KLW. Setting the world in motion

Page 1KLW. Setting the world in motion 1

KLW. Setting the world in motionKLW. Setting the world in motion


Interpipe – global steel pipe and railway product company

Interpipe is a global steel pipes and railway wheel, axle and wheelset producer

KLW is a single brand of Interpipe’s railway product division

Page 3KLW. Setting the world in motion

Interpipe at a glance. 2018

Global steel pipe and wheel producer:

Wheel sales – 189 thousand tons

Pipes – 668 thousand tons

In-house steel production:

973 thousand tons

Interpipe employees:

12 thousand people

Trade offices in seven countries

Logistically well connected to key markets in CIS, MENA and Europe

Customers in 80 countries

Interpipe is approved by major national operators of European countries, North America and other regions.


The brief history of the company

Origin of the company’s wheels productionThe starting point of the Interpipe and its KLW brand history was over eighty years ago when the first railway wheel was produced at Interpipe NTRP mill.

The key dates in our history1935 The first wheel was rolled off the production line1972 New production line for railway wheels and tyres was launched1979 Interpipe NTRP started to supply to Eastern Europe1984 Major modernization production program was introduced 1990 The first supplies of Interpipe NTRP wheels to India and China1999 Sales company KLW Wheelco was found in Switzerland2000 Interpipe was recognized as the largest railway wheels exporter2002 - 2008 Interpipe implemented a full program of significant investment to increase production capacities at the Interpipe NTRP mill2016 Interpipe launched new facilities for in-house wheelset assembling, additional finish-machining and finishing operations


Interpipe has divisional business structure


5 mills within 93 miles

Favourable location and compact layout of production mills

Dnipropetrovsk

Ukraine


KLW introduction

Karl Liebknecht Werk


Global wheel sales geography. 2018

In 2018 KLW wheel products were sold in more than 40 countries

- KLW regional offices % - share of sales in the region, tons

3% 22%33%

39%

3%


Wheel, axle & wheelset production cycle

Full production process is under control

100% self sufficiency with steel billets for wheel production


State-of-the-art steel mill Interpipe Steel

Scrap Processing capacity of Interpipe Vtormet: 1.35 mln tons per year

Screp collection network of 11 sites in 7 regions of Ukraine

Modern scrap processing equipment supplied by Senneboghen, «AKROS HENSEL»(Germany) and hydralic press cutters (Europe)

Steel making: in-house greenfield Interpipe Steel was built by DANIELI in 2012

Investment: 700 million USD

Annual capacity: 1.32 million tons of round billets per year

Actual production in 2018: 973 thousand tons of steel

Interpipe Steel has flexibility to make dean steel with no limits to utilize vacuum degassing


KLW provides its clients with:

More than 250 types of railway wheels, tyres and axles for freight and passenger wagons, locomotives and subway wagons

Design complied to individual requirements of clients In-house steel production Wide range of tyres EN, AAR and GOST certifications

KLW product portfolio


KLW committed to freight transportation

KLW supply wide range of freight wheelsetsDesigns Maximum speed, km/h

Axle load, t

ULT 25 120 25

ULT 23 120 23.5

ULT SF 120 25

ULT 90 120 22.5

ULT 1000 120 22.5

IBE 23 120 22.5

BA 314 120 25

BA 303 120 25

BA 004 120 22.5

BA 382 120 20

9073 120 20

BA 375 120 16 / 18

R61 120 25

813 A 120 22.5


Alternatives: ULT SF, BA 314, BA 303

ULT 25Ø 920, 25t

COMPONENT TECHNICAL DATA

WHEELSETDrwg № WS-001-18

Wheelset maximum load 25 t

Maximum speed 120 km/h

Wheelset weight 1 076 kg

WHEELDrwg № KP-0050-16 CV

Wheel steel grade ER7 Category 2

Nominal diameter / Worn diameter Ø 920 / Ø 840

Wear Range 35 mm

Tread profile EN 13715

Low stress wheel Yes

Braking Level Performance Acc. toUIC 510-5

Advanced: Low deflection and stresses with K blocks

AXLE Drwg № OC-0007-14R

Axle type BA 302

Axle steel grade EA1N Category 2

Axle length 2180 mm

Distance between axles boxes 2000 mm

NORMS

Wheelset - EN 13260Axle - EN 13261Wheel - EN 13262

CE Certificate: Module (CB/CD)

TSI: YES – Acc. to Commission regulation including Appendix C (EU) № 321/2013 amended by № 1236/2013 (EU) 2015/924 (TSI RST WAG)


Alternatives: BA 004

ULT 23Ø 920, 23.5t



Wheelset maximum load 23.5 t






Wear Range 35 mm






Axle type BA 002


Axle length 2180 mm


NORMS

Wheelset – EN 13260Axle – EN 13261Wheel – EN 13262




Alternatives: ULT 25, BA 314, BA 303

ULT SF (Standard Freight Axle)

Ø 920, 25t









Wear Range 35 mm





AXLE Drwg № OC-0018-16

Axle type ESFA


Axle length 2180 mm


NORMS





Alternatives: KWL 90, 9090

ULT 90 (for Franco-Spanish Bogies)

Ø 920, 22.5t, UIC Gauge 1435mm





Wheelset weight 1133 kg




Wear Range 35 mm





AXLE Drwg №OC-0014-17

Axle type KLW 90


Axle length 2350 mm


NORMS





ULT 1000Ø 1000, 22.5t, UIC / Spain Gauge








Nominal diameter / Worn diameter Ø 1000 / 920

Wear Range 35 mm





AXLE Drwg №130.92.32.00.01

Axle type Spanish Axle


Axle length 2350 mm


NORMS





IBE 23Ø 920, 22.5t, Spain Gauge 1668mm









Wear Range 35 mm




Standard

AXLE Drwg №130.92.32.00.01

Axle type Spanish Axle


Axle length 2350 mm


NORMS



TSI: YES – Acc. to Commission regulation (EU) № 321/2013 amended by № 1236/2013 (EU) 2015/924 (TSI RST WAG)


Alternatives: ULT SF, ULT 25, BA 303

BA 314Ø 920, 25t






WHEELDrwg № KP-0012-15



Wear Range 35 mm




Standard


Axle type BA 302


Axle length 2180 mm


NORMS





Alternatives: ULT SF, ULT 25, BA 314

BA 303Ø 920, 25t









Wear Range 35 mm




Standard


Axle type BA 302


Axle length 2180 mm


NORMS





Alternatives: ULT 23

BA 004Ø 920, 22.5t






WHEELDrwg № KP-0016-03C



Wear Range 35 mm




Standard


Axle type BA 002


Axle length 2180 mm


NORMS





Alternatives: 9073, BA 381

BA 382Ø 840, 20t









Wear Range 35 mm






Axle type BA 002


Axle length 2180 mm


NORMS





Alternatives: BA 382, BA 381

9073Ø 840, 20t









Wear Range 30 mm




Standard

AXLE Drwg № OC-0008-18

Axle type 9073


Axle length 2200 mm


NORMS





BA 375Ø 730 and Ø 760, 20t, UIC and Spain Gauge





Wheelset weight 775/861 kg



Nominal diameter / Worn diameter Ø 730/760 /680

Wear Range 35 mm




Standard

AXLE Drwg № 90.00.01.A

Axle type BA 188


Axle length 2180 mm


NORMS





R61Ø 920, 25t, Brake Disc









Wear Range 35 mm


Low stress wheel No

AXLE Drwg №130.92.62.00.01

Axle type with Brake Disc


Axle length 2180 mm


NORMS





813 AØ 813, 22.5t









Wear Range 35 mm


Low stress wheel No


Srandard


Axle type BA 002


Axle length 2180mm


NORMS

Wheelset - EN 13260Axle - EN 13261Wheel - EN 13262 TSI: NO


KLW produce railway wheels for freight and locomotive transport from steel grades B, C and D

KLW produces AAR wheels for USA and Canada

Drawing Standard Application

В-38 KP-0035-11 AAR M107/M208Freight wagons with high axle load

Е-28 KP-0041-11 AAR M107/M208Freight wagons with high axle load

H-36 KP-0055-05A AAR M107/M208Freight wagons with high axle load

J-33 KP-0058-05A AAR M107/M208Freight wagons with high axle load

J-36 KP-0059-05A AAR M107/M208Freight wagons with high axle load

P-33 KP-0022-18 AAR M107/M208Freight wagons with high axle load

K-36 KP-0022-18 AAR M107/M208Freight wagons with high axle load

E-40 KP-0060-05A AAR M107/M208 Locomotive transportA-41 KP-0061-05A AAR M107/M208 Locomotive transportD-42 KP-0062-05A AAR M107/M208 Locomotive transportA-43 KP-0063-05A AAR M107/M208 Locomotive transport


KLW aims to provide its clients with high-quality transport products and services for heavy or oversized shipments, which are often critical for world economic development and functioning.

KLW mastered and certificated wheels from new high impact steel grade “D”.

New steel grade “D” carries a special chemical composition and heat treatment, which provides mechanical properties of strength and ductility according to the standard AAR M 107/208.

KLW has developed new sizes of wheels for heavy traffic with an axle load of 32,5 tons.

KLW committed to Heavy Haul


Since 2014 KLW produces KLW produces axles in compliance certificate of axles with requirements of TSI CR RST WAG “Production quality management system” and EN 13261 "Rail Transport. Wheel sets and trolleys. Axles. The requirements to the product.“

ANNUAL CAPACITY OF FINISH MACHINED AXLE PRODUCTION TOTALS 10 000 PIECES PER YEAR.

KLW produce railway axes

Diameter of body, mm

Axle length, mm Axle load, t Certificate

ESFA 173 2180 25 EN 13261

BA 302 173 2180 25

BA 002 173 2180 23,5

G7’’x12’’ 203,2+3,175 2266,95+/-1,6 AAR M 101

K6½’’x9’’ 187,325+3,175 2213,768+/-1,6


KLW: Smart solutions for passenger transport

Wheels for passenger traffic such as EMU/DMU wheels have high performance and a design made in accordance to requirements of each customer.

KLW SOLUTIONS ARE THE COMBINATION OF QUALITY, SAFETY AND FLEXIBILITY.

Wheels are designed and produced according to clients request or drawings with special requirements.

Outside diameter

Inside diameter

Width of rim

Diameter of hub

Height of hub

Diameter of hole in hub

Thickness of disc

Mass

D, mm d1, d2, mm

H, mm d, mm L, mm d0, mm t1, t2, mm

kg

700-1269 600-1100 95-160 185-350 150-250 110-120 15-80 165-1050


Commitments to quality approved withinternational certification

System of quality management

•ISO 9001 (TUV CERT, Germany)

•AAR M-1003 (Association of American Railroads, USA)

•ISO/TS 22163:2017 (DQS)

•Certifications from leading railway operators:

•AAR/ Association of American Railroads

•DB/German Railroads

•Railtrack/Operator of railway infrastructure of Great Britain

•OBB/Austrian Railroads

•PKP/Poland Railroads

•SZ/Slovenian Railways

•BDZ/Bulgarian Railways

•ZSSK/Slovakian Railways

•RS FZhT/Russian Railways

•Ukrsepro/Ukrainian Railways


KLW provides high level of service to customers

In 2016 KLW finished investment project which is aimed: to provide customers with additional services on finishing bore in the wheel, to increase machining capacities for machining and finishing processes, to add machining activities not performed earlier like drilling of web, to improve the quality of surface protection of the wheels, to improve the control systems of output quality, to assemble wheelsets

Investment: 16.2 million USD

Equipment

Lathes for increased outputFor finish machining of the bore in the wheel hub for mounting of wheelsFor bore drilling of the disc for the installation of brakes disc

For the coating with operating covers

Modernization of wheel control and acceptance stand

New control measuring equipment


In 2019, a new line for finishing machining of railway wheels will be launched. KLW will be able to:

Scale-up production of finish-machined wheels by 13,900 tons/year (about 42,000 pieces/year)

Increase wheel production for suburban diesel and electric trains and high-speed transport

Investment: 14.2 million USD

New facilities:

Automatic line for full-profile wheel machining

Automatic geometry control unit

Wheel balancing machine

High-precision wheel finish-machining unit for drilling and boring

Investments for increasing wheel production


Reliable partner of rail operators, wagon builders and wagon keepers


INTERPIPE NTRP

RAILWAY WHEELS PRODUCTION

INTERPIPE NTRP

RAILWAY WHEELS PRODUCTION


Interpipe committed to safety

Interpipe key priority: health, safety and well-being of its employees in all of the Company’s business activities.

Interpipe has identified the hazards and risks associated with its activities and invested substantial financial and organizational resources to minimize and eliminate these risks.

Interpipe & KLW has opened Common Medical Centre of Interpipe (CMC), which introduced a systematic approach to providing medical assistance to all the employees of the Company.

Interpipe & KWL provides safe working conditions according to international norms and standards of OHSAS 18001 and ISO 14001.

KLW corporate safety man


Interpipe NTRP. Railway products

Production in 2018: 189 800 tons / 461 426 wheels

Railway wheels under KLW brand are produced at the company's Interpipe NTRP mill in Dnipro, Ukraine.

Interpipe NTRP has eighty years of experience in manufacturing of railway wheels.


Railway wheel production


Wheel production facilities and processes

Process Facility

Steel mill Electric Arc Furnace, Ladle-Furnace, Vacuumator, Blank Continuous Casting Machines

Forging and heat treatment Annular Furnace, MN presses

Machining of the wheels Turning-and-boring lathes, drilling lathes

Web shot blasting Pangborn unit

Marking Hilti marker or percussion pistol, robotic marking

Quality control UTS-600 machine, impact pendulum-type testing machine, universal computerized testing machine “Hydropuls Sinus 250”, balancing machine, hardness testing machine

Painting Full-automatic painting line


Interpipe NTRP:Railway axle and wheelset production shop

The capacity of the line for railway axle production is 10,000 finish-machined pieces per year.

Railway axles and wheelsets are certified in line with requirements of EN and AAR standards.


Railway axle production


Railway wheelset production


Thank you!

KLW. Setting the world in motion

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