OEM Update August 2014 by I-Tech Media Pvt Ltd

OEM UPDATE MAHENG/2009/33944

Vol 6 Issue 3 • Pages 68 • Mumbai

For Efficient Manufacturing

An I-Tech Media Publication

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

CONTENTS Cover Story Integrated CAD/CAM benefits die & mould industry �� 14

Quick Update Red Lion expands its Graphite series of HMIs ��8 Renishaw highlights metrology products at AMTEX ��8 Europafilter: one filter, three functions ��10 Ace Micromatic concludes house show on turbine blade machining ��10 HARTING expands its product portfolio ��12

CAD & CAM Technology drives die & mould industry ��18

CAD/CAM simplifying manufacturing process ��22

Machine Tools Safety of machinery: when standards encourage technology evolutions ��26 High-torque Ethernet servo motor drives ��28

Facility Optimising factory cranes operation ��30 Design criteria of ladle crane ��32

WMI Konecranes launches new open winch crane ��36

PVC Leaders KBL believes profitability through sustainability ��38 Grundfos encouraging water and energy conservation ��40 Shakti Pumps focusing on solar pumping solutions ��42 “Energy efficiency is not a USP, it is considered given” ��44 ABEL eyes on various sectors including power ��46

Process Max Pure aiming max in water treatment industry ��48 KHD Valves offers flush bottom valves ��48 UPF 150: high head stainless steel submersible motor pumps 50 UNINAM: one-stop solution for industrial products ��50 FIBRO rotary table combinations yield maximum productivity �52 Environ offers energy efficient aerators ��52

Factory Visit Racold’s factory: making of efficient water heaters ��54

52 August 2014 n OEM Update n 4

Event ��56 New Projects ��64 Tenders ��65

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August 2014 n OEM Update n 6

Dear Readers, Following the industry trends of adopting IT (Information Technology) to achieve greater efficiency, industrial manufacturing sector has witnessed total transformation through optimisation of IT. Today, CAD/CAM technologies have become inherent for almost every spectrum of product designing. CAD/CAM software along with visualisation and simulation software are increasingly being used in manufacturing and designing of products and machineries. Computer-aided design (CAD) helps designers develop 3D parametric designs for the products to be manufactured whereas computer-aided manufacturing (CAM) is the subsequent computer-aided process after CAD. CAM is used to control machine tools and related machinery in the manufacturing process. In this issue, we have discussed on the increasing importance of CAD/CAM in industrial manufacturing space especially in die and mould making. With latest 3D CAD and CAM software, die-mould shops are able to process long, complex mould programs at extremely fast speeds while achieving levels of accuracy and finish previously unobtainable. Industry experts expressed that with adoption of modern CAD/CAM technologies, dependency up on highly skilled manpower and higher lead time has been decreased drastically thereby decreasing the overall production costs. Together, CAD/CAM can play vital role in making manufacturing process lean, precise, and efficient. Integration of CAD and CAM is called CAD/CAM and if integrated properly CAD/CAM can yield better result. Integrated CAD/CAM offers many benefits as it eliminates extra and costly data translation, automates many manufacturing authoring processes, uses integrated validation tools throughout the process and keeps the data organised. This issue has also discussed key advantages of using integrated CAD/CAM. Pumps, valves and compressors (PVC) are the integral part of any process industry. After a couple of years of slowdown, the PVC market in India is inching toward growth. Based on the theme ‘PVC Leaders’, this issue features a few major players in the field of PVC and talks on their achievements. Hope you’ll enjoy reading the whole issue as always. Please do send me your comments at editor@oemupdate.com

Quick Update

Red Lion expands its Graphite series of HMIs New communication and connectivity modules provide an integrated solution for diverse industrial environments

ed Lion Controls, one of the global experts in communication, monitoring and control for industrial automation and networking, has recently announced that it has expanded its Graphite series of Human Machine Interface (HMI) operator panels with two new plug-in communication modules. Designed for use with Graphite HMIs, which already support more than 300 major industrial protocols,the CAN and J1939 modules provide the communication and connectivity. The customers just need to add powerful HMI functionality to their systems. Red Lion’s new communication and connectivity modules allow customers to leverage the graphite host to integrate CAN and J1939 protocols into a single solution. Originally developed for in-vehicle networking of passenger cars,the CAN and J1939 protocols are also used for heavy-duty construction vehicles, trains and rail vehicles, engine controllers and in building automation applications. When added to Graphite HMI operator panels, these modules remove the need for external communication gateways, saving time and money by simplifying the programming and installation costs. “From factories to extreme remote locations, Red Lion’s highly successful Graphite series is the industry’s first rugged HMI to allow customers to easily connect,monitor and control processes across a broad range of industries,” explained Jeff Thornton, Director Product Management, Red Lion Controls.

Launched last year, Red Lion’s Graphite HMIs offer a built-in web server that enables users to monitor and control applications via PCs, tablets or smartphones. SMS text-messaging and email alerts provide early warning of process issues, which helps avoid costly downtime. n

Renishaw highlights metrology products at AMTEX A

t the AMTEX exhibition, which took place recently at the Pragati Maidan, Delhi, from 25–28 July, Renishaw highlighted a range of process control solutions. These solutions help tackle the increasing drive to lean manufacturing, from new technologies for pre-process machine calibration, to on-line and off-line post-process measurement. The solutions presented were as follows:

OMV Pro software OMV Pro software includes more advanced CMM-type capabilities with an extended range of geometric dimensioning and tolerancing (GD&T) functionality, plus the ability to work with multiple alignments in a single program, an advantage in working with multi-axis machine tools. The software includes simulation capability, an intuitive graphical interface and crystal-clear reporting format that make it accessible to shop-floor staff.

Equator gauging system In off-line measurement systems, the company has to offer Equator gauging system which is a radical new alternative to traditional dedicated gauging. It is a patented low-cost design is capable of high-speed comparative gauging for inspection of high-volume manufactured parts. It has been developed and proven on the shop-floor in collaboration with August 2014 n OEM Update n 8

industry-leading companies in multiple industries and applications. Equator can switch between parts in seconds, perfect for flexible manufacturing processes or accepting parts from multiple machines.

QC20-W wireless ballbar QC20-W telescoping ballbar is an innovative calibration tool to allow testing in three orthogonal planes through a single reference point. A single, simple hardware setup means quicker testing and the ability to produce a representative volumetric measurement of positioning accuracy.

PH20 5-axis probe for CMMs PH20 5-axis touch-trigger system is designed to improve measurement speeds on co-ordinate measuring machines. This increases touch-trigger CMM throughput up to three times, using fast, infinite, rotary positioning head touch capability for high-speed point capture with minimal CMM movement. The PH20 uses two-axes of head motion to minimise CMM movement and associated dynamic errors at higher measurement speeds. Its inferred calibration feature determines head orientation and probe position in a single operation, eliminating the need for calibration at each orientation. n

Quick Update

Europafilter: one filter, three functions G

reenEclipse Technologies India Pvt. Ltd. is the authorised distributor of Europafilter, Sweden in India.

down to 100 nano (0.1 µm) and below. This is done without chemicals, which have the disadvantage that they remove or neutralise the oil additives.

Europafilter is an offline oil filter, also called side stream filter, based on cellulose filter technology. It can be deployed for any kind of heavy machinery and hydraulic equipment that use engine oil and lubricants.

Europafilter can be used effectively to clean the following types of oils: • Gear oil / gearbox oil • Lubrication oil • Transformer oil • Turbine oil • Compressor oil • Hydraulic oil • Cooling oil • Fuel and engine oil.

Europafilter technology was developed from a NASA satellite application, where oil changes were not possible and oil had to be maintained at the highest cleanliness level. Europafilter incorporates three functions in one filter system: 1. Ultra filtration: EF500HY traps all types of particle, both large and small down to 0.1 microns up to 3 kgs of contamination can be trapped. 2. Slows down oxidation: Not only does the filter restrain the oxidation, it also traps deposits and resins 0.1 µm, 99 per cent reduction that form when the oil oxidises 3. Reducing water: The same filter that traps particles also absorbs all types of water from the oil – bound, free and emulsified and filtering salt. This can absorb 3 litres of water.

The EF2100 series comes with a range of additional options. Different ways to check flow, oil heating for cold conditions and high viscosities, different types of stands, mobile variants, system with spill tray and overfill protection, different varieties of oil supply as air pumps and pressure reducers and EX classed systems across all the various explosive zones (ATEX).

Filtration system Europafilter’s unique and patented EF500HY capillary filtration system absorbs water effectively and removes majority of solid particles which are harmful to the machine

Europafilter’s performance has been proven in sectors such as manufacturing, maritime, oil & gas industry, energy, mining, heavy vehicle, pulp & paper, automotive, railways, defence, agriculture etc. n Contact: GreenEclipse Technologies India Pvt. Ltd. KRS Infra Business Park, 51MCHS, HSR Layout, Sector 4, Bangalore – 560102 Tele: +91-8138024444 E-mail: getipltd@gmail.com www.europafilter.asia

Ace Micromatic concludes house show on turbine blade machining A

The component which was machined during the demo was twist and tapered turbine blade of 190 mm length. This was machined from rough to finish with a cycle time of 2 hours 10 mins, which is approximately 20 per cent lower than the cycle times achieved on similar machining centres available in the market.

ce Micromatic group, one of the India’s largest machine tool conglomerates, recently concluded its house show in Hyderabad. This was the first house show in Hyderabad where a live machining demo was made, specifically for turbine blade manufacturers. The vertical machining centre, Super Winner manufactured by Ace Manufacturing Systems, an Ace Micromatic group company, was displayed. This machine has a table size of 800 X 400 mm, standard spindle speed of 6000 rpm with an option for higher spindle speed up to 8000 rpm.

August 2014 n OEM Update n 10

The machine is provided with BT-40 spindle and HSK spindle is also available as an option. The machine can be provided with either Fanuc or Siemens CNC control system.

The house show evoked tremendous response and appreciation from all customers who showed keen interest in the outstanding machine performance and features. n

Quick Update

HARTING expands its product portfolio H

ARTING Technology Group is expanding its product portfolio with the addition of a new locking system and also offering products in transponders and penetration purpose categories.

forces to be absorbed from the outside. Furthermore, extending cables in machinery can be performed quickly and conveniently.

Versatile RFID transponders for optimal performance

Han Hood Link ensures reliable locking

Through the panel with Han-Yellock The feed-through housing of the HanYellock connector family promises to make it easier to lay cable through several rooms in comparison to existing cable feed through systems. This new solution for panel feedthrough not only facilitates handling, but also offers considerable robustness and an IP 67 degree of protection in plugged-in condition.

Ha-VIS RFID Han Hood Link

Now it is possible to create simple cable-tocable connections with the new Han Hood Link offered by HARTING. A special contour and internal seal now make it possible to connect two standard HARTING 16B hoods while simultaneously achieving an IP 65 degree of protection. The special feature of this system is that it is made entirely of a resistant elastomer. This provides optimum protection against external mechanical forces, as well as good resistance to oils and gases. A special contour and internal seal now enable the connection of two standard HARTING 16B hoods while simultaneously achieving an IP 65 degree of protection. The Han Hood Link locks and seals in a single system, while housings can be quickly assembled and disassembled with minimal effort â&#x20AC;&#x201C; all without tools. A simple and robust locking element is particularly advantageous in stage technology, due to the risk of connectors falling from heights and the associated damage to the locking device upon impact. This impact can be prevented by the elasticity of the new Han Hood Link, which enables mechanical August 2014 n OEM Update n 12

The company has also come up with Ha-VIS RFID VT 86 (HT) RFID transponder whose main features include robustness, temperature resistance, high protection class, performance in difficult environments. The legal and local regulation of the frequency bands that have been released for use represents a challenging aspect of UHF RFID wireless technology. Currently, two frequency bands are of relevance: the EU-band (865-868 MHz) and the US/ASIA band (902-928 MHz). A transponder which successfully functions within both frequency bands qualifies the product for global use. Since the Ha-VIS RFID VT 86 (HT) transponder was designed for the aviation industry, the transponder can be deployed worldwide. In other applications relevant for HARTING, e.g. MRO scenarios (maintenance, repair, operations) in industrial environments, transponders are frequently used exclusively on-site. HARTING now offers this field of applications RFID transponders from its HaVIS RFID VT series, which are designed and optimised for the respective band in use. The result of this optimisation is a significant increase in read ranges with no impact on minimal design size.

Han-Yellock feed-through housing

Unlike standard feed-through systems, the HARTING solution is pluggable. To this end, the standard bulkhead mounted housing from the connector series has been complemented by the addition of a metal housing whose shape is similar to the upper part of the housing of the Han-Yellock. The system makes handling easier. Cable sets can be completely pre-assembled and assembled with the flange at the point of penetration. The robustness achieved is also good as the housings are impact-resistant on both sides of the connector. Contact: HARTING India Pvt. Ltd. Abhishek Bimal Assistant Marketing Communications Manager 7th Floor (West Wing), Central Square II Unit No.B-19 Part, B 20&21, TVK Industrial Estate Guindy, Chennai - 600032 Tele: +91-44-43560415 Fax: +91-44-4356 0417 Email: abhishek.bimal@HARTING.com www.HARTING.in

Cover Story

Integrated CAD/CAM software that combines CAD, CAM, electrode design and CMM programming capabilities in one system can save your time and efforts in many ways

Integrated CAD/CAM benefits die & mould industry T

here are, broadly, two types of integrated CAD/CAM systems: One is CAD-centric, which is designed for people or companies that have standardised on a particular CAD system, and want the benefits of compatibility and associativity that integrated CAM can bring, and second is CAM-centric, which is designed for NC programmers who need CAD functions to do their work more efficiently. The difference in centricity is a qualitative thing, and comes largely from the focus of the vendors who create the software, and the workflow in which the software is used.

Benefits and processing It is found that integrated CAD/CAM offers many benefits as it eliminates extra and costly data translation, automates many August 2014 n OEM Update n 14

manufacturing authoring processes, uses integrated validation tools throughout the process and keeps the data organised. “Integrated CAD/CAM provides more flexibility to the user to make programming without any data conversion loss,” points out Nitish Shukla, Business Manager, Cad Macro Design & Solutions Pvt. Ltd. “Manufacturing process becomes simpler, easily transferring to the CAM personnel. It avoids double time work, as well as knowledge transferring.” It is a fact that a majority of tool rooms are in the small and medium sector which are run by passionate people. Often, these tool rooms employ specialists who do most of the tool design and manufacturing. Such specialists require an integrated CAD/CAM software that will not only allow them to

Nitish Shukla, Business Manager, Cad Macro Design & Solutions Pvt. Ltd.

Manufacturing process becomes simpler, easily transferring to the CAM personnel. It avoids double time work, as well as knowledge transferring

Cover Story Figure 2

Figure 1

Vineet Seth, Managing Director, Delcam Software (India) Pvt. Ltd.

Integrated CAD/CAM software helps in design, machining and inspection of electrodes, supporting a wide range of EDM equipment make necessary changes to the input CAD model, but will also help them generate toolpaths for a given tool, die or mould. Figure 1 shows a typical (traditional) process, split-up in stages to manufacture a plastic injection mould. Noticeably, the process is longer and takes many different applications and resources, until the job is finally done. This will result in a longer time-to-market as well as increase in overall cost. With an integrated CAD/

CAM system, a new process can be defined as shown in figure 2. It is apparent, from the figure 2, that one integrated team with one CAD/CAM system now ensures better communication; less data transfer, less chance of error as a more reliable process, less re-work, less management. It also means that there is no need for 2D drawings to be created separately for design communication to the shop floor. It also

allows simulation of tool operation based on input mould configuration parameters. In addition to this, the integrated CAD/CAM software has built-in intelligence and is also a knowledge based software. This allows the software to use components from standard catalogues like Hasco, DME, DMS, Kishin, Futaba etc., while understanding how mould

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15 n OEM Update n August 2014

Cover Story

components fit together - so the system suggests appropriate sizes. Features, such as holes, pockets, bosses and other prismatic features are recognised automatically in CAM software and appropriate strategies are applied for NC machining. “Integrated CAD/CAM software helps in design, machining and inspection of electrodes, supporting a wide range of EDM equipment. The system provides the CAD element of the overall solution, in particular, the option to merge fragmented faces into a single, continuous surface and so produce cleaner, simple electrode geometry,” says Vineet Seth, Managing Director, Delcam Software (India) Pvt. Ltd. “This simplification makes subsequent operations, such as adding draft to complex regions of the model, much easier and also improves the operation of many of the direct modelling tools in the software.” Automatic scripts for leading machine tools like Exeron and JDMA EPX, AgieCharmilles (Agievision and CT Millennium controls), Makino EDM, Mitsubishi Electric, ONA EDM, OPS-Ingersoll, Sodick and Zimmer & Kreim can be generated, thereby limiting manual intervention to a minimum. Scripts are the EDM equivalent of CAM programmes for machine tools. They provide an automated process for the programming of the machine, instead of users having to program manually from a set-up sheet.

integrated CAD/CAM tools help them by making the above processes interlinked and efficient,” adds Mr Seth.

support team at CAD MAcRO is providing trial version for evaluation and they will even provide the support.

Actual implementation

Performance of Indian market

In earlier times, companies had to benchmark against traditional processes, thereby educating their customers on the benefit of an efficient CAD/CAM system. This was a long process, and it often meant that they had to go back to the basics. However, a change has been observed in recent years.

Over the years the Indian toolroom industry has built a reputation for not only being economical in cost, but being able to make the most critical moulds in certain well known toolrooms in the country. The industry can compete head to head with its counterparts on global platform. Though there are a few concerns, this is more as a result of policy paralysis than anything else.

“In the past 10 years, a sea change has been observed. Many of our customers now are aware of the benefits an advanced CAD/ CAM system brings to the table, and they are geared up to make certain changes to their existing processes, in order to be more efficient,” says Mr Seth. “Implementation of a CAD/CAM system requires us to study the customers’ profile – what they do, how they currently do it, what are their bottlenecks and finally how much time and money they are spending to do this. We then assess the appropriate modules that will give them added benefits, and then start implementing these in a phase wise manner.” Usually, most companies require a bit of hand holding in the initial stages, but they then start innovating better with the new technology that has been implemented. “We brought the integrated CAD/CAM package in for CAM-centric ones. It will be easier for the users to modify the needs and adopt as per machine conditions which requires modification after getting model from the user. Our focus is on wire EDM and CNC turning,” informs Mr Shukla. “For those designers who do not have much knowledge about the machining and machines, integrated CAD/CAM can modify as per the requirements of the job.”

“Indian toolroom industry currently is in a delicate situation. While the larger toolrooms are on an expansion path or technological upgradation path, the largest market that they cater to is currently facing low volumes,” analyses Mr Seth. “Smaller and mid size toolrooms are finding it difficult to justify expansion and tend to largely compete on low pricing. It is due to this situation that capital investment is one of the core challenges in the Indian industry.” It is paramount to appreciate that quality comes at a price, and any hasty decisions or cheaper alternatives lead to unwise investments in equipment that deteriorates progressively in a shorter span of time. This is one of the biggest challenges, as a low paying investment is likely to drag other better parameters of the company down with it. “SMEs have to gain advantages of CAD/CAM technology for their mould making process. However, even today many companies are using unproductive older methods and older versions of software. It leads them to lose their quality and on time delivery. Still we have a lot of potential in this market,” believes Mr Shukla.

For better tomorrow The automated process is much easier and quicker, especially when a number of electrodes are being used on the same component. Furthermore, the direct link removes the human error that could always be possible with manual programming. It is now possible to update the script files based on information gathered during the inspection of the electrode. The new script file can then provide accurate process information to the EDM machine, avoiding the need for manual updates. “Since modelling, mould/tool design, CNC milling and electrode making are important parts of the die and mould segment, August 2014 n OEM Update n 16

CAM solution for CNC WIRE EDM technology Mr Shukla also informs about one solution that Cad Macro offers i.e. new version of MAcRO WIRE 2.4 Auto Programming Tool for CNC WIRE EDM with latest technologies. Its application features include gear profile, simulation with offset etc. MAcRO WIRE supports all major CNC WIRE EDM post processors of machines like Mitsubishi, Makino, Chmer, Excetek, Accutex, Agie Charmilles, Sodick, Electronica etc. It can also be customised according to the user defined structures. The 4-axis (complex) wire path can be created with ease even if both top and bottom profiles contain unequal entities. The

Mr Seth believes, “When Indian toolrooms will start utilising scientific methods and global business approach, along with their experience, they will be profitable as well as they will also set a benchmark which will perhaps be a big challenge to its competitors in the near future.” What the industry needs to do is work towards better quality, better service and better lead-times, all at a competitive price. This will be possible only when they are able to do the right work, employing the right people with the right ability, and using the right equipment at the right time. n

Technology

Technology drives die & mould industry

Die and mould industry in today’s era is getting prospered in many ways with the help of technology. This article talks about such important technology drivers

oday India is considered as one of the fastest growing economies in the world and many foreign companies can be seen investing in Indian projects. No wonder that like many other sectors, die and mould sector is also putting all its efforts to support the precision industries with some advanced technologies and trying to provide the best solutions to meet the ever-increasing requirements. Let us have a look at these effective technology drivers that are making an impact being a vital part in growth path of the industry.

Technology drivers CNC CNC technology is changing rapidly, and the changes are helping to improve the productivity of machine tools used in the mould industry. “Faster central processing units (CPUs) are at the heart of many CNC changes,” says August 2014 n OEM Update n 18

Vaibhav Aggarwal, MD, Expo Machine Tools Pvt. Ltd. “However, the improvements go beyond just faster processing, and the speed itself touches on many different CNC advances. With so much that has changed in recent years, it’s worthwhile to present a summary of the state of mould-making CNC technology today.

we have developed for solving customers’ problems,” says Ken Takahashi, Managing Director, Sodick Technologies India Pvt. Ltd. “These products are now the source of the competitive strength. Our products find applications in automobile, aerospace, medical, electrical, electronic industries and many more.”

Linear motors A machine is only as good as its controller and its motion control system, since it is directly responsible for the movement of the axes. The linear motor drive system is found to be superior to a rotary motor with ball screw drive system. The linear motor drive system relies on direct feedback from a linear scale for positioning, reporting an exact position and not a theoretical position.

This technology has improved significantly in recent years in both performance and acceptance. Commenting on the trend Mr Aggarwal says, “Every IMTS sees more machining centres offered with linear motors, and to date, Fanuc has shipped more than 1,000 units. Some of the GE Fanuc’s advances have resulted in machine tool linear motors with a maximum force of 15,500 N and a maximum acceleration of 30 G. Other advances have led to smaller size, lighter weight and more efficient cooling.”

“The linear motors and ceramics have revolutionised the electric discharge machines (EDMs), the V-LINE system in injection moulding machines are all solutions

It is clear that all of these changes serve to enhance the benefits linear motors offer over Contd. to 20

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Technology 18

Contd. from

rotary motors. These benefits include higher acc/dec rates, superior position control and higher stiffness, improved reliability and inherent dynamic braking. “Sodick has accumulated a rich portfolio of knowledge and expertise in linear motors including the know-how for the design and production of linear motors, best suited for various types of machines,” believes Mr Takahashi. Linear motor drive system is simple in mechanism and easy to assemble as well. Moreover, it generates power efficiently due to little energy loss. Some of the more advantages of linear motor drive system are as follows: • High speed and high acceleration control system • Fast response due to no delay of motion control • High accuracy and repeatability when coupled with linear glass scales • Direct drive - no couplings or belts, no back lash or lost motion • No vibration on axes, no sticks-slips • No maintenance and longer life. Five-axis As CNCs have become more powerful, CNC manufacturers have been able to add more five-axis features. Capabilities once found only in high-end controls are now available in mid-range products. Most of the features have to do with making five-axis machining easier to use for shops that have little five-axis experience. Mr Aggarwal adds, “Nowadays five-axis machining is increasingly being applied to complex mould work. The technology can reduce the number of setups and/or machine tools required to produce a part, thereby minimising work-in-process inventory and reducing total manufacturing time.” Today, accessible CNC technology can deliver all of these benefits to the five-axis machining process: • Eliminate the need for qualified tooling • Allow tool offsets to be set after the part program has been posted • Support ‘machine anywhere’ programming, so that posted programs are interchangeable from machine to machine • Improve surface finish • Support various machine configurations, so the program no longer has to account for the spindle pivots or the work piece August 2014 n OEM Update n 20

pivots. This is now accounted for by parameters at the CNC.

How does technology help Having the right machines, with the right technologies specifically suited for high speed, hard milling of complex dies and moulds enables low labour-cost.

Ken Takahashi, Managing Director, Sodick Technologies India Pvt.

“With new technology machines, tools rooms are able to reduce cycle times and lead-times, lower labour costs through unattended machining processes, gain more business by offering rapid prototyping, highperformance milling and no-polish EDM burning, all while reducing total operating costs,” says Mr Aggarwal.

The linear motors and ceramics have revolutionised the electric discharge machines (EDMs), the V-LINE system in injection moulding machines are all solutions we have developed for solving customers’ problems

With latest 3D CAD and CAM software, die-mould shops are able to process long, complex mould programs at extremely fast speeds while achieving levels of accuracy and finish previously unobtainable. Hence dependency up on highly skilled manpower and higher lead time has decreased thus decreasing the overall costs.

isolates the work-piece and prevents any leakage current flowing from the body of the machine. Such work-piece isolation helps to detect optimum spark gap and maintain the servo voltage accurately even at the high frequency low current skim passes.

“Frequently a mould can be made in one continuous operation, eliminating multiple setups, manual handling and the need to move parts from machine to machine,” adds Mr Aggarwal. “Moreover, the superior finish speeds up overall production even more by eliminating hand polishing, the most timeconsuming part of traditional mould making.”

Initiatives being taken Being proactive, the current industry players are taking some promising initiatives to offer their solutions in order to meet the requirements in die and mould industry. It is useful to know the same. Mr Aggarwal informs about the initiatives being taken by Expo Machine Tools in this regard. Some of which are: • Introduction of new technology in the machine shops • High end quality assurance and quality control instruments • New machines from Japan, USA And Germany • Proper workshops training for the employees • Recruiting skilled employees with proper training. Ceramics is a material indispensable for ultraprecision machining because of its extremely small thermal expansion coefficient. Further ceramic being highly resistant, completely

In fact, ceramics offer a wide range of advantages when compared with other materials such as steel or plastic. Ceramic is light and yet hard, stable and resistant to ageing, it doesn’t rust, has a high electrical resistance, and scarcely changes at all under the effects of heat as its coefficient of thermal expansion is one third that of cast iron. In other words, ceramics are ideal for EDM. Sodick owns technologies for producing ceramic products that support highprecision positioning such as high-rigidity machine structural components, informed Mr Takahashi. Sodick machines are considered to be lightweight and high-rigidity structure, thanks to their key components made of proprietary ceramic products (FINEXCERA series). Further, in Sodick wire-cut EDM machines ceramic components are used in critical areas such as the upper and lower arms, base plate and pedestals. In Sodick die-sinker EDM work table and Z-axis quill are the major parts made from ceramic.

End note Die and mould industry is being driven today by continuously evolving technology, which in turn is making the industry more efficient and promising through increased productivity. n

Technology

CAD/CAM is considered to be a utility used for futuristic product development. This article talks about how it is proving to be a helping hand for manufacturing process in particular

CAD/CAM simplifying manufacturing process T

oday technology can offer substantial support to all the activities of design and manufacturing. The implement enabling this miracle is named CAD/CAM with which creativity and imagination can perfectly be harmonised with computers. CAD/CAM involves usage of computer software to both design and manufacture products across various industry sectors.

Role of CAD/CAM in manufacturing process CAD/CAM technologies play an integral and a very vital role in making manufacturing process lean, precise, and efficient. CAD helps designers develop 3D parametric product designs that are ‘manufacturable’. Vikas Khanvelkar, MD, DesignTech Systems Ltd., says, “Based on the designs, the companies can align, assign and arrange for the necessary tools, machineries, peripherals and equipment required for manufacturing these products. CAM is a manufacturing August 2014 n OEM Update n 22

programming software that helps manufacturing machineries efficiently.”

Whereas H K Madhu, Technical Director, SIM Technologies Pvt. Ltd., comments, “CAD/CAM allows us to not only innovate and design the products, but it is also the solution to CNC machining products in more efficient, profitable and smarter way than ever before. From the production of rockets to toys, CNC manufacturing rely heavily on the CAD/CAM software that is developed today as a key solution.” “CAD is the use of computer technology for design and design documentation. CAD/CAM applications are used to design a product and program manufacturing processes, specifically CNC machining,” points out Rajiv Bajaj, Head- Manufacturing, Autodesk India and SAARC. “CAM software uses the models and assemblies created in CAD software to generate tool paths that drive the machines which transform the

designs into physical parts. These softwares are often used for machining of prototypes and finished parts.” According to Indian Machine Tool Manufacturers’ Association (IMTMA), the industry’s market size is estimated to be almost ` 2.1 billion, with domestic production meeting only 33 per cent of the demand while imports account for 67 per cent of the total consumption. The Indian manufacturers have opportunities galore in key sectors like automobiles and consumer durables where they can benefit by moving to CNC machines and leveraging on innovative CAD/CAM technologies for higher productivity and quality to gain a competitive edge.

Latest innovations As CAD/CAM is becoming a strong yet smart solution nowadays, it is now interesting to see what latest technological innovations this field has been experiencing in recent time.

Technology “Digital prototyping is one of the major innovations that has revolutionised the CAD/CAM industry,” comments Mr Bajaj. By connecting every phase of the design process through a single digital model, Digital Prototyping solution enables the testing and optimisation of 3D CAD designs, help to drive innovation, achieve higher quality, and hasten the time to market. It can help grow revenue, spur innovation, and deliver quality products faster than ever by: • Creating more innovative concepts and engineering more accurate digital prototypes • Performing simulations on digital prototypes to optimise designs • Streamlining documentation, data management, and collaboration • Developing compelling, realistic visualisations to experience products before they are real • Designing, visualising, and simulating factory layouts. Mr Khanvelkar also describes the new innovations being observed in the field as follows: • Digital Manufacturing: Digital manufacturing helps companies to create 3D simulations of plant design.

This technology best helps companies configure most optimised workflows and manufacturing processes taking into account, assembly line designs, robotics analysis and simulation, ergonomics analysis and many more. This in turn helps design plants that augment manufacturing efficiency, performance and effectiveness thus helping companies reduce wastage of time, money, man efforts, materials and machines. • Direct Digital Manufacturing: Direct digital manufacturing is a new offering in additive manufacturing machines, which help through their patented FDM (Fused Deposition Modelling) technology to produce parts/models/products that can be used for end-use applications. Ideal for small batch production such as jigs, fixtures and mould, these machines are easy to operate, compatible with all the leading CAD software and help build parts quicker, easier and accurate in production grade ABS + plastic material. • Prototyping for dental applications: OrthoDesk 3D printers, an offering in polyjet technology, helps eliminate the need of taking physical impressions and thus is a cleaner and efficient process. It

is easy to use, and includes specialised dental printing materials. It can also store the models digitally. • PLM: PLM encompasses the entire product life-cycle right from concept design, engineering detailing, simulation and analysis through to manufacturing. It is the nervous system of the R&D departments and helps companies optimise and configure ideal workflows

Vikas Khanvelkar, MD, DesignTech Systems Ltd.

CAM is a manufacturing programming software that helps in manufacturing machineries efficiently.

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Technology the machining tree, which delivers quick access to any point in the machining process,” adds Mr Madhu.

CAD/CAM in factory

H K Madhu, Technical Director, SIM Technologies Pvt. Ltd.

From the production of rockets to toys, CNC manufacturing rely heavily on the CAD/CAM software that is developed today as a key solution.

and processes for product development, knowledge and data storage and management. • A pre CAD cum pre CAE Software: This is a new concept in CAD/CAM technology. A software named sT Inspire from Altair engineering is a concept design software that helps generate mathematically proven design and a CAD software for engineering detailing. sT inspire is an intuitive concept design software with topology analysis feature.

New age combination SolidWorks and Mastercam together form a widely used modelling software and CAM solution, so one can program parts directly in SolidWorks, using toolpaths and machining strategies preferred the most by shops around the world. “SolidWorks makes feel easy with

Rajiv Bajaj, Head- Manufacturing, Autodesk India

Digital prototyping is one of the major innovations that has revolutionised the CAD/CAM industry

August 2014 n OEM Update n 24

Now the next question to be answered is ‘how can these technologies be introduced in the factory?’ Well, Mr Madhu answers as: “Introduction of these new technologies in a company, or to arrange for the company to utilise them can give substantial advantages in terms of cost and time required for making a model. In particular, it has been observed that, the introduction of these technologies can lead to take a liking to it and tries to use it at all stages of the production process, possibly fully in house. Also paved way for sustainable production such as a Product-Service System (PSS), have been proposed, particularly in developed countries.”

Commitments A rising graph of use of CAD/CAM in many applications has made current players in industry to offer various solutions. Lets have a look at what commitments do they have in this regard. Autodesk delivers CAM solutions to a broad range of users, from designers and engineers to CNC programmers, regardless of their CAD tool of choice. HSMWorks and Inventor HSM software are integrated CAM solutions offerings from Autodesk. Whether it is about producing prototypes or finished parts, these products put the designers in control by delivering: • Integration: Seamless integration with Inventor 3D CAD software and SolidWorks offers an intuitive user experience • Performance: Native multicore, 64-bit CAM engine makes easier work of the most demanding tool path calculations and post-processing jobs • Quality: Efficient tool paths reduce cycle time, reduce machine and tool wear, and produce the high quality finished parts. Autodesk has also made CAM in the cloud a reality with the help of Fusion 360. “Our Autodesk CAM tools are now completely integrated inside Fusion 360, enabling the next generation design-to-manufacturing workflow,” informs Mr Bajaj. “It allows the user to take advantage of collaboration of tools and shared data storage with unparalleled ease-of-use and flexibility when

creating programs for milling machining projects.” “Our approach to Digital Prototyping is unique in that it is scalable, attainable, and cost-effective, which allows a broader group of manufacturers to realise the benefits with minimal disruption to existing workflows, and provides the most straightforward path to creating and maintaining a single digital model in a multidisciplinary engineering environment,” believes Mr Bajaj. “DesignTech is engaged in distribution of products in all CAD/CAE/PLM categories and also undertakes implementation of the same. We are also involved in providing product design and engineering services to the customers in India and abroad,” informs Mr Khanvelkar. “DesignTech CAD Academies offer introductory and advanced training on using these tools. We help our customers leverage these technologies for reducing their cycle time of bringing the new products to market.” On other hand, Autodesk has recently acquired Delcam, one of the world’s leading suppliers of advanced CAM software with a vision to continue expansion into manufacturing and fabrication. Autodesk also plans to accelerate the development of a more comprehensive Digital Prototyping solution and deliver a better manufacturing experience. “Our SIMTEK is an easy step to choose the right CAD/CAM product,” advises Mr Madhu and adds, “SIM Technologies enjoys today a customer base of more than 1,000 large/ medium/small organisations and continues to grow within a variety of industries and engineering markets, which we have served in terms of engineering design service, manufacturing service, CAD/CAM/CAE software solution.”

Bottom line According to Mr Madhu, the true cost of CAD/CAM is how much a CNC business is losing every day by not implementing it into the manufacturing process. This is really the truth of it considering the competitive climate of our current manufacturing economy. In all, it can be seen that current players’ innovative approach to the product development process helps reduce reliance on physical prototypes and bring more innovative products to market ahead of the competition. n

Machine Tools

Safety of machinery: when standards encourage technology evolutions “A safety product must be efficient, easy to install, ergonomically designed, and its impact on the productivity must be minimised”

ne may wonder whether the standards and directives that regulate our industry are slowing down technological evolution. As far as safety of machinery is concerned, the new standards have directly contributed to the adoption of electronic and programmable security systems. This is mostly due to the fact that both end users and providers are present in the standardisation committees. End users express their needs, and safety solution providers focus their R&D teams on these needs. Standards are then established that are shown to maximise safe production. The standardisation process has been created this way so that end users avoid dealing with archaic rules that can inhibit productivity without improving worker safety. First, what kind of regulations are we talking about exactly? There is a difference between “directives” and “standards”. Directives are laws, and they describe the goals that must be reached, including a series of generic principles (“protect the worker at work”, for example). We understand easily why directives don’t need to be renewed very frequently. The standards, on the other side, consist in sets of technical rules. They describe some methods to fulfil the directive. That’s why they are updated more frequently than directives (every two or three years). Rockwell RA safety

What was the need that led to the latest standard in safety for machinery? It was twofold. It was about increasing productivity and safety at the same time. Before this standard, the only way to ensure safety functions was to turn off the energy in the machine. This principle has some limits because the worker must wait for the machine to reset, and the reset can fail. With the new standard, published on 1st January 2012, there is more focus on the probability August 2014 n OEM Update n 26

of a failure. It’s a new way of thinking. The technology used to stop the machine is not an issue any more. What’s important now is to be sure that the machine won’t hurt the worker. Instead of shutting down the energy, we make sure the equipment won’t start again for any unintended reason. To comply with these new rules, automation engineers have to perform a risk analysis of their machines and evaluate their probability of failure. By doing that, standardisation authorities make the end users consider the safety aspects of their machine from the very beginning of the projects. Because in many production lines where safety is considered later in the project, the safety systems can be deactivated or overridden by workers who find them inconvenient. What’s more, by controlling exactly which part of the machine has to be stopped and which part can run, end users can think about new possibilities. For example: what are the tasks that can be done during the time the worker is placing new products in the machine?

Distributed by

Rockwell Automation has been working for several years on this concept of simultaneously improving safety and productivity. It has made its voice heard in the standardisation committees. That’s why Rockwell Automation has made huge investments in its safety offering and placed more focus on integrating safety functions (in the drives or in the PLC, for example). A safety product must be efficient, easy to install, ergonomically designed, and its impact on the productivity must be minimised. Rockwell Automation has also placed more emphasis on the programming and design aspects, not only on hardware. Rockwell Automation recently launched two software applications that help the automation specialists develop their safety functions. Both applications can be downloaded for free. The first one is Safety Automation Builder. With this graphical tool, the user knows what kind of safety functions must be implemented on a machine, depending on the results of the risk analysis. Safety Automation Builder also helps choosing the right characteristics for the components (for a light curtain, for example, it would be the height and the resolution). The second application, Safety Accelerator, is more focused on programming. It gives access to a large library of safety functions that automation specialists can easily adapt or combine. With these applications, Rockwell Automation helps developers save time in programming, while helping reduce the risk of error. Finally, Rockwell Automation has developed a free series of safety function documents. Safety function documents are preengineered application guides to provide a complete safety solution. The documents provide detailed information outlining the functionality, performance and products that are required for each safety function. They also come with a produced SISTEMA Performance Level calculation as outlined in EN ISO 13849 1. n

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Machine Tools

High-torque Ethernet servo motor drives

BB has enhanced its ranges of servomotor drives for the Ethernetbased motion control systems market with variants that can substantially increase the speed of machinery and automation systems while also reducing bill-ofmaterials costs. By redesigning the drives’ power stage, the latest iteration of ABB’s MicroFlex e100 and e150 servo motor drives can now deliver peak current levels that are three times the continuous rated current, and sustain that peak output for up to three seconds. This provides the torque to substantially increase the speed of moves and machine cycle times. In some cases, ABB expects that the generous three-second overcurrent capability will allow motion system builders to use a smaller size of drive - reducing system building costs dramatically, and potentially the footprint of systems as well. The new design increases the drives’ level of overcurrent capability from 200 per cent to 300 per cent. This can be particularly relevant for system builders employing new generations of high performance servo motors with neodymium magnets, as these tend to offer a peak current capability August 2014 n OEM Update n 28

that is at least three times the continuous rated current level. The three-second overcurrent capability of the drives may then be exploited to increase the acceleration of movements. As many common types of automation and machinery have a lot of repetitive movements coupled with dwell periods, this can have a dramatic impact on overall cycle time and throughput. These types of operational modes can be found in many applications such as feeding materials, parts handling, assembly, filling, packaging, labelling, sampling and robotics. In addition to the 300 per cent overcurrent facility, program the drives can be programmed operate in a 200 per cent overcurrent mode. This choice provides users with a means to optimize one or more axes of a motion control system for higher dynamic acceleration or higher RMS torque depending on the load conditions and motion cycle of the particular application. “This torque enhancement greatly increases the application potential of feature-rich servo motor drives that are already noted for their ability to satisfy automation applications without requiring additional hardware or options,” says David Greensmith of ABB.

“The multi-protocol Ethernet capability and local intelligence mean that the applications potential is truly versatile. The new higher torque mode now provides an excellent match for the capability of the latest generations of high performance permanent magnet servo motors.” The new 3-second 300 per cent overcurrent capability is now incorporated as standard on ABB’s MicroFlex e150 and e100 ranges of servo motor drives. MicroFlex e150 drives are compatible with real-time EtherCAT, plus EtherNet/IP, Modbus TCP and TCP/ IP protocols. MicroFlex e100 drives are compatible with the real-time Ethernet Powerlink protocol, plus EtherNet/IP, Modbus TCP and TCP/IP. ABB’s MicroFlex e150 range offers a choice of three single-phase drives with continuous current ratings of 2.5, 5.25 and 7.5 A. The drives are compatible with EtherCAT, EtherNet/IP, Modbus TCP and TCP/IP protocols, providing a ‘universal’ Ethernet drive platform that can be employed in many different ways to suit applications - from networked systems hosted by PLCs or other devices, to motion control systems with distributed intelligence. n

Industry Analysis

Optimising factory cranes operation Finishing product E.O.T. crane with magnets & revolving crab 2X11 T - 18.85 M span

Double girder cantilever cranes 2T - 6M span / E.O.T. cranes 5T - 24 M span

Storage E.O.T. crane 2X3,2 T - 21.35 M span (Image courtesy: Jaso India)

In a factory, cranes need to be scheduled so as not to interfere with each other to achieve reliable operation in time. That’s where scheduling of factory cranes becomes important, something which has been less talked about (Satis)Factory crane scheduling Factory crane scheduling means allowing one or more hoists to move along a single horizontal track that is normally mounted on the ceiling. When a production schedule for the plant is drawn up, cranes must be available to move materials from one processing unit to another at the desired times. One crane may be required to yield (move out of the way) to permit another crane to pick up or deliver its load. Basically scheduling means managing of moment of EOT cranes in factory.

Need and importance of factory crane scheduling Now the question arises that is it that much essential to have factory crane scheduling in practice? Well, to know this, its need and importance should be understood. “The importance of a crane starts from the construction of the factory itself, the capacity and weight of the crane are fundamental for the design of the factory structure,” says Saikat Bagchi, Director-Marketing, Sales and Business Development, Jaso India Pvt. Ltd. August 2014 n OEM Update n 30

He adds, “The crane should be the first machine installed in the factory, because it will help in the installation of all the other machines. A proper and organised scheduling will save time and money to the company.”

Safety measures

to ensure involvement of all team members in the journey towards zero harm.” Commenting on the safety measures practised by Jaso India, Mr Bagchi informs, “We offer safety measures like running alarm or horn, overload limit switch, 3ph

While operating such critical equipment like crane in factory operations, it becomes very necessary to implement some overall safety measures, especially for workers in order to have their safety. This in turn ensures smooth, reliable as well as trouble-free operation. “Demag Cranes works towards the objective of ‘Zero Harm’. Zero harm means think safe, work safe and home safe,” explains Deepak Desai, General Manager, Operations, Demag Cranes & Components (I) Pvt. Ltd. “To achieve this objective, roadmaps which cover various safety and environmental improvement aspects are tracked and monitored by the management team through use of mile markers within the road map. Safety performance of the organisation is also tracked through different leading and lagging indicators. Initiatives are being taken

Saikat Bagchi, Director-Marketing, Sales and Business Development, Jaso India Pvt. Ltd.

The importance of a crane starts from the construction of the factory itself, the capacity and weight of the crane are fundamental for the design of the factory structure

Industry Analysis indications, anti-collision devices, emergency stop provisions and limit switches for hoisting and travelling etc.”

services from their side to meet the evergrowing requirements of the market. Let us go through the same.

Products offered today

“Demag Cranes, being a Terex brand, is one of the world leaders in the areas of inplant material movement and industrial drive solutions. Having served the Indian market since 1997, the company caters to the needs of its customers with the high standards of innovation and quality,” assures Mr Desai. “In India, Demag Cranes offers a wide range of products and services, which is a perfect blend of German designing standards and Indian manufacturing expertise.”

In the area of factory crane scheduling, to get desired results, it is required to have efficient and reliable equipment used for the purpose. The good sign is that the current players are offering pretty promising products and

Deepak Desai, General Manager, Operations, Demag Cranes & Components (I) Pvt. Ltd.

Demag Cranes works towards the objective of ‘Zero Harm’. Zero harm means think safe, work safe and home safe

The product range offered by Demag includes: • Process cranes: for heavy duty ranging from 50T to 400T • Standard cranes: for medium duty applications ranging from 2T to 80T • Modular cranes: for automobile and workshop applications • Hoists and accessories • Drives. Moreover, Demag offers after sales services including installation and commissioning, professional crane audits, annual maintenance contracts and health check

ups, refurbishment, safety inspections, and training. “The manufacturing facility at our Chakan plant has standard cranes, process cranes and jib cranes in operation. The installed cranes are workshop duty cranes intended for medium duty usage. Neither continuous nor batch production takes place at the plant,” informs Mr Desai. “As each crane is customised to customer requirements, job manufacturing activity is followed. One jib crane is assigned for each work station and material flow and transfer between two work stations is catered to by overhead travelling cranes. To ensure optimum flow and maximum usage of all work stations, multiple overhead cranes have been installed in each bay.” Jaso India offers EOT cranes, monorails, jib cranes, transfer trollies, gantry cranes, solo rope hoists, cantilever cranes, etc. in factory cranes category.

Conclusion To make factory operations satisfactory, it is essential to have a crane scheduling in practice. However, needless to say, it needs to be developed in required directions as well so as to meet the increasing needs of different operations. n

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31 n OEM Update n August 2014

Expert Column

Shop assembled - four girder ladle crane: 280T+80/20T for Steel Authority of India Ltd, IISCO Burnpur

Design criteria of ladle crane Ladle cranes have utmost importance with respect to production efficiency of steel melting shop. Hence, the selection of ladle cranes is vital. However, enough wisdom is not meted out in its selection with respect to its specification, choosing of materials and components.

ny steel plant will be requiring ladle cranes whether it is of 3MT or 5MT. Capacity of the ladle crane may also vary depending on the ultimate size of the SMS (steel melting shop). When the procurement of these cranes is initiated by smaller size steel plant, the price becomes the essence which to my mind is not correct. The price hurdles are to be ignored to a lesser extent if not to a greater extent not to sacrifice the operational efficiency of the steel plant i.e. SMS as well longevity of the crane. By saving money during the time of initial procurement stage will not be a wise decision because itâ&#x20AC;&#x2122;ll pilferage more and more money in the long run because of troublesome operation of the crane.

4137 is employed and in international market, people recommend FEM and CMAA standard. There are distinct advantages with respect to FEM standard because; it reduces the size of wheel, optimising the size of hook. But, the feels that from all the standards available for this particular crane, FEM is the best one for some of the following reasons:

Design standard to be followed There are various concepts of selection of this crane are prevailing. In Indian market, ISAugust 2014 n OEM Update n 32

Double girder ladle crane: 225T/60/12.5T for Jindal Steel & Power Ltd, Raigarh

Expert Column • Wheel load calculation is not based on mean load and ultimately the manufacturer is able to derive the optimisation of wheel. • This design standard provides accurate compatibility of wheel and rail size. • Classification of mechanism is distinctly spelt out and so the design has a wide choice to select. • Provides very detailed guidelines to check fatigue. • Rope and rope drum selection is very accurate. Following are the parts which are very critical while selecting a ladle crane for 3 MT to 5 MT SMS. VVVF drive: Nowadays, most of the modernised steel plants use this drive against the conventional slip ring motors concept. The usefulness of VVVF drive is discussed as below. Wire rope: Wire rope of adequate strength and construction is to be used to withstand the rigorous operation. Hook block assembly: Stresses are generated in wire rope and hook block assembly pin which causes the premature failure of the crane. So, adequate design criteria must be kept in consideration. The better composition of materials of EN series is employed as pin for the hook block assembly to counter the stress. Wheel: This component is also very important as far as longevity and smooth operation of this ladle crane is concerned. The higher hardness of around 400 BHN or 58/RC is nowadays desired by many of customers to counter wear and tear arises out of operation. Another aspect is to use EN-28 material for better life and strength of the wheel to withstand the impact load for Features

Capacity: 2 ton, 3 ton

Capacity: 3 ton, Cylinder Operation: Double Pump

Capacity: 1000 kg, 2000 kg, 3000 kg Operation: manual or by 220/440 V AC Application: for lifting and transporting regular shaped loads within the shop, plant, warehouse, garage and outside on level flooring

E-mail: ashwin@maclifton.com

Advantages

Standard AC Squirrel cage motor No maintenance used which is maintenance free and readily available Step less speed variation from Wide speed range min to maximum speed. Hence any speed setting possible No rotor contactor and rotor Fewer complexes cable required Smooth starting and smooth Less mechanical fatigue hence stopping offers jerk less operation longer life of mechanical parts The over load protection, under Fewer complexes voltage protection and on/off operation are in built, hence no external Contactor and protection relay needed Micro speed achieved without Micro speed in range of 5% to adding any additional hardware 100% Electrical braking before Brake life is more, less wear mechanical braking, hence less and tear of brake liner wear and tear of brake shoe Controlled tandem operation Good RPM control for tandem possible operation by feedback control The parameter display and fault On line fault display hence less display by LCD/ LED display downtime Low loss and power saving

Power saving

Starting current is less than Jerk less operation and saving conventional DOL starting in power consumption

33 n OEM Update n August 2014

Expert Column continuous operation and also offers the smooth performance but only difficulty is that EN-28 material is scarcely available. Mostly, C55Mn75 with hardness of 250 to 280 BHN or SAE5160 material is used for good health of the ladle crane. However, when it comes to bigger size of the ladle crane and criticality of the operation is severe, then use of EN-28 material is recommended.

Two girder ladle crane: 350T/75T/20T for L&T Special Steels & Heavy Forging Ltd, Hazira

Conventional Arrangement Arrangement with four motors with two motors & one and two planetary gearbox planetary gearbox system system

Main Hoist hoisting scheme

Functioning of Emergency Brake

Two motors and one planetary Four motor drives through two gearbox is provided. gearboxes with in-built planetary. Rope drums are mechanically connected through bull gear, which synchronise drum motion

Mechanical failure on any part of driving system between motor and rope drum will lead to free fall of load.

Main Hoist’s motor sizing Considering capacity and quantity of motor, KW rating of motor increases which leads to non standard higher size of motor. Maintenance & initial cost of motor will be more.

The selection of motors falls into a standard size considering four motors, which reduces maintenance cost & initial cost of motor.

Main hoist gearbox sizing Large size (non-standard) input Due to two planetary gears unit, planetary gears are required the size is reduced. because of one planetary gearbox. Case-1 : When one Main Hoist’s motor failed, then the crane operates by other the crane operates with other set motor at half the rated hoist’s of motors at half the rated hoist’s speed at 100% load. speed at 100% load.

Mechanical failure of any part of driving system between motor and rope drum will lead to over speeding of motor and rope drum shaft. This over-speeding will be sensed either by encoder mounted on motor shaft or by the limit switch along with mounted on the rope drum shaft, and the power shut off will take place immediately either through encoder or through limit switch or through both the devices. Hence, the service brakes on input shaft will come into action immediately and hold the load.

During free fall of the load from any height considering gravitational force, load starts failing down with very high speed and torque. Under such condition, the emergency brake will apply with an additional impact. This abnormal impact may cause damage to the crane’s main structure i.e. on the end carriage necks between rail and More number of service brakes wheel, and may shear off. are provided on input pinion shaft. Even in the case of failure of one brake, other brake can hold the total load and stops the free fall. So, in this system, under any situation, there will be no free fall.

Case 2 : When two Main Hoist’s motors failed, then Crane operation stops with Crane operates at half the speed load. Lowering of load will be a with two motors with 100% load. problem. Case 3 : When input pinion of Main Hoist’s gear box failed No redundancy, crane stops 100% redundancy, crane can with emergency disk brake. operates at half the speed with (need of urgent brake down 100% load by the other planetary maintenances) gear train. Arrangement of Emergency Brake One set of emergency disc brake (imported make) to be mounted on each rope drum along with the suitable over speed protection device. In case of mechanical failure, the speed of the load will exceed to the rated maximum speed and the emergency brake will be applied immediately to hold the load by sensing over speed.

Rope drums are mechanically connected through gear rings. On the input side of the gearbox, an independent shaft is provided which is connected to the output gear directly through a in built gear train. A service brake is mounted on the input shaft that acts as an emergency brake itself.

This emergency cum service brake is connected paralled to the MH To accommodate emergency disc motor through encoder, which is brake on the rope drum flange, mounted on hoisting motors. additional space is required which leads to more hook No emergency disc brake is approach and headroom. required on rope drum. Hence, hook approach and headroom can be improved to achieve customer’s requirement.

August 2014 n OEM Update n 34

Design aspect of ladle crane: Kinematics of the four motors V/s two motors Across the world, there is an ongoing debate between the two kinematics: four motors and two motors. Some people still prefer two motors kinematics whereas some prefer four motors kinematics. Though there is nothing wrong to go for two motors kinematics, there is a significant advantage of using four motors kinematics which are discussed in Table 2 owing to the fact that main hoisting mechanism performs well in this kinematics. After incorporating all the above features in manufacturing, selection of components, selection of painting supported by the full fledged quality system for incoming and outgoing materials, we have got break through in overseas market but crux of the situation is that the buyers / customers procurement departments’ approach relevant for Indian steel plants should be more pragmatic. They must give more insight in the greater reality of procurement of this critical crane exercising their wisdom. n Authored by B.D. Basu, Director (Contracts), Anupam Industries Ltd. [The views expressed in this article are those of the author’s]

Industrial Cranes

WMI Konecranes launches new open winch crane

e-Ton, the new open winch crane from Konecranes is packed with features that not only improves the efficiency of material handling, but also brings ease in maintenance

or decades, open winch technology has been the backbone of manufacturing industries in India. Even though the manufacturing industry evolved, machines became more efficient, processes became more streamlined; crane technology remained age-old and could not satisfy the expectations of emerging entrepreneurs of India. The new e-Ton Crane series is a result of understanding of customers’ needs and Konecranes’s expertise and experience in design, manufacturing, installation and maintenance of thousands of cranes in various Industries

Straight up and straight down Two ropes with multiple reeving designs avoid any transverse motion of the hook while moving up or down. So, loads are lifted straight up and brought down to the exact place. This not only makes e-Ton cranes easy and safe to operate but also helps in handling more loads in lesser time.

Maintenance made easy e-Ton crane series is packed with features which makes maintenance an easy job. High performance and reliable bearings, the arrangement of mechanical and electrical components, plug and socket connections, August 2014 n OEM Update n 36

energy chain, advanced electro-hydraulic thruster brakes are just a few examples. Every component selection, design and layout of e-Ton cranes has been done in a way to make maintenance easy, reduce uptime and improve availability of the cranes for material handling demands.

Configured for value Lighter weight and better hook approach offers savings in structural costs. It can result in either use of more floor area or designing buildings smaller, either way; it justifies the initial investment in e-Ton. “The best-in-class motor KW ratings and features of e-Ton brings can reduce operational and maintenance costs over the years and offer better economy per tonne of material that is handled by cranes,” the company claims.

Compact, yet spacious The innovative mechanical configuration of the E-Ton helps in reducing the hook approaches, thus offering more usable workspace. Yet, it has enough space, ladders and platforms to access all critical components during maintenance. For a better optimisation of space, Konecranes has developed headroom and hook approaches that have been minimised, thus offering

maximum space for other operations above and below the cranes, which consequently helps enhance safety and enables customers to better utilise the working space at their facilities.

Modular, yet flexible The e-Ton crane series is based on modular design concept. The predefined parameters reduce the time to design the crane and helps in offering faster deliveries. Yet, customers can choose the options they need for improving productivity of their processes. Every crane operation process is different, thus their specific needs are too. e-Ton can also help here by customising cranes to meet individual application requirements — for brand new cranes or the modernisation of existing ones. Also when modernising existing cranes with e-Ton, enhanced flexibility matches the design and process requirements. n Contact: Abhijeet Das Marketing & Communication WMI Konecranes India Ltd., Pune E-mail: abhijeet.das@konecranes.com Tele: +91-20- 40047470

PVC Leaders

KBL believes profitability through sustainability “KBL is one of the three manufacturers in the world who have manufactured and installed 200 kW canned motor pumps for nuclear application,” says Aniket Kulkarni, Divisional Manager, Corporate Strategy & Business Development, Kirloskar Brothers Ltd.

irloskar Brothers Limited (KBL) Is a global fluid management company headed by Sanjay Kirloskar, Chairman and Managing Director. Established in 1888 and incorporated in 1920; KBL is the flagship company of the $ 2.1 billion Kirloskar Group. Mr Kulkarni talks about the contribution of KBL to Indian PVC sector and other related things.

Graph over the years KBL is one of the largest manufacturers and exporters of pumps in India and also one of the largest infrastructure pumping project contractors in Asia. Kirloskarvadi, the flagship plant of KBL and one of India’s first industrial townships, completed 100 years of its inception in March 2010. Core businesses of KBL include large infrastructure projects (water supply, power plants, and irrigation), project and engineered pumps, industrial pumps, agriculture and domestic pumps, valves and hydro turbines. KBL is excelling in many fields like power sector, water resource management (water supply, sewage treatment and desalination), oil and gas, marine, defence and irrigation. Along with its vast national presence, KBL has presence in countries like USA, Italy, France, Germany, UAE, Singapore, Bahrain, Netherlands, Egypt, Oman, South Africa and others. KBL has 7 manufacturing plants in India in Kirloskarvadi, Dewas, Kondhapuri, Shirwal, Coimbatore, Kolhapur and Ahmedabad.

application,” informs Mr Kulkarni. “It is also the first company to introduce Concrete Volute Pumps in India. Recently the company has partnered with Tata Power in order to set up the world’s largest circulating water pumping system for them.”

Contributions to the Indian PVC sector KBL has developed and manufactured a quality technological marvel to cool down 500 MW fast breeder nuclear reactor project underway by Bharatiya Nabhikiya Vidyut Nigam Limited (BHAVINI). KBL manufactured three Primary Sodium Pumps (PSP) weighing 135 tonnes with a handling capacity of 5.16 lakh litres of liquid sodium per minute when installed at Prototype Fast Breeder Reactor (PFBR). At 590 rpm, these marvels will handle liquid sodium at 400 C to 550 C. Recently KBL has also come out with new series of its unique kind, Lowest Life Cycle Cost (LLC) series of pump. This range of pumps sustains efficiency over longer period of time and has a low life cycle cost as compared to the conventional pumps.

August 2014 n OEM Update n 38

KBL promotes the cause of sustainability through its business activities and solutions. The company lays stress on energy efficient solutions and products based on green energy. LLC TM pumps, which deliver high energy efficiency sustained over the entire product life-cycle is a case in point. Solar photovoltaic module driven pumps are being promoted to address the challenge of rising energy cost. Mr Kulkarni adds, “KBL is a partner in the Indian Nuclear Energy Program. It is one of the few pump manufacturing companies in the world and the only Indian pump manufacturing company to have been awarded N and NPT stamp by ASME, USA.”

Future outlook Performance during the last fiscal The company’s performance improved in terms of profitability. This achievement is despite a fall of 7 per cent in revenue over the previous year and a slowdown in the economy. This was possible due to focused efforts at improving contribution and bottom line. The efforts made in the international market yielded results. Now, revenue from international business is 33 per cent of the company’s consolidated revenue.

Achievements “KBL is one of the three manufacturers in the world who have manufactured and installed 200 kW canned motor pumps for nuclear

this, we will be selective in projects business and accept orders which will be cash positive throughout project life-cycle,” says Mr Kulkarni. It has taken project management practices to the next level.

Current focus “KBL continues to remain focused on profitability and cash generation. In line with

As need for pump increases so five years from now KBL plans to ensure the availability and supply of technologically advanced pumps which consume less and give more. Keeping in mind increased demand for water will create increased need for pumps, Mr Kulkarni comments, “Five years from now we see increase in demand for water due to increasing population and urbanisation.” He adds, “We expect our initiatives further strengthen our position in Indian market and help us leverage our strengths outside the boundaries of India.” n

PVC Leaders

Grundfos encouraging water and energy conservation “Not only our products are energy efficient and consume less water, we also are involved in many endeavours which help create awareness about water and energy conservation,” informs Mahathi Parashuram, Head – Public Affairs, Grundfos Pumps India Pvt. Ltd.

rundfos India provides pumps and pumping solutions for various applications including heating and hot water service systems, cooling and air-conditioning systems, industrial applications, pressure boosting and liquid transfer, groundwater supply, domestic water supply, sewage and wastewater, dosing, chlorination systems, disinfection systems and pumps running on renewable energy. Ms Parashuram explains how the company is trying to create awareness about water and energy conservation.

approach to creating the innovative solutions for its customers, based on their unique demands. The company also has solar pump offerings for rural and agricultural applications to help address the lack of electricity in some of these locations. Since 2001, Grundfos has sold 8,800 solar pumps and this has had a positive impact on the socio-economic lives of so many villagers throughout India. It also conducts water and energy audit for companies thereby helps them conserve these resources.

Grundfos Growing Globally

Last fiscal got affected

Grundfos Pumps India Pvt. Ltd. (Grundfos India) is a wholly owned subsidiary of Grundfos Holdings. Grundfos India is responsible for sales of Grundfos products in India, Bangladesh, Bhutan and Maldives. Aligning to its global sustainability focus, Grundfos India is committed to sustainability.

“Like most industries, the pump industry was affected by the economic slowdown last fiscal. Grundfos has also been affected by the same factors as other industries,” says Ms Parashuram. “However, from a long-term basis, the pump market has immense growth potential due to factors such as increasing demand for water combined, declining per capita water availability, and investments in infrastructure, industrialisation and urbanisation.”

“Not only our products are energy efficient and consume less water, we also are involved in many endeavours which help create awareness about water and energy conservation,” informs Ms Parashuram. “Grundfos India is working towards helping Indian industries and corporates save both energy and water not only through its highly energy efficient products but also through the energy and water audits it conducts. These audits are a complete system analysis of the energy and water consumption. Post the analysis the energy audit team recommends the best solutions to right size the systems; thereby helping conserve both these resources.” Grundfos has further strengthened its offerings with Grundfos iSOLUTIONS, an August 2014 n OEM Update n 40

Current focus “We want to increase our market share across the segments that we have product offerings. We are focusing on higher localisation and exports too with some products ‘made in India for India’, which we expect will contribute to growth in the coming years,” says Ms Parashuram. The company aims to increase its presence in the price sensitive domestic pump market with the Italian brand ‘DAB’ – which will cost lower compared to Grundfos. Moreover, Grundfos India is also looking at expanding its distribution network in the coming years.

Major initiatives taken Grundfos India has been in India for more than 15 years now and its steady growth and increase in market share speaks lot about the acceptance of high quality and energy efficient pumps in the country. The company also contributes towards energy and water conservation by reducing its own impact on the environment. Its headquarters in Chennai is India’s first goldrated green building (LEED certification by USGBC in 2005) and is energy efficient with 100 per cent recycling of the sewage, rain water harvesting and with solar collectors and photovoltaics. Grundfos India’s factory also received the gold certification in 2011 from the Indian Green Building Council (IGBC). In August 2013, the Grundfos office building was elevated to a LEED EB Platinum certification. “We were the first ones to introduce the concept of Low Life Cycle (LLC) since early 2000. As pioneers in water technology and pumping solutions, we will continue to raise the industry standards through our innovative and sustainable products,” assurers Ms Parashuram. In addition, it is also working with students from elementary schools to universities to spread awareness on sustainability (energy and water conservation). The company encourages school visits to its facility to showcase the Green Building concept. Grundfos India has been successful in reaching out to 503,000 students since 2010. Through these students the company is influencing their family, friends and communities to conserve water. n

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PVC Leaders

Shakti Pumps focusing on solar pumping solutions “We are playing a vital role in renewable energy solutions particularly solar pumping solutions and capturing an increasing market share in pump industry and solar pumping systems,” says Dinesh Patidar, CMD, Shakti Pumps (India) Ltd.

he announcements in the union budget making an overall allocation of ` 1,000 crores for the renewable energy sector with a focus on solar energy is likely to benefit the industry as a whole. Also an announcement of 1,00,000 solar pumps in the current budget indicates a more promising outlook towards solar pumping segment. Mr Patidar shares his views in this regard and talks about overall performance of Shakti Pumps as well.

Journey so far Established in 1982, Shakti Pumps (India) Ltd. is now one of the leading energy efficient stainless steel pump manufacturers and exporters in India with a strong presence in more than 100 countries across the world. Its product portfolio consists of stainless steel pumps and motors to meet the needs of agricultural, horticultural, industrial and domestic sectors as well as commercial and industrial buildings. The company believes that its products offer best in class energy efficiency, lower maintenance and longer life owing to superior quality and innovative technology. The advantage of Shakti Solar Pumps is that they can run on both solar power (DC) and the power sourced from the grid (conventional AC power) with a very high discharge rate for extended periods.

During the last fiscal Shakti Pumps reported a strong performance last fiscal. Its total revenue for the year August 2014 n OEM Update n 42

ended March grown by 41.4 per cent growth over the previous year, while its net profit registered a 43.7 per cent growth over corresponding previous year.

proving not only to be a cost effective solution to the farmers but for the government as well, as this will reduce their power subsidy bills quiet considerably.”

The results are supposed to be a vindication of the company strategy of delivering quality and innovative products. It also mirrored its strong focus on exports supplemented by a growing presence in the domestic market. All of these resulted in increased sales, net profits and operating margins.

The company has identified the huge potential of solar pump market in India which is a feasible and adaptable in Indian context where grid electricity is often erratic or nonexistent as far as rural areas are concerned. Solar pumping systems can be installed even at the remotest location where grid power is not available. According to the views of the company, large scale use of solar pumping systems will ease pressure on demandsupply gap.

Target for the current fiscal Going forward, Shakti Pumps has decided to expand its presence in the domestic market by tapping the fast growing industrial segment with more value added products. It has also made a strategic shift in its dealership model that has begun in April of this year. In fact, it is now appointing dealers who will be exclusive outlets to sell its products. The company believes this will help it to serve farmers better as they will now opt for what is required and not what is necessarily offered to them. The company is confident about touching a turnover of about ` 400 crore in FY 15.

Major contributions “We are the first to launch stainless steel submersible pumps in the India which was revolutionary move in the pump market,” informs Mr Patidar. “We have successfully launched India’s first AC solar pump which is

After five years “We see ourselves as a company that brings even more innovative solutions to the Indian pump industry by offering energy and cost effective solutions to its customers particularly the farmers,” says Mr Patidar. “We are playing a vital role in renewable energy solutions particularly solar pumping solutions and capturing an increasing market share in pump industry and solar pumping systems.” The company has already expanded its footprint in exports into new geographies like Argentina, Austria, Afghanistan, Czech Republic, Costa Rica, Columbia, France etc. And it projects itself as an aspiring company with an urge to grow by leaps and bounds and touch its vision target of ` 5,000 crore by 2021. n

PVC Leaders

“Energy efficiency is not a USP, it is considered given” “Air compressors being one of the most ubiquitous industrial workhorses energising modern day factories, hospitals, workshops and residential complexes, their demand is expected to be recurrent,” says Amar Kaul, VP and Business Head for Compressed Air Systems and Services business of Ingersoll-Rand India

ngersoll-Rand (India) has recently rolled out an aggressive plan for growth in India. In this interview, Amar Kaul talks on the trends and technological advancements in the field of compressors and his company’s commitments.

Most importantly our vision is to bring to the Indian industry a level of service that is only seen in the consumer space as of now. We have already made couple of strides on this direction and have been well received in the industry.

Ingersoll Rand has been in the industry for so many years. How has the experience been so far and what kind of growth is expected? The experience has been very fruitful and the response from the industry as I see is really overwhelming. We have been one of the oldest American investments (dating back to 1921) in India and one of the first companies to make India the global sourcing hub for product lines.

How do you see your company establishing in Indian market? Over the past few years, we have been consistently investing in initiatives that have improved our productivity and this continues to be the journey of operational excellence. Ingersoll Rand is at the forefront of customer-centric innovation and we are constantly innovating products and solutions that are relevant to the Indian market and our customers. To sum up, our innovative approach, customer-first and solutionising mindset has driven us into the position of market leaders.

Ingersoll Rand has been pioneer in bringing into the country centrifugal technology as well as the award winning “Nirvana” energy saving rotary compressors. Ingersoll Rand had the courage to invest in manufacturing of Centac in India, in 1989, when centrifugal technology was barely known and hardly accepted. This approach has been handsomely rewarded by the market. Over and above bringing global innovations to India, we will continue to design and develop local innovative solutions for customers in India. August 2014 n OEM Update n 44

Market opportunities are governed by the mega trends that define the economic progress. Growing population and scarcity of power become the basis industries in all verticals like FMCG, F&B, pharma, and power coming up with strong growth potential. Air compressors being one of the most ubiquitous industrial workhorses energising modern day factories, hospitals, workshops

and residential complexes, their demand is expected to be recurrent. As I said earlier, there is a greater demand for energy efficient (low life cycle cost or operating cost) and minimum maintenance (high reliability) machines. Today, the purity of air has become the most important element if you have critical oil-free applications which are catered to by our Class 0 range of oil-free compressors for rotary screw and centrifugal technologies. Similarly, if you have a multiple-compressor installation, advanced controllers — coupled with extensive system audit services enable our customers to have optimum air efficiency, consistent flow, pressure and extended life of system components. Tell us about the products and services you are offering in the field. Ingersoll Rand offers a wide range of compressors from 0.75 to 4,500 kW and has several firsts to its credit, including its distinction of being the first company to introduce centrifugal compressors to the country. Ingersoll Rand is among the first manufacturers to offer compressors on rental in order to help customers avoid huge investments. Besides compressors, Ingersoll Rand offers the widest range and technologies for air treatment and filtration

PVC Leaders solutions-air dryers, filters; storage solutions-air receivers; energy savings controls solutions like system pressure and flow controllers, variable speed drives, remote monitoring as well as the energy saving compressed air modular piping and distribution solutions for increasing the overall efficiency of the entire system (demand, supply and distribution side), besides reducing the maintenance costs and downtime. The plant audit solution services deliver a unique combination for overall optimised efficiency, reliability and operations. Centac, our centrifugal compressor range, has been our flagship product in our industrial compressor range. Ingersoll Rand India proudly celebrated the milestone of shipping its 1,000th Centac package from the Naroda plant facility last year. Considering this new wave of energy efficient air compressors, Ingersoll Rand recently launched a new range of D series refrigerated air dryers that offer unmatched energy efficiency, low cost of ownership, higher uptime, traditional Ingersoll Rand reliability, and environment friendliness with use of Zero ODP refrigerant, adaptability to tropical conditions, and superior serviceability. How do you look at the compressors industry in India? We see a definite shift from oil-injected compressor technology to class O oil-free compressor technology. In centrifugal compressor space, we see a movement from small and medium capacity machines to large capacity machines. Today, energy efficiency is not a unique selling proposition, it is considered given. Customers prefer solutions that have the lowest cost of ownership. Often compressed air systems in factories and facilities are not energy efficient. System owners have great opportunities to improve operating margins and reduce costs through energy savings. As every industry tries to cut down costs, audits of compressed air systems help in reducing hidden costs and ultimately contribute to increase in revenue. Ingersoll Randâ&#x20AC;&#x2122;s Audit Solutions offers services that help our customers identify potential leakages and take corrective actions to conserve energy. Some of the real cases after acting on actions from energy audit have had pay back of less than six months after which is pure savings. Through our experience in handling energy audits, we have seen that the audit processes are extremely educational and informative. We encourage our customers to participate and learn the methodology during such audits apart from just monitoring and implementation. With compressed air being one of the poorly managed industrial utilities, there is enormous opportunity to change the way it works now. How Ingersoll is leading the way through local innovation to cater industries like power, textile, iron & steel, automobile and general industries? Our dedicated product management and engineering teams continuously work on understanding customer needs and then work backwards on Innovation with best of the technologies based on efficiency and sustainability. With a strong team of world-class professionals, we are able to provide superior service experience to our customers at any given time. We have already graduated multi steps from old concept of AMC (Annual Maintenance Contract) to Package Care and Package Care +.

The above suite of service packages in summary means insurance of our machines at customer site. Customers also appreciate that we ensure uninterrupted supply of quality AIR and they focus on their core competence. We invested heavily on remote monitoring to monitor the performance of our machines remotely. This ensures that before the machine brakes down, our service technician is at the door step. These are some of the innovations that we thrive on over and above the product innovation. For catering to specialised engineered compressor packages, Ingersoll Randâ&#x20AC;&#x2122;s highly specialised and expert teams can handle large projects for customised solutions and provide a one-stop solution right from conceptualisation, design, installation to audit control. Our team of experienced engineers works closely with the customers to design packages which are passed through stringent quality tests and inspection before shipping to the customer location. Would you like to talk about your future expansion plans? As mentioned earlier, we will continue invest in customer centric innovations, partner with our customers to make them successful in their business. The simple philosophy is that if we help our customers be successful and grow, we automatically will grow and be successful. We will continue to invest in our services suite to being in the levels of service that industry would not have seen before. n

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PVC Leaders

ABEL eyes on various sectors including power “We hope the way ABEL has been welcomed into the Indian power sector by providing efficient high concentrate ash disposal solution, the same trend would be achieved in other sectors such as mining, paints, sewage treatment,” hopes Vicky Chawla, Executive Engineer, ABEL Pump Technology.

BEL, headquartered at Büchen, Germany, focuses on reciprocating positive displacement pumps – on development, design, manufacturing, marketing and, last but not least, service. Mr Chawla talk about the company’s focus and its performance up till now.

ABEL establishing itself The company specialises in reciprocating positive displacement pumps for varying flow rates and pump pressures with the particular core competence in membrane pumps. Together with ABEL’s usual quality standards, this design principle of the hermetically sealed pump is especially suited for abrasive, aggressive and even shear-sensitive media. “Thanks to our technological advantage in mechanical membrane pumps, ABEL has earned a well respected reputation around the world,” says Mr Chawla. “Solids handling pumps for paste-like and non-Newtonian media and high pressure plunger pumps round off our range of high-capacity pumps.” ABEL in now one of the leading names in the piston diaphragm pumps segment being used in the power sector in India for long distance high concentrate ash slurry disposal. The company has supplied pumps to various public and private owned Indian companies, namely NTPC, APGENCO, TGENCO, IndiaBulls, Reliance, Jindal and many others. August 2014 n OEM Update n 46

Previous fiscal show “The last fiscal did see a down slide in the performance of the company which was in sync with the trend in the Indian economy,” admits Mr Chawla. “We hope the optimism in the business world and the proactiveness of the current power holders proves to cause a turnaround in the power sector.” The number of pumps sold in the last fiscal was down by about 70 per cent from the previous fiscal. ABEL’s major focus for the past 8 years in India has been on the power sector, which did take a beating in the last 2 years due to various reasons ranging from political to financial, resource availability to improper planning. The other sectors like cement, waste water management, mining were slow moving as well, with various private players hoping for some welcoming changes in policies with the change in the decision makers of the country.

“At ABEL we believe in satisfied customers being our main profit. We sell pumps not only for a commercial advantage but also provide solutions to problems being faced by the clients using conventional technology and pumps,” shares Mr Chawla.

Performance on scale “We have been successful in giving a satisfactory solution to various end users, by providing piston diaphragm pumps, which are easier to maintain, reliable, have less operating costs, less downtime and highly efficient as compared to conventional options available in the market,” believes Mr Chawla. ABEL pumps are supposed as heavy duty piston diaphragms pumps which can pump highly abrasive, corrosive media having high flow rates to long distances without the need of multistaging and the need of frequent replacements and maintenance.

A look into future

Aim for current fiscal

ABEL is already considered as one of the leaders in the European market and features among the top companies in the global scenario.

The company’s aim for this fiscal is to spread awareness on the advantages of piston diaphragm pumps over the centrifugal/ lobe/screw/AOD pumps. It hopes to regain the growth in power sector and also make inroads into paints, mining sectors in a big way.

“We hope the way ABEL has been welcomed into the Indian power sector by providing efficient high concentrate ash disposal solution, the same trend would be achieved in other sectors such as mining, paints, sewage treatment,” hopes Mr Chawla. n

Process

Max Pure aiming max in water treatment industry With the development of its own pump with the brand name of FILMAX, Max Pure is now establishing itself firmly in water treatment industry

ax Pure Water System Pvt. Ltd. is an importer and supplier in water treatment industry. It is also a member of Water Quality Association, USA since 2005 and an ISO 9001:2008 certified company. Max Pure is also certified with NSIC-CRISIL rating SE 2B for performance and financial strength. The company has its head office in Surat and sales offices in the major cities of India like Delhi, Nagpur, Ludhiyana, Jaipur, Udaipur, Indore, Ahmadabad, Rajkot, Surat, Chennai, Secunderabad, and Bangalore etc. Today Max Pure is one of the leading and trusted names as supplier of genuine components and plants in water treatment industry. Now the company has developed its own pump with brand name of FILMAX. The company believes it as its high quality pump with economic price range. In fact, the company has launched the series of

products with brand name of FILMAX and PURE-MAX, etc. The company is having tie up with national and international level for the procurement of water treatment product like water filter cartridge, water pump, reverse osmosis elements, filter housings, QC fittings, TDS meter, and antiscalant-balls etc. The company is a distributor for sales and distribution of Vontron’s RO element. Vontron Technology Co. Ltd. is specialised in R&D, manufacture and technical service of RO and NF membrane elements owning the core technology and capability for fabrication of membrane sheet. Vontron is one of the biggest professional manufacturers of compound RO membranes in China, and is the provider of system design and applied service with powerful technical support. Vontron owns and operates its producing plant in Guiyang, amounting to a total yearly

capacity of 10 million sq. m. of RO/NF membrane sheets. n Contact: Max Pure Water System Pvt. Ltd., Near Bharat Petrol Pump, Opp. Bharat Cancer Hospital, Kumbharia Road, Saroli Surat, 395010. Tele: +91-261-2643894 Mob.: +91-76000 10480 www.maxpure.com

KHD Valves offers flush bottom valves K

HD Valves Automation Pvt. Ltd. has presented flush bottom valves which find their applications in reactor vessels, autoclaves, other pressure vessels for handling abrasive, slurry, pulp, viscous material or semi solid media. These valves do not require any lubricants. Packing option is available as per service condition to suit for high temperatures. The company offers a tailor made design do suit your reactor/vessel nozzle pad dimensions. Also third party inspection is offered by the company.

August 2014 n OEM Update n 48

Salient features: • Design option : upward opening (stem travel in the vessel) downward opening (stem travel in the valve body), ram type (piston) • Seating option : stellited, metal to metal or soft seat. • Stem design : rising stem, (open / close position indicating type) • Type : jacket / non jacket • Material: cast steel , SS 304, SS 316, carbon steel or any • Construction: special alloy to suit the customers’ requirement • Size range : 15 mm to 150 mm. n

Process

UPF 150: high head stainless steel submersible motor pumps K

SB Pumps in India has launched UPF 150 series of stainless steel pumps augmenting its 150 mm size of submersible motor pumps. These radial flow type pumps can deliver up to 15 m (50 feet) per stage and are available in 6 hydraulics viz. UPF 60, 80, 100, 125, 150 and 200. Hydraulic components like impeller, stage casings, are made from investment cast high-quality stainless steel. This ensures longer life of the pump sets. Pump and motor shaft is made from stainless steel (Grade 420) offer excellent torque values. Bronze bearing bush and carbon v/s chrome steel thrust bearing ensure trouble free smooth operation. These pumps are coupled with 150-mm (6-inch) motor to give head up to 350 metres and discharge up to 44 cubic metres per hour. Motors are available in wide

range up to 18.5 kW (25 HP). Proven German technology ensures high-efficiency of motors which in turn results in low power consumption. UPF pumps find wide applications in irrigation, drinking water supply schemes, farm houses etc. The product is backed by KSB Pumpsâ&#x20AC;&#x2122;s wide dealer and service network across India. n Contact : Suhas Shiras (Sr. Manager â&#x20AC;&#x201C; Dealer Business) KSB Pumps Limited, Mumbai-Pune Road, Pimpri, Pune 411 018 Tele: +91-20-27101234 E-mail: suhas.shiras@ksb.com

UNINAM: one-stop solution for industrial products U

ninam Industrial Marketing, an ISO 9001:2008 certified organisation, has emerged as one of the leaders 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 customers all over the country. It has around 200 products in its product range i.e. pneumatic and electrical actuator operated valve, solenoid valve, water 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, HVAC mounts/HP hoses, FRL (filter, regulator, lubricator) Rubber expansion joints and S.S. bellows etc. from leading companies such as Zoloto, Amco, Fouress, ATAM, Resistoflex ,Parker Legris for lifelong trouble-free service. 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. August 2014 n OEM Update n 50

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, fertilisers, dairy, paint and heavy engineering etc. n

Process

FIBRO rotary table combinations yield maximum productivity

otary tables bring movement into modern production. This applies all the more when they drive up plant productivity in combined form as NC multiaxis combinations. In addition to power, dynamics and precision, the tried and trusted FIBRO features of endurance and reliability in particular all play a decisive part.

FIBRO standard multi-axis combinations have a modular design based on the extensive FIBRO range of construction components. The drive units for the swivel axes are provided by FIBROPLAN rotary tables of different sizes powered by worm gear units. Both FIBROPLAN rotary tables and, to optimise speed and acceleration, direct-drive FIBRODYN rotary tables are used for the machining axis. The number of rotary tables on the machining axis varies. In addition to the standard models, FIBRO rotary tables in all series and models can be used for multi-axis combinations. In realising customised solutions, the special expertise of FIBRO engineers is also in demand as in the exceptional depth of production of the

rotary table specialists. Numerous projects in a wide range of sectors around the globe demonstrate how significantly users are profiting from the high level of solutions expertise and the worldwide service network at FIBRO.

Features • Standardised, modular range for fastest possible delivery times • As an additional machining axis for maximum efficiency • Flexible positioning and machining options for minimal setup times • Machining axis with worm gear drives for maximum rotary milling torques or direct drive options for maximum acceleration and the highest possible speeds. n

Environ offers energy efficient aerators W

hen evaluating aeration systems, a total performance and cost of operational analysis is critical. The components of this analysis should include an evaluation of the initial capital cost of system installation, all operating and energy costs, and projected maintenance costs. Also included should be an analysis of how well the systems perform the four basic functions as follows: • Provide sufficient oxygen transfer to promote biological treatment • Provide sufficient mixing to ensure homogeneity of mixed liquor suspended solids and to prevent solids settling • Respond to varying process conditions to maximise energy efficiency • Provide reliable service, without costly maintenance and downtime, and without reduction in oxygen transfer capability. In diffused aeration system, as the blower blows hot air, the temperature of the effluent rises by 5°c to 8°c due to which the oxygen transfer efficiency reduces. While in mechanical aeration system the temperature of the effluent reduces by 5 C to 8 C and August 2014 n OEM Update n 52

hence oxygen transfer efficiency increases. The distribution of air is not equal in this system. It is equally distributed in all the four corners of the aeration tank by mechanical aerators.

Environ’s solution Environ claims that its energy efficient aerators accomplish mainly offer efficient aeration, excellent mixing, operational flexibility and a life expectancy of 12 - 15 years with minimal maintenance. If the aeration tank depth is more than 2.75 metres, there will be settlement at the floor level, which will create septic conditions and

in turn zero D.O. level. Nowadays, as due to the space constraint, most of the tanks are designed with higher depths. it is the duty of the aerator manufacturer to change the design of the aerator impeller considering the depth of the aeration tank, believes Environ. However, it is not possible without doing the experiments or proper R&D. Environ has its own R&D division in India, wherein it carries out oxygen transfer test as per American standard and Wrinkler’s procedure, before placing the prototype aerator in the market. Secondly, it runs all the aerators and agitators for two hours, as per our quality assurance plan. n

Factory Visit

Racold’s factory: making of efficient water heaters Racold Thermo’s Chakan plant manufactures 6 lakh products per year and aims to expand its product range. After a visit to the factory, Swati Rana writes about the process involve in making of efficient water heaters

acold Thermo Ltd., an ISO 9001:2008 company, is a fully owned subsidiary of Ariston Thermo Group, Italy. In India, Racold’s fully integrated water heater plant started in Chakan near Pune and has been in operation since 1999. Spread over 21 acres, the plant manufactures electric, gas and solar water heaters. Ever since its inception, Racold Thermo has been changing standards in the Indian water heater industry by bringing in new technology, enhancing the aesthetics, quality, durability and performance of the product. The plant manufactures 6 lakh products per year. The company has won the Energy Conservation Award from Bureau of Energy Efficiency (BEE) four times in a row for electric storage heaters. August 2014 n OEM Update n 54

Challenges One of the main challenges that water heating industry faces is how to make a product that can last in any water condition. Commenting on this aspect, Mathew Job, MD, Racold Thermo Ltd., says, “We felt the product we sell anywhere else in the world may not work well in India. We did lot of R&D locally and developed Super Polymer High Performance (SPHP) technology to manage the hard-water condition in India.” The company’s plant in Chakan has an R&D centre, which has helped Racold to produce energy efficient products. It is pertinent to mention that, Ariston Thermo, the parent company of Racold, invests 58 million Euros yearly in R&D worldwide.

Manufacturing process Electric water heater contributes 70 per cent

of Racold’s business. Racold Thermo has the complete in-house manufacturing process of water heater. The process starts with the manufacturing of top and bottom dome of the water heater. Round shaped flat stainless steel sheet is moulded into the container. In trimming operation the collar of the container is removed. After the top and bottom dome is ready it’s sent for flange and pipe welding. Different model has different cylinder. Stainless steel sheet is then rolled and welded to form a cylindrical shape. In Circum MIG welding process, top and bottom dome along with cylinder of water heater are welded together to form the inner body of water heater. Sand blasting inside and outside, smoothens the surface of the inner body of water heaters. With the help of SPHP technology the product is made corrosion free. The heating element is added and the product is tested to check

whether it withstands upto 8 bar hydraulic pressure, which is the highest pressure. The puff used for insulation is manufactured in the factory to make the product more energy efficient. Once the inner body of the water heater is insulated, the product is sent for assembling where the outer body of the water heater is positioned. Once product is all set, it’s sent for packaging. The company has also come up with its new range of product in electric water heater section i.e. Eterno and Altro.

Vacuum tube and flat plate collector The solar market is growing very quickly due to electricity shortage and the increasing cost of electricity. As India has abundant sunshine, there is a huge scope of growth for solar market. Racold Thermo started manufacturing solar water heater in early 2005. The company provides vacuum tube collector and flat plate collector in solar water heating section. The plant manufactures all the components like the inner tank, outer body, thermostat, heating element etc. to ensure the quality of the product. In 2012, Racold introduced solar water heaters in two categories: Vacuum tube and flat plate collector. The tube technology provides maximum heating efficiency. Each tube is made up of two high quality glass tubes of optimum length to ensure excellent solar absorption. The inner container is insulated with high density injected PUF to provide maximum heat retention. The tube has a unique V shaped SUN-MAX reflector. This ensures maximum absorption of solar energy as the rays are reflected back on to the tubes, thus increasing the product’s efficiency. Whereas the flat plate collector has a specially designed contact area that allows superior heat absorption. Thick aluminium fins and copper pipe used in its construction ensure longer life and higher efficiency. The fins are painted black to absorb more heat from the sun’s rays. Box structure is designed with pre-coated steel that makes for a tough and sturdy collector. Solar water heater contributes 25–28 per cent in Racold’s business and is one of the fastest growing sectors.

Safety measures “We have safety committee and there are certain rules and regulations. There are 500 employees working in the factory and safety trainings are provided to all of them,” says Mahesh Bhangale, GM Manufacturing, commenting on the safety measures taken by the company. “The factory has an automated fire alarm, which triggers with the increase in room temperature. Hazardous waste released from the plant, are given to the waste management for disposal.”

Localisation In past, the company was primarily dependent on local products, but now it offers both local and international range. Today Racold products are available in 10,000 stores across the country and now it plans to extend the tally to 12,000 stores.

Roadmap for Racold According to Mr Job, since 2012, Racold has been growing approximately 30 per cent per year. Their objective is to double their business every 3 years. The company aims to expand its product range and availability in the market. Talking about its expansion plans Mr Job says, “Expansion happens on many fronts, one is of course in terms of product range. We have introduced a new product range in 2012; we also have the possibility of bringing some of the products from the other global markets of Ariston.” n

Event

electronica & productronica India 2014 – bigger than ever Bhupinder Singh, Acting CEO and CMO, MMI India gives an overview of the electronica India 2014 and productronica India 2014 shows to be held at BIEC, Bengaluru during 23 - 25 September

What are the USPs of electronica India and productronica India trade fairs? The major USP of these trade-fairs are that they are a complete electronics manufacturing shows. Participating firms span the entire electronics manufacturing spectrum - production equipment, SMT, EMS, components, assemblies, semiconductor and materials. We see electronica India and productronica India 2014 as a turning point. The shows highlight to both exhibitors and visitors India’s prowess in the electronics manufacturing sector. We have received strong participation from EMS companies and also will be featuring a seminar on EMS by ELCINA. We also have exclusive exhibitor pavilions on Defense, CLIK, IPC India, MSME and LED.

How far have the shows electronica India and productronica India evolved in the last two years? Compare to Delhi the fairs would be 25 per cent bigger. This year around 350 exhibitors representing 600 companies including principals, agents and representative companies from 25 countries will present their products and solutions. Last year, though most of the other shows in this category suffered the visitor turnout shortfall, but our show managed to receive around 12,000 visitors from all across the world.

How will these shows go about in boosting the electronics ecosystem in India? These shows are closely interlinked to the August 2014 n OEM Update n 56

world’s leading trade fairs electronica and productronica in Munich. With the coming together of the industry, we aim to drive further growth within the next few years and to boost the business for the Indian electronics industry. The trade-fairs have always been supported by Department of Information Technology, Ministry of communications & Information Technologies (DeitY) and over 15 industry associations working for the development of the Industry. Also, the fact that it’s being held in Bangalore adds value as the South Indian market has been the hub of the electronics Industry.

How does electronica India and productronica India benefit the participants/exhibitors? These trade shows are amongst the best promoted brands in India. In addition to the high number of focused visitors, the presence of potential buyers of electronica hall in the adjoining productronica hall is the big advantage. The shows also have a fine mix of domestic and international exhibitors which enables a very dynamic exchange of information and expertise. The shows, like in earlier editions will also host a series of high powered technical conferences. These conferences we believe will go a long way in keeping the Indian electronics industry abreast with the fast changing global technology trends and emerging opportunities and will showcase the

latest investments opportunities. electronica India and productronica India display the trends with innovative products, new technologies and presents the latest topics and plays the important role of an enabler for the manufacturability of electronic goods. This year IPC India will be co-located with electronica India and productronica India. This means that visitors and exhibitors get even more value for their participation. IPC India will conduct technical seminars, workshops and more on PCB technologies and designing.

Can you throw some light on the new exhibit areas? electronica India and productronica India 2014 will represent special focus on strategic electronics – defence and aerospace. Another special area at this year’s show will be the EMS Zone which provides a great opportunity for EMS companies to exhibit within a common area next to their national and international competitors. In addition the fairs this year are segmented into semiconductor, LED, cables and connectors, MSME zones to offer a better overview to the visitors.

What about International participation in the show? This year we will feature country pavilions from the Singapore, Germany, Taiwan, China, and participation from over 25 countries. n

Event

Grand representation of logistics sector: India Warehousing Show products live and functional. Also, allowing them to interact face to face with the manufacturers, suppliers and dealers. The show also featured US pavilion, Supply Chain Zone, Automation4Logistics, Packaging4Logistics and international pavilion. Anuj Mathur, Managing Director of Reed Manch Exhibitions said on the huge success of the event, “The show has been designed in such a manner that it helps you in procurement of complete intralogistics solutions for your warehouse, manufacturing unit or your distribution centre”.

he 4th India Warehousing Show lifted the spirit of logistics industry by bringing complete supply chain solutions on one platform from 8-10 July at Pragati Maidan in New Delhi. Exhibition featured 210 exhibitors, 380 live technologies from 25 countries and was attended by 7,818 trade visitors representing 220 cities globally. The show was appreciated for being business matchmaking & learning platform for the industry. Displaying complete range of solutions including warehousing infrastructure, material handling equipment, automation solutions, storage solutions, logistics and supply chain altogether – IWS 2014 gave its attendees the benefit of choosing, exploring and experiencing

Commencing the show’s inauguration ceremony, Dinesh Rai, Chairman of Warehousing Development & Regulatory Authority said, “India Warehousing Show is an important event for logistics industry and has been crucial in bringing industry together. Such events play the role of growth catalyst.” Some of the key speakers were Shreyas Malkan, AVP – SCM at Reliance Communications Limited; Vijay Wadhwani, Sr. GM Supply Chain Management at Relaxo Footwears; Amit Banerjee, Head Supply Chain & Demand Fulfilment – India at Tata Motors; Abhik Saha, Director – Supply Chain at Benetton India; Ashok Khurana, Regional Business Head at Google Enterprise India and Hemanth DP, COO Hub Development, Cargo Business & Free Trade Zone at GMR, Hyderabad. n

57 n OEM Update n August 2014

OEM

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61 n OEM Update n August 2014

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August 2014 n OEM Update n 62

COMMERCIAL PARTNERS Ace Micromatic Group............................................................................ 21 Akzo Nobel India Ltd...............................................................................11 Annair Controls....................................................................................... 63 Bosch Rexroth India Ltd....................................................................... IFC CAD MAcRO Design & Solutions Pvt Ltd............................................... 29 Crane-Bel International Pvt Ltd.............................................................. 43 Dormer Tools India Pvt Ltd..................................................................... 19 Electro Steel Engineering Company...................................................... 62 Environ Engineering Company............................................................... 39 Fibro India Standard Parts Pvt Ltd......................................................... 17 G R Cranes & Elevators......................................................................... 33 Graebert India Software Pvt Ltd............................................................. 27 Green Eclipse Technologies India Pvt Ltd.............................................. 25 igus India Pvt Ltd.................................................................................... 41 IMTMA.................................................................................................... 13 Jaso India Pvt Ltd................................................................................... 31 Kanti Automatic Systems........................................................................ 35 KHD Valves Automation......................................................................... 63 Mather & Platt Pumps Ltd........................................................................ 7 Omron Automation Pvt Ltd................................................................... IFC Power Build Ltd.................................................................................... IBC Pratham Filter Industries........................................................................ 66 Radiant Engineers.................................................................................. 23 Red Lion Controls................................................................................... 15 Robinsons Cargo and Logistics................................................................ 5 Sameer Sales Corporation..................................................................... 62 Shalimar Engg. Company...................................................................... 33 Siemens Ltd............................................................................................. 9 Silver Water Technology......................................................................... 61 U K Systems........................................................................................... 45 Uninam Industries.................................................................................. 62 Valvoline Cummins Ltd.......................................................................... BC WMI Konecranes India Ltd..................................................................... 37

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63 n OEM Update n August 2014

New Projects

Textiles

Environment protection

BKS Textiles implements a woven fabrics manufacturing project at Palladam Hi-Tech Weaving Park, dist. Tiruppur, Tamil Nadu. The project will involve installation of 24 Rapier looms in addition to the existing 60 Sulzer looms in the existing plant premises. Location: Tiruppur, Tamil Nadu Status: Under Implementation Contact: B K S Textiles Private Limited , Registered office: No.2/316, Kungumapalayam Pirivu, Palladam - Tirupur Main Road, Palladam, Naranapuram PO, Coimbatore, Coimbatore - 641664, Tamil Nadu Tel: 91-4255-256789/ 256799 Email: mail@bkstextiles.in Website: -www.bkstex.in,-www.bkstextiles.in

Gujarat Alkalies & Chemicals plans to construct a 7.5 Kms pipeline at Dahej, dist. Bharuch, Gujarat. The pipeline is for disposal of treated effluent into the gulf of Khambhat, parallel to the adjusting pipelines. Location: Bharuch, Gujarat Status: Planning Stage Contact: Gujarat Alkalies & Chemicals Limited, Plant address: P. O. Dahej, Taluk Vagra, Bharuch - 392130, Gujarat Tel: 91-2461-256317/ 91-2641-256315/ 256316 Fax: 91-2641-256220 Website: www.gujaratalkalies.com

Drugs and Pharma

Airports

Anvitha Life Care plans a 200 TPA bulk drugs & intermediates manufacturing project at Athivaram, dist. Sri Potti Sriramulu Nellore, Andhra Pradesh on 4.5 acres.The project is planned for completion in June 2015. Location: Sri Potti Sriramulu Nellore, Andhra Pradesh. Status: Planning Stage Contact: Anvitha Life Care , Administrative Office: Plot No: 2 To 9, Rose F2&F3 First Floor, Justice Square Apartments, Rajas Garden, Judges Colony, Noombal,Thiruverkadu, Chennai, Chennai - 600077, Tamil Nadu Email: prakasam.tangirala@gmail.com

Kannur International Airport plans to construct a terminal and control tower buildings at Mattannur, dist. Kannur, Kerala. Tenders have been invited. Work on the project is expected to commence in August 2014. Location: Kannur, Kerala Status: Planning Stage Contact: Kannur International Airport Limited, Registered office: Parvathy, TC 36/1, Chacka NH Byepass, Thiruvananthapuram, - 695024, Kerala Tel: 91-471-2508668/ 2508669/ 2508670 Email: managingdirector@kannurairport.in Website: www.kannurairport.in

Non conventional energy

Engineering Products

Capture Solar Energy plans a 75 MW solar park in Pune, Maharashtra. The company has received USD 125 million funding from Cyprus-based photovoltaic solar solutions provider Concept Solutions & Innovation for the project. Location: Pune, Maharashtra Status: Planning Stage Contact: Capturesolar Energy Limited, Administrative Office: 5 & 6, A Wing, Shubham Heights, Next To IDBI Bank, Warje Malwadi, Pune - 411058, Maharashtra Tel: 91-20-60500503/ 60500504 Email: info@capturesolar.com Website: www.capturesolar.com

Kapoor Imaging plans a 365 TPM pre sensitized aluminium offset plate manufacturing project at Siruvada, dist. Tiruvallur, Tamil Nadu. The project is planned for completion in 8 months from zero date. Location: Tiruvallur, Tamil Nadu Status: Planning Stage Contact: Kapoor Imaging Private Limited, Corporate office: No. 3, Masilamani Road, Balaji Nagar, Royapettah, Chennai, Chennai - 600014, Tamil Nadu Tel: 91-44-43471000 Fax: 91-44-43471020 Website: www.kapoorimaging.com

Sugar

Thermal Power generation

Dalmia Bharat Sugar & Industries plans an integrated sugar project in Maharashtra. The project will come up either in dist. Solapur or Beed or Kolhapur depending on the financial source obtained. Location: Maharashtra Status: Announcement/Conceptual Stage Contact: Dalmia Bharat Sugar & Industries Limited, Plant address: Tehsil Panhala, Asurle Porle, Kolhapur - 416229, Maharashtra Tel: 91-2328-236112 Fax: 91-2328-232123. Website: www.dalmiasugar.com

Pashamylaram Common Infrastructure plans a 1 MW coal-based co-gen power project at Village Pashamylaram, dist. Medak, Telangana on 15 acres. The project is waiting for environmental clearance. Location: Medak, Telangana Status: Planning Stage Contact: Pashamylaram Common Infrastructure Private Limited, Registered office : 23-39/1, Jyothi Nagar, Ramachandrapuram, Hyderabad, Hyderabad - 502032, Telangana Email: mlnreddyskht1@gmail.com

Automotive components

Primary steel production

Fiem Industries implements an automotive lamps and parts manufacturing project at Village Karsanpura, dist. Ahmedabad, Gujarat. The unit will manufacture head lamps, rear combination lamps, tail lamps, side indicator lamps, fog lamps and other automotive lamps & parts. Location: Ahmedabad, Gujarat Status: Under Implementation Contact: Fiem Industries Limited, Administrative Office : 32, Milestone, GT Road, Kundli, Sonipat - 131028, Haryana Tel: 91-130-2219172/ 2219173 Website: www.fiemindustries.com

Uttam Galva Ferous, plans a 6 MTPA integrated steel project at Kuduthini Village, dist. Bellary, Karnataka. The project is in nascent stage. Location: Bellary, Karnataka Status: Announcement/Conceptual Stage Contact: Uttam Galva Ferous Limited, Corporate office : Uttam House, 69, P. D Mello Road, Mumbai, Mumbai City - 400009, Maharashtra Tel: 91-22-66563500 Fax: 91-22-23485025 Email: gss@uttamgalva.com,marketing@uttamgalva.com Website: www.uttamgalva.com

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August 2014 n OEM Update n 64

Tenders nOIL & GAS

Company Name: GAIL (India) Limited Tender Detail: E-tender for procurement & installation of USM based metering skid system at NTPC Jhanor under Bharuch Maintenance base Location: Vadodara Documentation Sale from: 17-July-2014 Documentation Sale to: 20-August-2014 Documentation Fees: Rs.1,686/- (1,500 + service tax @ 12.36%) EMD: Rs. 800,000/Closing Date: 20-August-2014 Address: Manisha Circle, Old Padra Road, dist. Vadodara, Gujarat – 390015 Tel: 91-265-2330888 Website: www.gail.nic.in; www.gailtenders.in Contact: Mr. S.P. Tadavi, Manager (C&P) Phone: 91-265-2330888, Extn: 385 Email ID: sptadavi@gail.co.in

nPort

Company Name: Kandla Port Trust Tender Detail: Allotment of land admeasuring 25 Acres for purpose of Godowns [including structures] on 30 years lease on as is where is basis at Kandla Location: Kandla Documentation Sale from: 18-July-2014 Documentation Sale to: 12-September-2014 Documentation Fees: Rs. 5,000/EMD: Rs. 20,500,000/Closing Date: 12-September-2014 Address: Business Development Cell, P.O.Box 50, Administrative Building, Gandhidham, Kutch, Gujarat – 370201 Tel: 91-2836-238055 Fax: 91-2836-239055 Email: bdc@kandlaport.com Website: www.kandlaport.gov.in

nCement

Company Name: Government Of Karnataka Tender Detail: Balance work in providing cement concrete lining in KM No 90, 94 and 98 of UTP Main Canal (Under Package L-1) Location: Haveri Documentation Sale from: 15-July-2014 Documentation Sale to: 6-September-2014 Documentation Fees: Rs. 5,000/EMD: Rs. 420,000/Closing Date: 8-September-2014 Address: Executive Engineer, KNNL, UTP Division, Rattihalli, Haveri – 581116, Karnataka Website: www.karnataka.gov.in

nRenewable Energy

Company Name: Karnataka Renewable Energy Development Limited Tender Detail: Development of 500 (Five Hundred) MW of Solar PV and/or solar thermal power plants in the State of Karnataka

Location: Karnataka Documentation Sale from: 19-June-2014 Documentation Sale to: 20-August-2014 Documentation Fees: Rs. 7, 500/EMD: Rs. 1,000,000/Closing Date: 20-August-2014 Address: No. 39, “Shanthi Gruha”, Bharath Scouts & Guides Building, Palace Road, Dist. Bangalore-560001, Karnataka Tel: 91-80-22208109 Fax: 91-80-22257399 Name: Prabhakar S K Designation: AGM Website: http://kredlinfo.in/

nMedical Equipment

Company Name: Government of Karnataka, Department of Medical Education Tender Detail: Procurement of Medical equipments to New Medical Colleges Location: Karnataka Documentation Sale from: 03-July-2014 Documentation Sale to: 30-August-2014 Documentation Fees: Rs. 550/EMD: Rs. 30, 000/Closing Date: 30-August-2014 Address: Director Chamber, Director of Medical Education, Ananda Rao Circle, Dist. Bangalore-560009, Karnataka Tel: 91-80-22287784/22874750 Fax: 91-80-22875798 Website: www.karnataka.gov.in

nRailway

Company Name: East Central Railway Tender Detail: Hiring of 02 nos. of passenger carrying vehicles for transportation of Electric crew in DHN division Location: Dhanbad Documentation Sale from: 28-July- 2014 Documentation Sale to: 2-September-2014 Documentation Fees: Rs. 2,000/EMD: Rs. 19,140/Closing Date: 3-September-2014 Address: Mr. Anand, Office of the Sr. Divisional Electrical Engineer (G), DRM Office, East Central Railway, Dhanbad-826001, Jharkhand Mobile no: 91-9771426360 Website: www.ecr.indianrailways.gov.in Company Name: NMDC Limited Tender Detail: Supply, Erection, testing and commissioning of one number lump ore stacker for Donimalai Project in Karnataka Location: Donimalai Documentation Sale from: 8-July-2014 Documentation Sale to: 15-September-2014 Documentation Fees: Rs. 5,000/EMD: Rs. 500,000/Closing Date: 15-September-2014 Address: Materials Management Wing, 2nd

Floor, 10-3-311/A, Castle Hills, Masab tank, Hyderabad-500028, Telangana Tel: 91-40-23538713, 91-40-23538714, 91-4023538715 Fax: 91-40-23538711 Website: www.nmdc.co.in

nAir Force

Company Name: Indian Air Force Tender Detail: Procurement of OSA-AK-M spares Documentation Sale from: 5-June-2014 Documentation Sale to: 15-September-2014 Closing Date: 29- September -2014 Address: Room No. 278. DTE Of Proc Air Head Quarter, Vayu Bhavan, Rafi Marg, Central Delhi-110011 Tel: 91-11-23010231 Website: www.indianairforce.nic.in Company Name: Indian Air Force Tender Detail: Supply of spares for MIG-23 27 aircraft Location: New Delhi Documentation Sale from: 5-June-2014 Documentation Sale to: 18-September-2014 EMD: Rs. 34,140/Closing Date: 18-September-2014 Address: Room No. 278. DTE Of Proc Air Head Quarter, Vayu Bhavan, Rafi Marg, Central Delhi-110011 Tel: 91-11-23010231 Website: www.indianairforce.nic.in Company Name: Indian Air Force Tender Detail: RFP for supply of spares for an-32 aircraft Location: New Delhi Documentation Sale from: 30-May-2014 Documentation Sale to: 11-September-2014 EMD: Rs. 7,11,120/Closing Date: 11-September-2014 Address: Room No. 278. Dte Of Proc Air Head Quarter, Vayu Bhavan, Rafi Marg, Central Delhi-110011 Tel: 91-11-23010231 Website: www.indianairforce.nic.in

nPower

Company Name: Odisha Hydro Power Corporation Limited Tender Detail: Renovation & Modernisation with new Turbine-Generator Power Generating Unit-1 to 6 (6X60MW) of Balimela Power House at Balimela, Malkangiri, Odisha, Location: Odisha Documentation Sale to: 18-August-2014 Closing Date: 18-August-2014 Address: Odisha State Police Housing & Welfare Corporation Building, Vanivihar Chouk, Janpath, Bhubaneswar-22, Odisha Tel: 91-674-2542983, 2542802, 2545526, 2542826 Email: ohpc.co@gmail.com , md@ohpcltd.com Website: www.ohpcltd.com

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65 n OEM Update n August 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.