OKUTAMA KOGYO CO LTD JAPAN
EXPERIENCE OF BUILDING STEEL WORKS FOR 2 X 600TPD LIMEKILNS
ESSKAY MACHINERY (P) LTD, INDIA
ESSKAY MACHINERY PVT. LTD., India (EMPL) was established in 1983 as an Engineering Industry located at Bhubaneswar. The company has been engaged in manufacturing of sophisticated equipment’s for Steel Plants, Aluminum Plants, Fertilizer Plants, Thermal Power Plants, Refineries and Petrochemicals.
The Company executes jobs as per different codes like ASME, TEMA, BS, DIN, IS and ISO.
Okutama Kogya Co Ltd, Japan started mining and selling limestone in 1946. Further in 1961 started the manufacturing of the quicklime and in 1965 started manufacturing slaked lime. In 1967 established Mizuho Kenzai Co Ltd to manufacture crushed stones. In 1975 started manufacturing of PCC. In 1995 started manufacturing if slaked lime for flue gas treatment. In 2002 established Niigata PCC Co Ltd. In 2003 established Yokohama Kairyodo Center Co Ltd to carry out PFI business for the Sewage Works Bureau of City of Yokohama.
In 2007 established Sanyo Taiheiyo Lime Co Ltd, for which they procured the technology from QualiCal International Srl Italy for 2 x 600tpd PFR Limekilns. The steel fabrication work for this project was awarded to Esskay Machinery Pvt Ltd, India in March 2008.
The total tonnage of the work was Approx 1000 MT to be delivered in 6 Months on FOB Vishakhapatnam Port India basis.
Meticulous planning, from the procurement of the raw steel till the loading of the goods on the ship, was made through brainstorming sessions between Esskay, Okutama & QualiCal teams and work was started in March 2008.
A team of four Quality Managers was deputed by Okutama at Esskay Machinery Workshop to check the quality of the workmanship.
The workflow of the Okutama Quality Managers was as follows:
> Checking the Quality of the Raw Steel Plates / rolled sections
> Check & Certify the Marking on the plates to give clearance to cut / bend
> Check & Certify the cut parts for the assembly
> Check and Certify the Assembled Sections for the welding
> Check and give clearance for the Shot Blasting of the items
> Check and Certify the Welded Structure to give clearance for the painting
> Check and Certify the final product for loading on the truck in sections
> Check and give clearance for loading of the sections in containers at Port
The entire Kiln Steel structure was fabricated in parts, suitable for transportation in containers. Numbering and joint marking was made on all the structures for easy assembling and final welding at Okutama Site in Japan.
This was a historical project for EssKay Machinery Pvt Ltd, India as this was the first time an Indian Workshop has done the Steel Fabrication Job for a Japanese Company and exported it.
The project was completed within the agreed scheduled time of 6 months, adhering to the Quality Norms of Okutama Kogyo CO Ltd.
Satyajit Mohanty, Director of Esskay Machinery says “Working with the Quality Managers of Okutama Kogyo Co Ltd, Japan, his team has learnt a lot technically and culturally. This project has enhanced the workmanship and outlook of his workers towards Quality and their current logo is “Quality First Work Must”
Since 2008 the quality norms followed for this project are implemented by Esskay in all their projects and the results are appreciated by all their clients in India and abroad.
The Plant at Okutama Kogyo Co Ltd after the erection is completed looks like :
