INDUSTRIAL TRAINNING REPORT On Vijay transmission pvt. Ltd.

Submitted by

DIWAKAR MISHRA
in partial fulfilment for the award of the degree of BACHELOR OF ENGINEERING in ELECTRONICS AND TELECOMMUNICATION ENGINEERING

SUBMITTED TO:- V.I.T.S ENGINEERING COLLEGE, RAIPUR

JUNE 2010

CHHATTISGRAH SWAMI VIVEKANAND TECHNICAL UNIVERSITY

BONAFIDE CERTIFICATE

Certified that this project report MOBILE TOWER CONSTRUCTIONis the bonafide work of DIWAKAR MISHRA work under my supervision. who carried out the project

SIGNATURE

SIGNATURE

Mr. ANAND SHUKLA TRANING PLACEMENT OFFCIER

Mr. PRAVEEN BHUTEY SUPERVISOR

DEPT. ELECTRONICS AND TELECOMMUNICATION

VINDHYA INSTITUTE OF TECHNOLOGY AND SCIENCE, PARASTRAI ROAD ,DHARSIWA RAIPUR C.G 2

Acknowledgement
Many lives and destinies are destroy due to the lack of proper guidance direction and opportunity. It is in this respect I feel that, I am in much better condition today due to continuous process of motivation and focus provided by my parents and teacher in general .The process of completion this project was a tedious job and require care and support at all stages. I would like to highlight to role played by individual toward this. I am eternally grate full to honourable principal R.PURSWANI for providing us the opportunity and infrastructure to complete the project a partial fulfilment of B.E .degree. I am very thankful to prof. Sanjay Gupta Head of department for his kind support and faith in us. I am also thank full to all visible and invisible hand which helped us to complete this project with a feeling of success.

DIWAKAR MISHRA
DECIPLENE;- ET&T

INDEX

S No.
1

DISCRIPTION
Introduction

PAGE No.
7 8 5.7.2010 6.7.2010 8.7.2010 9.7.2010 10.7.2010 12.7.2010 14.7.2010 15.7.2010 18.7.2010 22.7.2010

DATE

2
Flow chart of plant

3
Manufacturing process

9 9
How to built a cell phone tower

3.1 3.2
Types of tower

11-14 15
Planning

3.4 3.5
Raw material

16 17
Engineering

3.6 3.7
Fabrication

17-19 19-20
Galvanizing

3.8 4 Reference

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CONTENTS

CHAPTERS
CHAPTER:-1

CONTENT
Introduction of organisation flow chart of organisation, how to build a cell phone tower. Types of tower, gs-ct-01, communication tower, gs-ct-02, communication tower, gs-mt-01, microwave communication steel tower, gs-ct-04, communication tower, gs-ct-05, communication tower.

CHAPTER:-2

CHAPTER:-3

Planning of project, raw material for project, engineering , fabrication: cutting ,burning, forming ,welding, galvanizing: metal protection ,zinc coating. Reference

CHAPTER:-4

CHAPTER:-1

INTRODUCTION
.VIJAY TRANSMISSIONPVT. LTD is a group which construct a mobile towers. This company was establish 0n 1987 in raipur , urla . Mr .SANJAY PALIWAL is a owner of this company . This project is designed so that student can understand the technology used in now a days for making mobile tower .which is used for many purpose for development of countries like in radio station ,for TV broadcasting, receiving and sending the signal for communication between two systems and etc. During the manufacturing process of mobile tower so many instrument and devices are used, which should be operated by highly experienced engineers. To construct a complete mobile tower we need lot of money , patient ,and man power which is very difficult to maintain all this with follow safety instructions. All this manufacturing process are efficiently done by the help of various latest technologies which is mentioned in this project in a very easy way.

RAW MATERIAL ARE RAW MATERIAL SHOULD GALVANIZINGsxa COME TO THE PLANT BE STORED FOR CHEKING

MEASURING DEPT.

FABRICATION SHOP

READY TO DISPATCH

QUALITY CONTROL

GALVANIZING SHOP

FLOW CHART OF PROCESSING

HOW TO BUILD A CELL PHONE TOWER

2500000 That is the average cost of a cell tower. Some will go for less, some will go for more, but you will need at least that much to complete the project. Alternatively, you will need to find a bank loan that you personally guarantee with other collateral. Do not expect to have the bank finance a tower construction project like they would finance a commercial building. A Unique Piece of Property- If one of your neighbours has a piece of property that is similar to yours in size and zoning classification, you are wasting your time. Check with your local zoning office and ask for a copy of their zoning ordinance as it pertains to a cell phone tower. If you don't have the only parcel within 1/2 mile or more that is suitable for a tower, the wireless carrier will simply lease space from your neighbour or negotiate a cheap lease with you. Make sure the piece of property is large enough to meet the "fall zone" criteria for placement of a cell phone tower. Knowledge of where the wireless carriers need a cell phone tower. Many landowners erroneously think that they have the perfect piece of property for a cell phone tower. To be blunt - the chances are less than 2.5% that you actually do. Trying to develop a cell phone tower on a specific piece of property without knowing where the wireless carriers need to be is foolish. There is not one tower company that I am aware of that finds the property first and then tries to determine where the wireless carriers need a cell phone tower. Unfortunately, the only people who know where the wireless carriers need a tower are the people that work for that wireless carrier. Don't assume that just because coverage is poor that a cell phone tower is needed at that location. You could easily be off a few miles from where the tower is needed. Letter of Intent from a Wireless Carrier In most jurisdictions, you need a letter of intent from a wireless carrier to get approval for a tower. If there is no zoning in your area- we don't suggest building a tower- period. To get a letter of intent, you must show that you either own the land or have a ground lease signed with the landowner permitting you to build a tower.

CHAPTER:-2

10

TYPE OF TOWERS
As traditional telecommunication equipment, COMMUNICATION TOWER is featured in wide application, standardized design, matured technology. The communication towers manufactured by vijay tower has been exported to many countries, such as India, Indonesia, Malaysia, etc.

GS-CT-01, Communication Tower

Should carry out production of the Communication Towers as per drawings and requirements provided by Purchaser. Always, propose to use the releva Chinese National Standard and equivalent Chinese raw material.

GS-CT-02, Communication Tower

Should carry out production of the Goods as per drawings and requirements provided by Purchaser. Always, propose to use the releva Chinese National Standard and equivalent Chinese raw material.

11

GS-MT-01, Microwave Communication Steel Tower

1. Should carry out production of the Communication Towers as per drawings and requirements provided by Purchaser. Always, propose to use the relevant Chinese National Standard and equivalent Chinese raw material.

GS-CT-03, Communication Tower

1.55m telecommunication tower. 2. Should carry out production of the Communication Towers as per drawings and requirements provided by Purchaser. Always, propose to use the relevant Chinese National Standard and equivalent Chinese raw material.

12

GS-CT-04, Communication Tower

1. 50m telecommunication tower. 2. Should carry out production of the Communication Towers as per drawings and requirements provided by Purchaser.

GS-CT-05, Communication Tower

1. 50m telecommunication tower. 2. Should carry out production of the Communication Towers as per drawings and requirements provided by Purchaser. Always, propose to use the relevant Chinese National Standard and equivalent Chinese raw material.

13

CHAPTER:-3

14

PLANNING

There are so many department are required for running any industries .Planning is one of the department in a company . They should be planned how we can manufactured a complete tower .they calculating the quantity of raw material and man power supply to complete a project in a fix time which is given to a customer . First, determine what needs to be done as opposed to how it should be done. Figure out what the load criteria is for a tower, what the limits are on the guy radius, what the soil conditions are (if known), what antennas and lines need to be installed, etc. In other words, determine what the final project needs to include and what standards will apply. As a minimum for a new structure, the current version of ANSI/EIA/TIA 222 should be met, along with any additional strengthening for ice or unusual conditions. Once those criteria have been determined, preferably in cooperation with the station's consulting engineer, a full set of specifications should be prepared. That applies whether or not any bidding is involved. The specifications and the contract clarify what all parties involved will do and how they should interact with each other. There are several points that need to be seriously considered to reduce each party's liabilities, especially those of the station and engineer. If something does goes wrong, the tower company may not have a choice in how the situation is handled. Often, the insurance companies involved will try to subjugate their damages. That means the insurance companies can sue parties in the name of the insured to recover their losses. In addition, that rigger who has always been a good old boy may disappear like the morning fog if something really goes wrong. That is why everyone's liability needs to be nailed down by contract before any work is done. The detailed specifications are good for all parties. In my experience, dependable tower companies are in favor of tight specifications. The specifications protect the tower company by identifying the conditions that the company must meet.

15

Raw Materials
The most important substance used to manufacture tower is steel. Steel is an alloy of iron and a small amount of carbon. For structures that do not require very high strength, a common form of steel known as carbon steel is used. By definition, carbon steel contains less than 2% of elements other than iron and carbon. Carbon steel exists in a wide variety of forms. The most important factor in determining the properties of carbon steel is the amount of carbon present, which ranges from less than 0.015% to more than 0.5%. For structures that require great strength, particularly in tower designed to lift very heavy objects, a variety of substances known as high-strength low-alloy (HSLA) steels are used. HSLA steels contain relatively low levels of carbon, typically about 0.05%. They also contain a small amount of one or more other elements that add strength. These elements include chromium, nickel, molybdenum, vanadium, titanium, and niobium. Besides being strong, HSLA steels are resistant to atmospheric corrosion and are better suited to welding than carbon steels. Depending on the exact design of the tower, a wide variety of other materials may be used in manufacturing. Natural or synthetic rubber is used to make tires for mobile tower. Certain structural components may be manufactured from various metals such as bronze and aluminum.

16

ENGINEERING
Very few machines exist in as wide a variety of designs as tower. Before the tower is constructed, the manufacturer must consider the site where it will be used and the weight it will need to lift. In addition, tower are often modified to suit the needs of the user. For these reasons, it is not much of an exaggeration to say that no two tower are exactly alike. Tower used for industrial purposes are generally designed to remain permanently in one location. These tower often perform repetitive tasks that can be automated. An important type of industrial tower is the bridge tower. Traveling on tracks attached to two horizontal beams, known as a bridge, a trolley enables the movement of the bridge tower. Usually, the bridge itself can be moved along a pair of parallel rails, allowing the tower to reach a large, rectangular area. A bridge tower may also be designed so that one end of the bridge is supported by a central pivot while the other end moves on a circular rail, allowing a large, round area to be reached. An overhead traveling tower is a kind of bridge tower in which the rails are located high above the ground. Usually supported from the ceiling of a building, an overhead traveling tower has the advantage of causing no obstruction in the work area. Tower used in construction often perform a variety of tasks and must be controlled by highly skilled operators. Construction tower are divided into mobile tower and tower tower. Mobile tower are mounted on trucks or crawlers in order to travel from place to place. An articulating tower is a mobile tower in which there is a joint between two sections of the boom, allowing it to move in a way similar to a knuckle in a human finger.

17

FABRICATION

A typical steel fabrication shop Fabrication, when used as an industrial term, applies to the building of machine, structure and other equipment, by cutting, shaping and assembling components made from raw material Small businesses that specialize in metal are called fab shops. Fabrication comprises or overlaps with various metalworking specialties: Fabrication shops and machine shops have overlapping capabilities, but fabrication shops generally concentrate on the metal preparation aspects (such as sawing tubing to length or bending welding, and assembly, whereas machine shops are more concerned with the machining of parts on machine tool. Firms that encompass both are also common. Blacksmithing has always involved fabrication, although it was not always called by that name. The products produced by welders, which are often referred to as weldments, are an example of fabrication. Boiler marker originally specialized in boiler, leading to their trade's name, but the term as used today has a broader meaning. Similarly, millwright originally specialized in setting up grain mills and saw mills, but today they may be called upon for a broad range of fabrication work. Ironworkers, also known as steel erector, also engage in fabrication. Often the fabrications for structural work begin as prefabricated segments in a fab shop, then are moved to the site by truck, rail, orbarge, and finally are installed by erectors.

18

Metal fabrication is a value added process that involves the construction of machines and structures from various raw materials. A fab shop will bid on a job, usually based on the engineering drawing, and if awarded the contract will build the product.

Engineering
The fabricator may employ or contract out STEEL DETALERS to prepare shop drawings, if not provided by the customer, which the fabricating shop will use for manufacturing. Manufacturing engineers will program CNC machines as needed.

Cutting and burning

The raw material has to be cut to size. This is done with a variety of tools. The most common way to cut material is by shearing. Special band saw designed for cutting metal have hardened blades and a feed mechanism for even cutting. Abrasive cut-off saws, also known as chop saws, are similar to miter saws but with a steel cutting abrasive disk. Cutting torches can cut very large sections of steel with little effort. Burn tables are CNC cutting torches, usually natural gas powered. Plasma andlaser cutting tables, and water jet cutter, are also common. Plate steel is loaded on a table and the parts are cut out as programmed. The support table is made of a grid of bars that can be replaced. Some very expensive burn tables also include CNC punch capability, with a carousel of different punches and taps. Fabrication of structural steel by plasma and laser cutting. introduces robots to move the cutting head in three dimensions around the material to be cut.

Forming
Hydraulic break presses with v-dies are the most common method of forming metal. The cut plate is placed in the press and a v-shaped die is pressed a predetermined distance to bend the plate to the desired angle and hand powered brakes . wing brakes are sometimes used. Tube bending machines have specially shaped dies and mandrels to bend tubular sections without kinking them. Rolling machines are used to form plate steel into a round section. English wheel or Wheeling Machines are used to form complex double curvature shapes using sheet metal.

19

Machining
Fab shops will generally have a limited machining capability including; metal lathes,mills, magnetic based drill along with other portable metal working tools.

Welding
Welding is the main focus of steel fabrication. The formed and machined parts will be assembled and tack welded into place then re-checked for accuracy. A fixture may be used to locate parts for welding if multiple weldments have been ordered. The welder then completes welding per the engineering drawings, if welding is detailed, or per his own judgment if no welding details are provided. Special precautions may be needed to prevent warping of the weldment due to heat. These may include re-designing the weldment to use less weld, welding in a staggered fashion, using a stout fixture, covering the weldment in sand during cooling, and straightening operations after welding. Straightening of warped steel weldments is done with an Oxy-acetylene torch and is somewhat of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel will have a net contraction, upon cooling, in the direction of the sweep. A highly skilled welder can remove significant warpage using this technique. Steel weldments are occasionally anneald in a low temperature oven to relieve residual stresses.

Final assembly
After the weldment has cooled it is generally sand blasted, primed and painted. Any additional manufacturing specified by the customer is then completed. The finished product is then inspected and shipped.

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GALVANIZING
Galvanization (or galvanisation) classically refers to any of several electrochemical processes named after the Italian scientist Luigi galvani Now the term generally refers to an electrode position process used to add a thin layer of another metal to an item made of steel, in order to prevent rusting. More recently, though, the term has been broadened in common usage to include applying a protective metallic coating to an underlying piece of metal, using a process called hot dip galvanization, which produces similar results, but which does not employ electrochemical deposition. Meanings

Electricity
Originally, "galvanization" was the administration of electric shocks (in the 19th century also termed Faradism, after michale faraday It stemmed from Galvani's induction of twitches in severed frogs' legs, by his accidental generation of electricity. This archaick sense is the origin of the meaning of galvanic when meaning "affected/affecting, as if by a shock of electricity; startled".Its claims to health benefits have largely been disproved, except for some limited uses in the form of electroconvulsic therapy (ECT). Later the word was used for processes of electrodeposition. This remains a useful and broadly applied technology, but the term "galvanization" has largely come to be associated with zinc coatings, to the exclusion of other metals.

Metal protection
In current use, the term refers to the coating of steel or iron with zinc. This is done to prevent galvanic corrosion (specifically rusting) of the ferrous item. The value of galvanizing stems from the relative corrosion resistance of zinc, which, under most service conditions, is considerably less than those of iron and steel. The effect of this is that the zinc is consumed first as a sacrificial anode, so that it cathodically protects exposed steel. This means that in case of scratches through the zinc coating, the exposed steel will be cathodically protected by the surrounding zinc coating, unlike an item which is painted with no prior galvanizing, where a scratched surface would rust. Furthermore, galvanizing for protection of iron and steel is favoured because of its low cost, the ease of application, and the extended maintenance-free service that it provides. The term galvanizing, while correctly referring to the application of the zinc coating by the use of a galvanic cell (also known as electroplating), sometimes is also used to refer to hot dip zinc coating (commonly incorrectly referred to as hot dip galvanizing). The practical difference is that hot dip zinc coating produces a much thicker, durable coating, whereas genuine galvanizing (electroplating) produces a very thin coating. Another difference, which makes it possible to determine visually which process has been used if an item is described as
21

'galvanized', is that electroplating produces a nice, shiny surface, whereas hot dip zinc coating produces a matte, grey surface. The thin coating produced by electroplating is much more quickly consumed, after which corrosion turns to the steel itself. This makes electroplating unsuitable for outdoor applications, except in very dry climates. For example, nails for indoor use are electroplated (shiny), while nails for outdoor use are hot dip zinc coated (matte grey). However, electroplating and subsequent painting is a durable combination because the paint slows down the consumption of the zinc. Car bodies of some premium makes are corrosion protected using this combination. Nonetheless, electroplating is used on its own for many outdoor applications because it is cheaper than hot dip zinc coating and looks good when new. Another reason not to use hot dip zinc coating is that for bolts and nuts size M10 or smaller, the thick hot-dipped coating uses up too much of the threads, which reduces strength (because the dimension of the steel prior to coating must be reduced for the fasteners to fit together). This means that for cars, bicycles and many other 'light' mechanical products, the alternative to electroplating bolts and nuts is not hot dip zinc coating but making the bolts and nuts from stainless steel (known by the corrosion grades A4 and A2). Electroplated steel is visually indistinguishable from stainless steel when new. To determine whether a part is electroplated or stainless steel, apply a magnet. The most common stainless steel alloys (including those used for bolts and nuts) are un magnetic or only very slightly attracted to a magnet.

Zinc coatings
Zinc coatings prevent corrosion of the protected metal by forming a physical barrier, and by acting as a sacrificial anode if this barrier is damaged. When exposed to the atmosphere, zinc reacts with oxygen to form zinc oxide, which further reacts with water molecules in the air to form zinc hydroxide. Finally zinc hydroxide reacts with carbon dioxide in the atmosphere to yield a thin, impermeable, tenacious and quite insoluble dull gray layer of zinc carbonate which adheres extremely well to the underlying zinc, so protecting it from further corrosion, in a way similar to the protection afforded to aluminium and stainless steel by their oxide layers. Hot-dip galvanizing deposits a thick robust layer that may be more than is necessary for the protection of the underlying metal in some applications. This is the case in automobile bodies, where additional rust proofing paint will be applied. Here, a thinner form of galvanizing is applied by electroplating, called "electro galvanization". The hot-dip process slightly reduces the strength of the base metal, which is a consideration for the manufacture of wire rope and other highly-stressed products. The protection provided by this process is insufficient for products that will be constantly exposed to corrosive materials such as salt
22

water. For these applications, more expensive stainless steel is preferred. Some nails made today are electro-galvanized. As noted previously, both mechanisms are often at work in practical applications. For example, the traditional measure of a coating's effectiveness is resistance to a salt spray. Thin coatings cannot remain intact indefinitely when subject to surface abrasion, and the galvanic protection offered by zinc can be sharply contrasted to more noble metals. As an example, a scratched or incomplete coating of chromium actually exacerbates corrosion of the underlying steel, since it is less electrochemically active than the substrate.

Galvanized surface with visible spangle The size of crystallites in galvanized coatings is an aesthetic feature, known as spangle. By varying the number of particles added for heterogeneous nucleation and the rate of cooling in a hot-dip process, the spangle can be adjusted from an apparently uniform surface (crystallites too small to see with the naked eye) to grains several centimetres wide. Visible crystallites are rare in other engineering materials. Protective coatings for steel constitute the largest use of zinc and rely upon the galvanic or sacrificial property of zinc relative to steel. Thermal diffusion galvanizing, a form of sherardising, provides a zinc coating metallurgical on iron or copper based materials similar to hot dip galvanizing. The final surface is different than hot-dip Galvanizing; all of its zinc is alloyed. Zinc is applied in a powder form with "accelerator chemicals" (generally sand but other chemicals are patented). The parts and the zinc powder are tumbled in a sealed drum while it is heated to slightly below zinc's melting temperature. The drum must be heated evenly, or complications will arise. Due to the chemicals added to the zinc powder, the zinc/iron makes an alloy at a lower temperature than hot dip galvanizing. This process requires generally fewer . The dull-gray crystal structure formed by the process bonds stronger with paint, powder coating, and rubber overloading processes than other methods. It is a preferred method for coating small, complex-shaped metals and smoothing in rough surfaces on items formed with powder metal.

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CHAPTER:-4

24

REFERENCE
1. Ariponnammal, S. and Natarajan, S. (1994) tower phenomena X Asx, Pramana Journal of tower contructionVol.42, No.1, pp.421-425. Barnard, R.W. and Kellogg, C. (1980) Applications of mobile tower Michigan Mach, J., Vol.27, pp.8194. Shin, K.G. and Mckay, N.D. (1984) how construct a good tower, Proc.Amer.Contr.Conf., San Diego, CA, pp. 1231-1236.

2.

3.

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