We Assure Quality

QUALITY DOSSIER

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Kirloskar Brothers Limited (KBL) is a leading global fluid management organization. KBL is the largest manufacturer and exporter of Centrifugal Pumps and Valves in India. Established in 1888 and incorporated in 1920, Kirloskar Brothers Limited (KBL) is the flagship company of Kirloskar group in India. The core business of KBL is Industrial Pumps, Engineered Pumps and Projects, Agriculture and Domestic Pumps, Valves, Motors, Hydro turbines and anti Corrosion Products.

By virtue of its pronounced competitive edge in terms of skilled engineering manpower, technological strengths and infrastructure, KBL is an internationally acclaimed pump manufacturer.

The company’s product range comprises of end suction pumps, solid handling pumps, submersible pumps, concrete volute pumps, vertical turbine pumps, canned motor pumps, monobloc pumps. KBL manufactures pumps to meet various national and international standards like IS, BS, DIN, ISO, JIS, API etc.

KBL has offices in all continents with satisfied customers worldwide. Our wide-range of fluid engineering equipments finds applications in all sectors, to mention a

few are Water, Irrigation, Industry, Power, Building & Construction, Defence, Oil & Gas, Distribution and Customer Sales and Services.

We take this opportunity to quickly highlight the key differentiation areas at KBL:

• “AAA” Technology-Products are Appropriate, Adaptable and Affordable

• Excellence in Manufacturing, Design, Development and System Engineering

• An ISO 9001, ISO 14001 and OHSAS 18001 company with all manufacturing facilities under one roof, KBL has state-of-the-art machining facilities, ferrous and non-ferrous foundries, testing facilities at one of the Asia’s largest Hydraulic Research Centre

• Manpower with excellence in Engineering, Research, Design and Marketing

• Capabilities to provide Turnkey Fluid Handling Solutions

3 3• Wide pump range - 4 m /hr to 120000 m /hr

‘Yamuna’, Global Headquarters of Kirloskar Brothers Limited is among the green buildings in India with LEED Certified Platinum Rating

c ompany Profile

The name Kirloskar is synonymous with quality and dependability in the engineering industry. Pioneering industrial revolution in India, Kirloskar group has contributed immensely in every field of its operation during its 120 year-long journey and holds a place of repute in the industry for its good business values and customer focus.

Our Commitment

The philosophy of Kirloskar has at its base the idea that all industrial endeavors must positively impact life and society around it. It is a confluence of mind and matter to create and generate such power which can impact human life in a positive way. Our commitments are a part of the imbibed values and ethos we follow to meet our goals and the customers' expectations from us.

Our Value System is the backbone of every action. These values are the Foundation of KBL and shall be responsible for its success, growth and widespread reputation in years to come. It is the basis of enhancing our ability to serve customers and to be more competitive.

We believe in continuous improvement on the basis of a long term Vision and continual innovation.

Total Fluid ManagementUnder One Roof

PackagedPumpingSystems

Anti - CorrosionProducts

EPC Pump

Projects

CivilConstruction

andPiping

Cast Iron, Spl. / Alloy Steel

andNon Ferrous

Foundry

Agricultural,Domestic,Industrial

andEngineered

Pumps

Valves

Motor

Q uality Philosophy

KBL MISSION

we shall be known globally as a reliable, innovative and cost effective solution provider in hydraulic machines and systems.

KBL VISION

We shall be amongst the first five pump companies in the world, by year 2015 and become the

preferred choice of customers as well as employees.

ertificationsCThe ISO certifications of our Quality Management System are a reflection of our ongoing efforts towards design process to achieve the highest possible Customer Satisfaction.

Besides stringent quality approach KBL also works on continuous improvement of its environmental

performance. Primary objectives of this approach are increasing energy efficiency, safe handling of foundry activities, absence of restricted and hazardous media to make our product more

sustainable.

Kirloskar Brothers Limited puts high priority on safe working environment. The company meets all safety

regulations of concerned markets and goes beyond it to provide safer products.

There has been continuous upgradation in product safety with new technology brought in.

CERTIFICATIONS

CERTIFICATIONS

ssociation with Global Consultants and EPC ContractorsA

TGA-ZM-30-90-00

TE IL

Product quality is continuously upgraded to meet the ever increasing Customer/Market needs. Our products are certified to international standards like CE, FM, UL etc. KBL is in the process of obtaining N-stamp certification.

roduct ApprovalsP

Certificate No. 111b

Supplier quality standard specifies management system requirements for use in the supplier shop and to assure quality and continues improvement in supplier’s performance.

KBL follows a standard process to develop the necessary competence and to meet the specific quality requirements of KBL products at suppliers end.

S upplier Quality

Quality Inspection

Inspection activities are carried out by trained quality professionals. Most advanced technologies are used for non-destructive material tests on components. The inspection is supervised by trained NDT professionals.

Radiography Testing Liquid Penetration Testing Magnetic Particle Testing Ultrasonic Testing Helium Leak Testing

ASME SEC III-,NB, NC, NDASME SEC VASME SEC VIIIASME SEC IXASTM B16.34*

REFERENCE CODES USEDTEST ACTIVITIES

NDT Testing

Quality Planning

Careful planning of manufacturing process and the definition of required checks at hold points are laid down in document 'Quality Assurance Plan'. These Quality Assurance plans are documents to be strictly adhered to.

Quality Control

Incoming inspection guarantees that only material and procured components meeting the strict requirements are used. To make sure that only material of impeccable quality are passed on, nonconforming parts are conspicuously marked 'rejected'. Final inspection is the conclusive testing instrument to ensure that only conforming components are dispatched and this is documented in inspection documents. It is the responsibility of in-process inspection to check the execution and correct measurements between the individual manufacturing steps.

Supplier Quality Management

• Assessment

• Training

• Performance monitoring

• Statistical process control

• Process upgradation – Poka Yoke

• Value engineering

• QMS certification

• Manufacturing excellence ( 5S, Kaizen, etc.)

Quality Inspection

Ultrasonic Testing

Liquid Penetrant Testing

Magnetic Particle Testing

Helium Leak Testing

Radiography Testing

Non Destructive Testing

Destructive Testing Facilities

Destructive material tests on samples give additional proof of material quality. Material tests and metallographic examinations are conducted in our own laboratories or in state-accredited testing institutes. These tests are carried out and evaluated exclusively by trained and authorized personnel. The test results are forwarded to the customers in the form of quality certificates.

Name of Instrument

Universal Testing Machine

Hardness Testing Machine (BHN)

Hardness Testing Machine (Rockwell)

Hardness Testing Machine (Digital)

Impact Testing Machine

List of Destructive Testing Machines

Calibration of Equipment

The measuring instruments used for geometrical checks like gauges templates and other measuring instruments are subject to a strict, regular and documented calibration process. For this KBL has well–equipped gauge and instrument rooms covering a wide range of calibrated instruments to ensure product quality.

Balancing Machines

We have world class balancing machines of Schenk make with a capacity upto 5 tonnes and rotor diameter of 2.5 m with a resolution of 0.1 gm.

Seven machines are available in horizontal and vertical arrangements. These machines cover a wide range of sizes and accuracies.

Hydro Testing

Test Facility Capabilities

SR. NO.

1

2

3

4

Testing Facility

• One of the largest Hydraulic Research Center's (HRC) in Asia testing for pumps at duty condition up to 5000 kV

3and discharge up to 50000 m /hr

• Closed circuit NPSH testing capabilities

• Computerized data acquisition system

• Sump model study facility

• Conceptualized and built under the guidance and supervision of British Hydraulic Research Association

• Testing at 50 Hz and 60 Hz frequency covering all global supply voltages (3.3 kV /6.6 kV /11 kV /13.2 kV)

y r u i R e h e tH d a l c es rc C n er

PARAMETER

3Flow, m /hr

Head, m

Power Supply3 Ph 50 Hz

Crane Facility

1

50000

120 11 kV (HT) - 4500 kW6.6 kV (HT) - 2500 kW3.3 kV (HT) - 1500 kW

10/50 Tonne(crane hook height 18.5 m)

15 Tonne(crane hook height 18.5 m)

2 Tonne(crane hook height 4 m)

TEST LOOP NO.

2

3500

800

3

2500

250 6.6 kV (HT) - 2500 kW3.3 kV (HT) - 1500 kW440 V (LT) - 500 kW

10 Tonne(crane hook height 12 m)

4

10000

200

S pecial Process

• Seamless pattern manufacturing

• State- of- the art painting and paint

quality inspection facilities

• Investment casting

• Well equipped metrology lab

• Heat treatment facilities

• CED coating

• Coordinate measuring machine

• Specialized test facility for

fire fighting pump sets

• Repli-casting

Seamless Pattern Manufacturing Facility

Paint Shop Facility

Surface preparation before painting. Surface as per SSPC-SP-grades.

Painting is carried out in enclosed paint booths. We can offer painting for different paint schemes in Epoxy and PU categories. We are experienced in meeting the specification requirements of global EPC contractors and customers like Bechtel, Alstom, Shell etc.

Adhesion Test as per ASTM 3359

Holiday Testas per ASTM D 5162-01

Dry Film Test (DFT) as per SSPC-PA-2

For achieving world class quality levels, special manufacturing and testing facilities have been established as follows

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