annual report 2011-12 - Heavy Engineering Corporation Limited

ANNUAL REPORT 2011-12
RESEARCH & DEVELOPMENT ACTIVITIES
The company continued its efforts for the technology up gradation and development of products/systems during the year.
I. Specific areas in which R&D activities were carried out by the company are detailed below :-
III.
IV.
ANNEXURE-A
RESEARCH & DEVELOPMENT,TECHNOLOGY ABSORPTION,ADAPTATION,
INNOVATION AND ENERGY CONSERVATION
• Design development and manufacture of Rotating Head Stock Spindle Assembly, Bottle Boring facility and programmable movement of Steady
Rest for CNC Deep Hole Boring machine. The machine was supplied to OFC, Kanpur.
• Development of Motorised swiveling of Arms for Radial Drilling machine. Modified machine was supplied to BHEL, Jagdishpur.
• Development of 100T capacity Tundish Traverse for ISP.
• Development of 65T and 60T Scrap charging Traverse for BSP and ISP respectively
• Design development of pushing mechanism with drive for Coke pusher for 4.45m Coke Oven Battery for DSP.
II.
Import Substitution Efforts
Following important items were manufactured and supplied
• CNC Deep Hole Boring Machine, Model BDH-140N with special features like Rotating Spindle Head Stock, Bottle Boring facility & Programmable
Steady Rest Movement.
• 7 nos. of 5 Cum Rope Shovels to CIL subsidiaries
• Phased dispatch of 2 nd Dragline 24/96 to NCL.
Technology Absorption, Adaptation and Innovation
i) The 1 st CNC Under Floor Wheel Lathe Machine out of 7 nos. was assembled and tested at HEC, Ranchi by engineers of M/s Hegenscheidt –
MFD, Germany. HEC team has absorbed the assembly technology and assembled next 5 machines themselves without the assistance of M/s
Hegenscheidt – MFD.
ii) Upgradation of 2650T Press
To reduce the overall cycle time, production of size forging, upgradtion of 2650T Press was initiated and completed.
Energy Conservation
Foundry Forge unit of the company is the most energy intensive unit which consumes more than 75% of total electrical energy and 100% of Coal.
Various efforts made for reduction in melting cycle helped in substantial reduction in specific electricity consumption in the melting area during
the year 2007-08. However, due to production of high quality steel the energy consumption had gone up during 2008-09 onwards. In addition,
electric arc furnaces need upgradation, as these were installed in 60s. Delay in upgradation of Arc Furnaces also affected specific Power consumption.
Company continued its thrust to reduce power consumption. Power consumption in melting area are as under :
Power Consumption (KWH) per Ton of Liquid Metal
Production
2011-12 2010-11 2009-10 2008-09 2007-08 2006- 07
917.99 960.31 937.35 981.46 868.72 1029.69
The various steps being taken in Foundry Forge unit to bring down energy overall consumption and specific energy consumption are as under:
• Reduction in maximum Demand of Power by proper load planning.
• Use of energy efficient high pressure sodium vapor lamps/Tube lights.
• Replacement of MG Sets by Static Transformers and Rectifiers.
• Use of ceramic lining in Furnaces and by installing programmable controller in electric pit furnace.
• Reduction in heat cycle time for melting furnaces etc.
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