Industrial visit report, 2015KEL, Mamala 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 stateof-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 Dept: Of Mechanical Engineering Page 1 fabrication of pressure vessels and other industrial steel structures. specializes in the design. Rajasthan for ITD Cementation India Ltd. hoist Upper Tunga. 1. vertical gates. stoplog gate.2. The KEL structural division. head stocks for railway coaches and wagons. with a capacity of 1200 MT per annum undertakes the design and construction of steel bridges. by this division on a turnkey basis. all over India.2 STRUCTURAL DIVISION The Structural Engineering Division of KEL in its Mamala Unit.2 MAJOR PROJECTS UNDERTAKEN Gerusoppa Dam. hoists Narmada Project for J P Associates Dept: Of Mechanical Engineering Page 2 . Mamala 1. stoplog gate. rope drum hoists. 2015 KEL. Karnataka for Karnataka Power Corp. gantry crane Mansi Wakal. Radial gates. hoists and controlling equipment.1 PRODUCT RANGE Hydraulic gates. Fabrication of structural steel.Industrial visit report. Suspension bridges. Ltd. 1. bogie bolster. Hydro-mechanical works – Penstock. factory buildings. Railways bogies. gantry crane. 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.2. as per customer specification. Karnataka for Karnataka Neeravari Nigam Ltd. storage tanks. stoplog gate. Udaipur. For the Railways. Radial gates. KEL undertakes the fabrication and manufacture of bogie frames. was established in 1969. Government Departments. Ernakulum. to manufacture supreme quality transformers. Over the years. Public and Private Sector Companies. for decades. This division. Mamala Slide gates Bogie frames for BFAT Wagons for BEML Bogie frames for EMU Coaches for ICF 1.1 Transformer The Transformer Division of KEL at Mamala.Industrial visit report. relying on the unmatched quality of KEL transformers. A fitting testimony to the trustworthy performer the robust energy efficient transformers of KEL. with the technical assistance of ‘BHEL’. electricity boards across India perfectly maintain a healthy power distribution supply system. ISO 9001 certified by TUV.3 TRANSFORMER DIVISION Fig 1. boasts of a long sustained list of extremely satisfied clients. Dept: Of Mechanical Engineering Page 3 . 2015 KEL. many of whom who have stood by KEL. for various State Electricity Boards. 1. to get ISO 9001 Certification. compatible to the standards set by the Bureau of Energy Efficiency (BEE). are type tested at Central Power Research Institute. procurement. commissioning and servicing of transformers. The KEL transformer factory is one of the first few transformer factories in India. Certified by TUV. is all set for substantial growth. 33 kV Class. By exploring new vistas. 1.4 QUALITY SYSTEM ISO 9001 Quality Management System for design. testing.6 DIVISIONS OF KEL Dept: Of Mechanical Engineering Page 4 . 33 kV class – of types such as oil-filled and resin impregnated dry type. 2015 KEL. In this pursuit of excellence. KEL transformers. 1. and energy efficiency.Industrial visit report.5 PRODUCT RANGE Distribution Transformers of ratings upto 5. 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. emerged as a major player in designing and manufacturing Distribution Transformers of ratings up to 5. in technological excellence. uses state-of-the-art software to design world-class transformers. on load tap changing with Automatic Voltage Regulation. By forgoing new alliances. approved by the national test house. is yet another speciality of KEL. various state electricity boards and power corporations in the country.000 kVA. Mamala The transformer division with an annual production capacity of 6.000 kVA soon after its inception. optimized for maximum reliability.00. durability. manufacturing. Banking on its inherent strength. erection.000 kVA. the Transformer division of KEL. the resourceful design department of KEL. Manufacturing custom-built transformers. and an uncompromising commitment to quality. for specific requirements. Inductor Type brushless alternator for automobiles and for charging systems in diesel engines – 12 V.6. 2015 KEL. head stocks for railway coaches and wagons.1 TRANSFORMER DIVISION AT MAMALA UNIT Distribution Transformers of ratings upto 5000 kVA. Fabrication and manufacture of bogie frames. LOCO.6. fabrication and commissioning of hydraulic gates and hoists and their controlling equipment. bogie bolster. Future-ready Product Range: Resin Cast Dry Type. Dynamic Reactive Power Compensation and Furnace Transformers. fabrication of pressure vessels and other industrial steel structures. High frequency alternator – 400 Hz. Special Application Transformers such as EMU.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. storage tanks.Industrial visit report. upto 100 kVA. Design and construction of steel bridges. 1. on load tap changing with Automatic Voltage Regulation. factory buildings. 24 V upto 50 A. Dept: Of Mechanical Engineering Page 5 .2 STRUCTURAL ENGINEERING DIVISION AT MAMALA UNIT Design.6. Mamala 1. 33 kV class – of types such as oil-filled and resin impregnated dry type. 1. DC. Mamala Ground power units for starting Avro and Dornier aircrafts and for powering Boeing aircrafts.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.Industrial visit report. 2015 KEL. AC power frequency and high frequency power pack for missile firing auxiliary power support.6.7 MACHINES AND EQUIPMENTS 1. BLDC Fan 1.1 PRESS BREAKER Dept: Of Mechanical Engineering Page 6 . Ground Support units with dual voltage system for starting fighter aircrafts.7. 2015 KEL. 1. most commonly sheet metal . is a machine tool for bending sheet and plate material.2 MILLING MACHINE Dept: Of Mechanical Engineering Page 7 . The bottom tool is mounted on the table with the top tool mounted on the upper beam. connected to a table at the bottom and on a moveable beam at the top.It forms predetermined bends by clamping the work piece between a matching punch and die. Mamala Fig 1.7. two C-frames form the sides of the press brake.Industrial visit report. Specification: Model number: 08 /80 HH SL NO / year : 8/2000 Stroke /min : 300 mm Main motor HP/RPM: 10/1460 BENDING PROCESS Typically.1 Press breaker A press brake. also known as a brake press. with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation. drilling. turning. Often automated.7. Because of variations in orientation. or deformation. milling machines have varying functions and different operating principles. facing. operation and application. milling machines can be positioned in either vertical or horizontal orientation to carve out materials based on a pre-existing design.2 Milling machine Milling machines are tools designed to machine metal. knurling. 1. 2015 KEL. and many milling machines are CNC-operated. and many milling machines can perform multi-axis machining.Industrial visit report. and other solid materials. Milling machines are capable of dynamic movement. both of the tool and the workpiece. although manually and traditionally-automated milling devices are also common. These designs are often CAD directed.3 LATHE A lathe is a machine tool which rotates the workpiece on its axis to perform various operations such as cutting. wood. Dept: Of Mechanical Engineering Page 8 . sanding. Mamala Fig 1. and camshafts. metal spinning. thermal spraying. 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.Industrial visit report. The workpiece is usually held in place by either one or two centres. Most suitably equipped metalworking lathes can also be used to produce most solids of revolution. parts reclamation. gun barrels. Examples of objects that can be produced on a lathe include candlestick holders. which is a special type of milling machine. plane surfaces and screw threads or helices. 1. thus it is used for a broad range of parts and quantities. metalworking. Compared to other gear forming processes it is relatively inexpensive but still quite accurate. Lathes can be used to shape pottery.7. and glass-working. and cutting sprockets on a hobbing machine. at least one of which can typically be moved horizontally to accommodate varying workpiece lengths. or to a faceplate. cutting splines. using clamps or dogs. baseball bats. table legs. Dept: Of Mechanical Engineering Page 9 . musical instruments (especially woodwind instruments). bowls. The teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob. crankshafts. cue sticks.4 GEAR HOBBING MACHINE Hobbing is a machining process for gear cutting. Mamala Fig 1.3 Lathe Lathes are used in woodturning. Other work-holding methods include clamping the work about the axis of rotation using a chuck or collet. Ornamental lathes can produce three-dimensional solids of incredible complexity. the best-known design being the potter's wheel. 2015 KEL. 5 ROLLING MACHINE Dept: Of Mechanical Engineering Page 10 .Industrial visit report. Mamala Fig 1.4 Gear hobbing machine Specification: Type : FO-10 M/C No : 0421163 Max Dia : 1 m Cutters : 3. 2015 KEL.5 to 10 module 1.7. When rolling.5 Rolling machine A Plate Rolling Machine is a machine that will roll different kind of metal sheet into a round or conical shape. Mamala Fig 1. They are different kinds of Technology to roll the metal plate: 4 Roller machine: Anatomy. With the Side-Rolls all the way in. It can be also called “Roll bending machine” “plate bending Machine” or “rolling machine”. One Pressing Top-Roll. you have the least mechanical advantage. For example. 1. Two Pressing Side-Rolls The 3 Roll Variable Geometry works by having all three rolls being able to move and tilt.7. and two Side-Rolls. the Pinching-Roll. The flat metal plate is placed in the machine on either side and "pre-bent" on the same side. The Side-Rolls are what produce the mechanical advantage. The Side-Rolls move on the horizontal plane. The Top-Roll moves on the vertical plane. 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. then you have the maximum mechanical advantage. 2015 KEL.6 DRILLING MACHINE Dept: Of Mechanical Engineering Page 11 . a Top-Roll. 3 Roll Machines (Variable Pitch aka Variable Geometry): Anatomy. The Side-Rolls do the work of bending.Industrial visit report. With the Side-Rolls all the way open. The Pinching Roll holds the plate. 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.7. Mamala Fig 1. specially-shaped bits can cut holes of non-circular cross-section. As the accuracy in dimensions in grinding is on the order of 0.Industrial visit report.. Exceptionally. Grinding is used to finish workpieces that must show high surface quality (e. This forces the cutting edge against the workpiece.50 Dept: Of Mechanical Engineering Page 12 .7 GRINDING MACHINE A grinding machine. The bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. often multipoint.25 to 0.000025 mm. in most applications it tends to be a finishing operation and removes comparatively little metal. about 0. a square cross-section is possible. 1. often shortened to grinder. 2015 KEL. is any of various power tools or machine tools used for grinding. low surface roughness) and high accuracy of shape and dimension. which is a type of machining using an abrasive wheel as the cutting tool. The drill bit is a rotary cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece via shear deformation. cutting off chips (swarf) from the hole as it is drilled.g. Fig 1.this generates so little heat that even with no coolant. or using the features of numerical controls. there are some roughing applications in which grinding removes high volumes of metal quite rapidly. the temperature rise is negligible. 2015 KEL.7 Grinding machine Grinding machines remove material from the work piece by abrasion. However.8 SHAPER MACHINE Dept: Of Mechanical Engineering Page 13 .Industrial visit report. 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 . which can generate substantial amounts of heat. 1. The grinding machine consists of a bed with a fixture to guide and hold the work piece. The speed is determined by the wheel’s diameter and manufacturer’s rating. grinding is a diverse field. Thus. and a power-driven grinding wheel spinning at the required speed.7. The coolant also benefits the machinist as the heat generated may cause burns. 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. Mamala mm depth. grinding machines incorporate a coolant. The grinding head can travel across a fixed work piece. To cool the work piece so that it does not overheat and go outside its tolerance. except that it is (archetypally) linear instead of helical. The heavy ‘arm’ moves backwards and forwards. but smaller.) A shaper is analogous to a planer.7. (Adding axes of motion can yield helical toolpaths. has also done in helical plaining. Cutting diameters of more than 10/15mm is very hard work with a normal hand held hacksaw. Its cut is analogous to that of a lathe. The ram is moved back and forth typically by a crank inside the column. hydraulically actuated shapers also exist. Dept: Of Mechanical Engineering Page 14 .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. 1. Mamala Fig 1.9 POWER HACKSAW Power hacksaws are used to cut large sizes (sections) of metals such as steel. cutting on the backwards stroke. Therefore power hacksaws have been developed to carry out the difficult and time consuming work. 2015 KEL.Industrial visit report. rather than the entire workpiece moving beneath the cutter. and with the cutter riding a ram that moves above a stationary workpiece. First developed in the late part of the 19th century. and consumable or nonconsumable electrodes.7. Today it remains an important process for the fabrication of steel structures and vehicles.Industrial visit report. and consumable or nonconsumable electrodes. Arc welding processes may be manual. 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. or slag. Dept: Of Mechanical Engineering Page 15 . Today it remains an important process for the fabrication of steel structures and vehicles. or fully automated. vapour. semi-automatic. or fully automated. They can use either direct (DC) or alternating (AC) current. First developed in the late part of the 19th century. The welding region is usually protected by some type of shielding gas. semi-automatic. vapour. arc welding became commercially important in shipbuilding during the Second World War. Arc welding processes may be manual.9 Power hacksaw 1.10 WELDING 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. 2015 KEL. arc welding became commercially important in shipbuilding during the Second World War. The welding region is usually protected by some type of shielding gas. Mamala Fig 1. or slag. The direction of current used in arc welding also plays an important role in welding. and as a result. In arc welding. since any fluctuation in the distance between the wire and the base material is quickly rectified by a large change in current. the positively charged anode will have a greater heat concentration and. but the electrode can be charged either positively or negatively. because they maintain a relatively constant current even as the voltage varies. Consumable electrode processes such as shielded metal arc welding and gas metal arc welding generally use direct current. In welding. changing the polarity of the electrode has an impact on weld properties. are most often used for automated welding processes such as gas metal arc welding. and as a result. If the Dept: Of Mechanical Engineering Page 16 . which in turn causes the heat to increase and the tip of the wire to melt. For example. as a result. arc length is kept constant. a number of different power supplies can be used. returning it to its original separation distance. This is important because in manual welding. 2015 KEL.10 Arc welding To supply the electrical energy necessary for arc welding processes. if the wire and the base material get too close.Industrial visit report. the voltage is directly related to the length of the arc. and submerged arc welding. Mamala Fig 1. flux cored arc welding. the arc length and thus voltage tend to fluctuate. Constant voltage power supplies hold the voltage constant and vary the current. it can be difficult to hold the electrode perfectly steady. the current will rapidly increase. Constant current power supplies are most often used for manual welding processes such as gas tungsten arc welding and shielded metal arc welding. The most common classification is constant current power supplies and constant voltage power supplies. In these processes. and the current is related to the amount of heat input. a positively charged electrode causes shallow welds. during which a given arc welder can safely be used. Duty cycle is a welding equipment specification which defines the number of minutes. Non-consumable electrode processes.11 Gas welding Oxy-fuel welding (commonly called oxyacetylene welding. A welder with a 60% duty cycle must be "rested" for at least 4 minutes after 6 minutes of continuous welding. Alternating current rapidly moves between these two. respectively. as well as alternating current (AC).S. has been addressed with the invention of special power units that produce a square wave pattern instead of the normal sine wave. increasing weld penetration and welding speed.Industrial visit report. while a negatively charged electrode makes deeper welds. or gas welding in the U. a negatively charged electrode results in more shallow welds. Failure to observe duty cycle limitations could damage the welder. such as gas tungsten arc welding. Alternatively. One disadvantage of AC. an 80. For example. resulting in medium-penetration welds. French engineers Edmond Fouché and Charles Picard Dept: Of Mechanical Engineering Page 17 .) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals. With direct current however. GAS WELDING Fig 1. eliminating low-voltage time after the zero crossings and minimizing the effects of the problem. 2015 KEL. within a 10 minute period. can use either type of direct current (DC). Mamala electrode is positively charged. the fact that the arc must be re-ignited after every zero crossing.or professional-grade welders typically have a 100% duty cycle. oxy welding. it will melt more quickly. because the electrode only creates the arc and does not provide filler material. Commercial. We got some practical experience along with theoretical knowledge. Dept: Of Mechanical Engineering Page 18 . In oxy-fuel welding. A common propane/air flame burns at about 2. is used to increase the flame temperature to allow localized melting of the workpiece material (e.500 °C (4. instead of air. and an acetylene/oxygen flame burns at about 3. instead. in recent decades it has been less widely utilized in industrial applications as other specifically devised technologies have been adopted.500 °C (6.530 °F). Mamala was a very good experience. Filler material depends upon the metals to be welded. as well as repair work. The systematic arrangement of the various department in the firm is a noticeable thing. atmospheric air) are not considered oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel cutting requires two isolated supplies. burning it into a metal oxide that flows out of the kerf as slag. besides forge welding. It is still widely used for welding pipes and tubes.630 °F). 2015 KEL. Oxy-fuel is one of the oldest welding processes. CONCLUSION Industrial visit at KEL. steel) in a room environment. a welding torch is used to weld metals. Mamala became the first to develop oxygen-acetylene welding in 1903.g. In oxy-fuel cutting.000 °C (3. a propane/oxygen flame burns at about 2. Still used in industry. The molten pool is generally supplied with additional metal called filler. Torches that do not mix fuel with oxygen (combining.[1] Pure oxygen. Most metals cannot be melted with a single-tank torch. The cooperation of workers within the firm is an appreciable one. fuel and oxygen). a torch is used to heat metal to its kindling temperature. We got practical experience on different machines and equipments in the firm. A stream of oxygen is then trained on the metal. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal.330 °F).Industrial visit report.