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Vulcan Industrial Engineering Company Limited

Vithal Udyognagar, Anand, Gujarat

| GST  24AAACV2931Q1Z2

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Vulcan Industries was founded in 1971 in Mumbai, India. Initially Vulcan dealt with mud pumps & trading in drilling accessories. Meanwhile Vulcan also offered consulting services to various end users. It then graduated into manufacture of drilling accessories which made a mark for itself among the mining companies in India.

We shifted our base from Mumbai to Anand in 1985 with a vision to venture deeper into the manufacturing activities. Between late 80s & 90s the company saw a rapid growth rate in manufacturing facilities and the number of employees. As we introduced mining equipments spares and special industrial gearboxes, the number of employees multiplied.
Expansion
With time and requirement we set up our new unit in 2003. It catered to the requirements of standard industrial gear boxes & accessories. Within a span of four years another unit was set up at Sunav. It concentrated on the manufacture of mining replacement parts, sub-assemblies, fabricated components & special gear boxes.
Today
Today Vulcan is spread over three units of 20,000 sq meters constructed manufacturing area with state of the art manufacturing facilities covering its three divisions. Apart from the offices in India it also has its sales divisions in USA and South Africa. Vulcan has made its presence felt in various industries like Mining, Cement, Steel, Power, Material Handling, Sugar etc. Vulcan has also developed distribution network in all major mining areas worldwide.
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Nature of Business

Manufacturer

Year of Establishment

1971

Legal Status of Firm

Limited Company (Ltd./Pvt.Ltd.)

GST Number

24AAACV2931Q1Z2

Raise Bore Drilling

Raise Bore Drilling

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Fabricated Components
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Fabricated Components

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  • Vulcan manufactures & supply fabricated components like Dipper Handle, Dippers (Buckets), Saddle Block, Crawler Frame, Boom for Rope Shovels & Tubs, Buckets for Draglines.
  • Fabricated components carries heavy load under severe working conditions. Vulcan understands it very well. Latest computer software with 3D modeling is used for stimulation of the component to identify possible stress points so that corrective measures can be taken to avoid possible fatigue failure during operation.
  • Significant aspect of these components is that they should be lighter in weight to optimize machine capacity & efficiency, and at the same time it should have high strength to avoid fatigue failures. Dippers (Buckets) not only go under continuous fluctuating load but also have to withstand against abrasion.
  • Selection of right grade of material plays important role in long trouble free operation of these components. Vulcan uses special grade low alloy steel which are lighter in weight but have high tensile strength to meet the above requirement.
  • Welding is carried out by qualified welders with approved welding procedures. Stress relieving is done by thermal/vibration method. Stringent Quality control practices like dye penetration, X ray, UT & other NDT tests are carried out at every stage of welding.
  • Precision machining is carried out on latest technology CNC machines to achieve high accuracies for proper fitment & smooth operation eliminating possibility of failure.
  • Tubs are manufactured in segments. Controlled assembly is carried out in the workshop to maintain flatness & level of seating surfaces of gear / rail path on tub & maintaining coaxially between gear & rail (swing) circle with respect to central pintle axis.

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Drums, Sheaves & Pulleys
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Drums, Sheaves & Pulleys

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  • Vulcan manufactures & supplies Hoist Drum, Boom Point Sheave, Crowd Sheave for Rope Shovels & Hoist / Drag Drums, Fairlead Pulleys, Sheaves for Draglines.
  • Drums are manufactured by special casting methodology to get castings free from blowholes. The rope grooves are induction/flame hardened to reduce the wear & tear.
  • Vulcan has also introduced new technology wherein Drums are made of Forged fabricated design which has more load carrying capacity. Rope grooves are induction/flame hardened to 54 – 57 HRC hardness. Drum Seals used are also induction hardened. Drum Shaft is manufactured out of volume hardened forged alloy steel precision machined for proper assembly of drum.
  • Vulcan also caters to rebuilding of Drums by re-lagging. Drums are completely NDT checked before & after for possible cracks. Worn out grooves are fully built up covering complete groove profile using special welding electrodes. Re-machining is carried out on CNC operated machines and grooves are brought to original dimensions. Grooves are induction/flame hardened to 54 – 57 HRC hardness. Bearing bores are rebuilt to original dimensions. Vulcan delivers total crack free & stress relieved Hoist Drums.
  • Sheaves & Pulleys are manufactured in both conventional cast design and new forged fabricated design. Grooves are induction/flame hardened 54 – 57 HRC hardness.
  • Vulcan also caters rebuilding of Sheaves. Worn out grooves are build up using special welding electrodes/wires. Grooves are then machined to high finish smooth surface. Shovel Boom point Sheaves are induction/flame hardened to 55 HRC & Dragline Sheaves to 57 HRC hardness. Sheaves are NDT checked before & after rebuild to ensure defect free repairs.

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Gears & Pinions, Pinion Shafts
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  • Hoist Gear

Vulcan manufactures & supply spur or close gap herringbone design Hoist gears for Shovels & Draglines. Hoist Gear is manufactured with conventional alloy steel casting or with new forged fabricated design with core hardness 330 – 360 BHN. Teeth are fully contoured induction hardened 54 – 57 HRC hardness.

  • Hoist / Drag Intermediate gear, Gear Shipper Shaft, Final Drive Gear

Gears are manufactured from forged alloy steel blanks or in some cases forged fabricated design with core hardness 330 – 360 BHN. Teeth are generated by hobbing & are full contoured induction hardened & tempered to 54 – 57 HRC hardness with quality AGMA 8-9/DIN 8. Shot peening is carried out for better fatigue strength.

  • Hoist /Drag Intermediate Pinion Shaft, Swing Pinion, Swing Pinion Shaft, Final Drive Pinion, Motor Pinion Shaft.

Pinions and Pinion Shaft are manufactured from forged alloy steel proof machined bars with core hardness 330 – 360 BHN in single helical / herringbone design. Teeth are generated by hobbing method & are case carburized / full contoured induction hardened & tempered to 58 – 62 HRC hardness with quality AGMA 8-9/DIN 8 or with ground finish with quality AGMA 11-12/DIN 6.

  • Swing Shaft, Shipper Shaft, Drive Shaft.

Shafts are manufactured from forged alloy steel volume hardened bars. Final heat treatment is done when rough machining is within ¼ of final diameter. This increases overall strength & spline thread hardness. Bearing seating diameters are ground for proper fitment of bearings. Splines are cut by generation method on gear hobbing machine to ensure proper contact with mating parts.

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Under Carriage Components
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  • Vulcan manufactures & supplies Undercarriage components like Standard & Oversized Drive tumblers, Idler Wheel, Lower Roller Assembly etc.
  • Vulcan manufactures Idler Wheels, Drive Tumblers out of special alloy steel using State of the art castings technology & ultrasonically tested for defect free casting. Vulcan also offers Drive tumblers with work hardened steel casting having manganese content 18% as cost effective solution.
  • To work with used track chain, Oversized Drive tumblers are also manufactured with increased pitch and wider lugs to compensate with elongated pitch of Track Shoes. Oversize Drive Tumblers are also offered in both special alloy steel & work hardened steel casting options.
  • Vulcan manufactures & supplies complete Lower Roller Assembly which comprises of Roller, Pin & Bushing.
  • Rollers are made out of special alloy steel forging with core hardness 330 – 360 BHN to absorb the shock load. Surface is hardened to 50 – 55 HRC hardness by special spinning in Salt bath. This helps Rollers to work under severe mine conditions including contact stresses, abrasion & shock. Surface hardened rollers maintain contour longer which helps maintain shoe path contour longer. Special surface hardening increases not only Roller life but also shoe life is extended. This results in long term savings as it cuts down replacement costs & machine downtime.
  • Pins are made of alloy steel forged bars & are deep induction hardened with ground finish to reduce wear. Special grade non ferrous centrifugally cast bushings are used to increase life.
  • Vulcan supplies Lower Rollers in assembled condition with bushings to avoid the hassles of fitment at site.

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Racks & Rack Pinions
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Racks & Rack Pinions

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  • Vulcan has developed Racks by close die-forging. Racks are machined on CNC Vertical Machining Centre. Vulcan supplies Racks duly welded & machined for easy replacement at site.
  • Vulcan has specially developed close dies for each type of racks.
  • Rack Pinions are made out of forged alloy steel which has much superior grain structure, higher tensile / yield strength point & greater impact strength in place of original casting design for better durability.
  • Unique method is developed for Rack pinions to produce tooth profile on CNC machines which gives better contact pattern with Rack & withstand heavy fluctuating reversible load.
  • Rack Pinions are heat treated with improvised quench process which increases wear strength & withstands in extreme cold conditions.
  • Internal splines are cut by latest generation CNC form broaching machine to ensure proper contact with mating parts.

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Bushings & Washers
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Bushings & Washers

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  • Vulcan manufactures & supplies Bushings, Thrust Washers in both ferrous & non ferrous material of constructions.
  • Bushing & thrust washer being comparatively low value parts normally much attention is not given for quality of these parts. However they play a significant role in extending the life of more expensive & critical parts.
  • Bushing & Thrust washers are the first line of defense for critical parts of Shovels & Draglines. They are used to absorb abrasive wear. Bushings & Thrust Washers are designed & manufactured to provide delicate balance of toughness & softness required to protect surfaces & maximize life of critical components.
  • Vulcan understands this well & hence is manufacturing bushing by centrifugal casting method only. Different alloys are used for different applications. Spiral Lubrication grooves are provided to ensure proper and even lubrication.
  • Ferrous bushings are of alloy steel & manufactured by centrifugal casting method which gives performance at par with forged bushings. Bushings are fully heat treated to strengthen the assemblies.

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Helical Gear
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Helical Gear

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  • Case hardened and ground helical gears. Hardened and lapped spiral bevel gears.
  • Amply rated bearings. Housing of grey cast iron or Fabricated Construction.
  • Forced or Splash lubrication. Nominal transmission ratios according to modified R20 series.
Reuction Size Ratio Rating (kW)
Single (VAN/VAH) 080 - 560 1.25:1 - 06:10 3.8 - 10600
Double (VBN/VBH) 112 - 800 6.30:1 - 22.4:1 5.4 - 10500
Tripple (VCN/VCH) 160 - 800 20.0:1 - 125:1 3.0 - 02950
Quadruple (VDN/VDH) 225 - 800 112.00 - 630 1.7 - 01190

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Bevel Helical Gear
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Bevel Helical Gear

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  • Case hardened and ground helical gears. Hardened and lapped spiral bevel gears.
  • Amply rated bearings. Housing of grey cast iron or Fabricated Construction.
  • Forced or Splash lubrication. Nominal transmission ratios according to modified R20 series.
REDUCTION SIZE RATIO RATING (kW)
DOUBLE (BBN) 080 - 560 005 - 018 17.5 - 7350
TRIPPLE(BCN) 112 - 800 014 - 100 02.2 - 3100
QUADRUPLE (BDN) 160 - 800 100 - 630 01.2 - 1040

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Loose Gears
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Loose Gears

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  • VULCAN has the capabilities to manufacture any kind of Gear spares for any duty and application - be it standard Gearbox spares, Spur, Helical, Bevel-Helical, Double-Helical Gears, Cluste
  • r Gears etc.
  • VULCAN has got capability to manufacture large and coarse pitch gearing in accordance with IS/DIN/AGMA standards. Gears can be produced with maximum diameter of 3000 mm and pitch up to 40 modules.

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Drill Pipes
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Drill Pipes

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  • Vulcan manufactures Flush jointed drill pipes made from ASTM-A 106 Gr. B Drill pipes has precision machined Pin and Box rotary shouldered connections which are protected by phosphatization to minimize galling. Vulcan drill pipes are of High quality, durable, accurate and maintains concentricity of the tool joints and the pipe to close tolerance to ensure long life.
  • Vulcan offers a choice when it comes to improved properties with desired grade of tubes like API Gr. D, E-75,X-95, G-105 or S-135 depending upon need of end user. Drill pipes are cold drawn / hot drawn tubing providing superior surface finish and tolerance.
  • Integral drill pipes are available from alloy steel SAE – 4145H and of a greater wall thickness duly heat treated for improved wear resistance properties. Friction / SAW/ CO2 welded joints and heat treated end pieces provide maximum strength and optimum durability and long service life.
  • Drill pipes can be ordered with a wide selection of threads including API and BECO. Full range of Subs and crossovers are available, all made of high quality steel and heat treated in the way as pipe end pieces for improved life.
  • Tool joints are manufactured as per API specifications. Threads are precision cut on CNC lathes and are 100% heat treated and tempered to produce a uniform microstructure, high ductility and other mechanical properties in accordance with API specifications.
  • Heat treating the threads ensures not only a long service life, but also simplifies joining and breaking-thereby cutting cycle time. To meet varying demands, we provide a selection of API threads.
  • The threads are phosphatized with zinc for antigalling treatment. Threads can also be carbo-nitrided on specific case to extend life of tool joints. Tungston spray can be provided on the tool joint surface for superior wear protection on special request.
  • Different drill pipe requires special wrench slots to suit the wrenching arrangement of the drill. Vulcan can provide any design of wrench for the given drill pipe. Users needs to specify the type of wrench slots required.

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Stabilizers
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Stabilizers

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  • Stabilizers ensures that the drill bit runs concentrically about its axis and thereby optimizes bit life and penetration rates.
  • The integral rib stabilizers are in Straight / spiral designs assures the best solutions for maximum stiffness. Straight ribbed stabilizers provide full drill string stabilization in piloting operation.
  • Spiral ribbed stabilizers provide full circumferential wall contact during all drilling operations.
  • Stabilizers are machined from special alloy steels, selected for balance in hardness, strength, toughness and resistance to yield in bending.
  • A Choice of wear resistance rib surfaces is available in tungsten carbide buttons or crushed tungsten carbide overlay.
  • Vulcan Roller stabilizers are specially designed for blast hole drilling, this provides an increased torsional strength and larger air circulation area. It’s pressed-in tungsten carbide compacts, working against deeply carburized precision honed, air cooled bearings assure long life.

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Rotary Deck Bushings
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Rotary Deck Bushings

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  • Rotary Deck Bushings assure you an enhanced drilling production, low maintenance and operational costs on your blast hole drills.
  • Our specially designed two piece bearing assembly replaces the frictional non rotating bushings which sits in the deck of a blast hole drill. This in turn gives drill operators extended drill steel life, increased penetration rates and lower rig vibration levels resulting in less downtime and overall reduction of drilling costs.
  • Bushings are available in hardened and extended configurations to suit multilevel operations.
  • The Rotary Deck Bushing has two layers. The inner and the outer rings are seperated with the help of bearing balls. The outer cage remains stationary while the inner cage is free to rotate.
  • During rotary drilling operations the bend casued on the drill pipe engages the inner cage of the Rotary Deck Bushing causing it to move with the Drill Pipe. Depending upon the size of the drill pipe the rotational movement of the inner cage is supported by two or more rows of balls.

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Eu Iu Ieu Drill Pipes
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Eu Iu Ieu Drill Pipes

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  • Large diameter tubing are made upset at the ends of the drill tube to provide greater strength and reduce turbulence to a minimum.
  • Upset may be external or internal in accordance to API specification.
  • Heavy internal and external upset provides bending strength in excess of tube body.
  • The tool joints are welded to the pipe by Friction / Saw / Co2 welding to produce a high integrity solid state weld connection between tool joint & upset end drill pipe.
  • OD or ID weld rams are removed and post weld heat treatment is done of the heat affected zone.
  • Vulcan IU / EU pipes are available with NC-26 to NC-50 specifications.

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Planetary Gear
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Planetary Gear

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This series includes a large number of sizes. The gear units comprise two or three planetary gear stages which can be combined with different primary gear stages like helical, bevel gear stages, worm or a combination of the above.

reduction ratio output torque rating (nm)
double 025:1 - 040:1 15000 - 1650000
tripple 045:1 - 180:1 15000 - 1650000
quadruple 125:1 - 250:1 15000 - 1650000

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Pin Bush Coupling
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Pin Bush Coupling

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Flexible Pin and Bush Coupling, standard series available in various sizes

Feature Values Unit
Torque Range 100 upto 1,350,000 Nm
Diameters 98 upto 1600 mm
Elements Available in 60 and 80 Shore hardness

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Raise Boring Drill Pipes
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Raise Boring Drill Pipes

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Vulcan is associated in supplying drilling accessories to Rotary drilling method of boring ventilations shafts, man ways and other mine operations.
All raise bore drill pipes are designed to meet the specific drilling machine capabilities.
The drill pipe is designed to suit the combined torsional / tensile requirement as well as the unit length and wrenching configuration.
Raise bore drill pipes are integral and optionally even higher strength series integral drill pipes can be supplied.
All rotary thread connections are machined on CNC lathe.
Standard strength series of Raise bore drill pipes are manufactured from SAE-4145H grade steel.
Higher strength series of Raise Bore drill pipes are manufactured from SAE-4340 grade steel.

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Drill Collars

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  • Drill collars are heavy weight integral drill pipe which are used as weight which forces the bit to penetrate the formation being drilled.
  • Vulcan drill collars are capable of supplying sufficient weight in order to rotate at desired speed the bit requires for best performance.
  • Selection of properly engineered drill collar is useful tool in achieving minimum cost of drilling.
  • All drill collars are full length heat treated to obtain the best physical properties. The drill collars are made from SAE 4145 H Grade steel.
  • Drill collars are bored in a way to ensure close tolerance of bore alignment. Threads are cut on CNC lathes to API Specifications.

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Idler Wheel

Idler Wheel

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Lower Roller Assembly

Lower Roller Assembly

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Motor Pinion

Motor Pinion

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Swing System (Slew Bearing)
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  • Vulcan manufactures & supply complete Slew bearing assembly for Shovels & Draglines which comprises of Rails, Swing Roller Assembly, Swing (Rack) Gear & Carrier Ring with all the clamping.
  • Vulcan supplies Swing gear for Shovels in conventional alloy steel single piece casting volume hardened to 240 - 260 BHN hardness. Teeth are cut on MAAG gear shaper with adequate fixtures for uniform cutting. Forged steel gears with hardness 320 - 360 BHN for extended life can be made on requests.
  • Vulcan has also designed Swing gear with two piece design for Shovels for easy maintenance. The two joint pieces are double dowelled to ensure adequate resistance against separation forces acting on the gear.
  • Vulcan has designed Carrier Ring with two piece construction. The unique design has proven to be extremely successful. Carrier Ring is manufactured with alloy steel forged bars & precision machined.
  • Rails are manufactured out of medium carbon alloy steel duly volume hardened to withstand wear & tear. Rolling surface is given proper taper and finish for smooth rolling. Modified rail design with increased collar thickness increases life of the rail. Replaceable thrust collar design can also be provided.
  • Swing rollers are manufactured from forged steel duly volume hardened to avoid wear & tear. Rollers are machined accurately on CNC machines giving proper taper and collar contour. Rollers can be supplied with special polymer bushings for smooth operation.
  • Vulcan can supply complete Swing System as per new design which facilitates easy replacement without dismantling the upper deck which is time consuming & expensive, or individual components can also be supplied as per original design.

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Pins Equalizer Pins
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Pins Equalizer Pins

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Pins are manufactured from medium carbon forged steel. They are deep induction hardened & ground for heavy shock load.

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Power Sharing Central Drive
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Vulcan also undertakes to special one of jobs according to the requirement of customer. This includes engineering, design, manufacture and also reverse engineering wherever required

Advantages

  • Input and out put shaft in the same line
  • Input helical and depending on number of stages 2nd or 3rd stage will be of double helical herringbone gears.
  • Out put with fork coupling or Torsion shaft with geared coupling.

Accessories

  • Out put with fork coupling
  • water oil cooler
  • Can be supplied with control panel for lubrication system.

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Rotary Kellys
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Rotary Kellys

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  • Rotary Kelly is the heavy Square, Hexagonal or triangle steel pipe that, by engaging the rotary drive bushing by means of the Kelly drive bushing, trans
  • mits rotating force through the drill string to the bit. Rotary Kelly are made from SAE 4145H steel.
  • The steel bars are heat treated to obtain best physical properties and to provide a combination of strength, hardness and ductility.
  • The solid heat treated bars are bored to the required specifications.
  • The ends of Kellys are upset and the mid portion can be maintained to provide Square, fluted or Hexagonal sections as per requirement.
  • The threads are cut on CNC lathes to the required API Specifications.
  • The kellys are provided with a hardness range of 285 to 341 BHN and a minimum IZOD impact value of 40 ft/lb are guaranteed one inch below the surface at room temperature.

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Rotary Subs
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Rotary Subs

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  • Rotary Subs are available in reduced section subs mainly Straight Subs, Kelly saver Subs and Shock Subs.
  • Straight subs are used in the initial drilling of the pilot hole to ensure the maximum hole straightness at this vital stage.
  • Saver subs are used as throw away items in a raise bore drill string to save the more expensive drill string components from premature damage.
  • Shock subs are designed to be used between the drill and the drill pipe, on top-drive machines, to dampen shock loads created by the action of the bit. Excessive vibrations or shock loads impart damage to the drill bit, rotary- drive components, drill mast and main machinery. The elasticity provided by the bonded rubber segments of the shock subs helps to protect both drill and bit under adverse drilling conditions.
  • Vulcan Subs are made from SAE- 4145 H Grade steel and heat treated to obtain the best physical properties. Threads are cut on CNC lathe and are phosphatized to prevent galling during initial make up.

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Bcv, Bbp, Bvp & Bpp
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Bcv, Bbp, Bvp & Bpp

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Bevel gear stage, case hardened with lapped or HPG or ground gear teeth depending on load factor.
Sun gear and planet gears are case hardened and ground planet gears are supported with self aligned roller bearings
Internal ring gear out of high-alloy quenched and tempered steel, and the internal spur gear produced by hobbing or shaping.
Load distribution is by a self-aligning sun gear, which is connected with the bevel gear shaft through gear coupling.
Planet carrier with shaft out of nodular graphite cast iron.
Thrust load from the mill absorbed by tilting pad thrust bearing.
Housing out of fabricated steel heavily ribbed, circular form; thus, passing on the thrust load equally and directly into the housing wall.
Bearings; calculated service life at least 85 000 hrs.
Dust and oil proof seals on the input and output shaft along with labyrinth seals.
On type BVP type gearboxes, a helical gear stage (case hardened and ground) is added between bevel and planetary gear set thereby reducing the size of bevel set.
The upper housing section is split and the front part of it can be taken off without having to remove the complete gear unit from the mill. Thus, the input shaft bearings or the bevel gear set can be easily replaced.

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