Gear Box

The company’s Transmission Division has state of the art Gear manufacturing facilities consisting of CNC Machining and Turning Centres, special purpose machines like, HOFLER Gear hobbing & grinding machines, In-house heat treatment furnaces which contribute to enhanced molecular structure of gear.

KPCL has established strong presence in :

• Power Industry - Gearboxes for Steam Turbines, Wind Turbine and Hydro Turbines
• Steel Industry - Gearboxes for Pinion Stands, Roughing Mills, Ladle Tilters, Sizing Mills & other applications.
• Sugar Industry - Gearboxes for Mill Drive - Planetary & Helical Gearboxes, Conveyor Gearboxes, High speed Gearboxes for CO-GEN power plants.
• Cement & Minerals Industry - Ball Mill & Kiln Drive Packages, Conveyor Gearboxes
• Rubber Industry - Banbury Mixer drive Gearboxes, Extruder Gearboxes.
• Plastic Industry - Extruder Gearboxes.
• Paper Industry - Mixers Drive & Calendar Application gearboxes.
• Material Handling Industry - Gearboxes for Stacker Reclaimer, Heavy Capacity Hoists, Bulk Material Conveyors, Apron Feeders & Elevators.
• Marine  -  Drive propulsion Gear boxes.
• Railway - Turbo Transmissions for Locomotives & Axel Drive power packs.
• Open Gears, Segment Gears and High Precision Double Helical Gears.
• Refurbishment - Import / other make Gearbox substitution as drop in solutions.

The salient features of KPCL gearboxes include:

• Design, manufacturing and testing as per AGMA and API standards (with latest versions).
• KPCL takes pride in achieving fully indigenized Gearbox for 50 MW for Power generation.
• Grinding finish up to DIN CLASS 3/4 for High Speed Gearboxes & DIN CLASS 5/6 for Low Speed Gearboxes.
• Successfully developed Journal bearings in-house with infinite life used.
• Antifriction Bearings are sourced from reputed manufacturers - SKF, FAG, TIMKEN etc.
• For High speed Gearboxes - Double helical gearing results in no thrust generation from the gearbox & with subsequently no thrust bearing on either rotor.
• Energy efficient Gearboxes.
• Noise level equal to or less than 85-88 db(A) achieved.
• Non-contact type vibration values of the rotors lower than the designed values are achievable because of the precise manufacturing processes.
• Less Noise and Vibration due to inbuilt accuracy of gear.

Customized engineering and special manufacturing facilities involving high precision gear grinding machine.

• In-house capability of SCADA controlled Heat treatment facility for Diameters up to 1500 mm & weight 3 Tons.
• Gear Cutting for single & double helix capacity up to 2500 mm for Internal & External Gears.
• Gear Grinding for single & double helix capacity up to 2500 mm for Internal & External Gears.
• Precise Grinding Machines housed in temperature & humidity controlled environment.
• Fully equipped Machining centers capable to handle jobs up to 5000 mm size.
• Co-ordinate measuring machine with capacity - 4000 X 2500 X 1500 mm
• Overhead cranes equipped to handle components / Gearboxes up to 40 Tons.
• Gearbox Load test beds equipped up to 1 MW range.
• No Load test infrastructure in place for gearboxes up to 50 MW range & Input RPM up to 12000 rpm.
• Clean room facility for high precision assemblies.
• Dedicated captive power for Test beds & Heat treatment.
• In-house foundry for CI & AL castings used in KPCL gearboxes.