This report covers the experience, which I got in "SUMMER TRAINING" Firstly I was introduced in the Cement Mill & Packing Plant section. In operation of cement mill the clinker first come from the clinker storage piles to the clinker hopper through the deep bucket conveyor. Then transferred to the polycom, where it crushes and then fed to cement mill for further grinding and mixing. There is also a recirculation system, which again feed the coarse material to the polycom. The very fine material from cement mill is then stored in the cement silo. From the cement silo the cement is fed to the packers, where it filled in the bags of 50 kg. Then I was introduced in the Raw Mill & Coal Mill section. In the field I got the knowledge of various Instruments like pressure transmitters, temperature transmitters, pressure gauge, proximity switches, flow switches, level switches, temperature sensors like RTDs & thermocouples, weigh feeders, metal detector & metal separator etc. The brief discription of various field Instruments are given seperately.
1.1 INTRODUCTION
Aditya Cement is a unit of Grasim Industries Ltd of Aditya Birla group. Aditya cement the plant with 1.5 million tones per Annum capacity was commissioned in a record time in March 1995. Aditya Cement has adopted the most modern dry process technology with sophisticated instrumentation ensuring uniform quality, thus making it a Cement plant of 21st Century. The product BIRLA PLUS is one of the market leaders and continuous to consolidate its leading position in the market. The total project cost of Aditya Cement was Rs.430 Corers. Aditya cement is one of the most modern cement plants with all its major equipments supplied by the world major and renowned Krupp Polysius of Germany and Quality Control systems by Gamma Matrix of USA.
FIG 1. ADITYA BIRLA CEMENT PLANT
2.1. SPECIFICATIONS
Microprocessor: 89c51 Memory: Display:
Operating temperature: -10 C to +50 C. assigned as totalizer outputs. Analog output: 0-20mA/4-20mA isolated o/p corresponding to any one function.
- Actual federate
- Belt load - Belt speed - Weigh feeder set point. Impulse o/p: 2-relay output corresponding to Totalizer1 & Totalizer2 Interfaces: 2 digital I/O card (F-866) & 3 Analog I/O card (F-868) can be interfaced. Power supply: 220Vac +/- 15%. WEIGH FEEDER
FIG. 2.1
flashing.
During one belt revolution the zero point is corrected in order to improve the measuring precision. The deviation from the zero is measured and stored with plus or minus prefix. This value is now considered with each measuring of momentary load. Zeroing should be affected at setting in operation, change of module, mechanical modification and if the belt gets dirty. 2.5.2. CALIBRATION Condition: Weigh Feeder in stop condition and Belt must be empty. Press ECS & CL key simultaneously.
Now TUC-4 will ask for password. Enter the correct password & press HORIZONTAL (enter) Key. If password is correct then display show-Y. Scroll down to calibration with VERTICAL key press & enter key. TUC-4 will ask for RE_CALIBRATE?. Press enter for calibration.
Display will show DEADLOAD in upper line while some count is displated in lower line. To tare this value simply presenter key. Now display will indicate 0000 d in lower line. To move for SPAN calibration, press VERICAL key.
2.5.3. DROP TEST An exact calibration of the weigh feeder is possible only with original material since all influences concerning belt, measuring system and material characteristic are considered.
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A. First WF is started and let it run for a while in order to have mechanical equipment and electronics in operational temperature.
B.
reweighed on a static scale of an accuracy of better than 0.1%. The correction can be achieved by entering net Tachometer frequency which can be calculated as under: New Ft = old Ft * (value of 1/ actual material weight) PLC: TUC-4 has an in buit PLC, that is used to control the digital input, output & internal memory flags (marker). The PLC continuously operates on the control program in the following sequence: - Transfer hardware I/P into the RAM. Execute instruction in the control program (SPSS). - Transfer output process image to the hardware outputs.
2.5.4. INPUT, OUTPUT & MARKER These are one bit variable that can have LOW or HIGH status. Inputs are signal from outside to the control program, and outputs are signal from the control program to the external system. Markers are internal variable and serve as memory within the control system. They are available outside the control system when they have been copied onto outputs.
This diagram depicts the basic process of cement blending and storage.
FIG. 2.2
CHAPTER 3
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BELT WEIGHER
It is a system used to measure the feed of material to any m/c through belt conveyor. We are using it in many location. In Raw mill it is being used.
3.1.1.TRANSOM ASSEMBLY Three segment precisely machined roller having life lubricated seated bearing with labrine set form assembly. Transom assembly could be of single or multi rollers depending upon the accuracy required 3.1.2. LOAD CELL Precision strain gauge load cells are used in SANCO belt weigher. Aluminum along with labrine assembly makes the enclosure totally dustproof. Material weight is transferred to load cells through labrine, precision loadcell gives o/p in mV, which is processed in signal conditioner. Amplified o/p of load cell is transmitted to main processing unit. 3.1.3.TRANSDUCER SPEED Sanco has developed a special high resolution digital speed transducer. The o/p of this transducer is proportional to belt speed. These speed transducer senses the speed through contact wheel, or it can installed on extended shaft motor. 3.1.4. MAIN PROCESSING UNIT This unit contains following types of cards for manipulation of signals 1.Power supply for +5V(m-505) As the name suggest it generates the power supply for system. Since unit is based upon microprocessor so it need +5V supply free from ripple. 2.I/O board (m-501) This receives the techo output and 4 to 20 mA from local panel indicator of load signal here these are conditioned. 3.ADC card (m-502)
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Here load signal is converted into digital form and given to processor card and o/p generated by processor card is converted into analog form for CCR indication. 4.Processor card (m-503) Here speed signal and load signal are multiplied in digital and o/p also in digital form is generated which the feed rate. Now this o/p goes to ADC card which converts it into analog form for CCR. 5.Isolated 4-20 mA Generated (m-504) This generates another 4-20 mA signals which are electrically isolated and sent for local indicator.
- This will be displayed at counter 1 position. - Use data enter key and enter code 0100 - Press enter key.
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6.System will ask whather we went to run tare program(At counter 1). - 'No' will be displayed at counter - 2 position - For zeroing we have to run run Tare programme.
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- Display would change from'No' to 'Yes' - Press enter key to run programme. 7.Now tph indication will become 0.00 and counter 1&2 will be steady. 8.After one minute of starting the Tare programme check 4 ma O/P to CCR for empty belt. IF not 4 mas , adjust through POT in card M-504.
Voltages 3.0 V DC (Test weigh - 8 each side) 3.0 V DC (Test weigh - 8 each side)
600TPH 400TPH
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To ensure long life in its operation environment a thermocouple is protected in an open or closed metal protecting tube or well. Since the thermocouples usually in a location remote from the measuring instrument, connections are made using special extension wires called compensating lead.
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FIG. 4.1
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Fix the calibration tag duly filled on the pressure Transmitter after calibration.
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6.4 CAPACITANCE TYPE LEVEL SENSOR Capacitance is formed between the sensing probe and the vessel wall/ground. When the material level changes there is corresponding change in the value of this capacitance because of the difference in the dielectric constant of the material and that of air. The electronic circuit converts the capacitance into DC signal which causes the relay to operate.
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The electronic speed switch is ideally suited to monitor any repetitive motion, whether rotational or translational. In fact it is best suited for the speed monitoring of critical element of any material handling system, such as belt /screw conveyor, elevators, crushers, drag chain, rotary feeders etc. It senses the under speed /over speed conditions in the systems by non contact method and provides out put contacts for protection, control and interlock purposes. Application include ,detection in jamming in feeders, sequential interlocking on conveyors, detection of blade breakage in reclaimer chain, motion detection, fan speed monitoring etc. The speed switch comprises of a sensor probe and a monitor unit. A sensor probe is a non contact type inductive proximity switch, which picks up speed information, evalutes it and provides necessary outputs. The proxi potted probe is dust and water tight and the monitor in steel sheet or cast Alluminium, epoxi printed housing is dust tight pulses are clearly visible through the transparent window on cover. The terminal strip which can accept conductor up to 2.5 square mm, speed setting knob, the range switch and the bypass trip setting knob all are accessible only after opening the cover. Proper markings are provided for test points and external conditions. Different housings are available to suit individual requirements. The sensor probe are available suit individual requirements. The sensor probe is available in threaded housing, either thermoplastic or metallic with two clamping nuts, maving size as per selection table.
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With the unit connected the "SUPPLY ON" and "RELAY ON" LED light up as the supply is switched on During the initial bypass time, which is initiated by supply on the output relay remains picked, independent of speed. It is further held only. if the speed reaches the set value, before expiry of the bypass. The relay then drops whenever the speed falls below the set value. it can again pick up, if the system speed picks up to healthy running condition. The pulses LED on and off in response to the actuation and deactuation of the probe.
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In our plant LS is queried from mines. So it may happen that some metal pieces can come together with .If these metal pieces allowed to pass through machinery it could damage machinery. So to detect metal, detecting device is used on the belt weigher which senses the metal and divert the material to right side for short duration.
8.1 DESIGN
The metal detecting device consists of two components the probe and the amplifier, both which are interconnected with one coaxial cable. The probe will be furnished to match your conveyor belt width. There is a single probe and a tendom probe available. The planer single probe will usually be mounted underneath the conveyor belt. The tendom probe consists of two planer probes one of which will be mounted underneath the conveyor belt while the other probe will be held above the belt by special support.
8.2 FUNCTION
A high frequency AC voltage is fed from the amplifier to a coil in the probe via a 75 ohms coaxial cable. This generates an electromagnetic field. If a metal piece comes into this field, induction currents will be generated that drain power from oscillator.
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If depending upon the selected sensitivity an unwanted metal piece in the conveyed material is identified by the electronics. In the amplifier, the o/p relay will switch to its other state for about 0.5 seconds. The o/p relay has two potential free NO/NC contacts that are wired to the terminal strip. These contacts can be used to stop the conveyor belt or to activate an injection device.
Check the voltage between m3(signal point ) & m1(graund) and it Check the voltage between m2 & m1 it should be between 5 -7 v dc Check the voltage between m4 & m1 it should be between 14 v dcv Check the voltage between m5 & m1 it should be between 5 v dc v Put the probe at sensitivity port and set 0.0 volt by use of r 32 pot.
would be 6.66 v dc by pot r 44. otherwise changed with pot r8. dc otherwise changed with pot r12. dcv dc otherwise changed with pot r13.
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smock twice, sensitivity to opacity level is increased and alignment of the modules is made easier. The measurement value is compared to a reference value previously determined with no smoke in the light path. The resulting ratio is a transmittance value for the measurement path. This ratio can then be converted to units of optical density and stack exit opacity and dust concentration.
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During the stack mode, the light beam passes through the beam solitter. The beam travels through the objective lens,LCW2 (center segment), an air window, across the stack, into a retroreflector. The retroreflector, by means of a corner tube, reflects the light through the srack, air window, LCW2 and objective lens. The beam strikes the beam splitter and is reflected in the detector .The detector (a photo diode) converts the light to a voltage that can be processed. The desired spectro response is achieved by a narrow green band filter on the detector.
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FIG. 9.1
CHAPTER 10
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VIBRATION MONITOR
VIBROCONTROL 1000 Vibration monitoring system is used to monitor and measure machines vibrations. The system measures the rms value of vibration velocity in accordance .
10.2 SPECIFICATIONS
1. measuring principle: 2. direction of measurmemt : Electrodynamoic sensor horizontal +/- 5 deegree verticle +/- 20 degree verticle +/- 105 degree
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CHAPTER 11
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GAS ANALYSER
11.1 PRINCIPLE
O2 MEASUREMENT - PARAMAGNETIC TYPE CO MEASUREMENT - INFRARED TYPE DUAL CHANNEL SAMPLE (1) SAMPLE (1) SAMPLE (1) SAMPLE EXHAUST CLEAN SOV 2-5 SOV 2-4 SOV 2-2 &2-1 ON ON ON
11.1.1 DEFINITION
In order to obtain accurate results the analyser must be callibrate d with a gas of accurately known concentration of zero callibration gas as given or specified on the Test Certificate of Gas Cylinder supplier. ZERO GAS : : O2 Bal. Nitrogen Channel 1: Oxygen Channel 2: Carbon Mono Oxide 100%Nitrogen CO
CALLIBRATION GAS
11.2 PROCEDURE
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A) ADJUSTMENT OF ELECTRICAL ZERO, USING ZERO GAS -Open gas cylinder and set pressure to < 1.5 bar by regulator. -Turn the select knob to zero gas at panel. -Set the sample flow in rotameter between 0.3 to 1 ltr ./ min.
SELECT CHANNEL NO. -1 (OXYGEN ) & CALLIBRATE IT. KEY TO BE PRESS DISPLAY FUNCTION ENTER ENTER 0-1(xxxx) CODE 0 O-1(xxxx) COMMENT Channel - 1 selected i.e. Oxygen for zero Enter code 10 by pressing up & down keys Actual zero level will be displayed Wait at least the entering furnishing period. If the actual & nominal values-levels agree, next function can be selected using function keys. If the two values disagrees Enter 0-1(0.00) this automatically adjusts zero for o2. press function keys to finish the adjustment mode.
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KEY TO BE PRESS DISPLAY FUNCTION ENTER ENTER ENTER 0-1 (xxxx) S-1 (xxxx) S. -1(xxxx) s.-1
COMMENT Channel - 1 selected i.e. Oxygen for zero Enter the correct code, entered. Feed the actual concentartion - level Wait at least the flushing period. If necessary , enter the true gas set-point. if not already
CHAPTER 12 SAFETY
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Safety is utmost requirement for any plant because by taking proper measures against accident we can increase the profit of company and can save manpower from injury. Safety is totally an Egineering system. According to Bell Telephone inotto No job or service is so urgent that we cannot take time to perform our work safely Safety an attitude, a state of mind that must be sustained in work environment
12.1 ACCIDENT
Unwanted undesirable events which has potential to hit injury to a person or a loss of property 12.1.1. CAUSE OF ACCIDENT Unsafe act Unsafe condition UNSAFE ACT:
Lack of knowledge No provision of safety attachment Inattention Leakage of oil, water, steam etc Hurry Dust fumes & temperature Violating safety Condition of ladder/scrapped/stair Overconfidence Worry & hypertension Lack of experience 12.1.2. HOW TO PREVENT ACCIDENTS? Use of proper safety devices
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Toxic & inflammable materials store process to be isolated Preventive & periodically maintenance of equipment By training of employees through video, audio , lectures etc To motive the people to make active part for creating awareness in the plant Use of personal protective equipment
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During the period of TECHNICAL TRAINING I had undergone through various technical training programme as well as personality development Programmes, that help me to develop myself as a professional as well as social acme. Some of them are:
13.3 OTHERS
1. 2.
Seminar given by Siemens on various Drives, Relays, Transmitters etc. Failure analysis of rotary equipments (Mechanical Bearings).
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14.1 QUARRYING
Natural (primary) raw materials such as limestone/chalk, marl, and clay/shale are extracted from quarries which, in most cases, are located close to the cement plant. After extraction, these raw materials are crushed at the quarry site and transported to the cement plant for intermediate storage, homogenization and further preparation. Corrective materials such as bauxite, iron ore or sand may be required to adapt the chemical composition of the raw mix to the requirements of the process and product specifications. The quantities of these corrective materials are usually low compared to the huge mass flow of the main raw materials. To a limited extent, secondary (or alternative) raw materials originating from Industrial sources are used to substitute for natural raw materials and correctives. In the same way as traditional raw materials, they may be fed to the quarry crusher or more commonly directly to the cement plants raw material preparation system.
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Today, modern computerised methods are available to evaluate the raw material deposits and to optimise the long-term and short-term production schedule.
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takes place on site. Specific installations are required such as coal mills, silos and storage halls for solid fuels, tanks for liquid fuels, and the corresponding transportand feeding systems to the kilns. The thermal fuel consumption is largely dependent on the basic process design applied in the burning of clinker.
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Portland cement is produced by intergrinding cement clinker with a few percent of natural or industrial gypsum (or anhydrite) in a cement mill. Blended cements (or composite cements) contain other constituents in addition such as granulated blast-furnace slag, natural or industrial pozzolana (for example, volcanic tuffs or fly ash from thermal power plants), or inert fillers such as limestone. Mineral additions in blended cements may either be interground with clinker or ground separately and mixed with Portland cement. Grinding plants may be located remotely from the clinker production facility. The different cement types have to be stored separately in cement silos prior to bagging and dispatch.
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FIG. 14.1
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