In conclusion, we may note that ANKIROS-2018 was a good platform for the presentation of DPL production capabilities and for the experience exchange with colleagues from metallurgical industry.

We express the endless gratitude to our colleagues for the rewarding work at the exhibition. We are absolutely confident that new acquaintances will grow into mutually beneficial business relations.

Only distilled water is used for cooling since it gives the possibility to avoid the sediment formation on the cooling system vessel walls. Nevertheless, earlier purchased distilled water was expensive, had poor quality and led to losses during TFC operation.

Therefore, our own distiller for pure water for TFC operation was successfully purchased and installed during the overhaul at DPL.

During the tour, senior pupils listened to a short story about the work of a modern foundry and were also invited to participate in the process of parts measurement by using the coordinate measuring machine FARO GAGE.

We trust that our young guests enjoyed the excursion to the foundry. Hopefully, one of them will become a student of the relevant faculty in one of the universities in future, and later on, will become a member of our team, since DPL is a promising place to work with modern equipment, interesting tasks and decent wage level.

We would like to express special gratitude to S. Kizhaev – the Associate Professor of Mechanical Engineering faculty of Ukrainian State Chemical Engineering University – and to T. Demchenko – Deputy Director of Slobozhanskaya School № 1 – for their assistance in organizing the vocational guidance event.

The PM system is a set of various works, aimed to technical maintenance and equipment repair, performed according to prearranged plan. In terms of maintenance content, complexity and frequency, scheduled repairs are divided into current, average and general overhaul, where the last one is the most expensive and time-consuming process. Conducting of general overhaul is a great achievement of DPL.

Summing up the results of the recent overhaul, we would like to admit the high level of responsibility, discipline and qualification of the maintenance team. Due to the availability of organizational practice and financial arrangement all planned works were performed efficiently under normal operating conditions. Main overhaul results by sectors are presented below.

Molding department. All inserts and other FBO spare parts have been replaced. It will ensure precision of the machine during blend molding and, accordingly, reduce the quantity of defective products. In addition, the such kind of works were performed, which with minimal financial investment are very costly in terms of time and human resources. Thus, Chief Power Engineer and Instrumentation Automation Engineer conducted a revision of all electrical sensors, performed modernization of molding machine in order to increase its reliability by installing a special supplementary unit. The achievement of casting conveyor highest efficiency became possible as well due to overhaul performance at DPL.

Sand-blending unit. The mixer and supplementary mechanisms (elevators, conveyor belts, etc.) have been repaired, which will ensure uninterrupted operation of the sector for the next working period. Should be mentioned that the buckets were manufactured by DPL own forces (from the creation of the mold till the direct manufacturing).

Melting department. An revision of 4 TFC (thyristor frequency converters) was performed, water pool for furnace cooling was cleaned. According to the results: up to 3 m³ of sediment were eliminated (the previous cleaning was performed last spring). Also, our own distiller for pure water for TFC operation was successfully purchased and installed. Earlier purchased distilled water had poor quality and led to losses during TFC operation.

Finishing department. The repair of catheads has been completed, the issue with shot-blasting machine spill has been solved. Next points of the agenda are financing the repair of the second shot-blasting machine and installation of the third in sand-blending department.

Electromotors. Overhaul covered the repair of about 70% of electric motors: bearings, sealing elements were replaced in order to eliminate dust and fractions penetration and to prevent the electromotor combustion.

In addition to repair works on the manufacturing sectors, special attention was paid to improving the employees’ conditions. We started the implementation of a fundamentally new approach in the outfitting of locker rooms with separation into functional areas. Equipment was moved during the overhaul, so all the forces of mechanical repair division will be directed to the outfitting of new locker rooms for staff.

The operational experience and analysis of financial indicators for the idle hours cost make the benefits obvious. Thereby, overhaul is certainly a necessary process. According to the overhaul results we may talk about the main goal achievement – the prevention of emergencies, of increasing equipment depreciation and, consequently, the increase of efficiency. Suchwise, mechanical repair division already focused on planning the overhaul for the next year.

Dear valued Colleagues and Partners!

Our work is only for strong, persistent, hard-working people!

We would like to express our endless gratitude for your daily work, fruitful cooperation and dedication to the common cause!

Kindly accept our sincerest wishes of good health, happiness, prosperity and great professional achievements for you and your families!

We are proud to share that this year we have become a part of the grandiose running event: our athlete and activist – Human Resources Director Elena Dorotskaya – easily crossed the distance of 21 km, once again proved herself not only as a professional in the field of HR but demonstrated a high sports training and active civil position as well!

In order not to lose the base given to students by educational institutions, to add modern and practical skills to this knowledge and to train graduates for work in manufacturing, the management of our company decided to collaborate with specialized educational institutions and to provide an opportunity of internship at “DPL” for students.

Over the past two years, in cooperation with tutors and lecturers of colleges and universities we help students to apply their theoretical knowledge in practice, trying to convince them to work in their specialty. For example, our foundry provides an excellent opportunity for operators of CNC machine tools to keep pace with the times due to the availability of modern equipment. Thus, this job is not only interesting, but also well paid.

Many young specialists return to our foundry after practice as employees, therefore, we are proud to announce the project of cooperation with profile educational institutions successful and promising for the students themselves and for us as an employer.

Main advantages of this equipment are the following:

•  New modern and reliable furnace design (safe operation, minimal environmental pollution, long life service).
•  Adjustment performed by Indemak team.
•  Melting volume 1.5 tons + 1.5 tons.
•  Frequency of 50Hz (the average frequency of mixing allows for better metal melting and for complex alloys castings production).
•  Ability of both furnaces to work together from one installation.
•  Uniformity of alloy and chemical structure on each individual melting.

The benefits listed above provide an increase in production volumes and improve the quality of products.

New machine will significantly increase the productivity and quality of produced cores by using the COLD BOX method. The main technological advantages of this method are:

• high dimensional accuracy of cores and castings;
• equable strength distribution of the core by its cross-section;
• ability to manufacture cores, combining delicate and massive elements;
• obtaining more complicated cores without additional technological operations for assembling.

Thereby, launch of the new equipment will guarantee the increasing of casting quality and will allow us to master and launch your most complicated multi-sheeted parts within the shortest time frames.

]]> http://dpl-foundry.com/en/modernization-of-the-workshop-for-foundry-cores-manufacturing/feed/ 0 http://dpl-foundry.com/en/purchasing-of-new-melting-furnaces-indemak-2/ http://dpl-foundry.com/en/purchasing-of-new-melting-furnaces-indemak-2/#comments Thu, 01 Feb 2018 07:48:19 +0000 admin http://dpl-foundry.com/?p=3937 LLC “Dnepropromlit” is one of the leading companies, which produces goods of high-strength spheroidal graphite iron, alloyed iron and heat-resistant steel. In order to maintain a leading position in the foundry market, we actively expand the list of manufactured goods, implement innovative casting technologies and optimize technological processes by investing in the purchase of new equipment.

New melting furnaces INDEMAK (Turkey) were purchased by “Dnepropromlit” as a part of manufacturing modernization project. Supplied furnaces are characterized by convenient design, safety, minimal air pollution and long-life service. The new equipment allows to increase the production of liquid metal, to improve the quality of alloys. After the performance of commissioning works we will increase our production capabilities by expanding the range of manufactured castings with heavy castings (weight up to 2.5 tons).

Our main task is to implement your foundry manufacturing projects with maximum efficiency, based on best technical solutions, within the shortest timeframes.

Choose the best, we won’t fail!

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