Presentation

on
Manufacturing Process of Tower Parts
BRIEF PROCESS HAPPENED IN PLANT

INTRODUCTION

INNOGRATION 1967
PLANT CAPACITY-42000tn
1000KV TESTING TOWER
DEPARTMENTS: PROJECT AND PLANNING
QA
YARDS
PRE-PRODUCTION
STORES
SAFETY
COMMERCIAL
MATERIAL
LOGISTICS
PRODUCTION
FABRICATION
GALVANISATION
PE

PROCESS AND DOCUMENTATION FLOW

WORK FLOW

DEPARTMENT

MARKETING

AWARD OF
CONTRACT

WO & BAR
CHART(L2)

CENTRAL
PLANNING

WO

LOA/ WO

MEETING
(ALLOCATION OF
PROJECT)

PRS
RELEASE OF
DRAWING

D&D
BOM
SKETCH
DRAWING

CONTINUE

PREPRODUCTI
ON
BOM
SKETCH
DRAWING
PROTO

SKETCH &
BOM
PREPRATIO

MONTHLY
PRS

PROTOTYP
E TESTING

PRS

FINAL
BOM &
SKETCHES

PROJECT/SI
TE
PR
S

CONTINUE
C

C
PRS/LOA/L2/BOM

PLANNING
IPP/IDP/MRP/
SCHEDULING
(MIR/RS/PO)

IPP & IDP

MRP INDENTS

RECEIPT OF STEEL BY
RAW MATERIAL

RELEASE FOR
PRODUCTION
D

MATERIAL
PROCUREMENT

CONTINUE

D
MIR/RS/IPP/IDP

PRODUCTION

QC IN
PROCESS

FABRICATION

RS
IPP/IDP
GALVANISATION

QUALITY

CLIENT
INSPECTION OF FG

QC IN
PROCESS

MICC & IR

CONTINUE
PROJECT
DEPARTME
NT
BUNDLING PLAN
PACKING LIST

FINISH
YARD

LOGISTI
CS

SHIPPING

DISPATCH
COMPLETION
CERTIFICATE
(PACKING LIST)

BUNDLING
/PACKAGING

DISPATCH OF
MATERIAL

SHIPPING

ACCOUNT
DEPARTMENT
(BILLING)

PLANNING OUTPUTS
Outputs

Department

Integrated Production Plan

All Departments

Integrated Dispatch Plan

All Departments

MRP

Materials Department------Vendors

Shop Scheduling

To Scheduling

Bundling And Packing List

Dispatch Section (Raw Yard, Finish Yard)

Billing document preparation

Before Dispatch to Billing

Daily Weekly Monthly MIS

Prepared by all departments

CRITERIA: BILLABLE LOT AND PRODUCTION AND

DISPATCH
Billable Lot Formation
Type of structure
Erectable tower
batches
L2
Lot Weight
Delivery plan
Load Avaibility
Proto

Dispatch Plannig

L2 Schedule
Delivery Requirement
Load
Proto
Steel and BNA time
Inspection
Delivery cycle (90
days)

PRODUCTION
Shop Floor

Raw Yard

Fabrication

Inspection

Galvanizing

Finish Yard

CNC: STAMPING
PUNCHING
CROPING
6 CNC
4 WITH CAPACITY 4500 HOLES AND 7 MT
2 WITH CAP 3500 HOLES AND 6 MT

NOTCHING:

F CUT
C CUT
B CUT
POCKET CUT
CORNER CUT
CAP: 7MT 1500

BENDING

Close Bend
Inside Flange
Heel Bend
Outside Flange
Peek
Jogal Bend
Tamper Bend

DRILLING
HEEL CUTTING
WELDING

SKETCH
MIR
ROUT SHEET
M/C LOADING PLAN
RUN TIME DASHBORD
DAILY PRODUCTION REPORT
OVERALL EQUIPMENT EFFICIENCY(OEE)
AVALABILITY*PERFORMANCE*QUALITY

INSPECTION REPORT
MIS
WIP

GALVANIZING

LOADING
DEGREASING
PICKLING
RAISING
FLUXING
DRYING OVEN
HOT ZINC DIPPING
QUENCHING
PASIVATION
QA

GALVANIZING..

LOADING
DEGREASING
To remove oil, dust, paint and grease from surface of material
Alkaline solution is used along with degreasant which form emulsion

PICKLING
To remove impurities(rust, inorganic contaminants, stains etc)
3 TANKS ARE AVALAIBLE OF different acidic strength
Iron concentration(<160gm/ltr)
hydrogen embrittlement

RAINSING
Should not be acidic ph>3
To remove acid from surface of steel

FLUXING
To avoid oxidation of steel
Mixture of Zncl2 and NH4cl
Formation of zinc ammonium chloride film(Zn2(NH4)2Cl4)
Dipping the fluxed material in molten zinc produces HCL and other toxic gases

DRYING OVEN
LPG GAS AND HSD IS USED AS FUEL
TEMP-70-150 C
To avoid spurting temp difference is minimised

HOT ZINC DIPPING(GALVANISATION)

To protect tower from rusting
Zinc grade 99.8 is used
Temp-445to 460dc
Adding of aluminum, and nickel a/c to requirement
Formation of layer
Gamma, delta, zeta, eta layer

QUENCHING
Cold water

PASIVATION
Dichromate solution is used
To avoid direct contact of zinc to atmosphere
Reduces reactivity

QA

Quality Assurance

Standards used: IS , British, American(IS,BSEN, ASTM)

Raw Materials Standards:

Mechanical Testing(yield strength, ultimate tensile strength , elongation,bend test)

Dimensional and Weight Testing
Visual Testing
Chemical Testing(C, Si, Mn , P other element concentration )

Fabricated material Q/A:

1st , 2nd and 50th pieces should be similar
Material checking report(tolerance/parameters)
Total length ,rolled and cut edge
Hole size ,Back Mark , Distance between holes
Temperature , bend line , bend slope (Bending)

Galvanized material Q/A:

Preece test
Adherence test
Weight & thickness of zinc coating

QA AT DIFFERENT STAGE
Inventory

Fabrication

At
At Shop
Shop Raw
Raw Yard
Yard
Checking
Checking the
the quality
quality of
of steel
steel and
and BNA
BNA
Root
Root Sheet
Sheet

Before
Before heading
heading to
to galvanizing
galvanizing inspection
inspection yard
yard
Piece
Piece wise
wise checking
checking wrt
wrt to
to root
root sheet
sheet
Green
Green Paint
Paint

White
White Rust
Rust
Black
Black Spot
Spot
Alco
Alco Meter
Meter Test
Test
Temperature
Temperature
Check
Galvanizing Chemical andCheck
Chemical and ph
ph value
value

Bundling
Bundling

Finish Yard

IT Department

Brief introduction to all the IT processes.

PRS from Sites

LOA/L2
Bar Chart (IP)
IPP/IDP
MRP to material deptt
TDC

Scheduling plan (MIR & RS)

KEC Estimator

Planning

Materials

MRP From planning

Rolling schedule/ Consolidation
PO
Inspection Offer
MICC Generation
PGCIL call register (domestic)
CIP (From Client)
Dispatch
Unloading at Raw Yard

Finish Yard

Generation of Dispatch document

RS Status is changed to 95
BTD From Sites
RVP to Logistics
Loading slip preparation
Challan
Invoice
Way-Bill(domestic)
ARE (IP)
Gate pass

Raw Yard

Material procurement process

Stock transfer
Q/A at vendors place
Lorry arrival At Plant
MICC, MTC, Weighting Slip , challan checked
Unloading to raw yard
ME
Unloading Slip Generation
GRN Generation
T-Hold(QA)
Ready to schedule

Logistics

To deliver right product at right place in right time with

optimum cost
DI (delivery instruction on the basis of supply bar chart)
RFQ(request for quantity)
BG(bank guarantee)
LR(lorry receipt)
CHA(custom handling agent )
CI (custom invoice)
AWB(Air Way bill)

Tower accessories

Conductor
Earth wire
Damper
Hanger
Insulators
Arcing horn
Bird guard

Types of Tower

HORIZONTAL
Single Circuit
(Types: A, B ,C ,D)
Used for high KV transmission lines
Difficult to design & manufacture
Features:
Legs
Waist
K-Frame
Boom
Cross-arms
Earth wire peak

VERTICAL

Double circuit
(DA,DB,DC,DD)
Multi Circuit
( MA,MB,MC,MD)
Used for lower KV Transmission
Easy to design & manufacture as
compare to Horizontal towers
Features :
Legs
Body
Cross-arms
Earth wire peak

Store

Except steel , Zinc and BNA everything is purchased by store

department
Scrap Disposal
e-auction is conducted
a third party conducts this auction
Major scrap: steel , zinc
H-1 gets scrap
1 lac as EMD , Registration No , PAN No ,TIN etc

PR(purchase requisition)is made in order to place some order

GRN(goods receipt note)
Fuel purchasing : LPG , HSD

Thank You!!!!!!