Report of study on KLR industries

Submitted by,
AMAR NATH BODDEPALLI.











About KLR industries:

KLR INDUSTRIES LIMITED, today a well known organization at home and abroad as three
letter brand image KLR, started its journey two and half decades ago in the year of 1985 as a
small unit by the name KLR UNIVERSAL to manufacture button bits, a tool used for water
well drilling application, has grown into a prominent player in the field of drilling industry.
KLR has made a name for itself not only in its mother-land but also earned a distinct place in the
global market. Considering its growth potential in global markets, KLR set up its second
manufacturing facility in Sharjah, Dubai, which is the business hub for many industries. KLRs
product range includes drilling equipments for the application of waterwell, mining, piling,
geological survey, construction etc.
A wide range of products are manufactured in KLR, they are

Drilling Rigs
Hammers
Button Bits
Self Propelled Skid Mounted Rig
Drilling/Pole Erection Rig
KLR Cluster Hammer
Hand Pumps
Mineral Water Units
Friction Welded Induction Hardness Drill Rods.

Work flow in KLR industries,



Raw
material
Cutting
Forging
Inspection
Rough
turning
Inspection
Turn
drilling
Force&
chamfer
Finishing
Inspection
Spline
milling
Round
milling
Skinning
F/H holes
Inspection
HT
Face
drilling
Inspection
Processing
Inspection
Sales
RIG
A drilling rig is a machine which creates holes in the ground. Drilling rigs can be massive
structures housing equipment used to drill water wells, oil wells, or natural gas extraction wells,
or they can be small enough to be moved manually by one person. sample sub-surface mineral
deposits, test rock, soil and groundwater physical properties, and also can be used to install sub-
surface fabrications, such as underground utilities, instrumentation, tunnels or wells. Drilling rigs
can be mobile equipment mounted on trucks, tracks or trailers.
Parts of Rig:
Mast
Mast Raising Cylinder
Feed Cylinder
Winch Cylinder
Rotary Head Gear Box(RH Gear Box)
Transmission Gear Box(PTO/TG Box)
Winch Gear Box
Hydraulic system
Mud Pump/ Air Compressor
Bottom Guide
Stabilizers/Jacks
Drill Bits
Hammer
Drill Rods
Pillar
Chakkar sheet
Control Panel












Description:

Mast:
Mast is heart of the Rig. Mast is a big pillar that carries the RH gear box and is
useful in moving the drill rods vertically upward and down ward direction. Mast moves
horizontal to vertical while operation with the help of Mast Raising Cylinder.

Mast Raising Cylinder:
Mast Raising cylinder is a hydraulic cylinder that pushes the mast to raise up and
stand vertical to perform drilling operations.

Feed Cylinder:
Feed Cylinder is useful in providing the upward and downward movement of drill
rods move up and downward for performing drilling operations.

Winch Gear Box:
Winch gear box is used to lift the drill rods and ease the process of adding drill
rods to increase the depth of drilling.

Rotary Head Gear Box:
RH Gear Box provides the rotary movement required for the drill bit. RH gear
box is used to increase or decrease the RPM of drill rods according to the drilling
operation. It gets the rotary movement through a hydraulic pump placed on the top of RH
Gear Box.

Transmission Gear Box:
Transmission Gear Box is placed at the propeller shaft of the vehicle. It is used to
run the hydraulic unit of rig while operation and also useful for movement of the vehicle
for transportation.

Hydraulic System:
In a Rig the whole system runs through Hydraulic System. There is a tank that
stores the oil, a pump is used to supply this oil to various parts of the rig in order to
perform various operations such as using the Mast Raising cylinder, Feed Cylinder,
Stabilizers, RH gear box, etc.



Mud Pump/ Air Compressor:
Mud pump/ Air compressor are used depending on the type of soil formations.
Mud pump is used of soft formations and air compressors are used for hard formations.
They play a key role in performing drilling operation, they go down into the drilling hole
through the drill rods and comes out bringing out the cuttings.

Bottom Guide:
After Mast is raised vertically bottom guide make the drill rods pass through the
bottom guide as the name it self indicates that it acts like a direction guide for the drill
rods.

Stabilizers:
Stabilizers/Jacks are used to level the vehicle to ensure that the hole is vertically
downward and also relieves pressure on tyres of the vehicle.

Drill Bits:
Drill Bits are the basic unit that crush the surface making hole and perform
drilling operation. There are various types of drill bits(depending on the type of drilling
operation and the soil formation).

Hammer:
Hammer provides the hammering action provides a short, rapid hammer thrust to
pulverize relatively brittle material and provide quicker drilling with less effort

Drill Rods:
Drill Rods are joints of hollow tubing used to connect the surface equipment to
the bottom hole assembly

Control Panel:
Here all the rig controls are mounted and whole rig is operated through this control panel.

Pillar:
Pillar acts as the support for Mast. It is strong enough to hold all the weight of
Mast and also the attached drill rods.

Chakkar sheet:
Chakkkar sheet is the surface layed for mounting the rig.


Sections:

Rig Section
Rig service Section
Cylinder Section
Drill Rod Section
Hammer Case Assembly Section
CNC Section
Gear Box Section
Heat Treatment
RRB Section
QC
Bit Section
Domestic & Exports Marketing
Purchase Department



























Rig Section:
In this section construction of Rig is done. All the parts in Rig are mounted on the
surface. This gives the finishing touch to a RIG and makes it fit for the drilling operations.
Rig Service Section:
In Rig Service Section, the rigs which are in use comes for general maintenance and with
few repairs are done.
Cylinder Section:
Here the cylinders are manufacture to perform various operations like Mast Raising
Cylinder, Feed Cylinder, Jacks, etc. Here assembly of a cylinder is done. Piston rods are inserted
into the cylinders and fitted. It is checked thoroughly for leaks and its functioning.
Drill Rod Section:
In Drill Rod Section hallow rods are taken and attached to coupler through friction
welding process. It undergoes annealing process, Induction process and Tempering to maintain
hardness with in the rods.
Hammer Case Assembly:
In Hammer Case Assembly Section, Various parts all together are assembled.
Various parts in Hammer are:
Hammer Case
Coupler
Control Tube
Check Valve
Spring
Top Valve
Rubber Spaces
Plug
Piston
Piston Bush
Bit Lock
Front Chuck
Bit
CNC Section:
In CNC Section various machining operations were done.
Work Instruction:
Job dimension checking
Jaws adjusting
Steady rest adjusting
Selection of tool and changing
Operation Process:
Program selection
Program checking
Tool off set adjusting
Measuring job offset
Visual inspection after operation
Inspection with gauge
Unloading

Gear Box Section:
Gear Box is an assembly of various parts like,
Gear box body
Pinion gear
Deep groove ball bearing
End cover
Taper roller bearing
Deep groove ball bearing
Main spindle
Oil seal
Spacer top & bottom
Tube pump adapter
Tube pump
Key tube pump adapter
Motor mounting adapter
Motor
Mid screw assembly
Hex bolt
Spring washer, etc
Heat Treatment:
In Heat treatment the process is Hardening for strength, Methanol & LPG mixture is used
for producing required heat energy.
Various processes in Heat treatment are:
Carbonising
Annealing
Normalising
Hardening
Tempering
Stress releaving
Rock Roller Bit Section:
In RRB section, there are various processes as leg manufacturing process, slab milling, carbide
insert profiles.
Operation is done on vertical machining to achieve consistent dimension valve. Shirt tail
turning is done on CNC. Thrust button fitment. Buttons are pressed through hydraulic press into
the holes on the rollers.
QC:
QC is useful to check the quality and accuracy of the product manufactured. QC approval
is necessary for every product to ensure that it does not fail while operation. If the product
accuracy is <90.85% then it is to be rejected. If its accuracy is >96% it needs to rework.
Bit Section:
Here the bits are manufactured through various machining processes like,
Forging
Rough turning
Number punching
Turn drilling
Total length chamfering
CNC
Spline milling
Round milling
Plushing hole, etc.

Domestic & Exports Marketing:
Domestic Marketing is for customers with in India and Exports Marketing is for customers out of
India.
Here the process is

Enquiry generation
Technical specifications
Forward to customers
Raise quotation
If accepted
Sales order
PPC
Purchase order
Production
Delivery





Purchase Department:


Sales order
PPC (Requirements raised)
Purchase department
Requirement of parts
Quotations from dealers
Price, T&C
QC in store
Bills