A REPORT OF INTERNSHIP TRAINING AT

BY

FARHAN AHMED
(05Es48)
M.U.E.T JAMSHORO
DG Khan Cement Company receives 6.3kV three phase supply from the
wapda at its grid station. It also has a power production plant that also
generates 6.3kV. Supply from both these sources come to the main
Substation 718. Here a panel named Bus Coupler synchronize and combines
both these supplies and given to the electrical substation of different areas.
Following hierarchy shows the power distribution.

WAPDA POWER HOUSE

Main
Substation
718

Raw Mill Kiln Inlet Kiln Outlet Cement Mill Pack House
Substation Substation Substation Substation Substation
348 428 448

Substation
Substation is the mean of collecting and then distributing power to different
motors and electrical appliances of its area. Basic construction of every
substation is similar. The 6.3kV supply from main substation comes to HT
Panel of the substation.

HT Panel
High Tension Panel or HT Panel contains a
vacuum breaker. It is also protected by
over voltage relay an under voltage relay
which trip the breaker and cut supply to
other panels. The HT Motors are given
supply from this HT Panel as they run on
6.3kV. After HT Panel supply from Bus
Bars goes to Transformer Panel. The
front view of HT Panel is shown in fig.
Transformer Panel
The transformer panels also contain vacuum breakers. The supply from HT
Panel is given to the Step Down Transformers through these breakers. The
transformers step down 6.3kV in to 690V for frequency Drives motors and
440V for LT Motors.
Main Distribution Board (M.D.B)
MDB is the distribution Panel for the LT motors. The step down transformer
supply 440V to MDB. The MDB has many safety breakers. There are one or
two MDBs in a substation that give supply to a group of motors. Supply from
MDB is given to the MCC Panels.
Motor Control Centre (M.C.C)
Motor control centre is the mean of safety, control and automation of a motor
from substation or either from CCR. MCC for every motor is separate. Every
MCC contains

• Q11 Main Circuit Breaker fixed type,

hand operated with door operated
mechanism.
• F3 Bimetal Overload Relay
• F11 Circuit Breaker
230VAC, 6.8VA
• K1 Air Break Contactor
230VAC, 2NO+2NC
• K2 Auxiliary Contactor
3NO+1NC
• K3 Auxiliary Contactor
2NO+2NC
230VAC, 6.8VA

Motor Control using PLC

Motor is fitted at the site area and it is impossible that it is continuously
monitored. PLC is the mean to observe its operation and any fault occurred
any time. Microcontroller of PLC, infact contain program that enable it to take
action and can give command to motor according to the conditions.
MCC has three inlets that are connected to the three phases Bus Bars of 440V.
Then inside it goes to main circuit breaker Q11, and then comes K1 contactor
and three phases goes to F3 Relay. From F3 these three phases connected to
the motor fitted at its location. The electrical drawing for this circuit is shown
below.
PLC Signals
MCC also has nine outlets pins for PLC connection and signals transmission.
PLC signal are basically 48Vdc or 24Vdc in newer version.
Whenever short circuit occur either in motor windings or in MCC, the main
breaker Q11 automatically trip. Its auxiliary contacts are used by PLC signal
which closes and a MCC Fault signal goes to PLC. If for suppose motor jams
and it has to draw extra current
then the bimetal overload relay
heats up and it trip the K1
contactor and Over Load signal
goes to PLC. To stop the motor
in emergency cases a lever is
present at the site near the motor
it is turn around to stop motor
manually. In such a case an
Emergency Stop indication goes
to PLC. Sometimes it is required
to start and stop motor manually
for maintenance purpose, 1st permission is taken from the CCR and then motor
is granted to be operated manually. In such cases Local Start signal goes to
PLC. By taking an overview of single line diagram it is cleared that if F11 and
Q11 is ON and there is no overload signal also motor is not stop emergently
then a Ready signal goes to PLC which indicate that every thing is OK and
motor can be start. In such case an output signal is generated by the PLC
called Command which energize the K1 contactor and motor starts running.
While running, a signal named Return goes to the PLC which is indication
that motor is running.
 PROCEDURE
RAW MATERIALS
The mill process starts from the storage yard. In storage yards lime stone
and shale are stored by stackers coming from mountains on two separate
conveyers belts. From lime stone yard Reclaimer and from shale yard Side
Scrapper, place material on a conveyer belts. These two materials first stored
in hoppers. Two hoppers for each of them. There are four following raw
materials used in cement process.
• Lime Stone
• Shale
• Iron Ore
• Silica Sand
RAW MILL FEED
Materials from hopper are put on the Dosimat (a large moving belt).
Two Dosimats are present that can weight the material placed on that. By
increasing or decreasing the speed of that belt the feed can be changed. These
two Dosimats place their material on a single conveyer belt that put it direct in
to the raw mill from the top.

RAW MILL
The Raw Mill is the mean of grinding Raw Materials in to a fine
powder. It has four big rollers that are able to freely move. The Raw Materials
from the top fall on the basement disc. This large disc is made to rotate by a
H.T slip ring induction motor having name R1M03 of following ratings.

Sr Quantity Rating
1 Voltage 6300V
2 Current 308A
3 Power 2650kW
4 RPM 993
5 Power Factor 0.82

The rollers then pressed down mechanically on the rotating disc and any
material come under the faces of these rollers is converted in to fine powder.
An ID Fan R121M01 is installed behind mill. Its main purpose is to provide
hot gases from the Kiln. These hot gases soften the hard materials and make it
easy to grind.
AIR SEPARATOR
Air Separator is a mean of collecting the powdered material from the
mill. It is present at the top of mill. The blades of the fans circulate at a high
speed and make the powder to create a cyclone. The cyclone lifts up along the
walls of mill and the blades push that material in to a duct. This duct opens at
the top of a storage silo. This silo is also called as Constant Feed Silo or
simply CF Silo.

INSTRUMENTS

The area from the storage yard to the top of the CF Silo comes under the Raw
Mill section. Many instruments are installed at different places. These
instruments perform the basic functions of measuring
• Temperature
• Pressure
• Level
• Velocity
• Flow
• Position

The following major components are installed at different locations.

• Speed Monitor
• Metal Detector
• Electromagnetic Separator
• Load Cell
• Encoder
• Pt 100
• Vibration Sensor
• Level Limit Switch
 SPEED MONITOR
The conveyer belt is made up of strong rubber. This belt is roll over at the
rolling pulleys at the starting and end of the belt. One of the rollers is made to
move using a motor. The other roller moves by belt. The speed monitor is
always installed at the opposite end of motor. It is fixed at the distance of 1 to
5cm from the moving roller. The speed monitor has an impulse monitor inside
it. The impulse frequency ‘Fc’ generated by the moving part to be monitored
is compared with the frequency ‘Fr’ present on the sensor. This ‘Fr’ can be set
by the mechanics according to the requirements.
The output switching circuit of the sensor is
Closed if Fc > Fr
Open if Fc < Fr.
The speed monitors are particularly suitable for the detection of under speed
that is when speed of the moving part ‘Fc’ falls below a threshold ‘Fr’ this
causes the output circuit to switch off.

USES
This unit provides an economic solution to
the problems of
• Detecting Slip
• Belt Breakage
• Drive Shaft Shear
• Overload

Connection with PLC

Every instrument transmits it signal to the PLC from where it is transferred to
CCR so that any fault or alarm can be observed from the control room at any
time. It is a digital instrument; it first sends its signal to a SD Box (signal
digital) fitted at the site. This box is the mean of power supply to the
instrument and receiving signal from the instrument. The connection of every
speed monitor with plc is done as follows.
PLC Panel SD Box No
Address Pos A1X7
Speed Alarm Low W1A07O1 DI 100039 A1.1109 55 DI+
+48Vdc
0Vdc
1:
Black
2: Brown
3: Blue
 METAL DETECTOR
Working Principle
In its simplest form, a metal detector consists of an oscillator producing an
alternating current that passes through a coil producing an alternating
magnetic field. If a piece of electrically conductive metal is close to the coil,
eddy currents will be induced in the metal, and this produces an alternating
magnetic field of its own. If another coil is used to measure the magnetic field
(acting as a magnetometer), the change in the magnetic field due to the
metallic object can be detected.

Alarm Response
Here in industry it is installed within the conveyer belts that carry raw
materials. Any type of metal piece must be removed before inserting this
material in to Raw Mill. Otherwise it can damage the parts of mill or cause
any defect. Whenever this coil or detector detects the metal piece an alarm
signal goes to PLC and a command instruction operates the conveyer belt
diverter, just ahead of the detector, which directs the incoming material to the
waste bin for a particular time and metal piece is removed in this way.

Electromagnetic Separator

Sometimes it happens that many of the iron pieces come along the raw
materials. It is necessary to remove them out of the material before going into
the mill. For this purpose a rolling belt of iron is installed over the belts taking
the material in the hoppers. This belt is electrically magnetized and a strong
magnetic field is produced by it. Any iron piece comes under this magnetic
field is attracted by that belt which rolls and separate them out into the bin.

LOAD CELL
Construction
Two ring strain gauges are bounded concentrically on each of upper and
lower faces of the measuring body and connected to form a wheat stone
bridge. Any change in the resistance is detected by wheat stone bridge and a
mA signal is send to PLC.

Operating Principle
The load cell is most vital link within the measuring chain of an electronic
scale. It is designed as measured value transducer. It proportionally converts
the mechanical input variable force into electrical output variable voltage. The
specially designed load cell mounts ensure correct load input to load cells.

Specifications

Nominal Characteristics 2.85mV/V

i/p Resistance 4480Ω±50Ω
For 0.33t-470t
o/p Resistance 4010Ω±0.5Ω
Ref Supply Voltage 30V

Advantages
• Freedom for maintainess
• High sensitivity
• High accuracy even at minimal loading
• High corrosion protection through use of stainless steel

Pt100 SENSOR
The resistance to the flow of electricity in metallic materials varies with
temperature. This can be used to good effect in platinum resistance detectors.
Platinum is particularly stable both electrically and mechanically and is also
stable with respect to time, producing a relatively linear change in resistance
versus temperature.

Working Principle
Because the output resistance change to temperature is relatively small, it
follows that lead lengths and resistances are therefore important features. In
general when lead lengths are short, or can be considered as an acceptable
additive content, two wire configuration is sufficient.

Resistance at 38.51 ohms

Tolerances for 100 ohms Thermometers
fundamental interval

Temperature Class A Class B 1/10 Class B

Nominal ± ohm ± °C ± °C
°C °F ± °C ± ohm ± ohm
Value

-200 -328 18.52 0.55 0.24 1.3 0.56 0.13 0.06

-100 -148 60.26 0.35 0.14 0.8 0.32 0.08 0.03

0 32 100.00 0.15 0.06 0.3 0.12 0.03 0.01

100 212 138.51 0.35 0.13 0.8 0.30 0.08 0.03

200 392 175.86 0.55 0.20 1.3 0.48 0.13 0.05

Platinum resistors are most commonly 100 ohms at 0 °C and 138.51 ohms at
100 °C. They are available in different grades according to the accuracy
required and can be supplied as duplex sensors, two independent sensors on a
single former.
LEADS
Pt100 sensors are supplied with 2, 3 or 4 wire
connections and, unless otherwise specified, will
be supplied as 3 wire type 7 x 0.2 mm Cu PTFE
insulated, with two red wires indicating one end
of the element and one white wire indicating the
other. Alternative types of wire insulation can be
supplied.
Pt 100 is used here to measure the temperature of these phase windings of HT
motors. The bearing temp is also measured using this sensor. The measured
temperature is displayed at the analog meter TEMAX installed at the site.

VIBRATION SENSOR
During grinding the raw mill faces many jerks due to some large and huge
material pieces. These vibrations doesn’t effect the mill operation unless cross
the limits. These vibrations are continuously sensed and if they reach beyond
limits the mill is tripped by vibration sensor.
Whenever a structure moves, it experiences acceleration. Measuring this
acceleration promotes an understanding of the dynamic characteristics that
govern the object's behavior. The data can be used to modify response,
enhance ruggedness, improve durability, and/or reduce noise and vibration.

Capacitive Accelometer
Accelerometers are sensing transducers that
provide an output proportional to acceleration,
vibration, and shock. Capacitive accelerometers
measure a change across a bridge circuit. Rather
than resistance, however, they measure a change
in capacitance. The sensing element consists of
two parallel plate capacitors acting in a
differential mode. They rely on a carrier
demodulator circuit or its equivalent to produce
an electrical output proportional to acceleration.
When the sensor is accelerated by vibration on a test structure, the spring mass
experiences a force proportional to the mass of the spring mass and is
governed by F = ma. Consequently it converts the changes into a voltage
signal compatible with readout instrumentation.

LEVEL LIMIT SWITCH

It is used for limit detection in silos with fine grained or powdery bulk solids.
It can be used in all bulk solids which are not adhesive and those which do not
cause builds up or bridges. It is made up of stainless steel.

Operation
Symmetrical tunning fork is excited
piezoelectrically, and then it vibrates in
air at its resonant frequency. Being
covered with bulk solid dampens the
oscillation and the electronics circuit
activates a switch, contact less. The tips
of lines are especially sensitive while
base of the fork is insensitive.
 PROCEDURE
The fine powdered of four raw materials is stored in the CF Silo. There is an
iron bin under the base of the Silo. The gate below the CF Silo is opened for
particular time and the bin is filled up with material. The load cells below the
bin continuously weighing the bin weight. The opening of bin leads to the
conveyor belts that end up to the bucket elevator.
Kiln Feed
The kiln feed is measured by the principle of Loss of Weight (LOW). The
time of gate opening of bin is measured and total loss in the weight of bin is
calculated by load cells. e.g. If gate is opened for 10 min and total loss in the
weight is 10 tons, then the kiln feed is 60 tons/hr.
Pre Heater
The bucket elevator carries material and put that in to the top of pre heater
cyclon. Pre heater are the group of cyclones arranged in zig zag manners. The
material is fed from the top and hot gases from the tertiary Air Duct is blown
upward. The hot air heats up the material and when it reaches to the kiln its
temperature reaches up to 900ºC. In the kiln the materials heated up to
1300ºC.
Rotary Kiln
The rotary kiln, slightly inclined, is long cylindrical heated kiln that is lined
inside with fire bricks. The fire is busted from the coal gun present at the inlet
or outlet side. The material is melted and all the ingredients are mixed
chemically. The kiln is rotated
with the help of a Frequency
Drive Motor of following
ratings. This rotation enables
fluid to flow forward. Using
Frequency Drive the speed of
the motor and hence kiln speed
can be changed.

Sr Quantity Ratings
1 Voltage 690V
2 Current 790A
3 Power 780kW
4 RPM 993 r/m
5 Power Factor 0.85
Cooler
The melted material after the kiln enters in to the cooling section. It has large
blower fans that are fitted after some distance on both sides. After cooled
down we get the hard black solid named Clinker. The Clinker is then taken
on the screw conveyer to the hammer crusher which breaks large pieces of
clinker in to small granules. These granules are then taken to the clinker yard
on the conveyer belts.
Cement Mill
Clinker is then put in to the vertical cement mill along with gypsum. There are
three section of cement mill which has rolling balls. 1st section has larger
balls, 2nd has medium balls and 3rd one has even smaller ball that completely
crushes the clinker in to fine powder that is we called cement.

INSTRUMENTS

The area from the CF Silo to the clinker yard comes under the Kiln Section.
Many measuring instruments are installed and fitted in this portion. The major
of them are,
• Gas Analyzer
• Thermocouple
• Kiln Longitude Pos Monitor
• Kiln Angular Pos Monitor
• Pressure Sensor
• Ultrasonic Level Instrument
• Capacitive Limit Level Switch
• Flow Monitor

GAS ANALYZER
There are two Gas Analyzer installed for kiln Section. One is at the top of the
preheater and 2nd is at the bottom before the kiln inlet. 1st one is named as top
analyzer other is called as bottom analyzer. The basic purpose to measure the
quantity of gases inside the kiln is to check that either complete and accurate
combustion of material is occurring or not.
Gas Analyzer is not a single unit. It comprises of a complete system with
following equipments.

• Gas Probe
• Pre Conditioning Unit (PCU)
• Gas Monitoring Unit (GMU)
• Water Tank
• Water Control Panel (WCP)
• Water Heat Exchanger

Gas Probe
The gas probe is 2m long made up of stainless
steel. It is continuously cooled with water
enabling it to withstand against temperature up
to 1200ºC. A dry ceramic filter is mounted in the
neck of probe outside the kiln to prevent
material extraction.
Pre Conditioning Unit (P.C.U)
From the probe the sample gas is transported to PCU through a heated PTFE
hose. PCU is stainless steel cabinet, installed close to the probe. Its main
function is to cool the sample gas to approx 5ºC and remove resulting
condensate. It also contain diaphragm pump for the sample gas, valves to
control the compressed air cleaning and purging.
Gas Monitoring Unit (G.M.U)
The gas monitoring unit contains the
actual gas analyzer and calibration
system. It also has flow monitors and
regulators. In one corner a PLC panel
is also present that take the data from
gas analyzer.
Water Tank
The water tank supply cooling water to the probe. It is maintained at a
constant temperature of 70ºC or within the range 65ºC to 98ºC.
Water Control Panel (W.C.P)
 It contains water pumps and ball valves for flow adjustment. It also has flow
indicator and a solenoid valve Y19 for emergency cooling. Y19 is normally
open which requires a voltage to hold it closed. During normal operation
pump runs and Y19 is closed. If power failure occurs then Y19 opens up and
water pressure from tank cool the probe until tank empties. Operator has about
30min to take out the probe.
Water Heat Exchanger
After leaving the probe the cooling water is re circulated to tank via the heat
exchanger. The exchanger contains a fan which starts when temperature
becomes high.
Measured Gases
The gas monitoring unit has following three gas analyzers with indicated
ranges.

Units Range Output

1. O2 Analyzer 0-25% vol 4-20mA
2. NO Analyzer 0-5% vol 4-20mA
3. CO & 0-30% vol 4-20mA
CO2 Analyzer 0-2000ppm 4-20mA

PLC Signals and Connections

Analog Signals from gas analyzer panel first reaches to the SA Box NO
W1SA01 fitted at the site. Then through multicore cable data is transferred to
the PLC Panel as shown in the figure.

O2 Concentration W1A50A1A01 AI 300001 A1.208 1 AI+

1+ +/source
1- 0/source

CO Concentration W1A50A1A02 AI 300002 A1.208 2 AI+

+/source
2+
0/source
2-
AI+
NO Concentration W1A50A1A03 AI 300003 A1.208 3
+/source
3+ 0/source
3-
AI+
CO2 Concentration W1A50A1A04 AI 100015 A1.208 15
15+ +/source
0/source
15-

THERMOCOUPLE
 The most common devices used for
sensing temperature include
thermocouples, resistance temperature
detectors (RTDs), and thermistors.
Thermocouples are the most widely used
device for sensing temperature. They are
simple and efficient, and provide a small
voltage signal proportional to the
temperature difference between two junctions in a closed thermoelectric
circuit. In its most basic configuration, one junction is held at a constant
reference temperature while the other is placed in contact with the medium to
be measured.
Working Principle
The thermocouple is frequently used as the sensing
element in a thermal sensor or switch. The principle is
that two dissimilar metals always have a contact
potential between them, and this contact potential
changes as the temperature changes. The contact
potential is not measurable for a single connection (or
junction), but when two junctions are in a circuit with
the junctions at different temperatures then a voltage of a few millivolts can
be detected. This voltage will be zero if the junctions are at the same
temperature, and will increase as the
temperature of one junction relative to the
other is changed until a peak is reached.
The output from a thermocouple is small, of
the order of millivolts for a 10°C temperature
difference, and Fig shows typical sensitivity
and useful range for a variety of the common
types. Of these, the copper/constantan type is
used mainly for the lower range of
temperatures and the platinum! rhodium type
for the higher temperatures.

Temperature W1A53N1 AI 300009 A1.1209 9 AI+

+/ Source 9+ +/source
o/ Source 9- 0/source

PRESSURE TRANSDUCER
 A pressure transducer is a transducer that converts
pressure into an analog electrical signal. Although there
are various types of pressure transducers. It can be
working either of the following two principles.
Strain Guage Pressure Sensor
One of the most common is the strain-gage base
transducer. The conversion of pressure into an electrical
signal is achieved by the physical deformation of strain
gages which are bonded into the diaphragm of the
pressure transducer and wired into a Wheatstone bridge
configuration. Pressure applied to the pressure
transducer produces a deflection of the diaphragm
which introduces strain to the gages. The strain will
produce an electrical resistance change proportional to
the pressure.
Capacitive Pressure Sensors
Capacitive Pressure Sensor computes capacitance using the boundary element
method and can be used in conjunction with Pressure Transducer to compute
the pressure-capacitance response of a capacitive pressure sensor. The benefits
of Pressure transducer are that it doesn’t require meshing the gap between the
diaphragms and sensing electrode(s) and that it fully accounts for electrostatic
fringing fields. The latter may be important if the sensing electrode has
perforations, as is often the case. As in other cases, Capacitive Pressure
Sensor is first used to compute the pressure-displacement relationship of the
sensor and then Pressure transducer is used to determine the pressure-
capacitance response.
Electrical Output of Pressure Transducer
Pressure transducers are generally available with three
types of electrical output; millivolt, volt and 4-20mA.
In the Industry 4-20mA are best used.
4-20 mA Output Pressure Transducers
These types of transducers are also known as pressure
transmitters. Since a 4-20mA signal is least affected
by electrical noise and resistance in the signal wires,
these transducers are best used when the signal must be
transmitted long distances. It is common to use these
transducers in applications where the lead wire must be
1000 feet or more.

ULTRASONIC LEVEL INSTRUMENT

It comprises of two portions one is sensor and other is
transmitter. It is installed at the top of the silos and hoppers. It is
used to the measure the level of powder, granules of solids and
also level of liquids. It basically uses ultrasonic waves for
measurement.
Working Principle

The sensor uses ultrasonic measuring principle. A

sensor mounted above the product directs ultrasonic
pulse through air towards product surface with
partially or fully reflects the pulse back to the sensor.
The echo is detected by the same sensor now acting as
a directional microphone and converted into electrical
signal.
Measurement
The time between transmission and reception of the pulse called run time is
directly proportional to the distance between the sensor and the product
surface. The distance ‘D’ is determined from velocity of sound ‘c’ and the run
time t by the formula
D = c* t/2

Capacitive Level Limit Switch

It is used for limit detection in silos containing bulk solids (for max and min).
Used according to the application if for max level it energizes the output relay
on activation and the belt or motor filling that silo can be turned off.
Working Principle
The rope probe with weight and silo wall form the two
electrodes of capacitors with a high frequency voltage
between them. The limit value is based on the principle of
a discharge circuit. As long as probe is in the air with
dielectric constant of Єr = 1 then the discharge time
constant is
Τ = R*CA
Where R is the circuit resistance and CA is the capacitance of capacitor formed
by the probe and silo wall. If a bulk material with higher dielectric constant
moves into the electrical field between the probe and silo wall, then the
capacitance increase and with it the time constant. The change in the time
constant is evaluated output relay is operated according to switching mode.

FLOW MONITOR
Electronic flow monitor is designed to monitor the flow of both liquid and
gases. The system is made up of monitoring head MK301. A cable with cable
connector and control unit SW 301.Calorimeter flow monitoring avoids the
need for moving parts in the flow stream.
The desired switch points either min or max may be set by means of
preselector. A linear analog output (4 – 20mA) proportional to flow rate is
provided and any difference with reference will operate the output circuit and
flow is controlled.
The correct flow status is clearly indicated by lighted green LED. Red Led
indicates no flow and opening of relay contact.
Range
Liquid min 10mm/s
max 5m/s
Gases min 2m/s
max 100m/s