klw. setting the world in motion · kss 1600 sawing unit, manufactured by linsinger company from...

KLW: setting the world in motion

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KLW. Setting the world in motion


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KLW brand

KLW is the wheel brand of global steel company Interpipe. Interpipe is one of the largest producers of railway wheels in the world.

KLW is a single brand of Interpipe’s wheel division consolidating sales to all of our strategic markets.


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Interpipe – international company, producer of steel pipes and

railway wheels

Global steel pipe producer

Production, 2012 – 1,1 mln tons of steel pipes:

Seamless pipes: 830,000 tons Welded pipes: 260,000 tons

Third largest producer of forged railway wheels in the world

Production, 2012: 205,000 tons

Revenues 2012: US$ 2 bln

Third largest producer of forged railway

wheels in

the world


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KLW Wheelco – the major supplier and the largest exporter of the

railway wheels


Vertically Integrated Business Model

Global net work of sales

offices

Pipe & wheel

production Steel production Scrap processing

Interpipe Steel

Modern electric steel smelting

complex

INTERPIPE NTRP

INTERPIPE NIKO TUBE

INTERPIPE NMPP

Ukraine, Russia, CIS

Europe

Middle East

North America

Scrap Processing &

Collecting Plant


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Strategic investment – Interpipe Steel

In 2012 Interpipe has launched new electric steel

melting complex Interpipe Steel.

The new mill ensures the provision of company’s

plants with high quality billets for the production of

seamless pipes.

Investments into the project amounts to 700

million USD.

When Interpipe Steel reaches its full capacity in

2014, it will become the largest electric steel

smelting complex in Eastern Europe. Its capacity

will amount to 1.32 million tons of round wheel

and pipe billets per year.


In 2012 pipes were sold in 64 countries, wheels were sold in 25 countries

A Global Sales Geography

10% North America

19% CIS

28% Russia

28% Ukraine

7% MENA

7% Europe


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INTERPIPE NTRP

RAILWAY WHEELS PRODUCTION


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Production site – INTERPIPE NTRP

Railway wheels under KLW brand are produced at the

company's Interpipe NTRP mill in Dnepropetrovsk,

Ukraine.

Steel melting shop in the mills structure enables us to

enforce quality control at all stages of product

manufacturing – from steel melting to the acceptance

test of wheels and tyres.

The mill has more than seventy years of experience in

manufacturing of railway wheels.

In 2012 total Internal rejection level made less

than 1%


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Production capacities

Project capacity:

Steel – 530 thousand tons

Wheels – 250 thousand tons

Tyres – 62 thousand tons

Steel pipes– 1024 thousand tons


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Huge experience in the market place

1935 The first wheel produced

1970 Ten millionth railway wheel produced

1972 New production line for railway wheels and tyres launched

1979 Wheels under KLW brand started to be supplied across

Eastern Europe

1984 A major modernization program at railway wheels shop

introduced

1990 The first supplies of KLW wheels India and China made

1999 Sales company KLW Wheelco found in Switzerland

2000 Interpipe recognized as the largest railway wheels exporter

Interpipe implemented a full program of significant

investment to increase production capacities at the Interpipe

NTRP mill

2002

2008


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Certification of railway products

Quality Management System

ISO 9001 (TUV CERT, Germany) AAR M-1003 (Association

of American Railroads, the USA)

Products have been certified by the leading railroad

operators:

AAR/Association of American Railroads

DB/German Railways

Railtrack/Operator of the Great Britain railway infrastructure

OBB/Austrian Railways

PKP/Polish Railways

SZ/Slovenian Railways

BDZ/Bulgarian Railways

SBB/Swiss Railways

MAV/Hungarian Railways


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WHEELS PRODUCTION TECHNOLOGY WHEELS PRODUCTION TECHNOLOGY


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Interpipe NTRP wheel rolling workshop structure

The wheel rolling production includes the following:

Press rolling line for production of wheels with diameters from 650 to 1269 mm

Press rolling line for production of wheels and tires

Mechanical finishing floor for wheels

Heat treatment floor for wheels and tyres

Shot peening line for wheels

Non-destructive testing line for wheels and tyres (ultrasonic, magnetic particle

testing, and hardness control)

Finishing floor for wheels and tyres


Linsinger sawing unit (Austria)

Project investments: USD 3.744 million

Commissioned: 30.07.12.

Output capacity achieved:

KSS 1600 sawing unit, manufactured by

Linsinger Company from Austria has the

productivity of 21 cuts / hour.

Wheel production technology at Interpipe NTRP



Continuously cast billets' stock



Metal for production of wheels comes to the blank

production section of the wheel rolling workshop in

the form of continuously cast billets (CCB)

The list of works, carried out by the blank

production section of the wheel rolling workshop,

includes CCB cutting into single bars, notch cutting,

and breaking.

Blank production section


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Rolling area

Ring furnaces are used to heat billets for rolling.


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Press rolling line Rolling area

Press rolling operations are conducted by the

following units:

press 20 MN

press 50 MN

press 100 MN

wheel rolling mill

press 35 MN


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Press rolling line Heat treatment floor for wheels

The heat treatment floor is used to

subject wheels to

thermostrengthening

for formation of a set of steel’s

mechanical properties:

discontinuous quenching of rims

with subsequent tempering.


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Mechanized line for wheel treatment by shot

The following has been introduced:

technology of wheel treatment by shot

to clear the wheel disk surface from scale

technology of wheel disk surface

hardening by shop


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Mechanical finishing floor

In 2008, in the framework of the strategic investment program, the Company installed and

commissioned the automated line for the full-profile finishing of railway wheels with the capacity

of 100 thousand mechanically finished wheels a year. The floor is equipped with 4

"HEGENSCHEIDT" Company machines for mechanical finishing of wheels.

CNC line (SEDIN, Russia) with the capacity of 50 000 pieces / year for the finishing of wheel

centers and tyres. The finishing of the locomotive wheels will become the result of the current

modernization.


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Automated wheel control line

It consists of the following units:

Unit to control geometrical parameters

of railway wheels, manufactured by

"Amest" (Czech Republic)

Unit to control hardness of railway

wheels, manufactured by "Ernst"

(Switzerland)

Unit for ultrasonic testing of railway

wheels, manufactured by "Starmans"

(Czech Republic)

Magnetic Particle Inspection unit,

manufactured by "Ultracon – service"

(Ukraine)

Bar-coding machine for railway wheels


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Automated wheel control line

Supplementary equipment for acceptance

and control of the mechanically finished

products:

Numerically controlled machine for

maintenance trueing of railway wheels,

manufactured by OJSC "Krasnodar machine-

tool plant" (Russia)

Numerically controlled machine for drilling,

milling and boring, manufactured by OJSC

"Sterlitamak machine-tool plant" (Russia)

Unit to control and eliminate unbalance of

railway wheels, manufactured by "Diamex

2000" (Russia)


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Thank you!

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