Kel IV Report

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CHAPTER 1 KEL, MAMALA

1.1 INTRODUCTION

KEL is one among the largest, most vibrant, and productive Public Sector Undertaking, and is fully owned by the Government of Kerala. A multi-product engineering company, consistently catering to an envious client base, ranging from the army and air force of India to world-renowned space research organizations, highly competent engineering companies to mammoth institutions likes the Indian Railways. The company with four state-of-the-art manufacturing units spread across Kerala has a pan India presence with marketing offices in major metros and select cities.

Established in 1964 in the State of Kerala, India, the Kerala Electrical & Allied Engineering Co.Ltd. (KEL) is a multifaceted company fully owned by the State government. Through it’s five production facilities, located in various districts of the State, this ISO 9001: 2000 complaint company provides basic engineering services / products besides executing projects of national significance for high profile clients like the various defence establishments.

The company manufactures and markets products like general purpose brushless alternators, brushless alternators for lighting and air-conditioning of rail coaches, medium power and distribution transformers as well as structural steel fabrications.The product categories for defence applications include high frequency alternators, frequency convertors, special alternators and power packs for missile projects. The power packs designed and supplied by the company for missile projects like Falcon, Prithvi, Trishul and Akash have been pioneering efforts. The company has also supplied special alternators to the Army (Military Power Cars) and Air Force (Radar Applications).

The company’s all-India marketing network with regional offices in all metro cities cater to major institutional clients like the State Electricity Boards, Indian Railways and various defence establishments besides the general market clients

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1.2 STRUCTURAL DIVISION

The Structural Engineering Division of KEL in its Mamala Unit, specializes in the design, fabrication and commissioning of hydraulic gates and hoists and their controlling equipment used in dams for power and irrigation projects. Many such projects have been successfully executed, by this division on a turnkey basis, all over India.

The KEL structural division, with a capacity of 1200 MT per annum undertakes the design and construction of steel bridges, factory buildings, storage tanks, fabrication of pressure vessels and other industrial steel structures, as per customer specification. For the Railways, KEL undertakes the fabrication and manufacture of bogie frames, bogie bolster, head stocks for railway coaches and wagons.

1.2.1 PRODUCT RANGE

Hydraulic gates, hoists and controlling equipment. Fabrication of structural steel. Railways bogies, Suspension bridges.

1.2.2 MAJOR PROJECTS UNDERTAKEN

 Gerusoppa Dam, Karnataka for Karnataka Power Corp. Ltd.

 Hydro-mechanical works – Penstock, stoplog gate, gantry crane, hoist

 Upper Tunga, Karnataka for Karnataka Neeravari Nigam Ltd.

 Radial gates, rope drum hoists, stoplog gate, gantry crane

 Mansi Wakal, Udaipur, Rajasthan for ITD Cementation India Ltd.

 Radial gates, vertical gates, stoplog gate, hoists

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 Slide gates

 Bogie frames for BFAT Wagons for BEML

 Bogie frames for EMU Coaches for ICF

1.3 TRANSFORMER DIVISION

Fig 1.1 Transformer

The Transformer Division of KEL at Mamala, Ernakulum, was established in 1969, with the technical assistance of ‘BHEL’, to manufacture supreme quality transformers, for various State Electricity Boards, Government Departments, Public and Private Sector Companies. This division, ISO 9001 certified by TUV, boasts of a long sustained list of extremely satisfied clients, many of whom who have stood by KEL, for decades. A fitting testimony to the trustworthy performer the robust energy efficient transformers of KEL. Over the years, relying on the unmatched quality of KEL transformers, electricity boards across India perfectly maintain a healthy power distribution supply system.

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The transformer division with an annual production capacity of 6,00,000 kVA soon after its inception, emerged as a major player in designing and manufacturing Distribution Transformers of ratings up to 5,000 kVA, 33 kV Class. Manufacturing custom-built transformers, for specific requirements, is yet another speciality of KEL. The KEL transformer factory is one of the first few transformer factories in India, to get ISO 9001 Certification. KEL transformers, approved by the national test house, various state electricity boards and power corporations in the country, are type tested at Central Power Research Institute, Bangalore

Through in-house R&D efforts, KEL transformers were customized to suit stringent requirements and trends innovations continue as an on-going process to deliver specific transformer types and designs of various ratings. In this pursuit of excellence, the resourceful design department of KEL, uses state-of-the-art software to design world-class transformers, optimized for maximum reliability, durability, and energy efficiency, compatible to the standards set by the Bureau of Energy Efficiency (BEE).

Banking on its inherent strength, in technological excellence, and an uncompromising commitment to quality, the Transformer division of KEL, is all set for substantial growth. By forgoing new alliances. By exploring new vistas.

1.4 QUALITY SYSTEM

ISO 9001 Quality Management System for design, procurement, manufacturing, testing, erection, commissioning and servicing of transformers. Certified by TUV.

1.5 PRODUCT RANGE

Distribution Transformers of ratings upto 5,000 kVA, 33 kV class – of types such as oil-filled and resin impregnated dry type; on load tap changing with Automatic Voltage Regulation.

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1.6.1 TRANSFORMER DIVISION AT MAMALA UNIT

 Distribution Transformers of ratings upto 5000 kVA, 33 kV class – of types such as oil-filled and resin impregnated dry type; on load tap changing with Automatic Voltage Regulation.

 Future-ready Product Range: Resin Cast Dry Type, Special Application Transformers such as EMU, LOCO, Dynamic Reactive Power Compensation and Furnace Transformers.

1.6.2 STRUCTURAL ENGINEERING DIVISION AT MAMALA UNIT

 Design, fabrication and commissioning of hydraulic gates and hoists and their controlling equipment.

 Design and construction of steel bridges, factory buildings, storage tanks, fabrication of pressure vessels and other industrial steel structures.

 Fabrication and manufacture of bogie frames, bogie bolster, head stocks for railway coaches and wagons.

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.6.3 TRAIN LIGHTING ALTERNATOR DIVISION AT KUNDARA UNIT

 Inductor type brushless alternator for train lighting and air-conditioning -1 kW to 40 Kw with RRU/ERRU

 12 kW alternators specially designed for powering Janashatabdi Express Trains of Indian Railways.

 Inductor Type brushless alternator for automobiles and for charging systems in diesel engines – 12 V, 24 V upto 50 A.

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 Ground power units for starting Avro and Dornier aircrafts and for powering Boeing aircrafts.

 Ground Support units with dual voltage system for starting fighter aircrafts.

 DC, AC power frequency and high frequency power pack for missile firing auxiliary power support.

 BLDC Fan

1.6.4 LT SWITCHGEAR DIVISION AT OLAVAKKOD UNIT

 Fuse Switches

 Changeover Switches

 Porcelain Fuse Units and Cutouts

 Distribution fuse boards and industrial type switch boards

 Distribution Boards (SPN & TPN 2 to 16 ways)

1.7 MACHINES AND EQUIPMENTS

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Fig 1.1 Press breaker

A press brake, also known as a brake press, is a machine tool for bending sheet and plate material, most commonly sheet metal .It forms predetermined bends by clamping the work piece between a matching punch and die.

Specification: Model number: 08 /80 HH SL NO / year : 8/2000 Stroke /min : 300 mm Main motor HP/RPM: 10/1460  BENDING PROCESS

Typically, two C-frames form the sides of the press brake, connected to a table at the bottom and on a moveable beam at the top. The bottom tool is mounted on the table with the top tool mounted on the upper beam.

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Fig 1.2 Milling machine

Milling machines are tools designed to machine metal, wood, and other solid materials. Often automated, milling machines can be positioned in either vertical or horizontal orientation to carve out materials based on a pre-existing design. These designs are often CAD directed, and many milling machines are CNC-operated, although manually and traditionally-automated milling devices are also common. Milling machines are capable of dynamic movement, both of the tool and the workpiece, and many milling machines can perform multi-axis machining. Because of variations in orientation, operation and application, milling machines have varying functions and different operating principles.

1.7.3 LATHE

A lathe is a machine tool which rotates the workpiece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation.

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Fig 1.3 Lathe

Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, parts reclamation, and glass-working. Lathes can be used to shape pottery, the best-known design being the potter's wheel. Most suitably equipped metalworking lathes can also be used to produce most solids of revolution, plane surfaces and screw threads or helices. Ornamental lathes can produce three-dimensional solids of incredible complexity. The workpiece is usually held in place by either one or two centres, at least one of which can typically be moved horizontally to accommodate varying workpiece lengths. Other work-holding methods include clamping the work about the axis of rotation using a chuck or collet, or to a faceplate, using clamps or dogs. Examples of objects that can be produced on a lathe include candlestick holders, gun barrels, cue sticks, table legs, bowls, baseball bats, musical instruments (especially woodwind instruments), crankshafts, and camshafts.

1.7.4 GEAR HOBBING MACHINE

Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities. It is the most widely used gear cutting process for creating spur and helical gears and more gears are cut by hobbing than any other process since it is relatively quick and inexpensive.

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Fig 1.4 Gear hobbing machine Specification: Type : FO-10 M/C No : 0421163 Max Dia : 1 m Cutters : 3.5 to 10 module 1.7.5 ROLLING MACHINE

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Fig 1.5 Rolling machine

A Plate Rolling Machine is a machine that will roll different kind of metal sheet into a round or conical shape. It can be also called “Roll bending machine” “plate bending Machine” or “rolling machine”. They are different kinds of Technology to roll the metal plate:

4 Roller machine: Anatomy; a Top-Roll, the Pinching-Roll, and two Side-Rolls.

The flat metal plate is placed in the machine on either side and "pre-bent" on the same side. The Side-Rolls do the work of bending. The Pinching Roll holds the plate.

3 Roll Machines (Variable Pitch aka Variable Geometry): Anatomy; One Pressing Top-Roll,

Two Pressing Side-Rolls The 3 Roll Variable Geometry works by having all three rolls being able to move and tilt. The Top-Roll moves on the vertical plane. The Side-Rolls move on the horizontal plane.

When rolling, the Top-Roll presses the metal plate between the two Side-Rolls. The advantage of having the Variable 3 Roll is the ability to roll many thicknesses and diameters of cylinders. For example; The Side-Rolls are what produce the mechanical advantage. With the Side-Rolls all the way open, then you have the maximum mechanical advantage. With the Side-Rolls all the way in, you have the least mechanical advantage.

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Fig 1.6 Drilling machine

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the workpiece, cutting off chips (swarf) from the hole as it is drilled. Exceptionally, specially-shaped bits can cut holes of non-circular cross-section; a square cross-section is possible.

1.7.7 GRINDING MACHINE

A grinding machine, often shortened to grinder, is any of various power tools or machine tools used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece via shear deformation. Grinding is used to finish workpieces that must show high surface quality (e.g., low surface roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in grinding is on the order of 0.000025 mm, in most applications it tends to be a finishing operation and removes comparatively little metal, about 0.25 to 0.50

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mm depth. However, there are some roughing applications in which grinding removes high volumes of metal quite rapidly. Thus, grinding is a diverse field.

The grinding machine consists of a bed with a fixture to guide and hold the work piece, and a power-driven grinding wheel spinning at the required speed. The speed is determined by the wheel’s diameter and manufacturer’s rating. The grinding head can travel across a fixed work piece, or the work piece can be moved while the grind head stays in a fixed position.

Fine control of the grinding head or table position is possible using a Vernier calibrated hand wheel, or using the features of numerical controls.

Fig 1.7 Grinding machine

Grinding machines remove material from the work piece by abrasion, which can generate substantial amounts of heat. To cool the work piece so that it does not overheat and go outside its tolerance, grinding machines incorporate a coolant. The coolant also benefits the machinist as the heat generated may cause burns. In high-precision grinding machines (most cylindrical and surface grinders), the final grinding stages are usually set up so that they remove about 200 nm (less than 1/10000 in) per pass - this generates so little heat that even with no coolant, the temperature rise is negligible.

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Fig 1.8 Shaper machine

A shaper is a type of machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of helical. (Adding axes of motion can yield helical toolpaths, has also done in helical plaining.) A shaper is analogous to a planer, but smaller, and with the cutter riding a ram that moves above a stationary workpiece, rather than the entire workpiece moving beneath the cutter. The ram is moved back and forth typically by a crank inside the column; hydraulically actuated shapers also exist.

1.7.9 POWER HACKSAW

Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting diameters of more than 10/15mm is very hard work with a normal hand held hacksaw. Therefore power hacksaws have been developed to carry out the difficult and time consuming work. The heavy ‘arm’ moves backwards and forwards, cutting on the backwards stroke.

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Fig 1.9 Power hacksaw

1.7.10 WELDING

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ARC WELDING

Arc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is usually protected by some type of shielding gas, vapour, or slag. Arc welding processes may be manual, semi-automatic, or fully automated. First developed in the late part of the 19th century, arc welding became commercially important in shipbuilding during the Second World War. Today it remains an important process for the fabrication of steel structures and vehicles.

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Fig 1.10 Arc welding

To supply the electrical energy necessary for arc welding processes, a number of different power supplies can be used. The most common classification is constant current power supplies and constant voltage power supplies. In arc welding, the voltage is directly related to the length of the arc, and the current is related to the amount of heat input. Constant current power supplies are most often used for manual welding processes such as gas tungsten arc welding and shielded metal arc welding, because they maintain a relatively constant current even as the voltage varies. This is important because in manual welding, it can be difficult to hold the electrode perfectly steady, and as a result, the arc length and thus voltage tend to fluctuate. Constant voltage power supplies hold the voltage constant and vary the current, and as a result, are most often used for automated welding processes such as gas metal arc welding, flux cored arc welding, and submerged arc welding. In these processes, arc length is kept constant, since any fluctuation in the distance between the wire and the base material is quickly rectified by a large change in current. For example, if the wire and the base material get too close, the current will rapidly increase, which in turn causes the heat to increase and the tip of the wire to melt, returning it to its original separation distance.

The direction of current used in arc welding also plays an important role in welding. Consumable electrode processes such as shielded metal arc welding and gas metal arc welding generally use direct current, but the electrode can be charged either positively or negatively. In welding, the positively charged anode will have a greater heat concentration

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electrode is positively charged, it will melt more quickly, increasing weld penetration and welding speed. Alternatively, a negatively charged electrode results in more shallow welds. Non-consumable electrode processes, such as gas tungsten arc welding, can use either type of direct current (DC), as well as alternating current (AC). With direct current however, because the electrode only creates the arc and does not provide filler material, a positively charged electrode causes shallow welds, while a negatively charged electrode makes deeper welds. Alternating current rapidly moves between these two, resulting in medium-penetration welds. One disadvantage of AC, the fact that the arc must be re-ignited after every zero crossing, has been addressed with the invention of special power units that produce a square wave pattern instead of the normal sine wave, eliminating low-voltage time after the zero crossings and minimizing the effects of the problem. Duty cycle is a welding equipment specification which defines the number of minutes, within a 10 minute period, during which a given arc welder can safely be used. For example, an 80. A welder with a 60% duty cycle must be "rested" for at least 4 minutes after 6 minutes of continuous welding. Failure to observe duty cycle limitations could damage the welder. Commercial- or professional-grade welders typically have a 100% duty cycle.

 GAS WELDING

Fig 1.11 Gas welding

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding in the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals, respectively. French engineers Edmond Fouché and Charles Picard

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became the first to develop oxygen-acetylene welding in 1903.[1]_{Pure oxygen, instead of}_air_,

is used to increase the flame temperature to allow localized melting of the workpiece material (e.g. steel) in a room environment. A common propane/air flame burns at about 2,000 °C (3,630 °F), a propane/oxygen flame burns at about 2,500 °C (4,530 °F), and an acetylene/oxygen flame burns at about 3,500 °C (6,330 °F).

Oxy-fuel is one of the oldest welding processes, besides forge welding. Still used in industry, in recent decades it has been less widely utilized in industrial applications as other specifically devised technologies have been adopted. It is still widely used for welding pipes and tubes, as well as repair work.

In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metals to be welded. In oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A stream of oxygen is then trained on the metal, burning it into a metal oxide that flows out of the kerf as slag. Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel cutting requires two isolated supplies, fuel and oxygen). Most metals cannot be melted with a single-tank torch.

CONCLUSION

Industrial visit at KEL, Mamala was a very good experience. We got some practical experience along with theoretical knowledge. We got practical experience on different machines and equipments in the firm. The systematic arrangement of the various department in the firm is a noticeable thing. The cooperation of workers within the firm is an appreciable one.