STUDY OF QUALITY

INSPECTIONS IN
MANUFACTURING OF
TRANSMISSION TOWERS
DEEPAK KUMAR PANDEY

M TECH INDUSTRIAL ENGINEERING

RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT
 CONTENT

1. Introduction of Company………………………………………..…Page no.3

2. Field of Study…………………………………………………….…Page no. 3

3. Manufacturing Process of Transmission Towers………….………Page no.4

4. Raw Material……………………………………….…………….. Page no.4-5

5. Fastenings…………………………………………………..……….. Page no.5

6. Quality Check…………………………………………………….. Page no.5-6

7. Storage……………………………………………………………..... Page no.6

8. Cutting of Materials…………………………………………...…… Page no.6

9. Marking and Measurements………………………………………. Page no.7

10.Machining and drilling………………………………………….. Page no.7-8

11. Various Inspection Process………………………………..…… Page no.9-17

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 1.INTRODUCTION OF COMPANY

The company(Amitasha Enterprises Pvt. Ltd.) where project work was done is located in MIDC,
Industrial Area, Hingna Road,Nagpur - 440016 , Maharashtra Amitasha Enterprises Pvt. Ltd. is listed in
Trade India's list of verified sellers offering supreme quality. Amitasha Enterprises Pvt. Ltd. was established
in 1993 with a modest plant capacity of 600 MT per month for manufacturing Transmission line
Towers, Substation structures, Telecommunication Towers and Railway Electrification Structures
in association with KEC International Ltd. - World’s Largest Tower Manufacturing Company.
AMITASHA, after a successful association of initial seven years with KEC International Ltd., has
over the past 15 years established itself into a respectable entity by itself, capable of manufacturing
Transmission Line Towers up to 5,000 MT per month. Since that first order from KEC there has
been no looking back for AMITASHA, which is now confidently associating with major Multi-
Nationals for large Power & Telecommunication projects within India & Abroad.
During the last 2 years AMITASHA has established itself as a dependable supplier of Module
Mounting Structures for various domestic as well as overseas client.

Business Type: Manufacturer/Supplier.

Products: Transmission Tower, Nuts and Bolts (Fasteners)

2.FIELD OF STUDY

The purpose of visit was to study Quality Inspection Process, Acceptance Sampling Process and
Inspection Standards company refer for their products. Starting From Raw material Inspection to
the Final product Inspection, all the operations are done in the factory unit by Quality Control
Department of the company.

Sequence of operations in the factory unit.

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 3.MANUFACTURING PROCESS OF TRANSMISSION TOWERS
Manufacturing Process of Transmission Towers and the flow of materials and products can be
easily be understood by the following flow chart.

Detailed flow chart of the company

4.RAW MATERIAL
The raw material used for manufacturing of Transmission towers are steel angle bars. It can be in
different sizes and different profile types i.e. L, V, T-shape and flat angle bars (see Fig 6), iron net
and other sheet metal etc. Steel in normal condition itself is corrosion resistant but for further
improvements HDG and paints are applied.
Raw material is chosen according to the structural parts, for example most heavy steel angle bars
are chosen for the purpose sizes for structural member of Transmission tower. Raw material is
directly purchased from the suppliers and as the company has mass production so different
suppliers supply raw mater is according to Indian standards and specifications.
Its quality is checked both by suppliers and company itself because in such case of designing tower
for the age of 25 years, the tower material must be chosen according to standards. Steel angle bars
are directly transported to company storage and they are further sent to machine shop for further
processes after quality check.

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 Different steel profiles

5.FASTENINGS

Fastenings are the necessary parts of tower which are used to fasten the different part of towers.
They are used only during erection of towers and are supplied by suppliers. The supplier itself is a
company(registered under the name of Anshika Fasteners) that makes different fast nuts, washers
and anchor bolts which are used to fastening in different types and sizes i.e. bolts, nuts, washers and
anchor bolts which are used to fasten leg joints to the foundation.
Fastenings are also transported directly to company storage and its quality is checked both by the
supplier and the company. When company’s orders are confirmed by clients then a complete tower
structure and fastenings are transported to sites for final erection of Transmission tower.

Fastening

6.QUALITY CHECK

When raw material and fastening products get to the factory, it is needed to check the quality of
products. The factory’s QA department has responsibilities to assure the quality of both of them.
There are Four sessions that are responsible for their quality check, one is for raw material and
second is for Inprocess Inspection, Third is for Final Inspection and Fourt one is for fastening.
Mostly the raw material is supplied by suppliers and its according to standards but if some wrong
material and any material which does not meet the company requirements is found, is informed to

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supplier or sent back. The QC department is mostly responsible for the quality check of fastening
which is supplied by the suppliers. All of the fastenings are checked step by step. The company has
different charts and tables according to standard and different gauges are used too for checking
lengths, diameters, threads and some other dimensions according to drawing. Some measuring tools
i.e. vernier caliper and micrometer are also used.
Drawing samples are also provided to suppliers so that they could supply the fastening according to
Imitate enterprises standards and requirements. So, for that, quality is checked twice, both by the
supplier (Anshika Fasteners) and the QC department of Amitasha Enterprises

7.STORAGE

The factory has its own vast storage where they store raw material, fastening products and some
different tools. There is a storekeeper who works in store and keeps the things in order. The store
has two main departments, one is for raw material and fastening and another is for tools. They both
are supervised with the same management. Different kinds of documentation are used for storage
use. Material issue, material required, material shortage, material purchasing, order sheet and some
other documentation are used for the purpose of production line and quality control and quality
assurance department.

COMPANY STORAGE SYSTEM

8.CUTTING OF MATERIAL

After the raw material is issued from the storage the next and first operation of manufacturing is
cutting of angle bars that are done with the presses. Before cutting the angle bars it needed to
measure and have to do some marking according to required sizes. There are three presses in the
factory which are used to cut different angle bars in different shapes and sizes and then material is
sent to machine shop.

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 9.MARKING AND MEASUREMENTS

When the angle bars are cut in the size then the next process is about markings according to
measurements on it. Different drawings are used for each part and marking is done according to the
available drawings. At this stage, as it’s the first and main stage of the manufacturing of
Transmission towers, the workers who do the marking job are well experienced and they do the
quality check themselves at same time during marking process.
Different tools like scribers, as shown in Figure and different colors of chalks or temporary paints
are used for the purpose of marking.

Types of scribers

10.MACHINING AND DRILLING

When marking is finished, the material is ready for machining processes. For that, the factory has
about six drilling machines and different grinding machines. Actually, when the marks are ready
and points are located the holes in angle parts need to be done by drilling process that is quite
precise. Workers have to be well trained so that they can use exact tools and drill the right sizes of
holes because when the tower will go for site for erection then there should not be any play
between tower members. That can cause all tower breakage when its windy or bad weather like
storm etc.
Technical documentation work need to be done by using Auto Cad in which, the use of part
numbers in drawings and different scaling work need to be mention. Work need to be done
according to the drawings and some inspection need to perform to check either if the parts are
manufactured according to drawings or if there are some mistakes. The work needs to be done by
workers under the guidance of foremen and some faulty parts have to be fixed under the guidance
of concerning supervisor and foremen.

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 Drilling machine

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 11.QUALITY INSPECTION PROCESS

1. Raw Material Inspection-

1.1 Used Raw Material – M S AND HT ( Angles, plates and Bars)

1.1.1 Visual check for surface finish

a. Sampling plan – Refer table 1.
b. Acceptance Norm – IS 2062/ BS EN 100 25
c. Testing Agency – Amitasha Enterprises
1.1.2 Physical Properties
a. Sampling plan – One sample for 40 MT.
b. Acceptance Norm - IS 2062,IS:1608,IS:1852,IS:1599,BS EN 100 25
c. Testing Agency - Amitasha Enterprises/ Third Party Lab
1.1.3 Chemical Composition

a. Sampling plan – One sample for 40 MT of part thereof.

b. Acceptance Norm – IS 2062/ BS EN 100 25
c. Testing Agency - Supplier’s Works/ Third Party Lab

1.1.4 Dimensional checks and sectional tolerance

a. Sampling plan- Refer table No. 1
b. Acceptance Norm- IS 808/IS 1852/ BS EN 10056, As Per Table 1
c. Testing Agency - Amitasha Enterprises

1.2 Zinc
1.2.1 Chemical composition
a. Sampling plan- One sample for 50 MT
b. Acceptance Norm – IS 209, Zinc Purity of minimum 99.95% for ingots.
c. Testing Agency – Third party Lab

2. INPROCESS INSPECTION
2. Fabrication
2.1.1 Cutting
a. Sampling- 1st piece and every 50th piece
b. Acceptance Norrm- IS 802 ( length tolerance ±2mm)
c. Testing agency- Amitasha Enterprises
2.1.2 Stamping
a. Sampling-1st piece and every 50th piece
b. Acceptance Norm- Letter size 10*16 mm or as per Clients requirements.

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 c. Testing Agency – Amitasha Enterprises
2.1.3 Punching
a. Sampling-1st piece and every 50th piece
b. Acceptance Norm- IS 802 part 2 shop drawing.
c. Testing Agency – Amitasha Enterprises
2.1.4 Notching
a. Sampling-1st piece and every 50th piece
b. Acceptance Norm- shop drawing tolerance ±5 mm on length cut.
c. Testing Agency – Amitasha Enterprises
2.1.5 Heel cutting
a. Sampling-1st piece and every 50th piece
b. Acceptance Norm- shop drawing tolerance ±5 mm on length cut.
c. Testing Agency – Amitasha Enterprises
2.1.6 Bending
a. Sampling – 100% piece
b. Acceptance Norm- shop drawing tolerance +-5 mm on length cut
c. Testing Agency – Amitasha Enterprises
2.1.7 Final Inspection of fabricated parts
a. Sampling – Min 5 piece or 10% of lots size for inhouse and min 10 pi or 10% of lot
size
b. Acceptance Norm – Verify parameter from 2.1.1 to 2.1.6
c. Testing Agency – Amitasha Enterprises

2.2 Prototype/model assembly

a. Sampling- One structure of each type. (Needed when customer is new or requirements are
changed)
b. Acceptance Norm- Approved drawing of bolted material interchangability of bolted
member to be verified
c. Testing Agency – Amitasha Enterprises

2.3 Galvanising
2.3.1 Surface preparation
A. Degreasing( acid based solution)
 Sampling- One sample per day
 Acceptance Norm- IS 2629, Strength of solution – 4-12%
PH – 2 to 4 , sp. Gravity – 1.01 to 1.03
 Testing Agency – Amitasha Enterprises

B. Acid pickling (HCL Solution)

 Sampling- One sample per day
 Acceptance Norm- IS 2629 , Fe 125 gms/lit , sp gravity – 1.13 to 1.30
 Testing Agency – Amitasha Enterprises

C. Rinsing / Cleaning
 Sampling- Random basis
 Acceptance Norm- IS 2629
 Testing Agency – Amitasha Enterprises

D. Prefluxing ( ZnCl and NH4Cl solution)

 Sampling- One sample per day
 Acceptance Norm- IS 2629 ,sp gravity 1.1- 1.3, Ph value 4-5

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  Testing Agency – Amitasha Enterprises

E. Preheating
 Sampling- One sample per day
 Acceptance Norm- IS 2629, (70º-150º C.)
 Testing Agency – Amitasha Enterprises

2.3.2 Diping (Galvanising)

A. Zinc bath temperature
 Sampling- Hourly check
 Acceptance Norm- IS 2629, Temperature 450º-460ºC
 Testing Agency – Amitasha Enterprises

B. Thickness of zinc coating

 Sampling- 2 sample per shift
 Acceptance Norm- IS 2629/ISO 1461/IS 6745/ IS 4759 , customer specification
 Testing Agency – Amitasha Enterprises

C. Weight of zinc coating

 Sampling- 2 sample per shift
 Acceptance Norm- IS 2629/ISO 1461/IS 6745/ IS 4759 , customer specification
 Testing Agency – Amitasha Enterprises

D. Adhesion of zinc coating

 Sampling- 2 sample per shift
 Acceptance Norm- IS 2629/ISO 1461/IS 6745/ IS 4759 , customer specification
 Testing Agency – Amitasha Enterprises

2.3.3 Quenching in running water

 Sampling- 2 sample per shift
 Acceptance Norm- IS 2629

2.3.4 Di- chromating

 Sampling- 1 day per sample
 Acceptance Norm- IS 2629 /comparison with standard solution
 Testing Agency – Amitasha Enterprises

3.0 FINAL INSPECTION

3.1 Raw material ( steel)
a. Physical property
 Sampling- Random basis
 Acceptance Norm- refer clause 1.1.2
 Testing Agency – Amitasha Enterprises

b. Chemical properties
 Sampling- Random basis
 Acceptance Norm- refer clause 1.1.3
 Testing Agency – third party

3.2 Identification Marks

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  Sampling- Random basis
 Acceptance Norm- refer clause 2.1.2
 Testing Agency – Amitasha Enterprises

3.3 Quantity checks

 Sampling- Random basis
 Acceptance Norm- bills of material / offer list
 Testing Agency – Amitasha Enterprises

3.4 Galvanising Test

3.4.1 Thickness of zinc coating
 Sampling- Random basis(max 1 sample /20MT lot )
 Acceptance Norm- IS 4759 /IS 2633/ISO 1461/< 5mm thk 65micon >5mm thk 86 micron
 Testing Agency – Amitasha Enterprises

3.4.2 Weight of zinc coating

 Sampling- Random basis(max 1 sample /20MT lot )
 Acceptance Norm- IS 4759 ,IS6746 ,BS729 <5mm thk 460gm/ mtr > 5mm thk
610gm/mtr.
 Testing Agency – Amitasha Enterprises

3.4.3 Uniformity of zinc coating

 Sampling- Random basis(max 1 sample /20MT lot )
 Acceptance Norm- IS 2633, IS 2829 , ISO 1461
 Testing Agency – Amitasha Enterprises

3.4.4 Adhesion of zinc coating

 Sampling- Random basis(max 1 sample /20MT lot )
 Acceptance Norm-IS 2629 ,ISO1461
 Testing Agency – Amitasha Enterprises

3.5 Dimensional and Visual checks

 Sampling- Refer 1.6
 Acceptance Norm –Ref clauses 2.4.1 to 2.1.8
 Testing Agency – Amitasha Enterprises

4.0 Bundling
 Sampling- Random basis
 Acceptance Norm- Packing lists
 Testing Agency – Amitasha Enterprises

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 TABLE 1
SAMPLING PLAN FOR VISUAL AND DIMENSIONAL CHARACTERISTICS OF
STRUCTURAL STEEL
SAMPLING PLAN AS PER IS:2500,LEVEL 2, AQL 1.5
LOT SIZE SAMPLE SIZE ACCEPTANCE REJECTION NO.
NO.
2-8 100% INSPECTION 0 0
9-15 8 0 1
16-25 8 0 1
26-50 8 0 1
51-90 8 0 1
91-150 32 1 2
151-280 32 1 2
281-500 50 2 3
501-1200 88 3 4
1201-3200 125 5 6
3201-10000 200 7 8
10001-35000 315 10 11
35001-150000 500 14 15
150001-AND OVER 800 21 22

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IS 2062:2011

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 EXTRACT OF IS 209:1992
ZINC INGOT SPECIFICATION

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EXTRACT OF IS 802 (PART 2) -1978

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