PRESENTATION ON

ANUBHAV NEPAK

PELLETIZING OF IRON ORE

Pelletizing of iron ore produces spheres of typically 818 mm (0.310.71 in) diameter. The process combines agglomeration and thermal treatment to convert the raw ore into pellets with characteristics appropriate for use in a blast furnace. Iron ore pellets are not pressure formed. The raw materials are rolled into a ball, then fired in a kiln to sinter the particles into a hard ball. The reason iron ore pellets are preferred to iron ore powder is air flow in blast furnaces, if the iron ore was powder than CO would not be able to pass up through the layers in a blast furnace.

PREPARATION OF RAW MATERIAL

Additional materials are added to the iron ore (pellet feed) to meet the requirements of the final pellets.

This is done by placing the mixture in the pelletizer, which can hold different types of ores and additives, and mixing to adjust the chemical composition and the metallurgic properties of the pellets.

In general, the following stages are included in this period of processing: concentration / separation, homogenization of the substance ratios, milling, classification, increasing thickness, homogenization of the pulp and filtering.

FORMATION OF RAW PELLETS

The formation of raw iron ore pellets, also known as pelletizing, has the objective of producing pellets in an appropriate band of sizes and with mechanical properties high enough to maintain its usefulness during the stresses of transference, transport, and use.

Both mechanical force and thermal processes are used to produce the correct pellet properties.

From equipment point of view there two alternatives for industrial production of iron ore pellets: drum and pelletizing disk.

THERMAL PROCESSING
In order to confer to the pellets high resistance metallurgic mechanics and appropriate characteristics, the pellets are subjected to thermal processing, which involves stages of drying, daily pay burn, burn, after-burn and cooling (in a cooling tower). The duration of each stage and the temperature that the pellets are subjected to have a strong influence on the final product quality. Processed Taconite pellets as used in the steelmaking industry.

Typical Process flow chart

GRINDING PLANT

PELLETIZING PLANT

POWER SCHEME FOR PELLET PLANT

33KV , 3 PHASE , 50 Hz , O/H LINE FROM SEML EXISTING SOURSE

BREAKER 33KV , 1250 AMP VCB

TRANSFORMER 10/12.5 MVA 33/6.6 KV DYN 11 6.6 KV SWITCH BOARD IN LBSS

6.6 KV SWITCH BOARD IN LBSS

6.6 KV 1250 AMP

PELLET PLANT CCR ROOM

6.6 KV, 1250 AMP , 40 KA FOR 3 SEC

HT MOTOR

XMER

XMER

XMER

BALL MILL

TRANSFORMER 2.5 MVA 6.6/0.415 KV

TRANSFORMER 2.5 MVA 6.6/0.415 KV

TRANSFORMER 2.5 MVA 6.6/0.415 KV

FEEDER 415 V TO DIFFERENT MOTOR AND DRIVES

EMERGENCY MCC FOR LTPD AL BUS , 2000 AMP , 415 V 3 PHASE

DG 1010 KVA

SOME ELECTRICAL COMPONENTS WHICH ARE MOSTLY USED

TERMINAL CONNECTOR

CONTACTOR
It is a spring actuated mechanism having a set of double-breaking power contacts. It also have a set of auxiliary contacts, generally 2 NO & 2NC, which are used for control wiring.

DISTRIBUTION BOX

1 Phase 4 Lines

1 Phase 8 Lines

3 Phase 12 Lines

3 Phase 24 Lines

EARTH LEAKAGE CIRCUIT BREAKER

EARTH LEAKAGE CIRCUIT BREAKER

ELCB
is used for the protection against electrical leakage in the circuit. When somebody gets an electric shock or the residual current of the circuit exceeds the fixed value, ELCB cuts off the power within the time of 0.1s automatically protecting the personal safety and preventing the equipment from the fault. ELCB also protect the circuit against over load and short-circuit.

MINI CIRCUIT BREAKER

It is used for protecting the circuit against overload and short circuit. It can be used in lighting and electric motor distribution system.

MINI CIRCUIT BREAKER

It is used to control electric energy in distribution network and is having overload and short circuit protection

RESIDUAL CURRENT CIRCUIT BREAKERS

It is used to open a circuit automatically in the case of an earth leakage fault between phase and earth and/or neutral greater than a set current generally 300mA. It is used in domestic, commercial and industrial installations.

MIRCO SWITCH

GENERAL RELAY
Suitable for DC or AC circuit switching in various automation devices, process control and communication equipments

The plug-in base of the relay is used with standard 8 and 11 pins socket

ISOLATING SWITCHES

DIRECT ON LINE STARTER

DOL magnetic starter is mainly used for controlling motors up to 7.5 HP .It also has an OVER LOAD RELAY for protecting the motor against overloading.

STAR-DELTA STARTER

STAR DELTA Starter

STAR-DELTA STARTER IS GENERALLY USED FOR CONTROLLING MOTORS ABOVE 7.5 HP AND CONSISTS OF FOLLOWINGS: 1. ONE MAIN CONTACTOR 2. ONE STAR CONTACTOR 3. ONE DELTA CONTACTOR 4. ONE ON-DELAY TIMER 5. ONE OVERLAOD RELAY 6. SET OF AUXILLARY CONTROL CONTACTS

STAR-DELTA STARTER POWER WIRING DIAGRAM

THERMAL OVERLOAD RELAY

MOTOR CONTROL CENTRE

An MCC is a large enclosure designed to house standard motor control equipment. The unique characteristic of an MCC is that the motor controls are contained in plug-in units. Ability to Plug In control components can plug in and unplug instead of having to wire each device. For example: a combination starter can be plugged into a motor control center just like you would plug in a household device such as a lamp. However, in an MCC, the user can feed much larger loads. Note that industrial motors operate on three phase power, unlike a typical household device; this is why MCC units have three power stabs plus a fourth stab to provide a means for grounding.

MOTOR CONTROL CENTRE

Advantages of MCCs
Lower Wiring and Mounting Cost Only one set of incoming power wires needs to be routed to the MCC. The MCC distributes power to all devices through its power bus network. MCC units are pre-wired. Rather than mounting each of many small enclosures to the wall, a whole MCC can be quickly mounted to the floor. Expandability Neater Appearance Reduced Downtime problem is traced to an MCC unit easily, it can be unplugged and a spare unit can be quickly plugged in. A single MCC unit can be serviced while all other units remain energized.

Standard MCC in one large enclosure

Increased Level of Safety

MCCs incorporate extra safety features, such as handle interlocks to prevent the removal of a unit when it is energized, and nonconductive barriers to protect personnel from energized bus bars.

Reduced Space Requirements Faster Delivery

MCCs are standardized which increases efficiency in production and reduces delivery time.

Supervisory control and Data acquisition system SCADA SCADA is required in PLC System for Operator to Interact with Control system Visualization of Process Graphically, Interactively Control and Monitor the Process from a Single Location Acquire Process Data for Storage, Report Generation, and analysis Transmit Process Data to MIS and Integrate the Process with MIS General facilities required in SCADA A good SCADA should have following minimum features Alarm Generation, Annunciation and Alarm Storage Process Event Logging, Event Messages Report Generation and Trending Graphical User Interface, Power full Graphical Library Dynamic Data Exchange between various Applications Open Data Base Connectivity- ODBC, OPC Compatibility API Interface , Scripting using C/VB For advanced functionalities Web Server, Web Monitoring, Messaging and GSM Communication Strong Internal Data Base for Data Storage

VFD Basics

A VFD in a block diagram.

The Purpose Of VFD

1. 2. 3. 4. 5. 6. Energy savings on most pump and fan applications. Better process control and regulation. Speeding up or slowing down a machine or process. Emergency bypass capability Protection from overload currents Safe Acceleration

VFD Basics

Sample PWM-equivalent circuit with waveforms.

VFD Basics

Advantages

Sometimes getting a little more speed out of the motor can increase the flow just enough to satisfy the demand. When there is capacity in the motor and the VFD can be programmed to do this, a new, larger motor does not have to be purchased and installed. The VFD can run 10 to 20% higher in speed and make up for lost capacity in a flow-and-demand type of system. However, many motors as built are not balanced for these speeds.

PURPOSE OF SOFTSTARTER

EVOLUTION OF INDUSTRIAL CONTROL SYSTEMS.

Traditional Relay Based Control Systems - Based on Series of wired Relays, On/off Inputs,Sensors, Starters
Relay Based systems with Microprocessor Based Controls for Process Control Custom Built Control Systems Based on Micro Processors Complete Control System with PLC/DCS based on Modular General Purpose Hardware and Custom specific Software PLCs - PROGRAMMABLE LOGIC CONTROLLERS

COMPARISON BETWEEN QUANTUM AND MIRANO. QUANTUM :

CPU: 140CPU 67160. CONTROL VOLTAGE: 110VAC I/P, 24VDC O/P. MAX I/O HANDLING CAPABILITY:DI/DO-30000, AI/AO- 1900. SCAN TIME: 10.28 K BOOLEAN INS/M SEC.(TOTATL SCAN TIME IS GOING 250 TO 300 MILI SEC.) CPU REDUNDANCY: YES. PROTOCOL SUPPORT: MODBUS, MODBUS +, USB TYPE TER PORT. WEB SERVER MODULE: YES INTERNAL MEMORY: 1 MB. EXTERNAL MEMORY: 7 MB. RIO COMMUNICATION: REDUNDANT.

MIRANO :

CPU: BMX P34 2030. CONTROL VOLTAGE: 110VAC I/P, 24VDC O/P. MAX I/O HANDLING CAPABILITY:DI/DO-1024, AI/AO- 256. SCAN TIME: 25-30 MS(APPROX.) CPU REDUNDANCY: NO. PROTOCOL SUPPORT: MODBUS TCP/IP , CANOPEN, USB TYPE TER PORT. WEB SERVER MODULE: YES INTERNAL MEMORY : 4MB.

OUR EXISTING PLC: QUANTUM AND MIRANO: Hard ware required for communication architecture.
QUANTUM CPU (140 CPU 67160) :
Communication module. (140 NOE 771 01) Two NOE or Modbus Ethernet card are there in the CPU rack. One NOE is communicating with all mirano plc. Another NOE is communicating with Vijeo Citect SCADA and the programming software.

MIRANO CPU (BMX P 34 2030) :

Communication module: (BMX NOE 0110).
One inbuilt Modbus Ethernet port and one Canopen port is there in the CPU by which mirano communicate with the Quantum and other miranos. And one BMX NOE card is in the rack for communicating with the drives , soft starters and Tesys u.

PLC Communications Fundamentals

ETHER NET ETHER NET is the widely used network for Local area connection (LAN) ie Between computers, between PLC and PC and with other devices. This method is particularly used For communication between PLC and PC D in Ind.Automation field.
1 The Advantage of Ethernet Technology is that the Data can be transmitted at High Speed(10/100MBPS) and More Volume of Data can be transmitted. Besides that here we are using MODBUS RS-485 protocol and CANOPEN Protocol.

Engineering Station

Vijeo Citect 7.01Server

Vijeo Citect 7.01Client

Vijeo Citect 7.01Client

Siemens Controller
A

Profibus Master to MB TCP

BALL MILL

Cooler & FP

GRATING

Proportioning

OGP

Emergency

RMHS- 7C Disc Pelletizer LT Feeder

RMHS -7A/B

Kiln

MIXER

HEAVY OIL

Reservoir

OUR ARCHEATECTURE

CCR control room

Quantum primary Quantum secondary

Modbus to Fiber optic converter

CCR MCC B A RIO 2 RIO 3 A B A BALL MILL MCC Fiber optic cable A B A RIO 9 DISC MCC RIO 8 RIO 4 A B RIO 7 B RIO 6 B GRATE MCC RIO 5

B
A

Modbus to Fiber optic converter

QUANTUM TO MIRANO COMMUNICATION:Ethernet or modbus Ethernet doesnt work in a distance more than 80 To 100 meters. In that case fiber optic media is used. Here for grate mirano plcs, mill feed thickener plcs and for lbss plc Fiber optic media is used. The architecture is: 1.Quantum->Ethernet switch->Ethernet to fiber optic converter->Liu ->Fiber optic cable->Liu->fiber optic to Ethernet converter-> Ethernet switch->MIRANO. (Where distance is more than 100 meters.)
2. 1.Quantum->Ethernet switch (VIA CAT 6 CABLE) ->Ethernet switch->MIRANO. (Where distance is less than 80 mtrs.)

Mirano to Drive, soft starter and TESYS U communication:.Drive soft starter and tesys u all communicate through MODBUS RS 485. But mirano supports only Modbus TCP/IP. So a converter from modbus rs 485 To Modbus tcp/ip is required for fetching data to mirano plc. Thats why etg are required. The architecture is: MIRANO->Ethernet switch->ETG or media converter->drive or soft starter or TESYS U. One ETG can read up to 8 device data.

Supervisory control and Data acquisition system SCADA Here we are using Vijeo Citect in server client architecture. Vijeo Citect server :Version: 7.0 Tag- 15,000. Server:-2 redundant server are in CCR named as server 1 and 2. If one fails secondary server pc will take over. Client:- there are 3 client computer. Two are kept in CCR room and one is kept in ball mill. All client are tagged as client-1, client-2 ,client-3. Below the communication procedure is shown.

CCR control room

Citect Server 1 (pri) Quantum primary Citect Server 2 (Sec) Citect client 1 Citect Client 2

Ethernet switch

Quantum secondary

Ball mill control room

Ethernet switch Liu Fiber optic cable Liu Citect client 3

Fiber optic converter

Fiber optic converter Mirano plc For OGP PCC Mirano plc For MFT

Te-Sys T
Input Details: L1-Local start command L2-Belt sway switch L3-Pull cord L4-Emergency switch L5-Zero speed switch For local operation ,Input L2,L3,L4 should be healthy. For remote operation,all inputs except L1 and L5 should be high and ZSS should come within 30 seconds of starting of the motor.

All the Tesys-T are communicating in canopen protocol and all the Te-Sys U and drives are communicating on modbus protocol. All the data is sending to the Quantum PLC from M340 PLC through TCP/IP protcol where Cat 5 cable is used.

SENSORS ( Field Instruments )

Sensors with transmitters are the field devices placed in the field who actually sense the parameter and send the analog signal to the control hardware. The analog signals used are Ohm (RTD), mV (Thermocouple), 4-20 mA, +/10 V, etc

WIDELY USED SENSORS ( Field Instruments )

RTD : Output in Ohms (Temperature) Thermocouples : Output in mV (Temperature) Pressure Transmitters : 4-20mA, 0-10 V .. Flow Transmitter : 4-20mA, 0-10 V .. Level Transmitter : 4-20mA, 0-10 V .. Conductivity meter : 4-20mA, 0-10 V .. Density meter : 4-20mA, 0-10 V .. pH transmitter : 4-20mA, 0-10 V .. And Many more

Introduction to Thermocouple

What is a thermocouple? A thermocouple is a sensor for measuring temperature. It consists of two dissimilar metals, joined together at one end. When the junction of the two metals is heated or cooled a voltage is produced that can be correlated back to the temperature. The thermocouple alloys are commonly available as wire.

 What are the different thermocouple types?

A thermocouple is available in different combinations of metals or calibrations. The four most common calibrations are J, K, T and E. There are high temperature calibrations R, S, C and GB. Each calibration has a different temperature range and environment, although the maximum temperature varies with the diameter of the wire used in the thermocouple. Although the thermocouple calibration dictates the temperature range, the maximum range is also limited by the diameter of the thermocouple wire. That is, a very thin thermocouple may not reach the full temperature range.

Knowledge gained in training duration

. Planning and proper utilization of resources. Maintaining daily maintenance report, log book & History Books. Conceptualizing the predictive and preventive maintenance plans. Electrical Upkeep and maintenance of plant machinery. Manpower Planning and shift arrangement. How to work individually at times as well as in a team & manage workers with right attitude & behavior.

THANK YOU