Powering
Development

T&D Turnkey Solutions

KPIL has over 4 decades of experience in executing Complex Transmission Line Projects upto 1200 KV & Green Field Substations Projects upto 765 KV AIS & 400 KV GIS.

We have experience of working as EPC Contractor on HVAC (High Voltage Alternate Current) and HVDC (High Voltage Direct Current) transmission lines up to 800 kV.Tower Testing Capabilities of upto 1200 KV Towers , Tested 540+ Towers in last 24 years. The Company has completed more than 30,000 Km length of transmission line contracts; which includes the toughest terrains like mountains, desserts, river crossing etc. in various typical weather conditions of more than 40 countries. It is renowned for delivering to utmost satisfaction and trust worthy performances.

As an established EPC player with a strong Integrated Engineering Arm, Test & R&D Center with Helicopter erection simulation facility, logistically approachable plants, multifunctional multi-location Project Management Skills, KPIL owns sufficient fleet of field equipment that includes more than 50 sets of Tension Stringing Equipment (TSE) and wide range of Cranes & Forklifts, Meggers and other power testing equipment.

KPIL plays the role of proud principal for its CRM / Supply chain system and enjoys the high respect from its associate vendors spread across the globe. They have always been supportive to make the Company the best competitive and techno-economical bidder in various Global contracts.

All these efforts have been growing under the world class customized induction schedule, a global benchmarked safety guideline and an environment friendly working culture for its personnel, customers, vendors and associated work area.

Achievements:
• Experience of delivering FastTrack / short Gestation Projects
• Among the largest construction equipment base
• Built strong Brand equity amongst the customers - Delivery, Quality & Safety
• Currently executing projects in over 30 countries
• Successfully completed large Projects in very challenging Geographies/ Terrains
• Construction workforce of over 15,000 people across the globe

Projects Name:
• Bhutan (ongoing project)
• Kenya
• Zambia (ongoing project)
• Srilanka
• Bhopal (India)
• Egypt (ongoing project)

Substations

We have experience working on both AIS (Air Insulated Substations) and GIS (Gas Insulated Substations), completing GIS projects up to 400 kV and AIS projects up to 765 kV. KPIL has executed projects in diverse terrains including mountains, snow, deserts, plains, near coastal areas, and river crossings. Our company boasts a world-class, in-house engineering and construction team capable of delivering projects globally.

Currently, KPIL is engaged in several ongoing projects worldwide, spanning locations such as Sweden, Norway, Brazil, Tunisia, Tajikistan, Mauritania, UAE, Qatar, Senegal, Botswana, Cameroon, Sri Lanka, Bangladesh, Nepal, Bhutan, Chile, Suriname, Guyana, Tanzania, India, and more.

Distribution Network

KPIL carries out complete Engineering, Procurement and Construction works of Distribution Networks.

The works include:

• MV lines – up to 33 kV (Overhead on Concrete/Steel/Wooden poles or Underground Cables)
• LV lines – 415 V (Pole mounted with aerial bunched cable or conductor)

• Distribution Substation – 33/0.415 kV or 11/0.415 kV
• Packaged Substation including RMU (Ring Main Unit) – 33/0.415 kV & 11/0.415 kV

Solar Power Projects

KPIL undertakes Solar energy projects in EPC basis.

• Entire Installation process from Design to operation, covering wide range of services such as Site Surveys, optimized electromechanical design, Procurement, handling of Permits & commissioning.

• Technology selection & installation of Solar PV Modules associated with module mounting arrangement with FT (Fixed Tilt) or SAT (Single Axis Tracker) to suit the site condition.
• MV converter station, associated evacuation infrastructure including the EHV/UHV Transmission line with LI-LO arrangement.
• Offer Technical advice & solution with high quality equipment, maintenance & services as per the Grid code.
• Demonstrate PR Guarantee for Short Term & Long term backed with O&M.

Manufacturing

KPIL has one of the largest tower fabrication capabilities in the world giving it advantages in cost efficiency and economies of scale. The Health Safety Environment initiatives of the Company has not only ensured safe working environment for the staff but also won accolades from both national and international clients as well as government bodies.

KPIL has integrated steel fabrication plant which includes in-house galvanizing, painting and robotic welding. Capacity is 240,000 Tons per annum. KPIL’s manufacturing plants have state-of-the-art fabrication equipment such as CNC machines, drilling machines and EOT cranes. The Company takes pride in its well-trained, skilled and specialized engineers and technicians as well as well-defined testing equipment and established quality assurance plan offering international standard quality products.

Plant is certified by all required ISO such as 9001, 18001, 45001, etc.

Fabrication Facilities :
More than 45 CNC punching / drilling machines / PLC / Milling, Capable of handling Angle sections up to 250 x 250 x 35 mm and Plates across the three plants.

Integrated Quality Control System and Material Testing facilities :
Heavy Duty EOT cranes for CNC shops & galvanizing zones, loading & unloading cranes, lifters & carry mobile cranes, tractor etc.
The state of the art CNC machines are operated by trained operators/technicians which guarantees quality punching, drilling, cutting, stamping and fabrication, critical for transmission industry. This also applies to hydraulic presses and machine tools and fixtures, furnace to handle plates or angles for bending operations.

KPIL has sufficient high capacity powerful cranes and pick-n-carry mobile cranes of different capacities that enable smooth material handling. The machines are equipped to process the steel conforming to BSEN, ASTM, JIS, DIN, IS, AS & Euro norm specifications

Galvanizing Facilities :
KPIL has automatic temperature controlled galvanizing bath size meeting international standards or customer’s specific requirements. Microprocessor controlled galvanizing furnace and the pre-heating of flux ensures uniform drying and preheating of steel by oven to give a clear surface finish and at the same time ensuring uniform zinc coating.
Automatic temperature controlled galvanizing bath capable of meeting customized coating requirement of ASTM, EN or any other Indian and International standards.

KPIL plants are amongst the most modern manufacturing facilities in the country. All the plants are certified under ISO 9001:2008 standards. The chemical waste of its unit is treated as per prescribed environmental standards.

Achievements
1.Delivered over 45,000 towers across the world
2.Strategically located and integrated plants
3.Conformity to all major global standards and specifications.

Design & Engineering - Tower Testing & RD Centers

KPIL has world class design capabilities emanating from a rich pool of highly qualified and experienced team of design engineers combined with cutting edge technologies and an unparalleled experience of having designed virtually all types of towers across the globe. The Company focuses on innovation, safety and cost effective design solutions aligned to ensuring ease of manufacture and construction.

These are adhered to stringent technical and quality demands of the domestic and international clients. Its Design and Drawing department at Gandhinagar is recognised as R & D centre by Ministry of Science and Technology, the Government of India.

The Design department has adopted new material / new product in design of towers and foundation to achieve unique concept for ease of execution, safety and reliability of transmission lines. For surveying, KPIL has expertise to use the latest technology of Aerial Lidar & Terrestrial Lidar for generating accurate DTM data with speed.

Other Design and Engineering department capabilities include:

• 3D analysis & design software (PLS tower/I-tower/STADD III/PLS Pole) for optimizing use of Mild Steel and High Tensile Steel.
• BOCAD – 3D drafting software with automatic generation of shop drawings for fabrication, CNC data generation for manufacturing in CNC machines.
• PLS CADD for tower profiling.
• In house software for foundation & Pile designing and construction drawings.
• In house software for development of sag templates and generation of sag tension charts for line stringing.
• Developed tower designs up to 765 KV S/C & D/C as per IS/IEC/ASCE/DIN/ Vietnam standards.
• Developed detailing up to 1200 KV.
• Developed number of special designs like: Tall River crossing towers, Pile foundations, Raft foundation, Grillage foundation, Augur Foundations etc.

EPC with Financing Capabilities

KPIL and its subsidiaries can also facilitate funding for our customers by coordinating with various financial institutions/ banks and Export Credit Agencies (ECAs) from India, the Middle East, and Europe.

It has successfully secured/completed multimillion dollars projects across Asia and Africa under EPC + Finance model. These projects include Power Transmission, Distribution, Substations, Cabling, Road and Social Housing. Funding solution offered is for long term with long moratorium period and with reasonable finance costs. For more details, contact info@kalpataruprojects.com.