CONTENTS

1:-

Basic introduction

2:-

Basic electrical machines of consideration

3:-

Different type of motors

4:-

Concept of induction motor

5:-

Methods of starting

6:-

Methods of speed control

7:-

Arrangement of motors at mill 2

9:-

IP protection

10:-

Electrical insulation

11:-

Transformer

12:-

DC motor

13:-

Circuit breaker

14:-

Working of circuit breaker

INTRODUCTION
* WHAT IS CEMENT ?
> A kind of Adhesive.
It is a fine pulverized material which is it self is not a binder, but develops
the binding property as a result of hydration in presence of water.
> In Civil engg. it denotes - a substance which can be used to bind together
sand, broken stone or aggregates into a solid mass.
Cement is one of the core industries, which plays a vital role in the growth
of the nation. India ranks fifth among the cement producing countries in the
world and has come a long way, since the installation of the first cement
plant at PORBANDER in 1914.
India has the requisite quantity of cement grade limestone deposits, backed
by adequate reserves of coal.
Cement Manufacturing Process
1:- MINING
The cement manufacturing process starts from the mining of limestone,
which is the main raw material of making cement.
2:- CRUSHING, STACKING & RECLAIMING OF LIMESTONE
The lime stone crusher crush the limestone to minus 80mm size & discharge
the material into a belt conveyer which takes to the Stacker via the Bulk
material analyzer. The material is stack in longitudinal stock piles. The
limestone is extracted transversely from the stock piles by Reclaimer and
conveyed to the Raw Mill for fine grinding.
3:- CRUSHING, STACKING & RECLAIMING OF COAL
The process of making cement clinker requires heat. Coal is used as the fuel
for providing heat. Raw coal received from the collieries is stored in a coal
yard. Raw coal is crushed in a crusher. Crushed coal discharge from the coal
crusher is stored in longitudinal stock piles from where it is reclaimed by

reclaimer & taken to Coal Mill for fine grinding.

4:- RAW MILL GRINDING & HOMOGENISATION
Reclaimed limestone along with some laterite stored in there respective
hoppers is fed to the Raw Mill for fine grinding. The hot gases from the
clinker section are used in the Raw Mill for drying and transport of the
ground raw meal to the Electro Static Precipitator{ESP} where it is collected
& then stored and homogenized in concrete Silo.
5:- CLINKERISATION
Raw meal extracted from Silo now called Kiln feed is fed to preheated for
pyroprocessing. Cement clinker is made by Pyroprocessing of kiln feed in
Preheater and the rotary kiln.
6:- COOLING
Hot clinker discharged from the Kiln drops on the Cooler and gets cooled.
7:- CEMENT GRINDING & STORAGE
Clinker and Gypsum {for OPC} and also Pozzolana {for PPC} are
extracted from their respective hoppers and fed to the cement mills. These
cement mills ground the feed to a fine powder. The latter is sent to the
cement mill inlet for regrinding and the fine product is stored in concrete
silos.
8:- PACKING
Cement extracted from silos is conveyed to Automatic Electronic Packers
where it is packed in 50kg Polythene Bags and dispatched in trucks.

Fig:- CEMENT MANUFACTURING PROCESS

Packing plant view :- packer

Ash handling

BASIC ELECTRIC MACHINES OF CONSIDERATION

No doubt electricity and electrical machines are the back bone of any
productive plant, so far JAYPEE (cement division ) is concerned a number
of HT motors , generators, transformers ,circuit breaker are used for
operation of the plant.
Basically there are two working units in JAYPEE plant Rewa, one with
capacity of 25MW and other with 38.5MW. For the generation of this power
a captive producing plant is established in the plant with rating 132/6.6 KV.
This 132 KV is either generated in the plant or in faulty conditions taken
from MPEB.
Now for step down this voltage to a level of 6.6KV we use a number of
transformers, now this power is sent to the plant where secondary step down
is made from 6600/440V. For this purpose only in LC4 we have three heavy
transformers, made from CGL
This 440V is sent to control panel and MCC by bus duct, from where it is
send to a number of motors and other machines. However it is more clear
from the single line diagram shown in the next page. From single line
diagram it is quite clear that a number of HT motor and thousands of other
small rated motors from 2.7KW to 2650KW are used in LC4.

VIEW FROM LC4

MOTOR :An electric motor

converts
electrical
power to mechanical
power in its rotor
(rotating part). There are several ways to supply power to the rotor. In a DC
motor, this power is supplied to the armature directly from a DC source
while, in an induction motor, this power is induced in the rotating device. An
induction motor is sometimes called a rotating transformer because the stator
(stationary part) is essentially the primary side of the transformer and the
rotor (rotating part) is the secondary side. Unlike the normal transformer
which changes the current by using time varying flux, induction motors use
rotating magnetic fields to transform the voltage. The current in the primary
side creates an electromagnetic field which interacts with the
electromagnetic field of the secondary side to produce a resultant torque,
thereby transforming the electrical energy into mechanical energy. Induction
motors are widely used, especially polyphase induction motors, which are
frequently used in industrial drives .
.CLASSFICATION OF MOTOR:MOTOR

DC

AC

SPECIAL

SYNCHRONOUS

INDUCTION

1-PHASE

3-PHASE

Squirrel cage

slip ring

IN industries mainly three phase induction motor are used due to fact that
Self starting
Less armature reaction and brush sparking because of the absence of
commutators .
Robust in construction
Economical
Easier to maintain

5000 KW induction motor at electrical lab

A 3-phase power supply provides a rotating magnetic field in an induction

motor.
The basic difference between an induction motor and a synchronous AC
motor is that in the latter a current is supplied into the rotor (usually DC)
which in turn creates a (circular uniform) magnetic field around the rotor.
The rotating magnetic field of the stator will impose an electromagnetic
torque on the still magnetic field of the rotor causing it to move (about a
shaft) and rotation of the rotor is produced. It is called synchronous because
at steady state the speed of the rotor is the same as the speed of the rotating
magnetic field in the stator.
By way of contrast, the induction motor does not have any direct supply
onto the rotor; instead, a secondary current is induced in the rotor. To
achieve this, stator windings are arranged around the rotor so that when
energized with a polyphase supply they create a rotating magnetic field
pattern which sweeps past the rotor. This changing magnetic field pattern
induces current in the rotor conductors. These currents interact with the
rotating magnetic field created by the stator and in effect cause a rotational

motion on the rotor.

However, for these currents to be induced the speed of the physical rotor
must be less than the speed of the rotating magnetic field in the stator or else
the magnetic field will not be moving relative to the rotor conductors and no
currents will be induced. If by some chance this happens, the rotor typically
slows slightly until a current is re-induced and then the rotor continues as
before. This difference between the speed of the rotor and speed of the
rotating magnetic field in the stator is called slip. It is unitless and is the ratio
between the relative speed of the magnetic field as seen by the rotor (the slip
speed) to the speed of the rotating stator field. Due to this, an induction
motor is sometimes referred to as an asynchronous machine.
AC Induction Motor
Where
n = Revolutions per minute (rpm)
f = AC power frequency (hertz)
p = Number of poles per phase (an even number)
Slip is calculated using:

Where s is the slip.

The rotor speed is:

Induction motors are most commonly built to run on single-phase or threephase power, but two-phase motors also exist. In theory, two-phase and more
than three phase induction motors are possible; many single-phase motors
having two windings and requiring a capacitor can actually be viewed as

two-phase motors, since the capacitor generates a second power phase 90

degrees from the single-phase supply and feeds it to a separate motor
winding. Single-phase power is more widely available in residential
buildings, but cannot produce a rotating field in the motor (the field merely
oscillates back and forth), so single-phase induction motors must incorporate
some kind of starting mechanism to produce a rotating field. They would,
using the simplified analogy of salient poles, have one salient pole per pole
number; a four-pole motor would have four salient poles. Three-phase
motors have three salient poles per pole number, so a four-pole motor would
have twelve salient poles. This allows the motor to produce a rotating field,
allowing the motor to start with no extra equipment and run more efficiently
than a similar single-phase motor.

THREE PHASE INDUCTION MOTOR :Three phase induction motor is of two type based on construction of rotor
3- induction motor

Squirrel

cage

slip ring

SQUIRREL CAGE INDUCTION MOTOR:-

The most common rotor is a squirrel-cage rotor. It is made up of bars of

either solid copper (most common) or aluminum that span the length of the
rotor, and those solid copper or aluminum strips can be shorted or connected
by a ring or sometimes not, i.e. the rotor can be closed or semi closed type.
The rotor bars in squirrel-cage induction motors are not straight, but have

some skew to reduce noise and harmonics.

ROTOR OF SQUIRREL CAGE MOTOR AT ELECTRICAL LAB 1

STATOR OF SQUIRREL CAGE MOTOR AT ELECTRICAL LAB

ADVANTAGE OF SQUIRREL CAGE MOTOR

Simple and rugged construction
No brushes and no slip ring
Less maintenance required
SLIP RING INDUCTION MOTOR :Slip ring rotor replaces the bars of the squirrel-cage rotor with windings that
are connected to slip rings. When these slip rings are shorted, the rotor
behaves similarly to a squirrel-cage rotor; they can also be connected to
resistors to produce a high-resistance rotor circuit, which can be beneficial in
starting

SLIP RING INDUTION MOTOR AT GRINDING MILL

Specification of motor at mill 1

Power
2100 kw
speed
992 rpm
Duty
S1
IP
23
Insulation
F

Current (st)
Current (rt)
Voltage(st)
Voltage(rt)

ADVANTAGE OF SLIP RING INDUCTION MOTOR

High starting torque
Better speed control

2323A
730A
6600 V
1780 V

 External resistance can be easily connected through brush and slip

# Why slip ring induction motor extensively not used ?

Slip ring induction motor not used extensively Due to fact that it require
a. high initial cost
b.high maintenance required
both (squirrel cage & silp ring ) work on same principal but they differ in
their rotor construction.

# why starting torque of is poor in squirrel cage motor ?

The resistance can not be varied in squirrel cage induction motor as it is
possible in slip ring motor .the fix resistance of .the squirrel cage motor is
very low .at starting moment induced voltage in rotor has same frequency As
the frequency of supply .hence the starting inductive reactance gets higher
value at stand still condition .the frequency of rotor of is same as frequency
of supply at stand still. Now the case is that the rotor induced current in spite
of having higher value lag the induced voltage at large angle so this cause
poor starting torque at stand still condition.

HYDRA
MACHINE

REPAIR
WORK ON
MOTOR

Squirrel
Cage motor

Gear box

squirrel cage motor with gear box

table showing specification of squirrel cage motor :Power
75 kw
Temperature
Speed
1485 rpm
Current (rt)
Duty
S1
Voltage (st)
Ip
55
Insulation

75 C
129 A
415 V
F

STARTING METHOD OF POLYPHASE INDUCTION MOTOR:1.SQUIRREL CAGE INDUTION MOTOR

A.FULL VOLTAGE STARTING METHOD
1. DIRECT ONLINE

panel room 1

since industry have transformers in proximity hence all the squirrel cage
motors are direct online started ,otherwise only fractional kilowatt motor are
only directly started .
B. REDUCED METHOD STARTING METHOD
1.STATOR RESISTANCE METHOD
2.AUTO TRANSFORMER METHOD
3.STAR DELTA STARTER

2. SLIP RING INDUCTION MOTOR : Addition of rotor resistance

in factory LRS ( liquid resistance starter ) is used for starting slip

ring motor.

SPEED CONTROL OF MOTOR :The synchronous rotational speed of the rotor (i.e. the theoretical unloaded
speed with no slip) is controlled by the number of pole pairs (number of
windings in the stator) and by the frequency of the supply voltage. Under
load, the speed of the induction motor varies according to size of the load.
As the load is increased, the speed of the motor decreases, increasing the
slip, which increases the field strength of the rotor to bear the extra load.
Before the development of economical semiconductor power electronics, it
was difficult to vary the frequency to the motor and induction motors were
mainly used in fixed speed applications. As an induction motor has no
brushes and is easy to control, many older DC motors are now being
replaced with induction motors and accompanying inverters in industrial
application.
v/f control
no. of stator pole
varying supplied voltage
adding rheostat
METHOD OF SPEED CONTROL IN INDUSTRIES:In industries the speed of slip ring motor is controlled using GRR .
which stand for GRID ROTOR RESISTANCE .

GRID ROTOR RESISTANCE AT MILL 1

POWER & TORQUE EQUATIONS FOR A INDUCTION MACHINE

The input power to a three-phase induction machine is given by
Output power can be found by subtracting the losses from the input power
Losses
1. Stator Copper Loss. The stator resistive losses

2. Rotor Joule Loss. The rotor resistive losses. This is often called rotor
copper loss, but since the rotor conductors are aluminum, rotor joule
loss is the more correct terminology.

3. Core Loss, or Iron Loss. The losses due to eddy current and hysteresis
losses in the laminations. This can be calculated using the resistor Rc.
Often, core losses are grouped with friction and windage and stray
loss as rotational losses.
Rotor Power
The power transferred to the rotor is called the "Airgap Power". Consider the
equivalent circuit below (the core loss resistance has been removed and core
losses grouped into rotational loss).

From the above circuit, it can be seen that the total power transfer to the
rotor is given by

To find the power converted to the mechanical system the rotor joule loss
must be subtracted from the total rotor power

From the above equations, it can be seen that power converters to the
mechanical system is a function of the air gap power and slip:
Final output power may be obtained by subtracting the rotational loss from
Pconv.
Torque
As with all rotating mechanical systems in steady state, torque can be found
from the power and mechanical speed

In the case of an induction machine, the electromagnetic torque generated by

the machine can be found using

which gives

Writing the torque in terms of the rotor current:

Finally, to find the available shaft torque after rotational losses, the output
power must be used.

ARRANGEMENT OF MOTOR AT MILL 2

Oil
circulating
pump

Shaft for grinding mill

Gear
box

Stator
Slip ring induction motor
At
MILL2 (a)

rotor

Squirrel
cage
Motor
(b)

Arrangement of motor at mil 2

as we can see from above that slip ring HT motors used to drive the grinding
mill and squirrel cage LT motor are used in grinding mill .

the speed of slip ring motor is controlled using grid rotor resistance and that of
squirrel cage using variable frequency drive.

In
factory
mainly
motor
are air

gear box 1
cooled .supply is given to HT motor which have two protection a.overload
-relay
b.short circuit - fuse

the HT motor also have a differential current transformer (CT) which let you
know that fault has occurred .
one CT at motor and other at panel any fault occur will disturb the balance
condition of current and CT will sense it and will indication will be provided.
DIFFERENT TYPE OF CURRENT TRANSFORMER :-

1.MEASURING CT
2. PROTECTION CT
3. DIFFERTIAL CT

MAINTENACE WORK SLIP RING MOTOR AND CT

Differential current
Transformer at
Motor side
(slip ring motor)

MILL 4 MOTOR NAME PLATE

SPECIFICA.
FRAME
DUTY
POWER
SPEED
VOLTAGE(ST)
VOLTAGE(RT)

IS325
IRR7716
CONTINOUS
2650 KW
992
6600 V
1760 V

TEMP RISE
INSU CLASS
CONNECTION
AMB.TEM
STATOR
ROTOR
IP

75 C
F
STAR
45 C
289 A
910 A
54

induction motor (mill 4)

Squirrel cage motors

for oil circulation
INTERNATION
PROTECTION
(IP) :Ingress Protection (IP) ratings are developed by the European Committee for
Electro Technical Standardization (NEMA IEC 60529 Degrees of Protection
Provided by Enclosures - IP Code), specifying the environmental protection
the enclosure provides.
The IP rating normally has two (or three) numbers:
1. Protection from solid objects or materials
2. Protection from liquids (water)
3. Protection against mechanical impacts (commonly omitted, the third
number is not a part of IEC 60529)
Example - IP Rating
With the IP rating IP 54, 5 describes the level of protection from solid
objects and 4 describes the level of protection from liquids.

ELECTRICAL INSULATION
Electrical insulation systems are rated by standard NEMA (National Electrical
Manufacturers Association) classifications according to maximum allowable
operating temperature.
T(oF) = [T(oC)](9/5) + 32
1) Allowable temperature rises are based upon a reference ambient temperature
of 40oC. Operation temperature is reference temperature + allowable
temperature rise + allowance for "hot spot" winding.
Example Temperature Tolerance Class F:
40 oC + 105 oC + 10 oC
= 155 oC

In general a motor should not operate with temperatures above the maximum.
Each 10 oC rise above the rating may reduce the motor lifetime by one half.
It is important to be aware that insulation classes are directly related to motor
life.
Example - a motor operating at 180oC will have an estimated life of
only 300 hours with Class A insulation
1800 hours with Class B insulation
8500 hours with Class F insulation
CLASS
A

TEMPRATURE
105 C

B
130 C
H
155 C
F
180 C
tens of thousands of hours with Class H insulation
TRANSFORMER:-

BUS DUCT
OIL TANK

BREATHER

FINS

TEMP RATURE
CLOCK

NAME
PLATE

TRANSFORMER AND ITS PART

SPECIFICATION OF TRANSFORMER

KVA
VOLTAGE(P)
VOLTAGE(S)
CURRENT(P)
CURRENT(S)

2000
6600V
433 V
175A
2666 A

PHASE(P)
CONN.
FREQUENCY
IMPEDENCE V
COOLING

3
DY11
50HZ
6.86%
ONAN

Transformer is electrical machine that :1.transfer electrical energy from one circuit to another
2.does so without changing frequency
3.by electromagnetic induction
4.it is static device because it does not have any moving part
Owing to no moving part it often called static transformer and its very
rugged machine require minimum amount of repair and maintenance
owing to lack of rotation there is no friction and windage loss.
Further other losses are low so that efficiency of transformer is very high.
THERE ARE TWO TYPE OF

TRANSFORMER

STEP DOWN

STEP UP

Step down:Transformer which input voltage is high and it step down the output
voltage . means
Input voltage > output voltage
STEP UP :Transformer in which input voltage is less than output voltage means it it
step up the input voltage.

Input voltage < output voltage

NAME PLATE OF TRANSFORMER 1

TESTING OF TRANSFORMER:1.MEGGER TEST

2.POLARISATION INDEX TEST
3.SURGE COMPRESSTION TEST
4. HIGH POT TEST
PROTECTION IN TRANSFORMER :1.BUCHHOLZ RELAY
2.EF RELAY

3.DIFFERNTIAL REALY
4.HORN GAP
5.LIGHTING ARRESTOR
6. OVER FLUX RELAY
7.OVER VOLTAGE RELAY
8.OVER CURRENT REALAY
9.TEMPRATURE REALY
DIRECT CURRENT MOTOR:DC motors have a great & very smooth speed control because speed can
be controlled by varying field voltage but since the introduction of power
drives dc motors are replaced by induction motor .
In the late 1800s, several inventors built the first working motors, which
used direct current (DC) power. After the invention of the induction motor,
alternating current (AC) machines largely replaced DC machines in most
applications. However, DC motors still have many uses.

DC motor principle:- DC motors consist of rotor-mounted windings

(armature) and stationary windings (field poles). In all DC motors, except
permanent magnet motors, current must be conducted to the armature
windings by passing current through carbon brushes that slide over a set of
copper surfaces called a commutator, which is mounted on the rotor. The
commutator bars are soldered to armature coils. The brush/commutator
combination makes a sliding switch that energizes particular portions of the
armature, based on the position of the rotor. This process creates north and
south magnetic poles on the rotor that are attracted to or repelled by north
and south poles on the stator, which are formed by passing direct current
through the field windings. It's this magnetic attraction and repulsion that
causes the rotor to rotate.

Figure 3-DC Motor Construction with Feet Integral to Endshields

What is Circuit Breaker?

Definition of circuit breaker : - Electrical circuit breaker is a switching
device which can be operated manually as well as automatically for
controlling and protection of electrical power system respectively. As the
modern power system deals with huge currents, the special attention should
be given during designing of circuit breaker to safe interruption of arc
produced during the operation of circuit breaker. This was the basic
definition of circuit breaker.
Introduction to Circuit Breaker
The modern power system deals with huge power network and huge
numbers of associated electrical equipment. During short circuit fault or any
other types of electrical fault these equipment as well as the power network

suffer a high stress of fault current in them which may damage the
equipment and networks permanently. For saving these equipment and the
power networks the fault current should be cleared from the system as
quickly as possible. Again after the fault is cleared, the system must come to
its normal working condition as soon as possible for supplying reliable
quality power to the receiving ends. In addition to that for proper controlling
of power system, different switching operations are required to be
performed. So for timely disconnecting and reconnecting different parts of
power system network for protection and control, there must be some special
type of switching devices which can be operated safely under huge current
carrying condition. During interruption of huge current, there would be large
arcing in between switching contacts, so care should be taken to quench
these arcs in circuit breaker in safe manner. The circuit breaker is the
special device which does all the required switching operations during
current carrying condition.
Working Principle of Circuit Breaker
The circuit breaker mainly consists of fixed contacts and moving contacts. In
normal "on" condition of circuit breaker, these two contacts are physically
connected to each other due mechanical pressure on the moving contacts.
There is an arrangement stored potential energy in the operating
mechanism of circuit breaker which is realized if switching signal givent
he breaker. The potential energy can be stored in the circuit breaker by
different ways like by deforming metal spring, by compressed air, or by
hydraulic pressure. But whatever the source of potential energy, it must be
released during operation. Release of potential energy makes slidingof the
moving contact at extremely fast manner. All circuit breaker have operating
coils (trippingcoils and close coil), whenever these coils are energized by
switching pulse, the plunger inside them displaced. This operating coil
plunger is typically attached to the operating mechanism ofbreaker, as a
result the mechanically stored potential energy in the breaker mechanism is
in forms of kinetic energy, which makes the moving contact to move as
these moving contacts mechanically attached through a gear lever
arrangement with the operating mechanism. After a cycle of operation of

circuit breaker the total stored energy is released and hence the potential
energy again stored in the operating mechanism of circuit breaker by means
of spring charging motor or air compressor or by any other means. Till now
we have discussed about mechanical working principle of circuit breaker.
But there are electrical characteristics of a circuit breaker which also should
be consider in this discussion of operation of circuit breaker.
Let's have a discussion on electrical principle of circuit breaker.
The circuit breaker has to carry large rated or fault power. Due to this large
power there is always
dangerously high arcing between moving contacts and fixed contact during
operation of circuit breaker. Again as we discussed earlier the arc in circuit
breaker can be quenching safely if the dielectric strength between the current
carrying contacts of circuit breaker increases rapidly during every current
zero crossing of the alternating current. The dielectric strength of the media
in between contacts can be increased in numbers of ways, like by
compressing the ionized arcing media since compressing accelerates the
deionization process of the media, bycooling the arcing media since cooling
increase the resistance of arcing path or by replacing the ionized arcing
media by fresh gasses. Hence a numbers of arc quenching processes should
be involved in operation of circuit breaker.
Types of Circuit Breaker
According different criteria there are different types of circuit breaker.
According to their arc quenching media the circuit breaker can be
divided as1. Oil circuit breaker.
2. Air circuit breaker.
3. SF6 circuit breaker.

4. Vacuum circuit breaker.