Bollineni Castings and Steel Ltd. (BCSL)An ISO 9001 – 2000 Company

• 100% Quality• Timely Delivery• Optimal Price

WeStrive for

Hyderabad(Corporate Office)

Nellore(Foundry)

Offices

ProductsValve Industry

Gate, Globe, Check, Control, Wedge, Plug, Top entry / split Ball valves, Bonnet, Disc etc., Sizes from 12"- 48" and class range 150-2500Power Generation

Steam Turbines, Gas Turbines, blade rings Compressor Cylinders, Nozzle chest, Journal heads, covers, frame etc.,Mining Industry

Spindles, Hubs etc.,

Earth Moving Industry

Boom point, Boom foot, Rope sheave, Bearing Housing etc.,

Crusher Industry

Top body, Bottom body, Main frame, Swing Jaw stock, Fly wheels, Jaw plates, Mantle, Concave etc., General Engineering

Flanges, pinions, rollers, frames etc.,

Product RangeMATERIAL GRADES MAX WT/PC (T) APPLICATIONS

CarbonManganese Steels

ASTM A 27, A216, A352, DIN 17205 IS 1030, BS 3100

11.5 T Valve bodies, journal housings,

Journal frames, Magnet

Alloy Steel ASTM A 217, A 487,A 148, IS 2644,

EN 10213

19 T Turbine casings, Valve casings,Valves,

Mining spindles, hubs, Boom point

Stainless steel ASTM A 743, A351 5.2 T Valves

Manganese Steels IS 276 4.68 T 5248 jaw plate.

Facilities - Computerization

In - Use• AutoCAD Mechanical 2008• Computerization of Physical Testing LAB.• Image Analyzer

In - Process• Casting Simulation Software• Pro-E / Wild fire 3 • ERP / SAP

Suitable for manufacturing castings weighing single piece up to 35 MT.

Foundry Shop

1. 03 Bays of size 180 Mtrs x 20 Mtrs2. 01 Bays of size 110 Mtrs x 20 Mtrs

Machine Shop

3. 01 Bays of size 180 Mtrs x 20 Mtrs (under construction)

Supporting Facilities

Pattern Shop, Tool Room, PLC & PID controlled LPG Fired Furnace (6M x 5M x 2M) with quenching tank(14M x 6M x 2.5M)

Facilities - Production

Pattern Shop

Foundry has a well equipped pattern shop with highly skilled workmen for the manufacture of wooden, metal and polystyrene patterns.

Facilities - Production

Moulding Shop

•Imported Continuous Sand Mixer of capacity 30, 10 & 5TPH for Fenotec System

•Imported Mechanised Reclamation Plant (Italy) of 20TPH

•With the introduction of continuous mixer our capacity and capability of ramming is increased in addition to increase the productivity

Facilities - Production

Melting Shop

The melting shop is equipped with • 2 Nos. 8T capacity each medium frequency induction furnaces (Dual track)• 1 No. 15T capacity each medium frequency induction furnaces• 1 No. 25T capacity each medium frequency induction furnace• 1 No. 25T Ladle Refining Furnace (LRF)• Immersion pyrometer to ensure accurate temperature control

Facilities - Production

Fettling

Foundry is equipped with HEAVY DUTY shake-out system for easy stripping of castings from the mould boxes. Fettling operations like Shot blasting, pneumatic chipping and grinding are carried out by highly skilled team, giving the esteemed customers, products of excellent finish.

Facilities - Production

Heat Treatment

Desired metallurgical characteristics of castings are ensured with the latest heat treatment equipment which include 6m long x 5m wide x 2m high ceramic fibre lined LPG fired heat furnace with PLC- PID pulse firing sophisticated controls. Facilities include quenching tank facilities of size 14m long x 6m wide x 2.5m deep.

Facilities - Production

Machine ShopBCSL-Nellore has equipped with machine shop to undertake the machining of castings. The array includes: • Vertical boring machines (swing Dia 1m,1.5m,2.5m,3.5m)• Horizontal boring machines (spindle Dia 80mm & 1.8m ht)• Lathes • Shaping machines• Plano millers (6m long x 2m wide)• Radial drilling machines etc.,

Facilities - Production

The Foundry is backed by a modern Metallurgical Laboratory to monitor the quality right from the raw material stage to achieve the desired chemical and physical properties of the resultant products. Best of the equipment like:• Direct - Reading FOUNDRY MASTER• Micro Characterizer-Metallurgical microscope with Image analyser testing facilitiesare available in the laboratory

Facilities - Quality

NDT Testing Facilities • Radiography• Ultrasonic testing• Magnetic particle testing• Dye Penetrant testing

Apart from the strict in-house quality control measures, inspection and certification by TUV etc., are also involved.

Facilities - Quality

BCSL is ISO 9001, PED 97/23/EC & AD2000W0 system certified organization from TUV

All materials have their own internal standards.• Generally all the vendors are approved before placing any order.• All the measuring & testing equipment's are regularly calibrated.• Incoming material & products are inspected by reputed agencies like : Lloyds,

TPL, TUV etc., where ever applicable.

Facilities - Quality

Microsoft Word

Document

Process Maps and Performance Measures

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