Detailed Project Report on fabrication plant for lattice towers and tubular steel poles
Detailed Project Report on fabrication plant for lattice towers and tubular steel poles
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FABRICATION PLANT FOR LATTICE TOWERS
AND TUBELAR STEEL POLES
[CODE NO.3997]
Towers or masts are built in order to fulfil the need for placing objects or persons at a certain level above the ground. Typical examples are:
Single towers for antennae, floodlight projectors or platforms for inspection, supervision or tourist purposes.
Systems of towers and wires serving transport purposes, such as ski lifts, ropeways, or power transmission lines.
For all kinds of towers the designer should thoroughly study the user's functional requirements in order to reach the best possible design for the particular structure. For example, it is extremely important to keep the flexural and torsional rotations of an antenna tower within narrow limits in order to ensure the proper functioning of the equipment.
The characteristic dimension of a tower is its height. It is usually several times larger than the horizontal dimensions. Frequently the area which may be occupied at ground level is very limited and, thus, rather slender structures are commonly used.
Another characteristic feature is that a major part of the tower design load comes from the wind force on the tower itself and its equipment, including wires suspended by the tower. To provide the necessary flexural rigidity and, at the same time, keeping the area exposed to the wind as small as possible, lattice structures are frequently preferred to more compact 'solid' structures.
Bearing in mind these circumstances, it is not surprising to find that the design problems are almost the same irrespective of the purpose to be served by the tower. Typical design problems are:
• Establishment of load requirements.
• Consistency between loads and tower design.
• Establishment of overall design, including choice of number of tower legs.
• Consistency between overall design and detailing.
• Detailing with or without node eccentricities.
• Sectioning of structure for transport and erection.
A lattice tower, also called angle steel tower or electrical tower, is one kind of freestanding framework tower for power transmission line of all voltages, often designed as a space frame or a hyperboloid structure. They are widely used as an electricity transmission towers especially for voltages above 100 kilovolts, being as a self-radiating tower or a carrier of aerials, even an observation tower.
Lattice steel towers comprise of several different metal structural elements linked as well as products or welded. A variety of types of lattice steel towers exist. These towers may also be called self supporting transmission towers or free-standing systems, due to their power to help themselves. These systems are not always made from steel; they can also be made from aluminum or galvanized steel.
Lattice steel towers are made up of many different steel structural components connected together with bolts or welded. Many different types of lattice steel towers exist. These towers are also called self-supporting transmission towers or free-standing towers, due to their ability to support themselves.
Lattice towers provide the advantage of a smaller cost investment compared to others, since they use about half as much material as tubular towers. Yet the lattice tower still provides similar stiffness and reliability as tubular towers. Lattice towers allow wind to pass through the base and tower sections, decreasing the pressure and resistance on the structure. One disadvantage according to some people is the appearance of lattice towers.
Lattice structure Lattice steel towers are made up of many different steel structural components connected together with bolts or welded. Many different types of lattice steel towers exist. These towers are also called self-supporting transmission towers or free-standing towers, due to their ability to support themselves. These towers are not always made of steel; they can also be made of aluminum or galvanized steel. Self- supporting lattice structure are used for electricity transmission line tower. The lattice structure can be erected easily in very inaccessible location as the tower member can be easily transported. Lattice structures are light and cost effective.
A lattice tower is a framework construction made of steel sections. Lattice towers are used for power lines of all voltages, and are the most common type for high-voltage transmission lines. Lattice towers are usually made of galvanized steel. A lattice tower is usually assembled at the location where it is to be erected. This makes very tall towers possible (up to 100 meters - in special cases even higher). Assembly of lattice steel towers can be done using a crane. Lattice steel towers are generally made of angle-profiled steel beams (L- or T- beams). For very tall towers, trusses are often used.
COST ESTIMATION
Plant Capacity 100 Ton/Day
Land & Building (15000 sq.mt.) US$ 17.33 Lac
Plant & Machinery US$ 6 Lac
Working Capital for 2 Months US$ 30.86 Lac
Total Capital Investment US$ 56.11 Lac
Rate of Return 52%
Break Even Point 39%
INTRODUCTION
MAIN PARTS OF LATTICE TOWER
PEAK
HIGH VOLTAGE TRANSMISSION TOWERS
TYPES OF TOWERS ALONG TRANSMISSION LINES
EXAMPLES OF OVERALL DESIGN OF SUSPENSION TOWERS FROM DIFFERENT COUNTRIES
FREE STANDING LATTICE TOWERS
THIS TOWER FACE IS 1100MM WIDE FROM CENTRE-TO-CENTRE OF VERTICAL PIPES.
AIRCRAFT WARNING LIGHTS CAN BE SUPPLIED AND INSTALLED TO THE TOWER ON REQUEST.
TOWER TYPES
CLASSIFICATION ACCORDING TO USE
ANGLE TOWERS
PILOT SUSPENSION INSULATOR STRING
UNEQUAL CROSS ARMS
NORMALLY 4 TYPES OF SINGLE CIRCUIT TOWERS ARE USED AS DETAILED BELOW
A) "A" TYPE TOWERS :
B) "B" TYPE TOWERS :
C) "C" TYPE TOWERS
D) "D" TYPE TOWERS :
400 KV DOUBLE CIRCUIT TOWERS
RIVER-CROSSING TOWER
RAILWAY CROSSING TOWER
HIGH WAY CROSSING TOWER
TRANSPOSITION TOWER
MULTI CIRCUIT TOWERS.
WEIGHT OF DIFFERENT TYPES OF TOWERS
WEIGHTS OF TOWERS USED ON VARIOUS VOLTAGE CATEGORIES
FABRICATION
BOLTING
SPACING OF BOLTS AND EDGE DISTANCES
MAXIMUM EDGE DISTANCE POSSIBLE WITH MINIMUM ANGLE SIZE
WASHERS
THICKNESSES OF SPRING WASHERS
LAP AND BUTT JOINT
GUSSET PLATES
BRACING TO LEG CONNECTIONS
CROSS-ARM CONNECTIONS
STEP BOLTS AND LADDERS
ANTI-CLIMBING DEVICES
DANGER AND NUMBER PLATES
PHASE AND CIRCUIT PLATES
BIRD GUARD
AVIATION REQUIREMENTS:-
NUMBER PLATE
CIRCUIT PLATE
DANGER PLATE
MATERIALS FOR TOWER CONSTRUCTION
TOWER MAINTENANCE
USES AND APPLICATION
LIGHTING DESIGN
DIMENSIONS AND SPACING
TECHNICAL REQUIREMNT OF TUBULER POLES
SYSTEM DATA
MATERIALS AND PROCESS:
POLES SHALL BE DELIVERED IN A SWAGED OF STEPPED FORM.
B.I.S. SPECIFICATION
FACTORS GOVERNING TOWER CONFIGURATION
TOWER HEIGHT
MINIMUM PERMISSIBLE GROUND CLEARANCE
MAXIMUM SAG OF LOWERMOST CONDUCTOR
SPACING OF CONDUCTORS
VERTICAL CLEARANCE BETWEEN GROUND WIRE AND TOP CONDUCTOR.
ROLE OF WIND PRESSURE
VARIATION OF WIND SPEED WITH HEIGHT
WIND FORCE ON STRUCTURE
THESE ARE :
MAXIMUM & MINIMUM TEMPERATURE
COMPUTATION OF VARIOUS LOADS ON TOWERS
TRANSVERSE LOAD DUE TO LINE DEVIATION
WIND LOAD ON TOWER
LONGITUDINAL LOAD
TORSIONAL LOAD:
VERTICAL LOAD
WEIGHT OF STRUCTURE
MARKET SURVEY
GLOBAL POWER TRANSMISSION TOWERS AND CABLES MARKET SEGMENTATION:
SEGMENTATION BY VOLTAGE RANGE:
SEGMENTATION BY CURRENT:
SEGMENTATION BY TYPE:
SEGMENTATION BY REGION:
BY CONDUCTOR
HIGH TEMPERATURE
BY INSULATION
REGIONAL OUTLOOK OF LIGHT TOWER MARKET
COVID-19 IMPACT ON LIGHT TOWER MARKET
POWER TRANSMISSION LINES & TOWERS MARKET, BY REGION
MANUFACTURERS/SUPPLIERS OF LATTICE STEEL TOWER
FABRICATION PROCESS
(1) PROCUREMENT OF RAW MATERIAL
(2) FABRICATION
THE VARIOUS PROCESSES INVOLVED IN THE FABRICATION ARE AS FOLLOWS:
(A) FOR ANGLE
STRAIGHTENING
CUTTING
BENDING
PUNCHING AND DRILLING
HOLING
(B) FOR PLATES
TOLERANCES
(3) GALVANIZING
4) QUALITY CONTROL
(A) FOR RAW MATERIAL
TOLERANCE:
(B) FOR FABRICATION
STRAIGHTENING:
CUTTING:
PUNCHING AND DRILLING:
WELDING:
(C) FOR GALVANISING:
(5) MARKING OF MEMBERS FOR IDENTIFICATION
(6) PACKING TRANSPORTATION AND DELIVERY
FOR THIS PROJECT:-
RAW MATERIAL SUPPLIERS
M.S CHANNELS AND ANGLES
M.S PLATE
MIG WELDING WIRE ELECTRODE
GRINDING AND FINISHING WHEEL
ZINC INGOT
PICKLING CHEMICALS
SULFURIC ACID
(HCL) PICKLING ACIDS
PLANT AND MACHINERIES
COMPLETE PLANT AND MACHINERY
INDIVIDUAL :-
CNC ANGLE DRILLING MACHINE
CNC PLASMA PLATE CUTTING MACHINE
CNC MACHINES, CNC MACHINE TOOLS & LATHES
MILLING MACHINE
POWER HACSAW
GRINDING MACHINE
PUNCHING PRESS
POWER PRESS
SHEARING MACHINE
BENDING MACHINE
WELDING MACHINE
MIG WELDING MACHINE
HOT DIP GALVANISING PLANT
PRECISION MEASURING TOOLS
EOT CRANE
POWER TRANSFORMERS
ELECTRICAL PANEL
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
JIGS AND FIXTURE
RAW MATERIAL PHOTOGRAPHS
M.S CHANNELS AND ANGLES
M.S PLATE
MIG WELDING WIRE ELECTRODE
GRINDING AND FINISHING WHEEL
ZINC INGOT
PICKLING CHEMICALS
SULFURIC ACID
PRODUCT PHOTOGRAPHS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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