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AN INTRODUCTION
TO
Heavy Engineering Workshop
(A unit of Jaiprakash Associates Limited)

Designer& Manufacturerof :
♦ Hydro Mechanical Equipments
♦ Cement Plant Equipments including Kiln & Mills
♦ Mechanical Handling & Mass Transfer Equipment
♦ Pressure Vessels
♦ Turbine Runners (Repair & HVOF Coating)
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INTRODUCTION

Jaiprakash Associates Ltd. (JAL)is the flagship Company of the Jaypee


Groupand an acknowledged leader in the Construction of multi-purpose River Valley
and Hydro Power Projects, Thermal Power Plants, and Cement Plants on Turnkey
basis.The company has consolidated its manufacturing strength by establishing
Heavy Engineering Workshop (HEW) atRewa (M.P.),in the heart of India’s Cement
belt.

HEW is Rated 5 Star by British Safety Council (BSC), UK.


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Logistics & Area

LOCATION:Jaypee Nagar, Rewa, M.P., India


NEAREST DOMESTIC AIRPORT:Khajuraho (170 KM) /
Allahabad (160 KM)
NEAREST INTERNATIONAL AIRPORT:New Delhi
NEAREST RAILWAY STATION:Satna (50 Km)
: Rewa (14 Km) from workshop site.
NEAREST TOWN:Rewa, a District Centre (14 Km)
TOTAL LAND AREA : 103980Sq.m.
SHOP FLOOR AREA: 33630Sq.m.
♦ Covered Area:17690Sq.m
♦ Open Gantry:15940Sq.m
AUXILARY & SUPPORT SERVICES: 4695Sq.m
RESIDENTIAL COLONY: Exclusive Residential Colony
adjacent to large Cement Plant
of 7.0 MTPA capacity.
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MASTER PLAN OF WORKSHOP

Fabrication Equipment
DESCRIPTION QTY. SPECIFICATION
3 - ROLL PLATE BENDING “WITH PRE PINCHING” 1
90 mm Thk x 3.1 Mtr Width
THYSSEN WAGNER
4 - ROLL PLATE BENDING "WITH PRE PINCHING" 1
36 mm Thk x 3.0 Mtr Width
CJHOSUNG, S.KOREA
7 - ROLL PLATE STRAIGHTENING SKET, GERMANY 1 25 mm Thk x 3.0 Mtr Width
CNC PLASMA PROFILE CUTTING "MESSERS , 1
200 mm Thk x 18.5 Mtr Lg.
CHINA"
2 2000MM Web, with Welding &
"H" BEAM MANUFACTURING LINE
Straightening Facility
EDGE PLANING “TOS, CZECHOSLOVAKIA” 1 100 MM x 12.0 Mtr Lg.
HYDRAULIC PRESS & PRESS BRAKE (2 NOs.) 1 4000 KN

STRESS RELIEVING FURNACE 1 Capacity 3.5 Mx3.5M x 12.0M, Load-30T

Material Handling
15
EOT / MOBILE CRANES “AVON/ASIA” (10 NOs.) Up to 30T / 10T / 5T x 21 Mtr / 25 Mtr. Span
TYRE MOUNTED MOBILE CRANES “ 10
90 T / 12 T (HYDRA)
GROOVE/ESCORTS” (8 Nos.)
CHAIN MOUNTED MOBILE CRANE “P & H, USA” 1 30 T
63
MIG WELDING MACHINE Auto K 400 / Ranger
SAW MACHINES 10 CPRA 1200S, MESTRO 800

4 ROLL PLATE BENDING MACHINE 3 ROLL PLATE BENDING MACHINE 7 ROLL PLATE STRAIGHTENING

HYDRAULIC PRESS & PRESS BRAKE VERTICAL BORING MACHINE CNC PLASMA PROFILE CUTTING
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Key Machine Tools, Inspection &Testing Equipment

Machine Shop

DESCRIPTION QTY. SPECIFICATION


Spindle ∅160mm Travel 10.0Mx4.0Mx2.2M (Floor
CNC HORIZONTAL BORING MACHINE
Type)
“JUARISTI, SPAIN” 1
HORIZONTAL BORING
Spindle ∅125mm Travel 2Mx1.6Mx1.1M
MACHINE”WMW,GERMANY” 1
Travelling Column Type Milling M/C including
5 AXIS MILING MACHINE “JUARISTI, SPAIN”
1 Supporting Digital
1
CNC UNIVERSAL MILLING “MECOFF, ITALY” Longitudinal Travel 4.0M,Vertical Travel 1.5M
PLANO MILLER MACHINE “WALDRICH 1
Bed Length 20.5 M, Table 9.0Mx2M, V-Travel 1.5M
SIEGEN”
DOUBLE COLUMN PLANO MILLER 1 Bed Length 18.0 M, Table 2.06Mx10.3M
1 3.35 M ∅ x 2.7M Turning Ht with DRO & Grinding
VERTICAL BORING “FRORIEP, GERMANY”
Attachment
1
CNC VERTICAL BORING “UMARO, ROMANIA” 5.3 M x ∅2.5 M Turning Ht

HORIZONTAL BORING MACHINE 1 Spindle ∅125mm Travel 5.5Mx2.9Mx1.6M (Floor


“SCHARMANN, GERMANY” Type)
RUNNER COATING FACILITY BY ROBOT 1
600 X 175 with JP 5000Gun
“TEFA, USA”

VOM-50 PORTABLE UNIVERSAL RADIAL 3 Spindle ∅75 mm Travel 1.55 M (H) x 2.4 M (L) Arm
DRILLING MACHINE, VHS, CZECH, REPUBLIC Radius - 2270 mm

Inspection & Testing Equipment


TRANSPORTABLE INDUSTRIAL X-RAY “AGFA, 1 Capacity 65 mm Thk with LCD Display & Digital
GERMANY” Control
DIGITAL ULTRASONIC FLAW DETECTOR 1 Fingertip Probes ∅10/13 mm , Angle Beam 45°,
“AGFA, GERMANY” 60°& 70°
UNIVERSAL TENSILE TESTING 1 1000KN
UNIVERSAL PENDULUM IMPACT TESTING
1 Impact Energy 300Joule
MACHINE

7 AXIS CNC HORIZONTAL BORING MACHINE UNIVERSAL MILLING MACHINE S R FURNACE


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MANPOWEROVERVIEW
We are equipped to handle projects and heavy engineering products with well manned offices to
execute all projects and products to customers’ full requirement & satisfaction. We give below brief
description of various execution sections with some details of prominent staff in projects.

Process Engineering & Design

S.No. Designation Qualification Previous Experience


1. President Chemical Engineer Engineers India Ltd., + ESSAR
2. Sr. Vice President Electrical Engineer Chambal Fertilizer & Chemical Limited
3. General Manager Process Engineer National Fertilizer Limited

Supported by Engg.Staff - 08 Nos.

Equipment Design and Shop Fabrication Staff

Designation Previous Experience


Unit Head TriveniStructurals Ltd. &Tungbhadra Steel Products
Advisor Larsen & Toubro & CIMMCO
Sr. Vice President Bharat Heavy & Electricals Ltd.,
Head of Planning Bhilai Engineering Corporation
Head of Welding Larsen & Toubro
Head of QA TriveniStructurals Ltd.

Manning details of the workshop

S.No. Departments Sr. Executives Staff Operatives Total


Executives
1. Manufacturing - - - 2
1.1 Machine Shop 7 - 63 70
1.2 Fabrication 14 - 164 178
1.3 H-Beam 5 - 19 24
1.4 Sub. Contracting 6 1 - 7
1.5 S.B &P 2 - 1 2 3
2. Quality Control 18 - 1 19
3. Design 12 10 - 22
4. Planning 9 - 1 10
5. Maintenance 9 1 17 27
6. Despatch 4 - 2 6
7. Runner Repair Shop 11 - 25 36
8. S&P 1 2 7 4 14
9. F&A 1 4 2 - 7
10 P&A 2 9 - 11
11. EDP 3 - - 3
Total 4 106 31 298 439
Legend :
S.B. & P : Shot Blasting & Painting Section EDP : Electronic Data Processing
F&A : Finance &Accounts P&A : Personal & Administration
S&P : Stores & Purchase
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ILLUSTRATIVE LIST OF SOME PROMINENT CUSTOMERS

S.No. Name Type of Product Order Value When


supplied
(Year)

1. Dam Gates & related


Over Rs. 580 2008
Jaypee Baghlihar HEP equipment
million onwards
2. Jaypee Karcham Dam Gates & related
Over Rs. 350
Hydro Corporation equipment 2010
million
Limited
3. Vertical Raw Mills &
Gebr. Pfeiffer (India) Coal Mills for Cement Over Rs. 250
2010
Pvt. Ltd. Plants or Power million
Plants
4. Heavy Equipment for
PHB Weserhutte, S.A., Saudi Arabian based Over Rs. 130
2011
Spain cement plants million

5. Jaypee Nigrie Super Bucket Wheel


Thermal Power Project Stacker Reclaimers
Over Rs. 500
(1300 MW Super & CW Pipes Dia 2012
million
Super Thermal Power 3800 x over 3 Kms.
Station) long
6. Heavy Equipment for
ThyssenKrupp
Cement Plant Wagon Over Rs. 10
Industries India Pvt. 2012
Tippler million
Ltd., Pune

7. Prayagraj Power
Generation Com Ltd.,
(2000 MW Super Bucket Wheel Over Rs. 400
2013
Thermal Power Stacker/Reclaimers million
Station)

8. Pressure Vessels for


Kanpur Fertilizer & Over Rs.
Fertilizer Plant 2013
Cement Limited 35million
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PRODUCTS

HEAVY PLANT EQUIPMENTS


ROLLER PRESS & CLASSIFIER HOUSING
PREHEATER CYCLONE
KILN
VERTICAL MILL (RAW / COAL MILL)
IMPELLER
PREHEATER SUPPORTING H-BEAM STRUCTURE
PRESSURE VESSELS
HYDRO MECHANICAL EQUIPMENTS

RADIAL GATE (TRIAL ASSEMBLY) IMPELLER FAN BONNETED EMERGENCY GATE

RAW MILL FIXED WHEEL GATE INTAKE TRASH RACKS


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Product Range

LPRegenerator Column (Ammonia Plant)

LPRegenerator Column shown under fabrication

LPRegenerator Column ready for Despatch


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Product Range

LP Stripper Condensate Separator

Lean Solution Tank Vessel

KILN SHELL IMPELLER SHAFT HOIST SUPPORTING STRUCTURES


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Production, Dispatch&Dispatch-Value Trends


20000

18000

16000

14000

12000

10000

8000

6000

4000

2000 Production (Mt)


Despatch (Mt)
Despatch Value (RS, In Lacks)
0
2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

KILN SHELL SECTIONS (∅ 5.2 m) KILN SHELL SECTION (∅ 4.8 m)

PORTAL RECLAIMER BRIDGE RECLAIMER


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“We aim to achieve perfection in everything we


undertake and we have a commitment to excel.
It is the determination to transform every
challenge into opportunity; to seize every
opportunity to ensure growth and to grow with a
humane face that drives us.”

Jai Prakash Gaur


(Founder Chairman)

Workshop : Regd. Office: Head Office


Chijjwar Road, Jaypee “JA House’, 63, BasantLok, Sector – 128, Noida,-201304,
Nagar-486450, Dist-Rewa, VasantVihar, New Delhi- Uttar Pradesh, IndiaPh: +91
(M.P), India,Ph: +91 (7662) 11005, India, Ph: +91 (11) (120) 2470800 &4609000,
229144& 236118, 26141540 & 26147411 Fax : +91 (120) 4609464 &
Fax: +91(7662) 229143 Fax: +91 (11) 26145389 4609496