PRESENTATION ON

SUMMER TRAININGAT

KEC INTERNATIONAL LIMITED,JAIPUR

About KEC

Founded by Ramjibhai Kamani in 1945.

Became first electric power transmission company in Asia.

India’s second largest manufacture company of electric power transmission towers.

One of the world’s largest Power Transmission Engineering Procurement and Construction companies.

Supplying 3/5 of India’s demand for transmission towers.

Supplies Towers to more than 45 countries. Major Clients Of Company are USA, BRAZIL, ARGENTINA,AUSTRALIA etc.

KEC today is a 4000 crore turnover flagship company of RPG group

A transmission tower is usually a steel lattice tower, used to support an overhead power line.

Used in high voltage AC and DC systems.

Manufactured in wide variety of shapes and sizes, typical height ranges from 15 to 55 meters.

All the electricity stations, mobile networking, radio broadcasting and television antennas are connected via these towers.

Power transmission tower takes upto two weeks to be completed.

Introduction

SOME PRODUCTS OF THE COMPANY

ELECTRICITY TOWERS MOBILE TOWERS

RAILWAY ELECTRIFICATION TOWERS

ANGLES USED IN BRIDGES

NECESSITY OF TRANSMISSION TOWERS

Transmission towers are used to transmit power from one place to another.

Major application areas:

Mobile Networking Radio Broadcasting Television antennas Electricity transmission

YARDQUALITY ASSURANCEPRE PRODUCTIONFABRICATIONGALVANIZINGTESTINGASSEMBLYMAINTENANCE

Departments in KEC

MANUFACTURING PROCESS OF THE TOWER

flow chart

PROCEDURE FOLLOWED BY THE COMPANY FROM STARTING TO END

STAGE 1

• THE BASIC RAW MATERIAL OF A TOWER ARE THE STEEL ANGLES AS SHOWN IN THE FIGURE.

• THE RAW MATERIAL SUPPLIED BY THE CLIENTS OF THE COMPANY IS UNLOADED IN THE RAW YARD AREA OF THE COMPANY

RAW YARD AREA

A PICTURE OF RAW YARD AREA OF KEC, JAIPUR

STAGE 2

RAW YARD AREA QUALITY CHECK AREA

• IN QC AREA IT IS CHECKED WHETHER THE SUPPLIED MATERIAL IS UPTO CORRECT INTERNATIONAL STANDARDS OR NOT.

• IF IT IS NOT THERE IS A POSSIBILITY OF FAILURE OF TOWER.

• THE COMPANY HAS DIFFERENT CHARTS AND TABLES TO CHECK THE QUALITY OF THIS RAW MATERIAL.

• FROM QC AREA THE RAW MATERIAL IS FURTHER SENT TO THE FABRICATION AREA.

QUALITY CHECK AREA

A PICTURE OF QC AREA OF KEC, JAIPUR

QC AREA FABRICATION AREA

STAGE 3• IN FABRICATION AREA, THE

RAW MATERIAL IS FABRICATED ACCORDING TO THE ENGINEERING DRAWINGS PROVIDED BY THE ENGINEERS.

• FABRICATION INCLUDES THE FOLLOWING :

PUNCHING SHEARING BENDING

STAMPING BLANKING SPOT WELDING

STAGE 4

FABRICATION AREA GALVANIZING AREA

• IN GALVANIZING AREA, THE FABRICATED MATERIAL IS GALVANIZED TO PROTECT AGAINST CORROSION.

• THE ATMOSPHERIC MOISTURE CAN CORRODE AND DEGRADE THE QUALITY OF THE TOWER.

• ALSO THE RAIN ALSO AFFECTS THE TOWER QUALITY BADLY.

• THE MATERIAL IS COATED WITH ZINC BECAUSE OF ITS INERT NATURE TOWARDS WATER.

PROCESS FOW CHART OF GALVANIZING DEPARTMENT

Hot Dip Galvanization

It the process of applying a protective zinc coating on iron or steel by passing the metal through a molten bath of zinc to prevent it from rusting.

Temperature of molten bath is around 860°F(460°C).Zn+O₂=ZnOZnO+CO₂=ZnCO₃

Hot dip galvanization

CAUSTIC CLEANSING-The product is dipped into hot alkali solution to remove contaminants such as dirt, grease, paint markings and oil.

RINSING-Alkali is removed by washing lightly with water.

PICKLING-The product is dipped into a dilute solution of HCL to remove scales and rust.

RINSING-HCL is removed by washing with water.FLUXING-Zinc ammonium chloride is applied to

remove oxides and further formation of oxides on the surface of steel and promotes bonding of zinc to steel

Surface preparation

The steel is dipped into the molten zinc bath and held there until the temperature of the steel equilibrates with that of the bath.

Lead is often added to molten zinc to improve its fluidity and helps to prevent floating dross.

Galvanizing

Galvanized coating

steel

After hot dip galvanized steel item is removed from the galvanized bath it is immediately quenched in a sodium dichromate solution.The dichromate quenching cools the item so that it can be quickly handled and conditions the surface to maintain its bright appearance. Dichromate quenching will reduce white rusting problems.

Quenching

WHY IS GALVANIZING SUSTAINABLE?

Low Life Cycle Energy Resource Efficient

Recyclable

Long-life Cost Efficient

GALVANIZING AREA TESTING AREA

STAGE 5• AFTER COMPLETING

GALVANIZING, THE COMPLETED MATERIALS ARE SENT TO THE TESTING AREA.

• IN TESTING AREA, TESTING OF TOWER IS PERFORMED TO CHECK ITS STRENGTH DURING CHANING WEATHER CONDITIONS.

• IF PASSED TOWER IS DISASSEMBLED AND THEN SENT TO THE ERECTION SITE.

• IF FAILED, THE MATERIAL IS SENT BACK TO THE SUPPLIER AGAIN.

A PICTURE OF TESTING AREA OF KEC, JAIPUR

INSPECTION AND OBSERVATIONS

For checking zinc coating thickness, a special device called Elcometer is used

CONCLUSION

Training have helped us a lot in enhancing our inter and intra – personal skills there by

Furnishing our attitude, skill and knowledge dimensions. Further the guidance, support, co-

Operation and assistance provided by Engineers , workers and staff members at the KEC

INTERNATIONAL Ltd. helped us a lot in adapt ourself to actual working environment & Working

in coordination with other team members.

REFERENCES

KEC International Limited .Company’s Official Website (Reference made 4 June

2013) www.kecrpg.com/

Drawing sample of tower part. Dao Power co. (Reference made 27 June 2013).

www.daopower.com

THANK YOU!!!