Training Program for Mechanical Engineers

LTL Galvanizers (Pvt) Ltd.

Steel Fabrication & Hot Dip Galvanizing Plant

TRAINING PROGRAM FOR MECHANICAL ENGINEERS

1. Design & Fabrication of Steel Articles – 03 Months

S/ Training Module Duration

N
1 Raw Material Selection 02 weeks
 International standards for M/S & H/T Plates, Angles,
Flat irons, Channels & Fasteners
 Chemical & Mechanical properties of Steel and their
impact on hot & cold fabrication processes
 Chemical composition of steel and their suitability for
Hot Dip Galvanizing after fabrication
 Different grades of fasteners & raw steel and required
quality of steel for fabrication of articles.

2 Design & Drawing 03 weeks

 Modular design & development of erection drawings
 Development of shop drawings
 Use of software for design & drawing
 Standards followed during designing process

3 Steel Inspection 01 week

 Inspection of steel against the parameters as mentioned
in relevant standards
 Acceptance/rejection criteria for incoming raw steel

4 Fabrication 1.5 months

 In depth study on fabrication processes (shearing,
punching, notching, hot & cold bending, milling, drilling,
number stamping, etc.…)
 Selection and use of machineries for fabrication
 Configuration & maintenance of machineries
 Standards to be followed during the fabrication process
 Quality control during fabrication
 Correct Welding techniques and use of welding
instruments
 Standards to be followed during welding
 Welding quality testing
 Quality control during welding
 Training Program for Mechanical Engineers
LTL Galvanizers (Pvt) Ltd.
Steel Fabrication & Hot Dip Galvanizing Plant

Details of Machineries used in Fabrication Process

Equipment kW
1 Lathe Machine (Stroke length – 1.0 m; Bore 50 mm)
2 Shearing machine 22
3 CNC angle master 24
4 CNC Angle punching machine 15
5 CNC Plate punching machine 15
6 CNC Profile cutter
7 Notching machine 7.5
8 Number stamping machine 7.5
9 Angle shearing machine 9.3
10 Iron worker - Hydraulic 4.6
11 CNC Iron worker - Hydraulic 9.2
12 Iron worker - Hydraulic 7.5
13 Mechanical Iron worker 5.5
14 Milling machine 2 7.5
15 Milling machine 1 0.8
16 Drilling machine 1.1
17 Power saw 1.5
18 Air Compressor 5.5
19 Bending machine 3
20 Fork lift (02 Nos)
21 Mobile cranes (12 MT & 10 MT)

Software used in design & Drawing Process

 PLS CAD – For Profile Designs

 PLS Tower – For Tower Designs
 MS Tower – For Tower Designs
 STADD Pro – For steel structures Designs
 Training Program for Mechanical Engineers
LTL Galvanizers (Pvt) Ltd.
Steel Fabrication & Hot Dip Galvanizing Plant

2. Hot Dip Galvanizing – 03 Months

S/ Training Module Duration

N
1 Pre-Galvanize requirements 02 weeks
 Selection of steel with best chemical composition to have
best quality galvanized products
 Pre-Galvanizing requirements of steel articles and their
effect on galvanizing process and on final quality
 Inspection and identification of welding defects which
could leads to inferior quality galvanized products
 Correct design and fabrication methods of articles to avoid
distortions during Galvanizing.
 Venting and drainage requirements of steel articles
 Pre-preparation methods can be used to overcome the
defects of galvanized products

2 Hot Dip Galvanizing process 01 month

 In depth study on Hot dip Galvanizing process steps, De-
greasing, pickling, rinsing, fluxing, drying, galvanizing,
quenching, passivation, quality inspection & effluent
treatment process
 Use of chemicals and their individual & combined effects
on galvanizing process
 Quality of raw material used in Hot dip Galvanizing process
and relevant standards
 Metallurgy of Hot dip Galvanizing and characteristics of
bond formed.
 Inspection guidelines for galvanized articles
 Possible quality defects during and after galvanizing and
how to overcome those issues
 Process control (temperature, fuel, electricity, etc.…)
 Standards used in Hot Dip Galvanizing Process
 Process Quality control (control of chemical baths,
Nondestructive and destructive testing, etc...)
 Environmental & safety management

3 Comparison of Hot dip Galvanizing with other coating processes 01 week

 Initial and life cycle cost calculation for different coating
processes
 Characteristics of coating (Bond strength, abrasion
 Training Program for Mechanical Engineers
LTL Galvanizers (Pvt) Ltd.
Steel Fabrication & Hot Dip Galvanizing Plant

resistance, durability, etc.…)

 Determination of life time in different environmental
categories

4 Operation and maintenance of machineries 01 week

 Automatic control of gas furnace and troubleshooting
 Control of galvanizing fumes and fume suction process
 Operation & maintenance of Galvanizing kettle, drying
furnaces and hot gas pathway
 Operation & maintenance of overhead cranes, and other
lifting equipment and forklifts
 Operation & maintenance of filter press

Details of Machineries used in Galvanizing Process

Equipment kW
1 Gas burners (06 Nos) – Flat Flame 960
2 overhead crane 1 5
3 overhead crane 2 5
4 overhead crane 3 1.5
5 Circulation fan 1 11
6 Circulation fan 2 11
7 Circulation fan 3 2.9
8 Circulation fan 4 2.9
9 Circulation fan 5 2.9
10 Combution air fan1 7.5
11 Combution air fan2 7.5
12 Centrifuger 4.2
13 Air compressor 3.5
14 pump1 0.75
15 pump2 0.75
16 pump3 2
17 flue gas fan1 1.5
18 flue gas fan2 1.5
19 bath edge lacated motor1 2.9
20 bath edge lacated motor2 1.5
21 bath edge lacated motor3 1.5
22 Filter press 2.2
23 Fork Lifts (04 Nos)