KEC International Limited ,Jaipur

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A TRAINING REPORT
ON
“KEC International Limited,Jaipur ”
Guided By: Submitted By :
Mr. Manish Jain Jasvinder Singh
HOD, Mechanical Engineering Mechanical Engg
Department, Jecrc, Jaipur RTU Roll No-13EJCME852
Department of Mechanical Engineering
Jaipur Engineering College and Research Centre
Shri Ram Ki Nangal, via Sitapura RIICO
Tonk Road, Jaipur-302022 (RAJASTHAN) INDIA

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(FROM ST
JUNE-23TH
JULY 2016)

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CONTENTS
1. Training certificate
2. Acknowledgement
3. Abstract
4. Company Profile
5. Departments
(i) Personnel
(ii) Time Office
(iii) ProjectDepartment
(iv) Security Department
(v) Pre-Production Department
(vi) Model Assembly Shop
(vii) Tower Testing Department
(viii) Raw Yard & Finish Yard
(ix) Fabrication Shop
(x) Quality AssuranceDepartment
(xii) Galvanizing Department
(xiii) Tower Testing Process
6. Conclusion
7. Reference

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Acknowledgement
I wish to express profound happiness in forwarding this seminar report as an
image of our dedicated and sincere efforts. It is a pleasure to below my earnest
gratitude to all who generously helped by sharing their valuable experience &
devoting their precious time with me, without whom this seminar report would
never have been accomplished.
I extended my thanks & grateful to Dr.. Manish Shrivastava, Asst.
Prof, Mechanical Engineering Dept, JECRC, Jaipur whose guidance, teaching
And suggestions provided me the timely valuable inputs which enhance my
knowledge and skills.
I am highly indebted and thankful to Mr. Manish Jain (HOD,
Mechanical Engineering Dept, JECRC), Jaipur.
Lastly I am thankful to the almighty god for all their immense
blessings & guidance during the course of the research & development of the
seminar.
Jasvinder Singh
(13EJCME852)

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ABSTRACT
It is an immense pleasure for me to summit this training report as a Part of
“B.Tech.”in “Mechanical Engineering”. I have taken my practical training of
60 Days in “KEC International Ltd. Jaipur”.
I was exposed to real working environment and working condition in period of
training.
I have maintained a training report and recorded day by day accounts of
observation, impression and information gathered from situation personnel
and technical literature.
This report describes about the “PlantEngineering Process”in KEC
International Ltd. On basis of these collected information and guidance
provide, I have prepared a comprehensive training report.
Jasvinder Singh

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PREFACE
The objective or main motive of this practical training is to getting a true
practical knowledge about the industries, that how their industrial setups are
held, and their techniques used in industry technologies to be made or used in
the environment.
This report is presented on the basis of practical training acquired at KEC
International Limited, Jaipur. This report is on Plant Engineering Process with
relevant diagrams & by their proper description & explanation.
In spite of all my best efforts some unintentional errors might have eluded, it
is requested to abrogated them.

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3. COMPANY PROFILE
KEC International Ltd. which was known as Kamani Engineering
Corporation Ltd. was established in 1967 Jhotwara, Jaipur.
In 1982 this company was taken over by RPG enterprises. IN 1984 this
company was renamed as KEC International Ltd.
The RPG enterprises consist following companies in various following
fields:-
1. Transmission- KEC International Ltd.
2. Power-CESC,NPCL
3. Tyers- Ceat Ltd., PBCL,HNC
4. Technology- ZENSAR,RPG life science, RPG Cables Ltd., RAYCHEM
5. Retail-Retail
6. Entertainment-Saragama
KEC International Ltd. is a pioneer in the field of testing and supply of testing
and supply of high tension transmission line towers in India. It is the largest
tower manufacturing company in the world. It supplies about 40% of the
transmission towers in India.
KEC uses state of the art technology, including galvanizing aided designs,
CNC m/c and fully automatic galvanizing furnaces. Some of this m/c is
purchased from Europe. KEC uses sophisticated process quality control
equipment like digital UTM with computer interface etc.
KEC has one of the largest tower testing stations in the world. It is a matter of
pride for KEC that has been awarded ISO 9001 certification on April 26,
1995. It was also awarded ISO 14000 certification on March 11, 2000.
VISION
To be the leading international EPC company in the power transmission and
distributing providing superior value to customers & stakeholders.
MISSION
i. To be a global player in power transmission & distribution industries.
ii. To meet customers requirement in term of quality & time.
iii. To employ state of art technology & institutionalize process.
iv. To be the most costeffective construction & manufacturing company.
v. To providing a challenging & fulfilling work culture to employees.

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4. Departments
i. PERSONNEL
ii. TIME OFFICE
iii. PROJECTS DEPTT.
iv. SECURITY DEPTT.
v. PRE PRODUCTIONDEPTT.
vi. MODEL ASSEMBLY SHOP
vii.RAW YARD & FINSH YARD DEPTT.
viii.FABRICATION SHOPS I & II AND CNC DEPTT.
xi. QUALITY ASSURANCE DEPTT.
x. GALVANISING SHOP
xi.TOWER TESTING
i) PERSONNEL:-
This dep’t. includes finance & account section, Reception, Staff and HR dep’t.
of the industry. The head of the deptt. is industry division manager.
1. This deptt. Perform various following functions:-
2. Time management
3. Security
4. Conveyance
5. Welfares
6. Medical facility
7. Requirements of employees
8. Promotion of employees
9. Organizing the training programmers for students of various fields
ii) TIME OFFICE:-
This is the sub deptt. of the personnel deptt. The main function of this deptt. is
to take attendance of employees. There is an electronic punching m/c for
attendance purpose. The arrival & departure time is noted by this m/c when
employee punches his card in it and collect it. This m/c sends these data to
computers where these dates are registered by manually. This deptt. presents
daily attendance reports to personnel deptt.

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iii) PROJECT/PLANING DEPARTMENT:-
This deptt. do planning on the project. The aim of planning deptt. is to produce
the production of right quality at right time by using the bestand least
expensive methods. Production control, planning the production in advance,
setting the exact route of each items, fixing the starting and finishing dates for
each item, to give production orders and shop to lastly to follow up progress of
production according to production orders are made by this deptt.
Production Planning:-
The main work of the planning for productionis made by project deptt. This
deptt. distributes the work for fabrication shop & model shop. According to
the order, the drawings of project are sent to pre-production deptt. Draftsmen
draw sketches. After providing the sample pieces according to drawing model
assembly and tower testing is made. After succeeding it has to be started to
work on project and productionis to be started.
A bill of material is sent to planning deptt. To plan about the requisition of
material. To do simplification of this act of allocation project deptt. prepares
or maintain a stockregister based on section & length of material in stock.
These registers are maintained also by account section daily. This deptt.
controls the activity of fabrication shop & model shop.
Types of various grades are as:-
AL- stands for straight light section.
ALN- stands for straight light section with notching process.
AM- stands for straight section.
BM- stands for bending section.
iv) SECURITY DEPARTMENT:-
This is also sub deptt. of personnel deptt. The main work of this deptt. is to
provide safety to the plant. Gate pass & luggage is checked manually before
entering in the plant by this deptt. Employees and outsiders write their name,
time, meeting person with signature in a register.
v) PRE-PRODUCTIONDEPARTMENT:-
It is also known as template shop. It does not directly affect the production
work put through its help. The work is performed in a simple easier & also in
a faster way.
The main work of this deptt. Is to show the tower drawings of a tower in it’s
each member or we can say that this deptt. Prepares the sketches of various
parts of a tower actual section drawing. The other work of this deptt. Is to
prepare templates for various operations like punching, bending.

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vi) MODELASSEMBLY SHOP:-
In this shop the testing tower is fabricated. After the fabrication tower is
assembled in model assembly shop. If there is any problem produces then re-
fabrication also carried out manual power used. A tower can be assembled in a
single piece or in a number of pieces according to its heights.
vii) Tower TestingDepartment:-
The main function of this deptt. Is to perform tower testing.
There are three types of towers:-
1. Single circuit tower:-
It is made of only one circuit of over head power lines.
2. Double circuit tower:-
It is made of only double circuit of power lines.
3. Multipurpose circuit tower:-
It is made of for more than two circuits.
Products:-
Tower parts (leg members, clit, plates etc.)
Customer:-
The major customer of KEC is following:-
1. State board of electricity
2. Power Grid Corporation of India
3. Other reputed foreign clients in the field of power transmission
KEC also under takes turnkey projects for Railway electrification for power
distribution
Raw material:-
The raw material which is in the form of High Tensile Steel is purchased from
Hyundai (Korea) and Koreas (UK) and also from domestic market. This
material mainly comes in the form of angles & sheets.
Angle:-
An angle is the combination of two flanges of considerable length which are
perpendicular to each other.

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viii) RAW YARD&FINISHYARD:-
In raw yard material is stored according to their grade and size. The raw
material is purchased and issued to productionshop by this deptt. Steel is
important mainly from Hyundai (Korea) and Koreas (US) and also from
domestic market. The raw material comes in the forms of angles and sheets.
The raw material steel which is used here is high tensile steel and mild steel.
The max. Section and length of angle are respectively 250X250X35mm.
S.N SPECIFICATION GRADE COLOUR
MILD
STEEL
1. BSEN.10025 S235JR
S235JO
S275JR
S275JO
BLUE
BLACK
GRAY
ST.BLUE
2. IS2062 FE410WA
FE410WB
GREEN
GREEN
3. ASTM A-36 CANDY
4. JIS:3101 SS400 BROWN
HIGH TENSILE STEEL
5. BSEN:0025 S355JR WHITE
6. ASTM:A572 GR65 PINK
7. JIS:3101 SS540 YELLOW
Table no.-1

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Finish yard:-
In finish yard the finished products are stored. The galvanized items are
handed over to this yard after passing q.c.d.sprocedure. Galvanizing deptt.
Issue an M.I.R from to finish yard. This M.I.R from has three copies one to
finish yard, second to store account and third to records.
Finish yard office check the finish material according to M.I.R finished
material is taken from galvanizing deptt. With help of trolleys. A marker
marks the marking on the bundles of angles with help of marker.
IX) FABRICATION SHOP
i) PRODUCTIONDEPARTMENT:-
Production deptt. Consists fabrication shop I & II. All the operation is
performed in a sequence in this deptt. On raw material. The main aim of this
deptt. Is to producethe producing right quality and quantity. Instructions are
given to this deptt. By planning deptt. This deptt. Issues M.I.R. to raw yard &
raw material comes from raw yard at the basis of M.I.R. In this deptt. Shift in
charge takes attendance report of men resources & according to it work
allotment
Is done by him.
Process:-
The processeswhich are performed on various m/c are following.
A. Straightening
B. Shearing
C. Stamping
D. Punching
E. Notching
F. Chipping
G. Drilling
H. Grinding
I. Bending

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PROCESS FLOW DIAGRAM (CNC SHOP)
Fig. no.1 –Flow Chart of Process
STAMPING
PUNCHING
SHEARING
NOTCHING
BENDING
CHIPPING
GRINDING
HANDLING OVER TO GALVANISING SHOP

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A. STRAIGHTENING:-
The straightening m/c is used for angles to straighten them if there is any
default in them. The angle passes between two rollers which are oppositeto
each other & rotate by electrically means. The lower roller is fixed and rotates
about a fix axis but upper roller is movable and its position can be changed by
hand wheel. Pressure is adjusted manually. Thus the raw material is
straightened on this machine.
Fig no.2: Straightening M/C
B. SAWING M/C:-
This m/c is used for cutting the angles of heavy section. A belt saw is used in
this m/c and during cutting process a cutting fluid is also used for cooling
purpose. The max. Heavy section 250X250X35 is used for cutting angles
which have their section above 150X150XX15.

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C. STAMPING M/C:-
The letters, numbers & other figures are embossed on member no. , type no.,
project no.etc. This assists us in assembly shops. In case of bending of parts
the stamping is done after bending. By default, if there wrong stamping occurs
then re stamping is done.
Stamping is done as:-
H717S2397
This represents:
H-High tensile steel
717S- Project no.
2397- Member no
The average capacity of stamping m/c is 20MT per shift. In this m/c the power
is given by heavy crank.
Power to crank is obtained by a heavy duty motor with flywheel and gear
mechanism. Stamping angles are put on the machine with the help of
supporting table and operator used the foot lever by which crank, takes its
initial position for next stamping or to process continue.
D. SHEARING M/C:-
In the industry the raw material comes in the form of large angles. The angles
are cut according to the requirement by using this m/c. this m/c works on the
principle of hydraulic pressure. Cutting tooland die are used for cutting.
Cutting toolis made of HSS. The average capacity of this m/c is 20MT per
shift.
Fig no.3: Shearing Operation

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E. PUNCHING MACHINE:-
The main function of this m/c is to produceholes on angles at various
distances. The angles which have thickness up to 12mm are punched. This m/c
is based on hydraulic pressure principle. KECIL uses seven punching m/c. The
average capacity of this m/c is 5MT per shift.
Fig no.4:- Punching Operation
F. DRILLING MACHINE:-
The angles which have their thickness above 12mm are drilled. Forthis
purposethere are six radial arms drilling m/c. This m/c is rounded at 360. The
average capacity of this m/c is 2.25MT per day. This drill is made of HSS.
The m/c is operated manually.
G. CHIPPING MACHINE:-
This m/c is used for hell grinding. When we want to joint two angles. Then
hell grinding is done for eliminating the interference between angles clot.
Achiness’s toolis used for this purpose. This m/c is operated manually and
works on pneumatic pressure principle. The average capacity of this m/c is
1MT per shift.

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H. GUSSET SHOP:-
Gusset shop is the sub shop of FAB-I where the work is done only on the
plates. The plate type parts of tower are manufactured here.
Fig no.5: CNC M/C
I. NOTCHING M/C:-
The small cuts are made on the flanges of angles at any angle by this
m/c scrap is collected in boxes and then send to store. There are five
machines to this process. All of these work on hydraulic pressure
principle. The average capacity of this m/c is 5.5MT per shift.
1. F-cut
2. B-cut
3. C-cut
4. Notch
Fig no.6:-Notching M/C

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J. BENDING MACHINE:-
There are two methods of bending for angles:
1. Cold bending
2. Hot bending
In cold bending the angles is bended by using hammer. Templates are used to
check them. Cold bending is done for those angles which have their thickness
below 6mm.
The angles which have their thickness above 6mm are bended by hot bending
process.
For hot bending there is an oil furnace and a bending m/c which works on
hydraulic principle. Firstly the angles are heated on oil furnace and then it is
put along the bending die and pressure is applied by ram. So the angle bends
according to the shape of die. Then the angle is checked with the help of
templates. The average capacity of this m/c is 2.25MT per shift.
Fig no.7: Bending M/C

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X) QUALITY ASSURANCE DEPARTMENT:-
The main function of this deptt. Is to controlthe quality of manufacturing.
Inspection is made to assure quality. Inspection is determining function which
determines raw material, supplies, parts or finished products as they are
acceptable or not. As control becomes effective the need for inspection
decrease. This deptt. Determines the causes for variations in characteristics of
products and gives solutions by which these variations are controlled.
A. FUNCTIONS OF DEPARTMENT:-
Receiving inspection at KEC & vendors.
Quality management system (ISO-901).
Environmental management system (ISO-14001).
Process inspection (fabrication & galvanizing).
Client inspection & finish material inspection.
B. RECEVING INSPECTION:-
This inspection is done at KEC & at vendors. The vendors offer to companies
for purchasing material from their place. Then purchase order is given to
vendor and daily receipt is obtained by company from vendors of material. In
this inspection first visual & dimensional inspection is made according to
specified dimension & as per relevant specifications. Then mechanical testing
is done. Forthis yield stress, ultimate stress, % of elongation, impact test for
steel & wedge load, shear strength etc are obtained.
After it chemical testing is done and % of carbon, Sulphur, Phosphorus,
Silicon, Manganese etc. obtained. After this inspection report is made.

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C.QUALITY MANAGEMENT SYSTEM (ISO-9001):-
To obtain the ISO-9001 certificate the quality assurance deptt. Do some
special work set time to time these are following :
1.Internal audits
2.Customer complete analysis
3.Product audit
4.Update & distribution of standards & codes
5.Implementation of quality management system (ISO-9001)
6.Update of departmental procedures in line with ISO-9001 for it6s
effectiveness.
7.Co-ordination with managing director for quality management system.
D. ENVIRONMENTALMANAGEMENT SYSTEM(ISO-14001):-
To obtain ISO-14001 certificate the quality assurance deptt. Manage the
environmental system of plant and do following works:
1.Improve environmental performance
2.Green and clean environmental
3.Internal audits
4.Compliance of legal requirements
5.Ensuring safety & health
6.Conservation of natural sources
7.Co-ordinate with managing director for management system

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E. PROCESSINSPECTION (FAB & GALVANISING):-
Process inspection is done in Fabrication inspection
1.Route test
2.Inspection report
3.MR notes company standards
4.Customer standard
5.Approved sketches
6.Visual & dimensional inspection
7.Lot quality
8.Galvanizing coating on tower plant
F. INSPECTION SUMMARY
Okay - Release for further processing
Not okay - Rejected or accepted after re-work or sorting
Feed back to supplier for improvement
Salvaging or down grading or disposalof rejected material after review
k) GALVANISING DEPARTMENT:-
Galvanizing deptt. Is one of the most deptt. Of this plant. Tower parts are
galvanizing here. Environmental condition like rain, temp., moisture etc.
causes erosion of tower material which reduces tower life so for the safety of
tower from the erosion it is coated by zinc. This coating process is called
galvanizing.
Mainly there are two method of galvanizing:
1. Dry galvanizing
2. Wet galvanizing
The life time of wet galvanizing is drier galvanizing so KEC uses wet
galvanizing.

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PROCEDUREOF GALVANISING:-
Galvanizing is completed in different steps. There are ten tanks for this
purpose. The process is following in different tanks.
i. DGREASING TANK:-
VNS solution presents in this tank for removing grease, oil, dust etc. on the
material. The material is dipped in VNS solution about half an hour at the 30-
35ºC temps. VNS is a new cold acid degreaser.
ii. ACID PICKLING TANK:-
The material is dipped into HCL tank for removing rust, oxides, dust, oil etc.
from its surface after degreasing. Here this process is done in lower strength
tank of HCL is low.This process takes time about 40-45 min. This timing
depends upon the material.
iii. ACID PICKLINNG TANK:-
This tank also contains HCL acid but of higher strength. The material is
dipped in this tank for a considerable time to remove rust from its surface.
iv. RINSING TANK:-
The material is cleaned & cooled by dipping it in water tank because HCL
acid sticks on it during pickling.
v. ACID PICKLING TANK:-
This tank also contains HCL acid but of highest strength, the rust is removed
from the material by dipping it into tank.
vi. RINSING TANK:-
After pickling the material it is cleaned & cooled in water tank.
vii. PRE-FLUXING TANK:-
A light coating of zinc chloride & ammonium chloride is made on material
after rinsing at 40-60ºC temperature. Zinc chloride & ammonium chloride are
in 6-4 ratio. This process is done for preventing spotting during coating of zinc
in zinc bath.

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viii. ZINC BATH:-
There is mainly ZN in this bath at 460ºC temperature. AL & lead also present
these for surface finishing of material. This bath is fill 125mt zinc every
time.This bath consists of buffer plates & fuel is used light diesel oil for
heating it. The material is dipped into it and after certain time it is raised from
it. Thus the coating of zing is made.
ix. RINSING TANK:-
This tank consists water the material is dipped into it for cooling & cleaning
after zing coating.
x. RINSING TANK:-
This tank consists water & de oxidants VNS-X-75 for preventing oxidation of
material. The material is dipped into it at last.
Fig no.8 process of galvizing
XI) TOWER TESTING:-
In tower testing process the strength & capacity is tested. The tower is
assembled & erected at here & after the load is applied on tower for testing by
the load cell.
There are three types of loads which are applied:
1. Transverse load
2. longitudinal load

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3. Vertical load
These loads are considered according to the design of tower. These whole
considerations are acquired from Mumbai office. The load is applied on the
different part of tower according to consideration & client’s demand.
A. PROCEDUREOF TOWER TESTING:-
The galvanized test tower complete with required extensions will be erected
on rigid foundation are of testing station. The loads are applied as per data
sheets, which are submitted for approval before tower test.
In the design calibration Ultimate, Transverse, Vertical & Longitudinal loads
for cases are give. Tower is tested for loading cases indicated in the test data
sheet.
These loads will be applied in following steps for all load cases:
50% of Ultimate load
75% of Ultimate load
90% of Ultimate load
95% of Ultimate load
100% of Ultimate load
In the event of failure at less than 95 % of the specified design load, the failed
components are modified & structure will be rested to 100% of the specified
design load.
In the event of failure b/w 95% & 100% of the specified design loads. Support
shall be modified & rested.
In the event of failure at100% of the specified design loads but less than 1 min
in to the holding period, the client may acceptthe supportwithout
modification.
All the load cells to be used for testing will be calibrated before starting the
test with the help of UTM in the presence of the engineer. The test loading
will be applied as per calibration result.
B. PROCEDUREOF LOADING:-
The longitudinal, transverse & vertical loads are applied to tower wire ropes
using electrical winches.
Now transverse, vertical & longitudinal loads will be applied as per data sheet.
Applied loads are measured by dial indicators connected to the load cell
inserted b/w tower & wire ropes. The gradually increment of loads is 50%,
90%, 95%, 100% of the specified loads. Holding period for load stages below
100% shall be 1 min for 100% load stages.
After completing all the design loads test as required by the purchaser, tower
will be subjected to destruction test under normal condition by applying loads
in step of 105%, 110%, 115%, 120% ultimate failing occurs.

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5. Conclusion
In the corporateworld a technocrat is judged not only on the basis of technical
knowledge but also on his problem solving efficiency planning & ability to
work in a team exposure of technical knowledge to real world problems makes
a man professional conversant with the complexities involved in a job. In view
of such benefits, practical training has been made an integral part of my
curriculum.
The weeks of my first practical training were full of wonderful experiences.
Training has made me well acquainted with the necessities & the problems
that engineers a1ctually face during their jobs. It has also helped me a lot to
adapt myself to actual working environment & working co-ordination with
other team members.
This training helped me a lot in exchanging my inter and personal skills there
by furnishing my attitude, skills, & knowledge. Further the guidance, support,
co-operation and assistance provided by my colleagues & members at the
bank helped me a lot in developing the project.

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6. REFERENCES
The main sourceof reference for me during my training period have
been the people here working for the company since the company
started its production. They were the only source of information based
on which I have formulated the departments sections and camp to know
about the lacunas existing in the company. Though the presence of the
company website cann’t be ignored which acts as a good platform to
compare their productrange with the same category. The following are
the sources of information:
1.www.kecrpg.com
2.Kec project and planning manual.
3.R.K. Jain ……. 17th edition june 2009