annual report 2011-12 - Heavy Engineering Corporation Limited

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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. 10
• Replacement of centralized compressor unit with decentralized Air Compressor at the load centres. ANNUAL REPORT 2011-12 • Provision of Transparent Sheets at roof tops of production shops so as to utilize sunlight for illumination. Performance of Foundry Forge Unit in both physical and financial terms has been badly affected due to delay in upgradation program of 2650T press. Energy consumption in this area is quasi variable as such specific energy consumption has gone up despite overall reduction in consumption of electricity and Coal. Coal is used for producing producer gas. Quality of Coal and deteriorating condition of gas plant has resulted in increased consumption of coal. Energy Consumption details per Ton of physical production of FFP during the recent years are as under : Units Consumption per Ton of Production Particulars 2011-12 2010-11 2009-10 2008-09 2007-08 Electricity (KWH) 2853.50 2904.83 2554.47 2421.87 2436.91 Coal (MT) 5.44 5.55 4.62 4.49 4.32 Diesel (Liters) 13.16 24.11 24.62 20.35 18.93 11
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Page 3 and 4: GLIMPSES OF SOME IMPORTANT EVENTS S
Page 5 and 6: CONTENTS ANNUAL REPORT 2011-12 1. N
Page 7 and 8: BOARD OF DIRECTORS (As on 30.11.201
Page 9 and 10: ANNUAL REPORT 2011-12 DIRECTORS' RE
Page 11 and 12: ANNUAL REPORT 2011-12 Gross Margin
Page 13 and 14: ANNUAL REPORT 2011-12 The company d
Page 15: ANNUAL REPORT 2011-12 iii) that the
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Page 21 and 22: Annexure to the Auditors Report ANN
Page 23 and 24: 9. Statutory Dues A. According to t
Page 25: ANNUAL REPORT 2011-12 COMMENTS OF T
Page 28 and 29: OUR PROJECTS Conveyor System at New
Page 30 and 31: OUR PRODUCTS CNC Deep Hole Boring M
Page 32 and 33: ANNUAL REPORT 2011-12 service cost,
Page 34 and 35: ANNUAL REPORT 2011-12 STATEMENT OF
Page 36 and 37: ANNUAL REPORT 2011-12 NOTES FORMING
Page 38 and 39: NOTE NO.-9 ANNUAL REPORT 2011-12 Ty
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Page 52 and 53: ANNUAL REPORT 2011-12 12.11.2010. C
Page 54 and 55: ANNUAL REPORT 2011-12 ANNEXURE - I
Page 56 and 57: ANNUAL REPORT 2011-12 ANNEXURE - II
Page 58 and 59: ANNUAL REPORT 2011-12 Heavy Machine
Page 60 and 61: ANNUAL REPORT 2011-12 D. STOCK OF F
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