KCP HE's manufacturing facility is spread over 2 locations, Thiruvottiyur in Chennai and Arakkonam about 100 km from Chennai. Given below is a brief summary of both the facilities.
| Location | Plant Area (m2) |
Cover Area (m2) | Capacity Per Year (MT) |
Shop | Shop Dimensions |
Crane Capacity | Height Under Hook |
| Thiruvottiyur (1957) |
300,000 | 50,000 | 4,000 | Foundry (2) (8640 m2) |
240 m x 26 m 240 m x 10 m |
64 T 30 T |
12.5 m 12.5 m |
| 5,000 | Fabrication (3) (12,126 m2) |
190 m x 30 m 190 m x 30 m 300 m x 27 m |
30 T 30 T 300 T |
12.5 m 12.5 m 12.5 m |
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| Machining (3) (15,112 m2) |
118 m x 37 m 120 m x 26 m 300 m x 27 m |
50 T 50 T 300 T |
12.5 m 12.5 m 12.5 m |
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| Arakkonam (1984) |
40,000 | 10,000 | 1,500 | Fabrication (2) | 240 m x 26 m 190 m x 26 m |
50 T 30 T |
9 m 9 m |
| Total | 340,000 | 60,000 |
Thiruvottiyur Plant:
KCP HE Plant I at Thiruvottiyur, Chennai, setup in 1955, is one of the largest and fully integrated Heavy Engineering workshops in India that caters to a wide range of heavy mechanical equipments and sub-systems for the core sector industries. The facility consists of an integrated Steel Foundry, Heavy Fabrication, Heavy Machining & Assembly Shops.
Plant Gallery:
Foundry:
The Steel Foundry has the basic foundry infrastructure consisting of sand mixing plants, pattern shops, moulding tools, and heat treatment. A computerised optical spectrometer for chemical analysis upto 19 elements during melting sequence ensures chemistry of molten metal to suit diverse range of steel castings for different applications.Melting capacity of molten metal up to maximum 50 T and a single piece casting capacity of up to 30 T.
| Process | Equipment | Capacity | |||
| Melting | Induction Furnaces (4) Arc Furnace (1) |
3 T / 8 T / 13 T / 20 T 6 T |
|||
| Heat Treatment | Oil Fired Furnaces (4) / Electric Furnace (1) | 3.5 m (H) x 5.5 m (W) x 8.5 m (L) | |||
| Stress Relieving by internal firing method and large jobs using temporary furnaces | |||||
Fabrication Shop:
The Fabrication shop has 3 bays dedicated to Heavy, Medium and Light work and fitted with fabricating process equipment with a capacity to manufacture single piece weight of up to 350 T, Thickness of up to 250 mm, Diameter up to 660 mm and Length of 34 m.
The Fabrication shop consists of a group of forming machinery, which are supported with a large material preparation shop. These equipments use computer generated digital drawings and plate allocation diagrams for material profile generation. The welding technicians are fully qualified & specialised in various state of art welding methods. They undergo continuous training to be exposed to the new welding technology and best practices.
The Fabrication shop consists of a group of forming machinery, which are supported with a large material preparation shop. These equipments use computer generated digital drawings and plate allocation diagrams for material profile generation. The welding technicians are fully qualified & specialised in various state of art welding methods. They undergo continuous training to be exposed to the new welding technology and best practices.
Machining Shop:
The shop is spread over 3 bays dedicated to Heavy, Medium and Light with an assembly facility. A wide range of CNC based heavy machines are available capable of producing rough machining to finished components.
Apart from the above, specialised heavy machinery, various conventional machine tools like vertical boring machine, horizontal boring machine, lathes, radial and universal drilling machines, milling machines, jig boring machines, slotting machine, etc., are also available.
| Process | Equipment | Capacity |
| Gear Cutting | Gear Hobbing Machine (2) | 8.5 m Diameter x 45 Module |
| Pinion Hobbing Machine (1) | 800 mm x 4 m x 30 Module | |
| Machining | Vertical Turning Lathe (20) | 12 m Swing Diameter x 5 m |
| Double Column Plano Miller (2) | 10 m Bed Length x 4.2 m x 2.5 m | |
| Heavy Duty Lathe (6) | 7 m Swing x 25 m Length | |
| Horizontal Boring Machine (6) | 24 m Bed Length x x 200 mm Spindle | |
| Drilling Machine for Nozzle drilling (6) | Upto 100 mm | |
| Deep Hole Drilling (1) | 63 mm Diameter x 2 m Length |
Transport:
Sea Port: Close to Chennai, Ennore & L&T Katupalli ports with excellent facilities for transporting large size vessels. We also undertake site fabrication and erection in case of extra large equipments which cannot be transported. Road:Close to NH 4 (to Mumbai), NH 5 (to Kolkatta) and NH 45 to transport equipments up to 150 T. Airport:Approx 30 km from the Chennai Airport.
Arakkonam Plant:
KCP HE Plant II, located at Arakkonam about 100 Km from Chennai, established in 1984, is a dedicated heavy fabrication facility geared to specific customers' requirements.
| Process | Equipment | Capacity | |
| Profile Cutting: | Oxy Acetylene Gas Cutting (1) | 5 m x 25 m (W x L) | |
| Plate Bending: | Roll Bending Machine (2) | Cold Rolling to 75 mm Thick x 2500 mm (W) Cold Rolling to 36 mm Thick x 3000 mm (W) |
|
| Welding: | Welding Procedures | SMAW, SAW, GTAW, MIG, TIG, FCAW, ESSC, Tube Sheet, Overlays | |
| Heat Treatment: Stress Relieving & Annealing |
Oil Fired Furnace (1) | 8.5 m x 5.5 m x 3.3 m | |
| Surface Finishing: | Sand Blasting & Airless Spray Painting | ||
Plant Gallery:
Transport:
Sea Port: 100 km to Chennai, Ennore & L&T Katupalli ports with excellent facilities for transporting large size vessels. We also undertake site fabrication and erection in case of extra large equipments which cannot be transported. Road: Close to NH 4 (to Mumbai), NH 5 (to Kolkatta) and NH 45 to transport equipments up to 150 T. Airport: Approx 120 km from the Chennai Airport.
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