40-Channel Real Time Digital Control System
The sophisticated closed loop servo hydraulic loading system with Real Time Digital Control System has capability to apply the loads at 40 points simultaneously in three orthogonal directions, namely transverse, longitudinal and vertical with maximum capacities of 12000kN, 5500kN and 5000kN respectively. The test is closely monitored the application of loads and their directions from the control room.
The test pad is on the granite rock. The test tower is erected on the test pad and held in position using pre-stressed rock anchors. The test pad can accommodate towers having base dimensions up to 22.5 m x 22.5 m, cross arm width of 20 m on either side and height upto 80 m and has a total of 550 rock anchors each of 500 kN uplift capacity. The test pad can host square, rectangular, triangular lattice towers, guyed towers and monopoles of different diameters. The towers with 7000kN leg uplift force are tested so far.
Transverse Ram Station
The hydraulic actuators that apply the transverse loading on the test tower have a capacity of 12000 kN and are anchored firmly to a cellular box type reinforced concrete foundation structure located on the hill at approximately 46 m above the test pad level and behind a crest tower of 24 m high.
Longitudinal Ram Station
The longitudinal ram station on the hilltop at 65 m above the test pad level. It consists of three main anchor blocks and a 37 m long crest structure in front. Eleven actuators are connected to the main anchor blocks which can impart a load up to 5500 kN.
Vertical Ram Station
The vertical ram station is located at the ground level in front of the test pad at a distance of 50 m and has the loading capacity of 5000 kN.
Oil at high pressure (up to 300 bar) required for the working of the Rams is supplied from a central pumping unit comprising a variable delivery pressure compensated piston pump of 125 hp, housed in a building at the foot of the hill. The oil is passed through an on-line filtering system continuously to maintain the quality. The high-pressure oil is conveyed to the various rams station through high strength, special quality seamless pipes.
Load cell and calibration
Load cells need to be calibrated with reference to a proving ring and attached to the loading point prior testing of tower in presence of the Client. We have load cells in various capacities: 10 kN, 20 kN, 50 kN, 100 kN, 300 kN and 500 kN
Uninterrupted power supply during testing ensured with 250 kV generator with auto-main-failure (AMF) system
A tower crane of 50 kN capacity and 80 m height is used for assembling and dismantling of test towers. Tower crane has the capacity of 12kN at boom tip (50m) to 50kN at 14m from the mast.
Test pad expansion : 700 tonnes uplift
- Data acquisition capabilities for 48 channel
- Fork lift of 30 kN capacity
- Theodolite stations to measure the displacements
- Video camera for Live web telecasting
- Workshop facilities – welding, grinding, cutting, and drilling