SUMMER TRAINING REPORT

“BAJAJ ELECTRICALS LIMITED”

BACHELOR OF TECHNOLOGY

In

(Mechanical Engineering)

 

Submitted ByHarshit Srivastava (0805440406)

DEPARTMENT OF MECHANICAL ENGINEERING

BABU BANARASI DAS NATIONAL INSTITUTE OF TECHNOLOGY &

MANAGEMENT

GAUTAM BUDDH TECHNICAL UNIVERSITY, LUCKNOW

(2010-2011)

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INDEX

COMPANY PROFILE

HISTORY OF THE COMPANY

DEPARTMENTS IN BAJAJ ELECTRICALS

INTRODUCTION

HIGH MAST LIGHTING

CONCEPT

APPLICATION

SPECIFICATION OF HIGH MAST POLE

PLANT LAYOUT

THE PROCESS FLOW CHART

VARIOUS PROCESS

CONCLUSION

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1. COMPANY PROFILEBajaj Electricals Limited (BEL), a 72 year old trusted company with a turnover of

Rs. 2763 crores, is a part of the US $ 7 billion (over Rs 38,000 crores) "Bajaj Group". Bajaj Electricals Limited has six strategic business units – Engineering and Projects, Appliances, Fans, Luminaries, Lighting and Morphy Richards.

Bajaj Electricals has 19 branch offices spread in different parts of the country besides being supported by a chain of about 1000 distributors, 4000 authorized dealers, over 4,00,000 retail outlets and over 282 Customer Care centers.

Bajaj Electricals has distribution arrangements with Trilux Lenze of Germany (for Luminaries), tie up with Delta Controls of Canada (for Building Management Systems) and Securiton of Switzerland (for security systems), Morphy Richards of UK and Nardi of Italy (for Appliances), Disney of USA & Midea of China (for Fans). The company has also invested in Starlite Lighting for manufacture of energy saving lamps (CFL)

The company is also in the business of manufacturing erection & commissioning of transmission line towers [TLT], Telecom towers, Mobile telecom towers & Wind energy towers. Export of all BEL’s products except of its engineering & project business units is taken care of by group company Bajaj International Pvt. Ltd.

1.1 HISTORY OF THE COMPANY

The ‘Bajaj’ group of India owes immense gratitude to their founding fathers whose vision and dedication over the years has greatly helped to build a business house that can set standards in Indian industry.

Jamnalal Bajaj was the founder of the Bajaj Group. The adopted fifth son of Mahatma Gandhi and the Merchant Prince who held the wealth he created in trust for the people of his country. Trust the simple word that contains a whole philosophy handed down by Jamnalal Bajaj to his successors. He valued honesty over profit, actions over words and common good over individual gain.

Kamalnayan Bajaj, elder son of Jamnalal Bajaj, followed footsteps of his illustrious father and consolidated the Bajaj foundation. With characteristics foresight and pragmatic vision, he launched a steady diversification programmed, which gave the current name “Bajaj” both its shape and size. His unique management style created a work culture that matched well with the national spirit he had inherited.

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Ramakrishna Bajaj took over reins of the “Bajaj Group” in 1972 after Kamalnayan Bajaj and steered the group from strength to strength for over 22 years. He had also actively participated in the freedom struggle of the country. In post independent India, he had led the youth movement. All along, he actively strengthened the foundations of business through ethics and practices both within the group and amongst the business community as well.

Shekhar Bajaj, Chairman & Managing Director of Bajaj Electricals Ltd., started his career with Bajaj Sevashram after which he worked at Bajaj International, the group’s export company. Mr. Shekhar Bajaj joined Bajaj Electricals in 1980, became the managing Director in 1987 and took over as the chairman and Managing Director 1994. Mr. Bajaj is the Chairman of Bajaj Group companies Bajaj International and Hercules Hoist Pvt. Ltd. and on the Board of Directors of Bajaj Auto and IDBI Bank. He was the president of the ASSOCHAM, former President of Indian Merchant chambers (IMC) and council for fair business practices (CFBP).

1.2 RANJAN-GAON MANUFACTURING UNIT

Bajaj Electricals Limited has six strategic business units – Engineering and Projects, Appliances, Fans, Luminaries, Lighting and Morphy Richards. The engineering & projects business unit is accredited with ISO 9001 & is the leader in the field of illuminations engineering & lighting projects & commands a lion’s share of the high mast lighting system market with over 3000 installations countrywide. This division is supported with manufacturing facilities, which are also accredited ISO 9001-2000 & ISO 14001.

This business unit is a leading manufacturer & supplier of various types of galvanized components, designed, manufactured & tested as per international standard. The division has set up one of the finest state of art manufacturing facilities at Ranjangaon 50 km from Pune. The plant is capable of manufacturing high mast shafts, components of lattice towers used for lighting, power transmission, and communication, etc as well as octagonal & tabular lighting poles.

The plants has a sophisticated fabrication shop & countries biggest “Radio Remote Controlled Tunnel Enclosed Galvanizing Bath” having dimensions 13ML, 2.5 MD, 1.3 MW, which hold close to 250 tons of molten Zinc at 450°C round clock. The galvanizing plant is imported from GIEMCO, Italy & has an installed capacity 40000 tons per annum. The environment friendly galvanizing plant meets the European pollution control norms. The manufacturing facilities are approved by reputed organizations like power plants; state owned electricity board etc. and has registered the plant as their approved vendor. The plant is presently executing orders for Tata projects, Birla and Infocom Ltd etc. for the supply of fabricated lattice type structure.

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2. DEPARTMENTS IN BAJAJ ELECTRICALS LTD.

1. HR and Administration Department.2. Accounts Department.3. Quality Assurance Department.4. Purchase Department.5. Store Department.6. Dispatch Department.7. Raw yard Department.8. High mast Department.9. TLT Production Department.10. Galvanizing Department.11. Planning Department.(High mast & TLT)12. Pre Production Department.13. Plant Engineering Department.14. Logistics Department.

PRESENT BUSINESS OF THE COMPANY:

Bajaj brand is one of the premier and popular brands in the country today. Products marketed are fans, lighting, luminaries, appliances and turnkey lighting projects.

High mast lighting. Transmission line towers. Telecommunication Network Towers. Highway crash Guards. Turnkey lighting projects.

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CUSTOMERS:

All state Government owned Electricity Boards [TNSEB, RRVPNLAP.]. All Electricity Distribution company’s [REL, SUZLON, SPIC TATA

PROJECT]. All major industries [RIC]. Stadiums [Outdoor & Indoor]. Export Customers.

IMPORTANT CLIENTS:

Wankhede Stadium, Mumbai. Air port authority of India [AAI]. Bharat Petroleum Corporation Ltd. BHEL Simhadri. Chennai Port Trust. Chinnaswamy Stadium, Bangalore. CIDCO. Hindustan Petroleum Corporation Ltd. Indian oil Corporation Ltd. Jaipur Vidyut Vitaran Nigam Ltd.

Detailed report of manufacturing of the HIGH MAST poles at the RU II plant is described in the next pages.

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3. INTRODUCTION

3.1. HIGH MAST LIGHTING                 High Mast lighting is the concept in the field of area lighting popularized in India by Bajaj Electricals Limited (BEL). The high mast system takes care of specific and diversified needs of various clients

The government has taken concrete steps in the right direction to kick start the economy and focus on infrastructure development which is so vital for the economic growth of the country.  Poor infrastructure facilities have taken its toll and industrial growth has suffered all around.  Foreign investors are wary of setting up shop in India due to lack of modern facilities. Availability of reliable and adequate power has been another serious hindrance in the development of our economy.  Today Bajaj has a installed capacity of 1,25,000 MW but with the huge transmission and distribution losses, coupled with unchecked power thefts and rising demands, load-shedding and power-cuts have become the order of the day.

3.2. CONCEPT

The High Mast installations can be prominently seen at the city road junctions, domestic & international airports, railway yards, sea ports as well as tank farms to name a few. High mast lighting systems are designed to provide space efficient & easy installation, maintenance friendly operations and uniform lighting distribution need of large area lighting. The galvanized high mast shaft provides aesthetics in addition to other benefits such as corrosion resistance resulting into long life. The flexibility to mount luminaries in various combinations on these high masts enables to use this novel technique for any outdoor lighting application. High mast is a high pole (usually 30 metres) comprising of 3 nos 11 m long polygonal steel sections press-fitted together to form a single pole structure. This pole carries a lantern carriage at the top on which the

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floodlights are fixed. Installation of High mast is also much easier compared to the conventional lattice tower in which a large labour force is required. The 3 sections are easily assembled at site. The winch assembly is provided at bottom of the Mast and the wire rope is wound neatly and tightly on to winch, and head gear with cable etc., is provided on top section of the Mast.

3.3. APPLICATIONS

Area LightingAirportsCity JunctionToll PlazaSea PortsCar ParkSports StadiumTelecommunication MonopoleTransmission MonopoleFlag MastSignage MastHoarding Mast Traffic Signal Mast 3.4. IN-HOUSE FACILITY OF HIGH MAST MANUFACTURING

Bajaj Electricals Ltd (BEL), under its Engineering & Projects Business Unit, has set up a world class manufacturing facility at Ranjangaon (Maharashtra), about 55 km from Pune. The plant is equipped with the most sophisticated, computer controlled, state-of-the-art machineries like special purpose 1000 Ton Hydraulic Press Brake imported from LVD Belgium, fitted with CADMAN programme for finest accuracy, which is capable of bending 12 mm thick and 12 meter long single piece steel plates.

The imported critical machineries are:

1000 Ton 12 M long Press Brake with CADMAN software from LVD, Belgium Vacuum Plate lifting machine from Allen Wheeler, UK

CNC Profile Cutting machine from MESSER, (Germany) Shanghai

Submerged Arc Welding machines from; BODE, UK

Hot Dip galvanizing plant from GIMECO Italy.

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The hot dip galvanizing plant is one of the biggest in Asia which is environment friendly, tunnel-enclosed and with a EURO II compliant bath of size13.0 M length, 2.5 M depth and 1.3 M width, to take care of the needs of the entire in-house production.BEL has developed in house facility for civil & structural designs.

3.5. RANJANGAON PLANT EXPANSION:

Considering the demand of high masts for different applications, Street lighting octagonal “Bajaj Smart Poles”, Transmission line towers etc, Bajaj has completed expansion of plant by adding the capacity with capital expenditure of Rs. 15 crores at Ranjangaon.

4. SPECIFICATION OF HIGH MAST POLE

MAST STRUCTUREMast shafts are hot dip galvanized, continuously tapered of polygonal cross section presenting a good and pleasing appearance.

DYNAMIC LOADINGThe mast structure is designed as per TR No.-7 of Institution of Lighting Engineers of UK and are suitable to sustain an assumed maximum reaction arising from a wind speed (three second gust) as laid down by IS: 875/1987 (Part III) measured at a height of 10 metres above ground level. Wind excited oscillations are damped by the method of construction and adequate allowance is made for the related stresses. Stress analysis calculations are provided against specific request.

MAST CONSTRUCTIONHigh mast shaft is fabricated from high tensile steel plates confirming to BS EN 10025 or equivalent having minimum yield strength of 355 N/mm formed in polygonal shape and fillet welded and other components as per IS 2062. Detailed procedures and procedure qualifications are as per AWS Section D 1.1 & of Clauses 20 and 21 of BS5135.A Vandal and weather proof door with provision to padlock is provided to have clear access to the base compartment equipments like winch, motor, cable, termination etc;. The base flange welded to high mast shaft develops full strength of the section. In addition supplementary gussets are provided between the bolt holes.METAL PROTECTIONThe entire fabricated mast is hot dip galvanized, internally and externally as per BS EN ISO 1461 or equivalent.

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RAISING LOWERING ARRANGEMENTThe proven In-Tension design is provided comprising winch, head frame and stainless steel wire ropes.

HEAD ARRANGEMENTCast Aluminium pulley suitable for trailing cable and wire ropes are with bush bearing and stainless steel spindle provided with guides, separator and adjusters to prevent ropes and cables leaving their respective pulley grooves Pulley assembly is housed in a chassis integral with a sleeve which slips over the top of the mast and is secured axially and azimuth. Guides and stops are provided for docking of luminary's carriage. The complete fabricated assembly and canopy covering the pulley assembly is hot dip galvanized.

WINCHWinches are completely self sustaining without the need of any break/spring/clutch, self lubricating by means of oil bath, worm gear driven of ratio 53:1, grooved drums for tidy and smooth rope lay. Special termination arrangement of rope does not involve distortion of the ropes. The winch is designed to install or remove through the mast door.Name plate is provided giving the details of type of winch, SWL, operating speed and year of manufacturing and instruction plate for the type of the lubricant.

WINCH OPERATING POWER TOOLSIntegral or external (single phase or three phase) power tools are available for the operation of winch. Both Integral as well as external power tools incorporate mechanical torque limiter for safety of equipments. Suitable arrangements to couple the integral power tool and support the external power tool are provided. Provision is available to lower the luminary's carriage manually by handle.

LUMINARIES CARRIAGEThe standard luminary's carriage in two halves is of welded construction fabricated from durable round steel tube for aerodynamic effect and to act as conduit with holes in bottom side to take the wiring flexible cable. Arms with circular profile for mounting luminaries are welded to the ring. HDG clamps with S.S hardware are provided to mount the CG boxes and balance the weight on carriage to avoid eccentric load. Legs are welded to anchor the wire rope for 2 or 3 ropes.

LIGHTENING FINIAL & EARTH TERMINALProvision is given on canopy to fix the hot dip galvanized lightening finial fabricated out of ERW tube. Two number 12 mm diameter galvanized bolt with nut and washers are fixed on door stiffener to terminate the earth flat from earth pit.

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FOUNDATION BOLTSHot dip galvanized (exposed portion) high tensile studs are supplied with nuts; washer and anchor plate to cast in to the foundation is supplied for each mast.

MAINTENANCE CAGE (OPTIONAL)Hot dip galvanized maintenance cage is designed to carry two persons with maintenance equipment to do maintenance at mast head or for painting of the mast for special applications. Suspension ropes have safety factor of more than 10 (Supply of maintenance cage is against separate order only)

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5. THE PLANT LAYOUT

SHED 1: High mast pole section

SHED2: Octagonal poles, accessories and special projects

SHED3: Accessories

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6. THE PROCESS FLOWCHART

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7. PROCESSES

7.1. PROFILE CUTTING (Detailed Report)

MESSER CUTTING SYSTEMS

Specifications and data of machine:

1 Main voltage at the workshop 230/415V, 50hz

2 Energy feed side Left

3 Guiding side Left

4 Height of cutting table 700mm

5 Height of track 500mm

6 Track width 4000mm

7 Track length 16000mm

8 Maximum workpiece thickness 16mm

9 Oxy fuel cutting torch 2 Nos

10 The type of CNC controller Explorer 3

Gas supply system:

1 Type of gas O2, LPG

2 Torch type MSCW 250

3 Nozzle type MG 106

Process of cutting of sheets on CNC profile cutting machine:Page | 14

1. Cut sheets up to 16mm thick by plasma2. Cut sheets by gas for more than 16mm thick plates3. As per drawing feed the data through m/c monitor or fast cam4. Set the voltage, current as per thickness of plate5. Align the plate and cut the profile6. Check the dimensions and record in logbook F/RU2/02 along with the mast number

OVERVIEW OF THE PROFILE CUTTING MACHINE:

I. Function of the machine:This Omnimat T cutting machine is composed of electrical, mechanical

components and new automatic equipments for cutting steel plates. 1. The main use of this machine:It can cut straight lines and any kinds of curves when a single torch/ straight

beveling2. High accuracy:Omnimat T cutting Machine is driven on two sides the gantry carriage has high

rigidity. Transverse and longitudinal movements are coursed by motors, the precise gears and racks.

3. High cutting quality: It has the function of constant speed and kerf offset, so the cutting accuracy and cutting quality is very good.4. High automatic level: Omnimat T can automatically control the whole cutting process, includes the

automatic dropping to work place, automatic igniting, automatic turning of the cutting oxygen, automatic turning of the heating oxygen, automatic piercing, automatic cutting, flame extinguishes when cutting is finished, automatic rising and automatic returning.

5. With complete function of CNC: This machine is equipped with EXPLORER3 or other systems in its series. It can

receive signal from RS232 port and you can manually input from keyboard.6. Safety and reliability:The longitudinal carriage rolls on the tracks and moves briskly on link arm and upspring to eliminate the clearance between the guiding wheels of the carriage and track.

II. The main technical data and specifications:

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1 TYPE

Working lengthWorking widthTemperature of the workshopFuel gas

Omnimat T

Length of track-2000mmTrack gauge-1000mm0-45oCAcetylene, propane etc

2 Single torch suspension

Height of liftingSpeed of liftingIgnition voltagePower of the lifting motorThickness of gas cuttingThickness of plasma cutting

170mm/200mm/300mm20-60mm/sec7000v25.1W/60W6-100mm, 100-200mmAs plasma arc cutting system

3 Gas system

Longitudinal transportation of gas

Maximum consumption of oxygenPressure of the oxygenPurity of oxygenMaximum consumption of fuel gasPressure of fuel gas

Cutting oxygen,Heating oxygen,Acetylene, propane etc Depends on torch quantity1.2MPa≥99.6%Depends on torch quantity0.08Mpa

4 Total weight of machine About 2T-6T

III. Installation of the Gantry carriage The gantry carriage includes the transverse beam, the main wheel housing. The gantry carriage is an integral part.Before the hoisting you must finish the following work:

1. Ensure the hoisting equipments safety2. Prevent the gantry carriage from being deformed3. Adjust guiding wheel4. Rotate the longitudinal driving gear box at a certain angle to prevent the

collision between the gear and the rack5. Dismantle the chip cleaner6. Hoist the gantry carriage, clean the surface of the guiding wheel and move the

carriage on the longitudinal tracks slowly.

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7. When the hoisting is finished, inspect the contact level between the wheel housing and the track. If the contact is not good you can adjust the contact level and when the adjusting is finished, you can tighten the screw and the spring.

IV. Installation of the transverse carriage and the torch suspensionThe carriage can drive the steel belt and the steel belt makes the carriage move in the same direction. When you are installing the carriages you must ensure that the handle of the steel belt are open so that the steel belt can pass through them. The torch suspension is a basic assembly of cutting machine; it includes carriage system, cutting torch, gas system, Igniting system and automatic height adjusting system. One must inspect the vertical degree when installing the torch suspension assembly.V. Transmission systemIt includes longitudinal driving gear box, lifting gearbox, transverse driving gear box and the driving system in the torch.

1. The longitudinal driving system reduces the gear reducer, the pinion on the output shaft meshes with the rack on the track.

2. Transverse driving gearbox is same as longitudinal driving system and the lifting gearbox of the torch drives the pair of pinions by the DC servo motor. The torch can move up and down.

VI. Gas systemsFlame cutting is one kind of thermal cutting technology, the principle is heating part of the work piece to its burning point, and the heat produced by the flame makes the material being cut burn continuously. The melting dregs are blow off the cutting oxygen, so the kerf is formed. Because of this the heating oxygen cutting oxygen, fuel gas and the compressed air according the relative technology demands must be supplied continuously by the gas system during the cutting. So the gas system is the most important part to ensure the CNC cutting m/c working properly.

VII. Structure of assemblyThe m/c is divided into mechanical parts, gas system and electric system.The mechanical parts are:

1. The gantry carriage2. Longitudinal driving gear box3. Transverse driving gear box4. Torch suspension5. Straight triple torch6. Powder marking device7. Automatic igniting device8. Automatic height adjusting device9. High frequency punch marking device

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VII. Lubrication and maintenance

The maintenance engineers lubricate and maintain the machine which includes: Cleaning of Longitudinal tracks and racks every day. The parts use MoS2 lubricating cream.

The lifting gearbox in the single torch suspension, the lifting shaft and the guiding rollers in the single torch suspension, the ball bearings in the machine and the ball bearing with dust cover, all of them has lubricating cream in them.

Maintenance:

1. Longitudinal movementCheck the rolls, if there are Fe2O3 grains, clean and smear them with lubrication oil if necessary.

2. Transverse movementCheck the tracks, racks and steel belts on the cross beam, clean it if necessary, smear them with oil after they are dried.

3. Transverse carriageCheck all the transverse carriage and gripping devices, adjust them if necessary

4. The automatic adjusting deviceInspect the function of the automatic height adjusting device, adjust it if necessary, and if the sensor is destroyed, change it.

5. Gas systemInspect the control system and check all the valves and the connectors, if it is leaking, replace it. Regularly replace the fire back preventer.

6. Hoses: Check hoses and hose connections and tighten if necessary.

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7.2. BENDING

YSD PRESS BRAKE M/C:

Specifications and data of machine:

Sr No

SPECIFICATION SINGLE TANDEM UNIT

1 SOFTWARE USED CADMAN CADMAN -

2 NOMINAL FORCE 3200 6400 KN

3 MAX WIDTH 6000 12000 MM

4 MAX OPENING HEIGHT 9500 9500 MM

5 STROKE OF RAM 320 320 MM

6 ADJUSTMENT OF STROKE 320 320 MM

7 DEPTH OF GAP 710 710 MM

8 WIDTH OF TABLE 300 300 MM

9 APPROACH SPEED 100 100 MM/S

10 WORKING SPEED 10 10 MM/S

11 RETURN SPEED 95 95 MM/S

12 MAX. PRESSURE 28 28 MPa

13 MOTOR POWER 35 2 X 35 KW

14 OIL TANK CAPACITY 700 700 X 2 DM3

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Process of bending on YSD bending machine:1. Prepare a template for marking on plate or divide width of plate into no. of sides

requires or use proper existing template and transfer the dimension on the plate with marker.

2. Align the marked line with the permanent marker.3. Set the force according to the chart available on the machine and use pusher for

pushing the plates.4. Bend the first side and check the angle with bevel protractor. If any deviation in

angle occurs, correct accordingly for each mast.5. After correction, check for other bend. If the angle is found correct, continue for the

same for the mast.6. After last bend, put the no. with marker on the side of the mast.7. Record the data in logbook.8. Verify the template for its validation.

7.3. POLE CLOSING AND WELDING

I .Parameters in Welding / WPS (Welding procedure specifications): This procedure provides information regarding requirements of parameters during

various welding processes.

1. Submerged arc welding (SAW):a. Square Butt joint( BODE & EP-SAW):

Thickness(mm)

Current(A)

Voltage(V)

Polarity FluxClass

ElectrodeDia.(mm)

TravelSpeed

(m/min)

3-12 150-400 22-35 - A5.17 2-4 0.9-1.5

2. Gas metal arc welding (GMAW) (CO2 welding) :a. Single V butt joint:

Thickness(mm)

Current(A)

Voltage(V)

Polarity FluxClass

ElectrodeDia.(mm)

TravelSpeed

(m/min)

3-12 120-180 22-25 DC EP A5.18 0.8 0.25-0.3

b. Fillet jointPage | 20

Thickness(mm)

Current(A)

Voltage(V)

Polarity FluxClass

ElectrodeDia.(mm)

TravelSpeed

(m/min)

6-40 100-200 24-30 DC EP A5.18 0.8 0.25-0.3

3. Manual metal arc welding (MMAW):a. Fillet joint

Thickness(mm)

Current(A)

Voltage(V)

Polarity FluxClass

ElectrodeDia.(mm)

TravelSpeed

(m/min)

6-40 100-240 24-30 AC EP A5.18E7018

3.15/4/5 0.2-0.3

4. GMAW:a. Fillet joint:

Thickness(mm)

Current(A)

Voltage(V)

Polarity FluxClass

ElectrodeDia.(mm)

TravelSpeed

(m/min)

16-32 130-200 20-30 DC EP A5.18 0.8 0.25-0.3

5. SAW:a. Square Butt joint:

Thickness(mm)

Current(A)

Voltage(V)

Polarity FluxClass

ElectrodeDia.(mm)

TravelSpeed

(m/min)

16-32 400-550 24-30 ACEP A5.17 2.4 0.13-0.25

II. Machines used:

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1. Bode Semi Auto SAW machine:Specifications:Pole size across flats 60mm to 610mmPole wall thickness 3mm to 8mm. Material ST52Pole traverse speed 150mm to 3000mm/minPole angle to taper 0 - 2.0%Top roller clamping force Programmable by PLCSide roller clamping force Programmable by PLCControl voltage 110v, 50HzSupply 415v, 50Hz, 3ph

2. China pole closing and welding machine3. EP Pole closing and welding machine4. HDMT pole closing and welding machine

III. Welding defects:1. Blow holes2. Undercut welding3. Pock mark4. Zigzag welding5. Welding operation6. Uneven welding

IV. Preventive actions:1. Ensure proper preweld, finishing/ deburring2. Ensure correct machine setting parameters(Voltage, Current, Speed, etc) as per

thickness of pole3. Ensure no gas leakage4. Ensure proper clamping of poles5. Ensure flux heating at 200oC for 30 minutes before use on machine

7.4. STRAIGHTENING

Straightening of the welded poles is done by special purpose pole straightening press manufactured by TMP Engg. Works pvt. Ltd. The machine has a capacity of 50 tonnes and has a motor of 15 HP.

7.5. ACCESSORIES WELDING:

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Accessories such as canopy covers, head frames, base plates, brackets, etc. required for the various projects are manufactures in this division.

1. Base Plates2. Head Frames3. Canopy covers4. Stiffners

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Machines Used:

I. Shearing Machine

VIMEX PLATE SHEARING MACHINEType: 1270 X 10mmSr No: 262/12/05Mainly used for cutting plain sized sheet/plate, range from 4mm to 10mm and length from 1000 to 2000 mm.

II. Band Saw Cutting machine

Used for cutting pipes used in accessories welding.7.6. FINISHING

This process includes the operations like drilling, finishing, grinding, etc

Machines used:

1. Radial Drilling machineSpecification:

Model Z3050X16/1Maximum drilling diameter 5.0mmSpan 1600mmSerial no 50/0/367

7.7. QUALITY ASSURANCE INSPECTION

The Quality Control Department continuously tests and monitors the use of right materials, the processes and finishes. This ensures adherence to strictly defined standards of quality by Bureau of Indian standards and International Electro Technical Commission on illumination. Samples are periodically tested in our lighting application laboratory. The lab is equipped with the latest measuring and testing equipment Electrical, Mechanical, Thermal, Environmental, Optical and CAD facilities to check compliance with safety requirements.

7.8. DISPATCH TO GALVANIZATION

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The galvanization process is done at state of the art radio remote radio controlled Galvanising plant from GIMECO, Italy.The entire fabricated mast is hot dip galvanised, internally and externally as per BS EN ISO 1461.The complete fabricated assembly and canopy covering the pulley assembly is hot dip galvanized.

8. WASTE GENERATED IN THE UNIT

Non hazardous waste generated:

Type of waste Area

Paper waste All dept.

Steel scrap in black plates, angles, bars, etc Raw yard, HM

Scrapped plastic spool (welding wire) HM

Canteen food waste HR

Wooden scrap Store, finish yard

Gardening waste HR

Scrapped lifting wire ropes RU2

Scrapped lifting slings RU2

Scrapped lifting belts RU2

Hazardous waste generated:

Type of waste Area

Used paint drums FY

Scrapped electrical cables PE

Used bulbs and tubes PE

Used hand gloves and cotton wastes All dept.

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Used grinding wheels PROD

Scrapped copper welding wires PROD

Empty tins QA dept

Used lubricants PE

Used transformer oil PE

Used hydraulic oil PE

Used coolant oil PROD

Flux dust PROD

9. CONCLUSION

As a part of our training I was provided with complete technical knowledge and hands on experience in the production of High Mast poles. I was given exposure to all areas of production like profile cutting, bending, welding, finishing etc.

I even visited the Ranjangaon Unit 1 (RU1) and witnessed the various other processes including galvanization. Overall it was an educative and pleasant experience for me.

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List of references:

1. Bajaj High Mast lighting catalogue, www.bajajelectricals.com

2. Bode Semi auto SAW machine, www.bode.co.uk

3. Manual: CNC profile cutting machine, Messer cutting systems.

4. CNC profile cutting machine, www.messercutting.com

5. YSD Bending machine, www.ysd-hd.com

6. Radial Drilling machine, http://haven-equipment.en.made-inchina.com

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