A Training Presentation On KEC INTERNATIONAL LTD.

JHOTWARA,JAIPUR

INTRODUCTION ABOUT INDUSTRY

Jaipur, RajasthanCapacity36,000 MTs per annum of lattice towers

BRANCHES IN INDIA

Nagpur, MaharashtraCapacity55,000 MTs per annum of lattice towers

Jabalpur, Madhya PradeshCapacity60,000 MTs per annum of lattice towers

KEC PRODUCTES:-

TRANSMISSION

CABLES

RAILWAYS

DISTRIBUTION

TELECOM

WATER TREATMENT

SIMPLE STRCTURE OF TRANSMISSION TOWER

Arm

Foundation

Damper

Peak of transmission tower

The portion above the top cross arm is called peak of transmission tower. Generally earth shield wire connected to the tip of this peak.Cross Arm of transmission towerCross arms of transmission tower hold the transmission conductor.

Cage of transmission tower

The portion between tower body and peak is known as cage of transmission tower. This portion of the tower holds the cross arms

Department in kecPRE PRODUCTION

RAW FINISH YARD

GALVINISING SHOP

FABRICATION SHOP1 & 2 DEPT

PLANNING

TOWER TESTING DEPT.

QUALITY ASSURANCE DEPT.

Pre Production Department

1. Understanding the drawings made in Mumbai Design Department of KEC. 2. Making 2d drawings of each particular part in

Auto-Cad with full dimension. 3. Teaching labors about the drawings.

4. After making one sample model comparing that model with given design. 5. Than calculating the errors and making again an error free drawing. 6. Then again helping the labors in understanding the new Drawing and making the final model..

PRODUCTION PROCESSES

1. Straightening2. Bending3. Punching4. Cutting5. Stamping6. Notching7. Drilling8. Galvanizing

Production Procedure

• Straightening

When angles are imported they are not fully straight according to requirement . For that purpose roller

straightening machine is used.

Bending Bending is a manufacturing process that produces a V-shape,

U-shape, or channel shape along a straight axis in ductile materials

KEC use Hot Bending Machine, which bend the angles by heat treatment process.

Here angles are heated for 30 to 35 minutes and than hydraulic pressure is applied to bend

Punching, cutting & stamping

• Punching :- The main function of punching is to holes on angles at

various distance which have thickness up to 12mm.This m/c is based on hydraulic pressure principle.

• Cutting :- Cutting is the separation of a physical object, or a

portion of a physical object, into two portions, through the application of an acutely directed force.

• Stamping:-A stamp is a distinctive mark or impression made

upon an object, a device used to make it, or a distinctive sticker applied to an object

CNC machines are used to complete all these processes

Notching• Notching is a metal-cutting process, small cuts are

made on the flanges of angle at any angle.

Drilling

The angles which have their thickness above 12mm are drilled. For this purpose there are six radial arm drilling machines. These machines are rounded at 360’. The machine is operated manually.

Galvanization• Galvanization is the process of applying a protective zinc coating to

metal, in order to prevent rusting and corrosion. • Mainly there are two methods of Galvanizing : 1. Dry galvanizing 2. Wet galvanizingThe life time of wet galvanizing more then dry galvanizing so KEC uses

wet galvanizing.

• Procedure of galvanizing :- Galvanizing is completed in different steps. The process is following in different tanks.

Prepration for galvanizing

Degreasing Tank:- Caustic solution presents in this tank for removing oil, grease, dust etc. on the material. Material is dipped about half an hour at 30-35’c temp.

Acid Pickling Tank:- The material is dipped into HCL tank for removing rust, oxides, dust, oil etc. This process takes time about 40-45 min.

• Rinsing Tank:- The material is cleaned and cooled by dipping it in

water tank because HCL acid sticks on it.

• Pre-Fluxing tank:- A light coating of ZINC-CHLORIDE &

AMMONIUM-CHLORID is made on material. There are 60:40 ratio of zinc & ammonium chloride. It is used for preventing spotting during coating of ZINC in Zinc bath

• ZINK BATH:- There is mainly ZN in this bath at 460’c

temperature. AL & Lead also present these for surface finishing of material. The material is dipped into it and after certain time it is raised from it. Thus the Zn coating is made.

• RINSING TANK:- This tank consists water. The material is dipped

into it for cooling , cleaning after Zn coating.

Galvanizing procedure:-

After galvanizing and all production procedure, the product was sent either to

Quality department – In case of when angles are made first time for customer requirement ,

than sampling is necessary. So the quality department assembles the

manufactured tower if it founds any error it reports to preproduction department.

Or to

Loading Department In case when quality department is ok with angles, they directly go for

loading, than they dispatched to their desired location.