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REPORT ON

INDUSTRIAL VISIT OF

G.S ALLOY CASTING LIMITED

SUBMITED TO:-

SUBMITTED BY:-
INTRODUCTION:

-The G.S alloy casting Limited was Started in 1987 with


1800mt/annum and later grown into one of the biggest foundries in South India with
4800mt/annum.

T hey have accquired skills in producing castings ranging from few kgs
to 6000 kgs single piece in Plain Carbon Steels, Alloy Steels, Heat Ressitant Steels, Wear
Resistant Steels, Corrosion Resistant Steels.

GSAC manufactures and supplies castings required for Sponge Iron,


Cement, Crusing, Mining, Power Generation, Railways, Steel Plants, Valve Industries
and General ...

G.S alloy casting Limited was a casting based organization producing


diffrenent steel products based on different requirements of the customers.

Certification:

The G.S alloy casting limited was certified by AN ISO 9001: 2008
Company

Location:

• Location: Vijayawada, A.P, South India


• Well connected by trains
• Currently Connected to Hyderabad,Banglore and Chennai by Air.
• Land –Unit 1 : 4 acres –
Unit 2 : 9 acres

Materials;

We are capable of manufacturing castings from a broad range of steels.


Our range of materials include,
• Plain Carbon Steels
• Alloy Steels
• Chrome – Moly Steels for high temperature service
• Wear, Heat and Corrosion Resistant Steels
• Stainless Steel
• Ni Hard
• Manganese and High Chrome Steels
• Ductile Iron
• Creep resistant steel (aiming for qualification through Lloyds by January 2010
Major Product Groups

• Power Plants – Hydel and Thermal


• Crushing and Mining
• Valve & Pump manufacturers
• Cement Manufacturers and Cement Plant Manufacturers • Sponge Iron Plants
• Sugar Plants
• Die Manufactures
• Steel Plants
• Engineering Components
• Tyre Manufacturers

Major Customer List

• BHEL - Bharat Heavy Electricals Limited (Hyderabad, Varanasi, Bhopal & Trichy)
• L&T
•Audco India Limited - Valves
• Sandvik • Terex, U.S.A
• F. L. Smidth
• Boving Fouress
• Puzzolana Machinery Fabricators
• Hari Machines Limited
• BEML – Bharat Earth Movers
• Fives - Cail KCP
• Steel Plants – BSP, VSP& JSW
• GEA Energy Systems
• Metso, U.S.A
• Alstom
• Beekem
• Hofmann

Melting :-

• INDUCTOTHERM® Dual Track System


• Capacities: 20 MT, 15 MT, 5 MT, 2.5 MT, 1MT, 0.5 MT
• New Arc Furnace – 15MT (Commissioning – July)
• Total amount of Liquid Metal per heat : 50 MT
• Single piece casting capability – 30 MT
• Single Piece casting poured so far - 27 MT
• Bottom pouring Laddles – 20MT, 18MT, 12MT
• Oil fired laddle pre heater to maintain the laddle temperature at 600 oC
• Immersion Pyrometers
• Radiation Pyrometers
Moulding

• Co2 and No - Bake process


• Zircon and Chromite sand at intricate locations and Quartz sand (99.5% Silica) for
facing
• Sand Reclamation System - 6 MT/hr
• Continuous Sand Mixers - 12 MT/hr
• Batch mixers
• Sand Mullers
• Integral Test Bars
• As cast Heat No. traceability
• Use of high quality refractories for gating system and mould paints.

Heat Treatment

• Furnace Sizes : 7.5m X 5.5m X 3.5m ( 40 MT) and 4.0m X 3.5m X 2.0m (20 MT)
• With Digital Recorders, Auto cycle control and Direct firing
• Water Quenching tank
• Proposed to run by CNG (Compressed Natural Gas)

Quality Assurance

• ISO 9001:2000
• Spectro availability Unit 1 and Unit 2 (including Nitrogen analysis)
• UTM – 60 T , 40 T
• UT equipment available
• MPI equipment available
• Radiography outsourced to IRICO. Proposal for in-house in future
Observations :-

• .Intially that organization has two plants , after seeing the plant from outside
it was big organization
• It was melting the scraps iron material and get the iron ore from that to
manufature new products, they don’t produce new iron
• Firstly we observe the melting of scrap iron in the furnace, after thea they get
the ore
• After collecting the ore its was filled in the petterns of desired shapes, for this
they use the send in one stage of manufacturing
• After passing that stage it will undergo the hardning of ore to form the desired
shape
• After the completion of the hardning is will go to next stages like boring and
drilling, milling
• Finally they get the desired product
• The products was exported to desired places
• In plant there was no waste material, even the scrap came while making the
products that was also collected and is will also melted and get ore from it.

Vote of thanks

First of all we thankfull to the college principal K.V. SAMBASIVARAO sir ,


and head of the department of mba N.SIVA SURENDRA sir, for conducting a
knowledge enrichment programs for us.
At the same we are thankfull to the managing director of the
G.S alloy casting limited G.PRASADA RAO , for giving permission to visit their
organization and also our guide in organization K.RAMANA .

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