“KALPATARU POWER TRANSMISSION LIMITED”

A
Training Report

Submitted in Partial Fulfillment of the Requirements for the Degree

of
Bachelor of Technology
in
Electrical Engineering

Submitted By:
DIPEN S. KANTARIYA (15BEE154)

Department of Electrical Engineering

Institute of Technology, Nirma University,
Ahmedabad – 382481
July - 2017
 ACKNOWLEDGEMENT
I must acknowledge the strength, energy and patience that almighty GOD bestowed upon me to start
& accomplish this work with the support of all concerned, a few of them I am trying to name hereunder.

I would like to express my deep sense of gratitude to all faculties of Electrical Engineering
Department for their valuable guidance and motivation.

I would like to express my sincere respect and profound gratitude to Prof. (Dr.) P. N. Tekwani,
Professor & Head of Electrical Engineering Department for supporting and providing the
opportunity for training.

I would also like to thank all my friends who have helped me directly or indirectly for the
completion of my training.

No words are adequate to express my indebtedness to my parents and for their blessings and good
wishes. To them I bow in the deepest reverence.

- D. S. KANTARIYA (15BEE154)

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 LIST OF FIGURES

Figure No. Name of the Figure Page No.

Fig. 2.1 Block diagram of divisions in EOU plant 7
Fig. 2.2 Process flow diagram 9
Fig. 2.3 Galvanizing process 12
Fig. 2.4 Safety equipments 14
Fig. 3.1 Straightening machine (SSMB45) 17
Fig. 3.2 CNC A164T 19
Fig. 3.3 CNC A166T 20

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 LIST OF TABLES

Table No. Name of the Table Page No.

Table 1.1 Global presence of KPTL 2
Table 1.2 Clients of KPTL 4
Table 2.1 Colour code 8
Table 3.1 Machinery at KPTL 16
Table 3.2 Straightening machine (SSMB45 & SSMB32) specifications 17
Table 3.3 Hydraulic angle punching machine specifications 18
Table 3.4 CNC A164T & A166T specifications 19

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 LIST OF ACHRONYMS
DC : Direct Current
AC : Alternating Current
HVDC : High Voltage Direct Current
KPTL : Kalpataru Power Transmission Limited
EPC : Engineering, Procurement, and Construction
BOOT : Build, Operate, Own, and Transfer
MT : Metric Ton
AIS : Air Insulated Sub-station
GIS : Gas Insulated Sub-station
EOT : Electric Overhead Traveling
CNC : Computer Numerical Control
IS : Indian Standard
MW : Mega Watts

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 TABLE OF CONTENTS
ACKNOWLEDGEMENT III
LIST OF FIGURES IV
LIST OF TABLES V
LIST OF ACHRONYMS VI
TABLE OF CONTENTS VII

CHAPTER 1: COMPANY PROFILE 1

1.1 INTRODUCTION 1
1.2 GLOBAL PRESENCE 2
1.2.1 LANDMARK PROJECTS 2
1.3 BUSINESS AREAS 3
1.3.1 POWER TRANSMISSION & DISTRIBUTION 3
1.3.1.1 DESIGN & ENGINEERING 3
1.3.1.2 MANUFACTURING 3
1.3.1.3 TOWER TESTING AND R&D CENTER 4
1.3.1.4 SUB-STATIONS 4
1.3.2 INFRASTRUCTURE EPC 5
1.3.2.1 OIL & GAS INFRASTRUCTURE 5
1.3.2.2 RAILWAY INFRASTRUCTURE 5
1.3.3 ASSET CREATION 6
1.3.3.1 BIOMASS PLANT 6

CHAPTER 2: DEVISIONS & MANUFACTURING PROCESSES IN EOU UNIT 7

2.1 PRODUCTION 7
2.2 COLOUR CODE 8
2.3 PROCESS FLOW DIAGRAM 9
2.4 IN-PROCESS INSPECTION 11
2.5 QUALITY ASSURANCE 11
2.6 GALVANIZING 11
2.6.1 PROCESS STEPS 12
2.6.2 PROCESS FLOW DIAGRAM
2.7 STORAGE 13
2.8 DELIVERY WITH Q/C REPORT 13
2.9 TOWER ERECTION 13
2.10 SAFETY 14
2.10.1 SAFETY SLOGANS 14

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 CHAPTER 3: MACHINERY AT KPTL 15
3.1 SPECIFICATION OF MACHINES 17
3.1.1 STREIGHTENING MACHINE (SSMB45 & SSMB32) 17
3.1.2 HYDRAULIC ANGLE PUNCHING MACHINE 18
3.1.3 CNC A164T & A166T 18
CONCLUSION 21
REFERENCES 22

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 CHAPTER-1
COMPANY PROFILE
1.1 INTRODUCTION
Kalpataru Power Transmission Limited (KPTL) is amongst the largest players in the global
power transmission and infrastructure EPC space. KPTL today has established its footprints in
over 40 countries, executing projects with capabilities that deliver complete solutions covering
design, testing, fabrication, erection and construction of transmission lines, oil and gas
infrastructure and railways projects on a turnkey basis.

KPTL is part of the Kalpataru Group established in 1969. It is a diversified into Real Estate,
Power Generation and Transmission, Construction of Roads, Factories, Buildings and Oil and Gas
Infrastructure.

Over 2000 strong technical manpower of KPTL, the Company has an annual production
capacity of over 180,000 MT of transmission towers at its three state-of-the-art manufacturing
facilities in India and an ultra-modern tower testing facility, making it amongst the global largest
power transmission EPC Company. KPTL’s wide reach and presence includes international
geographies like Africa, CIS countries, the Middle East, SAARC, Asia-Pacific and the Americas.

In India, the Company has been partnering India’s accelerating infrastructure push by
executing EPC projects in Oil & Gas infrastructure and Railways infrastructure as well as
undertaking power transmission projects on Build, Operate, Own, and Transfer (BOOT) model.

KPTL’s Oil & Gas business includes providing EPC contracting services for cross-country
pipelines, terminals and gas gathering stations across diverse territories. The Company provides
end-to-end solutions through a well-qualified engineering and designing team for successful and
timely completion of projects.

KPTL’s Railway Infrastructure EPC vertical aids in accelerating economic development

in domestic and international markets by leveraging proven expertise in project management
capabilities, engineering & construction experience combined with strong technical and financial
support. The Company is providing railways EPC services for executing civil infrastructure, track
laying, signaling & telecommunication and over-head electrification projects for railways in India.

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 KPTL has successfully positioned its High Voltage Substation business both in air
insulated (AIS) and gas insulated (GIS) segment in domestic as well as international market.

Quality, Environment and Occupational Health & Safety are at the core and fore of every
KPTL project. The unwavering focus on global quality standards has ensured ISO 9001:2008, ISO
14001:2004 and OHSAS 18001:2007 certifications.

1.2 GLOBAL PRESENCE

KPTL is a truly global company with an international reach and presence, world-class
capabilities and capacities, widespread experience and expertise and best-in-class systems,
processes and standards, with a footprint spanning 44 countries in 5 continents.

Philippines, Malaysia, Vietnam, Indonesia, Thailand,

AUSTRALASIA
Bangladesh, Nepal

MIDDLE EAST Kuwait, Dubai, Abu Dhabi, Qatar, Syria, Turkey

Algeria, Djibouti, Ethiopia, Zambia. Nigeria, Kenya, Congo,

AFRICA
Tanzania, Mozambique, South Africa

EUROPE USA, Canada, Mexico, Peru

Table 1.1 Global presence of KTPL

1.2.1 LANDMARK PROJECTS

Congo
KPTL successfully completed rehabilitation work of over 2000 kms of 500 KV HVDC line
between Inga and Kolwezi. Funded by the World Bank, the project involved construction of access
road along the transmission line and replacement of around 700,000 insulators.
Kuwait
The USD 250 million project involved construction of 160 kms of 400 KV double circuit line at
Kuwait. The challenging project included working in extremely difficult weather conditions with
temperatures soring as high as 50-60 degree Celsius.
Ukraine
This landmark project of KPTL involved construction of 750 KV Transmission Line over a
distance of 350 kms between Revine and Kiev in Ukraine. The project scope involves mobilization
of massive resources and working through round the year, including the severe winter months with
temperatures as low as -25 degree Celsius.

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1.3 BUSINESS AREAS
1.3.1 POWER TRANSMISSION & DISTRIBUTION
KPTL provides end-to-end solution ranging from in-house designs, testing, procurement,
fabrication, erection, installing and commissioning of power transmission lines.
1.3.1.1 DESIGN & ENGINEERING
KPTL has world class design capabilities emanating from a rich pool of highly qualified
and experienced team of design engineers combined with cutting edge technologies and an
unparalleled experience of having designed virtually all types of towers across the globe. The
Company focuses on innovation, safety and cost effective design solutions aligned to ensuring
ease of manufacture and construction. These are adhered to stringent technical and quality
demands of the domestic and international clients.
1.3.1.2 MANUFACTURING
KPTL has three manufacturing plant with a total production capacity of 1,80,000 MT per
annum in India. While two of the manufacturing plants are located in Gandhinagar, Gujarat, the
third plant is located in Raipur, Chhattisgarh.
KPTL’s manufacturing plants have state-of-the-art fabrication equipment such as CNC
machines, drilling machines and EOT cranes.
Fabrication Facilities
More than 45 CNC punching / drilling machines / milling machines capable of handling
Angle sections up to 250 x 250 x 35 mm and Plates across the three plants.
Integrated Quality Control system and Material Testing facilities
Heavy Duty EOT cranes for CNC shops & galvanizing zones, loading & unloading cranes,
lifters & carry mobile cranes, tractor etc.
The state of the art CNC machines are operated by qualified and experienced engineers
which guarantees quality punching, drilling, cutting, stamping and fabrication, critical for
transmission industry. This also applies to hydraulic presses and machine tools and fixtures,
furnace to handle plates or angles for bending operations.
KPTL has sufficient high capacity powerful cranes and pick-n-carry mobile cranes of
different capacities that enable smooth material handling.
Galvanizing Facilities
KPTL has automatic temperature controlled galvanizing bath size meeting international
standards or customer’s specific requirements. Microprocessor controlled galvanizing furnace and
the pre-heating of flux ensures uniform drying and preheating of steel by oven to give a clear
surface finish and at the same time ensuring uniform zinc coating.
All the three plants are certified under ISO 9001:2008 standards. The chemical waste of its
unit is treated as per prescribed environmental standards.

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1.3.1.3 TOWER TESTING AND R&D CENTRE
It has capacity of testing of testing up to 800 KV of Double Circuit Tower and 1200 KV
of Single Circuit Tower, with 30×30 meters of base width and 85 meters of height. KPTL has
successfully tested more than 354 towers for various domestic and international clients ranging
from 220 KV to 1200 KV.
The company’s tower testing station has been accorded “Recognition of In-house R&D
center” by Ministry of Science and Technology, Government of India.
1.3.1.4 SUB-STATIONS
KPTL has developed capability to execute high voltage substations i.e. GIS or AIS up to
the highest voltage level. Capability also includes delivery of special substations for Railways. The
company has successfully executed complex projects in India, Afghanistan, Senegal and
Cameroon.
Landmark Projects
Sholapur – POWER GRID, India
The project scope includes extension of 400 KV AIS substations in 6 locations at Maharashtra,
Dadra & Nagar Haveli, Madhya Pradesh and Gujarat on EPC basis along with complete civil work.
Suva – GETCO, India
This is a 220/66 KV large green field substation project based on hybrid GIS technology with
3x100MVA transformers. GETCO, the state transmission company of Gujarat is the customer.
The project was successfully executed on time despite short execution schedule.

CLIENTS OF KPTL
CENTRAL PGCIL (Power Grid Corporation of India Limited)
STATE ELECTRICITY BOARDS OVERSEAS
GEB, Gujarat Powerlink, Australia
GETCO, Gujarat NPC, Nepal
MSEB, Maharashtra EJAT, Thailand
MPEB, Madhya-pradesh CFE, Mexico
RSEB, Rajasthan TNB, Malaysia
TNEB, Tamilnadu EVN, Vietnam
KPTCL, Karnataka PEEGT, Syria
APTRANSCO, Andhra-pradesh
Table 1.2 Clients of KTPL

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1.3.2 INFRASTRUCTURE EPC
Infrastructure development is at the core of nation building and a key factor in India’s future
growth. KPTL is participating in nation building through its two verticals –
• Oil & Gas Infrastructure EPC
• Railways EPC
1.3.2.1 OIL & GAS INFRASTRUCTURE
KPTL undertakes EPC contracting for cross-country pipelines, terminals and gas gathering
stations for oil and gas sector across diverse territories.
KPTL has built up competencies and credentials in EPC contracting in Oil & Gas sector,
comprising of the following key areas-
Fabrication, erection, installation and construction of cross country pipelines, City Gas
Distribution Systems, Central Gas Gathering and Field Gathering Stations,
installation of process packages/vessels/columns, fabrication & erection of plant piping, plant
structures, installation of large rotating and static equipments etc.
KPTL has constructed and commissioned more than 3,200 km cross country pipelines over
80 intermediate stations like Terminals, Pumping stations, Pigging stations, Block valve
stations etc. for hydrocarbon service (8’’ to 48” diameter) under various projects, all of which have
been won against Global Competition.
1.3.2.2 RAILWAY INFRASTRUCTURE
KPTL is executing civil infrastructure, track laying, signaling and electrification projects
for railways in India. The Company has also executed an international turnkey project in
Bangladesh.
KPTL is capable of offering the entire range of services on a turnkey basis in the railway
infrastructure projects globally. The services includes:
 Civil infrastructures including earthworks, bridges, tunnels, station buildings and facilities
 New track laying & rehabilitation of existing tracks
 Railway electrification and power systems
 Metro railways
 Private railway sidings

Landmark Projects
Tata Steel plant – Kalinganagar (Odisha) (Ongoing Project)
This project involves design, supply, erection, testing and commissioning of railway electrification
work of existing/proposed railway tracks, switching post including modification of existing 25 Kv
AC, 50 Hz single phase Overhead Equipment (OHE) at Tata Steel Plant, Kalinganagar, Odisha.

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As the site location has hilly terrains and undulated alignment, the Polygonal Over Head
Equipment at 25 Kv AC 50 Hz systems has been designed for maximum wind pressure of 178
kg/sqm.
Ahmedabad-Palanpur (Gujarat) – CORE (Ongoing Project)
An Overhead Electrification (OHE) project for Central Organization for Railway Electrification
(CORE). The Project scope involves design, supply, erection, testing & commissioning of 25 Kv,
50 Hz, single phase, AC electrification works including Traction sub-station (TSS) in the state of
Gujarat.
1.3.3 ASSET CREATION
As part of its objective to drive long term value and growth, KTPL has been actively
concentrating on Asset Creation in the form of Power Transmission Line BOOT Projects,
Sustainable Bio-mass plants as well as diversifying into newer business through its subsidiaries.
1.3.3.1 BIOMASS PLANT
Biomass Power Plants are an integral of inclusive development at KPTL as these projects
generate rural employment as well as contribute positively to a greener environment by
converting waste materials into clean energy.
KPTL has set up a Biomass plant at Padampur in the Ganganagar district of Rajasthan in
2003. This plant uses agricultural waste and crop residues (biomass) as
inputs and generates 7.8 MW of power.
KPTL has set up another biomass plant in Tonk District of Rajasthan in 2006 of 8 MW
capacity. This plant also uses agriculture waste and crop residues (biomass) as inputs.
Both Plants have logistics infrastructure to collect approx. 200,000 MTs of such inputs
every year.

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 CHAPTER-2
DEVISIONS & MANUFACTURING PROCESSES IN EOU UNIT

DESIGN

PLANNING & CNC

PROGRAMMING

PRODUCTION

DEVISIONS IN EOU
PLANT
INSPECTION &
QUALITY ASSURANCE

GALVANIZING

BUNDLING &
DISPATCHING

Fig 2.1 Block diagram of divisions in EOU plant

2.1 PRODUCTION
In production department different process and operation are done. These processes mainly
include:
 Straightening
 Shearing

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  Punching
 Drilling
 Stamping
 Cutting
 Notching
 Bending
 Welding
 Galvanizing

Before all this processes are done, the material is drawn from yard. Then material issue copy is
made. Issue copy which is made by planning department is forwarded to production department
according to plan and then issued material is loaded for fabrication.
The material is identified from the colour code.
For different orders, different materials are required, and for different materials, different colours
are painted at the end of the angles for the purpose of identification.

2.2 COLOUR CODE FOR IDENTIFICATION OF STEEL

NO. TYPE OF STEEL COLOUR

Mild Steel IS 2062

1. W/o any colour
Gr. A or Equivalent
High Tensile (HT) IS 8500
2. Orange
EN 10025 S355JR or Equivalent
High Tensile (HT) IS 8500
3. Green
EN 10025 S355JO or Equivalent

4. Non confirming steel Sky-blue

GIS G3101
5. Purple
Gr. SS 540

6. BS 4360 Gr. 55C Yellow

Table 2.1 Colour code

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2.3 PROCESS FLOW DIAGRAM

Fig 2.2 Process flow diagram

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STREIGHTENING:
During this process steel flange or various steel sections like ‘L’ angle section, ‘T’ section, ‘C’
(channel) section, etc. are straightened with the help of mechanical straightening machine.
Straightening machines are either operated manually by workers or automatic CNC Machines.
SHEARING:
During this process steel flange or various steel sections like ‘L’ angle section, ‘T’ section, ‘C’
(channel) section, etc. are cut with the help of mechanical shearing machines. Steel flange of
smaller thickness are cut by manually operated machines while plates of more thickness are cut by
automatic CNC machines.

PUNCHING:
Punching is the process of making holes of different diameters in the steel flange or various steel
sections like ‘L’ angle section, ‘T’ section, ‘C’ (channel) section, etc. in a single go. Punching is
suitable for steel plates having smaller thickness. It is done by automatic CNC Machines.

DRILLING:
Drilling is used for making holes of different diameters in the very thick steel flange or various
steel sections like ‘L’ angle section, ‘T’ section, ‘C’ (channel) section, etc. It is done by automatic
CNC Machines.

STAMPING:
During this process particular letters and numbers are marked on the steel flange or various steel
sections like ‘L’ angle section, ‘T’ section, ‘C’ (channel) section, etc. Stamping is done to mark
the type of the steel, to stamp the Job number and also for the identification of the proper part
while assembling the transmission tower at the actual project site.
NOTCHING:
During this process the corner of the steel flange or various steel sections like ‘L’ angle section,
‘T’ section, ‘C’ (channel) section, etc. is cut or lightly notched which forms a slant cut.
Following types of cut are done in the notching:
 Corner cut
 V cut
 C cut
BENDING:
During this process particular letters and numbers are marked on the steel flange or various steel
sections like ‘L’ angle section, ‘T’ section, ‘C’ (channel) section, etc. are bended according to the
required angle. Bending is done by hydraulic bending machine or manual hammering after heating
the steel flange in furnace till it reaches the red hot temperature.

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2.4 IN-PROCESS INSPECTION
1. Straightening
2. Cropping
3. Stamping
4. Punching/Drilling
5. Edge security
6. Drilling and punching hole to hole distance
7. Notching
8. Bending

2.5 QUALITY ASSURANCE

 It is a very important procedure after the production to check and confirm that all the
mechanical operations are performed well and work piece is prepared according to the
blueprint.
 QA department checks the material quality, assurance and do inspection on the steel and
certify it after inspection.
 Various quality tests are done on the steel and then QA department will give the certificate.

2.6 GALVANIZING:
Galvanizing is the last step of production. In this process final finishing is given to the steel flange
to withstand the adverse environmental condition in future.

2.6.1 PROCESS STEPS FOR HOT DIP GALVANIZING

 Loading: In this process the processed steel plates are loaded towards the galvanizing
section with the help of crane.
 Degreasing: In this process the steel plates are cleaned using a caustic solution like NaOH.
The steel flanges are dipped into NaOH solution. This removes oil, grease, dirt, and paint.
Then NaOH solution is rinsed off.
 Pre-fluxing tank: In this process the steel flange are dipped into the solution of ZnCI2 and
NH4CI. It is used to inhibit oxidation of the cleaned surface upon exposure to air. The flux
is allowed to dry on the steel and aids in the process of the liquid zinc wetting and adhering
to the steel.
 Pickling: The steel is pickled in an acidic solution like HCL to remove mill scale i.e. FeO,
Fe2O3, Fe3O4, etc. oxides from its surface. Then HCL is rinsed off into water tank.

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2.6.2 PROCESS FLOW DIAGRAM FOR GALVANIZING

Fig 2.3 Galvanizing process

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  Oven bath: In this process the steel flange are dipped into hot water bath.
 Zinc bath tank: In this process the steel flange is dipped into molten Zinc solution which
is 450 degree hot held there until the temperature of the steel equilibrates with that of the
bath.
 Quenching: The steel is cooled in a quench tank to reduce its temperature and inhibit
undesirable reactions of the newly formed coating with the atmosphere.
 Dichromating: It is done to protect the steel flange from atmosphere and rusting. It
protects the Zinc layer too.

2.7 STORAGE: After all the process of production and finishing is completed the processed
materials are then stored according to their dimensions, types of the parts and preference of
dispatching.

2.8 DELIVERY WITH Q/C REPORT: After the packaging process, these material are prepared
for the delivery. Then they are loaded in to the trucks with the help of the cranes. Then they are
dispatched according to the preference of the material to be used at the site. All the materials are
loaded along with Q/C report.

2.9 TOWER ERECTION

 The Tower Erection is the Clearance of the mass production of any order to be completed.
 Before going for mass production of transmission towers for any project, prototype testing
is required.
 First of all the parts of the newly designed prototype tower is fabricated and then testing of
the tower parts with its section wise assembly is done by the Tower Erection Team of the
company.
 After the fabrication of the required parts and angles for the tower to be manufactured, all
the parts are transported to the erection site.
 The erection site is situated at a distance nearly 1 km from unit-2, KPTL.
 Another site for erecting the tower is situated at Majra, Sabarkantha.
 It has advanced facilities and a high capacity crane for actual evolution and vertical
Erection of the prototype tower.
 On completion of the erection process, the detailed report is to be submitted by the tower
erection department to the planning department at the plant.

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2.10 SAFETY
Safety is most important in the production plant. That is why KPTL urges and gives first priority
to safety aspects. There are many safety equipments provided by the company to their workers
and employees. First aid kit is available at the plant.

Fig. 2.4 Safety equipments

2.10.1 SAFETY SLOGANS
There are many slogans one can see on the walls of plant like,
 “Safety presence of mind, Accident absence of mind”
 “No safety know pain, know safety no pain”

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 CHAPTER-3
MACHINERY AT KTPL

MAKE
KPTL MACHINE
No. MACHINE SERIAL
IDENTIFICATION NO.
NO.
SSMB45,
1. STREIGHTENING M/C-1, 2 STR-1, STR-2
SSMB 32
HYDRAULIC ANGLE MARKING MRK-1, MRK-2,MRK-3,
2.
M/C-1, 2, 3, 4, 5 MRK-4, MRK-5
HYDRAULIC ANGLE PUNCHING
3. P-1, P-3
M/C-1, 3
ACRO WHITENY PUNCHING
4. ACRO P-2
PRESS-2
HYDRAULIC VERTICAL PRESS-1,
5. VHP-1, VHP-2, VHP-3
2, 3

6. HORIZONTAL PRESS-1, 2 HP-1, HP-2

7. ACRO WHITENY SHEAR PRESS ACRO SHR-1

8. BENDING FURNACE-1, 2, 3, 4 F-1, F-2, F-3, F-4

HYDRAULIC NOTCHING M/C-1, 2,

9. N-1, N-2, N-3
3
DRILLING M/C-1, HMT RADIAL
10. D-1, D-2
DRILL-2

11. MILLING M/C MILLING-1

AIR COMPRESSOR-15T (IR), 45T AC-1, AC-2, AC-3, AC-4,

12.
(IA), VENUS, VARIYA, 5 AC-5

13. AIR DRYER-1, 2 AD-1, AD-2

14. BAND SAW M/C-1, 2 BSM-1, BSM-2

15. COOLING TOWER-1, 2 CT-1, CT-2

MIG-1, MIG-2, MIG-3,

16. MIG WELDING M/C-1, 2, 3, 4, 5
MIG-4, MIG-5

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 PLSHEAR-1,
17. PLATE SHEARING-1, 2, 3
PLSHEAR-2, PLSHEAR-3

18. UNIVERSAL BENDING M/C UBM-1

EOT CRANE-1, 2, 3, 4, 5, 6, 7, 8, 9, EOT-1, 2, 3, 4, 5, 6, 7, 8, 9,

19.
10, 11 10, 11

20. JIB CRANE-1, 2 JCR-1, 2

CNC MACHINES

21. CNC A166T A166T CNC-1

22. CNC A164T A164T CNC-2

23. CNC A124T A124T CNC-3

24. CNC DRILLING 803DX CNC-4

25. CNC DRILLING JX-2532-1 CNC-5

26. CNC DRILLING JX-2532-2 CNC-6

27. CNC APM 1412 A APM 1412 A CNC-7

28. CNC APM 1412 B APM 1412 B CNC-8

29. CNC PLATE DRILLING 1610-A CNC-9

30. CNC PLATE DRILLING 1610-B CNC-10

31. CNC PLATE DRILLING 1610-C CNC-11

32. CNC PLATE DRILLING 1610-D CNC-12

33. CNC CJ 100 J CNC-13

34. CNC CJ 110 A CNC-14

35. CNC CJ 110 B CNC-15

36. PRO-ARC CNC PLASMA CUTTING PLASMA-1

Table 3.1 Machinery at KPTL

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3.1 SPECIFICATIONS OF MACHINES

3.1.1 SECTION STRAIGHTENING MACHINE (SSMB45 & SSMB32)

The roller section straightening machine is most suitable for straightening of any rolled, drawn or
extruded ferrous and non-ferrous in cold condition.

No. Parameter SSMB45 SSMB32

1. Angle & Tee section Maximum 50*50*5 45*45*5
Minimum 130*130*12 100*100*10
2. Channel section Maximum 65*35 50*30
Minimum 200*75 100*50
3. Flat section Maximum 30*10 32*6
Minimum 100*40 70*20
4. No. of rolls 8 8
5. Roll diameter 360 290
6. Bearings Ball & Roller Ball & Roller
7. Lubrication Oil & Grease Oil & Grease
8. Speed in meter/min. 15 25
9. Motor power in HP 75 30
10. Applied weight in kg 13000 8000
Table 3.2 Straightening machine (SSMB45 & SSMB32) specifications

Fig 3.1 Straightening machine (SSMB45)

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3.1.2 HYDRAULIC ANGLE PUNCHING MACHINE

No.
1. Manufacturer FICEP ITALY
P-1 & Maximum 35*35*3
P-2 Minimum 75*75*8
2. Punching capacity
Maximum 75*75*8
P-3
Minimum 110*110*16
Table 3.3 Hydraulic angle punching machine specifications

3.1.3 CNC A164T & A166T

Automatic CNC punching and shearing lines for angles, specifically designed for transmission
towers:

MODEL

A164T A166T

1. Manufacturer FICEP ITALY FICEP ITALY

Punching capacity

Min. 40*40*4 40*40*4

2. Angle to be punched (mm)
Max. 160*160*19 160*160*19

3. Max. punching force (kN) 800 800

4. Max. dia. with standard tool (mm) 32 32

5. Punches per flange 2 3

Shearing capacity

6. Max. shear force (kN) 2200 2200

Drilling capacity

Min. 40*40*4 40*40*4

7. Angle to be drilled (mm)
Max. 160*160*20 160*160*20

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 8. Max. dia. to be drilled (mm) 40 40

9. Spindle speed (rpm) 180 - 620 180 - 620

Stamping unit capacity

10. Max. force available (kN) 80 80

11. Characters available (no.) 38 38

12. Character size (mm) 16*8 16*8

Table 3.4 CNC A164T & A166T specifications

Fig 3.2 CNC A164T

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 Fig 3.3 CNC A166T

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 CONCLUSION

Industrial Training at Kalpataru Power Transmission Limited was a very nice experience.
It was very interesting to know about various types of CNC machines and various kinds of
mechanical processes used for the manufacturing of transmission towers. Safety is very important
factor while working in the industry and it must first priority for every worker and employee. In
addition, training helped to develop self-confidence, to get experience about real life industrial
working situations and to improve communication skills while interacting with the persons from
various departments.

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REFERENCES

 http://kalpatarupower.com
 http://design-fabrication.com/products.php#
 http://www.arcowhitney.com/tower-fabrication.html
 http://www.advantagefabricatedmetals.com

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