Industrial Visits to KEC,Nagpur

A Report on
INDUSTRIAL VISIT
Of
Mechanical Engineering
Department
To
Butibori, Nagpur
On 22nd of February 2014
IInd&IIIrd Year Mechanical Engineering
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2nd& 3rdYear Students (Mechanical Dept.) at KEC International Ltd.
PPT Presentation by Company Executives
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Acknowledgement
T&P cell, MGI-COET, had organized an industrial visit for students of Mechanical
engineering at KEC international Ltd on 22nd of February 2014. It gives us
immense pleasure to present a report on Industrial visit undergone at KEC
International limited, Nagpur. The successful accomplishment of the project is the
fruit of the entire Mechanical Dept. we avail this opportunity to express our
hearted thanks to HRD & GS dept. of KEC International Limited ,Who gave us
this opportunity to have a visit & their valuable guidance and kind co- operation.
We, the Students of Mechanical Engineering are extremely thankful to Hon.
Principal of MGI-COET, Shegaon Dr. C.M.Jadhao and Prof. A.P.PATIL, HOD
Mechanical Engineering Department.
We wish to express gratitude to our T&P Guide Mr. Tushar Badhe for their firm
support during the Industrial visit. We also thank to all the employees of KEC Ltd,
those despite their busy work schedule helped and guided us during training
We also thank to the management of KEC International Limited, for giving us
permission for visiting the industry.
We are also thankful to faculty members Mr.PrashantDarade, Mr. RoshanMarode
and Miss. Ujwala Gawarguru for their kind support.
The guiding staff on site was very supportive to all students. We are sure that
this visit will help us in our future practical life and it will bring a positive
change in our thinking and practical behavior regarding education and specially
Engineering.
The students of IInd&IIIrd year Mechanical Engineering Students have enjoyed
the technical endeavor at both the organizations a lot. The company persons also
appreciated our students after the question answer sessions. Visit seems to be very
informative and gives good learning experience. It was the unique example of
‘EDUTAINMENT’ i.e. Education & Entertainment.
Students were well mannered and disciplined throughout the Tour and no injury or
anything bad happened during the industrial tour.
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Introduction
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KEC International Limited (formerly Kamani Engineering Corporation Limited) is
India's second largest manufacturer of electric power transmission towers and one
of the largest Power Transmission Engineering, Procurement & Construction
(EPC) companies in the world. It is headquartered in Mumbai, India and is part of
the RPG Group, engaged in laying of power transmission lines on EPC globally. It
also provides telecom infrastructure services, tower testing, satellite and GPRS
surveys, and hotline stringing services. It has operations in Algeria, Afghanistan,
Egypt, Ethiopia, Ghana, Kazakhstan, Kenya, Mali, Mozambique, Namibia,
Nigeria, Saudi Arabia, South Africa, Tajikistan, and the United Arab Emirates.
History
Ramjibhai Kamani founded Kamani Engineering Corporation (KEC) in 1945
which became the first electric power transmission company in Asia and a pioneer
in the field of electric power transmission and railway electrification. In 1950, the
company received an order from the Indian government to supply transmission
towers for the prestigious Bhakra Nangal Dam project and a steel tower fabrication
plant was established in Bombay in partnership with R. Foures, France. This was
augmented by a second unit in Jaipur, Rajasthan and by 1967; KEC was supplying
three-fifths of India's demand for transmission towers.
By the 1970s KEC had carried out turnkey power transmission projects in Iran,
Iraq, Kuwait, Saudi Arabia, Sudan, Egypt, Nigeria, Algeria, Mauritius, Indonesia,
Malaysia, Thailand, The Philippines, Australia, New Zealand, Brazil, the United
States and Canada. With eighty per cent of its turnover of almost INR 80 crores
(US$13 million) being earned through exports, KEC soon became the largest
manufacturer of transmission towers in India and the second largest in the world,
next in rank to SAE of Italy.
The company today
Today KEC International is INR 4000 crore (US$640 million) turnover flagship
company of the RPG Group.
The company currently is in the following major business areas:
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Power Transmission
Power Distribution & Design Services
Cabling
Telecommunications Infrastructure
Railway Infrastructure
Cables Manufacturing
Water Management
The company has manufacturing facilities in Nagpur, Jabalpur, Jaipur (Tower and
Steel Structural), Thane, Mysore and Silvassa (Cables).
In March 2010, RPG Cables was merged with KEC International.
In September 2010, KEC International acquired Houston, Texas based SAE
Towers, a group of operating companies incorporated in the United States, Mexico
and Brazil consolidated through SAE Towers Holdings, LLC. This acquisition
created the largest steel lattice tower manufacturer in the world with approximately
300,000 tons of annual production capacity.
Manufacturing
 Tower Manufacturing
KEC is the largest globally operated lattice tower manufacturing Company in the
world. It has a total manufacturing capacity is 311,200 MTs per annum spread
across five locations, three in India (Capacity: 211,200 MTs) and two in Americas
(Capacity: 100,000 MTs) - one each in Brazil and Mexico. In India, the
Company’s tower manufacturing facilities are located in – Nagpur, Maharashtra
(Capacity: 78,000MTs), Jabalpur, Madhya Pradesh (Capacity: 75,600MTs) and
Jaipur, Rajasthan (Capacity: 57,600 MTs). In addition to this, the Company also
has close associations with various Value Added Partners facilities who provide
exclusive capacity to the Company. The Company’s tower manufacturing units are
managed independently and are supported centrally by Procurement, Logistics, and
Quality Assurance, Planning and Commercial functions at Supply Chain. In
addition to this, the Company also has association with various vendors and
logistics service providers.
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Some of the features of these facilities are:
 State of Art Manufacturing technology with well-engineered lay out.
 In-house developed special purpose horizontal cum vertical bending press
for bending the different section sizes
 Capability of catering to zinc coat thickness in the range of 65 to 130
microns as per customer requirement
 Strong Steel sourcing capability
 Common ERP System across all Supply Chain manufacturing facilities
 Fully Integrated Planning system –Order to Delivery
 Capability of catering to tower wise bundling requirement of the customer to
enable storage and easy supply of tower to the desired locations.
 Engineering and Design
The Company has in-house design centers with a strong team of over 100 design
experts in India and Americas who continuously develop innovative, construction
friendly and cost- effective designs. It is equipped with the latest software’s like
PLS Tower, PLS Pole, PLS CADD, AUTOCAD, MICROSTATION, BOCAD and
Google Earth. It provides computerized engineering solutions, 3D analysis and
design depending on the size and complexity of the project, voltage range, weather
condition etc. The Company has an unparalleled strength in the design of very
complex and large towers with a state of the art in-house Design center. It has
designed Multi circuit, River crossing towers weighing approx. 300 M.T. with the
height of more than 150 meters per tower.
 Tower Testing
KEC has the distinction of being the only Transmission Tower Company in the
world to have four tower testing stations. It has three test stations in India and one
in Brazil. These testing stations serve the objective of satisfying customers about
design parameters of tower by subjecting Proto-Towers to various test load
conditions. The Company’s Nagpur, Maharashtra testing station is one of the few
testing stations in the world capable of testing towers up to 1,200 kV. The tower
testing station at Brazil is Americas largest. All the testing stations are strategically
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located near manufacturing facilities. They are capable of testing all types of
towers – Lattice Towers, Guyed Towers, Tubular and Mono Poles. The Company
can provide complete testing solutions to any type of transmission line
requirements.
VISIT CONCLUSIONS:
 We have gone through various manufacturing processes and the machineries
such as drilling machine, punching machine, plasma arc cutting machine,
notching machine, bending operation, hill milling, various furnaces,
galvanizing process etc. He also shows us CNC machine. A special type of
tool is used to measure the temperature of angle or sheet inside the furnace
known as pyrometer.
 During visit instructor shown us various types of cranes which were installed
in the industry such Goliath crane, cabin crane and overhead crane. In this
visit we all became familiar with working of the cranes.
 There is also a inspection department in workshop where inspection of the
manufactured component or job is done.
 A special and unique code is given to each part which they manufacture with
the process of manual as well semiautomatic stamping method. If the worker
found any error he rejects the job and if approved it is forwarded for the
further processing like galvanizing process.
 The process of galvanization takes place in following steps.
DEGREASING -> PICKLING -> PRE- FLUXING -> FLUXING -> DRY HOT -> DEEPING
IN ZINC -> QUENCHING -> DICHROMATING -> DRYING -> PACKING
While packing the entire material is packed in special type of boxes which are
totally paced using vacuum pressure. The life of galvanization is for 30 years.
 The first finished angles after galvanizing are assembled for a trial to check
whether the dimensions are according to design or not. Then only further
production proceeds.
 Final Finished product according to the design is packed in bunches and
forwarded to the project site for the installation and erection of the
transmission tower.
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