Pressfab Engineering India Pvt Ltd Unit III Introduction

PRESSFAB ENGINEERING INDIA PVT. LTDPRESSFAB ENGINEERING INDIA PVT. LTDPRESSFAB ENGINEERING INDIA PVT. LTDPRESSFAB ENGINEERING INDIA PVT. LTDUUNITNIT--III III

FORGING DIVISIONFORGING DIVISION

BRIEF INTRODUCTIONBRIEF INTRODUCTION--� Founded in year 1995 with established of small pressing components division.

� Closed die forging facility started in year 2009, installed belt drop hammers having capacity 1.5 T & 2 T.

� Heat treatment facility started in year 2009, installed boogie furnace having capacity 1 MT / Batch.

� Introduced Quality Management System (QMS) in year 2009. ISO 9001:2008 certification, certified agency-TUV AUSTRIA)

� Heat treatment facility was upgraded by installed batch type induction heating furnace in year Dec-2015.

� We specialize in Forged, Heat treated and Machined Components based on in-house Design and Development of Forging Dies, Machining jigs & fixtures, gauges and Manufacturing processes.

� Manufacturing components for OIL AND GAS INDUSTRY, VALVE INDUSTRY,AUTOMOTIVE INDUSTRY, GEAR INDUSTRY.

� We are serving approx 70% from domestic customers & 30% of export customers.

QUALITY POLICYQUALITY POLICY� Quality Policy To aggressively develop, manufacture and market our products to domestic and

foreign clients, achieving highest level of customer satisfaction through:

� Consistently meeting or exceeding customer requirements.

� Time bound deliveries.

� Concentrating our resources on designing and building quality into our products and services.

� Continuously improving process controls in all areas of our business. � Continuously improving process controls in all areas of our business.

� Encouraging our suppliers to enhance input quality.

� Attracting, retaining and developing motivated quality performers.

� Compliance to the legal and regulatory requirements applicable to our products.

LIST OF MAJOR CUSTOMERSLIST OF MAJOR CUSTOMERS

� VIRGO VALVES & CONTROLS PVT LTD- PUNE & COIMBATORE

(EMERSON GROUP)

� L & T VALVES LIMITED- COIMBATORE & KANCHIPURAM

� AMPO VALVES INDIAN PVT LTD- PUNE

� DELVAL FLOW CONTROL INDIA PVT LTD- PUNE

� BLISS ANAND PVT LTD- BAWAL HARIYANA

� ROTEX MANUFACTURERS & ENGINEERS PVT LTD- DIMBIVALI

� CAMTECH MANUFACTURING FZCO-UAE

� PENTAIR GULF VALVE- UAE

� VALVOSPAIN GROUP OF COMPANIES- SPAIN

CLOSED DIE FORGINGS FACILITYCLOSED DIE FORGINGS FACILITY

� BELT DROP HAMMERS

1.5T & 2T (2 No’s)

� OIL FIRED PRE-HEATING FURNACE

300 Kg/batch (2 No’s)

� FORGING WEIGHT

0.5 TO 60 KG

� MANUFACTURING CAPACITY

200 MT/MONTH

� FORGE PART DESIGN

SPHERICAL & PROFILE

FORGING PROCESS FLOW CHARTFORGING PROCESS FLOW CHART

10. Receiving of Raw Material

as per Specification

Challan & Mill T.C

START

Not OK

Storage of rolled

bars CAPA from SupplierVisual/Dimensional/

Chemical/UT Testing

(As per QAP)

InspectionAs per 'QAP' Return back to Supplier

20. R M CuttingAs per Route Card

Stage

Inspection

As per billet size given in route card

End pc.salvaging

30. Billet Heating

*

As per forging

temperature chart

OK

OK

Not OK

Not OK

Billet cut weight

verification

Scrap

Color code throughout & both faces of

the bar(s)

Size, H No, Material Gr, marking on

both faces of the bars


Scrap

Hot Inspection Rework Re-Inspection

*

40. Forging As Per Forging drg & process plan

50. Trimming /PiercingAs Per Internal Forging drg &

Process Plan

Not OK

Not OK

Scrap Note

1st PC/Hot

Inspection Report

As per process plan

Hot Inspection Rework Re-InspectionInspection Report

*

60. Final inspection

of the forgings

OK


*

H.T Process

As per Customer Material

Specification/PO Technical

requirements

Review Test

Certificate

Rework

Re-Heat treatment

Test Certificate

As per Customer Material

Specification/PO Technical

requirements

H.T Clarence

by QC

Mechanical &other supplimentory

requirements Lab Testing

Review Lab

Test CertificateTest Certificate

Full finish machining

process as per drawing

HEAT TREATMENT FACILITYHEAT TREATMENT FACILITY

BRIEF INTRODUCTION ABOUT INSTALLED HT FURNACEBRIEF INTRODUCTION ABOUT INSTALLED HT FURNACE� Furnace type: Induction heating batch type

� Furnace Capacity: 1500 Kg / Batch

� Working Temperature Range: 1150°C Max

� Furnace Calibration: As per API 6A Annexure ‘M’ /API 6D 24TH Edition / AMS 2750E

� Calibrated on temp: 600°C, 900°C & 1150°C

� Quenching Facility: Water Quench (Tank capacity-30,000 Liter with agitation & cooled water circulation )

� Quenching Time: Within 60 seconds

� Water quench temperature Within 11°C (Before/after quench)

HEAT TREATMENT FACILITY HEAT TREATMENT FACILITY

`FURNACE IMAGES

SOLUTION ANNEALING PROCESS OF F316L MATERIAL STAGEWISE IMAGES

MATERIAL GRADE’S FORGEDMATERIAL GRADE’S FORGED

• Alloy Steel (ST-52-3, EN-353, 20MnCr5, 42MnCr5)

• Carbon Steel (A105, LF2, C45, C50 & others)

• Austenitic Stainless Steel (F304, F304L, F316, F316L)

• Martensitic Stainless Steel (F6a / SS410)

• Duplex Stainless Steel (Gr.F51)

• Super Duplex Stainless Steel (Gr.F53 & F55)

• Nickel Base Alloys (Inc-718, Inc-625, Inc-825, Monel K400/K500)

MAJOR PRODUCT RANGEMAJOR PRODUCT RANGE

� Product Name: SSBV Design Ball

� Size: 15 NB to 300 NB

� Material Gr.: F304, F304L, F316, F316L, F51, Inc-718, Inc-625, Inc-825, F6A

� Product Name: TMBV Design Ball



� Product Name: Cryogenic Design Ball



MAJOR PRODUCT RANGEMAJOR PRODUCT RANGE� Product Name: Seat Ring



� Product Name: Ball Valve Body



� Product Name: Ball Valve Connector



MAJOR PRODUCT RANGEMAJOR PRODUCT RANGE� Product Name: Stem


� Material Gr.: F304, F304L, F316, F316L, F51, Inc-718, Inc-625, Inc-825, F6a

� Product Name: Trunnion


� Material Gr.: F304, F304L, F316, F316L, F51, Inc-718, Inc-625, Inc-825

� Product Name: Stem Housing


� Material Gr.: F304, F304L, F316, F316L, F51, Inc-718, Inc-625, Inc-825,

� Product Name: Trunnion Plate


� Material Gr.: F304, F304L, F316, F316L, F51, Inc-718, Inc-625, Inc-825

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Pressfab Engineering India Pvt Ltd Unit III Introduction