can save up to Rs 73,500 per machine per year. These trials were conducted vis-a-vis the traditional machines at their works. Similar trials done with SigmaWeld SAW 1,000 Amps welding inverter the customer has saved close to Rs 5,00,000 annually, thanks to their continual production needs. SigmaWeld can also arrange for demonstration and energy audits at clientsâ&#x20AC;&#x2122; works. SigmaWeld welding inverters operate so efficiently that they easily create payback within 1-3 years. They produce high-quality weld beads consistently, reduce rework and are light enough to move around with great ease. Electronics Devices Worldwide Pvt. Ltd. is a leading manufacturer of inverter-based machinery since 1974. The company is a brand leader in induction cap sealing, induction heating machines, die-electric preheaters, SigmaWeld welding inverters for arc, TIG, MIG, saw and welding automation solutions. SigmaWeld welding inverters are 100 per cent indigenously designed, developed and manufactured by its own R&D team. Even PCBs are developed, designed and manufactured in-house. This ensures that SigmaWeld is able to provide prompt aftersales service as well as immediate supply of spares including PCBs. In fact, SigmaWeld is able to provide customisation. Continuing with the energy-saving power sources, SigmaWeld is happy to launch its SigmaTherm induction heater for welding preheating and post weld heat treatment with specially designed PLC interface for P91, P22 and other materials. It comes complete with temperature programming, temperature logging and audio/visual alarms. n Authored byâ&#x20AC;&#x201D; Nimesh Chinoy, Marketing Director, SigmaWeld

Visit SigmaWeld at Weld India 2014 (Booth No G12 A, Hall No 11) from April 10-12, 2014. April 2014 n OEM Update n 36

Environ: leading with in-house oxygen transfer testing & hydraulic testing facility

nviron Engineering Company, Vadodara, claims to be the only manufacturer in India, who has got Oxygen Transfer Testing Facility, as per American standards and wrinkler’s procedure for aerators upto 150hp ratings. Environ has tested the aerators and got the results as follows: • Aurobindo Pharma Ltd., Vizag for 100HP 4 nos. on Sept 20, 2002 and achieved 2.24 kg of O2/HP/HR • Reliance, Hazira for 50HP on Sept 9, 2004 and achieved 1.6 kg of O2/HP/HR • Cheminor Drugs Ltd., Hyderabad for 30HP on July 18, 2000 and achieved 2.82 kg of O2/HP/HR • Pattancheru Enviro Tech Ltd., Pattancheru (APIDC) for 30HP aerator on Dec 17, 2004 and achieved 1.91 kg of O2/HP/HR • Dombivili Better Environment, Dombivili (CETP), MIDC for 40HP aerator on Feb 7, 2005 and achieved 1.98 kg of O2/HP/ HR • Deonar Slaughter House, Deonar for 30HP aerator on Aug 28, 2003 • Torrent Pharmaceuticals Ltd., Indrad (Ahmedabad) for 30HP aerator on Dec 13, 2006 and achieved 1.96 kg of O2/HP/HR • Kodinar Sugar Factory for their order of 4 nos. 30HP aerators • Hindustan Newsprint Ltd., Kottayam Dist. for 25HP aerator on Dec 9, 2004 and achieved 2.40 kg of O2/HP/HR • Tamilnadu Petro Products, Chennai for 25HP aerator on Feb 16, 1999 and achieved 2.20 kg of O2/HP/HR • South India Viscose (SIV Inds.), Coimbatore for their order of 10 nos. 20HP aerator on Aug 18, 1994 and achieved 1.72 kg of O2/HP/HR • Tamilnadu Petro Products, Chennai for their order of 20 nos. 10HP aerators on Nov 15, 1997 and achieved 1.70 kg of O2/ HP/HR oxygen transfer • Tamilnadu Petro Products, Chennai for 10HP aerator with 3 per cent salinity in effluent and achieved 1.03 kg of O2/HP/HR • Deonar Slaughter House, Deonar for 10HP aerator on July 01, 2003 • Gujarat Insecticides Ltd., Ankleshwar for order of 5 nos. 5HP aerators on Aug 02, 1999 and achieved 1.82 kg of O2/HP/HR • Vapi CETP for 40HP aerator on May 20, 2009. n

Pumps & Valves

Grundfos S-tube impeller: ready for the future Grundfos offers a solution to all these issues in the form of the S-tube impeller. The S-tube impeller is a tube-shaped impeller placed in a pump housing that matches the smooth tube shape through the entire pump with no obstructions or dead zones through the hydraulic. The simplicity of the S-tube impeller eliminates the need for advanced and costly add-on assemblies, which are designed to cut, shred or treat the wastewater as it flows through the pump.

raditionally, wastewater pump owners have faced a trade-off between larger free passage and high hydraulic efficiency. Several attempts have been made to increase the reliability level of wastewater pumps. Various kinds of impellers have been developed over the years, such as vortex, semi-open to single- and multi-channel impellers, and other more sophisticated creations. In addition to this, the very nature of wastewater is challenging, with dry solids content varying over time. Water use has not remained static either.

With the S-tube impeller, the efficiency is higher compared to other wastewater impellers as there are no edges, dead zones or cutting functions that get worn over time. Besides, the S-tube impeller features an innovative and patented labyrinth and sealing system for years of trouble-free operation. The S-tube impeller offers the highest hydraulic efficiency and best-in-class nonclogging capabilities for optimum reliability and lowest life cycle costs. The S-tube impeller and the new tube design through the pump provide many solutions. They are: â&#x20AC;˘ Efficiency: World-class hydraulic

efficiency up to 84 per cent without compromising free passage. â&#x20AC;˘ Free passage: Spherical free passage up to 160 mm, meaning better solids handling and greater non-clogging capabilities. â&#x20AC;˘ Simplicity: A design as simple and robust as a tube results in longer lifetime and lower maintenance costs The difficulties in designing high-efficiency impellers have traditionally been challenges with sealing against backflow, vibrations, abrasive wear and clogging. Interestingly, when Grundfos tested the S-tube in many wastewater installations across the world prior to its release, the company observed that, customers experienced substantially lower noise and vibration levels, reduced maintenance, and far better non-clogging capabilities than ever experienced previously. The S-Tube impeller is compatible with SE and SL ranges of pumps by Grundfos. The SL pump is designed for the transfer of drainage and surface water, domestic, municipal and industrial wastewater, and process water. n

KHD Valves: four-decade companion for industrial valves K

HD Valves Automation Pvt. Ltd. has been manufacturing industrial valves for the past four decades. Each and every valve passes through stringent quality control tests at every stage of production. Each valve is made perfect in all respects. Each valve is tested on in-house state-ofthe-art test bed as per the latest Indian BS and ASA standard for hydraulic and pneumatic testing. Standardisation of valves components manufacturing ensures easy inter-changeability; hence, maintenance becomes most easy. KHD Valves has manufacturing of

also experience in precision industrial

April 2014 n OEM Update n 38

valves and built-up enviable position for two decades in terms of quality and reliability demanded by its clients across the process industries and other vital industrial units. The company has necessary infrastructure of manufacturing testing, design and drawing. Ball valve

Plug valve

Sight glass

Butterfly valve

To keep pace with the fast changing world, KHD Vales has computerised most of its activities from designing to marketing. It has real appetite to design and develop new types of valves or tailor-made designs for customers. KHD Valves has been standardised for all critical services by renowned establishments. n

Suraj: shining name in producing stainless steel seamless & welded pipes

uraj Ltd., an ISO-9001, 14001, BS OHSAS 18001 certified company, is a manufacturer and exporter of stainless steel seamless and welded pipes, tubes and ‘u’ tubes and large diameter welded pipes in various sizes, grades and specifications as per customers’ requirement. The company has strong presence in global market, serving more than 70 countries including EU, Gulf, South East, US and Latin America. • Materials: All austenitic, ferritic, duplex and super duplex stainless steel • Specification: As per ASTM, ASME, DIN, NFA, JIS standard • Size Range: Welded 6.0 mm OD – 1016 mm OD Seamless 6.0 mm OD – 323.9 mm OD • Thickness: Welded 0.6 mm – 25 mm Seamless 0.8 mm – 25 mm • Length: Up to 30 metre long • Specialisation: Heat exchangers, heating elements, surface condensers, evaporators, digestors, instrumentation tubing and fluid piping • Application: Refinery, petro-chemical, food, pharma, fertiliser, oil and gas, breweries, sugar, ship building. Suraj also holds certificates for quality in accordance with AD2000 MERKBLATT W0 and pressure equipment directives [PED] 97/23/EC from TUV Nord and offer material under all national and international third party inspection. The company also has its own lab to examine various tests such as hydro test, eddy current, PMI, IGC, UT, RT, spectro analysis, mechanical properties and many others as per customer requirements. n Contact: Suraj Limited Suraj House, Opp. Usmanpura Garden, Ashram Road, Ahmedabad – 380 014, Gujarat Tel: +91-79-2754 0720/21

Pumps & Valves

Alfa Laval’s new tantalum range to minimise lifecycle costs for heat exchangers benefits of lower capital cost, long lifetime and minimal maintenance requirements results in significantly lower total cost of ownership compared to heat exchangers made of high-grade alloys, graphite, silicon carbide or glass.

Unique surface treatment

lfa Laval is launching a new range of tantalum heat exchangers that offer exceptionally high corrosion resistance of a solid tantalum heat exchanger, but at a much lower investment cost. The combined

Tantalum is one of the most corrosionresistant metals, but it’s also very costly, making solid tantalum heat exchangers extremely expensive. The new heat exchangers are made of stainless steel and have undergone a unique treatment where a thin layer of tantalum is metallurgically bonded to all surfaces exposed to corrosive media. The result is maximum corrosion resistance and mechanical stability at a low investment cost, making the technology affordable to a wide range of applications.

Designed for the toughest conditions The

new

tantalum

range

has

been

specifically developed for use with hot, highly corrosive liquids. The tantalum surface allows these heat exchangers to be used with most corrosive media at temperatures up to 225 C. Unlike many high-grade alloys, they can be used with mixed media and at variable concentrations.

Minimal maintenance costs The high chemical resistance and robust design minimises service needs. The only required maintenance is a cleaning-inplace procedure if the heat exchanger is operating in a fouling duty. The highly turbulent flow helps reduce fouling and makes cleaning-in-place procedures more effective. The steel core gives Alfa Laval tantalum heat exchangers high mechanical stability. The robust design gives them much greater resistance to thermal shock than glass, silicon carbide and graphite heat exchangers. n

ABEL compact membrane pumps

The main features of CM pumps

BEL Pumps India develops and manufactures reciprocating positive displacement pumps for varying flow rates and pump pressures, specialising in diaphragm pumps. Depending on the design, they are suitable for abrasive, aggressive and even shear-sensitive media. The company is recognised around the world as one of the technological leaders in mechanical diaphragm pumps from the past 65 years with high reliability and low maintenance cost. ABEL CM piston membrane pumps are single- or double-action specialised pumps that are used for difficult media. They are highly resistant to wear, even when used at high pressure over extended period of time. Their true double-membrane technology offers a high degree of safety. When used as a pump for feeding filter presses, the rugged, automatic flow rate control (which does not use complex electronics) is another impressive feature that makes even more reliable. April 2014 n OEM Update n 40

Operational reliability through double membrane technology, capacity up to 215 cubic m/h and create pressure up to 6.4 MPa (930 psi). Its tested design, optimal controllability, long life, serviceability are the other special features and advantages.

Advantages of ABEL CM ABEL CM piston membrane pumps enable the transfer of highly abrasive, even grainy suspensions by using high-strength special membranes and ball valves, which prevent the medium being pumped from coming into contact with the piston and other mechanical control elements of the pumps.

ABEL CM pumps: specialists for difficult media • For sludge transfer • Feeding filter presses, rotary kilns, or spray driers • Raw sewage transfer • Transfer of abrasive, corrosive, acidic, alkaline, pigmented, viscous and grainy media.

The use of big pulsation dampeners dependably avoids high pulsation and therefore the discontinuous discharge of the slurry over the entire pressure range. A frequency controlled drive allows exact flow adjustment in dependence upon the nozzle wear rate and thus a pressure control and an adaptation of the handling of various slip quantities to different granulates. n

Pumps & Valves

Caliberâ&#x20AC;&#x2122;s appreciated butterfly and wafer check valves hard faced with 13 per cent CR steel, flexible and wedge of WCB with 13 per cent CR steel hard facing. The stem is of 13 per cent CR steel and yoke bush of alloy iron. The body bonnet gasket is SS 304 spiral wound and the stem packing is of laminated flexible graphite. Butterfly valve

Butterfly valve Caliber offers a range of cast-steel gate valves outside screwed yoke type with bolted bonnet and flanged end connections for on/ off services. These valves are suitable for practically all non-aggressive media. These valves are manufactured as per standards like BS 1414 /API 600 and API 6D. They are tested as per standards BS 6755/API 598. They are rated for Class 150 services and flanged and drilled to ANSI B16.5 Class 150. These valves are available from 40 mm to 250 mm NB. The body and bonnet are carbon steel to ASTM A216 GR WCB, seat rings carbon steel

Gate valves are used in practically all applications involving steam, hot water, compressed air, ammonia, CO2, edible oils, petroleum products and scores of other general applications.

Wafer check valve Caliber offers a range of strainers to be used in the pipeline for the safety of the pipeline and connected equipment. They are offered in the â&#x20AC;&#x2DC;Yâ&#x20AC;&#x2122; type to minimise the pressure drop across the strainer. They come with flanged ends as per DIN ND 40/ANSI B 16.5 Class 150. These strainers are available from 25 mm to 200 mm NB, and we can offer these valves with IBR certificate in Form-III C also. The body and the cover plate are of ASTM

A 216 GR WCB and carbon steel respectively, and optimum sized stainless steel (304) mesh is provided to trap all the foreign matter. High tensile fasteners are provided. In spite of all Wafer check valve the precautions, there is always a possibility if some unwanted foreign matters present in the lines. These may damage the pipeline and the connected valves and other hardware. There is also possibility of the foreign matter getting between the working parts of any valve and making them unusable either temporarily or permanently. These strainers prevent the similar situations and avoid costly downtime and damage to the equipment. n

Die & Mould

Special refractory materials to withstand at high temperature The refractory materials should be able to withstand at high temperature/ sudden changes of temperature, load at service conditions

efractory concretes are by definition materials which are resistant to high temperatures, mechanical stress, and thermal stress, chemical and abrasive attack. They are designed for specific applications predominately in the metal industry, but are also used extensively in the chemical, cement and glass industries. Refractory concretes rely on a complicated mix of aggregate and binder, the most common binder being high alumina cement (HAC). Aggregates used will vary depending on the intended application. Refractories come in two general types: preformed and monolithic. Preformed includes bricks and large-scale monoliths. Monolithic are generally described as gun mixes and castables used as linings and coatings normally fired in-situ.

Role of refractory Refractory materials have a crucial impact on the cost and quality of steel products. The diversification on steel products and their cleanliness requirement in recent years have increased the demand for high quality refractory. Steelmaking requires high temperatures of the order of 1,600 C. In addition steelmaking handles high temperature phases like molten steel, slag and hot gases. These phases are chemically reactive; refractory materials are required to produces steels. High quality refractory April 2014 n OEM Update n 42

at a cheaper cost is the main requirement because cost of refractory adds into the cost of product.

Why it required? To minimise heat losses from the reaction chamber to allow thermal energy dependent conversion of chemically reactive reactants into products because metallic vessels are not suitable.

Refractory requirements The refractory materials should be able to withstand at high temperature/sudden changes of temperature, load at service conditions.

Important properties of refractories Melting point: Pure substances melt sharply at a definite temperature. Most refractory materials consist of high melting particles bonded together. At high temperature, glass fuses and as the temperature rises, the resulting slag increases in quantity by partial solution of the refractory particles. The temperature at which this action results in failure of a test pyramid (cone) to support its own weight is called, for convenience, the melting point of the refractory. Table 5.4 shows the melting point of some pure compounds used as refractories.

Platen of Testing Machine

Spherical Seat Center of Spherical Surface

Spherical Bearing Block Bedding Material (where required) Test Specimen Bedding Material

Porosity The apparent porosity is a measure of the volume of the open pores into which a liquid can penetrate as a percentage of the total volume. This is an important property in cases where the refractory is in contact with molten charge and slags. A low apparent porosity is desirable as it would prevent easy penetration of the

Die & Mould does not appear to be important from that point of view.

refractory size, and continuity of pores will have important influences on refractory behaviour. A large number of small pores is generally preferable to an equivalent number of large pores. Bulk density: ASTM C-134 using cubes 2 x 2 x 2 inches Bulk density (BD) can be defined as the ratio of the mass of the refractory specimen to its bulk volume (which includes the volume of the pore spaces). Bulk density gives an indication of the porosity of the refractory substance; low B.D. indicates high porosity and likewise low strength of the material and vice versa. A higher value of bulk density of a given refractory indicates enhanced volume

stability, heat capacity and resistance to slag penetration. BD is expressed either in pounds per cubic foot (lb/ft3) or kilograms per cubic meter (kg/m3). Cold crushing strength ASTM C-133 using cubes 2 x 2 x 2 inches This test helps in determining the strength of a brick. It tells us how much load that refractory can bear in cold conditions. The concept of testing CCS of a refractory material has perhaps, come from metallurgy. This is because it is rather rare for any refractory brick that it would fail simply due to load on it in cold condition. Therefore, the determination of cold crushing strength

Abrasion test ASTM C-704 using plates 4.5 x 4.5 x 1 Abrasion test or abrasion resistance test refers to the ability of refractory test specimens to resist the surface wear caused by the mechanical action of moving solids with high speed at elevated or room temperatures. This test determines the suitability of test items to be used in abrasive environments. The moving solid is the abrading material, which is either white fused alumina or black silicon carbide with specified grain size and chemical composition. This test helps in determining the relative abrasion resistance of refractory bricks at room temperature and can also be applied to castable refractories. The test result is calculated in terms of the loss in volume of the test items. This test method measures the volume of material in cubic centimetres abraded from flat surface at a right angle to a nozzle through which 1,000 g of size-graded silicon carbide grain is blasted by air at 65 psi in 450 seconds. n (Source: L&T)

Die & Mould

Fibro gas springs for mould making For all applications where lift movements are required parallel to mould opening, the tool designer has to resort to additional components. Normally, these are diagonal load pillars, spiral compression springs or latch locks. Fibro is now offering a user-friendly and low-cost alternative to be able to achieve additional lift movements plate to be moved so that the support plate is shifted by a certain distance. The use of Fibro Mould Line gas springs provides the same functions as a latch lock in conjunction with standardised norm elements for mould making. The possibility of pressure monitoring and force control proves to be very advantageous in this case. This makes it possible – contrary to a latch lock, for example – to diagnose an imminent malfunction in advance. During the procurement of the necessary spare parts, production can be continued without any changes. Depending on the installation, the replacement of the FML gas spring on the injection moulding die is possible. An additional aspect is the naturally given overload protection. Should a component, which is to be moved, be jammed – for example a stripper or an intermediate plate in a 3-plate tool – the latch lock can pull rigidly during the opening of the tool that is equipped with one until a component breaks.

FML gas spring (FIBRO Mould Line) The gas spring was developed especially for mould making and is characterised by its high force, its small size, a long service life of at least 1,000,000 strokes and a constant operating temperature of 120 C. The FML gas springs are approved as per the European Pressure Equipment Directive 97/23/EG (14th GSGV ordinance on pressure vessels).

be moved parallel to the mould opening in the separation level, the FML gas spring can be used. In the process, for example, this gas spring is placed behind the intermediate Fibro mould line gasdruckfeder

Depending on the spring type, the Fibro Mould Line gas springs naturally come with safety features (safer choice) such as safety piston rods as well as excess pressure and overstroke protection. For all applications where e.g. another intermediate plate and/or a slide unit is to April 2014 n OEM Update n 44

Unterverteiler Installation principle

Angußhaltekralle

With the FML gas spring, this is different. • Once the maximum force of the FML gas spring is exceeded, it remains in its position. • No component will be damaged. • After the removal of the jam, production can be resumed without delay. By the simple installation of the Fibro Mould Line gas spring and the elimination of the lateral machining for the fastening of latch locks on the mould, 60 – 70 per cent of the costs, compared to the use of latch locks, can be saved. n Contact: FIBRO GmbH Business Area Standard Parts P.O. Box 1120 DE-74851 Haßmersheim Phone 0 62 66-73-0 Fax 0 62 66-73-237 Email: info@fibro.de Website: www.fibro.com

dry-tech: ®

dry-tech® [ˈdraɪ]-[tekˈ] The lubricant-free, low-cost way to swivel, rotate, oscillate, move and achieve linear motion ... construct sustainably with dry-running polymer bearing solutions from igus . ®

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igus (India) Pvt. Ltd. 36/1, Sy. No. 17/3 Euro School Road Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura, Bangalore - 560048, Karnataka, India Phone +91-80-45127800 Fax +91-80-45127802 info@igus.in plastics for longer life ®

Case Study

Renishaw QC20-W ballbar system is a preventative maintenance tool for new and installed machines. Aquasub is using QC20-W ballbar to reduce maintenance costs, increase capacity and reduce scrappage

ith an increasing emphasis on Total Productive Maintenance (TPM), Coimbatore-based Aquasub Engineering, part of the Aqua Group, one of the largest pump manufacturing companies in Asia, started looking for solutions and on discovering that Renishaw had launched a new wireless QC20-W ballbar system, decided to get a demonstration. The scope and precision of data given on various machine errors with a QC20-W test amazed them. With up to 18 separate geometric, plug and dynamic errors diagnosed, this gives far more reliable diagnosis than their existing practices. The demonstration carried out on Aquasub’s machines proved that QC20-W ballbar was an essential health check tool for their TPM programme. April 2014 n OEM Update n 46

Pump maker extends life of its machine tools, reduces downtime by 10% Multiple benefits of QC20-W use To reduce the necessity of purchasing new machines, Aquasub want to maintain their 200 existing machines, many of which are 25 years old. K Senthil Kumar, General Manager, explained, “We would obviously prefer to maintain our old machines and return them to their original condition rather than buying new machines. This a more cost effective option than investing in new machines.” He added, “If we extend the life of a machine, the improved performance also reduces machine downtime hours, i.e. keeping our machines more efficient and in good condition, they are rarely down. In fact we have seen a 10 per cent reduction in machine downtime. We strive to be more pro-active and have detailed information on each machine so that the operator is aware

of the smallest technical issues. In order to extend the life of the machine we are also carrying out regular ongoing tests with QC20-W ballbar. We are now able to carry out 3 plane testing with a single set-up which has reduced our maintenance inspection time by 20 per cent.”

Aquasub AQUATEX centrifugal pump

Continued to 48

Case Study Continued from 46 f

Regular testing is the key Mr Kumar continues, “Test data from each machine is stored in the Ballbar 20 software history function. This allows us to schedule machine maintenance, and take remedial action before part quality becomes an issue. If the machines are in good condition then the component quality will have good repeatability. By incorporating QC20-W into our maintenance program we have significantly reduced scrap and faulty product.” The QC20-W is even used to test new machines after they are first installed, since damage during shipment from the machine OEM to the Aquasub factory could result in faulty components even from brand new machines.

The right tool Aqua Group has an extensive product range but all are destined for critical applications for agriculture, domestic or industrial water supply. With a capacity to produce 4,000 pumps a day, reliability of their 200 machine tools is of crucial importance to maintain deliveries. Aqua Group has a policy to continually improve its manufacturing capabilities

Aquasub reviewing QC20-W ballbar

through enhancement of knowledge, skills, technology development and continual improvement. By implementing a TPM programme they are ensuring that good quality practices are followed and identify scope for further improvement. Mr Kumar explained, “We used to base our machine performance reliability on an engineer’s word so the potential for human error was high. Now the

QC20-W ballbar provides us with overall machine diagnostics (circularity, squareness and backlash) from a single test. All the machine data is stored in Ballbar 20 software and creates a log of information about each machine’s performance that can be reviewed at the time or offline. We are no longer reliant on an engineer’s memory. The Renishaw QC20-W ballbar system is the backbone of our quality system.” n

Uninam: one-stop solution for analogue and industrial products U

ninam Industrial Marketing, an ISO 9001:2008 certified organisation, has emerged as one of the pioneers in providing complete analogue and industrial products with highly technical and committed sales personnel. Uninam is one of the leading authorised distributors and importers for industrial valves in India, serving over 500 satisfied customers all over the country. Uninam has around 2,000 products in its range in the following product range, i.e. pneumatic and electrical actuator operated valve, solenoid valve, instrumentation manifolds valves, two-way/five-way valves, fittings, flanges, boiler mountings, S.S. pipes and valves, plumbing and industrial valves, anti vibration mountings, VAC mounts/ hp hoses, rubber expansion joints and S.S. April 2014 n OEM Update n 48

bellows etc. from No 1 companies in India such as Zoloto, Amco, Fouress, ATAM, Parker Legris and Resistoflex for lifelong trouble-free service.

adequately trained by its principals of high repute, having world-wide presence and enjoying a distinct leadership position in the industry served.

Having extensive experience and catering to diverse engineering needs of the key sector such as power, oil and gas, refineries, petrochemicals, mining and metals, process chemicals, pulp and paper, pharmaceuticals, infrastructure, constructions and many more.

Uninam provides value-added engineering services to its clients. Over the past 15 years, the company has devoted itself to understand the nuance of industrial products. Today, Uninam has its presence across the industries and is serving chemical and petrochemical, power generation, oil and gas, pulp and paper, pharmaceuticals, food processing, mining, cement plants, plumbing and construction industries, steel plants, breweries, textiles plants, sewage and water works, air conditioning plants, fertilizers, dairy, paint and heavy engineering etc. n

Uninam Industrial Marketing have years of experience providing comprehensive technical solutions in industrial applications. Its endeavour is to offer advanced technological solutions in collaboration with its alliances, backed by robust service support. Its competent work force is

Speak Out

NNG: flexible, experienced navigation software for any hardware

“NNG was the first navigation developer, offering low cost and ultra low cost navigation software to the automotive industry,” says Peter Bolesza, Vice President - Eastern Europe and Emerging Markets, NNG LLC.

avigation has already experienced a strong growth over the last quarters, and it will continue to grow in 2014 and 2015. In an exclusive interview with OEM Update, Peter Bolesza shares everything about navigation industry as well as their mission — navigation for all.

NNG is one of the leading global players in navigation systems. How do you look at the journey of NNG in India? It’s been an exciting journey. The Indian navigation market is constantly changing and full of surprises. In 2010, I first travelled from Hungary to India to investigate the market and the opportunities. Since then, our business growth and the rising number of partnerships have lead us to open our Gurgaon office at the end of 2011 and launch solutions for all market segments (wireless, PND, automotive). Our strategic partnership with Ayana Navigation Solutions (ANS), in particular, has helped us to truly optimise our iGO navigation software for the Indian road system and Indian consumers. Easyto-use navigation, a local feature set and customer service are key in India. Navigation has already experienced a strong growth over the last quarters, and it will continue to grow in 2014 and 2015. NNG forecasts its main growth in the automotive aftermarket and line-fit segments.

How has been your partnership with Ayana Navigation Solutions? The cooperation between NNG and ANS is growing stronger continuously. Partners like Blaupunkt and Caska have reacted well to the fact that we have combined NNG’s global software expertise with ANS’s local market knowledge and service solutions. We’re planning to continue this cooperation and have started mapping out new markets like Middle East.

Could you brief us on ANS and NNG product range? We offer iPhone and Android smartphone solutions directly to the Indian consumers through the relevant online stores. To our local and global business partners, who act on the Indian automotive market, we offer aftermarket, dealer-fit and line-fit solutions. All in all, we’re able to offer a April 2014 n OEM Update n 50

flexible product solution, system integration, HMI, content, features and service solutions for every partner.

How big is the market for these products and what is your market share in India? It is still hard to estimate the number of navigation products and licenses for India in 2014 as no official study is available. However, NNG counts with 1,50,000 units across the automotive and PND segments. The total car sales in India for this year with onboard navigation is estimated at around 80,000-90,000. Half of that will come with factory-fit navigation; the other half installed by dealers. For the first, we expect NNG to reach a 45 per cent market share. For the latter, we expect a 40-50 per cent market share.

The Indian four-wheeler market is still dominated by small cars, what sort of navigation solutions you offer for this segment? Small and low-cost cars are exactly what NNG’s global automotive strategy is focused around. We want to enable “navigation for all!” NNG was the first navigation developer, offering low cost and ultra low cost navigation software to the automotive industry. This strategy has caused a snowball effect in the industry, forcing more and more car makers to join the movement by installing line-fit navigation into their new models. As car manufacturers have started realising that there is a consumer expectation for navigation, car buyers around the world are starting to understand that in-dash navigation is not a luxury anymore; it is affordable and brings numerous convincing advantages compared to smartphone and PND navigation. In India just like other emerging markets, we can serve the need for low-cost navigation solutions with NNG’s experienced software engine which enables a flexible product based on content, HMI and feature requirements, creating a product that fits into the price range of every car manufacturer. Our experienced engineers make the most out of every hardware without additional GPU hardware costs.

Please brief us on your expansion plans and growth strategies. NNG’s global and local growth plans are mainly focused around the automotive industry, aftermarket as well as line-fit projects. NNG

Technology is serving projects across all vehicle segments, including high end, low end, city cruisers, off-road vehicles, super sports cars and twowheeler navigation. Besides the navigation licenses that we supply to our partners, by 2015 the second-largest share of our revenue is estimated to come from online business, i.e. map and content updates through NNG’s official website. Content updates play a crucial role in keeping software solutions in the dashboard up-to date — not just for 1 or 2 years but for the entire life cycle of the car.

NNG plans to increase its market share to 70 per cent in 2014. How are you going to achieve this target? To many partners, we have already proven our capabilities: reliable and localized software, delivered on time, white-labelled, and running on the most suitable map and content package that is available on their particular market. At this point we enjoy an exceptional reputation in the industry, meaning industry players contact us based on recommendations by our partners. At the same time, we’re expanding the cooperation with existing partners. NNG is being awarded projects to cover more countries and car models.

NNG and ANS announce partnership with Blaupunkt. Can you talk more on this partnership? Since 2014, Blaupunkt has delivered its infotainment units to dealerships of different car makers with NNG’s iGO primo pre-installed. Among others, Suzuki and Nissan dealers throughout India do now offer these head units with their new vehicles. NNG has created the most suitable

software solution for this unit, including crucial features such as speed limits and NNG’s intelligent features which enable the driver to quickly react to bad traffic situations. All involved parties currently expect a long-term relationship as the initial customer and dealer feedback about the product has been extremely positive.

What sort of value addition it will make for the Indian OEMs? NNG’s navigation solution allows dealers and car makers to add a sought-after feature to their cars at a low price point. While passenger car sales have declined in 2013 and fuel prices are rising, we enable them to offer an attractive extra with their cars. Consumers demand easy to use navigation that allows them to find their destinations quickly and guides them reliably around the busy streets of India. And they demand all this at an affordable price. NNG makes it real: flexible and experienced navigation software for any kind of hardware at fast development times. n

Welding

Klinweld welding wires E

stablished in 1976, Klinweld offers best quality welding wires that are specially made for welding in all positions, in all Indian make and imported MIG/MAG/SAW welding machines with clean spatter less finish and deep penetration – continuous inline welding.

Applications • Automobile body, chassis, frames and brackets • Automobile silencers, petrol/diesel/gas tanks of all automobile, scooter, cycle spare parts and accessories • SAW Pipes, LPG Gas Cylinders, compressors, railway wagons, boilers, poles and steel towers • Steel furniture, scaffoldings and all other welding in general steel fabrication.

Quality 100 per cent fully guaranteed with test certificate and guarantee certificate and thoroughly checked before dispatch as per strict DNV ISO: 9001-2000 norms. All wires are electrolytic copper coated.

Production Total production capacity above 6,000 tons per annum. The company has dealers allover India and abroad to support the sales.

• • • • •

BHEL, Trichy L&T Ltd, Pithampur Mungi Brothers, Nasik, Pune ABB Ltd., Baroda Swaraj Mazda Ltd., Roper (Punjab)

Approvals Its welding wires are fully approved and being regularly used by many reputed companies such as: • Tata Motors Ltd., Pune • Hyundai Motors India Ltd., Chennai • Mahindai & Mahindra Ltd., Nasik • Suzlon Energy Ltd. Baroda, Gandhidham

Contact: Klinweld Wires Pvt. Ltd. Bandish Dodia (Sales and Marketing) 207, Timmy Arcade, Makwana Road, Marol, Andheri (E), Mumbai-400059 Cell: 9820134152, Tel: +91-22-28507504 klinweld@gmail.com, www.klinweld.com

Cybernetik’s robotic weld lines R

obotic weld lines now a days are becoming a standard requirement whether it is BIW line or axle weld line. Companies are ready to invest in such systems without compromising on quality. This is because of the acceptance toward new technology and services. Now, even companies are ready to pay in initial stages like feasibility study, which can be done easily through state-of-the-art 3D simulation packages and there accurate results. Cybernetik was come into picture when Bajaj Auto was producing 300 vehicles per day. Target was how it can be raised up to four folds. The company has done initial study. Bajaj Auto gave Cybernetik an opportunity and result was eye-opening in every manner. Cybernetik established complete automated man-less line of nine robots initially, with pallet return line and chassis dropping system. They were start producing more than expected, and current score is somewhere around six folds with half of man heads. This result was because April 2014 n OEM Update n 52

of continuous improvement program and incorporation of such systems and much more important was acceptance toward new technology. Later it become habitual, and people are now asking offers for robotic lines like conveyor lines. Cybernetik offered independent welding cells for spot as well as arc welding requirements. Offer includes complete end-to-end solutions which start from project feasibility to commissioning. Project feasibility and engineering are the main points which contributes major factor for seamless running of any robotic applications. Cybernetik did total engineering at every stages which includes robot selection, fixture study, material handling equipment etc. Total solution starts from design of overhead rails mounting structure to component storage trolleys. This gives tremendous satisfaction at every stage of the project in an organisation. The company is setting up entire line in its factory for internal as well

as customer trials. Its systems are completely tested in its premises before dispatch. Cybernetik has done robotic weld lines in multiples for three-wheeler and fourwheeler chassis shops. It is associated with ABB Robotics from the past 6 years, through which Cybernetik got world-class application exercises and study as an input in every sector requirements. Today, Cybernetik is offering robotic solutions with paint line for aluminium alloy members for shell building, which includes heavy duty, state-of-the-art handling facility with multiple size adaptability. n

Brand Report

igus CFRIP: cutting stripping cables time by 50% integrated into the cable prevents damaging of the stranded element when the chainflex cable needs to be stripped.

Strip 230 chainflex cables simply and safely Along with PVC control cables chainflex CF5, tearing thread in the outer jacket and the shielded version chainflex CF6, tearing thread in the inner jacket â&#x20AC;&#x201C; now the control cable families CF5, CF6, CF130 and CF140 as well as the complete multi-core motor cable families are equipped with the CFRIP thread. 230 chainflex cable types with integrated CFRIP tool are currently available. More cable series with integrated CFRIP are in development. n

he tearproof igus thread, introduced under the name of CFRIP for fast stripping of chainflex cables, is now integrated into 230 chainflex cable types. The CFRIP stripping aid has been added to all control cable series with PVC jackets and in motor cable families. Via the unique CFRIP principle, chainflex cables can be stripped quickly and safely in large lengths without damaging cores.

The CFRIP stripping cord, developed by igus, is simple and effective: Like a zipper it opens by simply pulling on the CFRIP tearing thread within the jacket to the desired length. Afterwards the appropriate cores can be taken out of the jacket with ease. With it, installers save up to 50 per cent of the usual required time for stripping. Apart from that, specific stripping tools are no longer required. The clever design of the tearing thread that is

Contact: Sreejith Menon Product Manager - Chainflex Mobile: +91-9342828642 sreejith@igus.in Igus (India) Pvt. Ltd. 36/1, Sy.No. 17/3, Euro School Road Dodda Nekkundi Indl Area - 2nd Stage Mahadevapura, Bangalore - 560048 Tele: +91-80-45127800 Fax: +91-80-45127802 www.igus.in

Abhijeet offers world-class injection and blow mould A

bhijeet Dies and Tools Pvt. Ltd. is one of the leading injection and blow mould makers in India. The ISO BVC 9000-2008 certified organisation caters to automotive, white goods and engineering industry worldwide. The company, founded 30 years back, is serving local and MNC alike in automotive sectors. Its current focus is in automotive business, comprising of 80 per cent of toolmaking business. The company makes injection moulds up to 2,000-tonne press. All its moulds are made in pre-hardened German P 20 steel and April 2014 n OEM Update n 54

designed at its design centre after careful study of customer requirements and considering his standards on moulds. The company has extensive water cooling and designed for ease of manufacturing and easy serviceability. Critical moulds are always analysed for mould-flow analysis to understand the flow of plastic in the mould. It makes soft (prototype) and black (production) moulds with equal ease and expertise.

projects where it would be supplying blow moulded part to Europe in days to come. It already supplies many moulded parts to local auto manufacturers. It has produced moulds for Ford, General Motors, HONDA, Honda Motorcycles and Scooters India, TATA, Mahindra & Mahindra, Pentair, Samsung and Bluestar, to name a few. Abhijeet Dies and Tools also supplies injection-moulded and blow-moulded parts.

Blow mould making is its other core skill. Abhijeet Dies and Tools has manufactured blow moulds up to 200-lit blow moulding machines for various automotive models. Currently, the company is working on certain

The other strength lies in mould testing area. The company has injection moulding machines up to 1,300 tonnes within the group and tie-ups with other moulders for machines up to 2,500 tonnes. n

INTEC 2014

15th Edition

INDUSTRIAL TRADE FAIR COIMBATORE

6th - 10th June 2014

CODISSIA Trade Fair Complex, Coimbatore - 641 014

2014

6 - 10 JUNE 2014 th

2014

2014 2014

INDUSTRIAL TRADE FAIR COIMBATORE 6th - 10th June 2014

Organised by

CODISSIA Trade Fair Complex, Coimbatore - 641 014

Exhibitors Profile

Machine Tools and Accessories l Hydraulics and Pneumatics Material Handling Equipments & Machinery l Foundry Equipments l Pumps & Fittings l Precision Tools, Cutting Tools, Dies & Moulds l Instrumentations Automation l Metallurgical Plant and Equipments l Industrial Electrical & Electronics l General Engineering l Machinery for Process Industry l IT Consulting & Service Providers l Fabrication Machinery & Equipments l Industrial Consumables l Factory Cleaning and Pollution Control Equipments

CODISSIA Intec Technology Centre

Platinum Supporter

Diamond Supporter

Silver Supporter

Conference Partner

The Chairman, INTEC 2014

CODISSIA G.D. Naidu Towers, Post Box No.3827 Huzur Road, Coimbatore - 641 018. INDIA Ph : 0422 - 2222396, 2222397 Fax : 0422 - 2222131 Cell : 99655 15182 E-mail : intec@codissia.com www.intec.codissia.com Online Media Partner

Stall Bookings Bookings Open

Brand Report

Han-Fast Lock in action The Han-Fast Lock boasts high assembly flexibility at high current-carrying capacity on the PCB. Applications demonstrate the performance of HARTING’s connection technology Industrial connector Han Q 4/2 in conjunction with Han-Fast Lock as high-voltage PCB connection

or PCB (Printed Circuit Boards) contacting of high-current contacts, the transition from the circuit-board contact to the PCB and the associated contact resistance represent a special challenge, specifically, because the respective connection solution impacts the circuit board layout, which necessitates an optimal solution for heat management. The longer the conductor lines, the lower the potential current-carrying capacity. The same effect occurs when several highvoltage contact points are in close proximity to each other, otherwise known as hot spots. For this reason, PCB layout designers take pains to keep conductor lines in power areas short and to place them as close as possible to the power elements such as transformers or power transistors (IGBT). The difficulty here is to minimise the amount of space taken up on the board for the connection point and create the possibility of plug-in power contacts. In the past, it was always necessary to attach an additional component to the PCB, i.e. to solder or attach it via a press-in connection.

Concentrationof temperature distribution of soldered PCB adapters

April 2014 n OEM Update n 56

Radical solution Han-Fast Lock now makes it possible to solve all of these challenges on the PCB with a single component. Processing, i.e. the crimping of the stranded wires to the contact, occurs outside the circuit board. Here, individual contacts are available for processing with a hand crimping tool, while reels are available for pro-cessing with an automatic crimping device. This plug-in connection technology meets all the demands on the connector concepts on the PCB: • High currents are applied to the circuit board • The connection points on the PCB can be freely positioned • Only one standard through contact hole is used for the connection • No additional processing steps are necessary • If necessary, the connection can be reversed. The Han-Fast Lock can employ any suitable connector to place high-voltage connections on the PCB. Here, the circuit board can be positioned in the device independently of the

Detail of connector Han Q 4/2 in conjunction with Han-Fast Lock

position of the connector. In addition, several different connectors with different connection cross-sections may be used simultaneously.

Applications There are manifold applications of Han-Fast Lock in lighting and stage equipment. The benefits of the mateable PCB connectorare realised by scenic lighting equipment for theatres and opera houses as well as by control units for lighting systems and machinery intelevision studios. In such applications, standard contact pads are located on the PCB as connection points for the three phases and the neutral conductor. Contact points can be positioned in the vicinity of transformers. Thus, the technology keeps the conductor lines short and prevents the formation of hot spots. Connections can be established quickly and reversed if service is required. n Authored by— Frank Quast, Head - Product Management Han, HARTING Technology Group, Frank.Quast@HARTING.com

Temperature distribution of Han-Fast Lock

OEM

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MART

Co2 MIG Welding Wires SAW Welding Wires For strong & spatterless welding of Automobiles Frames, Body, Chassis, Silencers, Spiral & Longitudinal Pipes Cylinders & all general Steel Fabrication.

Sales Network all over India. Manufacturers & Exporters:-

WIRES PVT. LTD.

An ISO 9001-2000 Certified Company

207, Timmy Arcade, Makwana Road, Marol, Andheri (E), Mumbai - 400 059. Tel: +91-22-2850 4848, 2850 7501, 2850 7502 Fax: +91-22-2850 7503 E-mail: klinweld@gmail.com Cell: 98201 34152 Website: www.klinweld.com

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COMMERCIAL PARTNERS AAA Industries........................................................................................ 43

EWAC Alloys Ltd.................................................................................... 27

Ace Micromatic Group............................................................................ 13

Makewell Electronic Services................................................................. 37

Ace Weld Engineers .............................................................................. 62

Mather & Platt Pumps Ltd........................................................................ 5

Associate Flexiweld Pvt Ltd.................................................................... 61

MGS Technologies................................................................................. 63

B. R. Kumar & Sons .............................................................................. 35

MP Electric & Refrigeration Pvt Ltd........................................................ 62

Chep India......................................................................................... 19-22

Omron Automation Pvt Ltd................................................................... IFC

Creative Engineers................................................................................. 25

Pushkar Engineers................................................................................. 65

Cybernetik Technologies Pvt Ltd ............................................................. 9

Quick Bird Refrigeration and AC Works................................................. 63

Dormer Tools India Pvt Ltd..................................................................... 17

Rtex Connectors..................................................................................... 60

Electra Welding Equipments.................................................................. 39

Sandvik Asia Pvt Ltd................................................................................11

Electronica India..................................................................................... 29

Sapcon Instruments Pvt Ltd................................................................... 66

Electronics Devices ............................................................................... 33

Shreeram Engineers ............................................................................. 59

Electro Steel Engineering Company...................................................... 60

Siemens Ltd............................................................................................ 3

Environ Engineering Company............................................................... 63

Suraj Ltd................................................................................................. 39

Easeweld Equipments (I) Pvt Ltd........................................................... 61

Uninam Industries Marketing Co............................................................ 61

Fibro India Standard Parts Pvt Ltd....................................................... IBC

Universal Welding Systems.................................................................... 65

Graebert India Software Pvt Ltd............................................................. 23

Valvoline Cummins Ltd.......................................................................... BC

HARTING India Pvt Ltd.......................................................................... 41

Varun Electrodes Pvt Ltd........................................................................ 37

igus India Pvt Ltd.................................................................................... 45

Vashi Electricals Pvt Ltd........................................................................... 7

Impex Engineering & Equipments Co.................................................... 64

Vermani Enterprises............................................................................... 31

KHD Valves Automation Pvt Ltd............................................................. 61

Welding Systems ................................................................................... 51

Kilndweld Wires Pvt Ltd.......................................................................... 61

Yogeshwar Engg Pvt Ltd........................................................................ 64

67 n OEM Update n April 2014

New Projects

Oil & gas exploration & extraction

Cement

Sintex Oil & Gas, a sister concern of Sintex Industries, is planning drilling of 9 exploratory wells in Block CB-ONN-2009/1 in dist. Patan, Gujarat. 3D Seismic DATA acquisition is in progress. Status: Planning Stage Location: Patan, Gujarat Contact: Sintex Oil & Gas Limited, Head Office: Kalol, Gandhinagar - 382721, Gujarat Tel: 91-2764-253000. Fax: 91-2764-253100. Email: info@sintex.co.in Website: www.sintex.in

My Home Industries is planning a Portland cement manufacturing project in dist. Jajpur, Odisha. Status: Planning Stage Location: Jajpur, Odisha Contact: My Home Industries Limited, Registered Office: 9th Floor, Block-3, My Home Hub, Madhapur, Hyderabad - 500081, Andhra Pradesh Tel: 91-40-66929696/ 66398686. Fax: 91-40-66929797. Website: www.myhomeindustries.com, www.myhomegroup.in

Non conventional energy

Automotive components

Ryatar Sahakari Sakkare Karkhane Niyamit is planning a 30 MW bagasse-based co-gen power project at Lokapur, dist. Bagalkot, Karnataka. The total land area is 200 acres, including an existing 5000 TCD sugar plant. Status: Planning Stage Location: Bagalkot, Karnataka Contact: Ryatar Sahakari Sakkare Karkhane Niyamit, Plant address: Rannanagar, Timmapur, Lokapur, Taluk Mudhol, Bagalkot - 587122, Karnataka Email: ranna_sugar@rediffmail.com

Cooper Corporation is implementing a 6 pcs/ day diesel engine manufacturing project at Additional M.I.D.C, dist. Satara, Maharashtra. Machinery has been ordered. The project is planned for completion in 2015. Status: Under Implementation Location: Satara, Maharashtra Contact: Cooper Corporation Private Limited, Registered Office: L 3, Additional M.I.D.C, Post Kodoli, Satara - 415004, Maharashtra Tel: 91-2162-240272/ 240273/ 240413/ 240702/ 240703. Fax: 91-2162-240271/ 240023. Email: contact@coopercorp.in Website: www.coopercorp.in

Metallurgical Industries

Petrochemicals

SAIL-SCL Kerala, a JV between Steel Authority of India and Government of Kerala, is implementing a 65,000 TPA steel rolling mill to produce TMT bars at Kolathara, dist. Kozhikode, Kerala. The estimated cost of the project is Rs. 650 million. Status: Under Implementation Location: Kozhikode, Kerala Contact: S A I L - S C L Kerala Limited, Plant address: Steel Nagar, P.B.No : 42 Kolathara, Kozhikode - 673655, Kerala Tel: 91-495-2483328/ 2483329/ 2483330/ 2483331/ 2483332. Fax: 91-495-2483043. Email: cs@steelcomplexkerala.com Website: www.steelcomplexkerala.com

Tide Water Oil Company (India) is planning the â&#x20AC;&#x2DC;ENEOSâ&#x20AC;&#x2122; brand lubricant oil manufacturing project in India. The company has signed an MoU with JX Nippon Oil & Energy Corporation, Japan, for setting up a 50:50 joint venture in India. Status: Announcement/Conceptual Stage Location: India Contact: Tide Water Oil Company ( India ) Limited, Registered Office: 8, Dr. Rajendra Prasad Sarani, Kolkata- 700001, West Bengal Tel: 91-33-22421086/ 22428210. Fax: 91-33-22421087. Email: tidecal@tidewaterindia.co.in Website: www.tidewaterindia.com

Textile

Ports

SRM Spinners is implementing a 12,000 spindles synthetic yarn-spinning project at Nanakpura, dist. Bhilwara, Rajasthan. Machinery has been ordered locally. Status: Under Implementation Location: Bhilwara, Rajasthan Contact: S R M Spinners Limited, Registered Office: Sukh Shanti, Sabun Marg, Bhilwara - 311001, Rajasthan Tel: 91-1482-227172. Fax: 91-1482-239400.

Gujarat Pipavav Port is planning an expansion and modernization of its port at Pipavav, dist. Amreli, Gujarat. The company has received approval from the Ministry of Environment & Forests (MoEF) Status: Planning Stage Location: Amreli, Gujarat Contact: Gujarat Pipavav Port Limited , Registered Office: Port Of Pipavav, Post Uchaiya Via Rajula, Amreli - 365560, Gujarat Tel: 91-2794-302400/ 302589. Fax: 91-2794-302413. Website: www.pipavav.com

Thermal Power generation

Ports

Pirpainti Bijlee Company (PBCPL), a JV of NHPC and Bihar State Power Generation Company (BSPGCL), is planning the 1320 (2x660) MW Pirpainti Supercritical Thermal Power Project at Pirpainti, dist. Bhagalpur, Bihar. 85% of Power generated from the project is to be absorbed by state Discoms as per Power Purchase Agreement. Status: Planning Stage Location: Bhagalpur, Bihar Contact: Pirpainti Bijlee Company Private Limited, Administrative Office: 1st Floor, Vidyut Bhawan, Bailey Road, Patna - 800001, Bihar Tel: 91-612-2236154. Fax: 91-612-2236852. Website: www.bsphcl.bih.nic.in

Kolkata Port Trust is planning to construct a new major port at Sagar Island, dist. Kolkata, West Bengal. The project has received approval from the Cabinet Committee on Economic Affairs. The project is planned for completion in 2019-20. Status: Planning Stage Location: Kolkata, West Bengal Contact: Kolkata Port Trust, Head Office: 15, Strand Road, Kolkata- 700001, West Bengal Tel: 91-33-22303451. Fax: 91-33-22304901. Website: www.kolkataporttrust.gov.in

Note: Above information is the sole property of domexinfo.in and can not be published without prior permission.

April 2014 n OEM Update n 68

Tenders nSTEEL

Company Name: Travancore Devaswom Board Tender Detail: The supply of stainless steel Kanikkavanchies. Location: Thiruvananthapuram Documentation Sale to: 22-April-2014 EMD: ` 50,000/Closing Date: 22-April-2014 Address: Office of the Executive Engineer, Estate Division, Travancore Devaswom Board, Nanthancode, Kawdiar Post, Thiruvananthapuram, Kerala -695003 Tel: 91-471-2310520 Website: www.travancoredevaswomboard.org Company Name: Chittaranjan Locomotive Works Tender Detail: Major repair work in Crane No. 7B & 7C of Bay No 3 at Steel Foundry / CLW/CRJ Location: Chittaranjan Documentation Sale from:11-March-2014 Documentation Sale to: 21-April-2014 Documentation Fees: ` 3,000/EMD: ` 54,000/Closing Date: 22-April-2014 Address: Steel Foundry, P.O. Chittaranjan, Dist. Bardhaman-713365, West Bengal Tel: 91-341-2525642 Fax: 91-341-2525582 Website: www.clw.indianrailways.gov.in Company Name: NMDC Limited Tender Detail: Ground Water Levels and Quality Monitoring in and around the project area of NMDC Integrated Steel Plant, Nagarnar, Jagadalpur, Chhattisgarh at the prescribed locations for two years / four seasons / year for the period 2014-15 to 2015-16. Location: Nagarnar, Jagadalpur, Chhattisgarh Documentation Sale from: 20-March-2014 Documentation Sale to: 21-April-2014 EMD: ` 7,500/- Closing Date: 21-April-2014 Address: 10-3-30011/A, Khanij Bhavan, Masab Tank, Hyderabad - 500028, Andhra Pradesh Tel: 91-40-23538713 Fax: 91-40-23538711 Email: jakamalakar@nmdc.co.in Website: www.nmdc.co.in

nOIL & GAS

Company Name: G A I L (India) Limited Tender Detail: E-tenders for two years AMC for Assistance in Mechanical Maintenance of Terminal, SV, IP Station, Pipeline Of DUPL, DPPL Pipeline network of GAIL Maharashtra Region. Location: Maharashtra Documentation Sale from:13-March-2014 Documentation Sale to: 22-April-2014 Closing Date: 22-April-2014 Address: 7th Floor, B Wing, Priyadarshini building, Eastern Express Highway, Sion (E), Mumbai400022Tel: 91-22-24045453 Website: www.gail.nic.in

nRAILWAY

Company Name: Southern Railway Tender Detail: Design, manufacturing, supply and erection of steel fabricated modular stacking arrangement for equipments of electric locomotives available at Electric Loco shed, Southern Railway, Erode. Location: Erode Documentation Sale from:11-March-2014 Documentation Sale to: 21-April-2014 Documentation Fees: ` 5,200/EMD: ` 113,840/Closing Date: 22-April-2014 Address: T. C. Johnson, Office of the Deputy Chief Electrical Engineer, Construction, Southern Railway, Ernakulam Junction, Ernakulam -682016, Kerala Tel: 91-484-2375083, 91-484-2377079 Email: dyceecners@sr.railnet.gov.in Website: www.sr.indianrailways.gov.in

nPOWER

Company Name: The West Bengal Power Development Corporation Limited Tender Detail: Annual Maintenance contract on turbine & auxiliary systems and piecemeal job of unit-1 to unit-5 (5 x 210 MW), BkTPP. Location: Birbhum Documentation Sale from:10-April-2014 Documentation Sale to: 24-April-2014 Documentation Fees: ` 2,000/EMD: ` 450,000/- Closing Date: 07-May-2014 Address: Office Of The General Manager, Bakreswar Thermal Power Station, P.O. BkTPP, dist. Birbhum-731104, West Bengal Tel: 91-3462-220201 Fax: 91-3462-220214 Email: bktpp@wbpdcl.co.in Website: www.wbpdcl.co.in Company Name: Tripura State Electricity Corporation Limited Tender Detail: Rural Electrification works of West Tripura District in Tripura under Rajiv Gandhi Grameen Vidyutikaran Yojna (RGGVY). Location: West Tripura Documentation Sale from: 06-March-2014 Documentation Sale to: 12-May-2014 Documentation Fees: ` 25,000/EMD: ` 1,000,000/Closing Date:12-May-2014 Address: O/O AGM (DP & C), Corporate Office, Bidyut Bhaban, Agartala, Tripura (West)-799001 Tel: 91-381-2307433 Fax: 91-381-2325345 Website: www.tsecl.gov.in Company Name: Tripura State Electricity Corporation Limited Tender Detail: E-tender for the work of rural electrification works of Khowai District in Tripura

under Rajiv Gandhi Grameen Vidyutikaran Yojna (RGGVY). Location: Tripura Documentation Sale from: 6-March-2014 Documentation Sale to: 2-May-2014 Documentation Fees: ` 25,000/EMD: ` 1,000,000/Closing Date: 2-May-2014 Address: O/O AGM (DP & C), Corporate Office, Bidyut Bhaban, Agartala, Tripura (West)-799001 Tel: 91-381-2307433 Fax: 91-381-2325345 Website: www.tsecl.gov.in

nPORT

Company Name: Kamarajar Port Limited Tender Detail: Request for Expression Of Interest (EOI) from firms port based industries for setting up of Port Based Industry / Special Economic Zone (SEZ) / Free Trade Zone (FTZ) at Kamarajar Port in India. Location: Chennai Documentation Sale to:16-April-2014 Closing Date:16-April-2014 Address: General Manger (Operations), Vallur Post, Chennai-600120 Tel: 91-44–27950032 Fax: 91-44-27950002 Website: www.ennoreport.gov.in Company Name: Cochin Port Trust Tender Detail: Study on Siltation for implementation of Nautical Depth concept in Cochin Port Location: Cochin Documentation Sale from: 7-March-2014 Documentation Sale to: 22-April-2014 Documentation Fees: `10,500/EMD: ` 200,000/Closing Date: 23-April-2014 Address: Chief Engineers, Cochin Port Trust, Cochin, Ernakulam, Kerala – 682009 Tel: 91-484-2666414 / 2666871, Extn. 2400 Fax: 91-484-2666414 Email: ce@cochinport.gov.in Website: www.cochinport.gov.in Company Name: Cochin Port Trust Tender Detail: Leasing of 1.14 ha. Of land for 30 years on annual lease basis for setting up of facilities for handling bulk cement and bagging plant in front of ernakulam wharf in W/Island on tender cum auction basis. Documentation Sale from: 29-January-2014 Documentation Sale to: 30-April-2014 Documentation Fees: ` 10,500/- + ` 150/(if required by post) EMD: ` 1,200,000/Closing Date: 30-April-2014 Address: Chief Engineer, Cochin Port Trust, Cochin, Ernakulam, Kerala – 682009 Tel: 91-484-2666412 Website: www.cochinport.gov.in

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69 n OEM Update n April 2014

Regd. No. MH/MR/NE/266/2013-15 • Posted at Tilak Nagar P.O. Mumbai - 400089 on 7th / 8th of Every Month • English • Monthly • Date of Publication: 1st of Every Month.