MAHARANA PRATAP UNIVERSITY OF AGRICULTURE & TECHNOLOGY COLLEGE OF TECHNOLOGY AND ENGINEERING, UDAIPUR DEPARTMENT OF ELECTRONICS AND COMMUNICATION

ENGINEERING A INDUSTRIAL TRAINING REPORT TAKEN AT: MODERN INSULATOR LTD. ( SIROHI)

Submitted To: DR. NAVNEET AGRAWAL

PLACEMENT & TRAINING INCHARGE ELECTRONICS AND COMMUNICATION ENGINEERING CTAE, UDAIPUR (RAJ.)

Submitted by: BHANWAR LAL

B.E. IV year

A REPORT ON
INDUSTRIAL TRAINING AT MODERN INSULATOR LTD. (ABUROAD SIROHI)

SUBMITTED BY BHANWAR LAL B. E (4th year) ELECTRONICS AND COMMUNICATION COLLEGE OF TECH.AND ENGINEERING UDAIPUR 2012-2013

Acknowledgement
An organization always follows the universal principle of Having its own color. It owes to show its uniqueness by having its own identity and individuality. These entities have their own set of norms and procedures which they practices in their daily professional life. Modern insulator ltd. is a great example of such unique organizations as it owns a very prestigious and successful reputation in this competing scenario. My training with Modern insulator ltd. is truly a great reward for my career as it provided me lots of benefits and knowledge and also acquainted me with skills and practices that will enhance my potential to work efficiently in any such organization in future. For such a great response and help I would really like to offer my sincere thanks and gratitude to all the people involved in the process starting with our Head Mr. R.K. SHARMA (factory manager) and all the department and functional heads and I would also like to thank Mr. Manish kumawat and all other employees of process and instrumentation department for giving their valuable guidance and being a great support during my complete training work. It would also be a great honor and overwhelming for me to work for such a great organization in future and learn more.

Table of content :
Company profile Award and certification Global exposure Introduction to insulator : Definition Types of insulator 1. Hollow insulator 2. Solid core post insulator: 3. Longrod insulator: 4. Railway insulator : Manufacturing of insulator I) storage Ii) slip house Iii) jiggering unit Iv) finishing unit: V) glazing unit Vi) firing unit: Vi) firing unit: Viii) testing section Ix) dispatch section: Testing of insulators 1. Routine test 2. Acceptance test 3. Type test. Distributed control system Instrumentation

a.) Safety instrument

1. Belt sway switch : 2. Pull cord switch: 3. Zero speed switch: 3. Zero speed switch: B.) Measuring instrument: Level sensor For temperature 1.rtd (resistance temperature detector) 2. Thermocouple For weight : 1. Load cell : 2. Weigh feeder Shell scanner For pressure : 1. Pressure transmitter 2. Differential pressure transmitter 4

For vibration : 1. Vibration sensor 2. Vibration monitoring system For speed : 1. Tacho-generator 2. Tachometer : Solenoid valve : Quality checking instrument X-ray analyzer Drive 1. Dc drives : 2. Ac drives (vfd) Conclusion

COMPANY PROFILE
Modern Insulators is pioneer in High Voltage Porcelain Insulators in India. The Company is managed by a very dynamic and professional entrepreneur, Mr.Sachin Ranka and his dedicated team. Modern Insulators Limited (MIL) was set up in 1985 in technical collaboration with Siemens AG, Germany, for manufacture of High Voltage Porcelain Insulators. MIL, now is one of the largest exporters in the country & has been honoured with various Export Awards from Ministry of Commerce. MIL manufactures Porcelain Insulators in the range of 33KV to 1200 KV. The main product categories are:

Solidcore post insulators for Disconnectors and substation requirements. Hollow insulators for SF6 Circuit Breakers, Lightning arrestors and Instruments transformers. Longrod insulators for overhead Transmission lines. Railway insulators. Linepost insulators for Distributions

AWARDS AND CERTIFICATION

ISO CERTIFICATION:-

1. ISO 9001:2008 2. ISO 14001:2004

AWARDS 1. TOP EXPORT AWARD 2004-05, 2. TOP EXPORT AWARD 2005-06 3. TOP EXPORT AWARD 2006-07, 4. TOP EXPORT AWARD 2007-08,

DEFINITION

An electrical insulator is a material whose internal electric charges do not flow freely, and which therefore does not conduct an electric current, under the influence of an electric field. A perfect insulator does not exist, but some materials such as glass, paper and Teflon, which have high resistivity, are very good electrical insulators Types of insulator 1. 2. 3. 4. Hollow insulator Solid core post insulator Longrod insulator Railway insulator

Hollow insulator : Modern insulator mainly started manufacturing of high strength alumina porcelain insulator required for high voltage and extra high voltage equipment. MIL manufactures wide range of high voltage of apparatus alumina porcelain bushing for use in high voltage SF6 circuit breakers, current and potential transformer lighting arresters. MIL enjoy a major share for hollow porcelain bushing SF6 circuit breakers and preferred supplies for switchgear manufactures like ABB, Areva, BHEL, Crompton Greaves, Siemens and other manufactures. MIL not only caters to above but also is preferred supplies for overseas division of ABB, Areva, Siemens and others. MIL has excellent facilities for testing hollow insulator for various application. Metal part of aluminium, malleable cast iron or SG iron used for assembly are supplied by reputed venders as per customer specification. Cementing method is adopted as per guideline given by Siemens who were the collaborator of modern insulators. Cement used is of special quality Portland cement collected from silos and stored in containers without scope of contamination and put into use within specified period. The cement undergoes test before it is cleared for assembly and same of the established practice of applying bitumen inside surface of the metal part and outside of porcelain sanded portion, providing cork , adoption of proper curing are all meticulously followed in supply of assembled insulators. The bushing are assembled in preciscon jigs ensuring parallelism and concentricity. Apparatus porcelain bushing Manufacturing capability Option 1(for type A B C D E) 1. Bore min. mm (d)_ _ _ _ _ _ _ _ _ _ _ 165 Bore max. mm(d)_ _ _ _ _ _ _ _ _ _ _ 400 9

2. Height max. mm(H)_ _ _ _ _ _ _ _ __ 2500 3. O. D. max. mm (D)_ _ _ _ _ _ _ _ _ _ _650 Option 2(for type A B C D E) 1. Bore min. mm(d)_ _ _ _ _ _ _ _ _ _ _ _ 115 Bore max. mm(d) _ _ _ _ _ _ _ _ _ _ __245 2. Height max. mm(H)_ _ _ _ _ _ _ _ _ _ 2150 3. O.D. max. mm(D)_ _ _ _ _ _ _ _ _ _ _ _425 Option 3(for type A B C D E) 1. Bore min. mm(d)_ _ _ _ _ _ _ _ _ _ _ _ _50 Bore max. mm(d)_ _ _ _ _ _ _ _ _ _ _ _200 2. Height max. mm(H) _ _ _ _ _ _ _ _ _ _1700 3. O.D. max mm(D)_ _ _ _ _ _ _ _ _ _ _ _ 400

Solid core post insulator: MIL has been in the field of manufacture of solid-core station post insulator made of alumina porcelain for more than a decade. Millions of insulator have been supplied by MIL to various projects in India and abroad for use in disconnecting switches and sub-station and insulator supplied have been giving satisfactory performance. The customer list includes the switchgear manufactures like ABB, Areva, BHEL, Crompton Greaves, Siemens and others. Alumina porcelain as per German Technology: The ceramic insulating body of solid-core station post insulators is made of high strength alumina porcelain in accordance with KER 110.2as per DIN/IEC standard. Porcelain in made of finest grade electrical porcelain and has high and consistent mechanical properties dense structure and zero moisture absorption. Design feature of MIL station posts: the shed profile with its spacing and shed overhang ensures user effective performance under all conditions. While designing resultant load from combined load should be considered for evaluating loading condition. CL + TL + RL -- 1 4.RC 5.TR 5.RR WhereCL-Cantilever load TL -Tension load RL-Torsion rating CR-Cantilever rating TR-Tension rating RR- Torsion rating 10

When the formula given in ANSI standard C.37.32.1972 is used to determine the short circuit forces on the post insulator, the maximum recommended working load can be extended to 100% of rated values. however it is acknowledged that this extension is allowed only because the force calculated are generally accepted to be at least 2.5times greater than the actual developed system forces. Different sizes for mechanical strength and creepage distances. Station post insulator for almost all the application are available for voltage range from 33KV to 800KV and maximum mechanical properties. The value of the creepage distance obtained must be increased by a factor KD where DM is the average diameter. Regular shed DM = De + Di
2

Alternating shed DM = Del + De2 +2Di 4 300<= DM <300mm: KD =1 DM <= 500mm:KD = 1.1 DM >500mm: KD=1.2 Longrod insulator: Long rod insulator manufacture from Alumina porcelain for use in high voltage transmission lines have been in use since 1960 in European countries. The experience reveals superior performance in electrical and mechanical properties , power arc and interference voltage behavior. They are manufactures according to the wet process technology from Siemens SG, Germany , who are pioneer in the field of electro porcelain for high voltage system. Alumina porcelain insulation in comparison with silica porcelain insulation offer enhanced dielectric strength ,higher resistance to thermal shock, higher mechanical strength and resistance to ageing with improved thermal conductivity. Advantage of long rod insulator: Absolute puncture proof 1. solid core long rod insulator manufactured by MIL by 100% puncture proof type A insulator as per IEC/IS specification. 2. Excellence service reliabilitysolid core long rod insulator made of high strength alumina porcelain can withstand continuous or changing mechanical, electrical and thermal influences. Superior dielectric, mechanical and thermal of long rod insulator improve the reliability of and stability of high voltage and extra high voltage transmission. 3. Excellence pollution performanceMIL provide the most pollution free insulator. 4. Improved voltage distribution and full power protection. 5. Very low radio and TV interference. 6. Reduced mentance and replacement cost.

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Railway insulator : MIL manufactures 25 kV OHE Insulators for Indian Railways. The insulators are duly approved by Research Designs & Standards Organisation (RDSO) of Indian Railways. The categories of Insulators available are as follows (1) Stay Arm - 1050 mm/CD (2) Bracket - 1050 mm/CD (3) 9 Tonne - 1050 mm/CD (4) 25 kV Post Insulators (5) Operating rod (6) Sectioning

Manufacturing Process
The various manufacturing units at MIL are as follows:

a) For manufacturing insulators

i. Storage ii. Slip House iii. Jiggering Unit iv. Finishing Unit v. Glazing Unit vi. Firing Unit vii. Assembly Unit viii. Testing Unit ix. Dispatch Unit

MANUFACTURING OF INSULATORS I) STORAGE

The different raw materials for manufacture of insulators are stored in the identified bins. The raw materials are:1) Calcined Chaibasa clay 2) Dolomite 3) Manganese dioxide 4) Chrome ore 5) Calcite 6) Talc 7) Ellur Clay 8) Than Clay 9) Quartz for brown glaze 10) Quartz 11) Feldspar 12

12) Bikaner clay 13) Pyrophyllite 14) Felcite 15) Sericite 16) Japan ball Clay

II) SLIP HOUSE

Slip house performs the following operations: 1. Weighing Different raw materials from the storage bins are collected and weighed according to the percentage co0mposition given by the E&D and according to the ball mill capacity to be charged. Weighing should be rounded to nearest multiple of least count. Then the weighing card is attached to the lot. A sample data for preparation of suspension body slip in a 5 ton ball mill for the first charge are as follows: Quartz Feldspar Pyrophylite Bikaner clay Felcite Pebbles 1053 kg 603 kg 653 kg 387 kg 201 kg 157 kg ( due to the presence of previously charged pebbles in the Ball Mill)

2. River-pebble charging: For initial charging of river pebble in the ball-mill after reling, large, medium and small pebbles are collected as per standard samples and weighed as per specification No. PPSL: 0100 R-2 and pebbles are charged as per the quantity specified. 3. Preparation of first charge Body slip: Weighed quantity of first charged raw materials are first charged into ball-mill by attaching a cone to its hole from the charging hole on the platform. The pebbles are cleaned with water before charging. Then specified quantity of water is charged into the ball-mill. The ball mill is run for the specified time and initial and final meter reading , time , ball-mill number are also noted. Then a little quantity of first slip is collected for checking slip parameters. Generally charging takes 1-2 hrs and ball-mill runs 14-16 hrs. 4. Preparation of second charge body slip Weighed quantity of second charge is charged into the ball-mill with required quantity of water after preparation of first charge body slip and the ball-mill is run for specified time. After complete grinding the ball-mill is stopped and sample is collected for checking slip parameters. Then the slip is is charged into mixing tanks and is agitated continuously. 5. Blunging return slip: Scrap and water returned by the process is charged into the blunger in specified proportions to get required specific gravity of the slip. Then it is blunged to achieve homogeneous slip. 13

Then the slip is transferred to return storage tank by passing through Vibroscreen. The timely removal of foreign materials from the Vibroscreen should be ensured. 6. Preparation of cake: The filter press cloth should be free from folding and clay sticking before pressing operation and this must be ensured. The adequate power pag pressure is applied and filter press is losed. The slip from the final tank is pumped into the press using plunger pump at 10-12 kg /sq. cm pressure to getcake of specified hardness as per process specification No. PS: 0100 R-Z. Then power pag pressure is released and cake is removed. Cake hardness is checked and cake is stored in specified area in stacks. Here the sliphouse work is completed.

III) JIGGERING UNIT

The cake from the sliphouse is fed into the plungmill. Plungmill makes dough of the cake and releases it in continuous cylindrical moulds. This continuous cylinder is cut into the required length by thread cutters. In some plungmills the cutting process is automatic. Then these moulds are shaped into required shapes by automatic jiggering machines. In case of pin insulators it is done manually by cutting machines.

IV) FINISHING UNIT:

First the tools and the smoothing plates are checked. Before finishing, the article should be checked and and defective ones should be discarded. Then the article is placed on the rotating wheel and adequate layer of mass is removed without affecting die formation. Finally smoothening plate is used over entire finished portion to achieve smooth surface finish. The rotating wheel should be at rest while placing and lifting the article. Ambient humidity is maintained in the finishing area by special water sprayers in order to control specified finishing hardness of the article. Then the articles are placed on tunnel drier cars and the cars are led into temperature drying chambers. The stream pressure / waste heat is regulated and temperature of each zone of dryer is maintained as per process specification No. PPS: 0202 R-1. The racks are pushed into the drier at one end and released at the other end. Necessary corrective action is taken in case the moisture exceeds specified limits. Specifications PPS: 0202 R-1 Parameters level 1) Charging Frequency 1 hrs. 2) Tunnel Drier Temperature Zone Temperature A. 1st zone 40 7 B. 2nd zone 557 C. 3rd zone Min. 70 D. 4th zone 9211 E. 5th zone Min 65

V) GLAZING UNIT Operations carried out:

1) CMC solution preparation 14

2) Sanding glaze preparation 3) Brown glaze preparation 4) Glazing operation 5) Sanding operation 6) Stamping and loading 1) CMC SOLUTION PREPARATION: Required quantity of water is taken in a bucket and then weighed quantity of CMC powder is added slowly to water with continuous stirring. The concentration of CMC solution should be as per specification no. PPS: 0203 R-0. The solution should be free from modules. 2) SANDING GLAZE PREPARATIONS: Measured quantity of sanding glaze is mixed with CMC solution and the mix is agitated for 30 min. 3) BROWN GLAZE PREPARATION: Brown Glaze from slip house is mixed with CMC solution as per process specification no. PPS:0203 R-0 for specified concentration. The glaze is agitated for 30 min before se. 4) GLAZING OPERATION: The visually inspected articles are loaded on the conveyor belt and article is again inspected for chipping, sharp edges etc. Such defects are removed by rubbing with sharp tools and steel wool. Sufficient compressed air jet is applied to the articles for removal of dust from the surface. Glaze is applied on the g portion of the article with the help of brush of specified thickness. Then the articles are loaded on glazing machines spindle. The water spray nozzle is adjusted for proper spraying. The glaze nozzles are also adjusted in such a way that the glaze is poor on the entire surface of the article for a specified glaze thickness. The glaze article is removed from the machine spindle and is placed on auxiliary turn table. Glaze from a portion of the article is removed with the help of sponging machine. 5) SANDING OPERATION: Sanding glaze is applied on the f portion of the article with brush of suitable width and then sanding grog is poured. The article is then turned upside down and then placed on the wooden planks with sponge bedding. Then the article is placed on another hand wheel. Sanding glaze is now applied on b portion of the article along with sanding grog. Then the articles are placed on the conveyor hangers. 6) STAMPING OPERATION: Stamping solution is prepared by mixing stamping powder with glycerin as per ratio given in process specification no. PPS: 0203 R-0. The solution is stirred till no nodes are left. A clean stamp as per rating is used to stamp the glaze articles. The articles are placed on the conveyor racks after stamping. At this point the job of glazing is completed.

VI) FIRING UNIT:

The firing work is done in the kiln. It is a continuous process. When one car is entering the kiln from the entrance door, one exits out through the exit door. The kiln temperature and the cycle time is maintained as per guide lines of E&D for controlling standard and routine rod thermal expansion at 250 and 650 deg C by making suitable adjustments of kiln operation parameters. When the wagon is discharged, the articles are unloaded for visual inspection. 15

VII) ASSEMBLY SECTION

The various operations performed during assembly are:
1. APPLICATION OF BITUMINOUS PAINT

Bituminous paint and thinner are mixed in specific ratio as per specification no. PPS: 0400 R0 for applying coating on cap, pin and shell surface which come in contact with cement mortar. This paint is applied on the pin by dip method and is allowed to dry before assembly. Paint is also applied on inside and outside grog portion of the cap by using a spray gun. The coated shells and caps are allowed to dry before assembly. 2. PREPARATION OF CEMENT MORTAR: Cement and quartz are mixed in cement mixer for 5 min. then the required quantity of water is added. Then the flow value of cement mortar is checked. If it is slightly less as specified in PPS: 0400 R-0 , then water is again added and mixed for 3-5 min. to bring it to required value.Cement mortar is poured inside the cap portion as well as the shell portion. A suitable cork is placed to insert the ballpin. The pin is placed manually. The shell is assembled in the cap and is pressed manually. The shell is twisted while pressing to eliminate entrapped air. The assembly quartz is sprinkled around the pin. The insulator is lifted and placed on the precuring chamber without disturbing the alignment of the components. 4. ASSEMBLY OFINSULATORS: Specified temperature and humidity of curing chamber is ensured during initial curing. This is called temperature curing. The temperature is attained by blowing steam into chamber from the boiler house. Then the insulators are water cured for 24-36 hrs. in underground water tunnels at specified temperature. Finally the insulators are air cured for 24 hrs.

VIII) TESTING SECTION

The testing section is described in details in a later section

IX) DISPATCH SECTION:

The tested insulators are packed in seasoned mango wood crates with weather proof nature. They are then dispatched to customers according to work orders.

TESTING OF INSULATORS
Testing of insulators is of three types namely: 1. Routine test 2. Acceptance test 3. Type test. 1. ROUTINE TEST It consists of three sub tests. They are: a) Physical verification test: After manufacture, the insulators are inspected visually for cracks and any visual physical defects. The defected ones are discarded. b) Routine Mechanical test: In this test 40 to 50% of rated mechanical load is applied on the insulators. The insulators incapable of bearing this load breakdown and are immediately discarded. c) Routine electrical test: 16

The insulators are subjected to high voltage discharge (up to 80 KV) for 10 seconds followed by proper frequency voltage discharge (up to 80 KV) for 5 min. Than the insulators which are punctured re labeled with red stickers and others with green stickers. In case of faulty insulators the normal blue discharge arc is changed to yellow flame and insulator is immediately removed by stopping the machine. 2. ACCEPTANCE TEST Acceptance tests are conducted as per is-731 and iec-575. Acceptance tests are also called performance tests. These consist of 7 tests. a) Verification of standard dimensions: The dimension of insulators are verified as per IS-731. They should confirm G.T.P. of drawing. Diameter, spacing, creepage distance also measured. Then eccentricity of insulators is checked by eccentricity testing machine. It needs venire height gauge and dial gauge for its measurements. It easures pin to cap spacing with venire gauge which should be according to specification. b) Temperature cycle test(TCT) This test is conducted to check the thermal stability of insulators. The entire trolley of insulators is dipped in hot bath for 15 minutes followed by dipping in cold bath for 15 minutes. This cycle is repeated three times. The difference in temperature between hot bath and cold bath should be higher than 70 deg C. Usually the temperature of hot bath is maintained at 85-90 Deg C with the help of water heaters. The temperature of cold bath is maintained at 15-20 Deg C with the help of water chillers. c) Mechanical Performance Test (MPT): This test is conducted as per IEC-575 in thermo-mechanical chambers. In this test 60% of rated mechanical load which is tensile is applied to string of insulators. The load is 4-6 tons. The load is applied for 24 hrs. Hence it is called 24 hr mechanical performance test. This test is done by thermo mechanical performance testing machine. d) Electro Mechanical test: For electrical test 50-60% of rated voltage at power frequency is applied to the insulators. For mechanical test Universal Testing Machine (UTM) is used where 60 tonne tensile mechanical load is applied to the insulators to measure mechanical strength and breaking load of metal parts. Breaking load must be less than rated value. e) Puncture test: This test is conducted to verify or note the voltage at which puncture of insulators occur. This is done in particular tank which contains transformer oil. First the insulator is dipped in the oil and then high voltage (AC) is applied to the insulators till puncture occurs and this voltage is noted. Puncture voltage should not be less than the specified voltage. f) Porosity test: The non-porous property of insulators is checked by porosity test. For this purpose a solution of methyl spirit and a dye (1%) is prepared. Broken pieces of insulators are dropped in the solution and then pressure is applied by the compressors to the insulator loaded chamber for some hrs. Then broken samples are taken out and again broken to check porosity. Pressure in the chamber should not be less than 153 kg/sq cm.

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g) Galvanizing test: This test ensures proper coating of zinc on metal parts of insulators to avoid corrosion. It consists of 2 tests: one for mass of zinc on metal parts and other for uniformity of coating. Mass of zinc coating on the cap should not be less than 610 gm/sq-m. For this test we need hydrochloric acid. First pin or cap is weighed and then it is dipped in HCL for sometime. After reaction it is again weighed and the difference in weights give weight of zinc. Then taking standard area of zinc coating mass in gm/sq.-m is calculated. Similarly pin or cap is dipped in copper sulphate solution (of specific gravity 1.186 gm/cc at 182 Deg. C) for 1min. to check uniformity of coating. This procedure is repeated 5 times. Uniform blue color indicates uniformity of coating . 3. TYPE TEST: Type test are conducted only once for not less than 2 insulators per batch. Some tests are conducted for both the insulators and some tests are conducted only once. All these tests should be conducted at specified atmospheric conditions, and then they must be corrected to 16 tests including 7 acceptance tests. Some of type tests are: a) Power frequency with standard voltage test b) Dry flash over voltage test c) Wet flash over voltage test d) Pollution flash over voltage test e) Impulse flash over voltage test f) Sweeping surge test g) Steep wave front test IMPULSE VOLTAGE WITHSTANDING TEST It is a type test conducted on insulators to check impulse withstands or flash over voltage. Impulse generator gives impulse for some time and voltage is noted. Impulse may be lightening or switching. For lightening impulse rise time is equal to 1.2 micro seconds 30%. Fall time is equal to 50 microseconds 20%. For switching impulse rise time is equal to 250 microseconds. Fall time is equal to 1250 microseconds.

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DISTRIBUTED CONTROL SYSTEM

Introduction to DCS:
Distributed control system is a very crucial part of our organization. There are numerous field equipments in a plant for safety and proper control of these equipments some control scheme is required. There are number of parameters to be checked and controlled (e.g. press, temp, pos) these parameters have to be kept within certain set point for the proper function of plant and good result. In present computer era, most of the controlling part is performed through computer on microprocessor. These turn out to be most efficient. Earlier and even today for small plants one single computer is used to control the whole plant but there were some underlying drawbacks of such a centralized control method. It could not prove its efficiency for lager plants since load will grow beyond its handling capacity resulting in improper control of the plant. The biggest drawback is that if computer fails whole plant will shut down. To overcome these drawbacks DCS, distributed control system came into existence. The control is distributed. It reduces load on particular system and failure of particular node does not affect other nodes and will not lead to the shut down of entire plant. This control scheme is DCS. DCS consists of interconnected network, LCN & UCN. TDC 3000 is a data acquisition and control system that can be tailored to meet your specifications. It can be small or highly complex system with hundreds of devices. We use TATA HONEYWELLS DCS, the TDC 3000.

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System Characteristic of TDC 3000

TDC 3000 DCS architecture:

DCS consists of interconnected network, LCN & UCN. TDC 3000 is a data acquisition and control system that can be tailored to meet your specifications. It can be small or highly complex system with hundreds of devices.

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1. HPM (High Performance Manager) :

Designed to provide flexible and powerful process scanning and control capability. It uses powerful multiprocessor dedicated to perform specific tasks. It consists of HPMM & I/0 sub-system. HPMM consists of communication processor and modem, I/0 link interface processor and control processor. HPMM redundancy can be optionally provided .The communication processor is optimized to provide high performance. N/w communication handling such functions as n/w data access and peer-to-peer communication. The control processor is the HPM resource dedicated to executing regulatory, logic and sequence functions. The I/0 link interface processor is the interface to the I/0 sub-system. The I/0 sub-system consists of redundant I/0 link and the I/0 processor. These I/0 processors handle all fields I/0 for both data acquisition and control functions. The I/0 processor provides functions as engineering unit conversion and alarm limit checking independent of HPMM. All control operations are performed in HPMM, with all data acquisition being performed in I/0 process. The process engineer has complete flexibility of choice. HPMM card file options: The basic advanced process manager sub-system configuration consists of a single. High performance manager module residing in HPMM card file. The card file also accommodates upto 10 IOP cards. The redundant HPM sub-system has two configurations: An HPM sub-system in which primary & secondary HPMMs resides in the same card file with also upto 5 IOPs. The card file is designated redundant HPMM card file. The preferred redundant configuration is comprised of 2 HPMM card files with HPMM in each. This provides : A primary HPMM. A redundant HPMM 40 IOP card slots.

HPM Architecture : HPM consists of: HPMM

Redundant HPMM card files.
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 Filed termination assembly. Power system. In HPM there are 3 files and in each these are 15 modules i.e. total 45 modules , out of these first 5 in file 1 is called HPMM. The remaining 10 are IOPS. I/0 Processors used in Lakshmi Cement: High level Analog Input (HLAI) Low level Analog Multiplier (LLMUX) Analog output (AO) Digital output (DO)

High level Analog I/P: Accepts upto 16 high level inputs. The inputs are configurable as single ended on differential in relation to mater reference ground. Analog output: Provides 4-20 mA outputs to proportioning cards such as valves: Digital 0/P: Provides 16 O/P that is isolated from each other. LLMUX: The FTA accepts one set of 16 low-level inputs such as thermocouples or RTDS. The inputs are sequentially multiplexed.

623-60 Ms-Dos Loader

Data Type Unsigned Integer Signed Integer Value Range 0 TO 65535 -32768 TO 32767

620 CPM is a self container processor consisting of a logic processor, user program memory, and 16-bit user resister area and I/O status tables. Timer and counter instruction preset & accumulator values and other data are contained in data register. Each counter & timer uses two registers & each register is 16-bit wide. Each 620 CPM system status table stores processor diagnostics information that can be accessed by the MS-LOADER or by control programme. 1. Contact instructions:22

Contacts are logic inputs that correspond to field devices or internal coils and can be used to input the ON/OFF status of field devices such as: Toggle switches Proximity switches Infrared switches/sensor Flow switches Level switches Push button

2. Coil instructions:Coils are logic line terminators (output) that correspond to field devices or internal coils and can be used to control the ON/OFF status of field devices such as: Indicator lamp Control relays Solenoids Motor starters Fans Alarms

*Specification :
1. Normally open (NO) Contact : **** Symbol -I I-

Programming keystrokes: - Press F1 to select the contact logic group. Press F1 to select NO contact. Enter desired address. Characteristics:- If the input is high (1) then it remains in on (healthy) condition and if the input is low (0) then it remain in off (unhealthy) condition.

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2. Normally close (NC) Contact :

**** Symbol -I / I-

Programming keystrokes: - Press F1 to select the contact logic group. Press F2 to select NC contact. Enter desired address. Characteristics:- If the input is high (1) then it remains in off (unhealthy) condition and if the input is low (0) then it remain in on (healthy) condition.

3. Transition ON Contact : **** Symbol -I /\ I-

Programming keystrokes: - Press F1 to select the contact logic group. Press F3 to select Transition ON contact. Enter desired address. Characteristics:- If contact has transitioned from OFF to ON , it is interpreted as being TRUE. If contact has not transitioned from OFF to ON , it is interpreted as being FALSE.

4.Transition OFF Contact

**** Symbol -I \/ I-

Programming keystrokes: - Press F1 to select the contact logic group. Press F4 to select Transition OFF contact. Enter desired address
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INSTRUMENTATION
a.) SAFETY INSTRUMENT: 1. Belt Sway Switch :
To prevent the excess swaying of belt on either side switches are attached, therefore, if the belt sways to the sides the switch is tripped which in turn stops the belt. Used in belt conveyors, deep bucket conveyors, bucket elevators.

2. Pull Cord Switch:

This switch is designed for the man and machine safety and to avoid accidents occurring due to system problems. Switches are attached to the belt at equal distances (nearly 15 meter per switch) and these switches are joined by cords. If the material splits from belt the switch is triggered. Also, in case of some accident the operator can pull the cord which triggers the switch and the belt is stopped. In belt conveyors, Pull Cord switches are useful for emergency stopping of conveyors from any point by way of pulling the rope connected to the switch. Applications: Belt conveyors, Deep bucket conveyors. Wiring: 2NO+ 2NC contacts Generally NC contacts are used, one for software while other for hardware.

3. Zero Speed Switch:

ZSS is used for controlling the speed of the belt by using non contact type proximity switch. It is based on induction principle. If the speed goes below the set point the contact is changed and the drive is tripped. The belt consists of a head drum to which the motor is attached and the tail drum to which a proximity is attached. There are four plunges which rotates with motor and on contact with the proximity the pulse is generated. The pulse is detected by the detector and sent to the controller. In case if the belt does not move due to jamming or any other problem the proximity will not generate the four pulse and the belt will be stopped. Components: 1. Inductive proximity (Normally NO type- 3 wire) 2. Zero speed controllers 3. Flap mounted on roller shaft. Features: 1. ITD pot is available for initial bypassing of zero speed. 2. RPM setting pots are also available for selecting RPM for particular application.
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Application : 1. Relay output indication 2. Power supply indication. 3. Two contacts are provided separately for hardware and software application. Wiring: Terminal 1 - 110 V ac, 50 Hz 2 - neutral 3 - NC 4-C 5 - NO 6 - NC 7-C 8 - NO 9 - For proximity 10 - For proximity 11 - For proximity

4. Boot Level Switch : These are the switches attached at the bottom of the
buckets of the bucket elevator. These are used for checking the level of the bucket, if the level extends switch will be tripped and thus the bucket elevators will be stopped.

b.) MEASURING INSTRUMENT: LEVEL SENSOR 1.NLG (Nucleonic Level Gauge) :

The level detection by nucleonic method is called Nucleonic Level Gauge is based on the principle of radiation absorption and attenuation by any material. Gamma Rays, the most commonly used radiation for industrial measurement. These photons can be penetrate through matter. This penetration depth depends upon the density of the material. Pentex Nucleonic Level Gauging System comprises three types of units: 1) Radiation Source Gamma Holder 2) Radiation Detector Gamma Detector 3) Monitor & Alarm Unit
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The source is also named as co 60. The detector is called GM Tube. We also used a water jacket to protect the GM Tube from heat. The source & detector are mounted opposite each other cyclone at appropriate level. Detector is connected through a 2-core cable with the controller. Detector receives the radiation from the source & sends out electrical signal equivalent to the intensity of radiation. The controller measures, indicates, comprises against a set threshold level and generates a alarm signal. The 2 core cable carries three types of signals such as a) Power for the detector from controller, b) Gamma radiation current pulses from detector to controller, c) Temperature alarm signal from detector to controller. In the controller, there are 5 LED such as: a) Alarm (System) : One red LED illuminates when any system fault is detected. The system fault is detected due to any of the following faults: I) GM tube failure II) Detector failure III) Short of open on the detector cable b) Alarm (Temp.) : This LED glows when a high frequency signal signifies excessive build up of temperature is received from the detector. c) Alarm (Level) : A red LED illuminates when material level crosses the limit level into the alarm zone. d) Mode : One red LED glows when the system is in CAL mode. e) Overflow : This LED illuminates when the gamma count exceeds 99 counts. Supply : For controller 110v Ac For detector 12v DC

For Temperature :
1.RTD (Resistance Temperature Detector) : It is an instrument used for measuring the temperature .RTD is used to measure the temperature for lower range. It is a PTC device (Positive temperature coefficient),that means resistance increases with increase in temperature.

Principle of RTD:

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RTDs are manufactured from metals whose resistance increases with temperature: RT = RO[1+a(t-to)] Where, Rt = Resistance at temperature t Ro= Resistance at standard temperature to = temperature coefficient

Platinum RTD are preferred due to its desirable characteristics including chemical stability, availability in pure form and electrical properties that are highly reproducible. Pt RTD range from -200oc to 850oc. The most common type is Pt-100 which has a resistance of 100 at 0oc. This RTD is used for measuring temperature in range 0 - 400oc like bearing temperatures of motors. Here we use the formula(100 R)*2.63 Where:- R is the resistance reading. RTD can be two/three/four wires RTD. The third & fourth wire helps in compensation and therefore more precise measurement. Here usually Pt-100 with 3 wires is used out of which 2 wires are short or the common wires .Thermocouples are more accurate and have wider range but RTD is more economic also Pt-100 is lightweight, stable & easily calibrated.

2. Thermocouple :
A thermocouple circuit is formed when two dissimilar metals are joined at both ends and there is a difference in temperature between the two ends. This difference in temperature creates a small current and is called the Seebeck effect after Thomas Seebeck who discovered this phenomenon in 1821.
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When there is a difference in temperature between the two ends of this circuit, a small voltage is formed within the circuit. This voltage or EMF (electro motive force) is usually measured in the 1/1000th of a volt (millivolt). Most peoples body produces more voltage than that! The higher the difference in temperature, the higher the voltage. If the right pairs of materials are used, these thermocouple circuits can be used to measure temperature. The junction that is put into the process in which temperature is being measured is called the HOT JUNCTION. The other junction which is at the last point of thermocouple material and which is almost always at some kind of measuring instrument, is called the COLD JUNCTION According to Seebeck effect if a circuit is formed consisting of two dissimilar metallic conductors and if the two junctions are at different temperature. Then a thermal emf is generated which causes of the flow of current through the circuit. The emf is a parabolic function of the difference in temperature below the two junctions given by e = At+Bt2

There are many types of junctions like J & K type. In insulator industry K type which has Nickel & Nickel chromium as the two wires is used. Hot junction is kept under temperature to be measured. At cold junction mV proportional to difference in temperature is generated. K type has a range of 0-12000C. This MV is measured or detected as it is by LLMUX or converted into mA through transmitter and then detected. APPLICATION: 1. Cyclone temperatures 2. Kiln inlet temperatures 3. Cooler temperature

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For Weight : Load cell :

Measurement of weights 1. Strain gauge type 2. diaphragm type 3. hydraulic type 4. spool type 5. Ring type. 6. Rotating packing machine. Strain gauge: (electric load cell) Principle: It gives output in electrical resistances which at all times is proportional to the weight being supposed by the cell. The cell depends upon a dimensional change of this member to produce a proportional change in the strain gauge which is connected into a Wheatstone bridge circuit where change in its resistance is accurately measured by an indicating instrument. These are excellent force measuring device. The device is calibrated against strain gauge output.

Weigh Feeder :
A weigh feeder is designed to continuously weigh the material amount transported on a conveyor belt. Belt load and speed are Continuously measured and multiplied with one another .The result is feed rate I = QxVx3600 Where I= Actual federate (TPH) Q=Belt load (kg/m) V=belt speed (m/sec) Load cells are attached to the belt, which weigh the weight of material per meter in kg/gm or tons/hr. By using tacho generator the speed of the belt is measured in m/s considering both the factors we get the weight measured in kg/s on T/H

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of the material on the belt. Used to measure and control the feed in the VRM and Cement mills.

Advantages:1. 2. 3. 4. 5.
6.

It replaces many analog panels. It simplifies tare weight calibration. It eliminates periodic check up. Stable performance. Indicates speed, weight, through put in desired engineering unit. Alarms can be easily performed.

Shell Scanner :
Shell Scanner is also a type of pyrometer. It is used here for measuring the temperature of the shell of the kiln. It is also a type of infrared pyrometer. It emits radiation such that it covers the complete shell as shown in the figure and then measures it temperature.

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For Pressure :
1. Pressure Transmitter used for measuring the pressure as well as draft. 2. Differential Pressure Transmitter used for measuring the difference
in two pressures.

Principle:
In pressure transmitter, by using diaphragm pressure or draft (- ve press) is measured. One of the diaphragms is fixed and pressure is applied to the other diaphragm. The reduction or increase in value of capacitance depending of application of pressure or suction respectively is measured. In differential pressure transmitter measurement is made by the difference in pressure causing the movement of both the diaphragm. Features: 2 wire system Input: 24 V DC Output: 4-20 mA DC Destination: HPM High Level Analog Input Application: 1) Cyclone draft 2) Inlet draft 3) Outlet draft 4) Bag house DP

For Vibration :
1. Vibration Sensor : In capacitive type one of the capacitive plates is kept
on the vibrating surface the movement of the plate causes a change in capacitance.
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Similarly in case of LVDT the core of LVDT moves due to vibration and the secondary of LVDT gives an ac output voltage. Used to measure the vibration of the VRM and fan vibration etc.

2. Vibration Monitoring System : Principle Of Operation:

Electro-dynamic vibration sensors convert mechanical vibration into an analogue electrical signal. The output voltage supplied by the sensor is proportional to the vibration velocity. The a.c. signal supplied by the sensor is amplified, rectified and adapted to the measuring span in the measuring amplifier. At the output of these circuit a d.c. voltage signal of 0 to 10v or a d.c. signal of 4 to 20 mA is available, which can be applied to various instruments such as indicating instruments or alarm signaling devices. In addition, the measuring amplifier enables 2 alarm limits to be set. A power relay is provided for each of the alarm limits, the throw-over contacts of which can be used to trip an alarm or to shut down the machine concerned. Vibration monitoring system helps to protect the machine through immediate detection. It monitors the absolute bearing vibration using velocity transducers which represents a reliable criterion for the vibratory behavior of a machine with ball or roller bearings. It minimizes the maintenance cost by recognize functional irregularity of the machine before damage.

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For Speed :
1. Tachogenerator :
Principle : In this the armature of the tachometer is connected to the machine whose speed is to be measured. When armature revolves in the field of permanent magnet emf proportional to the speed is generated. This can be measured directly or after suitable conversions to find the speed of the machine. In case of ac tachometers the permanent magnet is rotating type and emf is generated in the stator coil. Used to measure the speed of the fans, weigh feeders etc.

2. Tachometer :
Principle : Speed is usually sensed using tachometer coupled to the motor shaft. A tachometer is an AC or DC generator with a high order of linearity between its speed and output voltage. A DC tachogenerator is built with a permanent magnetic field. Typical voltage output is 10 per 1000 rpm. Classification : DC Tachometer- It consists of a small dc generator whose field is generated by permanent magnets and the armature is directly connected to the shaft whose rotational speed is to be measured. The output voltage of the tachometer is directly proportional to speed at which its armature is rotated. The generated E.M.F. is given by
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e.m.f= speed x flux (constant) AC Tachometer: This device is most commonly used for the measurement of speed of turbosets.It comprises of a stator coil with multiple pole pieces. A permanent magnet is installed in the shaft whose speed is to be measured. As the magnet on the shaft rotates, it induces voltage in stator coil every time it posses the pole pieces. The induced voltage is measured by a permanent magnet moving coil device which is calibrated in terms of speed.

Solenoid Valve :
It is used to change the direction of the diverter. By using solenoid valve air is sent in through one of the two pneumatic inlet ports which cause the movement of piston in cylinder this causes the movement of diverter. Solenoid valve has a plunger by the movement of which the inlet and outlet port open and close and piston of diverter is changed.

QUALITY CHECKING INSTRUMENT X-Ray Analyzer

To check the quality of production (final material) X-RAY machine is used. Following process is involved in the X-RAY analysis of material. Grinding Formation of tablets X-RAY analysis Firstly the material is grinded in the grinding machine. Then the tablets of grinded materials are formed by pressure vibration machine. Then these tablets are numbered and put into the X-RAY machine. In the XRAY machine X-RAYS are radiated from the tablets formed by material .Then the elements present in the tablets absorb the radiation according to their wavelengths and the percentage of material present in sample is displayed on the computer. Applications: It is used for analysis of final product. It is used to check quality of product.
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 Advantages:-y By X-RAY analyzer quality of product can be maintained. By X-RAY analysis the quantity of product mixed in product can be measured.

DRIVE
An electric motor is the source of motive power. An energy transmitting device delivers power from electric motor to the driven machine; it usually consists of shaft, belt chain, rope etc. the electric drive, consisting of electric motor, its power controller and energy transmitting shaft. The electric drives controlled through power electronics converters. The electric drives are mainly two types: DC drive AC drive

4. DC Drives :
DC motors are used in adjustable speed drives and position control applications. Their speeds below base speed can be controlled by armature voltage control. Speeds above base speed are obtained by field flux control. As speed control methods for dc motors are simpler and less expensive than those for ac motors, dc motors are preferred where wide speed control range is required. Phase controlled converters provide an adjustable dc output voltage from a fixed ac input voltage. DC choppers also provide dc output voltage from a fixed dc voltage. The use of phase controlled rectifiers and dc choppers for the speed control of dc motors have revolutionized the modern industrial controlled systems. The dc motors used in conjunction with power electronic converters are dc separately excited or dc series motors. Single phase dc motors Three phase dc motors Chopper drives.
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Separately excited: The speed can be controlled by varying (1) armature voltage control (2)field flux Base speed is defined as the speed at which motor runs under rated armature voltage, field current and rated armature current. Speeds below base speed are obtained by armature voltage control. During this control, armature current and field flux are kept constant so as to meet the torque demand. So the armature voltage control method is known as constant torque drive method because motor torque remains almost constant. T= constant Seed above base speed are obtained by varying the field current or field flux and by keeping armature voltage and armature current constant at their rated values. As flux decreases, speed increases so that motor e. m.f. remains almost constant. Field flux control also known as constant power method. P= EI Where P= power E = back emf I = armature current

5. AC Drives (VFD) : . 105

Adjustable frequency drives and most other AC drives that are available today are Pulse Width Modulated (PWM) drives of PWM drives. The rectifier converts input line power, which has nominally fixed voltage and frequency, to fixed voltage dc power. A filter then reduces the ripple voltage resulting from the rectification of the ac line. The inverter changes the fixed voltage dc power to ac output power of an adjustable voltage and frequency. The output waveform consists of a series of rectangular voltage pulses with a fixed height and adjustable width. Adjusting the overall pattern of positive vs. negative pulses establishes the output frequency. The width of the individual pulses is varied so that the effective voltage is regulated in proportion to the frequency. Proper motor performance requires an constant ratio of output voltage to output frequency (volts per hertz or V/Hz.
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CONCLUSION
To do training in such an esteemed organization like Modern insulator ltd has been a phenomenal learning experience for me. It was a joy ride for me in the field of instrumentation, and now on completion of training I have gained a very good knowledge in the field of instrumentation. The instrumentation department in the company is well equipped with the latest technology. All the working of various departments of the company is completely computerized. I have studied about the various instruments which play a very important role in plant security and measuring instruments. So this is all about the learnings at Modern insulator ltd within one month. I am thankful to all those people at Modern insulator ltd who directly or indirectly helped me in completing my one successful year at this plant. I would be really obliged if I get to serve for this company in future an advance my learning more.

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