Industrial visit report, 2015

KEL, 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 its 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 companys 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

Narmada Project for J P Associates

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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.

1.6 DIVISIONS OF KEL

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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.

1.6.3 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.

High frequency alternator 400 Hz; upto 100 kVA.

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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

1.7.1 PRESS BREAKER

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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.
1.7.2 MILLING MACHINE

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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.
1.7.6 DRILLING MACHINE

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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 wheels diameter and manufacturers 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.
1.7.8 SHAPER MACHINE

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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
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 nonconsumable 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.
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 nonconsumable 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
and, as a result, changing the polarity of the electrode has an impact on weld properties. If the
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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 Fouch 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.

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