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Beyond the technology excellence An exclusive interface with Colin Price Director Sales & Marketing- India, Renishaw Metrology Systems Pvt. Ltd. Pg. No. 59-62 Events Covered



An exclusive technology overview of various industry verticals of manufacturing sector (Refer Pg.12)

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Volume 12 No.9



DISA India Limited slated to launch its first ever “Made in India” CORE Machine and Manipulator Type Shot Blast Machine DISA and Wheelabrator have been reiterating the importance of technology-transfer in the industry and are enthusiastic that the industry will prioritize the same.


ISA - a World-leading foundry machinery manufacturer - and Wheelabrator - world’s no.1 surface preparation technology manufacturer - will be soon launching 2 new and highly innovative products; DISA’s �irst ever “Made in India” CORE Shooter Machine, 20 FP and Wheelabrator’s �irst ever “Made in India” Manipulator Type Shot Blast Machine, DS-I 1. These products are offered from DISA India operations based at Tumkur and Hosakote respectively. These pioneering machines will be unveiled at 61st Indian Foundry Congress and IFEX 2013. The event is scheduled to be held from 27th Jan – 29th Jan 2013 at Salt Lake Stadium, Kolkata. This event is India’s leading and only trade fair on foundry industry. “Our new launch will showcase DISA and Wheelabrator’s commitment to the Indian foundry industry. We are pleased to be the pioneers in bringing forth our very �irst ‘Made in India’ DISA CORE Machine and Wheelabrator manipulator type shot blast machine to the market. DISA and Wheelabrator have been reiterating the importance of technology-transfer in the industry and are enthusiastic that the industry will prioritize the same. Moreover, it is upto the 2 | JANUARY 2013 | ENGINEERING REVIEW

industry stalwarts to set the pace of progression in the industry.” said Mr. Viraj Naidu, Managing Director, DISA India Pvt. Ltd.

Product Snapshot :

DISACORE : The new DISA CORE 20 FP is designed for foundries wanting to increase their competitive edge with a �lexible and fast production of high-quality cores. DISA CORE 20 FP is German innovation at an attractive price. The bene�its of the product include, �lexible production suitable for multi-, vertical- or horizontal parted core boxes, fast production due to state-of-the-art control system and easy tooling change with DISA quick action clamping system and much more. DS-I1 : DS-I1 is the manipulator type shot blast machine offered from Wheelabrator global product range. The DS-I1 Shot Blast Systems is ideal for Light Metal, Cast Iron, and Forged Workpieces. The machines feature a combined shot blast and shot removal chamber. Depending on the particular application, the product can come with advanced and unparalleled handling arrangements etc. For more information write to : E-mail:

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Danfoss acquires full ownership of Danfoss turbocor compressors Danfoss extends the compressor portfolio up to 200 ton following the acquisition of Danfoss Turbocor Compressors.


anfoss, announced that it has acquired full ownership of the joint venture company Danfoss Turbocor Compressors, in which Danfoss has had a 50 percent owner’s share since 2004. The company develops, produces and markets high ef�iciency variable speed compressors in the capacity range of 75-200 ton per unit which are primarily used in very large commercial air-conditioning applications. Ricardo Schneider, CEO, Danfoss Turbocor Compressors commented: “We believe that Danfoss is the ideal single owner of this business because Danfoss is a global compressor manufacturer, a well-respected leader in our industry and committed to the longterm success of our business and our customers’ businesses. Danfoss Turbocor is a strong link in the Danfoss strategy to differentiate by innovation with variable speed high ef�iciency compressors. We are delighted to become 100 percent part of Danfoss, which will support Danfoss Turbocor in executing our ambitious plans”. Danfoss Commercial Compressors already has a strong position in the market for residential and commercial compressors, where the Danfoss inverter scroll compressor range is used in applications including rooftops, data centers, chillers, VRF. The acquisition of Danfoss Turbocor is set to secure the company’s leading position in variable speed compressor technology and thereby give the Danfoss Group decisive strategic advantages in the global air-conditioning and refrigeration market. According to Arup Majumdar, vice president marketing, strategy & inverter scrolls of Danfoss Commercial Compressors, the development of large capacity variable speed compressors addresses a global demand for more energy- ef�icient solutions for cooling and heating. “Our customers are increasingly seeking energy responsible solutions for air-conditioning and refrigeration. Danfoss Commercial Compressors covers this need with variable speed technologies that consume less energy and uses more ecofriendly refrigerants.” According to the International Institute of Refrigeration (IIR), 80 percent of the Green House Gasses (GHG) in the refrigeration and air-conditioning industry are released indirectly through the energy consumption of 4 | JANUARY 2013 | ENGINEERING REVIEW

refrigeration and air conditioning systems. The use of variable speed technology, however, signi�icantly reduces energy consumption – and, therefore, harmful emissions - by consuming energy based on actual demand. Variable speed compressors also have a better seasonal ef�iciency than traditional �ixed speed compressors. In countries where infrastructure investments are high in the areas of hospitals, large buildings and shopping malls, air conditioning demands must be met with the least energy consuming solutions. Danfoss Commercial Compressors has the broadest portfolio of energy-ef�icient solutions for cooling with a variable speed compressor portfolio covering residential, commercial and now also very large commercial segments with Danfoss Turbocor compressors. The application of the variable speed solutions from Danfoss can also contribute to the acquisition of green building status, thanks to the highly energy-ef�icient technology. The installed base of over 32,000 Danfoss Turbocor Compressors has already saved more than 1,500,000 tons of C02. The centrifugal compressor contributes to a smaller energy bill thanks to its high ef�iciency. It works without using oil as a lubricant. Instead permanent magnetic bearings replace the oil. This reduces the frictional losses making the compressor more ef�icient. The oil-free operation also reduces complexity while at the same time cutting costs. Danfoss Turbocor Compressors is headquartered in Tallahassee, Florida, and employs approximately 200 employees. The company has received prestigious awards for its technology including the AHRI Innovation Award and the U.S. EPA Climate Protection Award. The company becomes part of the Danfoss Commercial Compressors division but will continue to operate as an independent business. Danfoss Commercial Compressors has more than 1500 employees and production sites in Reyrieux, France; Arkadelphia, USA; and Wuqing, China. Danfoss has an established base of over 11 million compressors operating globally making Danfoss Commercial Compressors among the leading commercial compressor providers in the world. For more information

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Two business units with new management leadership change at Bosch Packaging Technology Uwe Harbauer takes over Pharma business unit Wolfgang Szczerba retires after 34 years at Bosch Walter Häcki appointed Senior Vice President Packaging Services


Mr. Uwe Harbauer, Senior Vice President, Business Unit Pharma, Bosch Packaging Technology

we Harbauer (48) takes on his new position as Senior Vice President Business Unit Pharma at Bosch Packaging Technology in Crailsheim, Germany, on January 1, 2013. He replaces Wolfgang Szczerba (59), who retires after 34 years at Bosch. Harbauer himself will be succeeded as Senior Vice President Packaging Services in Beringen, Switzerland, by Walter Häcki (48). Häcki already moved to his new position on November 1, 2012. Mechanical engineer Szczerba, who will celebrate his 60th birthday in January, started his career as development engineer in the Packaging Technology division back in 1981. In 2000, he became technical plant manager of the Crailsheim site, and since 2002 he has been responsible for Bosch Packaging Technology’s Pharma business unit.

Harbauer with long-term sales and service experience

His successor Uwe Harbauer also graduated in mechanical engineering and started working for Bosch Packaging Technology in 2000. He draws on many years of experience as head of sales of the Pharma business unit, and as senior vice president in charge of customer service. Most recently he held the position of Senior Vice President Business Unit Packaging Services in Beringen, Switzerland.

Walter Häcki takes over Packaging Services business unit 6 | JANUARY 2013 | ENGINEERING REVIEW

Walter Häcki (48) already took on his new position as Senior Vice President Business Unit Packaging Services on November 1, 2012. Swissborn Häcki graduated as trade merchant and, in 2000, started working for Sigpack Systems, which has been part of Bosch since 2004. He was head of supply chain management in Beringen, and member of the executive management in Budapest, Hungary. From 2008 to 2012, Häcki was responsible for Bosch Packaging Technology’s Chinese locations in Hangzhou (Zhejiang province) and Chengdu (Sichuan province). Chee Kiang Kang has succeeded Häcki in China. Kang worked as site manager in Singapore and has gained experience as a product manager in Germany in preparation for his new functions in China.

Internationally experienced executives

On behalf of the executive management, Friedbert Klefenz, president of Bosch Packaging Technology, thanked Wolfgang Szczerba for his commitment over the past decades. At the same time, he wished Walter Häcki, Uwe Harbauer and Chee Kiang Kang success in their new positions. “These appointments once again underline the long-term orientation of Bosch Packaging Technology. Both business units, as well as the entire division, will pro�it from long-term and international experience of their new managers,” said Klefenz. Based in Waiblingen near Stuttgart, Germany, and The ready reckoner for engineering & allied industry


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BUSINESS NEWS employing 4,700 associates, the Bosch Packaging Technology division is one of the leading suppliers of process and packaging technology. At over 30 locations in more than 15 countries worldwide, a highlyquali�ied workforce develops and produces complete solutions for the pharmaceuticals, food, and confectionery industries. These solutions are complemented by a comprehensive after-sales service portfolio. A global service and sales network provides customers with local points of contact. The Bosch Group is a leading global supplier of technology and services. In the areas of automotive and industrial technology, consumer goods, and building technology, more than 300,000 associates generated sales of 51.5 billion euros in �iscal 2011. The Bosch Group comprises

Robert Bosch GmbH and its roughly 350 subsidiaries and regional companies in some 60 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. Bosch spent some 4.2 billion euros for research and development in 2011, and applied for over 4,100 patents worldwide. With all its products and services, Bosch enhances the quality of life by providing solutions which are both innovative and bene�icial. The company was set up in Stuttgart in 1886 by Robert Bosch (1861-1942) as “Workshop for Precision Mechanics and Electrical Engineering.” The special ownership structure of Robert Bosch GmbH guarantees the entrepreneurial

Expansion of the portfolio along the entire value chain At Bosch Packaging Technology, the value chain includes laboratory phases and pretesting, primary and secondary packaging, standalone machines and complete systems. “The common denominators in this comprehensive portfolio are high quality and reliability. These attributes are consistently confirmed by our customers,” explained Wolfgang Szczerba, Senior Vice President Business Unit Pharma, Bosch Packaging Technology. 8 | JANUARY 2013 | ENGINEERING REVIEW

Mr. Walter Häcki, Senior Vice President Business Unit Packaging Services, Bosch Packaging Technology freedom of the Bosch Group, making it possible for the company to plan over the long term and to undertake signi�icant up-front investments in the safeguarding of its future. Ninetytwo percent of the share capital of Robert Bosch GmbH is held by Robert Bosch Stiftung GmbH, a charitable foundation. The majority of voting rights are held by Robert Bosch Industrietreuhand KG, an industrial trust. The entrepreneurial ownership functions are carried out by the trust. The remaining shares are held by the Bosch family and by Robert Bosch GmbH. For more information Web:

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Renishaw India :

Beyond the technology excellence

Mr. Colin Price, Director Sales & Marketing- India, Renishaw Metrology Systems Pvt. Ltd.




MARKET MONITOR Indis’s largest integrated power company chose EOS open platform enterprise energy management & control system for its load shifting program


A Triumph for Indian innovation : The 1200 kV UHVAC power system

INDUSTRY FOCUS 76 Power & Electrical - Electronics : Industry Performance in 2012 (India & global scenario) & forecast for coming years 88 POWERGRID to have remotely managed unmanned substations by 2013 92 Schneider Electric launches the third edition of Go Green in the city 94 Lutron to light up offices in United States Capitol 96 EMCO bags order worth Rs. 458 Crores from PGCIL for 800 KV HVDC transmission lines 98 Suzlon Group wins 105 MW order for projects in Canada

AUTOMATION SECTION IN FOCUS IPA : Bridging the industries with PROFIBUS & PROFINET technology platform 116

Omron introduces a powerful robust “ONE” automation platform 120

TECHNO BYTE 124 Everything remains different : Waaree Instruments Ltd. is becoming Baumer 126 Anybus Np40 128 Direct Part Mark considerations for automated manufacturing lines 130 Welding automation systems for the welding of various components and equipments

11th Annual Special



Business News .......................................................................................................... 02 12 | ENGINEERING REVIEW

| JANUARY 2013



REVIEW Monthly Magazine On Engineering & Allied Industry




Managing Editors Shilpa Kadam Shirish Dongre


Double fold production capability by 2015 & 70 % sheet metal fabrication in-house Ace Designers Ltd


JUNKER group : Grinding is our world, Driven by perfection 150

Siddharth Technocast : Allaying the casting needs 178

GEAR-MOTORS SECTION MARKET MONITOR Sumitomo Drive : The legacy of technology perfection Mr. Chandrashekhar Paradkar National Sales &Marketing Manager Sumitomo Drive Technologies, Pune, India


Gears & Motors : Industry Performance in 2012 ( India & global sceanrio) & forecast for coming years



208 Pumps & Valves : Industry Performance in 2012 (India & global sceanrio) & forecast for coming years

216 Process Industry : Latest technology trends 220 Vacuum systems chemical & pharmaceutical processes



226 Sparsh becomes the first India-based company to launch DVR series based on texas instruments’ New DaVinci™ Dm8107

Mr. Vijay Pimparkar GM, Godrej & Boyce Mfg. Co. Ltd.

Mr. T. P. Singh Director-S&M, FLIR Systems India Pvt Limited

INDUSTRY FOCUS 152 Haas : HE192 - CS 156 New metal cutting process for outer machining – ‘Pot- Broaching’ 180 Lamborghini saves €150K a year with Renishaw tool breakage detection systems 182 IndraMotion MTX micro from Rexroth: The compact CNC system for standard machines


Advisory Board (Editorial) Mr. G.Y. Banodkar Ex. Sr. Associate Director, Toyo Engg. Ltd.,

Mr. Gautam Kulkarni CEO, Hafi Elektra Pvt. Ltd



Editor Rajeev lyer

Mr. A. K. Ghosh Ex. Sr. Gen. Manager, Blue Star Ltd.,

PORTFOLIO SPERONI : 50 years of precision by Design

CEO Shekhar Dongre

MATERIAL HANDLING SECTION 186 Hours rather than days 188 Holcim, one of the largest producers of construction material worldwide, relies on drive technology from NORD DRIVESYSTEMS

230 Institution of Fire Engineers (IFE) : An apodictic voice of industry Mr. U.S. CHHILLAR, General Secretary, Institution of Fire ngineers

Product Review ....... 241 Project Update ....... 253


Marketing Team : Ladoji Pendurkar, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari Designer & Layout Arun Shinde, Pradeep Pillalamarri, Rahul Ramgude Circulation Executive Yogesh Pendamkar

ENGINEERING REVIEW : Head Office : Divya Publications, 3rd Floor, Harmony Building, Netaji Subhash Road, Court Naka, Thane (W) Thane-400 602 Maharashtra Tel: +91 22-25380574/75 Telefax: +91-22-25418254 E-mail:, Website: Branch Offices (Zonal): NORTH (Delhi & NCR regions) : Sandesh Jain : 09810837877 SOUTH (Chennai, Bangalore & Coimbatore) Y. V. Raghu : 09566141224 Hyderabad - R Tiwari : 09985381878 Kochi - Sanjeev Nair : 09846249568 EAST (Kolkata & Other regions) Shree D - 9819300464 WEST (Maharashtra & Gujarat) Pune - S.Kadam - 09833373371 Gujarat - Dinesh Shah - 9327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005


GERMANY: Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456,

FRANCE: MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE ITALY: Valeria VILLANI Tel.: +39 339 8610117, Via Firenze, Milano, Italia

SPAIN: Sofiane JEDIDI Mepax España Tel : +34 963 255 886, UK: Liz Jones Tel: +44 (0)1227 276016 ,

RUSSIA: Garri ZALTS Mepax Russia Tel: +7 495 576-7666 /

CHINA/South Korea/Taiwan: Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/

All rights reserved. No part of this magazine may be reproduced in any form without the permission of the Editor. ENGINEERING REVIEW is owned, printed & published by Shilpa Kadam, published from 3rd Floor, Harmony Building, Netaji Subhash Road, Court Naka, Thane (W) Thane-400 602 Tel: +91 22-25380574/75 Telefax: +91-22-25418254, Editor : Rajeev lyer. Important : Whilst care is taken prior to acceptance of advertising copy, it is not possible to verify its contents. ENGINEERING REVIEW can not be held responsible for such contents, nor if any losses or damages incurred as a result of transactions with companies, association or individuals advertising in the publications. Articles, interviews published in ENGINEERING REVIEW are the personal vie-ws and expressions of its authors. ENGINEERING REVIEW does not necessarily agree to it. ENGINEERING REVIEW can not be held res-ponsible for such articles / interviews. We therefore recommend that readers make necessary enquiries before sending any money or entering into any agreements with advertisers or otherwise act-ing on an advertisement in any matter whatsoever.


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We are well aware of our responsibility to the environment and our customers, and sustainability has been an important part of our company policy for many years. Find out more under: NORD DRIVESYSTEMS Pvt.Ltd. 282/2, 283/2, Village Mann, Taluka Mulshi, Adj.Hinjewadi MIDC-II, Pune- 411057 Maharashtra INDIA Phone +91 20 39801 - 200, Fax +91 20 39801 - 216, Member of the NORD DRIVESYSTEMS GROUP



Schneider Electric launches solar inverter sub-station at REI-2012



chneider Electric, the global specialist in energy management, launched the Solar Inverter Sub-Station (SISS) at the Renewable Energy India -2012, Greater Noida. SISS is a power conversion system operating between DC �ield and AC MV grid connections in PV Plant installations. SISS is a compact design, quali�ied for harsh environment present in Indian project sites. This design maximizes the inverter energy production ef�iciency and reduces risk of downtime. Schneider Electric is providing energy ef�icient integrated solutions to its customers including the SISS, array boxes, monitoring & control, and the grid connection substations. The SISS is a factory integrated, tested & validated plug & play power generating system that contains two Conext Core XC inverters, related DC combiner box, a stepup transformer, medium voltage switchgear and other accessories. This enables customers to reduce construction lead time, lower the costs of commissioning and enhance uptime thanks to quali�ied & reliable design. Mr. Olivier Blum, Country President, Schneider Electric India said‘’Schneider Electric is committed to provide bankable solar solutionsto help meet India’s growing demand for power. We are extremely proud to launch the Solar Inverter

Sub-Stationin India. This integrated solution will help our esteemed customers reduce the BOS costs and increase reliability of PV plant installations‘’ Schneider Electric provides bankable photovoltaic solutions for any size installation, together with a long-term support from a global company with over 175 years of experience. Schneider Electric products are present at every link in the energy chain, helping customers get the most ef�icient solar harvest from their installations thanks to quali�ied and reliable integrated solutions.

About Schneider Electric

As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in Utilities & Infrastructures, Industries & Machine manufacturers, Nonresidential buildings, Data centers & Networks, and in Residential. Focused on making energy safe, reliable, ef�icient, productive and green, the Group’s 130,000 plus employees achieved sales of 22.4 billion euros in 2011, through an active commitment to help individuals and organizations make the most of their energy. For more information www.schneider The ready reckoner for engineering & allied industry



| JANUARY 2013


India to showcase innovative solutions for sustainable and energy efficient production technology Automation, technology, innovation & more at HANNOVER MESSE 2013


annover Milano Fairs and Deutsche Messe unveiled their upcoming HANNOVER MESSE 2013 at a press brie�ing in India Expocentre, Greater Noida today, and 22nd November 2012. Hannover Messe 2013 is the world’s most important technology show, a powerful driver of investment in new technology and automation. The conference was addressed by Mr. Oliver Frese, Senior Vice President, Deutsche Messe, Mr. Mehul Lanvers-Shah, Managing Director, HMF India, Mr. R. Maitra, Executive Director, EEPC. Leading Indian companies including Crompton Greaves, Connectwell Industries Pvt Ltd, Janatics India Private Ltd., C&S Electric Limited, Raychem RPG Limited among others are expected to showcase innovative solutions that address energy ef�iciency in production operations at Hannover Messe 2013, to be held between 8th to 12th April 2013 at Hannover, Germany. At the press gathering, Mr. Mehul Shah, Managing Director, HMFI, said, “Indian companies have been participating in Hannover Messe for last 40 years. Hannover Messe, the much awaited event in the engineering world has plays a crucial role in promoting Indian engineering exports worldwide. Over 150 Indian companies are expected


to participate in the forthcoming Hannover Messe. Through a single exposure at Hannover Messe, Indian companies are able to reach markets not only in Germany, but also in entire Europe, The USA, Middle East, South-east Asia and Africa. Over 1000 businessmen from India attending Hannover Messe bring home new ideas and technologies to enhance their competitive edge.” Mr. Oilver Frese, Senior Vice President, Deutsche Messe, said, “As the premier international meeting place for decision makers and investors from industry, business and government, HANNOVER MESSE has shown time and again that it has the power and in�luence to kick off new trends and shape future developments. the fair will again be an international showcase of the highest caliber, where visitors will �ind the full range of solutions for all the big challenges facing all sectors of industry today. HANNOVER MESSE pro�iles the current state of the art in industry and previews key future trends.” Mr. R. Maitra, Executive Director, EEPC, said, “EEPC India (formerly Engineering Export promotion Council) is the oldest and the largest trade and investment promotion body set up under the aegis of Ministry of Commerce & Industry, Government of India. EEPC India has the total membership strength of more than 12,000 members ranging from large, medium and small scale enterprises. Over the years, EEPC India has played an instrumental role in promoting “Brand India” across the globe as EEPC has an India pavilion at Hannover Messe.”

About Hannover Messe 2013:

The spotlight will be on all the elements in the industrial value chain – above all, on industrial automation, energy, industrial components

supply, as well as new mobility solutions. 2013 line-up of leading trade fairs Industrial Automation, Motion, Drive & Automation, Energy, Wind, MobiliTec, Digital Factory, ComVac, Industrial Supply, Surface Technology, Industrial GreenTec & Research & Technology.


Hannover Milano Fairs India Pvt Ltd (HMFI), is a wholly owned subsidiary of two of the world’s leading trade fair organizers Deutsche Messe AG, Germany and Fiera Milano, Italy. HMFI have been bringing world class trade fairs into the Indian market for Indian and international enterprises since 2007. The strong international presence and the vast expertise and best trade fair practices of its parent companies are deployed in the fairs in India which is expected to boost trade which is the USP of fairs of HMFI. Exhibitors and visitors will gain from the professionalism of the international leaders.

About Deutsche Messe:

Deutsche Messe - based in Hannover, Germany - is the world’s foremost trade fair company. Deutsche Messe develops, plans and runs trade fairs and exhibitions in Germany and abroad as Hannover Fairs International with a Turnover – 410 Million $. Deutsche Messe was established in 1947; own the largest Fair Ground in the world with Indoor capacity of over 4.5 Lac square meters of display area. It organizes World’s Largest Engineering Trade Fair – Hannover Messe and World’s Largest IT Fair – CeBIT

Fiera Milano Group:

Italy’s largest Trade fair organizer owns the 3rd largest Trade fair venue with a Group Turnover – 150 million $. E-mail: The ready reckoner for engineering & allied industry


New Fluke laser distance meters instantly, accurately measure up to 100 meters Fluke 414D, 419D and 424D speed up measurements


luke Corporation introduces the Fluke® 414D, 419D and 424D Laser Distance Meters, which deliver accurate, point-and-click measurements up to 100 meters (330 feet). The laser distance meters are ideal for a broad range of building/construction, industrial, maintenance, and professional services applications.

New features available in these distance meters:

s Integrated compass: provides a “heading” for distance measurement. s Inclination sensor: assists with height tracking, leveling and indirect horizontal distance measurement when line of sight is blocked. s Automatic endpiece correction: when measuring from an edge or corner, a built-in sensor detects the position of the bracket and automatically changes the reference point.

The rugged dust- and splash-proof distance meters allow for easy measurement of hard to access areas, like high ceilings, without climbing a ladder. The three models provide the right features and price points for a wide variety of applications:

Fluke 414D

o Measures up to 50m (165 feet) with one button and an accuracy of +/- 2mm (0.079 in). o Easy, automatic math for area and volume; add and subtract with ease.


Fluke 419D s Measures up to 80m (263 feet) with even greater accuracy of +/1mm. s 3-line display plus storage for 20 complete displays. s Tripod mountable.

Fluke 424D

s Measures up to 100m (330 feet). s Feature-rich meter includes tilt sensor for hard-to-reach measurements, corner angle feature, compass, and more.

Pricing and Availability

The Fluke Distance Meters will be available from December 2012. For more information, visit: http://www. � For more information on Fluke tools and applications, or to �ind the location of your nearest distributor, call 1800 209 9110 , e-mail info.india@� or visit the Fluke Web site at http://www. �

About Fluke

Founded in 1948, Fluke Corporation is the world leader in compact, professional electronic test tools. Fluke customers are technicians, engineers, electricians, and metrologists who install, troubleshoot and manage industrial, electrical and electronic equipment and calibration processes.

Follow Fluke on Facebook.

Fluke is a registered trademark of Fluke Corporation. The names of actual companies and products mentioned herein may be the trademarks of their respective owners. For more information write to : E-mail:

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Atlas Copco launches a full range of nitrogen and oxygen generators


tlas Copco introduces 3 ranges of nitrogen and oxygen generators for on-site gas generation. With these innovative gas generators, companies can expand their existing compressed air installation to generate their own nitrogen and oxygen. An independent supply of onsite gas can realize signi�icant economies of scale as well as save on operational costs. Atlas Copco’s new range of on-site gas generators are designed to meet the highest purity standards and run economically for both large and small applications. On-site gas generation is more sustainable and cost-ef�icient than gas delivered in cylinders or bulk liquid supply, as it eliminates the operational and administrative costs ofordering, transporting, storing and delivering the bottles or bulk liquid incryogenic tanks. With an independent supply of nitrogen and oxygen, companies’ gas demand is always met in time, at the lowest cost.KoenLauwers, Vice-President Marketing of Atlas Copco’s Industrial Air Division comments: “With these new ranges of gas generators, our customers will dramatically increase their productivity. We help them to discover untapped saving potentials through economy of scale: combining their compressed air systems with the production of nitrogen and/or oxygen, serving their speci�ic needs.”

Membrane nitrogen generators for easy, cost-efficient gas generation

Atlas Copco’s membrane nitrogen generator (the NGM) is, thanks to its high ef�iciency and reliability, ideal for applications such as �ire prevention, tire in�lation, oil and gas and 24 | JANUARY 2013 | ENGINEERING REVIEW

marine. The NGM uses membrane air separation to produce nitrogen. A bundle of polymer �ibers acts as a membrane that allows nitrogen to pass and other gases (like oxygen, water vapor and carbon dioxide) to permeate. Compressed air goes in at the inlet and enriched nitrogen comes out at the other end of your nitrogen generator. Membrane technology generates nitrogen with an adjustablepurity between 95 and 99.5 % and �lows up to500m³/h.

PSA nitrogen generators for the highest purity

For those applications that demand high purities of nitrogen (up to 99,999%) at a smaller �low, the Nitrogen Generator (NGP) with PSA technology is the recommended solution. Based on the Pressure Swing Adsorption (PSA) technology, carbon molecular sieves adsorb oxygen molecules from compressed air. The Nitrogen Generator has two connected towers that work together to produce an almost continuous �low of nitrogen gas. The result: nitrogen purity levels from 95 to 99,999 % for �lows up to 1100 Nm³/h. Typical applications of the NGP are plastic molding, machining, purging analyzers, electronics, fruit storage and food and beverage.

PSA oxygen generators reliable, on-site oxygen


Oxygen is vital to processes in the medical world, in waste water treatment, �ish farming and ozone production. The OGP oxygen generator also makes use of PSA technology, with zeolite pellets that act as adsorbent. The output is oxygen with an adjustable purity between 90% and 95%, at �lows up to 200 Nm³/h.

On-site nitrogen and oxygen as part of a total solution

Atlas Copco now offers on-site gas generators which can be directly combined with an existing compressed air installation.With an independent supply of nitrogen and oxygen, companies can start saving on the operational and administrative costs of bulk and cylinder gas delivery. These 3 ranges of nitrogen and oxygen generators offer exactly the �lows and purities that different industrial applications need. This way, Atlas Copco becomes a one-stop-shop for compressed air, gas and service. For more information write to : E-mail:

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® & ™ are owned by Ansell Limited or one of its affiliates. ® All Rights Reserved 2012

ANSELL, GLOBAL LEADER IN HAND PROTECTION SOLUTIONS. Mechanical Protection, Chemical & Liquid Protection, Product & Worker Protection. As a global leader in hand protection Ansell offers a complete range of solutions and services to industry, providing protection while enhancing productivity. Mechanical Protection guards against cuts, abrasions, snags, punctures and hand fatigue. Chemical & Liquid Protection defends against harmful chemicals, oils, liquids and mechanical hazards. Product Protection shields hands and products from contamination. HyFlex®, AlphaTec®, TouchNTuff® gloves feature the latest innovations, leading the industry in safety and functionality. When you need the right solution for the most challenging jobs and environments, these gloves deliver and provide the highest levels of worker safety and comfort.



Tecpro Systems Limited receives an order worth ` 146.6 crore from Damodar valley corporation


ecpro Systems Limited (Tecpro Systems), a leading Engineering, Procurement and Construction (“EPC”) Company providing comprehensive range of services in Material Handling to Steel, Cement, Ports, Mining and other industries in Infrastructure sector, Coal handling systems, Ash handling systems & Balance of Plant (BoP) packages for Power Sector, has announced that it has received an order worth ` 146.6 crore from Damodar Valley Corporation for supply of Coal Handling Plant Package for BTPS ‘A’ (Bokaro Thermal Power Station) (1X500 MW) along with related services. Tecpro Systems has a high level of operational expertise in three functional areas that are vital in any project i.e. Design & engineering, Manufacturing and Execution. Tecpro Systems will undertake Design, Engineering, Manufacturing, Shop Fabrication, Assembly, Testing, Inspection, Packing, Installation Services including Erection, Civil and Structural works for the complete Coal Handling Plant Package for BTPS ‘A’ (1X500 MW). Commenting on the development, Mr. Amul Gabrani, Vice-Chairman & Managing Director, Tecpro Systems said, “We are delighted to announce this order in the coal handling space, as we continue to witness strong order in�lows despite subdued macroeconomic conditions. The order from Damodar Valley Corporation re�lects our leadership position in the coal handling segment along with proven execution capabilities. We will further continue to capitalize from the enormous opportunities given our order book visibility and presence across the entire value chain.” 26 | JANUARY 2013 | ENGINEERING REVIEW

About Tecpro Systems: Since the commencement of its operations in 2001, Tecpro systems has been instrumental in executing turnkey projects across steel, power, cement, ports and other core sectors. The company designs, engineers, manufactures, sells, commissions and services a range of systems and equipments to provide turnkey projects for the core infrastructure related sectors like power, steel, cement and other industries. Today, Tecpro Systems has in-house capabilities for providing comprehensive solutions in material and ash handling systems. The company has ventured into various complimentary businesses across different divisions of the power sector with a vision to build an integrated business serving the sector. As per CEA records, Tecpro Systems received the highest number of orders for coal handling plants during the elevent �iveyear plan (2007-2012). The company also forayed into the EPC segment and is executing a number of projects in the captive power plant sector and waste heat projects in the cement and steel sectors in addition to coal based captive power plants for various industries. Leveraging its capabilities in coal and ash handling, the company has also taken up turnkey BoP contracts in the thermal power generation sector. The business undertaken by the company broadly comprises four segment viz. material handling solutions, ash handling solutions, BoP/EPC contracts and other business such as air pollution control equipment. For more information write to : E-mail:

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Elecon Engineering bags two prestigious orders ~ ` 12.21 crores from NMDC Limited and ` 6.15 crores from MADRAS CEMENTS Limited~


lecon Engineering Company Limited, one of the India’s largest Material Handling Equipments and Transmission Products manufactures, announced that their MHE Division has procured two prestigious orders one of ` 12.21 crores from NMDC Limited for the Supply, Erection and Commissioning of one number Lump Ore Reclaimer including initial spares to client’s Bacheli Complex Project and second of ` 6.15 crores from MADRAS CEMENTS Limited for Supply of material handling equipments and other spares for Grinding Unit Project.

Information of order received:

1. Name of Client : NMDC Limited Type of Order : Supply, Erection and Commissioning of one number Lump Ore Reclaimer including initial spares to client’s Bacheli Complex Project Total Value of Order : ` 12.21 crores

2. Name of Client : MADRAS CEMENTS Limited Type of Order : Supply of material handling equipments and other spares for Grinding Unit Project Total Value of Order : ` 6.15 crores

Mr. Prayasvin Patel, Chairman and Managing Director, Elecon Engineering said, “We are pleased to have procured prestigious orders worth ` 12.21 crores and `6.15 crores and look forward to a long—term mutually bene�icial association both with NMDC Limited & MADRAS CEMENTS Limited.


This win is a big achievement for all of us at Elecon as we continue to maintain a healthy order book month on month.”

About Elecon Engineering Company Ltd. : Established in 1951, Elecon Engineering Company Ltd of Vallabh Vidyanagar, Gujarat, India, pioneered the manufacture of material handling equipment. During these six decades, Elecon has designed and implemented several landmark projects in India as well as abroad. From a modest start of design and manufacture of Elevators and Conveyors from which incidentally, the company derives its corporate identity. viz. “Elecon”. It has grown over the years to be known as a pioneer of the concept of mechanized way of Bulk Material Handling Equipment in India. During the span of more than 6 decades, Elecon has encompassed all the major core sectors through its supplies of highly sophisticated equipment bearing ample testimony of the symbolic mark of Elecon’s unbeatable technology. Elecon has thus, made its presence felt through consistent and satisfactory performance of its equipment in such core sectors as fertilizer, cement, coal/ power generation, chemical, steel plant and port mechanization etc., across the country. For more information write to : E-mail:

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| JANUARY 2013


DNV KEMA strengthens smart grid services in Asia Pacific

Don Bonnitcha has been appointed Director of DNV KEMA’s Management and Operations Consulting (MOC) Services in the Asia-Paci�ic division. “My aim is to grow DNV KEMA’s organisation in China and throughout the Asia Paci�ic and maximise the synergies between DNV KEMA personnel across the division.”

“The ties between China and Australia are strong and both countries are currently undergoing signi�icant changes in their electricity markets. I am con�ident that Don’s appointment will further strengthen the cooperation among industry players in the energy domain” – Bjorn Tore Markussen, Chief Operating Of�icer in DNV KEMA Asia Paci�ic.



nergy consulting and testing & certi�ication company DNV KEMA strengthens its smart grid-related services with the appointment of Don Bonnitcha as Director for DNV KEMA’s Management and Operations Consulting Services in Asia Paci�ic. Bonnitcha takes up his new position in December 2012 and brings with him extensive leadership experience and a proven ability to manage teams and delivering a broad range of consulting services for DNV KEMA in Australia and New Zealand. In his new role Bonnitcha will be responsible for the existing consulting teams in Australia, China and Singapore, and to further develop the DNV KEMA Management Operations and Consulting (MOC) business throughout Asia and the Paci�ic. The MOC services focus on energy Markets and Regulation (MAR), utility organisation Operational Excellence (OE), Power System Operation and Control (PSOC), Intelligent Networks and Communications (INC) and utility Risk Management (RMS). “I am delighted to join the DNV KEMA Asia Paci�ic Division and to be able to work with very experienced and knowledgeable teams to deliver on its development goals in this important market,” says Bonnitcha. “In the current energy environment throughout the Asia-Paci�ic region, nations are driving toward reduced reliance on fossil fuels, increased penetration of renewable sources, and meeting stakeholder demands for higher ef�iciency and reliability in power delivery. It is therefore important that utilities and energy suppliers have access to leading practices that are underpinning the adoption of automation technologies and applications, and smarter ways to operate power systems more ef�iciently.” “I am glad that Don has accepted this new position. With over 20 years experience, he brings with him a wealth

“Our clients in APAC have considerable growth and infrastructure expansion needs, for which Don is well-prepared in building upon our global capabilities to speci�ically anticipate and address their business challenges” – Rob Wilhite, Global Director for Management and Operations Consulting (MOC) Services in DNV KEMA.

of expertise in smarter ways to operate power systems more ef�iciently. We will also make use of his industry insights across the wider DNV KEMA operations and the �ive geographical regions we serve here in Asia,” says Bjorn Tore Markussen, Chief Operating Of�icer for DNV KEMA Asia Paci�ic. “The global MOC business in DNV KEMA is well-established and we have delivered projects for many years in China, India, Korea, Japan, South East Asia as well as Australia. With the anticipated need for more energy ef�icient operations, mainly through the application of smart grids and intelligent networks, we are now planning to expand our APAC teams to meet the future market,” says Rob Wilhite, Global Director for Management and Operations Consulting Services in DNV KEMA. “Under Don’s leadership, we will continue to build capabilities to address client business issues in key APAC regions, using global knowledge and methods but applied with local experience.” For more information write to : E-mail:

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Han® PushPull Signal: Reliable transmission for all important conductors



he new HARTING PushPull Signal connectors meet the demands of industry for the reliable transmission of energy, signals and data in all power ranges, consistently and in a uniform connector system. HARTING PushPull Signal has 10 contacts to transmit rated currents of 5 A with conductor wiring gauges of up to 0.75 mm². To ensure EMC interference immunity, the contact inserts are fully screened, as they are with RJ45 data connectors. Screened cables can be connected. The connectors have PushPull locking for reliable and intuitive connection. Perfect locking is indicated by an acoustic signal (a click). Hybrid applications can also be created with PushPull Signal. For

example, one part of a connector face can be used for energy transmission, whereas other contacts are available for communication. PushPull Signal connectors are obtainable in the PushPull 14 and 4 version series in accordance with IEC 61076-6-107. Han® PushPull version 14 is the preferred connector for decentralized automation in the �ield for data transmission and energy supply subject to the guidelines of the PROFIBUS user organization PNO and the automation initiative of German automobile manufacturers (AIDA). For more information HARTING India Pvt Ltd Website :

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Success story on the Indian market Freudenberg systematically expands its activities in India


reudenberg has been successful on the Indian growth market for over 90 years. Initially, business concerned trade relations with Indian companies to supply and purchase leather. The Indian market ranks among the most important growth regions for the diversi�ied Freudenberg Group, which specializes in the manufacture and sale of technically challenging products. In the 2011 �inancial year Freudenberg generated sales of approximately Rs.956 crores in India, a year-on-year increase of more than 20 percent. India’s pronounced economic attraction is also partly attributable to the envisaged vigorous infrastructure expansion set out in the Indian government’s 12th �ive-year plan. As Dr. Jörg Matthias Großmann explains; “Indian Government is planning to invest around US$500 billion in the period to 2017. That opens up many possibilities for us.” Airports, for example, need �ilters for ventilation and air conditioning, noise insulation for the ceilings, and professional cleaning products. “The sustained, very good development of our Business Groups in India is the result of our continuous commitment in the region,” Dr. Jörg Matthias Großmann, the Freudenberg Group’s Regional Representative in India and Chief Financial Of�icer of Freudenberg Chemical Specialities, stresses. “The Freudenberg Group will be systematically expanding its activities in India and backing its strategic targets with the corresponding investments.” Freudenberg’s present headcount in India is over 3,000. The most important markets for the Group are mobility, transport, health, the food industry as well as specialized services, energy, resources, industry, textiles, research and the residential sector.


As a global supplier, the Freudenberg Group develops, produces and markets technically challenging products and services mainly in the �ields of seals and vibration control technology, nonwovens, �ilters, specialty lubricants and release agents as well as mechatronics. Freudenberg’s most well-known consumer brand on the Indian market is GALA household products. Freudenberg has always had a global orientation and today has a presence in 58 countries; the Group operates 28 production and sales locations in India alone. “No globally active company can afford to be without a local presence in the attractive Indian market,” Dr. Jörg Matthias Großmann underscores.

India: Strong domestic market

One unique feature about India is the country’s relatively low dependence on the world economy compared with other emerging markets. This is due to the high share of gross domestic product (60%) attributable to the domestic market. “And the Indian market becomes even more interesting if we bear in mind that the middle class is expected to swell from the present 80 million to 400 million by 2020,” Regional Representative Dr. Jörg Matthias Großmann says. Demand for consumer goods, which contain many Freudenberg products in the form of parts or components, or where these products go into manufacturing such parts and components, will therefore grow accordingly. Freudenberg is currently investing in the Chem-Trend and Klüber Lubrication plants in Mysore where specialty lubricants, release agents and maintenance products are manufactured for the local and regional market. By 2016, Freudenberg will have invested a total of Rs.130 crores in the 40,000 m2 site and has also

purchased an additional 9,000 m2 of land. Mysore serves customers in sectors such as the automotive, energy, food and wind energy industries. India is a major player in the global wind energy market.

Technology know-how from India for India

Another major investment project is currently underway in Pune, where EagleBurgmann is building a new research and development center. The plans include a modern test center where state-of-the-art seals used in re�ineries, petrochemical and chemical plants, power stations and other sectors of industry will be tested by means of fully-automated, computercontrolled methods. The blueprint also includes additional production space. Building work is expected to be completed by spring 2013. In April 2012 Freudenberg Filtration Technologies India acquired the business of Pune-based Pyramid Filters Pvt. Ltd. The company develops air �ilter elements and systems for cleanroom applications in the pharmaceutical, medical, chemical and food industries. Freudenberg Filtration Technologies India provides high-ef�icient �ilter elements and systems for general industry and the automotive market as well as system solutions for productivity and ef�iciency enhancement in gas turbines and compressors. Freudenberg Filtration Technologies has expanded its portfolio in India with the acquisition of Pyramid Filters and now also offers customers a comprehensive �ilter range for suspended particles plus associated services. Customers also bene�it from Freudenberg’s expertise in application engineering and from the �iltration technology know-how of a global market leader. For more information write to : E-mail:

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Bangalore based HHV bags prestigious Russian order for a telescope mirror coater Bangalore based HHV bags prestigious Russian order for a telescope mirror coaterIn a path breaking initiative, HHV exports a very complex, high technology machine to an advanced nation like Russia


he Bangalore based Hind High Vacuum Co. Pvt. Ltd. (HHV), announced that it has bagged a prestigious Russian order for export of a machine for re-coating the giant mirror of a telescope in the Caucasus mountain observatory of the Sternberg Astronomical Institute of the Moscow State University. This is a path breaking initiative by HHV, the �lagship company of the HHV Group, a multi-technology group of companies involved in the design, development and manufacture of equipment and products in the �ield of Vacuum Technology, Solar Photovoltaic Energy and Thin Films. These days, when all one hears about is a cascade of Chinese products �looding into this country, it is a much-needed boost to the selfesteem of Indians to hear that an Indian company like HHV is exporting a very complex, high technology machine to an advanced nation like Russia. HHV has, in the last �ive decades, made its mark as a manufacturer of key equipment involving high vacuum for such demanding customers as ISRO, BARC, HAL and the like. “Till recently, the ability to design and develop such complex coating equipment for large mirrors was


limited to a few specialized companies in the advanced countries. HHV has now become a member of this select club by leveraging its expertise of designing and making vacuum-based equipment for depositing thin �ilm coatings.” said Mr. Nagarjun Sakhamuri, Managing Director, HHV. “HHV supplied its �irst machine for coating telescope mirrors in 2004 to the Indian Institute of Astrophysics for the Hanle observatory located in the Ladakh region of the Himalayas, at a height of 4570 meters above sea level. It is being used to coat the 2.1 metre diameter telescopic mirror of 1 tonne weight at the observatory.” Modern astronomical observatories which peer into deep space use advanced optical telescopes which have very large size mirrors with diameters of 2 metres and above. These mirrors are coated with a re�lective thin �ilm of aluminium or silver or an alloy of both. Over time, this �ilm gets damaged and tarnished due to oxidation, dust, impact of charged particles from space etc. Therefore, these mirrors need to be routinely cleaned by removing the old coating and coating fresh with a new layer of re�lective �ilm. Since the observatories are usually located in remote , high altitude locations ,the coating has to be done on the spot using special machines as it is very dif�icult to transport the fragile mirrors a large distance to a convenient location. This coating has to be done under high vacuum and very controlled conditions, so that the deposition is spotlessly clean, highly accurate and very uniform. In addition to that, the coating equipment needs to employ

specially designed and complex systems for safely, yet very accurately, handling the heavy mirrors of large diameters. In 2006, HHV supplied a coater to the Inter University Centre for Astronomy and Astrophysics (IUCAA) for its telescopic mirror at Girawali near Ghodegaon on the Pune-Mumbai high way at an altitude of 1000 metres above sea level. The concave, 2.2 metre dia. mirror has a thickness of 200mm and weighs about 250 kgs. In the �irst half of this year, HHV supplied a coating machine to the Aryabhatta Research Institute of Observational Sciences for its two new, state-of-the-art optical telescopes of 130-cm and 360-cm aperture at Devasthal, situated at an altitude of 2500 meters above Mean Sea Level, about 60 kms away from the town of Nainital in the lower Himalayas. It was a challenging assignment since the primary mirror of the bigger telescope has a large diameter ( 3.7 metres ), a thin cross section ( only 12 cm thick ) and a large weight ( 4.5 tonnes ). To top it all, HHV has supplied the coater at half the price quoted by a European company which is one of the leading global vendors of such machines. “It is because of the successful execution of the above domestic projects that HHV could win its �irst international order for a telescope mirror coater from Russia despite facing stiff competition from more established manufacturers in West Europe. The machine is being despatched in December 2012” added Mr Nagarjun Sakhamuri. For more information write to : E-mail: The ready reckoner for engineering & allied industry



| JANUARY 2013


HONEYWELL to improve operational efficiency at SIB; Erian generating company Honeywell MES Systems Will Increase Productivity and Optimize Production Ef�iciency.



oneywell (NYSE:HON) announced that it has been selected by Siberian Generating Company (SGK) to supply and implement new Manufacturing Execution Systems (MES) at both the JSC “Kuzbassenergo” and JSC “Yenisei TGC (TGC-13)” regional power generation facilities which are operated by SGK. As part of project, Honeywell will install its MES solution at four power plants located at the Kuzbassenergo facility and two power plants at the Yenisei TGC site as well as at SGK’s head of�ice in Moscow. Honeywell’s MES solution will improve the �low of information between head of�ice and the six sites, allowing SGK to continually monitor emissions and plant equipment health, manage repairs ef�iciently, and continuously improve maintenance practice by leveraging Reliability Centered Maintenance (RCM) analysis. In addition, Honeywell has worked with its local partner RVS to develop a full set of Key Performance Indicators (KPIs) which comply with Russian standards and will allow SGK to automate routine operations and sustain compliance with local regulations. At the plant level, the solution will also collect and store each plant’s entire maintenance history, including equipment faults, performance issues and degradation rates, helping plant operators identify long term trends, diagnose issues early and prevent potential problems before they occur. For senior management, Honeywell’s MES solution will enable better collaboration between facilities and convert plant data into

insightful information for better decision-making and improved overall business results. “Siberian Generating Company has a complex infrastructure of sites and facilities that must be managed and maintained effectively,” said Leonid Sorkin, CEO of Honeywell in Russia. “Honeywell’s industry-leading MES solution will help SGK to improve operational ef�iciency and plant reliability at both Kuzbassenergo and Yenisei TGC, helping it to consolidate its leading position in the Russian energy market both now and in the future.” Honeywell International (www. is a Fortune 100 diversi�ied technology and manufacturing leader, serving customers worldwide with aerospace products and services; control technologies for buildings, homes and industry; automotive products; turbochargers; and specialty materials. Based in Morris Township, N.J., Honeywell’s shares are traded on the New York, London, and Chicago Stock Exchanges. For more news and information on Honeywell, please visit Honeywell Process Solutions is part of Honeywell’s Automation and Control Solutions group, a global leader in providing product and service solutions that improve ef�iciency and pro�itability, support regulatory compliance, and maintain safe, comfortable environments in homes, buildings and industry. For more information : HONEYWELL

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Karma Industries Limited goes live with Infor LN Many Diverse Operations Uni�ied by Infor ERP Application


nfor, a leading provider of business application software serving more than 70,000 customers, today announced that Karma Industries Limited, a well-diversi�ied company with interests ranging from metal fabrication to trading, has gone live with Infor LN with the help of Infor partner Merino Services, a business consulting and IT services organisation.

News Points

s Karma Industries Ltd. needed �inancial consolidation at an apex level, integrated work�low for business control and to enable integration with add-on products such as Commodities & Equities to support the growth of business through its subsidiary and associated �irms Karma Commodities Limited and Karma Stock Trade Limited. The company has diversi�ied operations across multiple locations which were uni�ied on a single platform with Infor LN. s Karma Industries deployed Infor LN and integrated the human resource management, purchasing and inventory systems for online transaction processing from all locations, to provide faster availability of information. s Prior to deploying Infor LN, Karma Industries used Tally software. Karma Industries moved to the Infor LN application because of faster estimated time of implementation and Infor’s expertise in specialised industry applications and support to provide a well-suited application for Karma Industries’ complex business scenario.

Karma Industries Limited quote:

“Our vision served as the framework towards every aspect of our business by describing what is required to achieve the goal of continued stability and growth. With the Infor application we are achieving the requisites on a whole by analysing the 50 | JANUARY 2013 | ENGINEERING REVIEW

business,” says Rajesh Mehta, Managing Director, Karma Industries Limited

Merino Services quote : “Karma Industries was a very important win for Merino Services as it gave us an opportunity to extend our success footprint in the metal industry. Implementation was a success not just because of Merino Services’ strong consulting skills on Infor LN but also on the support extended by Karma Industries’ management team. With this success we welcome various metal industry organisations to capitalise on the success-driving capabilities of Infor and Merino Services,” says Rishi Bansal, Vice President – Global Business, Merino Services.

Infor quote: Mr. Souma Das, Vice President, Sales and Managing Director, India said: “At Infor, we take pride in serving our customers with latest business software solutions by continually developing our solutions. We believe in actively engaging with customers and partners to provide the solutions that meet their requirements and address their challenges. Merino Services has always helped us deliver best quality solutions to our clients.”

About Infor :

Infor is the third-largest provider of enterprise applications and services, helping 70,000 customers in 194 countries improve operations, drive growth, and quickly adapt to changes in business demands. Infor offers deep industry-speci�ic applications and suites, engineered for speed, using ground-breaking technology that delivers a rich user experience, and �lexible deployment options that give customers a choice to run their businesses in the cloud, on-premises, or both. For more information write to : E-mail:

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L&T delivers the 1st high speed interceptor boat to coast guard


arsen & Toubro (L&T), India’s leading engineering, manufacturing & construction major has achieved a major milestone in its continued effort to contribute to the defence of the country by delivering its 1st indigenously designed and constructed High Speed Interceptor Boat (IB) to Indian Coast Guard (ICG). The IB capable of achieving maximum speed over 40 Knots, was designed and constructed entirely through in-house efforts. This is the �irst of 36 such High Speed Interceptor Boats being constructed by L&T under a contract worth Rs. 977 Crs. from ICG. The IB has a full aluminium-alloy construction for reduced weight and is powered by twin water-jet propulsion systems to enable quick response which is vital for coastal surveillance activities. The interceptors have the ability to operate


effectively in shallow water which will be critical for near- shore action. These boats are expected to signi�icantly enhance India’s coastal security. The �irst boat has been commissioned into service at Coast Guard District Headquarters at Porbandar under the command of COMCG (North-western Region). Using the latest 3D software at L&T’s “state-of-the-art” Marine Design Centre, the boat was �irst developed as a virtual vessel in the of�ice environment to ensure compliance with operability, maintainability and buildability, before issuing the drawings to the shop �loor. During the recently concluded sea trials, the boat has achieved the stringent performance parameters of speed and endurance, which is a testimony to L&T’s sound ship design and construction capabilities. It also opens up avenues for possible export of such boats.

Background : Larsen & Toubro is a USD 13.5 billion technology, engineering, construction, manufacturing and �inancial services conglomerate, with global operations. It is ranked 4th in the global list of Green Companies by the reputed international magazine Newsweek, and ranked the world’s 9th Most Innovative Company by Forbes International. L&T is one of the largest and most respected companies in India’s private sector. A strong, customer–focused approach and the constant quest for top-class quality have enabled L&T to attain and sustain leadership in it s major lines of business over seven decades.

For more information write to : E-mail:

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Parker Hannifin Corporation opens ` 100 crore green field manufacturing facility at Chennai

Parker MWC Facility Chennai


arker Hanni�in Corporation (NYSE:PH), the global leader in motion and control technologies, inaugurated its �irst green �ield manufacturing facility at Chennai. The state-of-the-art, world class facility is built on a ten acre plot in Mahindra World City. The new manufacturing site will focus on production for the Filtration, Pneumatics and Drives, Sealing and Shielding businesses. The company has invested Rs. 100 Cr in setting up the facility. The new facility will manufacture broad range of products and systems for segments such as automotive, off highway mobile, telecom, oil and gas, mining, and primary metals. The Chennai facility targets the employment of 300 people in the next 2 to 3 years. With this facility and acquisitions Parker Hanni�in India plans to double their revenues within the next 5 years. Tom Williams, Executive Vice President and Operating Of�icer, Parker Hanni�in Corporation said, “The inauguration of our �irst green �ield manufacturing facility at Chennai and localization of our products demonstrate our commitment to 54 | JANUARY 2013 | ENGINEERING REVIEW

India as a key growth market. Our new Chennai facility will enhance our ability to support our customers locally here as we build our presence in new markets in India.” “Expanding business in Asia, and speci�ically India, represents a signi�icant aspect of Parker’s future growth strategy. Asia represents approximately 10% of our sales today but over time we would expect that to be as much as 20% as our target is to double our business in the region over the next several years. A signi�icant portion of our growth efforts in the region will be focused on India, as this country will play a critical role in our success in achieving these goals”, Mr. Williams added. Parker Hanni�in is committed to investments and long term growth in India. As part of the growth strategy, Parker has made �ive strategic acquisitions in India in the past two years and nine since 2005. Arijit Sen, Country Managing Director, Parker Hanni�in India said, “The investment in the new Chennai Parker India plant has established a strong foundation for our future success in India. Additional

manufacturing capacity at Chennai will help the company to cater to the demand for high quality products, engineering solutions and systems in India. We have currently only built the �irst phase of the project in Chennai of 166,000 square feet and we expand further by 100,000 square feet in the second phase.” The Chennai facility is designed as a Green Building and is in the process of being LEED certi�ied. This emphasizes Parker’s commitment to providing a comfortable and healthy working environment and to using eco -friendly material and improved water & energy ef�iciencies. Along with its investments in new manufacturing facilities and acquisitions, Parker India continues to invest into human resources, increasing its manufacturing talent and enhancing its product and system engineering capabilities. A well networked sales organization operating through regional sales of�ices is supported by an expanding base of Distributors & Parker Stores to cover the customers, markets and large industrial footprint of India. Besides the established markets in off highway mobile, oil and gas/ CNG, mining, primary metals and automotive, Parker India will be focusing on the exciting and fast growing markets in power generation, renewable energy, railways, defense, and life sciences– which represent strong growth opportunities as India continues to build its infrastructure.

For more information write to : E-mail: The ready reckoner for engineering & allied industry


Timken acquires Wazee Companies, LLC; Expands industrial service offerings Denver-based business provides electrical and mechanical solutions


he Timken Company announced its acquisition of the assets of Wazee Companies, LLC, a regional leader providing motor, generator, wind and industrial crane services to diverse end markets including oil and gas, wind, agriculture, material handling and construction. The addition of Wazee to The Timken Company’s process industries segment further expands the footprint of the Timken industrial services business. Based in Denver, Colo., Wazee had trailing 12-month sales through December 2012 of approximately $30 million. The acquisition brings Timken additional diversi�ied services including motor rewind, generator rebuild, electric controls, industrial bridge cranes and uptower wind maintenance and repair, operating from four western U.S. locations. “We continue to focus our strategy on further diversifying the Timken services portfolio,” said Carl Rapp, vice president of industrial services for Timken. “Wazee complements our industrial repair capabilities at existing customers and takes us into critical motor and generator services. “Wazee has a strong reputation in the region it serves and is led by an experienced management team,” said Rapp. “They bring great technical skills and provide an excellent footprint for us to expand our bearing and gearbox repair services.” Wazee currently operates out of four locations—two in the Denver area, one in Pasco, Wash., and another in Casper, Wyo. Wazee has more than 100 employees. The purchase includes assets from Wazee’s 2011 acquisition of H&N Electric, 56 | JANUARY 2013 | ENGINEERING REVIEW

Inc., which also offers repair, maintenance and overhaul services for critical motors and wind generators in the Paci�ic Northwest region.

About Wazee Companies, LLC

Wazee Companies, LLC, (www.wazeeco. com) is recognized for its quality, reliable service and workmanship repairing electric motors and generators, crane manufacturing and wind turbine service. Based in Denver, Colo., Wazee provides electrical and mechanical solutions to aerospace, manufacturing, municipalities, mining, power generation, oil and gas and other heavy industrial customers.

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Renishaw to focus on process control at IMTEX 2013


enishaw, the global engineering technologies company, has, over many years, developed expertise in the area of process control for manufacturing using precision measurement systems. At IMTEX 2013, which takes place from 24 to 30 January, in Bangalore, India, the company will be exhibiting a range of process control solutions, from pre-process machine calibration, to online and of�line post process control. This will include a range of new touch probes and software that increase machine tool automation, a new rotary axis calibration system, and new additive manufacturing machines. On show in hall 3A stall G102 will be the RLP40 and OLP40 lathe inspection probes, which offer a choice of signal transmission technologies – radio or optical – to make part set-up and inspection on turning centres accurate, simple and reliable. Measuring just 40 mm (1.57 in) in diameter and 58.3 mm (2.30 in) long, the probes provide unidirectional repeatability of 1 µm (0.00004 in) and can be used to reduce set-up times, scrap, and �ixture costs, while improving process control. Visitors to IMTEX 2013 will also see products for machine tools that help increase speed of manufacture. These include the Renishaw TRS2 tool recognition system, which takes typically less than one second to detect broken tools. Also being demonstrated is Renishaw’s twinprobe system which uses a single optical receiver for tool setting probes together with a spindle-mounted touch probe for component inspection, offering fast integration. This twin system comprises the OMP40-2


touch probe and OTS cable-less tool setter, which is particularly suitable for machines with twin pallets or rotary tables. At IMTEX 2013 Renishaw will also demonstrate a new surface �inish probe option for its revolutionary REVO® �ive-axis measurement system. The new probe allows surface �inish inspection to be fully integrated within CMM measurement routines. With a measurement capability of 6.3 to 0.05 Ra, the SFP1 surface �inish probe provides a unique ‘single platform’ that will eliminate the need for hand-held sensors, or the necessity to move parts to costly dedicated surface �inish measuring machines, reducing labour costs and inspection lead times. Using REVO, CMM users will now be able to automatically switch between part scanning and surface �inish measurement, with analysis all contained in a single measurement report. Also on show will be the Renishaw Equator™, a lightweight, fast and highly repeatable gauge that operators can use with ‘push-button’ simplicity. Equator’s innovative �lexible gauging technology is based on the comparison of production parts to a reference master part, which can greatly increase throughput and reduce scrap rates at a fraction of the cost of an equivalent custom gauging system. Equator can switch between parts in seconds, perfect for �lexible manufacturing processes or accepting parts from multiple machines. For visitors to IMTEX looking to source machine tool testing systems, Renishaw will also exhibit the QC20-W wireless ballbar system which assesses machine tool positioning and servo control performance,

and includes a volumetric testing capability. In addition to the convenience of wireless operation, the QC20-W telescoping ballbar is the �irst calibration tool to allow testing in 3 orthogonal planes through a single reference point. A single, simple hardware set up means quicker testing and the ability to produce a representative volumetric measurement of positioning accuracy. Continuing the theme of machine tool calibration, Renishaw will also be showing the new XR20-W rotary axis calibration system and XL80 laser interferometer. The XR20-W system works with the market leading XL-80 to allow the measurement of rotary axis positional accuracy to within 1 arc second. Totally wireless operation and modular mounting systems ensure suitability for a wide range of machines. Visitors to IMTEX 2013 will also see a new range of additive manufacturing technologies. Renishaw’s laser melting systems utilise a pioneering, additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD, using a high-powered �ibre laser. Parts are built from a range of �ine metal powders that are fully melted in a tightly controlled atmosphere, in layer thicknesses ranging from 20 to 100 microns.

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Renishaw India : Beyond the technology excellence

Mr. Colin Price, Director Sales & Marketing- India, Renishaw Metrology Systems Pvt. Ltd.

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Q. Can you brief us about RENISHAW’s global network & activities? Renishaw is a UK based company that was founded in 1973 and from its humble beginnings of a handful of people it has grown to over 3000 staff globally, over 1,900 of which are located in the UK, primarily at its �ive sites in Gloucestershire. We have direct Renishaw of�ices and staff in 32 Countries around the World. We have manufacturing facilities in the UK, Ireland, and India where we machine and assembly the majority of our products before shipping around the World. Last July we reported record turnover of £330 million for our �inancial year ending June 2012, powered by strong growth in all its key geographic markets, including impressive sales growth in India. To meet both manufacturing demand and to advance new R&D projects for both its metrology and healthcare businesses, the company currently has over 150 vacancies Worldwide. The company also continues to invest heavily for the future, in new product development, manufacturing capacity and service operations. For the year ended June 2012 Renishaw spent £48 million on R&D and engineering, and at the start of 2012 completed the purchase of the former Bosch alternator manufacturing site at Miskin, near Cardiff in the United Kingdom, making a clear statement of its commitment to UK manufacturing. This 193 acre site with 461,000 sq ft of existing buildings will service the manufacturing needs of the company for many years to come, and refurbishment of 63,000 sq ft of the facility is now underway to increase assembly and machining capacity. ENGINEERING REVIEW | JANUARY 2013 | 59


lutions to the Indian market directly for over twelve years and we continue to offer existing and new products and technologies as they are developed and available. As our new technologies and products are introduced we set the appropriate strategy to introduce them to both the Indian and global arena.

Q. RENISHAW has gain credible market share in computerized measurement technology industry, how did Renishaw India managed this significant growth? In India we recently opened a 4,875 square metre extension to our Pune facility. This expansion represents a near trebling of space at the Pune site, which is intended to meet the long-term growth needs for the company’s Indian operations in terms of product assembly, software development, sales & marketing, and customer support. The newly expanded facility, which now totals some 7,500 square metres, will include additional space for Renishaw’s Indian customer demonstration and training centre, which was �irst opened in 2008. With a rapidly expanding customer base and network of local of�ices, the extended space will be used to house larger numbers of CNC machine tools and co-ordinate measuring machines (CMMs) to aid pre-sales demonstrations and product training. To ensure the best conditions for metrology performance, one of the new demonstration rooms will also be tightly temperature controlled to 20 degrees Celsius, plus or minus 0.5 degrees. Renishaw Metrology Systems Private Ltd was set up in Bangalore in the year 2000 and subsequent regional of�ices opened thereafter in Delhi (Gurgaon), Pune, Chennai and Vadodara, supported by resident sales engineers in other important industrial centres.Total Renishaw employee numbers within India are now approaching 250 with 50+ working in our sales & marketing division. Q. How about RENISHAW’s initiatives in measurement technology space? Which are your focus areas? Offering innovative solutions that addresses today’s manufacturing problems is our focus. We pride ourselves in having a broad product portfolio covering metrology sectors and medical and all lines are equally as important to us.

Q. What are the market opportunities for RENISHAW products in India? How do you plan to position these products? As I have mentioned earlier, we have been providing our so60 | JANUARY 2013 | ENGINEERING REVIEW

Take some examples of two new exciting products we have recently introduced:In 2011 the company announced its �irst move into the gauging market, with the launch of its Equator™ versatile gauge, positioned as a radical alternative to dedicated gauges that signi�icantly cuts the costs of purchase, maintenance and �ixturing. The company also highlights that the new gauging system can be pre-programmed for multiple parts and takes just a few minutes to be re-programmed for any component design changes; a signi�icant bene�it over existing custom gauges. Equator™ is capable of high-speed comparative gauging for the inspection of high-volume manufactured parts and was developed and proven on the shop-�loor in collaboration with industry-leading companies in multiple industries and applications, including automotive, aerospace and medical. The company therefore believes that the result of all this testing is a lightweight, fast and highly repeatable gauge that operators can use with ‘push-button’ simplicity. The company also says that users of Equator can switch between parts in seconds, which is ideal for �lexible manufacturing processes or accepting parts from multiple machines. The new system is available with two levels of software, a programmable version for production engineers to create DMIS programs and a lower price, shop �loor system which allows those programs to be executed but prevents operators from making modi�ications. The Equator’s innovative and highly repeatable gauging technology is based on the traditional comparison of production parts to a reference master part. Re-mastering is said by Renishaw to be as fast as measuring a production part and immediately compensates for any change in the thermal conditions of a shop-�loor environment. The company also says that the Equator system can even be used in factories with wide temperature variations through a simple re-mastering process, which ‘re-zeroes’ the system ready for repeatable comparison to the master. Renishaw also says that Equator can be integrated into automated cells, using an optional I/O interface to connect it to a robot, or by outputting the gauging results to an SPC package. Some SPC packages are also said to offer the ability to connect to certain machine tool controls to update offset values, for true automated process control. Additive Manufacturing A surprise move Whilst the move into gauging may not have been a major

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surprise to industry observers, Renishaw’s decision to purchase additive manufacturing systems supplier MTT Technologies in April 2011 did raise a few eyebrows. Yet, for those close to the company, the decision to enter this emerging market seemed very logical. Renishaw’s laser melting is a pioneering additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD using a high-powered �ibre laser. Parts are built from a range of �ine metal powders that are fully melted in a tightly controlled atmosphere layer by layer in thicknesses ranging from 20 to 100 microns. The current range comprises the AM250 and the AM125 laser melting machines, both of which feature vacuum technology and low gas consumption. The machines have been designed by Renishaw for ease of use within a manufacturing environment and feature a touch-screen interface and various menu options for machine preparation and clean down. Machine robustness has been given high priority, adopting a ‘machine tool’ approach to use and serviceability. Renishaw says that this technology is already widely employed for the manufacture of custom medical implants, lightweight aerospace and motorsports parts, ef�icient heat exchangers, injection moulding inserts with conformal cooling channels, and dental copings and crowns. The Renishaw laser melting process is also said to give designers more freedom, resulting in structure and shapes that would otherwise be constrained by conventional processes or the tooling requirements of volume production. So as I said, two very different product offerings for two very different industries and applications highlighting where strategy and market positioning is all important.

Q. Brief us about the quality policy for the business? Renishaw has a very clear and simple global quality policy which is detailed in its Renishaw mission statement: “Renishaw will design, manufacture and supply metrology sysThe ready reckoner for engineering & allied industry

IN FOCUS tems of the highest quality and reliability to enable customers worldwide to carry out dimensional measurements to traceable standards. Our product offerings will enhance quality and productivity, and we will strive for total customer satisfaction through superior customer service. Our aim is to provide leading-edge technology by encouraging innovation to address our customer’s needs. We are committed to sustained growth through continued investment in product development and manufacturing methods. Renishaw wishes to be recognised collectively and individually as leaders and contributors in our �ield and our community. We wish to achieve our aims in a way that is caring, open and honest. Renishaw is an environmentally conscious and responsible company. We will strive to ensure that all aspects of the business have the least harmful effect on the environment.”

Q. Can you please elucidate the contribution of R&D in the success of RENISHAW products? For a company that invests so heavily in R&D, the launch of new products is a regular occurrence, but the past year has been signi�icant for Renishaw, with the launch of not one, but two wholly new product lines. The company has always followed the strategy and ethos that innovation is the key to continued long term success and Renishaw has and continues to invest heavily for the future, in new product development, manufacturing capacity and service operations. For the year ended June 2012 Renishaw spent £48 million on R&D and engineering, and at the start of 2012 completed the purchase of the former Bosch alternator manufacturing site at Miskin, near Cardiff In the United Kingdom, making a clear statement of its comENGINEERING REVIEW | JANUARY 2013 | 61


mitment to UK manufacturing. This 193 acre site with 461,000 sq ft of existing buildings will service the manufacturing needs of the company for many years to come, and refurbishment of 63,000 sq ft of the facility is now underway to increase assembly and machining capacity.

Q. Brief us about the quality policy for the business? Renishaw has a very clear and simple global quality policy which is detailed in its Renishaw mission statement: “Renishaw will design, manufacture and supply metrology systems of the highest quality and reliability to enable customers worldwide to carry out dimensional measurements to traceable standards. Our product offerings will enhance quality and productivity, and we will strive for total customer satisfaction through superior customer service. Our aim is to provide leading-edge technology by encouraging innovation to address our customers’ needs. We are committed to sustained growth through continued investment in product development and manufacturing methods. Renishaw wishes to be recognised collectively and individually as leaders and contributors in our �ield and our community. We wish to achieve our aims in a way that is caring, open and honest. Renishaw is an environmentally conscious and responsible company. We will strive to ensure that all aspects of the business have the least harmful effect on the environment.” Q. What do you think are the strengths of Indian measurement technology industry & How it is positioning itself against the global market? I have been travelling to India for the last eight years regularly and I have seen a marked change in the market and more generally in the mindset of manufacturing companies. Technology and automation are de�initely high on the agenda of Indian companies and there is a genuine willingness to invest in value adding technologies and products. This is one of the key reasons why India is a target market for overseas manufacturing companies. Q. Please highlight Global perspective of measurement technology industry and what is the differentiating factor? The World is becoming a smaller manufacturing arena with globalization, every company in every Country wants to remain competitive and offer the


best products, at the right time, at the best price, so generally this means technology plays a big part in allowing this to happen. Twenty years ago it was not so common to see probing systems �itted to CNC machines whereas nowadays it is very common to have a spindle and tool setting system installed on them. Companies recognize the importance of controlling process and reducing variation and waste much more in the last �ive years.

Q. What are the key technological trends that are driving computerized measurement technology industry? Most companies are striving for increased output, whilst reducing costs and reducing wastage. Renishaw has the product portfolio and metrology solutions to allow this to happen. From experience we know that companies are willing to invest in new technologies if they see a real bene�it from doing us. The technologies of today are rapidly changing the ways that customers think and adapt their manufacturing processes.

Q. According to you what is the forecast for the automation industry? Interesting question! I see a general slowing of the automotive industry in differing regions around the globe. India showed the �irst signs some six months back with four wheeler output being reduced between 30-50% and then Europe showed signs with production dropping off in various regions and countries. I would hope that this is a short term slowing and the automotive sector does tend to have 2-3 year production output cyclic patterns, again, depending on region and type. Q. According you what are the factors affecting to your business? As a metrology solution provider we are fortunate that our products offer bene�its for both existing manufacturing and measurement equipment and new. We �ind that when companies reduce spending on new capital equipment they are keen to maximize output and performance on existing assets and this is where we can offers our solutions to allow them to bene�it and add additional value and output.

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Indis’s largest integrated power company chose EOS open platform enterprise energy management & control system for its load shifting program 3) Analysis of 5 minute interval energy data from meters gives a clear picture to the client that by using Tata Power’s Thermal Storage system, they could shift their Central AC loads from peak hours to off peak hours, thereby reducing energy costs. Today, Energos system enables the accurate analysis and management of energy data with a view to control and drive down the energy costs of Supreme Business Park. Thus, Energos has been acknowledged for an excellent technical expertise, service and support.

About Energos:


ata Power gets Energos’Open EMS installed at Supreme Business Park, one of the high-rise commercial building with around 304 of�ices.

Supreme Business Park at Powai

Headquartered in Mumbai, Tata Power, one of the largest integrated power company in India has the presence in almost all the segments of the power sector including generation (thermal, hydro, solar, wind, geothermal and waste gas), transmission, distribution and trading. The company is one of the largest renewable energy players in India and is developing the country’s �irst 4,000 MW ultra mega power project at Mundra (Gujarat) based on super-critical technology. Tata Power has a strong global presence with hydro projects in Nepal and Bhutan, fuel assets and geothermal projects in Indonesia, logistics operations in Singapore, and partnerships with energy companies in South Africa and Australia.

Problem faced:

Under an innovative Demand Side Management (DSM) project, Tata Power has launched a Load Shifting Program. The program requires customers to


invest in Thermal Storage Units (TSU). Under this program; the customers can shift the load from peak hours to off peak hours. This becomes convenient for users to save the tariff which is high during peak hours. Under this program, HVAC units are operated in off peak hours typically at night and cold air is stored in these thermal storage units. In addition, Online Remote Energy Monitoring System is a necessity for measurement and veri�ication. EOS Cloud Server provides detailed data of the time of operation of each TSU. Data from EOS cloud is used by Tata Power Limited to calculate bene�it to customers. Thus, other load shifting projects are run by Tata Power on EOS Cloud. Supreme Business Park, an esteemed client for Tata Power are using Thermal Storage Programme.

Energos as the chosen solution provider:

1) Six EM210A Standard Smart Meters are installed in 6 chiller plants. 2) All the meters are daisy chained and are connected to the network through a Network Interface Unit (NIU) for dumping data on real time basis into the application. Hence, Energos EMCS Application acts as a middle layer.

Energos Technologies, headquartered in Vancouver, Canada provides an Open Platform Enterprise Energy Management & Control System. It is a software platform that integrates diverse systems & devices regardless of manufacturers, or protocol into a uni�ied platform that can be easily managed & controlled in real time over the internet. It has implemented Energy Management and Control Systems for Shoppers Stop, L&T, Piramal Life Sciences, Suzlon, Tata Power and others. Energos provides complete solution to Industrial, Retail, Telecom operators and Infrastructure companies in India. Our expertise includes Analytics & Business Intelligence, Mobility Solutions, Cloud Computing & Collaboration Technologies. From Energos Global Marketing Desk, For more information Web: Powered by

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The 1200 kV UHVAC power system


EEMA while clearly enthused by the huge august gathering stated that the initiation of 1200 kV AC technology was the tipping point in the Indian Transmission Technology. IEEMA, whose 25 members formed the bulk total 35 participants actively involved in the project. According to IEEMA “more such research and development initiatives are required in the country, this initiative also offers a huge opportunity to the domestic manufacturers to upgrade to 1200kV level and opens up the huge global markets for such exports”. India’s power system is poised for accelerated growth. Peak demand in India is expected to increase to more than 500,000 MW by 2027 for which installed generation capacity of about 700,000MW is required. Obviously, electricity generated needs to be evacuated, transmitted & distributed ef�iciently. Development of large transmission network for


transfer of bulk power over long distances poses various challenges including environmental & technical, particularly in a country like India where additional challenges like Rightof-Way (ROW), Environmental aspects etc.too are thrown up. RoW today is a critical constraint, given the reluctance of the landowners to part with their land. Further, majority of the power is generated in the north eastern region of India while the demand centers are primarily located in the more industrialized western, southern and central regions, this situation is however changing slowly with the planning & implementation of Ultra Mega power projects (UMPP) across the country and near to coastal areas. All these challenges with manifold increase of power transfer requirement necessitate quantum jump in transmission voltage level. The existing 400kV line can transfer about 600MW power whereas 800kV line has

loading capacity of 1200MW-2400MW. The transmission capacity of 1200kV is between 6000 MW to 8000 MW and hence a much needed solution for meeting above challenges. To meet the long-term power transfer requirement, a large transmission network is being planned in India interconnecting all the pocketed generating resources. Taking into consideration the increased power transfer requirement to meet the above challenges, an alternative 1200 kV AC transmission system between various regions is also being explored. In a �irst such initiative in the country, 35 manufacturers have joined hands with Powergrid to establish a 1200kV UHV AC Test Station at Bina, Madhya Pradesh, to initiate development of 1200kV transmission equipment indigenously. The test line is being constructed with two 1200kV test bays in which Continue on page no.70

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Continued from page no.68

the leading manufacturers are providing main equipments such as transformers, surge arresters, circuit breakers, instrument transformers and transmission line hardware and accessories. These test bays and test line shall be used for various �ield tests/ trials so that the results and feedback can be used for developing �ield proven equipment as well as to gain initial operational experience. Powergrid is likely to construct 1200 kV Transmission Lines between Wardha and Aurangabad to usher in 1200 kV era in the country.


The test bays and the test line shall be used by the manufacturers and Powergrid for various �ield tests so that the results and feedback can be used for developing the proven equipment of 1200kV system in India as well as gain initial operational experience. The test station is likely to be commissioned in early 2011. This endeavor shall bene�it the Indian Power sector and manufacturers as availability of 1200kV class equipment within the country will enable optimization of transmission cost and also help during the operation and maintenance phase. India is starved for electricity despite the Indian power system’s present installed capacity of about 162,000 MW. Demand for electricity is growing at an accelerated pace. Peak demand is expected to increase to more than 500,000 MW by 2027 for which installed capacity of about 700,000MW is required. To meet the growing demand, the government is actively working on increasing generation capacity and encouraging new investments in the sector especially through private participation through Single window clearances for UMPPs faster land acquisition & environmental clearances etc, zero customs duty for project imports. This is one part of the story. The other part of the story is that electricity generated also needs to be ef�iciently transferred over large distances and with minimum losses.. India being a large country the distances involved are quite long, particularly when the bulk of the power is generated by the pocketed generating resources in Eastern, North-eastern Regions and consumed in the with bulk load centers in the other regions. To interconnect these effectively and meet the longterm power transfer requirement, a large transmission network is being planned in India. However it is faced with many challenges like increased transmission losses, large short circuit requirements, Right-of-Way(RoW) and resultant environmental issues. Hence urgent solutions are needed to

overcome these challenges. After conducting extensive studies and in the given circumstances the Indian transmission utility, Powergrid felt that a1200kV transmission line would be the most apt for transfer of bulk power ef�iciently. The electricity transmission capacity of 1200kV system is between 6000 MW to 8000 MW - which is about twice as that of the 765kV system and is about 6 times that of the currently widely used 400kV system. To elaborate further, the existing 400kV lines on an average can transfer about 600MW power whereas 800kV lines have loading capacity of 1200MW-2400MW. However, As already mentioned higher Transmission voltage, has its own problems like requirement of wider transmission corridors (Right-of-Way or ROW), bigger & higher towers, resulting environmental impact due to larger use of space etc Increase in short circuit level, reduction of losses etc. We can get an idea about the Voltage vis-à-vis Right-of-Way requirements from the table 1.1 below You will note that higher transmission voltages increase the space required for creating a transmission corridor by almost 100% thereby increasing costs incurred in acquiring land (if it is �irst available) & the resultant environmental impact but at the same time it also enables bulk power transfer. 1200kV UHVAC system could the panacea for our power transfer issues. So what are the other countries doing? Let’s checkout the scenario in ultra high voltage bulk transfer systems elsewhere; ● The First 1200 kV system was �ield tested & commissioned in USSR in 1985 after 12 years of research, however it was unfortunately discontinued after disintegration of USSR. ● Japan started developmental work of 1000 kV UHV system in 1978. Japan has also developed 1100kV Continue on page no.72

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Continued from page no.70 test station which is in service since 1993. Developmental tests are still continuing. ● As usual China a late starter is catching up very fast. China started their 1100 kV UHV system developmental work very recently i.e. in 2005. In January 2009, 1100kV transmission project was constructed in China. Three (03) Numbers 1100kV Transmission Stations have been constructed and are in operation almost for a year. Further additional 1100kV Transmission project are under planning and design stage in China for bulk transfer of power. ● Other countries like USA and Brazil are also considering development of UHV AC transmission system in their network. Powergrid embarked on a historical journey and decided to set up a 1200kV National Test Station at Bina in Madhya Pradesh. Powergrid although boldly opting for a 1200 kV UHVAC system faced a major challenge - Lack of proven 1200kV technology, since even globally there is very little experience on successful use of 1200kV technology. The solution was to develop the technology indigenously which will also be advantageous to the nation in the long term. Powergrid decided to capitalize on the manufacturing and technology skills of the mature Indian electrical equipment manufacturers and decided to develop the required equipment with indigenous technology in


collaboration with CEA, CPRI, IEEMA and other equipment manufacturers. (The Indian electrical industry over the last 6 decades has evolved into a mature industry and acquired the necessary skills & technology to sustain itself in the long term). In fact today we can proudly say that 95% of all the equipment in India is of Indian make. An initial corpus of Rs 100 crores was set aside to start the Test Station initiative in 2007 with a �inal cost of about Rs 800 crores.

Establishment of 1200kV UHVAC Test Station at Bina (WR) – entails;

● Construction of 2 nos. 1200kV Bays and 2 nos. 400kV bays along with 2 nos. 1200/400/33kV 333MVA Transformers. ● Construction of two nos. 1200kV Test Lines of one km length (one single circuit and one double circuit) ● Setting up of Test facilities

A Project Steering Committee under the leadership of Powergrid and comprising of representative from Central Electrical Authority, electrical equipment manufacturers, CPRI and IEEMA in 2007 was formed. Since then 13 formal interactions have taken place, 33 leading electrical equipment manufacturers have entered into MoU with Powergrid and have got actively involved in this pioneering R & D project. With indigenous R & D and innovations the manufacturers have succeeded in the design, development, testing etc of the main 1200kV equipment like Transformers, Surge Arresters, Circuit Breakers, Instrument Transformers, Transmission Line hardware and accessories etc. Insulation Co-ordination was the biggest challenge for selection of technical parameters of various equipments like Surge Arrestors, Transformers, Circuit Breakers, and Instrument Transformers etc. The project is scheduled to be commissioned by end December 2010 and slated to create

history. Once commissioned, these test bays and test line shall be used for various �ield tests/ trials so that the results and feedback can be used for developing �ield proven equipment as well as to gain initial operational experience. POWERGRID is planning to construct the �irst 1200kV Transmission Lines between Wardha & Aurangabad (Line length 400 kM, Rs 800 Crores to usher in 1200kV era in the country. More projects will follow based on the success of Test Station

In conclusion this Indigenous R & D effort in addition to providing help to develop an ef�icient bulk UHVAC power transfer system in India will also lead to; ● Indigenous availability of equipment & proven technology ● Optimization of cost ● Ease of service. ● Opportunity for Indian Manufacturers to become global leaders in UHVAC technology.

1200kV transmission system initiative will help in the large scale ef�icient evacuation of power in the 11th and 12th Plan period. The 1200kV system is a step towards overcoming the challenges in the sector such as Right of Way, environmental considerations, optimization of cost, faster project implementation, co-ordinated development of transmission corridor together with other infrastructure, transmission capacity enhancement through upgrading, reduction of losses and integration of emerging technologies. All in all a Win Win situation for all involved in the project. For more information write to : E-mail:

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| JANUARY 2013



| JANUARY 2013


Power & Electrical - Electronics : Industry Performance in 2012 ( India & global scenario) & forecast for coming years


he power scenario -while assessing the existing technologies, we shall look at some unconventional technologies and how they have fared in recent times. At the end of the article we will examine the forecasts to see how they

will live up to the expectations in near future. Samya Beidas-Strom and Akito Matsumoto writing in the recent IMF report neatly summarize the �irst part as : U.S. natural gas and oil production has increased in recent years, driven largely by the commercialization of horizontal drilling and hydraulic fracturing (“fracking”) technology from shale rock. The “unconventional energy revolution” began in the natural gas sector during the past decade, and gas production rose 28 percent between 2005 and 2011, and continued to climb in 2012 albeit at diminishing rates. The rise in unconventional gas contributed to the plunge in natural gas prices, and producers have since focused on liquids-rich gas plays or have migrated to pure oil (or tight oil) plays. Since 2005, application of this technology has put an end to the trend Continue on page no.78

Top 10 Countries (Total Installed Capacity wise)

Sl. No



United States












Russia India

Germany Canada France

United Kingdom Brazil

Total Top Ten Total World

Installed Capacity (Thousand MW) As on January 1, 2003

Conventional HydroThermal Electric



Total MW

% Of World Total








139.6 91.4




61.7 8.2








26.3 4.8


21.0 1.5

62.5 412




21.2 2.9




12.5 2.0



17.4 0.7

0.02 1.5

10.9 1.4




37.52 55.5







111.7 76.9




25.22 6.75









100 %

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Continued from page no.76 decline in U.S. oil output by increasing oil production from unconventional formations �irst by maintaining total U.S. oil production at about 7 million barrels a day (mbd) until 2008 (8 percent of daily global production). More recently, from 2009 to the �irst half of 2012, oil output rose by about 2 mbd to about 9 mbd (10 percent of daily global oil production). This more recent rise stems largely from tapping unconventional shale deposits in North Dakota and Texas for “tight” oil and other liquid by-products (that is, natural gas liquids) through the use of techniques similar to those pioneered to tap unconventional shale gas. Hydraulic fracturing involves pumping a mix of water, sand, and chemicals into wells at high pressure, thereby cracking the rock containing the liquids. Horizontal drilling enables greater access to pockets of liquids, allowing more to be pumped to the surface. Application of this technique to hydrocarbon liquids (oil) was previously considered too challenging or uneconomic and has raised environmental concerns

notably about possible contamination of aquifers. “Oil” here refers to crude (conventional) oil, condensates, natural gas liquids, and unconventional oil. Unconventional natural gas is found in locations requiring special extraction technologies such as horizontal drilling and fracking. It includes shale gas, tight gas, and coal-bed methane; this gas is similar to conventional natural gas, with the only difference being that their extraction requires unconventional methods. Unconventional oil, such as shale oil (or tight oil), is recovered from shale using the same unconventional technologies as for shale gas but is conventional oil, similar in quality to light crude oil. The boom in unconventional energy affects other energy markets as well. The downturn in natural gas prices has led to displacement of coal in the U.S. electric power sector and decoupling of U.S. natural gas from crude oil prices. The displacement of coal is largely attributed to the shift from coal to natural gas by U.S. electric power companies in response to lower natural gas prices. On the one hand, coal displacement in the

Source : Energy Information Administration, U.S. Dept. of Energy; as updated on June 2005

Continue on page no.80

Top 10 Energy Generating Countries

Generation Net (Thousand MU) Sl. No.



United States














Germany India


United Kingdom Brazil

Total Top Ten Total World

2002 Conventional HydroThermal Electric




% Of World Total













478.21 49.05

265.47 28.45

6513.2 9905.81




346.77 22.89


59.96 4.74


1578.93 2619.10



134.14 71.75

156.60 17.76

414.92 83.64


1978.22 2546.01


27.86 2.82


27.54 4.09




191.76 292.15


1036.21 864.69







10262.09 15363.07

25.17 6.74








66.80 100 %

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Continued from page no.78 Top 10 Energy Consuming Countries Sl. No.



United States
















France Brazil

For the Year 2003 Consumption Net(Thousand MU)

% Of Total World Per capita Consumption consumption (Kwh)



3656.49 1671.23 811.51






United Kingdom 346.08

Total Top Ten Total World








1294.03 7438.41














64800.53 (55.38 % of World Total)

100 %


Source : Energy Information Administration, U.S. Dept. of Energy; as updated on June 2005; Population Source:- U.S. Census Bureau, International Database Top 10 Countries (Hydro Installed Capacity)

Installed Capacity (MW) Sl. No.


2003 Total



United States







2 3 5 6 7 8 9

10 11


Canada Russia India

Norway Japan


Sweden Italy Total Top Ten World Total

86075 69206 44828 26910 26319 21697 21074

16523 13557 470866 719928

11.96 9.61 6.23 3.74 3.66 3.01 2.93

2.30 1.88



Source: Energy Information Administration, U.S. Dept. of Energy, as updated on June 2005 80 | JANUARY 2013 | ENGINEERING REVIEW

United States has been bene�icial to Europe, where demand has increased because of substitution away from higher-priced fuels notably (non-U.S.) natural gas, whose price is still linked to that of oil and from a phase out of nuclear power. On the other hand, rising unconventional natural gas production has also led to a decoupling of U.S. natural gas prices from crude oil prices; gas prices have fallen to their lowest level in a decade. Rising unconventional oil production has also contributed to the stock build-up in the mid-continent, which led to a large discount in the price of U.S. West Texas Intermediate crude oil compared with internationally traded crude oil varieties for example, Brent and Dubai Fateh. The future of unconventional extraction is uncertain given its relative cost: crude oil prices would have to range between $50 and $90 a barrel to guarantee commercial viability (breakeven). Hence a drop in crude oil prices to levels seen during the 2008 slump could set back U.S. unconventional oil production. Despite uncertainty, industry analysts suggest that U.S. production could increase by 1 mbd annually until 2015, and possibly beyond. Moreover, because there are large tight oil reserves in other regions of the world, if commercially viable, extraction could offset declining production in maturing conventional �ields, thus alleviating concern about oil scarcity. Finally, abundant unconventional energy might not keep oil prices from rising in the short term, but it could have that effect in the long term because higher energy prices would stimulate unconventional oil development if oil prices remain above $80 a barrel. At the same time, energy substitutability depends on a number of factors: electric power companies switched from coal to natural gas as did the petrochemical sector, but a shift from oil to natural gas in transportation has proved to be much slower. Continue on page no.82

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Continued from page no.80

Slower Growth : Global growth slowed again during the second quarter of 2012 after rebounding during the �irst. The slowing has been observed in all regions. This synchronicity suggests an important role for common factors, many of which re�lected wide-ranging spill-overs from large country-speci�ic or regional shocks. A �irst shock was the rachetting up of �inancial stress in the euro area periphery in the second quarter. Second, domestic demand in many economies in Asia and Latin America (notably Brazil, China, and India, but also others) lowed, owing not just to weaker external demand

Source :

from Europe but also to domestic factors. Growth also decelerated in the United States.


The global economy has deteriorated further since the release of the July 2012 WEO Update, and growth projections have been marked down (Table1.1). Downside risks are now judged to be more elevated than in the April 2012 and September 2011 World Economic Outlook (WEO) reports. A key issue is whether the global economy is just hitting another bout of turbulence in what was always expected to be a slow and bumpy recovery or whether the current slowdown has a more lasting component. The answer depends on whether European and U.S. policymakers deal proactively with their major shortterm economic challenges. The WEO forecast assumes that they do, and thus global activity is projected to reaccelerate in the course of 2012; if they do not, the forecast will likely be disappointed once again. For the medium term, important questions remain about how the global economy will operate in a world of high government debt and whether emerging market economies can maintain their strong expansion while shifting further from external to domestic sources of growth. The

problem of high public debt existed before the Great Recession, because of population aging and growth in entitlement spending, but the crisis brought the need to address it forward from the long to the medium term.

Global Forecast : Several IMF reports argue that fundamental changes in implementation of structural reforms in various economies hold the key to come out from a slump. Structural reforms will be important in boosting growth and fostering global demand rebalancing while reducing associated vulnerabilities. In surplus countries such as China and Germany, reforms are needed to boost domestic demand; in de�icit countries such as Brazil and India, they are needed to improve supply. In Germany, structural reforms will be needed to boost the relatively low level of investment and, more generally, increase potential growth from domestic sources. In the near term, the underlying strength in the labour market should foster a pickup in wages, in�lation, and asset prices, and

Continue on page no.84

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| JANUARY 2013


Continued from page no.82

this should be seen as part of a natural rebalancing process within a currency union. By way of example, in�lation in Germany and the Netherlands, the other major surplus economy in the euro area, would have to be about 3 to 4 percent to keep euro area in�lation close to the ECB’s target of “below but close to 2 percent,” if in�lation in Greece, Ireland, Italy, Portugal, and Spain were kept around zero to 1 percent and in�lation elsewhere remained in line with the ECB target. This underscores the importance of wage and spending adjustments in the surplus economies for the proper functioning of the EMU. The Economic and Monetary Union (EMU) is an umbrella term for the group of policies aimed at converging the economies of all members of the European Union at three stages. Both the 17 eurozone states and the 10 non-euro states are EMU members. Previous reports for China have stressed the need for better pension and health care support to lower precautionary saving and boost consumption. Progress is being made on these fronts, but the measures will take time to exert their effects on demand. Meanwhile, support for demand continues to come mainly from measures that support more investment. An obvious risk is that the quality of bank lending could be further lowered, adding to already ample capacity in the export sector or boosting already-high real estate prices.


In India, there is an urgent need to reaccelerate infrastructure investment, especially in the energy sector, and to launch a new set of structural reforms, with a view to boosting business investment and removing supply bottlenecks. Structural reform also includes tax and spending reforms, in particular, reducing or eliminating subsidies, while protecting the poor. In this regard, the recent announcements

with respect to easing restrictions on foreign direct investment in some sectors, privatizations, and lowering fuel subsidies are very welcome. Brazil’s consumption boom has been a large component of its strong growth performance, and domestic saving and investment remain relatively low. Reforms could usefully focus on further developing the de�ined-contribution pillar of the pension system, streamlining the tax system, and developing long-term �inancial instruments.

Power Shortages : This slowdown is a continuation of the trend decline in OECD demand (except in Japan) owing to lower oil intensity. Much of China’s demand increase was reportedly to add to the country’s strategic petroleum reserve and, to a lesser extent, to support the stillexpanding vehicle usage and growth in petrochemical demand. India’s strong demand intensi�ied initially from irrigation needs given a weak monsoon and then from electricity blackouts and power shortages during the third quarter. Increased Japanese demand re�lects the use of oil for power generation after nuclear production was halted in the wake of the Fukushima disaster. Japanese demand is expected to remain high despite the restart of two nuclear plants during July 2012, given the country’s recent decision to phase out nuclear power by 2040. World’s total energy demand growth In recent years G3 countries’ �iscal positions have deteriorated, resulting in a sharp increase in public debt levels. This was driven largely by the �inancial crisis: public spending was increased to address �inancial institution problems and help maintain output in the face of diminished private demand. In addition, weak private demand has also led to lower public revenue. On the �inancial side, capital out�lows from the periphery to perceived

Continue on page no.86

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Continued from page no.84 and public balance sheets weighs on domestic demand.

Brazil: For 2012, the projection is based on the budget, subsequent updates to plans announced by the authorities and the �iscal outturn up to July 2012. In this and outer years, the IMF staff assumes adherence to the announced primary surplus targetand further increases in public investment in linewith the authorities’ intentions.

safe haven economies in the region (Germany, Switzerland, Scandinavian countries) have continued. These �lows contributed to declining yields on government bonds and have fostered expanded domestic lending in recipient economies, including for housing. Near-term prospects for Europe are weaker now than they were at the time of the April 2012 WEO. The forecast assumes that policymakers in the euro area succeed in containing the crisis through a combination of continued crisis management supportive demand management, and further advancement of measures to deepen �iscal integration and create a full-�ledged banking union. Still, uncertainty will constrain con�idence and activity for some time, and downside risks loom large. The baseline tells us that economic activity will pick up gradually, primarily in 2013. This increasing activity re�lects a number of factors, including improving external demand due to the pickup in growth in some major emerging market economies, a moderating pace of �iscal consolidation throughout much of the region. Spain is an exception given that consolidation must accelerate to meet de�icit targets in 2012–13 and a gradual further easing of �inancial stress in the euro


area periphery as �iscal adjustment advances, policy support increases, and policy credibility and con�idence improve. There are broad differences among European economies. In the euro area, real GDP is projected to contract at a rate of ½ percent in 2012 and to increase by ¼ percent in 2013. In the core economies, growth will broadly stall in 2012, except in the Netherlands, where intensi�ied �iscal consolidation is expected to contribute to contraction. Except for Ireland, which is in a bumpy recovery, the recessions in the economies of the euro area periphery have been deeper, and recovery is generally expected to begin only in 2013, once adjustment moderates. Growth in other advanced economies in Europe is projected to moderate to ¼ percent in 2012 before picking up in 2013. Domestic demand has generally remained stronger in many economies, re�lecting lower pre-crisis imbalances and balance sheet pressure, which, together with declining yields from safe haven in�lows, have helped cushion the spill-overs from the euro area crisis. One exception is the United Kingdom, where the �inancial sector was hit hard by the global �inancial crisis and where ongoing repair of overstretched private

China: For 2012, the government is assumed to slow the pace of �iscal consolidation; the �iscal impulse is assumed to be neutral

India: Historical data are based on budgetary execution data. Projections are based on available information on the authorities’ �iscal plans, with adjustments for IMF staff assumptions. Subnational data are incorporated with a lag of up to two years; general government data are thus �inalized well after central government data. IMF and Indian presentations differ, particularly regarding divestment and license auction proceeds, net versus gross recording of revenues in certain minor categories, and some public sector lending...

Russia: Projections for 2012–14 are based on the non-oil de�icit in percent of GDP implied by the 2012–14 medium-term budget, the 2012 supplemental budget, and the IMF staff’s revenue projections. The IMF staff assumes an unchanged non-oil federal government balance in percent of GDP during 2015–17.

For more information write to : E-mail:

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POWERGRID to have remotely managed unmanned substations by 2013 Mr. R.N. Nayak, CMD POWERGRID urges industry to manufacture line arresters



y 2013 all substations of POWERGRID will be unmanned. There will be cameras observing the functioning of the devices and equipment and the stations will be totally virtually managed remotely by the National Transmission Asset Management Centre at Manesar”, accordingto Mr. R.N. Nayak, CMD, POWERGRID. Mr. Nayak was speaking at IEEMA’s SURGEPROTECH – an International Conference on HV Surge Arresters Technology and Applications, organisedjointly with CBIP and POWERGRID today. He added that having 8 persons per substation was a waste of human resources. Mr.Nayakassuredall help to the industry for indigenous manufacture of new products and technology; and advised the industry to manufacture line arresters and MOV devices domestically in the coming years.Mr.Nayak further

said that, ‘’Linearresters are the future. We are ready to give our full support to the industry, but they should focus on manufacturing line arresters as these are urgently needed in the transmission lines in north Bengal, evacuating power from the North Eastern States ’’ Appreciating the manufactures for developing the 1200 kV system in India, Mr.Nayak said India needs more technologies to be indigenously manufactured. ’These kinds of technical conferences are majorly bene�icial for the manufacturers as well as the user utilities and Mr.Nayak urge IEEMA continues to organise such international technical conferences in the future as well.” Surge arrester is one of the most critical equipment for safe and reliable operation of electrical power system. Surge arrester plays an important role in limiting switching and lightning surges on main equipments like transformers, reactors and circuit breakers, etc., by diverting these surges to ground. The Indian Surge Arrester Industry has come of age and has been able to design, test and supply surge arresters up to 1200 kV operating level. Surge arresters required for the 1200 kV National Test Station at Bina have been developed indigenously which are in operation since February, 2012. The Indian industry has also developed the polymer housed surge arrester technology up to 1200 kV to meet the market requirements. To set the ball rolling J.G.Kulkarni, President, IEEMA spoke about the importance of the surge arresters in the modern India. ‘’This country requires a robust & healthy domestic electrical equipment industry, Continue on page no.90

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encompassing the complete value chain in power generation, transmission and distribution. The electrical equipment industry is not only crucial for the economy but also of strategic importance of the nation.’’ saidIEEMA President J.G. Kulkarni. Mr.Kulkarni further added that Indian electrical industry has developed a good global


image over the years. “The Indian electrical equipment industry has developed a diversi�ied, mature and strong manufacturing base, with robust supply chain, and a rugged performance design of products. There is also an emerging global reputation of Indian electrical equipment for sourcing of base products and components and

also of Indian transmission and other EPC contractors” Mr.N.S.Sodha, Executive Director, POWERGRID& Chairman Conference Organising Committee spoke about the need of surge arresters in the country. Prof. Volker Hinrichsen, Chairman of the Surge Arresters Technical Committee of the International Electrotechnical Commission, Geneva, gave the keynote address at the Conference. This Conference cum Tutorialswere conceived to help and understand the latest technological developments that this product has undergone for the bene�it of power sector. The audience included professionals from industry, utility engineers, developers, public lendingagencies, researchers and international experts.

About IEEMA IEEMA is a 65 year old apex industry association representing the Indian electrical, industrial electronics and allied equipment industry. IEEMA has over 775 members with a combined annual turnover of over US$ 25 billion. IEEMA is consulted for policy formulation as the industrygovernment interface, and evolves product standards alongside India’s standards setting body the BIS. IEEMA publishes statistics pertaining to trade and growth, export promotion, raw material price indices, etc. IEEMA facilitates industry–user interactions through international technical conferences, roundtables and training / tutorials sessions, and the monthly publication IEEMA Journal. It also organizes ELECRAMA, the largest transmission and distribution equipment and services exhibition in the world. For more information Web:

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Schneider Electric launches the third edition of Go Green in the city


chneider Electric, the global specialist in energy management, announced the launch of the third edition of Go Green in the City, its international competition focused on developing innovative energy solutions for smarter cities. Over the past two years, more than 1,050 teams representing 2,100 candidates from 9 countries (Germany, France, Turkey, Poland, USA, India, China, Russia and Brazil) participated in the competition. This success shows the global attractiveness of Schneider Electric to a young and increasingly female audience, and their growing interest and involvement in energy Go Green in the City aims to give a better understanding of the global energy challenge and to create a strong bond with the young and emerging talents throughout the world, future core players of tomorrow’s energy market. It is open to 190 universities in 19 countries. In teams of two, at least one of which should be a woman, students are encouraged to come up with viable solutions for energy management. The students apply by sending in a pitch of their idea by latest March 3rd 2013. The best proposals should reconcile increased demand for energy, social progress and environmental protection.


issues all over the world. This increasing popularity amongst engineering school students is con�irmed by ”The World’s Most Attractive Employers Survey” released by Universum, which ranked Schneider Electric as one of the Top 50 most attractive employers in the world in 2012. Encouraged by the success of the two previous editions of Go Green in the City, Schneider Electric decided to open the challenge to 10 more countries, thus bringing the total number of countries covered by this 2013 edition to 19. The new countries will include Mexico, Canada, as well as 8 countries from the East Asia region (Indonesia, Malaysia, Philippines, Thailand, Singapore, Vietnam, Korea and Taiwan). “By opening Go Green in the City to 10 more countries, Schneider Electric wants to respond to the growing concern students show for energy issues and raise awareness of the challenges facing the energy sector in both mature and new economies,” said Karen Ferguson, Executive Vice President, Global Human Resources at Schneider Electric. Go Green in the City aims to give a better understanding of the global energy challenge and to create a strong bond with the young and emerging talents throughout the world, future core players of tomorrow’s energy market. It is open to 190 universities in 19 countries. In teams of two, at least one of which should be a woman, students are encouraged to come up with viable solutions for energy management. The students apply by sending in a pitch of their idea by latest March 3rd 2013. The best proposals should reconcile increased

demand for energy, social progress and environmental protection. After a �irst selection of the 100 most interesting projects in April 2013, the students will have 5 weeks to develop their idea with the help of Schneider Electric mentor assigned to them. After a �inal selection process, 25 �inalist teams will be invited to Paris to present �inal project to a jury composed of Schneider Electric managers. The two members of the winning team will be offered a job to start their career with Schneider Electric. They will also have the opportunity to visit Schneider Electric facilities in different parts of the world and meet fellow employees, as well as being exposed to senior leaders.

About Schneider Electric As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in Utilities & Infrastructures, Industries & Machine Manufacturers, Non-residential Buildings, Data Centres & Networks and in Residential. Focused on making energy safe, reliable, ef�icient, productive and green, the Group’s 130,000 plus employees achieved sales of 22.4 billion euros in 2011, through an active commitment to help individuals and organizations make the most of their energy. For more information www.schneider

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Lutron to light up offices in United States Capitol Ecosystem technology to reduce energy consumption


ight control manufacturer Lutron Electronics has been tapped to provide lighting control systems in the United States Capitol. Lutron’s Ecosystem technology will be installed in the of�ices of the U.S. Senate Energy & Natural Resources Committee, U.S. Senate & Environmental & Public Works Committee and also in the of�ices of individual senators who comprise the committees. Lutron’s Ecosystem is a lighting control solution which includes daylight sensing, occupant sensing, dimming and personal control. The system senses changes in lighting needs based on the amount of natural light entering the building throughout


the day to improve productivity and to reduce energy costs. The installation of Ecosystem is expected to provide total lighting energy savings up to 60 percent. “Lutron’s focus has always been to help customers save energy and create a pleasant environment to work in,” said Manjul Trehan, Director-Sales (Indian Subcontinent). According to him cost savings come from better lighting control and EcoSystem lighting control solution is the best for the commercials and helps occupant to use only the exact amount of electric light whenever required. With more than 50years of experience in energy-saving innovation, Lutron’s light control technologies improve the lighting environment to enhance comfort and productivity in both commercial as well as residential projects. The decision to install Ecosystem for the of�ices in United States Capitol is a part of a “Green the Capitol” initiative. About United States Capitol (www. The United States Capitol is the meeting place of the United States

Congress, the legislature of the federal government of the United States. Located in Washington, D.C., it sits atop Capitol Hill at the eastern end of the National Mall. At the U.S. Capitol Building the Senate and the House of Representatives come together to discuss, debate and deliberate national policy; develop consensus; and craft the country’s laws. As the nation has grown so has the Capitol Building: today it covers well over 1.5 million square feet, has over 600 rooms, and miles of corridors. For more information on the United States Capitol please visit www.

About Lutron Electronics (www. Lutron Electronics, headquartered in Coopersburg, Pennsylvania, designs and manufactures energy-saving light controls, automated window treatments and appliance modules for both residential and commercial applications. Its innovative, intuitive products can be used to control everything from a single light, to every light, shade and even stand-by power in a home or commercial building. Lutron products make any space more versatile, while enhancing ambiance, comfort and productivity. They also save energy and make light bulbs last longer, making them an eco-friendly addition to the home and workplace. Founded in 1961, Lutron estimates that the installed base of its products saves the nation nearly 10 billion kWh of electricity, or approximately $1 billion in utility costs per year. Lutron manufactures more than 16,000 energy-saving products, sold in more than 100 countries around the world. For more inforamtion Web: The ready reckoner for engineering & allied industry


EMCO bags order worth Rs. 458 Crores from PGCIL for 800 KV HVDC transmission lines Based on a strong foundation of technology and with an in-house government approved R&D that works on cuttingedge technology, EMCO adapts to the continually evolving needs of the modern world in a customer- centric, environmentally sensitive and sustainable manner.


MCO Limited, one of the leading Indian electrical goods manufacturing company and an End to End Solution Provider in Power Transmission and Distribution Sector, has bagged a prestigious order worth Rs. 458 Crores from M/s. Power Grid Corporation of India Limited (PGCIL) for execution of 800 KV HVDC Transmission Line Tower Package TW-05 from Champa to Kurukshetra. This is part of the prestigious 800 KV HVDC overhead transmission line network to be laid from Champa pooling Station, Chhattisgarh to Kurukshetra, Haryana. It is designed to carry 6000 MW power from Power Generating Stations in Chhattisgarh to Northern Grid. EMCO has successfully commissioned more than 500 kms 765 / 400 KV Transmission Lines in the current �inancial year for PGCIL. EMCO has bagged this project after surpassing a stringent quali�ication requirement from the client and against very stiff competition. The orders also involve

supply of galvanized steel towers from the company’s facility located at Asoj, Gujarat.

About EMCO Limited Founded in 1964, EMCO LIMITED is one of India’s leading products and solutions provider up to 765 KV in power generation, transmission & distribution for utilities and industry. With more than 15 of�ices and 6 stateof-the-art manufacturing plants across India which are accredited for ISO: 9001:2008, ISO: 14001:2004, OHSAS: 18001:2007 and ISO/IEC 27001:2005 EMCO is supplying its products and solutions in India and more than 45 countries across the globe . Based on a strong foundation of technology and with an in-house government approved R&D that works on cutting-edge technology, EMCO adapts to the continually evolving needs of the modern world in a customer- centric, environmentally sensitive and sustainable manner. For more information E-mail-

EMCO has successfully commissioned more than 500 kms 765 / 400 KV Transmission Lines in the current �inancial year for PGCIL. EMCO has bagged this project after surpassing a stringent quali�ication requirement from the client and against very stiff competition. The orders also involve supply of galvanized steel towers from the company’s facility located at Asoj, Gujarat. 96 | JANUARY 2013 | ENGINEERING REVIEW

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Suzlon Group wins 105 MW order for projects in Canada


REpower and wpd Europe GmbH enter into contract for six projects in Ontario Order for 51 units of MM92 – 2.05 MW turbines, Service and maintenance agreement for 15 years

uzlon Group subsidiary, REpower Systems SE, has concluded a contract with wpd Europe GmbH, a subsidiary of project developer wpd AG, for the delivery of a total of 51 wind turbines. As part of this, a service and maintenance agreement (ISP) for a total of 15 years for the new projects was also concluded. The REpower MM92 turbines, each with a rated power of 2.05 megawatts (MW), are intended for a total of six projects, Whittington, Springwood, White Pines, Napier, Sumac Ridge and Fairview, to be constructed and commissioned in 2014. In order to serve its growing business presence in Canada and to meet the 50 per cent domestic content requirement of the Green Energy Act, REpower also announced to setup a new rotor blade manufacturing facility in Southern Ontario. Andreas Nauen, CEO of REpower Systems SE, said: “The 105-MW contract again shows that the cold climate version of our MM92 is very well suited to the conditions on the Canadian wind market. With our announcement of rotor blade production in Ontario, we are expanding our presence in Canada – a wind market with great potential – even further.” Helmut Herold, Managing Director of REpower Systems Inc., REpower’s Canadian subsidiary, added: “We are pleased that with our commitment in Ontario we are able to make an important contribution to local value creation. The project management and setup of a rotor blade factory involves the creation of several hundred medium to longterm jobs.” Member of the Board of Directors


of wpd Dr. Hartmut Brösamle, said: “Ontario is an important market to us. We have been active there since 2007 and an experienced team of ours will bring the �irst projects of more than 100 MW to the construction phase next year.” Suzlon Energy Limited One Earth, Hadapsar, Pune – 411 028, India Registered Of�ice “Suzlon”, 5, Shrimali Society, Navrangpura, Ahmedabad – 380 009, India Ian McRae, Managing Director of wpd Canada Corp., added: “Through the contract with REpower we are certain to have our wind farm equipped with reliable wind turbines and a sophisticated service concept. The local economy not only pro�its from clean and affordable energy but is also provided with new infrastructure in conjunction with the installation of the wind farms.”

Robert Hornung, President of the Canadian Wind Energy Association CanWEA, said: “This announcement provides further evidence of the wind energy industry’s ability to drive hundreds of millions of dollars in new investments across the manufacturing and supply chain sectors in Ontario. Besides playing a growing role in delivering clean and affordable energy to Ontario families, wind energy is creating very good jobs for our highly skilled workers and trades people. Following a near record year for new wind energy installations in Canada in 2012, Ontario is well positioned to attract even more clean energy investments going forward.” REpower in Canada: REpower has been operating in Canada since 2007 and since then has connected wind farms with a total output of 84 MW to the grid. In

the coming months, a further 350 MW in total will be connected. The headquarters of the REpower Systems Inc. are in Montreal. The company employs approximately 100 workers across the country.

About REpower: REpower Systems SE, a wholly owned subsidiary within the Suzlon group, is one of the world’s leading manufacturers of onshore and offshore wind turbines. The international mechanical engineering company develops, produces and markets wind turbines for almost any location – with rated outputs of 1.8 MW to 6.15 MW and rotor diameters of 82 meters to 126 meters. Furthermore, the company offers its customers project speci�ic solutions in the areas of turnkey, service and maintenance, transport and installation, as well as foundation planning and construction. The pro�itable and reliable systems are designed at the REpower TechCenter in Osterrönfeld and manufactured at its plants in Husum (North Friesland), Trampe (Brandenburg) and Bremerhaven as well as Portugal, India and China. With more than 2,900 employees worldwide the company headquartered in Hamburg can make use of the experience gained from the manufacture and installation of over 3,800 wind turbines around the world. REpower is represented by distribution partners, subsidiaries and participations in European markets such as France, Belgium, the UK, Italy, Portugal, Sweden, Poland and Spain as well as on a global level in the USA, China, Australia and Canada. For more information

The ready reckoner for engineering & allied industry

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otwane introduces its Digital High Voltage Insulation Tester 5KPI which is a versatile industrial grade Diagnostic Insulation Tester. It is a microprocessor based insulation tester for diagnosing insulation of all types of electrical equipments in electrical utility and large industries. 5K PI is suitable for testing insulation resistance of Power Transformers, Distribution Transformers, Motors & Generators, Current Transformers, HT Cables, Circuit Breakers and other switchgears. 5KPI is designed and developed in Motwane DSIR accredited research laboratory and is manufactured under stringent manufacturing process. The instrument comes in an easy grip tough industrial grade casing with detachable lid. Information is displayed

A fully intelligent insulation tester providing unique solution for complete insulation testing with 5 diagnostic modes PI, DAR, DD, SV and BDV, comes with international certi�ication of CE, EMC, IP 65 & CAT IV to ensure equipment as well as human safety.

on large backlit LCD for easy viewing during dim light condition. User de�ined algorithm for conducting spot insulation testing, polarization index, dielectric absorption ratio, dielectric discharge, step voltage and breakdown voltage test with three programmable timers. The instrument has internal memory for data storage (upto 1000 readings) and PC software for data management. 5KPI provides Programmable test voltage 250 ~ 5000V Insulation Resistance upto 10TΩ, leakage current upto 3mA. Simultaneous measurement of Voltage, Current and Capacitance, Digital and analog display, Mains / Battery Operation. For more details please contact at, 100 | JANUARY 2013 | ENGINEERING REVIEW

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Vending Motor for Snack Vending Machines






Vending Motor for Tea & Coffee Vending Machines



VND-380-C2 & VND-500-WP1 & VND-500-WP2 & VND-500-WP3

Bean Crusher Actuator Motor

Cigarette Vending Motor

Submersible Pump




Lunar make Vend Motors are the most advanced & superb quality & competitively priced Vend Motors available for the vending machine industry. These Vend Motors are available in different voltage, speed, torque & current rating as per the application. They are also available for different mounting configurations & circuit configurations and choice of output shafts. Lunar motors can design the Vend Motor as per the requirement for any type of Snack, Tea & Coffee, Book, Biscuit, Bottle & Can Vending Machines.

Lunar House, Excel Estate, Valsad â&#x20AC;&#x201C; 396 001, Gujarat, India Tel: 02632-227137, 227687, Fax: 02632-227797, Email:, url:



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       Renowned Waaree Instruments Ltd. performance with added innovation, quality and reliability â&#x20AC;&#x201C; due to improved processes at our Vapi factory.

Baumer Technologies India Pvt. Ltd. (Formerly known as Waaree Instruments Ltd.) 8/B ¡ 8th Floor ¡ 32 Corporate Avenue ¡ Mahal Industrial Estate ¡ Near Paper Box ¡ Off Mahakali Caves Road Andheri (East) ¡ Mumbai 400093 ¡ India ¡ Phone +91 22 6127 4000 ¡ Fax +91 22 2687 3613 ¡


IPA : Bridging the industries with PROFIBUS & PROFINET technology platform

Mr. Dileep Miskin, Secretary Indian Pro�inet Pro�ibus Association (IPA) The Indian Pro�inet Pro�ibus Association (IPA) through the promotion of Pro�ibus and Pro�inet protocols has been supporting the vision of the advancement of the automation industry. Currently there is a big challenge to upload data effectively to the IT management system in the �ield of automation. In such a scenario, IPA helps to educate various industries and institutes as well as connects Indian industries with the world’s most popular �ield bus Pro�ibus and technology-leading industrial Ethernet Pro�inet. In a tete-a-tete with Shweta Deshmukh, Dileep Miskin, secretary IPA revealed that although for several years automation was restricted to large scale industries but in recent times even small players are also showing keen interest to improve their throughput.


Q. What are the advancements in technology that IPA has promoted through Automation 2012? In the �ield of Automation, be it factory automation or process automation, there is a big challenge to upload the data effectively to IT management system. This will help managers to make decisions effectively. IPA through its PROFIBUS and PROFINET promotion has been supporting the vision with the best automation technology available. Our aim is to showcase the seamless integration of the technology independent of vendors. Since we are supporting Pro�ibus and Pro�inet in India since 2009, we are able to better connect the Indian industries with these advancements. Automation Expo is one of the India’s major event for Industrial Automation Business community. The show is dedicated to the introduction of the new automation techniques that can be used for supreme ef�iciency and productivity at various levels for different industries. It brings together various people from factory automation,

robotics, drives and controls, logistics, hydraulics and pneumatics, Building automation, pumps and valves and software solutions, together to display their products and developments on the latest technologies. As always, the industry is hungry for new technologies and this place gives you an opportunity to interact with the best of the technology minds. The Automation Expo is a 4 Days event this year it was from 7th September to 10th September hosted in Mumbai. Indian Pro�ibus & Pro�inet Assoication(IPA) activily participates in such events for technology promotion. IPA Booth was amongst the biggest stall in the Expo. The uniqueness of the booth was it displayed unity in diversity by bringing together all the key manufactures, distributors & promotors of Pro�ius tehnology together on a common platfrom. It was a collective effort of the IPA members including Siemens, Turck , Phoenix Contact, MB Connect, Pro�ichip,Helmholz, Conservtech, Deutschmann & UL Group. One of the most important and premier visitor of the IPA booth was the Chief Guest Mr. P A Sangma who inagurated the Fair. He appreciated IPA’s efforts towards techonlogy promotion and keenly discusssed with the IPA Sectretary about the new up bringings in the Pro�ibus Technology.

With such a grand kick start of the event by the visit of Mr. Sangama, the IPA booth was amongst the busiest stalls having maximum foot fall and overwhelming respose from the visitors. The visitors were not only indusContinue on page no.118

The ready reckoner for engineering & allied industry



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Continued from page no.116

trial technocrats but also pupil from the acadamics seeking information on the upcoming development. IPA members had one to one converstaion with the visitors apprasing about the new innovations and the upbrinings on the Pro�ibus & Pro�inet Technology and also the bene�its of the �ieldbus technology. The Association also conducted a conference which was another feather in the Cap of the IPA for technology promotion. The attendees of the event were various manufacturers, entrepreneurs, system integrators, students etc. The theme of confernce was Safety Pro�ile integration with Technology & the advantages of the technology The honorable IPA secretary Mr. Dileep Miskin, started the conference with welcome note took this grant event as a platfrom to release the IPA’s 7th News letter. Conference in presence of Mr. B R Mehta from Reliance, Mr. Reto from Pro�ichip, Mr Deshpande of Aker solutions , Mr Vikas of BARC, Mr Gupta from NPCIL were amongst the privileged guests. The �isrt speajer foir the evening was Dr. Mike Hennell who shared his knowledge about the industrial safety using IEC61508, the topics includes introduction to IEC61508 & Software Safety Life Cycle Process. Then Mr. Milind Kulkarni from Siemens appraised about the Pro�isafe pro�ile and it application in various industrail sectors for Energy saving. The Pro�isafe is a pro�ile specailly developed not only for effective energy mangement but also enery savings. Later the IPA secretary Mr. Dileep Miskin breifed the audience with the various diagnostic features that are buit inside the Pro�ibus protocol for error detection And fault �inding. Followed by Pro�ibus Mr. Sourav Ghosh from Siemens who spoke on Pro�ibus PA technology. The conference ended with vote


of thanks given by Mr. Shailesh Bhosale from UL Group of companies. Q. What is the role of IPA to promote automation industry? For several years the Automation sector was restricted to being dealt with only by the large scale industries. But in the recent times even the small and medium scale entrepreneurs are showing keen interest in Automation to improve their overall production. The application of information technology in the arena of industrial automation is becoming more and more dominant. Today, automation can be used as a tool to deal with the rising manufacturing costs. Enterprises are now using the strategy of combining the bene�its of automation and integrating it with the IT system to get the bene�its of cost optimization. That is the reason why today customers can expect connectivity from shop �loor to the top (management) �loor seamlessly. The Pro�ibus technology on the shop �loor with integration on top �loor with Pro�inet is a classic example of how best one can use the technology. Q. Could you brief us about the highlights of the conference convened by IPA in the recently concluded Automation 2012 exhibition on September 7? Q. What are the strategies adopted by IPA to promote its presence in the industry? IPA had initiated its activities way back in 2009 when we had �irst participated in IA 2009 – Hannover Fair in Mumbai. During this fair we had a common demonstration system with connectivity to multiple vendors’ devices working on pro�ibus. The idea was to showcase the seamless integration of the technology independent of vendors. We had continued it for the last three years when we always held the theme to the top most priority in showcasing the technology. We have also conducted various seminars in industrial and educational sectors besides hosting IPA road shows in different cities where the focus is on technology-based subjects. Q. What are the crucial technological trends that are driving the automation industry? In today’s world companies which can

adapt and innovate using industrial revolution information technology and global utilization of the resources alone can achieve signi�icant growth and success. The technological innovations of Pro�ibus and Pro�inet can be implemented in application areas like – Process Automation (PA), Motion and Drive (Pro�iDrive), Safety (Pro�isafe) and energy conservation and saving (Pro�iEnergy). Once these pro�iles are used the bene�its right from the manufacturing to the enterprise level can be evidently proven. This in turn leads to increase in ef�iciency, productivity and quality in the industry. Q. How do you foresee the future of the Indian automation industry? There are large opportunities for the Indian automation industry. Any manufacturing sector can be identi�ied and accordingly one can work towards ensuring growth in that area of manufacturing. To name -- the power, cement, steel and mines are some of the few sectors where automation can be effectively used. With the ease of availability of the automation and reduction in its costs, many small and medium scale industries are also working towards implementing it. Since IPA is also working towards spreading the technological know-how through various educational institutes, it is helping in promoting and providing excellence in technology training. This can further be enhanced by introducing basic training programs, enhancing employability and career growth which will help develop new breed which will be bene�icial for the Indian automation industry. Thus I de�initely see a very bright future for this industry. IPA secretary : Mobile no. # 91-9970006819 E-mail: secretary@pro� The ready reckoner for engineering & allied industry


Omron introduces a powerful robust “ONE” automation platform


mron Industrial Automation has released a new class of controller: Machine Automation Controller (MAC) supported by Sysmac Studio machine automation software. Omron’s NJ-Series MAC was created to integrate multiple, specialized controllers motion, logic, sequence, vision, operator safety and RFID tracking - with exacting system synchronization to deliver high performance throughput on a single controller. Different from conventional controllers and platforms, Omron’s NJ-Series MAC takes a fresh approach to resolve the integration of control technologies without degrading performance. At its simplest, the NJ-Series provides one controller for motion, logic and vision; Sysmac Studio software with a true integrated Development Environment (IDE) supporting programming, con�iguration, simulation and monitoring; all accessed by one connect ion to networks opt imized for factory automat ion informat ion (EtherNet/IP) and real-time scheduler to manage motion, network, and the user application updates at the same time to ensure perfect synchronization. Updating all three in the same scan is unique to Omron Industrial Automation’s NJ-Series MAC. It sets the performance benchmark top qualify for the MAC category: processing 32 axes and updating in one millisecond.

Evolution Driven by Market Demand

The NJ-Series MAC was purposely designed to meet the challenge from machine builders for a fully scalable, high-speed motion and the I/O controller with the ability to change


servo parameters on the �ly, integrated vision data, and keep all the servo motor shafts accurately synchronized. They need integrated and expanded capabilities for complete machine control without the ballooning costs of added processors and complexity to handle multiple motion axes at high speed with sequential and process control. The single software tool, Sysmac Studio, eliminates separate software products that make it cumbersome to design, develop and validate programs. The development environment offers time-saving simulation of motion pro�iles and integrated response from controllers and operator interface terminals.

Sysmac Automation Platform

Sysmac (SYStem for Machine Automation Control) is Omron’s powerful and robust automation platform with new machine automation controller -NJ-Series-that integrates motion, sequencing, networking, RFID tracking, and vision inspection; a new software - Sysmac Studio - that includes con�iguration, programming, simulation and monitoring; and a fast machine network - EtherCAT - to control motion, vision, sensors and actuators. One machine control through one connection and one software, is the way Omron de�ines true integration NJ-Series Controller . The NJ controller is designed for high speed and �lexibility. It incorporates an Intel processor proven for harsh industrial environments with fan-free operation, and runs under an RTOS. It is scalable with 16, 32 and 64 axis CPUs. Response time of less than 1ms can be achieved for application of up to 32 axes. The NJ

series accommodates most of Omron’s CJ-Series I/O, special application, and communication units, thus leveraging an existing investment in Omron hardware and retaining a customer’s established knowledge base to ensure smooth upward scalability.

Sysmac Studio Software

Created to provide full control over an automation system, Sysmac Studio software integrates con�iguration, programming and monitoring into one software. It delivers a true Integrated Development Environment (IDE) to eliminate several separate softwares that make design, development and program validation cumbersome. Graphics oriented con�iguration allows quick setup of controller, �ield devices and networks while machine and motion programming based on IEC61131-3 standard and PLCopen Functions for Motion Control cuts programming time. A smart editor with on-line debugging helps make programming quick and error free. Advanced simulation of sequence and motion control, data logging and data trace reduce machine tuning and setup. Sysmac Studio also offers an advanced 3D simulation environment to develop and test off-line motion pro�iles such The ready reckoner for engineering & allied industry


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About Omron Industrial Automation

as Cams and complex Kinematics. Intellectual property (IP) can be safely secured using 32-character passwords. Protection for the complete machine programming or a designed portion, e.g. speci�ic function blocks, can be blocked from being uploaded from the controller.

Our Network Connection: EtherCAT

The new NJ-Series controllers provide built-in connectivity to the world standard factory automation network, EtherNet/IP and the realtime , Ethernet-based machine control network, EtherCAT. EtherCAT is the fastest emerging network for machine automation. It is Omron’s de-facto machine network for its wide range of �ield and motion devices. It is a 100Mbps industrial Ethernet network compliant with IEEE 802.3 frames, capable of handling up to 192 slaves with refresh time down to 100Us and less than 1Us jitter. It achieves high accuracy for multi-axis synchronization thanks to its distributed slave clock mechanism. The EtherCAT network is simple to set-up with automatic address assignment for slaves and cost effective to install since it uses standard shielded Ethernet ca-


bles and connectors.

Factory Automation Network: EtherNet/IP EtherNet/IP provides reliable peerto-peer communication across the production line, integrating upstream and down stream processes and machines on a single network. It interfaces with Sysmac Studio Software as well as a wide range of visualisation solutions including Omron’s NS-Series HMIs and SCADA software. Faithful to our social and global policy, Sysmac meets the global standards such as EC Directives, cULus, Lloyd, and NK and is designed and manufactured with clean and re-cyclable material.

Offerings of Sysmac NJ-Series to its customers

● Ef�icient & Extremely Fast Network for Complex Motion ● Accuracy & Speed ● Reduced Hardware Cost ● One Stop Solution ● Simplicity In Wiring ● Easy For Troubleshooting & Maintenance ● Reduced Electrical Costing & Manhours ● Sysmac is a powerful robust “ONE” automation platform

Headquartered in Kyoto, Japan, OMRON Corporation is a multi-billion-dollar, diversi�ied company with business units producing industrial automation products, electronic components, healthcare equipment and ticketing systems. Omron Industrial Automation is a global leader providing complete automation solutions for industrial applications. Omron Automation - India caters to over 8 industrial applications encompassing the wide requirements of packaging, automotive, material handling, solar, food & beverages, textile & panel handling applications. In recent years we have been concentrating on the solution business which solves management problems on diverse production sites. Centering on the themes of quality, safety & the environment, we support manufacturing innovation worldwide with our unique sensing & controlling technologies. Omron is rapidly expanding its operations with focus on major cities namely Mumbai, Gurgaon, Bangalore, Pune & Chennai .Omron makes its presence felt across the vastness of India by appointing resident engineers to address the ever challenging requirements of the clients. A major factor in Omron’s progress globally & locally has been the strong commitment towards its customers keeping ‘Quality First’. For more information : Omron Industrial Automation E-mail:

For more information write to : E-mail: The ready reckoner for engineering & allied industry


Everything remains different : Waaree Instruments Ltd. is becoming Baumer

Waaree Instruments Ltd. Products are available under the brand name Baumer in India.


aaree Instruments Ltd. is becoming Baumer. Following the takeover of the Indian manufacturer of process measurement instruments by the Swiss Baumer Group at the end of 2010 the integration has now been completed. The company is now part of the global Baumer family as Baumer Technologies India, headquartered in Mumbai. The whole of the former product range known under the brand “Waaree Instruments Ltd.”, which has also been extended, is now available on the Indian market under the brand name Baumer. This includes pressure, temperature and level measurement instruments for the process industry. The products will continue to be


manufactured at the production site in Vapi. Processes and products have been continually optimized since the purchase of Waaree Instruments Ltd. by the Baumer Group. The change of name therefore goes hand in hand with a signi�icant increase in performance, quality and availability of the products. At the same time, customers on the Indian market will pro�it from a signi�icantly wider range of products for process measurement technology, which Baumer Technologies India can offer as a result of integration into the global Baumer Group. This includes a noticeably improved range of customized solutions. The same team of developers, engineers and managers who were

already involved with Waaree Instruments Ltd. in India and are very familiar with the market and its requirements will be taking care of this. “The change from Waaree Instruments Ltd. to Baumer is an inspiring development for us. Through the intense exchange with international colleagues and thanks to the valuable stimuli within the Baumer Group we can ful�ill our promises to deliver even more reliably in the future,” emphasizes Shyam Warialani, Managing Director of Baumer Technologies India. The Baumer Group is an international leading manufacturer and developer of sensors, encoders, measuring instruments and components for automated image-processing. Baumer combines innovative technology and customer-oriented service into intelligent solutions for factory and process automation and offers a uniquely wide range of related products and technologies. With more than 2,500 employees and production plants, sales branches and agencies in 36 subsidiaries and 18 countries, the family-owned company is always close to the customer. Industrial clients in many sectors gain vital advantages and measurable added value from the worldwide consistency of Baumer’s high quality standards and its enormous innovative potential. For more information, Baumer India Private Ltd. Web: For more information write to : E-mail: The ready reckoner for engineering & allied industry


Anybus NP40


New technology from HMS enables network connectivity for high-performance applications

he Anybus® NP40™ is a new network processor from HMS Industrial Networks that handles communication between an industrial device and any industrial network. The new processor is the core of HMS’s Anybus CompactCom™ 40-series in chip, brick and module formats. It is designed for demanding applications, especially targeting real-time industrial Ethernet.

Flexibility: One hardware platform, any network

The NP40 comes with support for all major Industrial Ethernet and Fieldbus networks. This means that a single hardware platform can support several different networks by simply downloading new �irmware. Consequently, there is no need to start a development project for each new network. The new technology makes life easier for device manufacturers since they can install a communication interface into a product and then simply download the �irmware they need before sending their products off to the end customer.

Performance: For demanding applications – Enabling motion and sync

The NP40 enables very low latency, down to a few microseconds. It


practically allows for ”zero delay” between the network and host API making it possible to support highperformance applications that require synchronization or motion pro�iles. “What we have seen over the past few years is that industrial Ethernet is now demanding more performance and a new architecture,” says Jörgen Palmhager, Chief Operating Of�icer at HMS. “The new industrial Ethernet networks are getting more and more specialized which requires a lot from a network processor that is to handle the ‘translation’ between different networks and protocols. In the NP40, HMS combines a powerful ARM Cortex M3 core with an FPGA fabric on the same chip, allowing both fast data transfer and real-time synchronization in hardware/FPGA. The NP40 technology gives users the best of both worlds. They get the speed and accuracy they need for demanding applications, and the �lexibility to adapt to different networks by simply downloading a new �irmware. The solution is based on MicroSemi Smart Fusion technology but integrates HMS’s unique blocks like our RTA™ (Real Time Accelerator) for industrial communication.”

Inside the NP40

The Anybus NP40 is a single chip network processor that includes a highperformance ARM core and an FPGA (Field-Programmable Gate Array) fabric. The ARM core runs the protocol and application stacks while the FPGA fabric is used to implement the various real-time Ethernet interfaces. A real-time-switch is integrated into the FPGA fabric and it supports synchronous cyclic messaging in real-time networks such as PROFINET IRT, Powerlink, EtherCAT and Sercos III. Since the network

processor is �lash-based, it can be re-programmed for several different industrial Ethernet networks. The NP40 is built on technology from Microsemi Inc. and the architecture is designed to combine performance, low power consumption and �lexibility in a single chip design.

Availability ?

The NP40 is already powering the network connectivity for industrial devices in pilot installations. The network processor will be on display on various tradeshows such as SPS/IPC/ Drives in Germany and the Rockwell Automation Fair in the US during the fall. The wider release of the network processor, as part of Anybus embedded solutions, will take place during 2013. The NP40, in combination with Anybus protocol and application software, make up the Anybus CompactCom C40 solution – a readymade network connectivity solution on a single chip. HMS Industrial Networks is the leading independent supplier of embedded network technology for automation devices. HMS develops and manufactures solutions for interfacing automation devices to industrial networks. Development and manufacturing takes place at the head of�ice in Halmstad, Sweden. Local sales and support is provided by the HMS branch of�ices in Chicago, Beijing, Karlsruhe, Milan, Mulhouse and Tokyo. HMS employs over 240 people and reported sales of €42.5 million in 2011. HMS was formed in 1988 and is listed on the NASDAQ OMX Nordic Exchange in Stockholm in the category Small Cap, Information Technology with ISIN SE0002136242. For more information HMS Industrial Networks

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| JANUARY 2013


Direct Part Mark considerations for automated manufacturing lines


or part tracking, manufacturers mark it with a permanent code, Direct Part Mark (DPM). These are used due to small size, error correction and data that can be stored as compared to traditional 1-D barcodes and as anti counterfeiting measures. Automated image-based ID readers can decode DPM, while laser scanners can read only 1-D linear barcodes, eliminating need to manually enter data during production and increasing ef�iciency.

Code Selection

Industry standards groups de�ine codes for given application like ISO 29158 (formerly known as AIM DPM). Data Matrix ECC200 is recommended and is used by industries in metal, glass, ceramic or plastic materials. Flexible and offers formats to encode between 6- 3,116 digits in a single code. It supports Reed Solomon error correction allowing code to be decoded even when 60% code is damaged.

Marking Processes and Placement

2-D DPM codes are marked on part depending upon material composition, part application and environmental conditions. The decision include part life expectancy, material composition, environmental wear and tear and production volume as also surface texture, amount of data to be encoded on each part, available space for and location of the mark. ● Dot Peening: striking a carbide or diamond tipped stylus against surface of material being marked. ● Inkjet printers: propel ink drops to part surface creating a permanent pattern of modules.


● Inkjet marking requires preparation of part surface, as it determines the level of mark permanence and contrast. ● Reading solutions must utilize lighting techniques to create contrast between indentations forming symbol modules and part surface.


● Fast marking of moving parts, offers good contrast. ● Used in automotive and aerospace industries due to demanding


lifecycle requirements. Location of code on a part can impact code readability and should be visible throughout manufacturing process and provide a “clear zone” free of part features and edges, noise/texture or other interference. Most dif�icult reading situations include cylindrical or shiny parts, creating code distortion and specular re�lection. Laser marking applies heat to parts that causes surface to melt, vaporize or change and depends on interaction of laser with the marking material. Applications are in semiconductors, electronics and medical device industries.

Anatomy of a Data Matrix Code

Data Matrix symbol comprises finder pattern, quiet zone, clocking and data region. Each individual element is referred to as a module (cell). The finder or L pattern consists of two orthogonal lines and is used to locate code position in view field. Quiet zone is free of all other markings that surround symbol on all four sides. The opposite sides of finder pattern are alternating dark and light modules, called clocking. Configuration of light and dark modules makes up data region to be decoded by the ID reader.

Data Encoding and Readability

Data encoding is information that is “stored” within the generated Data Matrix code. It is driven by company speci�ications or requirements of traceability project. When selecting data to encode, one should consider available space on part, as code size can affect readability. Readability de�ines how easy or dif�icult it is for a reader to read a code. If it is not readable, part is not processed and/or the production line stops. Manufacturers should achieve six-sigma read rates, 3.4 defects per one million reads.

Selecting a Solution

After selecting code type, encoding data, process and location for the mark, it has to read DPM codes on parts received from others and consistent mark quality cannot be guaranteed. Requirement is to provide high read rates, ensuring high throughput and complete traceability for readers.

1. Decoding Software

Code reading algorithms form basis for any image-based ID reader. Many variables impact code readability like

distortion due to part material composition, variations in part presentation or variability caused by manufacturing process. If bumps on part surface of a cast are similar in size or shape to dot peen marks of code, readability suffers as it blends in with bumps in surrounding image. Inspecting mark quality is called veri�ication and is in industry’s guidelines and takes place of�line. Successful code location within view field is first step in reading. Code pattern with consistent shape and size modules and different from other features provide reliable decoding. However, it can be challenging due to variations in surface texture, part presentation during process, variability of marking machines and changes that the parts undergo throughout their lifecycle.2DMax+™ technology, handles DPM codes no matter what the marking method or surface.

2. Image Formation

Reading solution should tolerate change in contrast, focus and degradation to code without changing parameter settings as these will lower installation cost and minimize bottleneck issues. When determining resolution requirements, higher resolution readers can maintain high PPM for larger view �ield, allowing for more positional uncertainty. For high-speed applications, standard resolution reader would provide faster performance. Lighting is important for DPM applications involving metals or other dif�icult-to-read materials as it can make or break a process.

3. Ease of Use

When readers are deployed it should communicate results to another device and integrate into existing plant networks. For establishing a communications link between a reader and a PC at the enterprise level, it should support standard network protocols, including: EtherNet/IP, PROFINET, MC Protocol and Modbus/TCP. Cognex Connect™ assures seamless and reliable communications link between Cognex products and factory network. For more information Web:

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Welding automation systems for the welding of various components and equipments



elding automation systems for the welding of various components and equipments , metal build up, hardfacing and metal spray applications. Welding is one of the most complex manufacturing process and is frequently the least understood and mostly ignored by the management. The right choice to provide large gains in quality , productivity and profitability in most welding applications is to automate the operation , Welding Automation results in, increased output, decreased scrap and decreased variable labor costs like dependency on skilled labour and their availability. Semiautomatic and fully automatic systems increase output by eliminating the human factor from the welding process. Production weld speeds are set at a percentage of maximum by the machine, not by an operator. With minimal setup time and higher weld speeds, a mechanized welding system can easily outpace a skilled manual welder Welding applications will bene�it most from automation if the quality or function of the weld is critical and if repetitive welds must be made on identical parts .Excellent candidates for automation include batteries, capacitor cans, solenoids, sensors, transducers, metal bellows, relay enclosures, light bulb elements, fuel �ilters, thermos �lasks, medical components, nuclear devices, pipe �ittings, transformer cores, valve elements and airbag components. Industries served using the welding process for hardfacing include fabricators, special equipment manufacturers , automobile part manufacturers , valve manufacturers , oil & gas,Tube & pipe mills, Pump manufacturers, Aerospace industry, metal recycling, cement, power generation, rock crushing, sugar cane shredding, steel mill rolls , dredging

and many more Welding automation can be in both semiautomatic and fully automatic form . Welding automation encompasses everything from high production, completely automated transfer lines to machines welding low volume heavy fabrications or pressure vessel weldments where a high degree of loading alignment and set up is required before the part is automatically welded. In semiautomatic welding, an operator manually loads the parts into the welding �ixture. Most semi automatic processes will be done on standard welding automation equipment and not specially designed .A weld controller then keeps the welding power source, motion of the torch, and parts to preset parameters. In some cases either the torch or part may remain stationary .. After the weld is completed, the operator removes the completed assembly and the process begins again. Semi automatic welding solutions includes components like simple x – y slides manual and motorised, Welding Oscillators , welding lathes ,turntables , positioners , rotators , and torch manipulators ( Column and Boom ), In fully automatic welding, a specially designed machine, or series of machines, loads the workpiece, indexes the part or torch into position, accomplishes the weld, monitors the quality of the joint and unloads the �inished product. Additional “part in place” and �inal product quality checks may also be designed into the machine if necessary. Depending on the operation, a machine operator may be necessary. These are complex digital nc or cnc controlled machines using pneumatic and hydraulic systems when required adequately supported by various types & numbers of sensor for sensing the position, motion & control of various Continue on page no.132

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TECH BYTES Continued from page no.130

speci�ied tolerances for welding? The answer to this question will attest to the quality of system purchased.

Some of the equipments required for welding automation : Manual and Motorized Slides

parts of system, welding parameters, loading & unloading of the job etc. Weld quality consists of two factors: weld integrity and repeatability. Electronic weld process controllers combined with mechanized torch and part motions with electronic recall of welding parameters results in a higher quality weld than can be accomplished manually. This offers instantaneous quality control. Furthermore, because a weld is made only once, defects are readily visible and detectable. In some cases, leak testing and vision systems can be integrated into fully automated systems to provide additional quality control. Repeatability is a function of the quality of the weld process controller and of the engineering of the machine motions. Mechanized welding provides repeatable input parameters for more repeatable output. Assuming the controller is functioning properly, the question becomes: Can the mechanisms of the machine position the parts or the torch within the


Manual and motorized slides are used to hold and provide �ine precise movements for adjusting of the welding heads in automated welding systems . The slides are available in various capacities from small size ( 4 kg ) having �ine step of the screw used in TIG / MIG / Plasma welding process to larger sizes of 70Kg load bearing capacity used in the submerged arc process . They can be �itted to give X, Y or Z axis movements to the welding head depending on the welding process and job requirement . The slides provide precise back lash free movements providing much needed versatility and innovativeness in the welding shop increasing productivity and ensuring repeatable high quality welds in the most dif�icult jobs .

Cold wire feeders

● Precise and controlled addition of �iller metal in TIG Welding . ● Helps weld parameters duplication eliminating welder skill . ● Dual Groove Drive Roll system accepts multiple wire sizes. ● Eliminates TIG rod stub loss . ● Cabinet encloses �iller wire spool ensuring cleanliness. ● Makes fully automatic TIG welding possible. ● Results are consistent and high quality welds


Weld Arc Weaver, commonly know as Welding Oscillator is the mechanism to simulate the condition of Weld Arc Weaving as done by hand by an expert welder. The motorized mechanism weaves the welding arc through Left / Right direction as an oscillatory movement over the weld surface ensures controlled spread of Arc Heat over the weld surface resulting uniform �low of weld pool due to smooth, uniform, stable & precise movement of Welding torch. Controlled & regulated

spread of Arc heat & Weld globules has a very distinctive advantage of excellent penetration at maximum Heat Utility ef�iciency. This also ensures reduction in the Heat Affected Zone, High Weld Metal deposit ef�iciency, Highly uniform Weld beads. Suitable for processes convenient to automate like TIG, MIG, SAW, FCAW, Plasma Welding or Cladding processes like PTA or Powder

Plasma Welding Key Advantages are,

Signi�icant improvement in Welding or Cladding process , Increased productivity with ease of operation for Multipass welding, Overall improvement in sidewall fusion & undercut ,High weld quality, uniformity & appearance. ● Higher weld speeds

Welding lathe

Welding Lathes have been engineered to provide a versatile , rugged and highly productive system for circumferential welding applications with repeatable results. Typical weld processes include Micro TIG, Micro plasma, TIG, Plasma and MIG. Custom built lathes for both circumferential and Linear welding can be provided with addition of mechanisms for movement of the torch . Welding lathes can be converted to a SPM to support simple or complex automation for welding when teamed with the power source , digital or analog controls , cold wire feeder , oscillator , X – Y slides and arc voltage controls. Manual operation can also be done with use of the basic welding lathe. Custom designed lathes and supporting automation can be designed and manufactured as per the job requirement.

Torch height controllers

Accurate control of Torch to work distance be it Cutting or Welding, plays very important role for the quality of the end result of the process. Torch Height Controller (THC) also know as Arc Voltage Controller (AVC) is the device which maintains the arc gap Continue on page no.134

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TECH BYTES Continued from page no.132

available. Due to its very nature of non contact sensing this system can help in more precise tracking with marginally higher speed of welding compared to contact type tracker. However the price factor due to laser, has played the important role on applicability of such advance system.

Cameras and displays

between the torch & the work piece. DC, Stepper or Servo motor driven vertical slide with motor driver & the controller allows the torch to move up or down depending upon variation in the weld pro�ile to maintain the constant arc voltage throughout the welding cycle as per the set value & other parameters. Arc voltage which acts as a Feedback to the controller as reference voltage, allows operator to set the Torch to Job gap as per the process & the quality requirement. This system is commonly know as Z-axis control.

Seam trackers

Weld seam tracking as the name suggests is an automated system which tracks & compensates irregularities in the weld seam and also tracks moving joint pro�iles during welding process. Types like contact or non-contact type trackers are available. Contact type tracker, depending upon the surface of the weld joint has a sensor in form of wheel, ball, needle which continuously remains in the physical contact of the surface through out the welding cycle. Generally spring loaded, the sensors’ movement is transmitted mechanically or electrically to the seam controlling device to maintain the arc to weld joint variation in controlled limits. The advanced non-contact type tracker involves laser beam which in form of a band is continuously travelled over the seam area. Depending upon the weld joint & the precision required, either single or double beam system are


Special cameras and video displays allows remote observation of the welding process showing the seam and the arc .In automated welding the system does not require skilled manual welding as all handling and movement of the job , welding head and �iller wire is done automatically by the system . This eliminates the need for physical presence of the welder close to the job . The display helps the operators’ by removing them from unhealthy and uncomfortable observation’s positions and they can be seated at a distance and monitor the welding process .

Welding positioners

Positioners provide steel fabrication shops a versatile and productive means for placing bulky fabrication jobs in the ‘downhand’ position . This reduces handling time and frequent use of crane. The positioners tables rotate at accurate and constant variable speeds and tilt through 135° with a high C.G. load rating and can be conveniently used for circumferential welding , saw and strip cladding , downhand position welding and assembling of intricate assemblies and many more applications.

Welding turntables

Welding turntables are designed to provide accurate and steady rotation from the smallest to the largest work pieces .

Welding rotators

Welding Rotators are probably the

most versatile and usefull positioning equipment in a fabrication shop .They are mainly used to rotate or position the cylindrical jobs for circumferential welding (TIG / MIG / Sub Arc) . The machine consists of a Drive unit and Idler unit which can be one or more and Control panel with pendant.AC geared motors with variable frequency drive is used for stepless speed variation .The rollers are made of Steel or moulded with polyurethane as per the job requirement.

Conventional rotators :-

These comprise basically two sets of rollers which are adjustable either manually across the frames or through lead-screw and ratchet, when changing from one diameter to another.

Self aligning rotators :-

The Rollers of these machines can be adjusted when loading to suit the diameter of vessel. Adjustment can be manual or motorized by sliding the Roller Brackets over the Base Frame equally in both directions through a lead screw having LH & RH threads. Thus a large range of diameters can be accommodated without need for any adjustment whatsoever.

Welding column and boom

Welding Column and Boom is also called as a Welding Head Manipulator . The welding head and oscillator is mounted at one end of the boom. The wire reel can be mounted at the front or at the rear end of the boom. The Column and Boom along with the welding rotators enable automatic circumferential and long seam welding For more inforamtion Web : The ready reckoner for engineering & allied industry



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Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 India T +91 80 6623 6000 F +91 80 6623 6060 E


70 % sheet metal fabrication in-house Ace Designers Ltd

Ace Designers Ltd. is the core company in the Ace Micromatic Group which holds Âź of machine tools production in India. Ace Designers produces vertical CNC lathes and small and medium size chucker type CNC. In 1979, 34 years ago, Ace Designers started developing CNC lathes for automotive industry, and the company has grown together with growth of Indian automotive industry.


The core company in the Ace Micromatic Group Ace Micromatic Group consists of seven companies including major companies such as Micromatic Machine Tools, which produces machine tools and Micromatic Grinding Technologies, which produces grinding machines. The group has 2,200 employees at present. Ace Designers, the core company in the group, released Chucker type CNC

Lathe Model LC-16 in 1986 and since then it has been producing Chucker type CNC Lathe machines and chucker type NC Lathes. At present, the company produces 3,000 units of CNC lathes of 18 kinds including Vertical CNC Lathes. As many as 120 units of the best- seller type machines and 10 units of special type machines are produced per month. More than 100 Continue on page no.144

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Functional and efficient High-performance non-cylindrical grinding with Lean Selection cam sEconomical and flexible machine design for the efficient manufacture of camshafts sReliable performance and attractive cost-benefit ratio sHigh material removal and high machine availability



Erwin Junker Maschinenfabrik GmbH India Branch Office 205, 2nd Floor Jewel Tower, Lane 5, Koregaon Park, Pune 411 001, India Phone: 020 260 538 96 Fax: 020 260 538 97 E-Mail:

24.-30.01.2013 Bangalore - India

Hall 2B Booth B105


Continued from page no.142 types are produced in various sizes and speci�ications. The company is constructing a new large-scale factory unit not too far away from the present facility. This new factory when completed will enable the company to increase its annual production to 4,800 units. Mr. Shrinivas G. Shirgurkar, Managing Director, Ace Designers Ltd.

More than 60% of demand for machine tools comes from automotive industry. According to the data published by Indian Machine Tools Manufacturers’ Association (IMTMA), the number of machine tools produced in India came down in 2008 after Lehman shock, but it has been on upward trend since 2010 when automotive industry started recovering. On demand side, after 60% occupation from automotive industry, the demand in other industries such as aerospace, power and energy, medical equipments, railways and defense continues. In India high-end machine tools are imported from Japan and Europe, and the machine tools from Taiwan, Thailand and Korea. Low-end machine tools are manufactured by Indian machine tool manufacturers. In the machine

Indian Machine Tools Demand and Local Production Amount / Indian Machine Tool Manufacturers’ Association (IMTMA) 144 | JANUARY 2013 | ENGINEERING REVIEW

tool industry, nearly 40% are locally made machine tools. In the local machine tool manufacturers, Ace Micromatic Group (lathes, machine tools and grinding machines), LMW (lathes), BFW (Machining Center), Jyothi (Lathes and Machining Center) are relatively larger companies taking a good market share. In India, at present although there are about 450 companies manufacturing machine tools and components, some 10 companies including those listed above take 80% of the market share. In India, city wise, Bangalore tops in machine tool manufacturing. The other Indian cities known for machine tool manufacturing are: Chennai and Coimbatore (Tamilnadu), Mumbai and Pune (Maharashtra), Badara and Ludhiana (Punjab), Ahmedabad, Baroda, Jamnagar Rajkot and Surendranagar (Gujarat). In Bangalore there are Japanese Machine Tool Manufacturing companies such as AMADA, Fanuc, Makino, Yuken, Muratec, Sodec, Mitsubishi Materials, Mori-Seki, Citizen Machinery, Mitsubishi Electricals, Okuma, Jaytec, Takizawa Ironworks, Yamzen and Brother Industries. 25% growth prospects for next 10 years In India the economy became slightly slow from the beginning of 2012, yet the domestic automobile sales are increasing considerably every month and it is expected that the trend will continue. According to Automobile Component Manufactures’ Association (ACMA), the growth rate for passenger cars is estimated at 4 times and for commercial cars it is estimated at 5 times and for twowheelers it is estimated at 2.5 times till 2020. Also, it is estimated that Continue on page no.146

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Laser Machine FO-3015NT + LST-3015FO

Bending Process with HDS8025NT/1303NT

Continued from page no.144

Work In Progress - Component waiting for weld operation after bending is over

2-3 billion USD will be invested in the industry to �ill the components’ demand gap. This prospect makes all machine tools makers to plan for expansion. Based on the automobile and automobile component industrial demand, IMTMA makes ambitious growth estimate of 25% in the next 10 years. The amount of machine production hit Rs. 36.2 billion in 2011, and export ratio is 3.7%. And the amount of machine import stood at Rs 67 billion. With this the total machine tools’ demand in India was Rs. 101.9 billion and it stood at 7th position in the international market. In 2009, Indian local production status was in such a situation that four times the local production was imported,

and the automotive industry is very much dependent on the imported machine tools. Yet, in the last 10 years, the technology level and the production power of Indian industry have improved to a great extent. Ace Designers is going to work for expansion and improvement of its present facilities after 2012. The company has started building new factory in order to meet the increasing demand in development and manufacturing of all ranges of machine tools from low end to high end. 40% growth prospects for 2012 According to Mr. Shrinivas G. Shirgurkar, MD of Ace Designers, the company has 187 engineers who work for R&D and production. With increased demand for local production because of domestic consumption, the company saw 25% growth in 2012 and we expect 40% growth for 2012. At the present facility, Bed, Column and saddle castings, the machine cover fabrication and controller �ixing are done. CNC controllers are of Fanuc-make. Some �ixtures and components such as LM guide are of Japanese- make. As far as machine covers are concerned, we have laser cutting machine FO 3015NT+LST 3015FO and two bending machines, namely, HDS 8025NT/1303NT in the sheet metal machine area. The blanks after cut in the laser machine are bent in the bending area and gathered model wise and taken to welding area for welding and then to assembly unit. Then the components are taken to power coating unit within the company and then components are gathered again model-wise in carts and then taken to �inal assembly unit. 3,000 units of CNC lathes per annum

Small NC Lathe assembly line 146 | JANUARY 2013 | ENGINEERING REVIEW

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Continued from page no.146

Machine Tool Cover weld operation executed by weld robot system

are produced in the Line Production System. In the Assembly �loor, line production is carried out based on the machine model. Components such as Bed, Columns and Saddle are �ixed and motors, actuators, sensors and other components are assembled and �inally the machine covers are �ixed. By and large, this kind of line production system is seen at all Japanese machine tool factories. Even in the production process also the Japanese standards are matching. As per the engineer who guided the factory tour, two shifts were there continuously for a long time and recently some of the parts for sheet metal processing were completed in one shift itself. In the blanking, laser machine FO 3015NTwith shuttle table is used, the sheets are changed, and cut parts are taken from the shuttle and sorted when the cutting processing done continuously. Two operators are there in the blanking process and two operators were seen in each bending machine. Mr. Shirgurkar, M.D, said

that if we look in a macro way, the economy will grow de�initely from now. Also, the demand for high- end imported machineries as well as local manufacturing capabilities in machine tools will improve and expand as local companies like ours are growing. For this growth, we are constantly looking forward to further investments. Our production will grow two-fold by 2015. We also aim at expansion of volume zone low and middle-end machines as well as consider producing highend machine tools too. Mr. Shirgurkar expressed that the machine cover design would be concentrated as European and Japanese manufacturers give importance here and we would give importance to the level of sheet metal fabrication in the �inal machine tool quality. -By Dr. P.Thanapandi, Japan, translated from the Original Article of Mr. Ishikawa, the President, Machinist Publishing Co., Ltd, Isehara, Japan published in “Sheet Metal Machine & Software” – a Japan Magazine

Controller Assembly Unit 148 | JANUARY 2013 | ENGINEERING REVIEW

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JUNKER group : Grinding is our world, Driven by perfection customer demands. JUNKER has �iled patents for over 80 inventions. These include such revolutionary innovations as the QUICKPOINT method. With achievements like these to its name, the JUNKER Group can look forward to a bright future.

Technologies for all applications and branches of industry

JUNKER production


he JUNKER Group: For 50 years now, JUNKER technology has been a shaping in�luence in the grinding industry. The JUNKER Group’s technological innovations and grinding solutions are developed in Germany and the Czech Republic and implemented around the globe. The corporate headquarters in Nordrach, Germany, provide strategic direction for our 12 production and distribution locations, as well as our global service network. At 50 years old, JUNKER is doing great - 1,200 employees, over 200 million Euro in annual revenue, a high equity ratio and over 150 machine con�igurations to match even the most sophisticated

The JUNKER Group offers a range of machines featuring ef�icient grinding solutions for every branch of precision grinding. Specially tailored, customerspeci�ic solutions allow us to meet any requirement. JUNKER offers innovative grinding solutions for everything from small series to sophisticated production lines for mass production. Both small to medium-sized businesses and global corporations count on the quality and capability of the JUNKER Company. Since 1962, JUNKER has sold over 4,000 machines throughout the world. Now, wind generators, solar modules, pumps and electrical engines are also being equipped with precision parts ground on JUNKER machines.

The JUNKER Technology Center

The JUNKER Technology Centers at our headquarters in Nordrach, Germany, and at our plant in Holice, Czech Republic, house a wide array of JUNKER grinding machines available for demonstrations and customerspeci�ic grinding tests. Quality analysis is also performed at the

The JUNKER Quality Control Center Technology Centers, using the latest in measurement methods. For many potential and current customers, this means an opportunity to test out the technical and commercial capabilities of the JUNKER machines on their own workpieces. The JUNKER Technology Centers are at the heart of research and development. They are also used for baseline testing of grinding technology on new workpieces and for developing individual grinding solutions. Unique machine concepts are also conceived here for many manufacturers.

Faster service world-wide

The JUNKER Group also offers JUNKER Premium Service, which includes training, hotline access, maintenance and spare parts services, production assistance and process optimization. These services ensure that JUNKER machines offer maximum availability. The value of an existing machine can also be increased through targeted optimization and upgrades. JUNKER Premium Service means fast, expert assistance 24 hours a day, 7 days a week, world-wide. It assures productivity and increases planning reliability. For more information Erwin JUNKER Maschinenfabrik GmbH E-Mail: Web:

The JUNKER Technology Center in Nordrach, Germany 150 | JANUARY 2013 | ENGINEERING REVIEW

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Haas : HE192 - CS


ELCO is perhaps the world’s leading brand name for garden secateurs, certainly Europe’s. The company manufactures around 1 million pairs every year at its Swiss headquarters, where two, fully automated Haas DT-1 CNC drill-tap machines have replaced conventional stamping with state-of-theart machining.

FELCO Trims Part Costs -

Located in the village of Les Geneveyssur-Coffrane, around 5km from Neuchâtel in the French-speaking west region of Switzerland, FELCO SA is a company with a history dating back to the end of World War II, when Félix Flisch, a trained �itter and turner, set himself what was at the time a very ambitious goal: to create the best pruning shears and sell them in Switzerland, Europe and beyond. Mr Flisch fabricated the �irst pair of FELCO secateurs in the garage of his home, alongside which the current factory still sits, today. The reliability inherent in their simple design, almost unchanged 70years later, caught the attention of winemakers at the region’s many local vineyards; with revenue from early sales, he set-up his nascent


business. The company’s early products were designed to offer comfort and ergonomics, inter-changeability of parts and durability – attributes which have since become common features of all FELCO products. Owners of FELCO secateurs made in the 1950s and 60s can still buy replacement blades and other components, in the unlikely event that they should fail. With the exception of screws and springs, all of the company’s secateurs components are manufactured at its Swiss plant - the two blades being, of course, the critical parts. Traditionally these are produced by stamping, a process practiced by almost all companies in the garden tools industry – until now. With the aid of the latest Haas DT-1 drill-tap-machining centres, integrated with robot loading and transfer, FELCO has differentiated itself by transitioning to CNC machined blades. “With our previous method we required several stamping machines to produce the blades,” explains the company’s Manufacturing Manager, Mr Sébastien Nussbaum. “The initial idea was to switch to an automated machining cell to mill and bore, instead of stamp. This is when we started to

look for a suitable CNC machining centre.” The company installed its �irst Haas, an EC500 CNC horizontal machining centre, in July 2011. A VM-2 vertical machining centre followed soon after, and thanks to their performance and reliability, Haas machines also climbed swiftly up the list of potential investments for the company’s latest project: the automated blade machining cell, where Mr Nussbaum says he wanted machines that could, amongst other things, change tools quickly. The Haas DT-1 has a high-speed, side-mount, 20-pocket tool changer, where chip-tochip times are just 1.8 seconds. “Together with a generous working area, powerful direct drive spindle and high rapids and accelerations, the Haas DT-1 machines offered me an exceptional price-speci�ication ratio,” he says. “They provide the foundation for a manufacturing solution that has changed the way we make our products.” FELCO’s two Haas DT-1s combine to form a single cell using Fanuc LR Mate 200iC vision-enabled robots, setup to orientate, load and transfer parts between the machines. The company splits the operations on the DT-1s – one for each side of the steel blades, which are handed either left or right by the robots. Operations to tolerances of 0.03mm include pro�iling, bore production, feature milling and blade point milling. Cycle times average out at around 40 seconds and annual blade volumes top 700,000! “Today, only FELCO is milling blades, and by doing so we get much higher quality compared to the stamped alternatives offered by our competitors,” says Mr Nussbaum. “Not only is milling a lot faster as a complete process, there is no grinding required to �inish the blades.” The new Haas cell runs seven days a week, 24 hours a day. FELCO has factory operatives in the plant between 05:00 to 22:00, who “keep an eye on Continue on page no.154

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TECH BYTES Continued from page no.152


things”, but during the hours 22:00 to 05:00 the cell works unmanned, lightsout – a period Mr Nussbaum refers to as the “ghost shift”. From its earliest days FELCO has sought to bring in-house every process required to manufacture its product range. This approach has allowed the company to systematically integrate technological advances into each stage of production and to enhance them with know-how acquired over 60 years. Today, FELCO is widely acknowledged as the leading brand in its �ield, and has six subsidiaries distributing its products in more than 120 countries. Cutting and pruning are seasonal, of course, by their very nature. In general there is no pruning in summer, so FELCO’s production continues for stock purposes only, with sales typically recommencing in the autumn, dropping off later in the year and recommencing in spring. In total, 90% of the one million secateurs produced at the FELCO factory every year are exported: 15-20% to the United States, with Europe the next big market. FELCO has a history of developing solutions in-house, even building its own machines in the past. “We did our homework before selecting the DT1 machines,” recalls Mr Nussbaum. “They were supplied by Haas Factory Outlet, Urma AG, and the robots were supplied by Robotec. We preferred not to ask for a �inished solution; instead, we wanted to assemble the cell and create our own process from scratch, simply because we have always done so and we have the in-house expertise. Re�lecting on how things are done differently compared to when he joined the company, Mr Nussbaum also summarises the challenges of keeping a well-established, Europe-based manufacturing �irm at the forefront of its market, given the competition it faces from companies located in lowercost regions of the world. “There were 15 people working in component manufacturing when I started in 2005,” he says, “whereas today there are only �ive. We’ve pushed to use CNC

wherever possible, to keep costs down and quality high. As well as replacing our 15-year-old stamping cell, the Haas DT-1 cell has allowed us to remove a number of old, FELCO-built machines and other conventional mills, which were not suitable or reliable enough for high-volume manufacturing. “It was also important that we improved the perception of FELCO as a manufacturer, bringing it into the 21st century. But, it wasn’t easy.

Without affordable technology like the Haas machine tool cell, it wouldn’t be possible. Salaries 30-40 years ago were quite low in Switzerland, and critically there was little competition. But, today you need CNC and you need automation if you want to maintain quality at high-volume and you want your products to remain affordable. It’s as simple as that!” For more information Web: Powered by

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New metal cutting process for outer machining – ‘Pot- Broaching’


n the era of competition, continuous improvement of process and procedure is a must. In the �ield of metal cutting Pot Broaching has the positive advantage of being a most simple and highly productive modern machining process for machining at the outer surface or periphery of the component, where repeatable product quality is required. In the PotBroaching, the material is removed by successive action of a series of transverse cutting edges arranged lengthwise in multiple broach sections, progressively increasing in size, incorporated and held in the PotBroach, used to machine and �inish the external surfaces of the work piece in a single pass. The essential feature of the Pot-Broaching operation is that there is no feed given to the tool as in other processes, and the teeth of the Pot-Broach are Self-Fed due to the gradual increment in the successive teeth during the rectilinear working movement between the tool and work piece. Therefore PotBroaching has become the simplest machining operation for metal cutting at the external surfaces or periphery of the components and the Broaching Machine is very easy to operate. Productivity improvement of ten times or even more is achieved with the Pot-Broaching operation, as the speed of metal removal by Pot-Broaching is vastly greater as the total metal cutting including roughing, semi-�inishing and �inishing of the component is done just in one pass, and this pass is generally


accomplished in seconds and even the clamping of job is not required, as the Broaching operation itself provides a force on the component. Therefore the Broaching operation may be completed in much shorter time as the time ordinarily taken for chucking / clamping the job is also saved.

The conventional machining operations used for metal cutting at the external surfaces are Milling, Shaping or some other machining processes are quite lengthy and even the processes do not give uniform accuracy. ThereforePotBroaching has given the birth to a signi�icantly superior and highly productive machining process requiring minimum manpower, extending its use in wide �ields of applications with exceptional savings on Machine and Tooling cost. The accuracy achieved and the ef�iciency demonstrated in heavy production by broaching is unmatched by any other process. Therefore broaching is especially suitable, rather essential for the industries where high ef�iciency, high level of accuracy and heavy production is required. The broaching operations are normally used for internal shapes like Square / Hexagonal / Octagonal holes, Splines, Key-ways and some other speci�ic shapes where the broach is pulled or pushed through a hole to remove the metal by the axial force applied by the Broaching machine to obtain the desired shape. Today, in the highly competitive market, the broaching has found its numerous applications including Surface Broaching and External Peripheral Broaching of various special / complicated shapes and Pro�iles. The Broaching process has become necessary for Automobile/ Auto parts, Cycle Parts, Hand Tools and many other large production engineering industries for the following distinguished advantages over the other machining processes: ● Very High Productivity and most

suitable for mass production. ● Consistency and accuracy in products. ● Various contours and complicated irregular shapes can be easily broached. ● Broached surfaces are highly accurate in size and shape hence close tolerances can be maintained. ● Remarkably �inished face. ● Extremely economical. ● Zero rejection. ● Expertise not needed.

Crane-Bel offer a wide range of Broaching Machines, including vertical Internal Pull Broaching Machines, Push Broaching Machines, Surface Broaching machines, Low-Height Broaching machines, Table-Up Broaching machines, Horizontal Broaching machines, Continuous Chain Broaching Machines for Very High Productivity and Pot Broaching machines for high production rates, cost bene�it, and ease of set up, operation and maintenance. Crane-Bel Broaching machines have earned an outstanding reputation for their productivity, reliability and economy. This reputation has been won by their unrivaled design, quality, manufacturing technology based on long experience in the �ield and strenuous efforts to offer distinguished broaching machines to the industry. The author of the article, Er. Ashok Kumar Gupta, is Founder and Chairman of Crane-Bel International P. Limited, an ISO 9001:2008 certi�ied company, engaged in manufacturing of a widest Range of Broaching Machines, Hydraulic Presses and Automation Systems for productivity enhancement. Mr. Gupta has about 45 years of experience of helping Industries in increasing the productivity, ef�iciency and pro�itability. He has specialisation in the �ield of Fluid Power Technology with expertise in Broaching and Automation. For more information/ E-mail: The ready reckoner for engineering & allied industry






















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| JANUARY 2013


SPERONI : 50 years of precision by Design ticularly suitable for the reaching of our high quality and durability objectives. As for the manufacturing of all the mechanical components, SPERONI directly develops all of its software products which have become a fundamental part of our systems; guided by our customer needs, the numerous software solutions are strategically developed in order to make all of the existing products available World wide.

Q. Could you brief us about overall business activities of your company (tie-ups, associations, reach, network)? Ever since our beginning in 1963, SPERONI has always applied it “Precision by Design” motto in all its work; each and every product that leaves our factory incorporates this. SPERONI is not an “assembly” company. SPERONI is directly involved in all of the phases which are and become characteristic of our products; all of these characteristics, for quality and reliability, make up the main difference between a SPERONI product and the competition. All of the manufacturing of key components needed in order to guarantee the unique quality of our products in time are carried out in our Sostegno plant with the use of dedicated systems; these systems are par-


Q. Can you elaborate more about the product portfolio & it’s applications? The functions and solutions characteristic of our market’s demand, have always been dictated by the development and the importance of the tool resource in the manufacturing environment. SPERONI has always supplied solutions to the speci�ic demands before anyone else, as documented by our long history. Today SPERONI offers a vast line of products and solutions in the �ields of Tool Preset, Measurement and Management, and Quality Inspection of the Manufacturing Process. The development of our product is based on the fact that our systems are means of production and as a result they have to produce tangible economic advantages for our customers. Q. Which are the some of your pioneering products you introduced in the market recently or Is there any plans to launch the new products? SPERONI has throughout its 50 years of history always been a leader in the �ield of Tool Presetting and Measurement systems. A few examples go all the way back to our beginnings when we introduced the very �irst fully automatic 4 axis Tool measuring systems in 1974 ! Our �irst Tool management applications date back to 1976 and mechanical clamping of the tool has always been a standard in our systems since 1963. Throughout the years we were the very �irst company to intro-

duce a fully integrated and Automatic Tool Presetting and Shrink Fit system in 1999 and the �irst to introduce a universal mechanical clamping system regardless of the tool-holder or pull stud. SPERONI was amongst the �irst companies to introduce a Vision system on a Tool Presetter in 1990 and a fully automatic dual spindle 6 axis system to measure turn broaching tools weighing over 800 Kg. In the more recent years we have introduced to the market the �irst automatic and universal mechanical clamping system for bench top machines, and at the current Imtex show we will be displaying our newest line of Tool Presetting and Measuring Systems called FUTURA. These are just a few examples of our 50 years of innovation: our future is full of innovative products developed to constantly improve ef�iciency in the shop �loor thus helping our customers run their manufacturing more pro�itably !

Q. How do you account R&D activity in your company? Research and Development activities at SPEORNI have play a key role. Due to the fact that we are not just an ‘assembly’ company, R&D touches every aspect of our business from sheer manufacturing such as milling, turning, grinding to our end product which can be a Tool Presetting and Measuring System or a complete Tool Management System including hardware and software solutions. Our development is carried out both in house, together with Universities and European Research centers as well and most importantly together with our customers who concur in the creation of new and innovative solutions that can bring immediate value to the manufacturing processes in different sectors of the industry. Q. Brief us about the quality policy for your business? In order to provide quality products The ready reckoner for engineering & allied industry


and services, you have to start from the inside. SPERONI has been an ISO 9001 certi�ied company for over 15 years and stringent quality checks are in place throughout our manufacturing and assembly departments as well throughout the company. Quality is one of those words and philosophies that can be easily marketed and painted well. Proofs of quality for SPERONI are our products that every day bring value to our customers. The longevity and reliability of our products are the most tangible examples of SPERONI quality. Q. How do you foresee “India” as a potential market , what are the prospects? India has the potential of becoming a great market for SPERONI and it is today one of our most important areas of investment. The attention of Indian customer to adaptive advance technologies is an important sign of the goals that Indian customers have set from themselves in bridging the technological gap in the shortest time possible.

Q. What are the distinguishing facts of global market as against the Indian market? If we take the European market as an example, the Tool Presetting and Measuring machine has been for years a key part of manufacturing processes and it is a technology which is understood and widespread. What we see in India is the willingness to explore new technologies and most importantly not to settle for cheap solutions. This is a very promising aspect for SPERONI because we are company who strongly believes that shortcuts in the end don’t pay off: quality and innovation have always been the only choice for us and our customers. Q. What are your strategies to improve your company’s position in Indian & global market as well? India is strategically a key market for us and we have a plan of constant investments for it in the next 5 years in The ready reckoner for engineering & allied industry

order to bring it up to par with countries such as the USA for example. In the USA we have been successfully established now for 20 years and have over 1,200 installations. We will grow our personalized service organization in order to be readily available to each and every customer. We at SPERONI follow our installations closely; from this attention we not only provide for the ever evolving needs of our customers, but also receive important and key suggestions in order to continuously improve the performance and ease of use of our products. The life of our systems on the market is frequently accompanied by use, maintenance and certi�ication contracts which are provided at known costs and guarantee the conservation of the value of the initial investment in time. Several SPERONI systems have done their job for over 25 years on three shifts with reliability and quality results which are incomparable, guaranteed! Q. According to you what are the factors affecting to your business? The globalization process is obviously affecting us and it is pushing us to become a more global company rapidly. In Europe this can be challenging today mainly due to that Europe is still being “shaped” and in some aspects created.

Q. What are the key technological trends that are driving the tool presetting and measuring systems industry? We need to pay a particular attention to trends. Sometimes trends can be misleading to some customers and ‘force’ them to buy into solutions that they don’t really need. One needs to always focus on quality and the longevity of this quality. SPERONI has always believed in the concept of upgradability and giving the choice to customers to grow their investment as their needs grow. There is allot of attention today to the software aspect and to the ability to integrate with ex-

isting systems as well as ‘complementary’ systems such as CAMs, etc. This is a good example of new needs which allow customers to reduce redundant data and have more accurate and aligned data when it comes to tool management. Having said this one should never forget the importance of the Tool Presetting and measuring system as a product able to accurately and repeatably measure tools !

Q. What is your vision for your company? Our Vision can be summarized by saying that SPERONI will continue to be guided by the needs of our customers in providing them with products and services full of FUTURE PROOF TECHNOLOGY ! Q. What are the issues you need to address that are related to your industry. I feel that our main challenges for the future can be identi�ied in the importance of separating the cheap from the cost effective ! In other words, quality and the importance of looking at a true investment as opposed to just getting a machine on the �loor, is one of the biggest challenges today. Marketing these days can be very powerful and it can sometimes be used to confuse customers and stir them away from the real important facts and aspects of an investment. This is why at SPERONI we ask our customers to challenge us and compare every aspect of the investment. A Tool Presetting and Measuring System is and should become a key part of the manufacturing process. Making the right choice is very important ! This is why we ask to compare apples to apples, look, touch, evaluate, ask and if doubt are there, we request to ask and ask again.



Siddharth Technocast : Allaying the casting needs


e are pleased to introduce ourselves as manufacturer and exporters of investment casting. We introduced ourselves as an ISO-9001-2008 (TUV) Certi�ied company manufacturing FERROUS INVESTMENT CASTINGS. The experience gained in more than 9 years, workers high specialization, the advanced technology used and the modern control and measurement equipments, One of the leading investment casting foundries.

Why to choose us? Superior finish & unmatched appearance :

We make use of wax and plastic investment castings as molds, to produce high-quality products with a �inish and look unmatched by those manufactured using other methods, such as, welded assemblies and sand castings.

Flexibility and versatility in design:

Since our process works with all the popular metal alloys, you have the freedom to choose from an incredible range of designs, without compromising on the strength and the quality of the �inished products. Furthermore, the range in designs available with this process


is far more as compared to those available with die casting, forgings, machined components, brazed or welded assemblies, sand castings, and powered metal.

Cost-Effectiveness & are Energy saving :

The ‘Near Net-Shape’ feature of our process not only reduces the labor costs involved and the amount of material waste generated, but it also provides engineers �inished components from non machine alloys. Thus, this process enables material and energy conservation.

inclusion of minimal casting defects, design �lexibility, and/or the ability to combine two parts into one casting. Tolerance of +/-0.15mm per 25 mm is the standard.

Range of products

● Diaphragm & Submersible pump like casing ● Impeller open & close ● Diffuser ● Gland ● Sleeve nut ● Stuf�ing Box ● Adaptor ● Liquid Chamber ● Manifold ● Bowl ● Middle ● Nrv Suction ● Motor Base ● Bush ● Thrust Bearing ● Ball valve ● Globe valve ● Diaphragm valve ● Top clamps for Machine Tools, etc.

Esteem customers / segment At present we serve to

Reduced scrap rate and longer tool life :

We emphasize the use of dimensional precision investment castings, surface �inishes, exact material speci�ications, and part or full elimination of machining and �inishing operations. This process reduces scrap rate due to a) higher integrity and b) closerto-tolerance parts. This process also promotes longer tool life in any machine operation due to a lower

● Pump Industry ● Valves ● Defenses ● General Engineering Components ● Hardware ● Aerospace Component ● CNC Machine Tools We heartily thank you for visiting us and request you to send us your requirement to the mentioned below contact details. We assure you of our best product quality & services always. Siddharth Technocast Mr Hardik Vikani - +919825084483 Mr Umesh Chaudhary Cell: +91-9925912795 Survey No. 84, Plot No 4 to 7, Near Archer Metal, Shapar (Veraval), Dist Rajkot 360024 (Guj) India Tel.: 2827-252294 Fax: 2827-25229 Email: Web: The ready reckoner for engineering & allied industry


incomplete and other components could be damaged.” However, SAME DEUTZ-FAHR was unhappy with the original detection systems, which used to take more than 21 seconds to check each tool. This led to the decision to retro�it Renishaw TRS2 tool recognition units to multiple machining Lamborghini tractors are produced to high centres across all standards of quality four FMS lines. Says Mr Galimberti, “With amborghini is a brand that all the cutting we do symbolises Italian passion in we know a lot of tools need checking, the world of supercars, but so a reduction on that time meant it also has a strong following signi�icant time and cost savings. Each in the agricultural world, due to a component needs at least 34 tool range of high performance tractors checks, so with the TRS2 check taking produced by SAME DEUTZ-FAHR. At less than 7 seconds, the cycle time for its headquarters and main factory in every part has been reduced by an Treviglio, near Milan, Italy, visitors average of 7.5 minutes - some 6% of are struck by the same passion for cycle time.” The TRS2 is a non-contact laser producing high quality products in an system dedicated to tool breakage advanced machining operation. Now detection, which allows the machine the company has improved ef�iciency tool to monitor tool length fully further by �itting cost-effective Renishaw probe equipment to multiple automatically during a machining cycle. Mazak machining centres, giving a In less than a second it can detect the presence of the tip of a rotating cutting spectacular return on investment. The �lexible manufacturing system tool so that if it has broken during the (FMS) cells produce transmission previous machining cycle, the system and gearbox components, all of which detects this and the machine can take require a large number of threaded immediate action without damaging holes. With some 70% of machining more components. The TRS2 tool time devoted to drilling and tapping, breakage detection system is also tools which vary in size from M5 to extremely easy to install with both laser M18 break frequently - undetected transmitter and receiver contained this would lead to scrap and wasted in one unit, which doesn’t need the machining time. As Luigi Galimberti, alignment of full tool setting systems Manufacturing Engineering specialist that feature two separate units. If a tool breakage is detected by for machining operations, explains, “We have used tool breakage detection the Renishaw system an alarm sounds for a long time on the Mazak machines, and the machining program is stopped. as machining cycles are fully automated Any logic could be employed at this and operators would have no idea if a stage, for example another identical ‘sister tool’ could be used instead and tap or drill broke. Without detection a component machining could continue, but the could still have a broken tool embedded; engineers at SAME DEUTZ-FAHR prefer subsequent operations would be to stop the process for an operator to

Lamborghini saves €150K a year with Renishaw tool breakage detection systems

After the retro�it of Renishaw TRS2 tool recognition systems, SAME DEUTZ-FAHR, manufacturer of Lamborghini, SAME and DEUTZ-FAHR tractors, has seen a dramatic reduction in the time for essential but nonproductive tool checking on four Mazak FMS cells.



check the part and make sure that no more damage occurs.

Clear cost savings and return on investment

Mr Galimberti explains that the decision to invest in the TRS2 tool recognition systems and the subsequent cycle time savings has been extremely successful. “After a detailed analysis, based on the cost to run machines, we know this equates to a saving of more than €150K in the �irst year. This is because most of the non-productive machine time taken to check tools has now been released to machine components. We have paid back the initial investment in the TRS2s in a matter of just 5 months.”The project to replace the tool breakage detection units was part of a general cost-reduction exercise. Continues Mr Galimberti, “When we started we had several options for improving machining productivity, but this was by far the best, the others would have taken much longer to pay back.”

The TRS2 tool breakage detection routine

Speed is the key feature of the TRS2, but it is also important that a broken tool is not missed or wrongly identi�ied as good. The tool is moved such that the tip is in the path of the laser beam emitted from the TRS2 and rotated at one of several set speeds. The TRS2 is looking for a pattern of re�lected light in its receiver from the cutting surfaces of the tool. During installation the transmitter beam is directed into a convenient position in the machine’s working volume, often crossing the path taken by the machine to perform a tool change, to minimise any extra traverse moves. The length of a good tool is recorded in the machine from a previous tool setting routine, so the machine knows exactly where the TRS2 tool recognition unit should detect the tip. The engineer programming the job chooses how frequently the tool needs checking, depending on their knowledge of how often the tool is likely to break. This could be part way through a machining operation, or often after The ready reckoner for engineering & allied industry

TECH BYTES come together on the assembly lines in a ‘Just-In-Time’ style.”

Lamborghini, SAME and DEUTZFAHR

brands The three types of tractor are all produced on the same production lines with common components. Each brand has a following in different regions, but as with many car manufacturers, it makes sense to share a common About Renishaw underlying design across different Renishaw is an established world leadLuigi Galimberti has seen component cycle models. The three companies came er in engineering technologies, with a times fall by 6% together over a number of years, strong history of innovation in product an operation has �inished and the tool starting as SAME in 1927 in Treviglio, development and manufacturing. Since is being returned to the tool carousel. who pioneered the use of diesel engines its formation in 1973, the company has Appropriate automation for on tractors. In 1973 SAME purchased supplied leadingedge products that inefficiency and quality Lamborghini tractors and in 1985 also crease process productivity, improve The philosophy employed in SAME acquired the German tractor company product quality and deliver costeffecDEUTZFAHR’s manufacturing is well DEUTZ-FAHR. In 2003 the group tive automation solutions. A worldwide network of subsidthought out, to maintain high qual- became a key shareholder in DEUTZ iary companies and distributors ity whilst minimising engines, which now provides exceptional service and costs, as Massimiliano produces all the group’s support for its customers. Tempesta, Manufacturengines. ing Engineering ManThe SAME DEUTZager, explains, “We have FAHR group has three Products include: a common platform plants in Europe - Italy, ● Dental CAD/CAM scanning and milling systems. strategy, not just in our Germany and Croatia. ● Encoder systems for high accuracy products but also in our The production at each is linear, angle and rotary position engineering principles, according to the size and feedback. with engineering knowlpower of the tractors, ● Laser and ballbar systems for edge coordinated here in which determines the TRS2 tool breakage detection performance measurement and Italy and shared across system common components calibration of machines. all the plants. Stock of involved. In Treviglio ● Medical devices for neurosurgical component parts is kept the plant produces tractors that vary applications. low by producing only what we need, between 50-140 HP, the German according to varying demand for dif- Lauingen plant produces tractors with ● Probe systems and software for job set-up, tool setting and inspection ferent models. We’ve done this in the 140-270 HP (soon to be up to 300 on CNC machine tools. machining operation with these very HP), and the Croatian plant produces ● Raman spectroscopy systems for �lexible Mazak FMS cells producing in- combine harvesters. non-destructive material analysis. dividual machined parts for the transIn line with the group’s mission and gearboxes. This is then geographic expansion, its Indian plant ● Sensor systems and software for measurement on CMMs (co-ordinate coordinated with other components to is currently being expanded, in Russia measuring machines). an assembly plant ● Styli for CMM and will shortly start machine tool probe its production of applications. tractors of 150 - 270 HP for the For more information Russian market and a new factory is being built in China, but all still Powered by retain common The TRS2 tool recognition system is used to check all e n g i n e e r i n g Lamborghini, SAME and DEUTZ-FAHR branded tools prone to breakage, with at least 34 checks per principles. tractors are all produced at Treviglio machined component The ready reckoner for engineering & allied industry


TECH BYTES Powered by

IndraMotion MTX micro from Rexroth: The compact CNC system for standard machines ● Drilling machines ● Milling machines ● Basic machining centers



he market for CNC machine tools is very diverse today and also requires low cost control and drive solutions for standard turning and milling machines. CNC system IndraMotion MTX micro from Rexroth is the ideal tool for these applications and is exceptionally affordable. IndraMotion MTX micro is the compact, simple, powerful, and nevertheless low-cost CNC solution from Rexroth for standard turning and milling machines. It consists of a custom HMI interface and a compact multi-axis drive controller with highcapacity CNC control and PLC.


● Easy to use and practical ● High reliability and production accuracy – down ● Machining times minimized ● Fast, easy commissioning of the turnkey system ● Small installation space in control cabinet required to accommodate compact multi-axis drive controller ● Direct connection to 200 - 500 V, 50 - 60 Hz supply mains without a transformer All of these advantages make IndraMotion MTX micro the most compact and high-performance CNC in its class.

IndraMotion MTX micro is the perfect CNC system for:

● Turning machines and basic turning centers


● Operating panels and software optimized for turning and milling machines ● Comprehensive technology-cycle library for easy, ef�icient solving of complex machining tasks ● Multiple technological functions for complete machining ● Compatible with the standard, performance and advanced versions of IndraMotion MTX ● Precon�igured software for turning and milling ● Engineering tools for easy, fast commissioning and diagnosis

IndraMotion MTX micro offers all functions and options for the standard turning machine without option list:

● Constant surface speed ● Tapping with or without compensating chuck ● Spindle turret axis ● Turning, drilling and milling cycles for complete machining

IndraMotion MTX micro covers the complete range for the standard milling machines:

● 2.5 D and 3D machining using up to 4 interpolating axes ● Direct programming of drawing measure ● Free positioning of the work piece coordinate system in space ● Drilling, milling and turning cycles for complete machining

Easy installation & Commissioning

IndraMotion MTX micro from Rexroth raises the bar when it comes to easy installation and commissioning of a high-performance CNC system. Basic projects are provided for applications involving a typical CNC machine. A turning machine, milling machine or turning center can thus be parameterized in no time by loading the software.

The high level of system

integration also offers decisive advantages with respect to assembly and maintenance:

● ● ● ● ●

Minimum number of modules Easy wiring Screw less terminals Ultrahigh availability Maintenance-free hardware

Easy Setup Documentation

The compact setup documentation is easy to understand but also comprehensive, since all relevant information is provided for you to quickly commission the CNC system.

List of contents

● ● ● ● ● ● ● ● ●

Choosing and connecting hardware Basic software installation Basic project and general settings PLC commissioning Commissioning and optimization of the drives IndraMotion MTX micro operating software Connection diagrams Overview of parameters Standard I/O assignment

Industry-focused engineering and applications support from Rexroth Our experienced team of industry experts provides advice and support to assist you during conceptual development and design of your solution:

● Selection of speci�ic automation components (hardware and software) for your application ● Detailed description of control and drive components, interfaces and data management ● Development of sample applications ● Active involvement in initial applications at your site ● Support during integration ● Individual support for the systematic and compliant issue of safety strategies For more information write to : E-mail:

The ready reckoner for engineering & allied industry





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Free 24 h Express Catalogue Technical Visit Sample Request Any other info...


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plastics for longer life

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Despatched in 24 h or today


Hours rather than days


New, quickly customised assembly transport frame for ready-to-install energy chains

gus has been producing preharnessed readychain energy chain systems for around 20 years. At the AMB 2012, igus is presenting a newly developed modular transport frame which has been designed to transport and �it these to the customer machine; this frame can be quickly adapted down to the last millimetre in order to allow quick and accurate interfacing with the machine. This will lead to a signi�icant reduction in process costs in machine and plant construction. At the igus location in Cologne alone, between 400 and 500 orders are currently pre-harnesssed every week by 127 employees working in three shifts. A further 13 project engineers are involved. In Quality Assurance, the functional safety of every single readychain system is tested using special testing equipment before it is dispatched. Five test �ields, around 1,800 test adapters and approx. 18,000 test programs are available for this

purpose. The dif�iculty lies in the detail. Currently, several weeks to months are required from the joint drafting of a provisional frame at the customer’s site through to steel construction and system delivery. Subsequent changes to the welded frames are then dif�icult do. For this reason, a modular transport and assembly frame has been developed made up of support and brace modules which �it into one. These are also telescopic, allowing lengths to be adapted easily and quickly at any point in the process. Various locking mechanisms ensure that components can also be added to later. The whole system is easy to move thanks to specially developed transport units. In cooperation with the customer, the system is put together on site within one day. If modi�ications become necessary due to changes on the machine, they can easily be realised at any time thanks to the versatility of the system. If the machine series is discontinued at the customer’s, the transport and assembly frame can be dismantled into its individual parts to be used again. This means the new frame is more environmentally friendly and sustainable, whereas up to now, transport frames have had to be disposed of at the end of series production. The telescopic frame is a way of reducing a company’s process costs, which are mainly labour costs. igus GmbH, Cologne: The readychain factory in Cologne has everything The reason is the shortnecessary for the fast, lean and high-grade production of pre-harnessed ened assembly times. cables: more than 3,000 m² of space, 127 employees, 13 project The faster the pre-harengineers. Purchasers, planners, order managers and sales employees. There are five test fields, around 1,800 test adapters and approx. 18,000 nessed energy chain test programs are available testing the readychain systems. system is delivered, 186 | JANUARY 2013 | ENGINEERING REVIEW

igus GmbH, Cologne: The new telescopic transport and assembly frame for completely pre-arnessed and tested energy chain systems from igus. Ecofriendly thanks to the unlimited re-usability of its individual modules, set up within only a few hours and profitable from only five systems per year. the shorter the mechanical engineer’s time needed. This allows companies to be more competitive and secure or expand market shares. This comparatively low-cost concept is pro�itable from a total of �ive machines produced per year, allowing mechanical engineers to bene�it from the advantages of the new modular frame even for small series. Powered by

For more information igus® GmbH E-mail: The ready reckoner for engineering & allied industry


Holcim, one of the largest producers of construction material worldwide, relies on drive technology from NORD DRIVESYSTEMS In its cement plants and concrete factories in Croatia, geared motors of different performance classes are used. Heavy duty is no problem for the NORD products - they are ready for any challenge. That is why both companies have now completed a three-year-contract for the exchange of older drives. Nenad Mackic, facility manager in the Sumber quarry, is completely satis�ied: We value the drive technology from NORD due to its high reliability and ef�iciency. Service and delivery availability are also the best. For good reason, we have been operating NORD products in our quarries for more than 10 years without experiencing problems. Powered by


olcim Ltd.,for a good ten years, the corporation has been represented in Croatia with six concrete factories, a cement plant and three quarry systems. From the beginning, Holcim Croatia has mostly used drive solutions from NORD DRIVESYSTEMS for the belt conveyor systems used in these facilities.

Drive spectrum for heavy-weight conveyor applications

NORD drive systems are ideal for all types of conveyors and suitable for almost all grades, lengths and speeds. Variable speed geared motors with frequency inverters are used for small bucket elevators, whilst unregulated single speed geared motors provide the higher performance required for larger systems. With an ef�iciency of about 95 percent, the gear units are available in a shaft, foot or �lange mounted versions to suit the application. The maximum capacity is up to 200 kW with a maximum torque of 50,000 Nm.

Drive technology in the cement plant: Ex-protection is also in demand

NORD drive solutions are used for all transportation and conveyor tasks in cement production. Some of the drives are designed for operation in explosive environments according to ATEX Zone 21 or 22. Primarily mid-size geared motors are used: Helical, parallel and bevel geared motors up to 45 kW, mostly with protection class IP55, depending on the respective task. A plus point for the dif�icult requirements is the


All bearing seats and sealing surfaces

are machined in a single stage on the latest CNC machining centres. The bene�its include extremely high reliability and exceptional sealing with safe handling of even the largest torques combined with high axial and radial load bearing, quiet running, low maintenance and exceptionally long operating life.

Company background

NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 2,800 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-speci�ic concepts and solutions, even for special applications, for example with energysaving drives or explosion-protected systems. The annual sales in the 2011 �iscal year amounted to about 412 million Euro. The company founded in 1965 now has over 35 subsidiaries worldwide. The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 200 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units. For more information NORD Drivesystems Pvt. Ltd. Web: For more information write to : E-mail:

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Now in India

Power Transmission of High Quality for your Machinery Welcome to power... welcome versatility. More power with more flexibility in perfect harmony technology. From the union of two Italian companies a new generation of engines and gearboxes. For a power transmission quality. To produce quality

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Sumitomo Drive : The legacy of technology perfection groups in the world. Even after 400 years, the Sumitomo family “business spirit” is alive in each of the Sumitomo Group companies. The core of the Sumitomo Group, listed below, consists of 20 companies who share the Sumitomo Emblem as well as many common values and ideals.

Mr. Chandrashekhar Paradkar National Sales & Marketing Manager Sumitomo Drive Technologies, Pune, India

Q. Please brief its journey from the inception & share some its milestones? The Sumitomo Group began more than 400 years ago when Masatomo Sumitomo opened a book and medicine store in the city of Kyoto, Japan. Over the next 100 years, the Sumitomo family developed a leading presence in copper re�ining, which led to the family opening the Besshi copper mine. From these beginnings, the Sumitomo Group continued to grow and diversify to become one of the largest corporate

Q. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition? Sumitomo Heavy Industries, Ltd. In 1888, a company was formed to provide equipment repair services to the Besshi copper mine. Almost 50 years later, in 1934, the company incorporated as Sumitomo Machinery Co., Ltd. to manufacture machinery for the steel and transportation industries in support of that period of rapid economic growth. In 1969, Sumitomo Machinery Co., Ltd. merged with Uraga Heavy Industries Co., Ltd. to create Sumitomo Heavy Industries, Ltd. The company continues to innovate and expand to meet the demands of new market frontiers. Today, Sumitomo Heavy Industries manufacture injection molding machines, laser systems, semiconductor machinery and liquid crystal production Machinery. Sumitomo Drive Technologies of Sumitomo Heavy In-

Sumitomo Drive Technology Cyclo Manufacturing Factory in Obhu Japan. 196 | JANUARY 2013 | ENGINEERING REVIEW

dustries began early in the 20th century. In 1911, Sumitomo Machinery Co., Ltd. began manufacturing directcurrent electric motors (3.7kW) for the Besshi copper mine. In the late 1930s, the company formed a technical cooperation agreement with CYCLO Getriebebau Lorenz Braren KG of Germany. In 1939, Sumitomo Drive Technologies was born when Sumitomo Heavy Industries, Ltd. began to manufacture CYCLO® Drives. In 2003, Sumitomo Drive Technologies was implemented as a global group brand to bind all power transmission businesses of the world. For more than 60 years, Sumitomo Drive Technologies continues to lead the world in knowledge and innovation in power transmission and control devices. Sumitomo Drive Technologies strives to be the “dependable partner” for our customers.

Q. What are the market prospects for your company products in India and How do you plan to position these products? CYCLO® Drives are also used for precision control. They combine the high strength and impact resistance of CYCLO® gears with very low backlash design. Because they are the component type, they are easy to install in customer machines. High precision alignment is made possible when combined with servo motors. This line is ideal for applications that require higher rigidity and precision stopping. They are Used in machine tools, industrial robots and factory automation equipment. The FC-A, F1C-A, F2C-A, F2C-C, F4C-D and F2C-T Series are available to suit different types of Applications. The STD and LB Series CYCLO® Drive can be directly connected to generalpurpose servo Motors. There are standard backlash models and low 6min backlash models. The IB Series P1 Type low backlash reduction gears use The ready reckoner for engineering & allied industry


a Sumitomo-unique planetary gear Mechanism. When combined with servo motors, they can be used in all types of precision alignment applications, such as robots for injection molding machines, machine tools and packaging machines.

Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition among industry? Why do customers prefer to use Sumitomo Drive Technologies products? The answer is that we offer the broadest range of products that are the most reliable and the highest quality available. The CYCLO® Drive products provide customers with almost limitless �lexibility and reliability in their applications. The revolutionary Hyponic products give customers highef�iciency performance in a compact design with hypoid gear technology. The Paramax product family provides industrial customers a strong, reliable gearbox that is designed for years of trouble-free service. Our development engineers design these products with years of proven expertise in the power transmission industry. The industry recognizes that Sumitomo Drive Technologies products are the most reliable on the market. By using careful planning and veri�ication testing over the entire development process, the engineers insure that these products are the most reliable and the highest quality available.

Q. Please elucidate in brief about the your company’s infrastructure & What are the measure that are being taken from the product manufacturing to distribution? More than 35 years ago, Sumitomo Drive Technologies began to develop a global presence in response to the challenges of the company mission to facilitate premier support of our partners’ needs that lead to the development of operations located around the world. In 1966, Sumitomo Drive

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Technologies established Sumitomo Machinery Corporation of America, the very �irst overseas manufacturing plant, in the United States to support the Western Hemisphere. In 1974, we signed a capital sharing agreement with CYCLO Getriebebau Lorenz Braren KG of Germany to bring further innovation to the Cyclo technology through technical collaboration of both companies. Eventually, the partnership formed Sumitomo (SHI) Cyclo Drive Germany,GmbH.The global Sumitomo Drive Technologies web extends to 50 countries with 9 main hubs, 5 manufacturing plants, 35 assembly plants, and 250 sales of�ices. Through this extensive web, we provide the world with high performance, reliable, and premium quality products and services. Our global web links the resources for marketing, procurement, production and distribution to support customers at a world-class level for speed and accuracy.

Q. Brief us about the R&D and Quality policy for your business? In striving to satisfy customers without compromising on the goals of innovation and reliability, Sumitomo Drive Technologies aggressively invests in Research and Development. As technology changes and improves, the power transmission and controls systems must also change and improve. To challenge the technical horizons of mechanical and electrical components, Sumitomo Drive Technologies relies on research to uncover new levels of performance, reliability, and quality. From these “seeds” of research come the technologies of the future and the creation of new products to better serve customer needs. The strength of our Research and Development efforts is in the ability to generate original concepts that transform into unique, customer focused products. Sumitomo Drive Technologies Research and Development believes that “what was not possible be-

Cyclo Engineering Of�ice in Japan.

fore is now possible.” Meet and exceed customers’ expectation, that is our passion.

Q. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? Government is now providing proper �inancial support and other Economic Bene�its to Small Scale Industries. The factors like excise duty, Exim policies are directly �inancially affecting Motion Control Equipment Industry as well established Industries because of increase in certain un-established Industries. Q.What is your vision for your company? We are always moving forward in pursuit of new ideas that inspire our partners to create new values that will change the world. Each of our skilled, knowledgeable, creative employees contributes to the creation of unique technologies and innovative solutions that meet and exceed our partners’ expectations. Our global network facilitates premier support of our partners’ needs. We stand poised to meet the challenges of today and tomorrow, so that our partners may walk with con�idence as industry leaders.

Always on the move

Sumitomo Drive Technologies: A dependable partner, creating Unprecedented change and opening up unseen worlds. That is who we are.



Gears & Motors : Industry Performance in 2012 ( India & global sceanrio) & forecast for coming years


ndustry experts claim that gears and motors sector in industry is highly competitive with very low margins, mechanical power transmission components market pose a challenging environment for growth. Despite being traditional solutions, gear boxes and gear motors provide advantages such as familiarity, reasonable life, high reliability, reasonable cost and universally serve most of the requirements of the industrial automation sector globally. Speed adjustment techniques have been employed to transmit mechanical power to power machineries ever since their advent in industries. Mechanical speed changer governed the market before the arrival of electric motors controllers for industrial power transmission. Presently, mechanical, electrical and hydraulic drives cater to this requirement, each delineating its pros and cons, necessitating a thorough analysis before narrowing down to one particular solution for any type of application. Customers in aerospace, automotive and manufacturing and process industries are offered a broad spectrum of mechanical power systems and component that include chain and belt drives, gear reducers (such as helical gear, worm gear, planetary gear), gear motors and so on to suit their application needs. The belt and chain drives market is mature and well established with the OEMs and more focused on enhancing the design and performance of the products. Mechanical drives such as chain drives are popular due to their ability to transmit high torque levels in a smaller form factor, but besides being economical for such applications, their maintenance cost is substantial. This includes cost towards lubrication, alignment and regular replacements due to wear and tear, hence requiring proper maintenance for continued optimal performance. As a result, the af-


ter sales support is observed to be of great importance in this market, as the customers demand best support from the vendor they purchase the mechanical components from. Additionally the market for these components is heavily dependent on strong customer-manufacturer relationships and satisfactory customer service is an important factor behind maintaining and acquiring market share. The simplicity of the design has allowed widespread acceptance of the gears technology. It is perceived to be the most cost-effective technology for industrial mechanical power transmission. Modular design and �lexibility in usage boost the cost effectiveness of the geared products. Its widespread acceptance has generated a massive customer base for gearbox and gear motors and this, in turn, is expected to improve the growth statistics of the industry. But today, the gears, gearboxes, geared motors and other mechanical power transmission equipment pose a challenging environment with low pro�it margins. Experiencing high competition with increasing number of market participants, threat from alternate advanced electrical power transmission technologies and reduced potency to penetrate newer application platforms has threatened their continued usage for numerous applications. Renewable energies are expected to bolster the demand : A shift towards more ef�icient gearbox and gear motor designs is expected to have a positive impact on revenue growth of gearbox and gear motors segment. The increasing demand for planetary solutions for better torque and precise process control is expected to enhance the revenue contribution, as these products are comparatively high priced for the bene�its they deliver. Major market trends include incorporating advanced gear designs, improving product quality, decreasing

product lead times, enhanced services offered and product differentiation for speci�ic applications. The future prospect of this industry is strongly correlated to the economic activity in the country, especially in core sectors like power, infrastructure, mining, oil and so on. The growing demand of power is expected to pave way for newer power projects and henceforth, increase the usage of geared components. The shift towards renewable resources of energy such as wind and solar is also expected to bolster the demand for geared components, as gearbox and gear motors form the vital components in construction of these renewable power generation units. It is essential that appropriate pricing of the product is done with appreciable features to attract end-user attention. To sustain the competition it is important to manage cost associated with production and offer lower prices. Cost advantage can be achieved by outsourcing the production of noncritical components to a low-cost manufacturer in regions, where labour and raw material are available at reduced prices. The �inal component can then be inspected and assembled by more skilled labour. Forecast : Shipments of precision geared products (gearboxes and geared motors with backlash ratings of less than 20 arc-minutes) were nearly 80 percent higher in 2012 compared to 2009 levels. Shipments of precision geared products (gearboxes and geared motors with backlash ratings of less than 20 arcminutes) were nearly 80 percent higher in 2012 compared to 2009 levels. However, uncertainty about the Eurozone economy and China’s decelerating economic growth are the leading factors in the more than one percent decline expected in precision Continue on page no.202

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MARKET MONITOR Continued from page no.200 geared product shipments in 2013. IMS Research, now part of IHS Inc., projects the market for precision geared products to reach an estimated value of nearly $1.7 billion with over 1.8 million units shipped in 2013. High precision gears are often rated according to their ability to live up to measurements in arcminutes, what then is an arcminute? An arcminute, in divisions of the circle or angular measures, a minute is equal to sixty seconds, or one sixtieth part of a degree. Precision gearbox shipments, which accounted for more than 95 percent of the precision geared products market in 2012, increased by more than 70 percent from 2009 levels due to pent-up demand for servodriven machinery and increased access to capital. A signi�icant amount of investments were made in the automotive industry, where demand for industrial robots used in the production of vehicles spurred a sharp increase in precision planetary gearbox shipments. Precision planetary gearboxes accounted for more than 82 percent of precision geared products shipped in 2011. Investment in new automobile manufacturing facilities is expected to continue, however at lower rates than those seen in 2010 and 2011. Sales of electric industrial robots to the automobile industry have slowed considerably in 2012 due to lower of demand for Japanese products from China and continuing weakness in the Eurozone economy. Precision gearbox and geared motor shipments into industry sectors such as materials handling, woodworking and printing are also expected to grow at a slower pace in 2013 following the ful�ilment of pent-up demand that resulted from the 2009 recession. Although precision geared product shipments to the food, beverage and tobacco industries are expected to decline in 2013, positive signs


of economic growth in the Eurozone and China could mean further growth of precision geared product sales from 2014 to 2016. Precision geared product sales to the robotics and machine tools industries, which accounted for approximately 39 percent of all precision geared products shipped this year, are forecast to grow at a mere 3.5 percent in 2013. However, the slowdown in these industry sectors is not projected to cause the total market for precision geared products to decline through 2016. Global Forecast : Gears and motors are very vital for not only automotive engineering but for almost all types of manufacturing activity. Therefore the views of an engineering giant point towards future in no uncertain terms. The GE CEO Jeffrey Immelt explains the trends in general, by saying that they have globalized around markets—not cheap labour. The era of globalization around cheap labour is over. Today GE goes to Brazil. It also goes to China. And it even goes to India, because that’s where the customers are. Global demand for gears and gear assemblies is forecast to climb 4.7 percent annually through 2013 to $169.5 billion according to the Freedonia group. Market gains will be driven by rising motor vehicle production, ongoing economic growth, increased manufacturing output and a shift in the product mix toward more expensive, energy ef�icient units such as seven- and 8-speed automatic transmissions. Strong demand in relatively small but fast-growing markets like wind and solar energy will also contribute to gear sales advances. Demand in developing parts of Asia, Eastern Europe, the Africa/Mideast region and Central and South America will outpace product sales in the United States, Western Europe and Japan. Market gains in the developing world will be fuelled by healthy economic growth, continuing industrialization

efforts and climbing personal income levels, resulting in higher motor vehicle and other manufacturing output. In addition, rising standards of living will help stimulate demand for motorcycles and other gear- containing durable goods, boosting both original equipment manufacturing and aftermarket gear sales. China and India will register some of the strongest market advances. China is expected to account for one-third of all additional gear demand through 2013 and will surpass Japan to become the second-largest national market behind the United States By 2018, total gear sales in China will exceed product demand in the United States. Market growth is also expected to be healthy in Indonesia, Thailand, Iran and Russia. Although advances will be less robust than in developing countries, gear product demand in the United States and Western Europe will increase as well spurred by renewed strength in motor vehicle output following a period of decline. Gear sales in Japan even prior to the recent tragic events there are predicted to slow noticeably, also negatively affected by a drop in automotive industry production and continued sluggishness in capital equipment markets. Also prior to the disaster, Japan anticipated a more favourable outlook for machinery manufacturing to provide some impetus to growth, along with the large numbers of gearcontaining equipment in use that would help support aftermarket gear demand. Only time will tell how that is resolved. The global market for gears and gear assemblies is heavily reliant on the motor vehicle industry. In 2008, seven-tenths of all product sales were automotive related, with motor vehicle transmissions alone accounting for 45 percent of the entire gear market. Transmission demand will also grow at a faster rate than accessory, driveline, steering and other motor vehicle gear sales through 2013, bolstered by an upturn in industry output in the United States, where more costly automatic transmissions are used in the vast majority of vehicles. The ready reckoner for engineering & allied industry

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Pumps & Valves : Industry Performance in 2012 ( India & global sceanrio) & forecast for coming years


umps and valves are designed or chosen primarily for their mechanical performance i.e. containment of pressure, �luid sealing and, in the case of pumps, pumping capacity. For reasons of economy manufacturers offer their products in a limited range of materials. Each of these materials is suitable for a range of common �luids, and has the advantage of being available with relatively short delivery times. However, for corrosive and/ or erosive �luids the user may require special designs (e.g. of seals) and/ or special materials, which increase cost and delivery times. The balance of cost versus the likelihood of failure due to corrosion must be taken into account along with the criticality of the component, i.e. what are the consequences of a failure. For example, a �irewater pump is a high criticality item and materials should be chosen so that there is no safety risk. When requesting non-standard items it is important to realise that most of the wetted components in a valve or pump are cast and hence an alloy with good foundry characteristics must be selected. A compatible wrought alloy must be selected for items such as shafts and stems. Even when an alloy is available as a casting, it may not have all the properties that are required. For example, phosphor bronze is sometimes used for pump impellers, but rarely for pump or valve bodies because of the dif�iculty in producing pressure tight castings in this alloy. If an alloy change from a standard material involves the production of wholly new patterns, the additional costs will be great, and it may be cost effective to consider an alternative alloy with similar properties which only requires minor pattern modi�ications. When selecting a pump or valve the user must provide the supplier with


details of the composition of the �luid to be handled (including trace chemicals), the pH, the temperature, the solids content and the �low rate. Other factors which are also required for cost effective materials selection are the desired life and the criticality of the component i.e. the consequences of an unplanned shutdown. Present scenario in India : Globally, a majority of the demand for pumps, valves and compressors is from their installations in varied enduser industries of oil and gas, power generation, and heavy industries (like cement and metal). The Indian market for this equipment also thrives on a similar global pattern, with demand primarily originating from the country’s widespread oil and gas exploration and production activities, re�ineries, and other core sectors. Commensurate to the vastness of the Indian end-user industry and the range of applications involved in each segment, the demand for �low control equipment is also high. Large-scale installations are witnessed every year and the demand continues to pick up at a healthy double-digit growth rate. As per Frost & Sullivan’s research, the cumulative market size for pumps, valves and compressors during FY 2010 was in the range of INR 120.0140.0 billion. Given the ubiquitous nature of the pumps and valves, the equipment contributes to the majority of value and unit shipments. MARKET TRENDS With global warming posing a great concern and stringent environmental regulations expected to be enforced in the coming years, the central and state governments in India are emphasizing on optimum utilization of power through various energyconservation measures. Equipment powered by renewable energy sources is expected to gain prominence in

the future. Stringent environmental regulations across different end-user sectors to reduce the carbon footprint through lower emission of greenhouse gases (GHG) are the major driving factors for this technology. Utilization of automation in pump, valve and compressor markets has enabled easy health monitoring. Remote monitoring and diagnostics play a vital role in ensuring smooth start up, continuous running, and safety of the plant and environment. Increasing awareness about automation among Indian endusers is likely to help in improving future productivity and reducing the maintenance cost. The concept of energy ef�iciency has caught up with the Indian end-user industry, and it is increasingly looking forward to solutions that can enable power savings. Motors, which are the dominant prime movers (of pumps, valves and compressors) account for signi�icant power consumption. Usage of electric drives, along with motors, enables advantage of controlling the power input based on the required output. For example, in the case of compressors, whose output is usually characterized by signi�icant �luctuations, periods of low-pressure demand and unused pressure represent lost energy. Equipment manufacturers have introduced energy-saving compressors with variable speed control to overcome this particular situation. A compressor with variable speed control is able to closely follow the �luctuating demand by varying the Continue on page no.210

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MARKET MONITOR Continued from page no.208 speed of the motor. Given the need to control costs and become more competitive, the end-users have begun to actively look for manufacturers who deliver energy ef�icient systems. Energy ef�iciency concerns have also impacted the selection of the product. One such trend is associated with the air compression application in the compressor industry. This application has, over a period, witnessed changing preference from reciprocating to screw to the ef�icient centrifugal compressors. MARKET OUTLOOK A stable economy, coupled with continuing investments in the core sectors, is expected to fuel the growth of the pumps, vales and compressors market in India. Banking on the ongoing infrastructure projects in the power generation, building services, metals, cement, water and wastewater, oil and gas, amongst other sectors, the total Indian market for this equipment is expected to grow at a much faster pace than that of the rest of the world. Key factors associated with growing economy, increasing middle class (prosperity and spending), rapid urbanization, and expanding infrastructure needs are also expected to translate into growth. Rising awareness levels about long-term cost savings from adoption of energy-ef�icient equipment (like in the agriculture sector, in the case of pumps), is expected to further spur the demand. Solar-powered Pumps : An ideal solution for an energy starved India, this is a new trend, and obviously due to lack of suf�icient number of manufacturers as well as lack of awareness, the solar-powered pumps are yet to come into their own. A solarpowered pump is a pump running on electricity generated by photovoltaics. The operation of solar powered pumps is more economical and has less environmental impact than pumps powered by an internal combustion engine -which are the most commonly


used water pumps for irrigation in rural India. Solar array (photovoltaic cells, solar panels) takes up 50% - 80% of the whole setup cost, which is the most expensive part. There are two major types of solar pumps, DC (direct current) and AC (alternating current). DC solar pump: ● Power output up to 3 kW ● Suitable for small to medium applications like garden fountain, landscaping, livestock drinking, irrigation, etc. ● Low-price (require 40% less solar panel compare to AC solar pumps) The solar industry has immense potential for a tropical country like India where around 45% of households, mainly rural ones, do not have access to electricity. The industry has witnessed rapid growth over the past few years and is projected to grow further in future. India is blessed with ample solar radiation and most part of the country receives 300 to 330 sunny days in a year. India receives solar energy equivalent to more than 5,000 Trillion kWh per year, which is far more than its total annual energy consumption. The country’s geographical location, large population and government support are assisting it to become one of the most rapidly emerging solar energy markets in the world. Consequently, the country is becoming a favourite investment destination for both local and global players. Demand for solarpowered street lights etc. has been shooting up in India. Mega-solar enegy parks are being contemplated today. Several states have started promoting solar based applications by giving incentives and tax savings. States like Gujarat and Rajasthan have formulated transparent and progressive regulatory framework in order to boost the solar industry. Besides, states like Delhi, Uttar Pradesh, West Bengal, Maharashtra and Chandigarh are promoting solar energy in rural, urban and semi urban areas. The forecast for different segments of the solar power industry based on

Global Pumps Market Forecast :

feasible solar industry include: ● Solar Street Lighting System ● Solar Home Lighting System ● Solar Lantern ● Solar Photovoltaic Pumps ● Solar Water Heating System ● Solar Cookers Some of the key players in the pumps sector today are BHEL, BEL, CEL, TATA BP Solar India Limited, Solar Semiconductor and Moser Baer India Limited. There is an obvious contradiction in the all-pervasive signs of recession, and yet there are segments that are thriving well. The global, growing demand for power has offset the effect of the recession on the power generation sector. If we extrapolate this trend, this growth is expected to reach sizeable proportions, as shown by some key factors and trends, including: ● A surprising 60 percent increase in global demand for electricity by 2030, led by growth in India and China ● The very signi�icant trillions of dollars in infrastructure investment in the industry to 2030 ● Also the projected growth in nuclear power, with China, Russia, India and the rest of Asia leading the way in future planned or proposed plants ( while Japan pulls out due to the recent Fukushima disaster, some Euro-nations have put a stop to nuclear ambitions) These trends promise notable revenue opportunities for pumps suppliers in both new plants and existing plant upgrades and refurbishments. Global Pump Forecast : Only a few years ago, nearly all major economies were in doldrums. The

Continue on page no.212

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MARKET MONITOR Continued from page no.210 world’s positive displacement (PD) and centrifugal pumps markets witnessed either �lat or negative growth in 2009. With the end-user segments experiencing the impact of global recession, a sense of panic prevailed. However today, the overall picture still remains obscured. The expected strength of pump revenue growth within the power generation industry depends on regional trends. There are too many �iscal and political factors at the local level which directly govern the perceived growth in the pump market to remain robust in near future. Experts opine that emerging economies, such as the BRIC (Brazil, Russia, India and China) nations, are expected to witness considerable growth over the short term of the forecast period, mainly due to infrastructure developments in these countries. Population growth, urbanization and the resulting increase in power demand will help fuel growth in the Asia Paci�ic. Pump demand is also expected to increase within the power generation sector in northern Africa and the Middle East, although recovery in southern Africa is expected to be slower. The MiddleEast and North African nations have witnessed another spurt in oil exploration, which provides a boost to the pump and valves industry in general. Almost all the developed nations, on the other hand, are dealing with the severely constricting after-effects of the worldwide recession. Investments in plant infrastructure and retro�it needs were deferred as long the slow down lasted. As the general economic environment improves in North America and Europe, pump revenues in this industry are expected to gradually return to moderate growth rates. Let us remember that solar-energy based pumps are also included in pumps and valves industry, a minuscule factor which is no longer insigni�icant with fossil fuels falling out of favour. Vital Trends and Issues : A number of conspicuous trends are


expected to affect pump demand in this industry throughout the forecast period, including the following positive trends: # There is no denying that the global warming and its cohorts have caused an enormous increase in awareness about environmental compliance. It has brought with it, increasingly stringent regulations having signi�icant impact on the market. This will continue to be a strong market driver for pumps used within the power generation industry, as well as in other industries. In addition, growing interests in alternative energy sources to counter greenhouse gas (GHG) emissions are likely to contribute to the growth. Solar-energy driven pumps, are a good example here Though the awareness and insistence of energy-ef�icient pumps was missing till recently, the focus on energy-ef�iciency offers a considerable potential for growth, mainly due to rising energy costs and the intense focus on driving costs out of process/ production. End users are increasingly seeking the optimization of their processes to reduce energy consumption. As PD pumps are suited for applications emphasizing more ef�iciency, this is expected to offer a great potential for suppliers of these pumps. Another factor here is the age-old maxim that needs drive demand, and demand drives development. We have seen that happen in automotive sector. Replacements/retro�its demand will increase- there is a picture of a ‘retired’ wind-pump having been retro�itted with solar panels in South Africa, elsewhere in this article. Increasing investments in the water and power generation sectors over the next decade, coupled with the rising trend of PD pumps replacing centrifugal pumps in applications focused on energy ef�iciency, are expected to fuel the growth of the displacement PD pumps market. Rising demand from the utility sector will continue to fuel the growth for centrifugal pumps. Of course, challenges also exist in the industry that can impede growth,

such as: ● Price pressure from low-cost participants has intensi�ied the competition, which can push suppliers to offer higher quality, ● More reliable and advanced technology at competitive prices. However, the price pressure is a restraining factor on the overall revenue growth potential of the pumps market. Although the impact of the global recession has been somewhat mitigated for the power generation sector as a result of the rising global need for power, a short-term impact from the economic slowdown will occur as production slowly ramps up, capital expenditure resumes and excess pump inventory is sold. Fiscal experts refrain from making such sweeping remarks because increasingly a region’s own response to recession, varies widely all over the world. Consolidation of the well-informed market: Both PD pumps and centrifugal pumps are commonly used pieces of equipment for power generation, as well as many other industrial process/ production areas. In mature markets, demand for such products typically �lattens out over a period of time owing to consistent supply, few technological innovations and the presence of supply-side competition. The power generation sector is a critical industry that cannot afford downtime. As such, the industry provides a consistent, if not stellar, rate of growth for the pumps industry. Within a reasonable period of time, the power generation sector may become far more vital for pumps and valves industry. Experts also tell us, the aftermarket business for pumps within the power generation sector will continue to generate growth, as plants undergo retro�its and upgrades. The opportunities for growth exist. The challenge will be identifying the fastest growing regions for the power generation sector, such as in the BRIC countries, while also taking advantage of the aftermarket opportunities in mature economies The ready reckoner for engineering & allied industry




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Process Industry : Latest technology trends


ega-plants: The world of plant engineering and construction is at the moment vacillating between the extremes: in China, India and on the Arabian peninsula, world-scale plants are springing up everywhere, and in Europe process engineers are trying out ideas for chemical containers and modular plant concepts. Manufacturers of bulk chemicals (commodities) such as fertilisers or primary plastics, including the basic �ilm materials polyethylene and polypropylene, are attracted to regions with raw material

Reliance Jamnagar Refining Plantthe world’s largest.

sources, such as the Middle East, where huge chemicals complexes are being built at this moment. For example: Saudi Arabia, location Jubail. Here, for US$ 20 billion, in a joint venture with Saudi-Aramco, Dow is conjuring up a factory out of the desert sand, with the intention of churning out three million tonnes of chemical products per year from 2016 on. Modular plant construction: Bigger, higher, further is the motto in major plant engineering and construction, which is increasingly moving its


base to the emerging markets. Faster, cheaper and more �lexible, in contrast, are the watch-words when the subject is �ine and speciality chemicals. If modular plant construction and chemicals containers are really going to be the answer to everything will come out in the wash. At the moment, at least, everyone with a name and reputation in the sector is looking into ideas intended to get the German and European chemicals industries back into top shape. All of this is running under the catch-word 50 Percent Idea and connects projects such as F3 Copiride or the Evotrainer by Evonik. The digital plant: Another facet of the 50 Percent Idea is the digital plant. Jürgen S. Kussi, Head of Plant Layout and Piping at Bayer Technology Services, is one of those convinced that this will switch on a turbine capable of reducing project development times, from the idea to the completed plant, by half. The trendsetter here is the chemicals giant BASF, which in 2010 launched an ambitious project with the self-introducing name Digital Plant @ BASF2020. The aim behind it: for every real plant, a digital plant should also exist. What is needed are standards and object-orientated integrated CAE systems which network 2D and 3D planning on an inter-tool and inter-disciplinary level. In addition: software which makes it possible to commission and maintain a plant on the basis of the planning data. Mega-plants: The Indian Oil Corporation has set up two new ‘mega’ plants at Hyderabad, to better compete with the two re�ineries built by Reliance Industries at Jamnagar (which were build on a record scale and in record time). Phase-I of the project was implemented over 54 months and was inaugurated this morning. Indian Oil Corporation Ltd. has registered a pro�it of Rs 9,611 crore for the second quarter of the �inancial year 2012-13 as compared to a loss of

Rs 7,486 crore for the corresponding quarter of the previous �inancial year; mainly due to release of Govt. Under recovery burden continues to grow; despite higher Government of India (GOI) compensation and upstream discounts net under recoveries remain substantial: The Oil Marketing Companies (OMCs) continue to suffer high under-recoveries on sale of sensitive petroleum products viz. domestic LPG, public distribution system (PDS) Kerosene and high speed diesel (HSD), because of control on their selling prices by Government of India (GoI), crude oil prices being at elevated levels and depreciation of the Rupee versus the USD. Though the gross under-recovery levels rose about 32% during H1 2012-13 to Rs. 856 billion (Rs. 649 billion during H1 201112) the net under-recovery for OMCs was marginally (10% yoy) lower at Rs 254 billion during H1 2012-13 (Rs 283 billion during H1 2011-12) aided by almost 100% increase in GoI compensation and about 39% increase in upstream discount. However, the collective net under-recovery continues to remain substantial at Rs. 254 billion in H1 FY 13, which has signi�icant bearing on the pro�its of OMCs as re�lected by their combined net loss of Rs. 235 billion in H1 FY 13. ( H1 means the �irst half of the �iscal year). Delays in cash compensation by GoI continue to impact the credit profile of OMCs: In the past, GoI has continued to demonstrate its support to OMCs especially in years of weak re�ining pro�itability like in FY 2009 and FY 2012, wherein net under-recoveries borne by the latter have been almost nil. GoI would have to provide signi�icant support to the marketing segments of OMCs in FY 2013 to keep under-recoveries at negligible levels, as the re�ining segments of OMCs are also expected to report low pro�its in line with modest interContinue on page no.218

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MARKET MONITOR Continued from page no.216 national re�ining scenario and high �luctuation in crude oil prices leading to inventory loss. ICRA believes that the GoI will continue to ensure an adequate under recovery sharing mechanism so that the net under recovery burden on the OMCs is low, in view of the multiple socio-political objectives that are ful�illed by these companies. Nevertheless, delays in the payment of cash compensation by GoI, sharp volatility in oil prices and/or exchange rates along with tepid outlook for the re�ining margins would continue to impact the credit pro�ile of the OMCs. Current status : With about 300 clear, sunny days in a year, India’s theoretical solar power reception, on only its land area, is about 5000 Petawatt-hours per year (PWh/ yr) (i.e. 5000 trillion kWh/yr or about 600 TW). The daily average solar energy incident over India varies from 4 to 7 kWh/m2 with about 1500–2000 sunshine hours per year (depending upon location), which is far more than current total energy consumption. For example, assuming the ef�iciency of PV modules were as low as 10%, this would still be a thousand times greater than the domestic electricity demand projected for 2015. Installed capacity The amount of solar energy produced in India in 2007 was less than 1% of the total energy demand. The gridinteractive solar power as of December 2010 was merely 10 MW. Government-funded solar energy in India only accounted for approximately 6.4 MW-yr of power as of 2005. However, India is ranked number one in terms of solar energy production per watt installed, with an insolation of 1,700 to 1,900 kilowatt hours per kilowatt peak (kWh/KWp).[11] 25.1 MW was added in 2010 and 468.3 MW in 2011. By July 2012 the installed grid connected photovoltaics had increased to 1040.67 MW, and India expects to install an additional 10,000 MW by 2017, and a total of 20,000 MW by 2022.


Insolation is a measure of solar radiation energy received on a given surface area and recorded during a given time. It is also called solar irradiation and expressed as “hourly irradiation” if recorded during an hour or “daily irradiation” if recorded during a day. The unit recommended by the World Meteorological Organization is megajoules per square metre (MJ/m2) or joules per square millimetre (J/mm2) . Practitioners in the business of solar energy may use the unit watt-hours per square metre (Wh/m2). If this energy is divided by the recording time in hours, it is then a density of power called irradiance, expressed in watts per square metre (W/m2). Future : Desalination is a must when megaplants discussed because today some of the existing plants are really enormous in size. The Ocean Is Becoming One of the Key Sources of Reliable and Draught-Proof Coastal Water Supply in the Next 10 Years; Seawater Desalination is Economical Today and Will Become Even More Cost-Competitive in the Future; The Future of Seawater Desalination Is Bright –20% Cost of Water Reduction in the Next 5 Years; Long-term Investment In Research and Development Has the Potential to Reduce the Cost of Desalinated Water by 80 % In the Next 20 Years. It is notable that most desalination plants are usually attached to power generating plants, utilizing their waste heat energy for desalination. Thus a double bene�it accrues. Solar Photovoltaics : mega-solar plants : This initial project will see the installation of a mega-solar power plant with maximum output of 8.5 MW on the former site of Makurazaki Airport (Makurazaki City, Kagoshima Prefecture). This project is the �irst time in Japan that a former airport site has been utilized for a mega-solar power operation. Makurazaki Airport opened in January 1991 as Japan’s �irst commuter airport. In light of mounting annual budget de�icits for the management

and operation of the airport, as well as future �iscal policy and the �inancial burden faced by residents, Makurazaki City decided to shutter the airport at the end of �iscal 2012 and lease the site to a mega-solar operator. Recently the Economic Times reported India’s ambitious plan to build giant power plants to meet growing energy needs has hit a roadblock as �inancial institutions ( FIs) have refused to fund future projects, saying the new norms make them unviable. The proposed new norms for ultra mega power projects (UMPPs) say the projects will be owned by power distribution utilities, and the quali�ied bidders will be mere contractors to build the project and collect fee through tariffs for 30 years. The utilities would own the land, denying power �irms the option to mortgage land to raise funds. India is densely populated and has high solar insolation, an ideal combination for using solar power in India. India is already a leader in wind power generation. In the solar energy sector, some large projects have been proposed, and a 35,000 km2 area of the Thar Desert has been set aside for solar power projects, suf�icient to generate 700 GW to 2,100 GW. Also India’s Ministry of New and Renewable Energy has released the JNNSM Phase 2 Draft Policy, by which the Government aims to install 10GW of Solar Power and of this 10 GW target, 4 GW would fall under the central scheme and the remaining 6 GW under various State speci�ic schemes. In July 2009, India unveiled a US$19 billion plan to produce 20 GW of solar power by 2020. Under the plan, the use of solar-powered equipment and applications would be made compulsory in all government buildings, as well as hospitals and hotels. On 18 November 2009, it was reported that India was ready to launch its National Solar Mission under the National Action Plan on Climate Change, with plans to generate 1,000 MW of power by 2013. The ready reckoner for engineering & allied industry

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Dry Vacuum systems chemical & pharmaceutical processes Article written by : Technical team of Everest Group

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or decades vacuum pumps are. being used for the various applications in the chemical, petro chemical & pharmaceutical processes, such as in product drying, freeze drying, solvent recovery, evaporators, dehydrators, crystallizers and for other general vacuum applications such as conveying, regeneration of molecular sieves, vacuum �iltration etc. The boom in the global market in re�ined chemicals, medicines and other products led to the increase in the use of the vacuum equipments across all the process industries. The major concern in chemical and pharma processes is to offer vacuum systems capable of handling corrosive and toxic vapors and gases. Earlier there were limited methods in the �ield

Typical Solvent Recovery System Using Dry Pumping System 220 | JANUARY 2013 | ENGINEERING REVIEW

of manufacturing which could help in reducing the waste contents but with the changing face of the world and the technological advancements industries learnt & shifted toward the advanced technology of Vacuum Pumps. Nowadays almost 75% of the Process Industries are using the vacuum pumps and allied systems in their applications. This has helped them to reduce their waste to a large extent and increased their production d2 pro�itability.

Talking of the conventional vacuum pumps, the following are the ones being used in the process industry:

● Liquid Ring Pumps/Water Ring Pumps ● Oil Sealed Pumps -..Rotary Reciprocating ● Steam Jet Ejectors. ● Water Jet Ejectors


For decades, applications demanding ultimate pressure below 1 mbar, Oil-sealed Rotary Vane Pumps were the most popular solution. All of the above (wet technology) utilize liquid media that can be Oil, Water, or Steam to generate vacuum inside the given volume or the process. During evacuation there is a carryover of the process solvent/vapor which contaminates the pumping media. The treatment of this contaminated medium is a major concern and a huge investment is required to treat it to The ready reckoner for engineering & allied industry


Photo: Single Stage Dry Screw Pump with Inlet vapor trap meet the norms of disposal set by the Pollution Control Board. Moreover, over a period of time the continuous contamination of the liquid media inside the pump leads to the corrosion & damage to the pumps internals, resulting in lower overall ef�iciency of the pump thereby affecting the process performance. This demands regular maintenance and has frequent breakdowns.


In the late 90’s, clean process requirements initiated the development of the dry vacuum pumps. In today’s date they are readily available and most of the process applications use dry pumps (EVEREST DRY SCREW VACUUM PUMPS) and dry pumping

packages (EVEREST SUPERVAC SERIES). Refer schematic diagram. The trend to replace lubricated pumps by dry pumps is now spreading over many other market segments. For the Pharmaceutical Industry, it has been quite easy to understand the bene�its of dry pumps, in terms of cost of ownership, process contamination, up-time and effective Solvent Recovery with practically zero discharge to atmosphere. Dry vacuum systems are the changing face of the technology in the world of process industries and turns out to be the ef�icient, reliable & eco-friendly for Pharmaceutical, Chemical & Petrochemical Industries. The technology offers many advantages over the traditional technology of Liquid media pumps and �inds its application in various process

related industries such as Distillation, Drying, Evaporation, Crystallization, Deodorization, Filtration & for general purpose vacuum. The major advantage of the Dry Screw Vacuum pumps is that they do not require any �luid (oil/water/ steam) inside them for the vacuum generation. This eliminates the contamination of the process vapours and provides better recovery of the vapours thus reducing the ef�luent generation. The dry pumps use fewer utilities thus cutting the operational cost as compared to other traditional vacuum pumps. The vacuum levels are highly precise and the volumetric displacements are consistent giving full ef�iciency in the process. A case study has been made by the team of EVEREST engineers in one of the leading pharmaceutical concern in India. The following bene�its were observed where conventional steam jet ejector systems were replaced by Everest Dry Pump combination.

Following are the benefits of Dry Screw Vacuum Pump over Steam jet Ejector System:

● Better Vacuum Level achieved. ● Distillation temperature is reduced. ● Steam consumption NIL, thereby reducing load on boiler, plant & allied equipments. ● Load on cooling tower reduced drastically. ● Load on Ef�luent Treatment Plant is reduced. ● Reduced speci�ic energy consumption by 30 - 35%. ● Zero start up time with option of quick start and stop. ● No vacuum �luctuation during feeding & circulation in the process. ● No loss of Solvent i.e. 100% solvent recovery enabled. ● Maintenance cost minimised as the dry pump offers robust solutions.

A study made by the team from Everest on the replacement of the Steam Jet Ejector system by Everest dry pumping system at

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Speaking about maintenance part, the maintenance of these dry systems is quite easy as compared to the traditional pumps as there is no �luid present, so frequent checks are not required to look for the contamination. These pumps only use oil for lubrication of gears which need to be checked over the prescribed period of time depending upon the properties of the lube oil used. Moreover as there are no rubbing parts inside the pump there is not much to be taken care of inside the pump, & hence the pump provides a trouble free working over years.


one of the leading Pharmaceutical Company is as tabulated below:

The above chart shows the bene�its gained by the replacement of the steam jet ejector setup with the Dry Screw Vacuum Pump technology. Though the initial investment with EVEREST Dry pumps is high but the operational cost is comparatively less resulting in shortest payback of 222 | JANUARY 2013 | ENGINEERING REVIEW

the machine and leading to various other bene�its such as less utilities, less waste disposal, better recovery of the product, thereby maintaining the quality of the product, reducing process temperatures etc. All these things lead to the eco friendly systems and highly ef�icient process results.


Since the pumps do not have any rubbing parts inside so there is no possibility of any breakdown. Moreover EVEREST is providing the pump internals with PFA coating of 60/i in order to enable the pump to handle corrosive and harsh gases passing through as a carry over to the process. Thus in case of any condensation taking place inside the pump there will not be any problem of cavitation, leading to longer life of the pump and trouble free operation even in mildly corrosive applications. For highly corrosive vapours, additional safety and better maintenance is required and team of Engineers at EVEREST have a solution for that as well. Similarly in case of applications where the gases have low ignition points, special accessories are provided with the pump in order to avoid any accidents in the plants. Everest has so for supplied 100’s of pump systems for a variety of applications and thus has good experience of the problems that can arise as well as the best possible solution for the same.

We are now confident in saying that: “Everest Does not only Provide Blower’s; Booster’s and Pump’s We Provide Complete Solutions “.

For more information Web: The ready reckoner for engineering & allied industry


Sparsh becomes the first India-based company to launch DVR series based on texas instruments’ New DaVinci™ DM8107

Sparsh promotes “Made in India” at Security China, Beijing



parsh®, the �irst India-based company to manufacture CCTV cameras and a leading supplier of electronic video surveillance products and solutions, launched “Made in India” series of DVRs developed with technology partner Texas Instruments Incorporated (TI) at the World’s largest Security Exhibition held in Beijing, China. In yet another landmark, Sparsh became the �irst company in India to launch 4,8 and 16 channel designed and developed DVRs based on TI’s DaVinci DM8107, which received a lot of appreciation

from the visitors. Mr. Sanjeev Sehgal, MD, Sparsh stated “We are very excited about our relationship with TI and getting the next generation video surveillance products to the market. We believe the �lexibility and scalability of the DaVinci DM8107 technology will allow us to bring more advanced surveillance products and solutions developed in India by us which would offer best in class security at affordable prices. We’re expanding our products and solutions to better address the next generation video surveillance needs.” “The DM8107 video compression engine can achieve more than 200 percent better compression ef�iciency to market standard, bringing unparalleled video quality to Sparsh’s customers,” ,” said Sean Murphy. Director of Marketing for TI’s Video Security Business “With this compression ef�iciency, half the storage is required to save data and half the bandwidth is needed to transfer the data without spoiling the quality of the image, which is essential when putting a video security system in place.” Sparsh’s Product Manager, Sumit Behl explained the high end features of the series which makes it suitable for any security need. Sparsh DVR series offers intelligent and smart functions, ideal for securing locations such as airports, railway stations, of�ices, hotels or any city at large. These intuitive and dependable DVRs offer best-in-class image quality and Continue on page no.228

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Continued from page no.226 pioneer with proven track record of a lot of �irsts, technical advancement, corporate maturity, and achievements. We are honored to have been recognized by the following awards and recognitions:

4, 8 and 16 channel digital video recorder based on TI’s DM8107 professional monitoring capabilities.

Key Features:

s Full 960H and Full D1 support s 100/200/400 FPS real time recording s TI’s DaVinci DM8107 s 3G-Wi-Fi Support s Motion detection & Audio detection s Heart beat keep alive mechanism s Internal SD card and NAS storage support s External sensor integration s HDMI output s HDD redundancy s Smart search

Application Areas

s s s s s s s

Airports Railway stations City surveillance Transportation facilities Commercial buildings Education facilities Financial institutes

With such numerous endeavors Sparsh has established itself as one of most trusted brand in electronic security products and solutions in India. With further international participation Sparsh is putting India on a global footprint powered by its “Made in India” state-of-the-art security products and solutions.

About Sparsh:

Sparsh®, an ISO 9001-2008 company, has revolutionized the Indian Electronic security market by being 228 | JANUARY 2013 | ENGINEERING REVIEW

India’s 1st�irm to manufacture CCTV cameras in India and focus on indigenous design and manufacture of technologically advanced electronic security devices. With an experience of a decade, SPARSH has solidi�ied its leadership position in the �ield of security products and solutions by developing and manufacturing cutting-edge security systems. Sparsh products leverage technologically advanced CCTV camera technology, widely appreciated by the clients for its unmatched security related features & uses image processing technology which provides scalable high performance imaging at a low cost. Customers appreciate the advanced security features and customization Sparsh®’ products offer and local service that maximize equipment uptime which has been the major reason behind having done installations at major Airports like Jammu, Amritsar, Goa and ATC tower Delhi, major Banks like PNB, SBI, UCO, Karnataka, Indian, Karur Vysya, etc, major government bodies like Archaeological Survey of India, PDIL, Ordnance Factory, CRPF, Army, Police, etc, major corporate like HCL, Hero Honda, Emami, Avantha, Ghadi, Luxor, Dainik Jagran, etc , major institutes like JNU, Lovely Professional, FDDI, Hillgrove, etc and installations in many other industry verticals.






s “Technology Evangelist of the Year-2012” by a pioneer IT magazine VARIndia. s Listed Among the “Top 100 Most Trusted Companies in India” by VARIndia. ET Now-IndiaMART Award “Leaders of Tomorrow, 2010” in Electrical and Electronics category. Winning three times in a row “Best Security System of the Year 2009, 2010 & 2011” by world’s largest electronics magazine Electronics for You (EFY). Elcina- Dun & Bradstreet Award for Entrepreneurial Excellence, 2009. Frost & Sullivan Award for “Entrepreneurial Company of the Year 2007- CCTV” award

About the Texas Instruments Developer Network

Sparsh is a member of the TI Developer Network, a community of respected, well-established companies offering products and services based on TI analog and digital technology. The Network provides a broad range of end-equipment solutions; embedded software, engineering services and development tools that help customers accelerate innovation to make the world smarter, healthier, safer, greener. For more information, contact: sparsh Securitech

SPARSH® is Indian security industry The ready reckoner for engineering & allied industry


Institution of Fire Engineers (IFE) : An apodictic voice of industry engineering profession. The Graduateship Examination conducted by the Institution is recognized by the Ministry of HRD, Department of Education, Government of India for appointment to the post of Divisional Of�icer/ Asst. Div. Of�icer and below in the Central and State Govts./ Public Sectors and Local Bodies & Industries Fire Services.

The main objectives of the Institution in force are as under:-



Q. Please elaborate about IFE (I) & its core functions? The Institution of Fire Engineers (India) was established on the recommendations of the standing Fire Advisory Council constituted by the Chief of Fire Services in India and headed by DG, NDRF & CD, Ministry of Home Affairs, Govt. of India. The Institution was founded in the year of 1973 as a premier nongovernment organization (NGO) and professional body registered under the societies act, 1860 as resolved in one of the meeting held under the chairmanship of the then Dy. Home Minister, Ministry of Home Affairs, Govt. of India Sh. B.N. Datar. IFE (I) is dedicated to the cause of �ire

s Conduct graduateship examination, which is recognized by Government of India s Publishing quarterly technical journal “Fire Engineer” s To associate with all organizations engaged in Fire Protection work and making signi�icant contribution in promoting Fire Engineering Services s Organizing Conferences and Seminars and Training Workshop as well as Exhibitions s Rendering technical advice on any speci�ic problem related to Fire & Life Safety. s To take-up assignments to evaluate Fire Risks to carry out Fire Safety Audit and to provide Fire Protection Scheme of Industries and Commercial Complexes. s To conduct training programme for various levels and to conduct coaching classes, to prepare students for various Fire Service Examinations s To ful�ill the objective of propagating & spreading the knowledge & education in the �ield of Fire Sciences, the Institution organizes International and National Continue on page no.232

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Continued from page no.230 Conferences, Seminars & Workshops.

Q. What ways IFE (I) assist to promote Indian Fire Industry? IFE (I) has indulged in various activities to promote the industry multidimensional way. It varies from technical support to testing facility to certi�ication assistance to generating business prospects. We have been actively involved for setting up new BIS standards for the �ire industry. Also we organize conference “Fire India” which is also assisted by exhibition which presents global business opportunities. We also serve industry through consultancy, audits and so on. Q. How IFE (I) has been contributing for setting new standard with BIS & other bodies? IFE (I) is represented on various committees & sectional committees of BIS on �ire and life safety and �ire�ighting. IFE (I) has MOU with NFPA (USA) & thus exchange of knowledge on �ire engineering sciences is a regular feature. Moreover IFE (I) has well stocked library where all the literature books & periodicals are available for the study. IFE (I) contributes through its panel of experts & the knowledge gained by deliberations, study & brain storming sessions for the cause of incorporation in standard.

Q. Have your Institution carried out any event recently to aware industry about the significance of the changing standard? Yes, IFE (I) recently organized one day seminar in Mumbai where �ire engineering industry representatives participated in a big way. The information was disseminated regarding the signi�icance of changing standard. Fire Protection Association also participated in the same. Q.Can you please elaborate your testing lab facility? The Fire Test and Research Laboratory is a unit of Institution of Fire Engineers (India). The Laboratory is operational since November 2005. Fire Test & Research Laboratory is the �irst NABL Accreditation for Laboratory for Fire Rating Tests. The laboratory customers are Fire Safety Equipment Manufacturers, Research and Development Laboratories, Regulatory Authorities which use Laboratory services for third party testing and certi�ication. The Laboratory activities consist of chemical and mechanical testing within laboratory premises


as well as �ield �ire testing. Our quality policy is based on Reliability, Integrity, Impartiality, Ef�iciency, Service in Time, Con�identiality and Technical Accuracy.

Q. What ways you can help international companies to establish in India? International �ire protection engineering companies regularly contact IFE (I) for setting up industry/ manufacturing units and also promotion of their products viz. �ire �ighting systems & �ire extinguishing medias. IFE (I) provides them necessary inputs in this regards. Q. What is the current growth rate and what is the expectation for the next year? Though the �ire industry in India has been an unorganized sector hence no consolidated data is available but IFE (I) is striving to organize Indian �ire industry through directory & other activities. But as a rough estimation the growth is 10-15% and is expected to reach 15-20% next year. Q. Indian Fire Industry has graduated itself very prominently in terms of quality and technical advancement but what could be more areas of improvement to bring it on international standards? There is a need for establishment for R&D facility with latest gadgets & infrastructure to evaluate the studies with regard to �ire incidents so that bene�it is drawn on the analysis arrived at to bring the standard of �ire protection engineering to the international level both active & passive �ire protection.

Q. How your new project of launching Fire Directory will help the industry? The directory will help industry to reach buyer segments and promote brands more emphatically. The directory will not only attract domestic but also international avenues in longer term. This will also help to represent the entire industry as organized sector to attract more ventures & investment from the international market.

Q. Would you like to give any message to the readers & industry? Fire industry unlike other sectors has more social responsibility as quality of product is directly proportional to the cost of life. Lets all strive to produce quality & technically superior equipments & impart knowledge and awareness for �ire and life safety among masses to serve the humanity. The ready reckoner for engineering & allied industry

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India Tools & Instruments Co.


ITI-1600 High-precision Digital ultrasonic thickness gage

India Tools & Instruments Co.


Model MCL 400 RMS

Taurus Powertronics Pvt. Ltd.


New Model: Testo 875i

Testo India


Pendant control station

Kumbhojkar Plastic Moulders


Peristaltic Hose Pump (With Imported Hose)

Moniba Anand Electricals Pvt. Ltd.


Krishiv India.


Speedfam (India) Pvt. Ltd.


Vibrocone™ Crusher



Welding Oscillator Digital Oscillator

Arcraft Plasma Equipments (I) Pvt. Ltd .


AXPERT-HIVERT series medium voltage variable frequency drive

Infrared thermometers with tft color lcd display & camera function

Pressure Relief / Safety valve “KRISHIV“ offer pressure relief valves

Speedfam double sided lapping & polishing machine Speedfam monochromatic checklite


Page no.

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AXPERT-HIVERT series medium voltage variable frequency drive


● Multilevel PWM control for friendly output. ● Built-in Multipulse converter meets IEEE 519-1992 Standard for harmonics. ● Variable torque/constant torque/vector control. ● PC software tools for setup and maintenance. ● Draw out cell structure-Series Conservation. ● No need of output �ilter for any cable length. ● Optional Manual/Auto bypass system. ● Networking through RS 485, Modbus, Pro�ibus & Ethernet. ● AXPERT HIVERT inverter is provided with complete self-diagnosis capability to monitor the system status on line. ● In event of any fault, the inverter will be automatically activated to take protective actions and save the time, cause and location of the fault. ● Instantaneous Power Loss Tracing Function.

/ Right direction as an oscillatory movement over the weld surface. Highly regulated oscillatory movement of an arc ensures controlled spread of Arc Heat over the weld surface resulting uniform �low of weld pool due to smooth, uniform, stable & precise movement of Welding torch Convenience, especially when a �iller is used in the weld pool, is the main purpose of the oscillator which ensure uniform spread of weld globules. Controlled & regulated spread of Arc heat & Weld globules has a very distinctive advantage of excellent penetration at maximum Heat Utility ef�iciency. This also ensures reduction in the Heat Affected Zone, High Weld Metal deposit ef�iciency, Highly uniform Weld beads. Suitable for processes convenient to automate like TIG, MIG, SAW, FCAW, Plasma Welding or Cladding processes like PTA or Powder Plasma Welding

Key Advantages are,

Available:- 3.3kV / 275kVA to 11kV / 14.5MVA

For more information Amtech Electronics (India) Ltd., E-6, GIDC Electronics Zone, Gandhinagar-382028. (Gujarat-India), E-mail- Tele: +91-79-23289101, 23289102, 23289103 Fax: +91-79-23289111.


Welding Oscillator Digital Oscillator

eld Arc Weaver, commonly know as Welding Oscillator is the mechanism to simulate the condition of Weld Arc Weaving as done by hand by an expert welder. The motorized mechanism weaves the welding arc through Left

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● Signi�icant improvement in Welding or Cladding process ● Increased productivity with ease of operation for Multipass welding ● Overall improvement in sidewall fusion & undercut. ● High weld quality, uniformity & appearance.


Stroke width : 0 – 25mm in steps of 0.2mm Stroke speed : 0 – 3000 mm per minute in steps of 5mm Number of Strokes : 0 – 60 per minute in steps of 0.1 stroke Left dwell : 0 – 9.9 seconds in steps of 0.1 seconds Right dwell : 0 – 9.9 seconds in steps of 0.1 seconds


● ● ● ●

Very precise Ball screw mechanism. Fully enclosed to avoid ingress of �ine particles, heat etc. Stepper motor driven for easy controllability. Stroke width of 0 to 50mm (Higher width available on request) ● Full digital control with easy programmability of parameters. For more information Arcraft Plasma Equipments ( I ) Pvt Ltd ENGINEERING REVIEW | JANUARY 2013 | 243

PRODUCT SHOWCASE 124 Diamond Industrial Estate , Ketkipada , Dahisar ( East ) Mumbai 400068, India . Tel - 00 91 22 - 28963247 , 28965890 , 28965745 Fax - 00 91 22 - 28966418 Sales Handphone - 00 91 - 9820684001 E-mail : Web :

Advanced pH Meter for research grade applications


Pressure Relief / Safety valve “KRISHIV“ offer pressure relief valves


rishiv India is Concern of JAGDISH ENGINEERING WORKS Manufacturer of Metering Pump .“ KRISHIV ” offer Pressure Safety / Relief Valves range from ¼” to 2” & Pressure setting up to 200 Kg/Cm2. These Valves


ole-Parmer offers Oakton pH 2700 – a GLPcompliant meter with pH measurement capability along with temperature. The pH range varies from -2.000 to 20.000 pH with accuracy of ±0.002 pH. The meter offers a new compact design that is over 40% smaller than other benchtop meters. The large display is easy to read even at a distance and features stability indication. All measurements include temperature display. The meter includes auto-buffer recognition for both USA and NIST pH buffer sets with upto 5 points calibration. A calibration due alarm function means no more out-dated calibrations. The water-resistant membrane keypad offers password protection for both set-up and calibration. Multiple pH slopes and offset display enables quick, easy electrode diagnosis. The electrode holder can be mounted on either side of the meter. The convenient pullout, quick-reference card keeps keypad functions at your �ingertips. By utilizing the RS-232 output; you can print required data or a calibration report with click of a button in the desired viewable format. Calibration report provides detailed information on the most recent calibration. It includes date & time, calibration standard(s), offset, temperature, number of days calibration is over-due, slope information, etc. For more information, Cole-Parmer Application Specialists: Cole-Parmer India Pvt. Ltd. 403-404, B-Wing, Delphi, Hiranandani Business Park, Powai Mumbai - 400 076, India Tel: +91-22-67162209 / 2222 Fax: +91-22-67162211 E-mail :


are normally used in all Industries Like Fertilizer Plants , Gas Industries , Pressurize Reaction Vessel & are also require for all Positive Displacement pumps, Wherever online pressure equipment’s are functioning & to avoid the overloading on the motor or due to choke up on discharge, these pressure relief valves are usually being used to release the excess pressure. Also require for close reaction vessels, when it goes beyond setup pressure there by releasing increased pressure in the vessel. Our valves are usable for steam release for which we are offering two seating i.e. silicon & S.S. in this valve. Here in case silicon seating is damaged or spoiled then valve also will give satisfactory performance since there is second seating i.e. stainless steel lapping seat is used as a continues seating , thereby valve is working in full capacity. We are also offering stellieted seating for the release of steam with particles. Krishiv also Offers Chemical Transfer Centrifugal, Electronic Diaphragm Metering Pump , PTFE Coating. For more information Krishiv India. (Vrutank Shah.) Goregaon- East , Mumbai:- 400063 Tel:- 09819292155 / 09322226290. E-mail :- Website :

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Pendant control station

umbhojkar Plastic Moulders are pioneer in the �ield of Industrial Engineering Plastics& famous for their product Festooning Systems / Cable CarrierAssembly [CCA] has 80 different types been developed to facilitate all types of cables and to suit all types of tracks. We now introduce 8-Way Pendant Control Station in our existing range of 2-Way; 4-Way 2Way + Emergency & 10 Way Pendant Control Station for cranes and hoists installed in various industries. For all pendants the body available in attractive color is injection moulded from Plastic Reinforced material, which prevents operator from hazardous electric shocks. The product exclusively designed has no sharp edges for easy handling. The elements used are Standard Switches S1 (NO) & S1 (NC) that are alternately mounted. MECHANICAL INTERLOCK has been incorporated in assembly so at a time only one switch will be activated while other gets locked. A delay arrangement is also done in assembly so as to have DOUBLE SPEED in operation. An EMERGENCY STOP / On-Off Key Actuator is standard switch that adds a safety measure. The use of rubber lining prevents it from dust and water splashes. The cable cone can accommodate cables of different diameter’s. A hook is provided to hang the pendant with metal chain thus avoiding the tension on the electric cable. For more information Kumbhojkar Plastic Moulders 129, Narayan Peth, Pune 411 030 Ph. 020- 24450055 Fax 020- 24480544

Peristaltic Hose Pump (With Imported Hose) SPECIFICATION : Capacity Range : 20LPHto30000LPH Head Range: 40.0 Mtrs. & more Electrical Motor : O.5 to 10 HP Sealing Arrangement: No Seal

FLOW – Pulsation M.O.C.


Hose tube suitable for liquid, end connector in SS-316/PP/ UHNW Titanium Outer casing C.I / Aluminum Roller SS316 with bearing bush/ Ball Bearing.

Salient features

Dry run, self priming. Seal less, Good for Slurry. Only hose tube in contact with liquid. Can handle solids. Reversible rotation to clean pipe line & pump.


To transfer Liquids / Paste / Viscous Liquids / Abrasive & Corrosive Liquids. In almost all types of industries.

Liquid handled

Fruit Salads, Dairy Products, Paper Pulp, Animal Feeds, Bentonite, Lime wash, Manure Slurry, Rubber Latex and Many more For more information Moniba Anand Electricals Pvt. Ltd. (MUMBAI) 5, Saphire Building, Gr. Floor, Tirupati Park, Sativalli Road, Village Waliv, Tal. Vasai (E), Opp. To Professional Couriers, Dist- Thane- 401 208, State- Maharashtra. INDIA | Tel.: 0250-6450425/26/27 Rakesh Engineer : +91 93230 13491 | Email:



he next generation of crushing technology: The Vibrocone™ crusher is the next generation of crushing technology combining the best of conventional crushing and grinding principles. The crusher can handle even the �irst stages of grinding. The whole comminution process is made much more streamlined, with great savings in investment, workload, energy and consequently, money. Material is crushed by means of multiple compressions and a large top size in the feed is accepted just as with a traditional cone crusher. Material is crushed in a thick material bed and exposed to optimal controlled force that can be adjusted, as in high pressure grinding rolls. Material is crushed against material, as in AG and SAG mills.

Features of the Vibrocone™ Crusher:

● ● ● ●

Upgrading for downstream ef�iciency Safer handling of uncrushable objects Supervised and regulated by automation Well recognized

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● Once operating conditions are set up for the speci�ic application the Vibrocone doesn’t normally require any human involvement. Crusher performance and power input as well as wear compensation is supervised and regulated around the clock by the automation. The warning system monitors the crusher and alert the operator there is a malfunction. For example, if an uncrushable object is stuck because it couldn’t pass the warning system monitor will alert the operator. In addition there is a historical database with all operating parameters in the control system to assist with performance analysis ● Maintenance procedures from conventional cone crushers are well recognized. For wear liner change, the regulating ring is hydraulically unscrewed and the main shaft is lifted out. In support of achieving Sandvik’s safety ambition, Vibrocone has no backing material for �ixing the mantle and concave. Additionally, all crushed material areas are separated from any mechanical parts of the machine and the crusher product is discharged via an outlet chute of just 500 x 500 mm. There is also a 360˚ access to the crushing chamber and dust seal from six hatches.


● Easy maintenance

The Vibrocone™ crusher combines the best of conventional crushing and grinding principles to produce an unprecedented amount of �inely crushed product. The particles are not only crushed between the liner surfaces in the crushing chamber; they are also to a higher degree crushed by each other in a high pressure inter-particle crushing action. The result is a crusher moving into the grinding performance area. This breakthrough gives Vibrocone extraordinary potential. With a P50=3mm (1/8”) mill feed, the grinding phase works much more ef�iciently.

Highlights of the Vibrocone™ crusher

● Safety has always been one of the cornerstones in Sandvik’s values. While developing Vibrocone™, a number of issues were worked on to achieve Sandvik’s ambition of providing the safest equipment on the market ● The Vibrocone design makes it possible to automatically detect and safely react to uncrushable objects like tramp metal. As uncrushable objects restrict the movement of the mantle the power input will drop immediately. Crushing will continue until the object has passed through. If by chance it gets stuck inside due to its size, the feed will stop. Operation can continue gently at reduced speed and force in order to empty the crushing chamber of material, so that the unwanted object can easily be removed 248 | JANUARY 2013 | ENGINEERING REVIEW

Changing the rules for comminution crushers are typically ten times more energy ef�icient than mills. By producing a much �iner mill feed, Vibrocone also handles the �irst stages of grinding – in a dry process. Off-loading work from the downstream milling process saves up to 30% energy. Meeting increases in energy prices and environmental regulations greatly bene�iting the bottom line.

For a better future

The Vibrocone crusher is in operation at copper, gold and iron ore mine sites, and provides highly increased ef�iciency in the comminution process. Substantial amounts of energy are saved which opens the door to a better future in mining. For more information, E-mail:


Speedfam double sided lapping & polishing machine Speedfam monochromatic checklite

peedfam offers a complete solution on Flat Surface Lapping & Polishing with its product that ranges from Lapping & Polishing Machines, Consumables to Measuring instruments. Speedfam Lapping & Polishing Machine array is adorned with Double Sided, Single Sided & Free Abrasive

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Machines and is now extending its horizon to Flat Honing Technology using Diamond or CBN to suit variety of Applications where Flatness and Surface Finish are decisive. These Machines are engineered to lap surface, �lat to the extent that can be measured in light bands. Speedfam machines are customized to suit customer’s speci�ic requirements. Beside machines, Speedfam serves with an entire line of Lapping & Polishing Accessories & Consumable required in Machining process. This range comprises of Lapping Plate, Conditioning Rings, Lapping Abrasives, Lapping Oil, Lapping Paste, Diamond Paste, Diamond Powder Polishing Pads, Polishing Compounds, Hand Lapping Plate, Carriers etc.,. These consumable governs the �inished quality of products as well as their lapping & polishing ef�iciency and are highly recommended to ensure even stock removal, �inished surface, increased production at reduced cost of Machining. Range of Speedfam Measuring Instruments consists of Monochromatic Checklite, Optical Flat, Check Flat, and Straight Edge & Filler Gauge. These instruments are used to check the Flatness pre de�ined prior to the Lapping & Polishing operation required to meet the process requirement. For more information Speedfam (India) Pvt. Ltd. A subsidiary of Speedfam Japan B 87, Addl. MIDC, Anand Nagar, Ambernath (East) - 421 506. District Thane., Maharashtra. Tel : 0251- 2620403 Fax : 0251- 2620406 Email : Web :


3. Multi function Clamp testers( AC/DC) 4. Clamp testers for high voltage circuit. 5. Harmonic clamp testers 6. Harmonic tester 7. Power recorder 8. Pocket type digital multi meters 9. Analog insulation resistance tester 10. Digital Insulation resistance tester 11. Low voltage detectors 12. Clamp earth testers

Overview of MULTI brand clamp AC leakage current clamps: Multi AC leakage clamp meters models are available in various current ranges starting from 2 mA to 1000A. The minimum resolution is as low as 1µA . Multi Ac leakage Clamp meter jaw size starts from 18mm to 108mm.These clamp meters are available in very compact size. Features like data hold, low battery , over load indication, maximum hold, fast sampling speed, memory , printer output, DC m V analog output are available. Model MCL 400 RMS , A True RMS clamp tester, having high sampling speed of 20 times/ sec, MAX HOLD function can be used for measurement of the instantaneous tripping leakage current of the circuit breaker is available in wide current measuring range from 40 m A to 400 A , resolution on the lower range being 0.01 m A

For more information Taurus Powertronics Pvt. Ltd. No.26, Mahadimane,12th Main, I Blk, Rajajinagar, Bangalore - 560 010. Tel : + 91 - 80-23012301 Fax : + 91- 80-23327736 Web: E-mail:

Model MCL 400 RMS

aurus Powertronics Pvt. Ltd. is pleased to introduce in the Indian market Precision test instruments manufactured by MULTI measuring Instruments Co. LtdJapan. MULTI has expertise in development and production of precision split core type current sensors measuring instruments and monitoring systems.

Measuring instruments from multi can be classi�ied into various categories such as: 1. AC Leakage current clamp testers 2. AC Clamp testers The ready reckoner for engineering & allied industry



he Testo 875i is the next step up from the entry level 875 model. The most outstanding feature is much higher sensitivity than the standard 875 model. A built in visual camera and a high speed 33Hz refresh rate is also included. In real terms this adds some stunning performance to the


PRODUCT SHOWCASE Testo 875i. 50mk of sensitivity (0.05°C) is a class leading marvel. In fact we have never before seen a 160×120 class detector delivered with this research grade sensitivity. The result is stunningly sharp and crisp imagery where even the most minute temperature difference is evident. The visual camera is also a bonus and certainly takes the hassle out of using a separate digital camera. When you squeeze the trigger the camera will simultaneously capture both thermal and visual. The visual is crisp and clear for an entry level model. Finally an upgrade to real time 33Hz performance is an awesome addition. This simply enhances the crisp image performance providing no lag or frame shudder as you quickly pan around. Once you’ve enjoyed the responsiveness of a high speed frame rate it is pretty dif�icult to go back to 9Hz. The real icing on the cake is the price. We will get all the above mentioned features in such low price is unbelievable. For more information



ataMan 200 adds Ethernet connectivity and liquid lens technology to the world’s smallest high performance �ixedmount reader. These new features enable faster communication speed, easier integration with factory controls, and software-driven autofocus for easy, hands-free setup. This is the �irst image-based reader to feature full Ethernet connectivity in a package the size of a matchbox. It is also the �irst to offer liquid lens technology, which makes it ideal for applications that have variable focus requirements. The Ethernet connectivity gives DataMan 200 users the advantage of real-time data and image transfer, and easier integration with plant controllers and information networks.

DataMan 200 Series Readers:

The DataMan 200 series offers industry-leading reading performance in a small product size with Ethernet connectivity for real-time tracking, image download, data 250 | JANUARY 2013 | ENGINEERING REVIEW

transfer and effortless plant integration.


● World’s �irst introduction of liquid lens technology provides rapid hands-free, software-driven autofocus with no moving parts and increased depth of �ield �lexibility ● Separate models available with three-position adjustable lens, liquid lens, and C-mount lens ● Integrated lighting and laser aiming ● Liquid lens technology, an optional feature of the DataMan 200, provides greater focal range, ease of setup, and faster response time. This unique technology adjusts the camera’s focus by applying an electrical charge to �luid within the lens.

With liquid lens technology, autofocus is achieved with a single software command. The lens also provides exceptional depth of �ield and �ield of view range, and, because it has no moving parts to malfunction or break down with use, the system is extremely rugged and resistant to shock, vibration and wear. Setup is simpli�ied with the use of two laser aimers. The laser targets are easily seen through the entire depth of �ield, enabling operators to quickly position the code to the reader. Like the DataMan 100, the new system features an easy-to-use interface for setting up the application, and supports a wide range of 1D and 2D codes including UPC/ EAN/JAN, Code 39, Code 128, Code 93, Interleaved 2 of 5, Data Matrix, QR Code, and micro QR Code. For more information Cognex Sensors India Pvt.Ltd Regus Level 6, Pentagon Towers P II, Magarphatta City, Hadapsar, Pune-411 028, India Tel: +91-20 40147440

Automations for Cantilever Sliding Gates.

● Cantilevered sliding gates available for a span of up to 30msuitable for securing commercial, industrial & public utilities. ● The advantage of using cantilevered gates is that they have noground track or foundation in the roadway hence vehicle does notexperience any bumps. ● Ideal for road surfaces which are uneven or

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greater degree of accuracy than a plain spirit level. They are used to level the foundations, or beds, of machines to ensure the machine can output workpieces to the accuracy prebuilt in the machine.

Infrared thermometers with tft color lcd display & camera function


sloping. ● Gate is not prone to getting blocked by leaves or dirt hencereduced maintenance. ● Smooth, quiet operation due to no supports at the bottom of thegate. ● Telescopic sliding gates are ideal for sites wheremaximum opening is required and back run isrestricted due to structural conditions. For more inforamtion Gandhi Automations Pvt Ltd Tel: 022- 66720200/66720300(200 lines) or E-mail us at

High precision electronic level FEATURES : 0.01 mm/m 0.01%




● Magnetic base securely attaches gauge to any metal surface ● Large LCD display reads upright at any angle. ● With backlight and Buzzer. ● Degree/slope conversion. ● Absolute measurement and reference measurement conversion. ● Measure data holding. ● Degree, mm/m and slope conversion. ● With data storage capabilities. ● With data output. ● Auto Power Off. ● Battery Type: 3V CR2032X3.

Application :

An engineer’s precision level permits leveling items to a The ready reckoner for engineering & allied industry

1. 2.2’’ TFT 320*240 pixels Color LCD display 2. Camera 640*480 pixels 3. Images (JPEG) & Video (3GP) 4. Micro SD memory card 5. Dual laser targeting 6. Date/time setup controls 7. Auto Power Off 8. High Temperature 9. Max, Min, DIF, AVG record 10. High and low alarm 11. Adjustable emissivity & Trigger lock Model ITI – 200 12. Type K input 13. USB interface 14. Readings memories 15. Humidity & Air temperature 16. Dewpiont & Wet bulb temperature 17. Language selection: English, French, German, Spaish

Speci�ication :

IR Temp. Range :-50 to 2200 deg c / -58 to 1832 Response Time :Less than 300ms Resolution 0.1°up 1000°, 1°over 1000° Basic Accuracy(IR) : ±1.0% of the reading Optical Resolution : 50:1 Distance to Spot Size Emissivity Adjustable : 0.10~1.0 Adjustable Basic Accuracy(IR) : ±1.0% of the reading Micro SD memory card : Max. support 8GB Weight : 494g

Accessoires :

3.7V Li Battery, Type K Temp. probe, USB cable, Carrying case with Calibration Certi�icate .


ITI-1600 High-precision Digital ultrasonic thickness gage

ltrasonic Thickness Gauges are designed to improve safety and ensure reliability of material subject to corrosion or erosion. Corrosion gauges with their dualelement transducers are the primary inspection tool used to measure the remaining walls of


PRODUCT SHOWCASE components such as pipelines, pressure vessels, storage tanks, and numerous other applications.. Precision gauges use single-element transducers to provide the thinnest range and highest degree of accuracy possible. Speci�ications:

Measuring Range

0.65 mm – 400mm (upto 500mm) (in steel)


mm/inch (selectable)

Sound Velocity

1000~9999 m/s


0.01mm/0.1mm or 0.001/0.01” selectable


Upto 2000 Groups (up to 99 Values for each �ile)


± ( 0.5%Thickness+0.04 ) mm


preset upper and lower limit

Work voltage

3V( 2 AA alkaline battaries)

Work mode

Single point and scan

Interface port


Dimensions Weight


136 x 72 x 20mm

Continuous working period

177 g

3.5 digit LCD with EL backlight

280 hours (with EL backlight off)

Common applications include metals and a variety of nonmetals (i.e. glass, ceramic, plastic, etc.).

Standard Delivery:

Main Unit,, TWO test Probes, Data Cable, Software, Coupling oil, Battery, Operation Manual, Carrying case. & Calibration Certir�icate Tracable to NPL-DELHI For more inforamtion India Tools & Instruments co Tel: 23428862 / 9819345050 E-mail:



he CDS6U & CDS6UTS Disconnect & test Terminal Block is used for measuring, control and regulatory circuits. They provide a clear functional advantage for the devices having the utility instruments and associated transformers. Separate testing points facilitate insertion of test probes. Disconnection is achieved by the means of a slide link operated with a Screw Driver. In CDS6U/ TS, the insulated test point screw system is integrated.


Terminal Pitch :- 8mm Connection Possibility :- 1.5 – 6 Rated Voltage :- 800V 252 | JANUARY 2013 | ENGINEERING REVIEW

Rated Current :- 41 A

These Terminal Blocks are preferred for the connections that involve safety requirements of the Electrical Supply Industry (ESI) Standards, British CEGB regulations and NTPC Applications. For more inforamtion CONNECTWELL INDUSTRIES PVT. LTD. D-7, Phase 2, M.I.D.C., Dombivli - 421 204, India Tel.: +91 251 3980 600, 3980 800; Fax: +91 251 3980 700 email: website :



he Flexible Corrugated Conduits are made up of high quality materials, they have extremely small bending radius. These Conduits offer good impact resistance and come with added bene�its like being UV Resistant, Halogen Free, Acid Proof and Flame Retardant in Nature.


Available Materials :Polyamide 6, Polyethylene, Polypropylene, Galvanized Steel & PVC Coated Galvanized Steel.

Temperature Range :- For Polyamide 6 -40 o Cto +105oC Continuous, +150oC Short Term :- For Polypropylene -40oC to +135oC Continuous, +150oC Short Termt :- For Polyethylene 15oC to +60oC Continuous

Resistant :- Polyamide 6 – Alcohol, Benzol, Greases, Mineral Oil, Diesel Fuel, Sea Water, Petrol etc. :- Polyethylene – Acid, Sea Water, Ammonia, etc. Protection Class :- IP 67 & IP 68

Application :

These Conduits �ind their applications in Machine Tool, Industrial Machinery, Chemical Machinery, Ship and Train Building, Switch Cabinet, Movable Machine Parts etc. For more inforamtion CONTROLWELL INDIA PVT. LTD. C-203, Prithvi Park, Plot No. 4,5 & 6, Sector 30, Sanpada, Navi Mumbai 400 705. (INDIA) Tel.: +91 22 2775 6293Fax: +91 22 2775 8767 Email:, Website: The ready reckoner for engineering & allied industry


IN SIDE Information on latest projects in India



Project Category





















The ready reckoner for engineering & allied industry


Tel : 011-26742920/ 940/ 960, Fax : 011-26742462, M: 9650309954



lans construction of new administrative building for chemical and electrical department LE college at Morbi. Completion period: 15 months. Location: Morbi, Gujarat Roads and Buildings Dept, Government of Gujarat National Sub Division, Arul Udaisil Road, P.W.D. Building, Morbi, Gujarat. Tel: 02822-240099


lans to construct auditorium building (phase-II) in multi art culture centre (Kala Parisar) at Kurukshetra. Consultancy bids would be �inalised in a month. Location: Kurukshetra, Haryana Government of Haryana Jay Prakash Kambol, Executive Engineer, Provincial Division No.1, Kurukshetra, Haryana. Tel : 01744-238530, 238066, M: 9813506501


lans to undertake infrastructure works for setting up the regional centre of Indian Institute of Mass Communication at Aizwal. The work is likely to start in two months. Location: Aizwal, Mizoram Indian Institute of Mass Communication Karnal A.K Thakur, Consultant Projects, Aruna Asaf Ali Marg, New Delhi - 110067, Delhi.

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he Buildings & Factories business has bagged order for the construction of multistoried residential towers in Bengaluru. Location: Bengaluru, Karnataka Larsen & Toubro Ltd S N Subrahmanyan, Whole- time Director & Sr. EVP, (Infrastructure & Construction), Mount Poonamallee Road, Manapakkam, P B no 979, Chennai-600089. Tel : 044-2528000, 22528080, Fax : 044-22493888, E-mail:


he Buildings & Factories business has bagged order for the design and construction of major IT campus facilities in NCR, Delhi. Location: NCR/Delhi Larsen & Toubro Ltd S N Subrahmanyan, Whole- time Director & Sr. EVP, (Infrastructure & Construction), Mount Poonamallee Road, Manapakkam, P B no 979, Chennai-600089. Tel : 044-2528000,22528080, Fax : 044-22493888,


lans construction of new building for centralized computer centre and digital resource centre for Maulana Azad National Urdu University, Gachibowli, Hyderabad. The work is likely to start in January 2013. Completion period: 12 months. Location: Hyderabad, Andhra Pradesh Budget: Rs. 5 crore Bharat Sanchar Nigam Ltd Mohd Yasin, Head of the Department, BSNL Civil Division No. III, Room No. 703, Adarshnagar, Hyderabad, Andhra Pradesh. Tel : 040-23223751, Fax : 040-23222982




apan based manufacturer of life saving medical devices, consumables, pharmaceutical glass products has recently set up a unit at Shirwal. This unit will manufacture arti�icial kidney (dialyser). Location: Shirwal, Maharashtra Budget: Rs. 700 crore Nipro India Corporation Pvt Ltd. Milind Pappu, MD Sayali D, Manager-Customer care, Plot No. E-1, MIDC Kesurdi Khandala, Taluka - Khandala, Dist. Satara -412802, Maharashtra Tel : 02169- 305050 E-mail:



lans to develop a 500 bedded advance super speciality hospital at Ranchi. The work will start in 5-6 months. Location: Ranchi, Jharkhand Health Medical Education and Family Welfare Department N M Ramkumar Sinha, Deputy Secretary, Namkum, Ranchi, Jharkhand. Tel : 0651-2490998


lans to set up 25 labs and 250 collection centres across the country by end of next �inancial year. Funding is planned through debt and equity. Location: Nationwide Budget: Rs. 300 crore Dr Lal PathLabs Arvind Lal, CMD, 5th Floor, The Pavilion, M.G. Road, Gurgaon -122001, Haryana, Tel: 011-3988-5050, E-mail:


lans to set up 10 specialised hospitals in cities like Chennai, Ahmedabad, Kolkata, Delhi, Varanasi by 2015 for treatment of heart diseases and cancer. These hospitals will have between 50-75 beds each. Location: Multiple Budget: Rs. 400 crore Apollo Hospital Dr Umapathy Panyala, CEO / Prathap Reddy, Group Chairman) Anuruba KGN, Asst Manager-Media and Comm, Bannerghatta Rd, Bangalore - 560076, Karnataka, Tel : 080-40304050,


lans set up a 40-bed hospital in Mahindra World City SEZ at Singaperumal Koil. The work is likely to start in a month. This facility would be ready by July 2014. Location: Kancheepuram district, Tamil Nadu Budget: Rs. 6 crore JSP Hospital Pvt Ltd. Mr. O V Jayakumar, MD Rama Subbu, GM, #70, Kancheepuram High Road, Chengalpattu Kancheepuram - 603002. Tamil Nadu. Tel: 044-27428851, 27426829. M: 09500844545




lans to set up 2.5-million tonne (mt) capacity lique�ied natural gas (LNG) receiving terminal in India.The company is exploring the feasibility of setting up two LNG storage tanks of 160,000 cubic mtr each along with Continue on page no.258

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| JANUARY 2013


Continue from page no.256 regasi�ication facility, a jetty and associated marine facilities. Foster Wheeler is appointed as consultant to prepare project report. Oil India Ltd (OIL) Ananth Kumar, Director (Finance), Plot No. 19, Near Film City, Sector 16A, Noida - 201301. Tel : 0120-2488304, 2488333 to 2488347, Fax : 0120-2488310,


lans to lay 1,065-km-long Paradip- Raipur-Ranchi pipeline that will supply LPG to bottling plants in Odisha and West Bengal. Location: Paradipm, Orissa Budget: Rs. 1793 crore Indian Oil Corporation Ltd (IOCL) V Sanjay Kumar, DGM, Udyog Marg, Sector-1, Noida - 201301, Uttar Pradesh, Tel : 0120-2448406 / 2448408, Fax : 0120-2448025/855.


lans to lay 710-km Paradip-Haldia- Durgapur pipeline that will transport re�ined products from Paradip re�inery to consumption centres located in Odisha, Chhattisgarh and Jharkhand Location: Paradip, Orissa Budget: Rs. 913 crore Indian Oil Corporation Ltd (IOCL) V Sanjay Kumar, DGM, Udyog Marg, Sector-1, Noida - 201301, Uttar Pradesh, Tel : 0120-2448406 / 2448408, Fax : 0120-2448025/855.


he company has completed the �irst phase of pipeline comprising 40 km that will connect the upcoming LNG import facility at Kochi to consumers in Kerala. The Phase-I of the pipeline will connect the Kochi terminal to Fertilizer and Chemicals Travancore’s (FACT) plant. The 879-km Phase-II pipeline to Mangalore and Bengaluru is under implementation and so far around 64.1 per cent of the work is completed. Location: Kochi, Kerala GAIL India Ltd. B C Tripathi,CMD Vandana Chanana, GM - Corporate Comm & CSR, Gail Bhawan, 16 Bhikaji Cama Place, R K Puram, New Delhi - 110066, Tel : 011-26172580,26182956, Fax : 011-26185941, E-mail: vchanana@




lans to undertake detailed engineering works for the construction of berth for handling bulk cargo and containers at new Mangalore port. Location: Mangalore, Karnataka New Mangalore Port Trust M.R Hedaoo, Chief Engineer, Department of Civil Engineering, Panambur, Mangalore - 575010, Karnataka. Tel : 0824-2407493, E-mail:


OCL and DPCL plans to develop 15 MTPA Lique�ied Natural Gas (LNG) terminal inside the Dhamra port. As part of Phase-I, 5 MTPA will be commissioned. Location: Bhadrak, District Orissa Budget: Rs. 10000 crore Indian Oil Corporation Ltd (IOCL) / Dhamra Port Company Ltd (DPCL) Antony Kant, Business Development Head, Fortune Towers, 2nd �loor, Chandrasekharpur. Bhubaneswar - 751023. Orissa. Tel: 0674-2303829 / 2301680, Fax : 0674-2303828,


agged project to provide mechanised handling facilities for Coal handling at Berth No. 11 at Port of Mormugao, Goa, on DBFOT basis from the Mormugao Port Trust. The project will have a minimum capacity of 2.33 mmtpa. The Continue on page no.260

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| JANUARY 2013


Continue from page no.258 concession period of the project is 30 years, including a construction period of 2 years. The work is likely to start in six months. Location: Mormugao, Goa Budget: Rs. 204.04 crore Gammon Infrastructure Projects Ltd Wasim Saddiqui – Head projects, Orbit Plaza, 5th �l oor, Veer Savarkar Marg, Prabhadevi, Mumbai – 400025. Tel : 022-67487200,


he company has received a letter of award from IL&FS Maritime Infrastructure Company on behalf of Dighi Port for a multipurpose berth, backup Yard development and utilities of multipurpose terminal on North side of Dighi port, Agardanda in Maharashtra. The EPC contract will take 545 days to complete. Location: Dighi, Maharashtra Budget: Rs. 168 crore IL&FS Engineering and Construction Company Ltd. C S Raju, Executive Vice President Business Development, # 6-3-1186 / 1&2, Plot # 12, IL&FS Engineering House, Begumpet, Hyderabad-500016, Tel : 040-40409540, 40409333 / 23408100, Fax : 040-40409444 / 23401107 M: 9849023378,,


lans construction of barge jetty at Tuna, Kandla port on build, operate and transfer (BOT) basis. Bids are currently invited. Location: Kandla, Gujarat Budget: Rs. 271.19 crore Kandla Port Trust R.Murugadoss, Chief Engineer, P.O. Box 50, Administrative Building, Gandhidham, Kutch, Gujarat Tel: 02836-233192, Fax : 02836-220050, E-mail:




lans to setup a 3 MW Waste Heat Recovery (WHR) based power project at Kasimitta. The work has not yet started. Location: Chittoor District, Andhra Pradesh Kanderi Fruitpack Pvt Ltd. Mohan Guru, Manager-Accounts, Kasimitta Village, Narayanavanam Mandal, Chittoor-517581, Andhra Pradesh, Tel : 09000011252,


lans to set up green �ield natural gas based small power plants in Golaghat District in Assam. Bids will be �inalised by February 2013. Location: Golaghat, Assam Assam Gas Company Ltd. Bhupen Borbabragohain, MD Sneha Patel Bhattacharya, Chief Engineer, P.O. Duliajan, Dist: Dibrugarh - 786602, Assam, Tel : 0374-2800202, Fax : 0374-2800557, M: 8011005280, Web:


lans to set up satellite power plants with gas engine driven generating sets in OIL’s installations at Duliajan, Assam Location: Duliajan, Assam Oil India Ltd. Duliajan - 786 602, Assam, Tel : 0374-2800427, 2800491, Fax : 0374-2800433, Continue on page no.262 The ready reckoner for engineering & allied industry



| JANUARY 2013

PROJECT UPDATE Continue from page no.260


lans to set up 2x800 MW coal based power plant at village Bavaliyari and Dholera in Dholera District. DPR is being prepared. Location: Ahmedabad, Gujarat P.M Parmar, Chief Engineer, Vidyut Bhavan, Race Course, Vadodara–390007, Gujarat. Tel: 0265-6612131,


lans to set up a 2x507 MW Gas Based Combined Cycle Power Plant spread over 300 acre at Maranahole Village, Belgaum. Necessary approvals are yet to come, so the work has not yet started. Location: Belgaum, Karnataka Budget: Rs. 4040.60 crore Luxor Energy Pvt Ltd. Nasir Mustafa, Project Manager, Sanali Estate, 2nd Floor, 5-9-225, Chirag Ali Lane, ABIDS, Hyderabad – 500001, Tel: 040-23202399/ 23203969, Fax: 040-23322674, E-mail:


lans to set up a 2x660 MW Thermal Power Plant spread over 900 acre at Mulvad Village, Bijapur. Necessary approvals are awaited. The completion is targeted by December 2013. Location: Bijapur, Karnataka Budget: Rs. 5902.80 crore Luxor Energy Pvt Ltd. Sanali Estate, 2nd Floor, 5-9-225, Chirag Ali Lane, ABIDS, Hyderabad –500001, Tel: 040-23202399/ 23203969, Fax: 040-23322674


lans development of 80 MW coal based power project on BOOT basis. RFQ scrutiny is in process. Location: Kotayam, Kerala Budget: Rs. 400 crore Hindustan Newsprint Ltd. George Panikar, DGM (Projects), Newsprint nagar-686616, Kotayam District, Kerala. Tel : 04829-256211-21, Fax : 04829-251911, 257587,


he subsidiary of Kalika Steel plans to set up a captive power plant. The capacity is expected to be around 10 MW.


Location: Chandrapur, Maharashtra Kalika Sponge & Power Pvt Ltd. Naresh, Director Praveen Sharma, GM - Marketing, F 18/19, Phase 2, Addl. MIDC, Jalna - 431203, Maharashtra. Tel : 02482-220213/ 220359/ 220920, Fax : 02482-220689, M: 09049997311,


lans modernisation of its 500 MW Unit 6 at Trombay Thermal Power Station comprising addition of coal �iring equipment and installation of pollution control equipment to make the unit work on coal, oil and gas, wherein all three fuels can be combined in any percentage. Location: Trombay, Maharashtra Budget: Rs. 1174 crore Tata Power Ltd. S. Padmanabhan, Executive Director, Strategy and Business Development Department, Corporate Center Block A, 34 Sant Tukaram Road, Carnac Bunder, Mumbai - 400 009, Tel : 022-67171000, 67171231, Fax : 022-67171950,67171953,


PSL Group company plans to set up 100 MW coal-based Captive power plant in Jharsuguda District. The work is yet to start on this project. Location: Jharsuguda, District Orissa Thakur Prasad Sao and Sons Pvt Ltd. Prof. DVR Rajakumar, VP, TPSL Group, Avani Signature, 2nd Flr, 91 A/1, Park Street, Kolkata-700016, West Bengal. Tel : 033-40071632/22267090, 22267091, Fax : 033-40071638.


lans establishment of 2x800 MW Uppur Thermal Power Project at Thiruvadanai, Ramanathapuram District. The commissioning is scheduled by December 2015. DPR is submitted. NOC obtained from Airport Authority of India for construction of 275m height chimney. Location: Ramanathapuram, District, Tamil Nadu Budget: Rs. 9600 crore Tamil Nadu Generation And Distribution Corporation Ltd (TANGEDCO) CE Projects, NPKRR Maaligai, 144, Continue on page no.263 The ready reckoner for engineering & allied industry


Continue from page no.262 Anna Salai, Chennai - 600002, Tel : 044-28520131,28520878, 28521915, E-mail: N.Sankar, Director / Generation


lans to set up North Chennai Thermal Power Project - Stage III (1x800 MW) at NCTPS Complex. So far, Feasibility report for the Project has been �inalized. EIA study of the proposed project has been completed and EIA report is under �inalization.CETHAR Consulting Engineers has submitted the Draft D. P.R. Also it is proposed to execute the project with imported coal. The project commissioning is scheduled by December 2015. Location: Chennai, Tamil Nadu Budget: Rs. 4800 crore Tamil Nadu Generation And Distribution Corporation Ltd (TANGEDCO) CE Projects, NPKRR Maaligai, 144, Anna Salai, Chennai - 600002, Tel: 044-28520131, 28520878, 28521915, N.Sankar, Director / Generation


lans establishment of 5x800 MW Cheyyur Ultra Mega Thermal Power Project. Necessary clearance are awaited. Location: Kancheepuram, District Tamil Nadu Budget: Rs. 18000 crore Tamil Nadu Generation And Distribution Corporation Ltd (TANGEDCO) N.Sankar, Director / Generation CE Projects, NPKRR Maaligai, 144, Anna Salai, Chennai - 600002, Tel : 044-28520131,28520878, 28521915, E-mail:


etting up 2640 (2x1320) MW coal based IPP at Kakarapalli. The work is underway and likely to complete by 2014. Location: Srikakulam, Andhra Pradesh East Coast Energy Pvt Ltd. Shankar, 7-1-24, B Block, 5th Floor, Roxana Towers Green Lands, Begumpet, Hyderabad - 500016, Andhra Pradesh. Tel : 040-66570665, Fax : 040-66570666, E-mail:,


lans to set up 1065 (3x335 MW) gas based power project at Faridabad. The land is yet to be acquired and clearances are awaited. Location: Faridabad, Uttar Pradesh Budget: Rs. 3400 crore Haryana Aban Power Co Ltd V Kaniyaappan, Director-Power, Janpriya Crest, 113, Pantheon Road, Egmore, Chennai Tamil Nadu. Tel: 044-28195555,


lans establishment of coal based 1x660 MW Supercritical power project as part of Ennore Thermal Power Station Expansion Project. EPC bids were recently invited. The project commissioning is targeted by December 2015. Location: Ennore, Tamil Nadu Budget: Rs. 4062.00 Tamil Nadu Generation And Distribution Corporation Ltd(TANGEDCO) CE Projects, NPKRR Maaligai, 144, Anna Salai, Chennai - 600002, Tel : 044-28520131,28520878,28521915, E-mail: N.Sankar, Director / Generation

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lans to set up 2x60 (120) MW Dibbin hydro power project at Nafra. MoEF clearance is in place. Land acquisition is under way. The completion is targeted in 2014. Location: West Kameng, Arunachal Pradesh KSK Energy Ventures Ltd Balkrishnan, Sr GM, 8-2-293/82/A/431/A, Road No:22 Jubilee Hills, ENGINEERING REVIEW | JANUARY 2013 | 263


Hyderabad - 500033, Andhra Pradesh. Tel : 040-23559922 to 25, Fax : 23559930, E-mail:,


lans to set up 400 MW Khab Hydro Electric Project in Himachal Pradesh. The project is in approval stage. Location: Shimla, Himachal Pradesh Himachal Pradesh Power Corporation Ltd. B.S. Negi, DGM (Elect. Cont.), Himfed Bhawan, Below Old MLA Quarters, Bypass Road, Tutikandi, Shimla-171005, Himachal Pradesh, Tel: 0177-2633826, Fax : 0177-2633813.,


lans to come up with 48 MW Malana III hydro electric project in HP. DPR is under preparation. The project is in approval stage. Location: Kullu, Himachal Pradesh Bhilwara Group Shatanu Agarwal, Chairman Bharat Singh, Company Secretary, Bhilwara Towers, A-12, Sector 1, Noida - 201301 (NCR Delhi) Tel : 0120- 4390138, Fax : 0120- 2531648, 2531745


lans to set up a 100 MW Wind Power Project spread over 378.62 acre at Koppal. The project is in preliminary stage. Scouting for land. Location: Koppal, Karnataka Budget: Rs. 694.94 crore Indowind Energy Ltd Rajas Sukumar, Sr. Vice President, Kothari Building, 4th Floor, 114, Nungambakkam High Road, Chennai - 600034. Tel : 044-28330867, 28331310, Fax : 044-28330208, E-mail:


lans to set up a 22 MW bagasse based power generation plant at Sangli. Land acquisition process is on. The work is likely to start in three months. Location: Sangli, Maharashtra Honai Infra Inginieurs & Sugar (I) Pvt Ltd Suryakant Pawar, Project Manager, 502, 5th Floor, Pride Kumar Senate,


Near ICC Tower, Senapati Bapat Rd. Pune - 411016. Maharashtra, Tel : 020-25673914 / 15


lans to set up 30 MW Dhukwa hydro power project at Dhukwa. Pre-quali�ication was recently invited. Location: Jhansi, Uttar Pradesh Budget: Rs. 300 crore Tehri Hydro Development Corporation Ltd A V Narayanan, Manager, Ganga Bhawan, Bye Pass Road, Pragatipuram, Dehradun 249201,Uttarakhand. Tel: 0135-2473469, 2430721/ 2432927, Fax: 0135-2438379/2436592, E-mail:, Web:


ashang hydroelectric project is coming up on Satluj basin in Kinnaur. MOEF had given clearance for the stage II & III of this project. This project is planned in four stages with a combined capacity of 243 MW. The work on stage I with an estimated capacity of 65 MW is already underway and the completion is targeted by January 2013. HCC is thecontractor for this stage. The stage II and III will come up by 2015. Currently the forest clearance to the stage 1 and 2 was challenged at the National Green Tribunal. Location: Kinnaur, Himachal Pradesh Himachal Pradesh Power Corporation Ltd S P Gupta, GM, GM Kashang Construction Circle, Himfed Bhavan Reckong-Peo, Distt. Kinnaur, Himachal Pradesh - 172107, Tel : 01786-222001, 223992, Fax : 01786-223992


he company is targeting to commission 100 MW solar power unit in Gujarat. So far they have commissioned 25 MW, the rest may take six months to start and complete in 3-4 years. Location: Surendranagar, Gujarat Louroux Bio Energies Ltd. Brijesh Shetty, Manager, 21, Satyam, 318, Linking Road, Khar West, Mumbai â&#x20AC;&#x201C; 400052, Maharashtra. Tel : 022-67733600, Fax : 022-67733666, E-mail:, Web: The ready reckoner for engineering & allied industry



| JANUARY 2013

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ACMA Automechanika New Delhi Seminar 8 â&#x20AC;&#x201C; 9 February 2013 Seminar Room, Hall 8, Pragati Maidan, New Delhi

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Engineering Review January 2013  
Engineering Review January 2013