Summary

Company Overview : EXEDY India Limited (Formerly Known Ceekay Daikin Limited)

History :
Limited and in Limited. Ceekay Daikin was established in 1973 as Ceekay Automotive 1987 the name of the company got changed to Ceekay Daikin

Ceekay Daikin is a leader in the field of automotive clutches. After its incorporation, in 1973 it entered into a technical collaboration agreement with Daikin Manufacturing Co. Ltd. In 1985 it commenced supplies to Maruti Udyog Limited. Ceekay Daikin's highly specialized line up of products encompasses a range of clutches for a range of applications - Clutch Disc Assemblies, Clutch Cover Assemblies from coil type/ Diaphragm spring/ DST type and Clutch Disc regular, Silent and unity type. In 2008 the manufacturing units are located at Noida in Uttar Pradesh and Aurangabad in Maharashtra with installed capacities of 1.2 million clutch cover assemblies and 1.8 million clutch disc assemblies per annum. Diversifying into the manufacture of clutches for two wheelers, a new project was set up at the existing unit of the Greater Noida plant to manufacture 1 million clutches per annum. Its clientele include companies like Bajaj Tempo, Eicher Motor, M&M, Maruti Udyog Limited, Tata Motors, Toyota Kirloskar, Swaraj Mazda, Honda, VST Trillers Tractor, Ghatge Patil Limited etc. In order to be competitive in market it is now introducing the 3 in 1 in the market. This 3 in 1 will be consisting of Clutch Disc, Clutch Cover and Clutch Release Bearing. It has its distributors located in nearly all the states like Andhra Pradesh, Assam, Chandigarh, Delhi, Goa, Kerala, Maharashtra, Orissa, Punjab,

Rajasthan, West Bengal, Uttaranchal. Excellent technology and precision engineering from Exedy Corporation (Formerly known as Daikin Manufacturing Co. Ltd.) Japan, has enabled Ceekay Daikin to attain a position of strength and leadership in quality.

Milestones Achieved :

1973 Established as Ceekay Automotive Limited. 1975 Entered into a technical collaboration agreement with Daikin Manufacturing Co. Ltd. 1985 Commenced supplies to Maruti Udyog Limited. 1987 EXEDY invests 25% in the equity of Ceekay. Equity raised Rs 10 million. Name of the company changed to Ceekay Daikin Limited.

1995 Annual capacity for 10,00,000 Clutch Disc and 6,00,000 Clutch Covers installed. Machines Installed for Diaphragm Spring and Wire Rings Production. 1997 Paid up Capital increased to Rs 35 million.

1998 Established Greater Noida Facility. Capacity Increased to 1.5 million Clutch Discs and 1.1 million Clutch Cover assemblies. Increasing capital stock to Rs. 40 million. EXEDY's stake increased to 32.5%. 2005 Noida Plant TS16949 certified. Aurangabad Plant TS16949 certified.

Snapshot :
Date of Establishment : 1973 Revenue Market Cap Corporate Address Chikalthana Maharashtra. Management Details : 42.1299 (USD in Millions) : 1273.419552 (Rs. in Millions) : Plot No. L 4, M I D C Industrial Area, Aurangabad 431210, www.ceekay-daikin.com : Chairperson Mahesh B Kothari

MD Akira Hirai Directors Akira Hirai, Bharat H Patel, C H Bhabha, Hetay Vora, Hidehito hisakawa, Hideshi Shiba, Homi C H Bhabha, Mahesh B Kothari, Pradeep B Chinai, Shreekant V Mehta, Sudhir Sathe. Business Operation Ceekay name of the Ceekay Daikin Limited. Background : Auto Ancillary : Ceekay Daikin was established in 1973 as Automotive Limited and in 1987 the company got changed to

Ceekay Daikin is a leader in the field of Automotive clutches. After its incorporation, in 1973 it entered into a technical collaboration agreement with Daikin Manufacturing Co. Ltd. In 1985 it commenced supplies to Maruti Udyog Limited. products range of Assemblies, Clutch Cover type/ Diaphragm spring/ DST type regular, silent and unity type. Financials (year ending Mar 2010) Mar 2010) Company Secretary Auditors : Hetay Vora : DL Shah & Co Ceekay Daikin's highly specialised line up of encompasses a range of clutches for a applications Clutch Disc Assemblies from Coil and clutch disc : Total Income Rs. 1615.217 million Net Profit Rs. -10.654 Million (year ending

Key Executives :
S. No.
1. 2. 3.

Name
Hetay Vora Akira Hirai Pradeep B Chinai

Designation
Company Secretary Managing Director Director

4. 5. 6. 7. 8. 9.

Homi C H Bhabha Shreekant V Mehta Bharat H Patel Sudhir Sathe Mahesh B Kothari Hideshi Shiba

Director Director Director Director Executive Chairman Whole Time Director

EXEDY Worldwide
Plants :
EXEDY have total 29 plants in the world. The Head Office is situated in the Japan. Except Head Office it have 6 more plants in the Japan. Exedy have 7 plants in Japan including Head Office, 2 plants in Europe, 2 plants in Saudi Arab, 2 plants in India, 4 Plants in China, 2 plants in Thailand, 1 plant in vietnam, 1 plant in Malaysia, 2 plants in Indonesia, 3 plants in Australia and 3 plants in U.S.A. In Japan i. Head Office ii. Ueno Division iii. Kawagoe Plant iv. DYNAX Corporation v. EXEDY Precision Co. Ltd. vi. Pronet Co. Ltd. vii.DK Pronac Co. Ltd. In India i. EXEDY India Limited (Ceekay Daikin Ltd.), (Aurangabad). ii. EXEDY India Limited (Ceekay Daikin Ltd.), (Greater Noida). In China i. ii. iii. iv. EXEDY (shanghai) Co. Ltd. Shanghai DYNAX Co. Ltd. EXEDY Chongqing Co. Ltd. EXEDY Guangzhou Co. Ltd.

In Australia i. EXEDY Australia Pty. Ltd. (Brisbane). ii. EXEDY Australia Pty. Ltd. (Sydney). iii. EXEDY Australia Pty. Ltd. (Melbourne). In U.S.A. i. EXEDY America Corporation. ii. EXEDY Global Parts Corporation (EXEDY DYNAX America Corporation). iii. DYNAX America Corporation.

In Europe i. EXEDY Clutch Europe Ltd. (U.K.) ii. Euro EXEDY clutch Ltd. (Hungary) In Saudi Arab i. EXEDY Middle East Fzco (Jordan) ii. EXEDY Middle East Fzco (U.A.E.) In Vietnam i. EXEDY Vietnam Co. Ltd. In Thailand i. EXEDY (Thailand) Co. Ltd. ii. EXEDY Friction Material Co. Ltd. In Malaysia i. EXEDY (Malaysia) Sdn. Bhd. In Indonesia i. P.T. EXEDY Motorcycle Indonesia. ii. P.T. EXEDY Indonesia.

Products :

The Exedy worldwide produces Clutches of Four-Wheelers and Two

Wheelers. The Products of EXEDY India Limited are listed below : 1. 2. 3. 4. Clutch Plate Assembly Clutch Cover Assembly One Way Clutch Kits & Components

CLUTCH PLATE ASSEMBLY ASSEMBLY

CLUTCH COVER

ONE WAY CLUTCH COMPONENTS

KITS &

Departments
Sr. No.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

:Name of Department
H. R. Engineering Production planning & control (PPC) Sales Purchase Production Tool room Quality Control Maintenance Despatch Store Finished Goods (FGS)

Organizational Structure :Designation

Managing Director Factory Manager Head Q. C. D. M. Head H. R. Head Finance

Name
Hideshi Shiba Shekhar C K. Suzuki Deepak Bansal N. N. Shah ji Gautam Lath

Department
Sales Quality Control Quality Control H. R. Finance

Asst. Manager Purchase Asst. Manager Engg. Asst. Manager Tool Room Dupty Manager PPC Sales Officer Senior Engineer Sales Engineer Sales Sr. Engineer Purchase Engineer Purchase Purchase Purchase Executive Purchase Accountant Account Executive Finance Accountant Sr. Accountant Exec. Sr. Engineer Prod. Sr. Engineer Prod. Production Asst. Manager Engineer PPC Engineer Tool Room Engineer Tool Room Room Jr. Enginner Tool Room Engineer QC Asst. Engineer Sr. Engineer QC Sr. Engineer QC Sr. Engineer HRD Asst. Japanese Interpreter HRD Exec. Maintenance Engineer FGS Asst. Store Incharge Store Asst.

Amit Bhaskar Y. Yamamoto H. Muramatsu Mr. Malay Manoj Dubey Himanshu K Vikash Yadav Nikhil Raina Parambir R Sita Rawat Somnath S Sohan Lal Kapil Kumar Santbir Singh Deepak Kumar Pravesh S V. S. Negi Khagendra S Tarun Kumar Praveen Kr. Navin Kumar Sujit Kumar Praksh C Amit Dabash Balwinder Singh Amit Srivastav Pranay Sharma P. Aggarwal Ashish sharma Narayan Singh Gajraj s Hukum Singh Vipin Pandey

Purchase Engineering Tool Room PPC Sales Sales Sales Purchase

Finance Finance Finance Production P.P.C P.P.C Tool Room Tool Tool Room Quality Control Quality Control Quality Control Quality Control Quality Control H. R. H.R. H.R. Maintenance FGS Store Store

ABOUT PRODUCT :-

Clutches
Basic purpose

Used to disengage engine from input shaft Clutch is a mechanism which enables the rotary motion of one shaft to be transmitted, when desired, to a second shaft the axis of which is coincident with that of the first.

Requirements of clutch
Torque transmission Gradual engagement Heat dissipation Dynamic balancing Vibration damping Size Inertia Clutch free pedal play

Types of clutches
Friction clutches Cone clutch. Single plate clutch. Multiplate clutch. Centrifugal clutch. Fluid flywheel.

Single plate clutch

A Flywheel

B Engine Shaft C Clutch Plate D Clutch Shaft E Pressure Plate F Bearing

Clutch components
Clutch plate. Clutch facing. Pressure plate. Springs. Bearing.
Clutch facing

G Clutch Spring

Clutch plate Plate)

Clutch Cover (Pressure

Multiplate clutch clutch

Semi-centrifugal

CLUTCHES IN CAR

Department - Maintenance
DEFINITION OF MAINTENANCE :The word maintenance is a noun derived from the verb To Maintain. Maintenance means the process of keeping something in good condition. It is also defined as the upkeep of industrial facilities and equipments. The definition of the maintenance that it is The combination of all technical and related administrative actions including supervision, with an aim to retain an item in, or restore it to a state in which it can perform its required function is quite comprehensive. This definition Clearly specifies two fields in Maintenance, namely, 1. Technical actions and 2. Associated administrative actions. Thus, while the technical actions come under the purview of maintenance engineering, the associated administrative actions are covered under maintenance management.

PVRIT Series Single Vane Pump :These Pumps are widely use as a source of hydraulic Power. They combines stable performance and Robust construction with a wide range of delivery rates.

Solenoid controlled pilot operated directional valves :These valves are composed of a solenoid operated pilot valve and a pilot operated slave valve, Thus changing the direction of flow in the hydraulic circuit. High Pressure High Flow :High Pressure [315 Kgf/cm2] along with high flow means compact system design. Lower Pressure Drop :System energy saving increased as pressure drop of each valve has greatly reduced.

Solenoid operated directional valves :-

The DSG01 50 series solenoid operated directional valve comes with two basic models : 1. Standard Type ------High pressure, high flow [315 Kgf/cm2, 631/min] 2. Shockless Type ----Which greatly reduces noise which is a result of spool change over and vibrating pipes. The optimum valve for any system can be utilized since many spool types, and various solenoids are all available, along with other optional function.

Flow control valve :These valves are pressure and temperature compensating type valves and maintain a constant flow rate independent of change in system pressure (load) and temperature (viscosity of fluid). They control flow rate of the hydraulic circuit and eventually control speed of the actuator precisely. Valves with an integral check valve allow a controlled flow & reverse free flow.

Pressure control module (PCM) :Designed to control double pumps of Hi-low systems. It unloads low pressure pump when system Pressure rises above the pressure set on unloader valve. It relieves high pressure pump when system pressure reaches the value. Solenoid unloading facility available as an option.

PLC - Programming Logic Control. MCCB - Moulded Case Circuit Breaker. MCB - Mutual Circuit Breaker.

Pressure Switch
Controls water pump

Turns on when system pressure drops to 20 (30) psi Turns off when system pressure rises to 40 (50) psi Low pressure shut-down in case well water level drops

Bench Drilling Machine

Forseen Use of Machine :The drilling machine was designed to be used with specific tools and for certain Machining operations. The most common machining operation is the drilling of the holes with helicoidal The drilling of holes is carried out by the combination of a drill turning movement and a feed movement in the turning spindle direction. drills.

Besides the helicoidal drill, other tools can also be used to drill holes. There is a great variety of drill types and shapes in the market which can be used on this machine, provided that they are designed for such a purpose and that can be fixed in the spindle taper. They will usually be the morse taper. The drill shanks should have the corresponding taper to the spindle in which they are to be fitted, or parallel shank if they are going to be fitted by means of a tool holder. Do not use tools which are not designed to be used in a drilling machine and that have been adapted.

Correct use of Machine :1. Not exceeding its working capacity 2. Operating the machine by qualified and trained staff and according to the points mentioned in the instruction book. 3. Working under the safety systems provided with the machine, checking them & keeping them. 4. Watching the safety measures mentioned in the instruction book & notice on the machine.

Piece Clamping :Tangential cutting forces and forces in the feed direction of the tool are mainly produced during the drilling process. The tangential force produces a moment of forces which make the piece being drilled turn. Therefore, the pieces to be drilled must be clamped in an appropriate device such as a drill chuck and the drill chuck must be correctly clamped to the machine table. For this reason the

machine table are provided with T slots.

Tool Fixing :The tools generally used in this machine will have parallel or taper shanks. Drill holders are normally used to fix the main spindle of the machine to the parallel shank tools. The fixing device has usually got three jaws, which hold the tool by the parallel part of the shank. These are used for small drill diameters ( upto 16 mm). The Bigger diameter drills usually have taper shanks or morse taper type. (One of the smaller diameter upto 16 mm can also have taper shank.) The housing in the main spindle to insert the tool is of morse type. It is very important to insert the tool taper correctly in the main spindle taper to avoid the tool falling from its housing when turning and provoke an accident. The coupling system itself of the tool male taper in the female taper of the main spindle is auto locking, But for it the surfaces of the tool taper and spindle taper must be in contact. To get the best possible contact , the surfaces of the tool taper as well as the spindle taper should be in good condition. Therefore, It is advisable to handle the tool as well as the main spindle of the machine carefully.

Chips during Machining :The Machining process removes material from the piece. The material is released in chips, which can be of different shapes depending on the material itself. The most common once are three types ; 1. Fragmented chips in small bits, 2. Short helicoidal chips and 3. Long helicoidal chips. The chips fragmented in small bits can be rejected from machining area and can be dangerous if they reach the eyes of the operator. To avoid this, it is advisable to wear safety glasses. The long helicoidal chips tend or roll up the tool and gain considerable volume before breaking, which is dangerous if they reach the operator as they may produce injuries. The reached volume may also displace the drill protector from its security position and increasing the risk of an accident. It is advisable to use chip breaking tools to machine materials which produce such chips.

PRECAUTIONS :1. Use recommended oils. 2. Follow lubrication periods. 3. Clean the machine every week by using rags & gas oil. 4. Handle the machine with care. Avoid any sudden pump. 5. If the machine is to be shut down for a long period, Lubricate all the machine surfaces using a suitable spray. 6. Securely clam workpiece before starting drilling. 7. Do not use loose sleeves in your clothes in order to get caught on tool.

8. Before proceeding to remove any component from the machine, carefully study component assembly.

BENCH DRILLING MACHINE

Operation Manual
Automatic Lubrication Unit (ALU):
(1) (2) (3) (4) (5) The unit consists of following major elements: Reservoir (6) Junction block with pressure reducing valve Electric Motor (7) Pressure Switch Rotary pump (8) Float Switch Relief Valve (9) Oil filler cum breather Bleed Valve (10) Suction Strainer It is made of CRMS sheets, duly painted, fitted with oil level window & drain plug. Oil Capacity 5 Ltr.

1. Reservoir :-

2. Electric Motor :Motor is normally of following specifications: .16 HP, 4 Poles, 415 volts, 50 Hz, 3 Phase. However at the time of dispatch it can vary according to the specific purchase order. Hence above specifications shall be verified again before giving power supply.

3. Rotary Pump :It is made of gerotor element. It is connected with the motor through a flexible nylon coupling. Inlet and outlet ports are of 1/8" BSP thread.

4. Relief Valve :Relief valve is adjustable type and normally set at 15 Kg/cm2 at the time of dispatch. However this setting is suitable for oil of 68 cst or more viscosity. If oil viscosity is less, this pressure may not be achieved. Oil of lesser viscosity shall not be used.

5. Bleed Valve :A small flow valve connected to a fluid process vessel or line for the purpose of bleeding off small quantities of contained fluid. Bleed valve's function is to remove air automatically. Normally it takes 15 to 30 seconds continuous running of motor to achieve automatic bleeding.

6. Junction block with pressure reducing valve :Junction block is a Manifold, inside which various parts are assembled in such a way that the pressure of the output line drops to 2 Kg/cm2 or less within 15 seconds after motor stops. At the same time the check valve inside does not allow pressure line to be empty. A pressure gauge is fitted on the top of the junction block. Output port is suitable for 6mm OD tube connections.(M10 XI Female threads)

7. Pressure Switch :The pressure switch has one NO and one NC contacts. It is sets at 12 Kg/cm2 at the time of dispatch.

8. Float Switch :-

Float switch is used as side mounted type. Its contacts are closed with oil in reservoir. In case of oil level drops below minimum level mark, the switch contacts get open. The switch is sensitive and all its parameters shall be taken of during its use.

9. Suction Strainer :This is made of 150 micron Stainless Steel washable mesh.

POINTS TO BE NOTED :
Always use clean quality oil as per machine manufacturer's recommendation. Oils of less than 68 cst viscosity are not recommended. Check the motor rotation direction, It shall be anticlockwise looking from the top. Also check motor specifications before giving supply. Always use earth connections. Check pressure switch and float switch specification before giving supply. Don't run the unit dry without oil. It may damage the pump. Clean the pump strainer at least once in 6 months. The unit is meant for intermittent operation. It shall not be run continuously.

ELECTRIC SCREW AIR COMPRESSOR

INTRODUCTION :The Rotary screw air compressor is a single stage, oil flooded, rotary compressor driven by motor through a coupling. The compressor casing accommodates a pair of male female helical rotors, machined with highest precision and mounted on bearings. The male rotor has four helical lobes which mesh with six flutes of the female rotor. The male rotor revolves at 1.5 times the speed of female rotor. The male rotor is driven by coupling through step up gears. The male rotor lobes rotate into the female rotor flutes, The air is trapped in the interlobal spaces and smoothly compressed until the lobe-flutes reach the outlet port. As continuous compression takes place in all the lobe-flute spaces, pulsation free air is delivered. The oil injected through the lower gusset of the compressor casing mixes with the indrawn air and ensures an efficient sealing between the rotors and casing, and at the same time, giving an intensive cooling during the compression process. Intercooling is not necessary because huge quality of lubricating oil cools the air as it is being compressed. The oil, which lubricates the compressor, seals the clearance spaces. The oil is cooled in the cooler by separate fan motor in case of air cooled models and by water in case of water cooled models.

Compressor Air Flow :The air is drawn in by the compressor through a two-stage-dry type air cleaner where the dirt particles are separated from the air by filter elements. The air then flows into the rotor casing from where it enters the interlobal space of the rotors axially. The rotors rotate so that the interlobal space opens progressively from inlet to outlet. This phase corresponds with the suction stroke of a reciprocating compressor. When the interlobal space is filled, it is isolated from the suction chamber by continued rotation. The volume of the interlobal space is reduced as meshing progresses from inlet to outlet. The air can not yet escape as long as the compression continues and also until the tips and the flanks of the lobes have passed the stationary edges arranged at the discharge end of the lobes gusset of the compressor casing. The oil not only absorbs the heat produced during the compression but also seals the gap between the rotors. After the passing of the stationary edges, the discharge commences, The interlobal space is reduced more & more until its volume is almost zero at the delivery end, and subsequently escapes through the discharge port. This process is repeated in each following interlobular space of two rotors, and practically continuous and even delivery of the air flow is produced by the rapid succession of the various discharge phases. The air oil mixture leaving the compression chamber through air discharge valve is direction to an air-oil receiver where most of the oil is separated from the air-oil mixture through an oil separator in which the oil mist is removed; & then if passes to outlet service valves through minimum pressure valve.

Compressor Oil flow :Oil is circulated by the receiver pressure to various parts of the compressor where it serves as lubricant, coolant & sealant; Cool oil is injected directly onto the rotors for limiting the temperature rise of the air during compression and sealing the clearances between the rotor lobes, casing and end plates. In addition oil is directed to the bearings and gears. The air which is being compressed mixes with the oil which is introduced into the compression chambers and forms mist. This air-oil mixture then enters the receiver.

SCREW AIR COMPRESSOR

(A.)

(C.)

(B.)

(D.)

VERTICAL PULL TYPE BROACHING MACHINE

Machine work Spline cutting

INTRODUCTION :Broaching is a process commonly used for producing splines, key ways and special shapes in a single pass of a tool. The operation needs either pulling or pushing the broach over the entire length of the job and rapid retraction of the broach. The process requires control over the force and speed of the broach.

MACHINE BODY :1) Base body : The base body is fabricated and machined body. The main body fixed on the base body with the help of Allen bolt. Coolant motor with pump mounted on the base body. Level indicator mounted on the base body. 2) Main Body : The main body is fabricated and machined body. The table and mounting plate, guide bar, main cylinder etc. connected with this body. 3) Cross Head : This is a movable part. Broach holder mounted in the center of holes of cross head. This is slide on the guide bar Cross head connected with cylinder's piston rod with the help of chuck nut. 4) Bush Cross Head : Bush mounted in the bore of cross head top and bottom side. This is use for perfect slide on the guide bar. 5) Flange : This is fixed on the cross head top & bottom side with the help of Allen bolt. 6) Guide Bar : Guide bar fixed in the main body. The cross head slide vertically on the surface of guide bar. This part machined and hardchrome plated for perfect sliding. 7) Table : Table fixed on the top side of machine. Fixture & Fixture mounting plate is fixed on the table. 8) Broach Cleaning Brush : This is used for clean the broach after broaching. 9) Coolant Pump : This is used for carrying the coolant on the piece. 10) Limit Switch Mounting Plate : Limit switch mounted on the bracket by this plate. 11) Limit Switch Rod (Retriever) : This is squire rod. This rod mounted on retriever frame.

We can fix any position of limit switch on this rod.

12) Limit Switch Rod (Main) : This rod attached with main body by welding & Limit switch mounted on it. 13) Limit Switch Adjustable Block : The broaching stroke adjusts with the help of adjustable block. 14) Limit Switch Stopper : Limit switch cut by this stopper. 15) Proximity Switch : This is used for component sensing. Proximity switch sensed by compress sensing pin.

THERMOPAC (BOILER)
PROCESS HEAT DIVISION

Constructional Features :The THERMOPAC is a fully automatic, coil type, oil fired, 3 pass, forced draught, packaged thermic fluid heater. The helical coil fabricated from steel tubes is constructed to form the combustion chamber and is placed at the center of two shells, one inside the other. The cell which is adjacent to the coil is called the inner shell and the one outside the inner shell is called the outer shell. The inner shell and the helical coil are concentric with the outer shell. Mineral oil, called thermic fluid, is circulated through the coil.

(a) For Oil Fired Units :The fuel burner is situated at the top center of the helical coil. The burner is down firing, forced draught type with direct electric spark ignition. The combustion Air fan and Fuel pump, are at the front base of the unit.

(b) For Gas Fired Units :A quick shut off valve, a gas strainer, solenoid valves for the burner and pressure reducing valves are mounted at a convenient position near the blower casing. A centrifugal type chemical process pump, supplied along with the unit, is mounted separately near the unit.

Operational features :The centrifugal type chemical process pump, near the unit, circulates the thermic fluid through the unit and the system. The thermic fluid returning from the user equipment is fed to the circulating pump through a combined deaerator and expansion tank. Vapours, gases etc. Are separated from the thermic fluid in this tank. The deaerator tank is connected to the expansion tank by pipes. The function of the expansion tank is to accomodate the increased volume of the thermic fluid, when it is heated. Thermic fluid expands by about 7% of its total volume for every 100 C rise in temperature. Heat liberated by burning fuel in the combustion chamber is utilised for heating the thermic fluid in the coil. The products of combustion, after they exchange their heat with the thermic fluid in the coil, are let out of the unit through the flue gas outlet. Insulation of the unit and combustion air preheating are achieved by circulating the fresh air for combustion through a double jacket formed by the inner shell and the outer shell surrounding the combustion chamber. A high degree of combustion air preheating ensures high thermal efficiency. After the rotary switch is put in "BURNER ON" position, the burner starts and the temperature of the thermic fluid goes on increasing to the required degree. The return temperature combistat keep the thermic fluid temperature under control by making the burner to work either ON-OFF or on modulation, as the case may be.

Sequence of Operations (For Oil Fired Units) :Following is the sequence of operations of unit : 1) When the electric main switch is put on, supply comes to the panel box.

2) Fuel oil preheating starts when the rotary switch is put on. (Applicable to FO operated units) 3) On making sure that sufficient water is bieng circulated through the pedestal and after the furnace oil temperature reaches 90 C, the push button switch for fuel air circulation kept pressed. The blower motor which also drives the fuel pump, starts and circulation of fuel oil starts through the fuel oil preheating tank and the burner rod. 4) On observing that the pump pressure gauge and circuit pressure gauge is showing steady pressure & after the fuel oil temperature crosses the minimum temperature mark of 105 C, The rotary switch is put in "BURNER ON" position. 5) The blower motor starts. The blower pushes air through the combustion chamber, driving away combustible gases (if any) from the combustion chamber. This is known as "Prepurging". At the same time fuel oil pressure is also developed ; as the blower and the fuel pump are driven by the same motor.

NOTE :- For units operating on light diesel oil, portions explaining the working of the fuel oil preheating system
above, are not applicable. 6) After Prepurging : (a) Sparking starts (b) Burner solenoid valve energises and oil is sprayed into the combustion chamber. (c) Flame is established and sparking stops. (d) Heating of thermic fluid starts.

Sequence of Operations (For Gas Fired Units) :Taps in the pump cooling water line are opened. When the electric main switch is put on, supply comes to the panel box. After ensuring that gas is available at correct pressure and after opening all the necessary valves in the gas train the rotary switch is put in "BURN ON" position. After prepurging : (a) Sparking starts. (b) Pilot gas solenoid valveopens and admits gas in combustion chamber. Pilot flame is established. A few seconds later, main gas solenoid valve opens and main gas flame is established with the help of pilot flame sparking stops after few seconds from start, flame continues. (c) Heating of thermic fluid starts.

CONTROLS AND SAFETIES :A.) On the Unit :-

The following contribute for the safe operation of unit : 1) Sequence Controller And Flame Detector :The sequence controller in conjuction with the flame detector ensures the following : i. Scavanging of the combustion chamber before every fresh firing of the burner. ii. No delay in the firing of the fuel and hence no accumulation of fuel inside the combustion chamber which eliminates the danger of backfiring. iii. Flame failure protection. On a working unit, If flame failure occurs due to some reasons, the unit is brought to lock-out position giving an alarm. Thus no accumulation of fuel and hence no backfiring is resulted. 2) Differential Pressure Switch :Pressure tapings are taken across the unit inlet and outlet and fed to the differential pressure switch. This switch does not allow the unit to function (Burner to fire) in case the flow of thermic fluid through the coil of the unit is insufficient. 3) Return Temperature and outlet temperature switches :The inlet temperature switch indicates and controls the temperature of thermic fluid at the inlet of the unit. The outlet temperature switch indicates and controls the temperature of thermic fluid at the inlet of the unit. In case this temperature exceeds the preset limit, the unit sounding an alarm. 4) Low Level Switch in Deaerator cum Expansion Tank :If the level in the deaerator and expansion tank is below the required level, this switch it makes the burner trip. 5) Stack Temperature Indicating Alarm :This control shuts off the burner and makes the unit to go into electrical lock-out position in case the stack (flue gas) temperature rises beyond its set value. If burner stops firing due to this control, It also an idication that desired heat transfer in not taking place in the combustion chamber. 6) Furnace Oil Temperature Switch :This control maintains FO temperature to a preset value by making the electric heaters to work ON-OFF. This switch shuts off the burner and makes the unit to go into electrical lock-out position in case the level of thermic fluid goes down beyond tolerable limits. When this switch takes over, the alarm is sounded.

7) Gas Pressure HIGH Switch For Gas Fired Units :For gas fired units there is a gas pressure switch which comes into action and de-energises safety relay in case of main gas pressure rises than the pressure switch setting and therefore, burner firing stops and unit goes to electrical lock-out.

B.) ON THE USER EQUIPMENT :It is advised to have the following devices on the user equipments : 1) Temperature Controllers and Automatic Valves :The temperature in the user equipment is the main parameter which needs to be controlled. This temperature is sensed by the probe of a temperature controller which indicates and controls the temperature when the temperature in the user equipment exceeds the preset limit, The temperature controller makes the automatic valve, fitted in the thermic fluid line of the user equipment, to close. Thus stopping the circulation of thermic fluid through that equipment. The temperature control makes the automatic valve to open again as the temperature in the user equipment drops down. 2) Safety Valve In The Thermic Fluid Circuit :Purpose of the safety valve is to ensure that the heater does not get over pressurised and the safety valve provides the heater coil by lifting up when the pressure rises beyond safety level.

Shot Blasting Machine

DESCRIPTION :-

The Machine consists of main blasting chamber made out of thick M. S. Plate properly stiffened and rubber lined from inside for long life. Either single or double doors fitted with a table for job loading. This table rotates in bearing housing through belt drive by a motor and reduction gear box unit. A turbine is fitted at the top of chamber which impinges steel shots on the jobs rotating with the table. The expelled shots fall in the bottom hopper and fed to the bucket elevator boot pulley through screw conveyor. Most of the dust in the main chamber is efficiently sucked into the dust collection unit. Any dust particles going along with the shots into the bucket elevator are separated in the dust separator unit. Then the clean shots are fed into the turbine again through manually/pneumatically operated valve provided just above feed funnel and feed spout assembly.

BARE WHEEL ASSEMBLY :The proper sequence of assembly and mounting of the wheel is as follows : 1. Mount the hub on the wheel, uniformly tightening all the eight screws, non-uniform tightening will result in wobbling of the wheel. 2. Insert blades in the slots and clamp them with springs. 3. Insert the centering plate, matching two driving pins fitted on the hub. 4. Insert the control cage and clamp it by projecting stud with a special clamping piece. The control cage is provided with slots and an arrow mark indicating the position of the opening of the control cage. 5. Fit the impeller on the shaft using 1/2 BSW bolts 6. Insert the feed spout with the rubber sealing ring into the control cage till it touches a collar in the control cage. Ensure proper clearance between the spout and the impeller and lock the spout in position. Rotate the wheel by hand to ensure free running.

DUST COLLECTOR UNIT :The efficiency of blast cleaning depends on the proper control of dust in the main chamber and steel shots. If not controlled this may prove even health hazardous. Hence, an efficient dust collector is always provided with the machine. The dust collector is made of sheet steel housing with tubes for fitting the filter bags. There are about 48 bags fitted by hooks at the top of a hook suspended frame which tilts on either side with the bags by shaking lever. The bags thus get clear-off sticking dust. The dust falls in the bottom hopper and is collected by opening the sliding gate. A centrifugal blower is fitted at the top of the housing. It sucks the air from the housing through the filter bags. The dust sticks to the bags and clean air is discharged in the atmosphere. It is very essential to shake the bags periodically to avoid clogging. Also check the condition of filter bags every month and replace the torn bags. Also check running of the centrifugal blower periodically. Power operated shaking arrangement can be supplied as on optional at extra cost.

OPERATING THE SHOT BLASTING MACHINE :A) Trial Run Without Load :
1. Put the selector switch on the control panel at ON position.

2. 3. 4. 5. 6.

Start dust collector. Start bucket elevator. Close door and start door motor. Ensure the working of limit switch, If the doors is not touching the switch adjust it. Start the turbine. Do not open shot feed valve. Check the noise and vibration level and any other failure noise. Check belt tension, Oil level in gear boxes, loose fitting etc. Let the machine run for 1520 minute.

B) Initial Feeding of Shots :

1. Start centrifugal blower. 2. Start bucket elevator. 3. Pour shot through the grating over screw conveyor in the main chamber. The shot pouring should be slow, otherwise this will jam the screw conveyor. 4. Fill minimum 200 Kg of shots to start the machine.

C) Adjusting Hot-Spot :
This is normally adjusted during trial runs at the factory, However it disturbed following procedure : Keep a 4-5 mm thick plate on the table in line with the turbine. Close door, do not start door motor. Start the dust collector and bucket elevator. Start turbine and feed shots for about 10-15 seconds. Stop machine and check the blasting effect, The Hot-spot should be near the center of table. Should the Hot-spot lie outside, adjust the control case in the desired direction by rotating it clockwise/anti-clockwise direction. Again follow the above procedure to check the blasting effect till the Hot-spot is adjusted.

1. 2. 3. 4. 5. 6.

Assembling of wheel as instructed above will give correct clearances at all important points and thus avoid any unnecessary wear of parts.

NO HAMMERING :During fitments or removal of parts, hammering will damage the bearings. The wheel should not be started while the shots are there. This will jam the wheel and subsequently burn the motor. Ensure correct sequence of operations as mentioned. This will always keep the wheel free of shots before stoppage. Check wear on control cage and impeller first after 24 hours run and thereafter every 8 hours of running. This is very easily done by opening the top cap of housing.

CHANGING OF BLADES :The blades are supplied in a set of 8 Nos having equal weight within +- 5 gms. Always change both blades diametrically opposite to each other to ensure proper balancing of wheels. Clamps the blades properly with the springs. Improper care while changing the blades will result in excess vibration due to unbalance

and damage other parts. Always check balancing of wheel before every change of blade set. This can be easily done on a static balancing stand. While balancing the wheel do not remove weight, Add weight and balance the wheel. Now the machine is ready for use.

RECYCLING OF SHOTS :The efficiency of blasting depends to a great extent on the shot being free of dust. The dust contents in the shots will lengthen the cycle time to get desired cleaning effect. Periodically cleaning of shots is absolutely necessary, also replenishment of spent shots is necessary. The shots can be throughly cleaned by recycling which is done as follows : 1. Remove impeller from turbine unit. 2. Turn control cage opening at bottom position. 3. Start bucket elevator. 4. Start dust collector. 5. Feed shots through turbine (Do not start turbine). 6. Run for 5 minute to clean the shots.

SAWING/BAR CUT MACHINE

DESIGNATED USE OF THE MACHINE : This sawing machine is designed for the cutting of metals only.

 Inflammable metals and alloys are explicitly excluded here. Another use or a use going beyond the limitation described above such as the cutting of non-metallic materials or of inflammable materials is not regarded as designated use. The Sawing machine shall only be operated by specifically trained person. The Sawing machine shall only be operated in compliance with the safety precautions and instructions. The sawing machine shall only be operated in dry, closed areas it shall not be operated in a potentially explosive atmosphere.

Safety Precautions when operating the Sawing machine :1) Make sure never to get near the running saw blade and saw band. Saw blades or Saw bands operate at high speeds and can cause severe and even fatal injuries. 2) Always watch the moving parts while operating the machine. 3) Do not enter the machine tables or any accessories.

Safety Precautions concerning the tool (Saw blade, Saw band) : Saw bands and Saw blades have very sharp teeth. So, always wear protective glove when you change the tool.

Material : Often the material has sharp edges that can cause severe cuts. Handle materials with care and wear working gloves where possible. Cut pieces often have burrs and are contaminated with coolant. It is essential therefore, to wear protective gloves. Ensure the safe material loading and removal. Appropriate material supports (e.g. roller tracks) or containers (For short cut pieces) must be provided on the indeed and on the out feed side to prevent the pieces from falling down. Use appropriate transport means to handle heavy workpieces. Observe the respective operating instructions and accidents prevention regulations in this case.

Handling of coolants : Coolants may contain additives that are hazardous to your health. Coolants can badly contaminate the water. They must not get into the ground water and must be treated and disposed off as special waste.

Avoid contact with your skin. Wear protective gloves when handling the coolant or material that is contaminated with coolant. Avoid the generation of mist by the correct adjustment. Wear breathing protection if oil mists occur.

Pneumatic Supply :Machine is requiring pneumatic air supply of minimum 5 bar pressure. Air line can be connected on the machine with air filter unit, mounted on the conveyor.

Optional Equipment :Chip Conveyor :

A chip conveyor can be inserted into the chip storage area of the machine. Chip conveyor required to fit on machine. If it is separately supplied with machine connect the electrical supply of chip conveyor motor through plug & socket.

Put a waterproof container under the ejection opening of the chip conveyor to make sure that The Chips are collected The Coolant is caught

Oscillate Table :
If oscillate table is separately supplied with machine, Fit oscillate table with two Nos M12 bolts on machine bed near the auto lubricant unit. Contact the two Nos hydraulic hose pipes with hydraulic cylinder off.

Auto Loader :
Auto loader for 4 to 6 meter stock to load the round bars/pipes automatically on the machine. After installation of Autoloader it is required to connect with machine by two hydraulic hose pipes and one electrical sensor cable.

MACHINES IN THE ORGANIZATION :-

M S E L T O M C IN , E U M N S&U IL IE A T R IS F A H E Q IP E T T IT S
S . R N . O M C IN N M A H E A E M N . \C O 4W E L & 2 W E L H E H E C IT A T R IC L Y

C U C C V RA S M L A E L T H OE S E BY R A
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 2 TH . P ss 5 yd re 6 TH . P ss 0 yd re 6 TH . P ss 0 yd re B la ce V 0 a n r -3 B la ce V 0 a n r -3 P j. W ld r ro e e P j. W ld r ro e e R nO t C e r u u h cke R nO t C e r u u h cke In L e C e r in h cke In L e C e r in h cke H n P ss (1 ) a d re T W E a sio /R xp n n W S kin T st /R tro g e 4 TH . P ss 0 yd re 16 57 17 51 16 59 15 17 15 18 1 /2 /1 8 5 2 6 1 /2 /1 8 5 3 6 17 52 17 53 M -3 1 S 33 M -7 7 S 80 AL 1 T -1 M -7 5 4 C -1 7 AT 1 L -0 31 7 A A A A A A A A A A A B A A A

C U C D CA S M L A E L T H IS S E B Y R A
1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3 6 TH . P ss 0 yd re 6 TH . P ss 0 yd re R e gM iv tin /C R e gM iv tin /C R e gM iv tin /C R e gM iv tin /C T rsio a C a cte o n l h ra ristic te r M ste /C 4 TH . P ss 0 yd re 32 7 16 58 17 50 N -0 T 1 N -0 T 2 N -0 T 3 N -0 T 4 A A A A A A A A

P E S R P A EM C IN GA E R S U E L T A H IN R A
2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 0 4 1 4 2 4 3 C u m tic L th h ck a a e C u m tic L th h ck a a e C u m tic L th h ck a a e C u m tic L th h ck a a e C u m tic L th h ck a a e C u m tic L th h ck a a e C u m tic L th h ck a a e C u m tic L th h ck a a e C u m tic L th h ck a a e B la ce V 0 a n r -1 B la ce V 0 a n r -1 B la ce V 0 a n r -1 D M ch e rill a in D M ch e rill a in D M ch e rill a in B a M ch e ro ch a in B a M ch e ro ch a in D M ch e rill a in C CD N rill M F r E dM /C o n ill T -3 0 V 0 01 00 2 /2 0 131 58 134 58 136 58 132 58 137 57 138 57 133 58 135 58 138 58 14 15 14 16 15 25 8004 741 8003 740 8002 740 0L00 5114 0L00 5115 A A A A A A A A A B A A B A B A A B A A

Q A U LITYC N R L A E O T O R A
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U ITY TIL
6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 7 0 7 1 Air C pre om ssor Air C pre om ssor Air C pre om ssor Air C m re r (Kirlo r) o p sso ska Air C p ssor (I R om re ) Air C p ssor (I R om re ) D S 1 (3 0 kv G et st 8 a) D S 1 (3 0 kv G et st 8 a) D Set 3 G D Se 4 G t
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C PB-3 0 C PB-3 0 C -6 PC 0 Kirloske r .. 99 6 9 3 60 25 8 0 23 01 25 7 8 23 92 V A 2 G 1ST T 8 VT 2 G 2 D A 8 N

G era U en l se G era U en l se G era U en l se G era U en l se G era U en l se G era U en l se G era U en l se G era U en l se G era U en l se G era U en l se

A A A A B A C A B A A A A

(6 5 kv ) 2 a (6 5 kv ) 2 a

P E S LIN R S E
7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 8 0 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 9 0 6 T Pre 50 ss 40 T P er Press 0 ow 31 T P er Press 5 ow 25 T P er Press 0 ow 25 T H . Pre 1 0 yd ss 25 T H . P ss 2 0 yd re 20 T P er Press 0 ow 16 T P er Press 0 ow 10 T P er Press 0 ow 10 T P er Press 0 ow 10 T P er Press 0 ow 6 T Po e Pre 3 wr ss 6 T Po e Pre 3 wr ss 6 T Po e Pre 3 wr ss 6 T Po e Pre 3 wr ss Sa ing M in w ach e Sa ing M in w ach e D co W F d r & L e e iler ith ee e ev ler D co W F d r & L e e iler ith ee e ev ler
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A A A B A A B A B A B A A A A B A A A B

HEAT TREA ENT AREA TM

91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 T empering Furnace T empering Furnace SQF Furnace Washing Machine 10 T Hot Press 10 T Hot Press 10 T Hot Press Nitrogen Plant 15N /m3 Chiller Vertical Rotary Furnaces Induction Hardener (HF Power DSP Load Checker SQF Furnace SQF Furnace Washing Machine T empering Furnaces Annealing Furnaces GSN Furnaces Ultra Sonic Washing Ultra Sonic Washing 3156 7080 1224 ----M/C-5-2824 M/C-7-3100 M/C-7-3101 ----423 3178 ----M/C-7-3099 1277 1278 ------------T HN-40HRC SCU-02 748/04/2008 Can use for both Can use for both Can use for both Can use for both Can use for both Can use for both Can use for both Can use for both Can use for both A B AA A A A B AA AA AA AA AA A B B B A A A B

ONE W Y CLUTCH M A ACHINING AREA

111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 CNC Lathe CNC Lathe CNC Lathe CNC Lathe CNC Lathe CNC Lathe CNC Lathe CNC Lathe CNC Drill Center CNC Drill Center CNC Drill Center CNC Drill Center CNC Drill Center Multi Head Drill M/C Multi Head Drill M/C Multi Head Drill M/C Multi Head Drill M/C Chamfer Machine T apping machine Drill Machine Drill Machine Drill Machine SLC-16-03 SLC-16-04 SLC-16-05 SLC-16-06 SLC-16-07 SLC-16-09 SLC-16-11 SLC-16-12 M-15-032 M-15-033 M-15-034 M-15-035 M-15-036 043. 03. 2008, 044. 03. 2008 045. 03. 2008, 046. 03. 2008 055. 10. 2009, 056. 03. 2009 63. 11. 2010 160. 03. 2008, 161. 03. 2008 290 5 09 803002 803007 1005006 B B B B B B B B B B B B B A A B B A A B B B

O EW YC U C A S M L A E N A L T H S E BY R A
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S O P E IN A DB N E IS GA E H T E N G N O D R IN R A
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M T R LH N L GE U M N A E IA A D IN Q IP E T
15 4 16 4 17 4 18 4 19 4 10 5 11 5 12 5 13 5 14 5 15 5 16 5 F rk L r o ifte F rk L r o ifte C o gT w r - 1 o lin o e C o gT w r - 2 o lin o e C o gT w r - 3 o lin o e H n P lle ad a t H n P lle ad a t H n S ke 1 T n a d tca r .0 o H n S cke 1 T n a d ta r .0 o E TC n O ra e H .L r yd ifte J C n ip ra e
st n d rd

M 2 -7 5 2 25 220

G n ra U e e l se G n ra U e e l se

A A A A A A A B C C C C A C C

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G n ra U e e l se G n ra U e e l se G n ra U e e l se G n ra U e e l se G n ra U e e l se G n ra U e e l se G n ra U e e l se G n ra U e e l se G n ra U e e l se G n ra U e e l se

E V O M N A F IE D YE U M T N IR N E T L R N L Q IP E S
17 5 18 5 19 5 E P U it 1 T n st E P U it 2 d T n n O C a in M il le n g /C --------12 63 F ra n o e n ilte tio f fflu t F ra n o e n ilte tio f fflu t H . O C a in yd il le n g B B B

T O IN A E O L G R A
10 6 11 6 12 6 13 6 14 6 15 6 16 6 T o & u rG d r o l C tte rin e S rfa G d r u ce rin e S rfa G d r (B ) u ce rin e ig MT 1R C d l ylin rica g dr rin e 9103 921 N -7 0 H 5 B 1 0 W 00 131 033 112 00 24 30 11 7 S a e in o T o h rp n g f o ls G d g rin in G d g rin in G n ra U e e l se G n ra U e e l se G n ra U e e l se T rn g u in B A A B B B A

Rd lD a ia rill L th a e

R WR A E E O K R A
17 6 18 6 19 6 Bn G dr e ch rin e D M ch e rill a in D M ch e rill a in ----M F & -1 0 G /P M 0 -----D G d g rill rin in D a te g ism n llin D g rillin C A C

P E A E BR P R D Y

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N te C riafo C o rite r ritic lity o M h e a f ac in s A )-M s C a A o t ritic l A- C a ) ritic l B - M d ra ) o e te C - N n C a ) o ritic l

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