Electrical Training Report
-
Upload
kabir-rajput -
Category
Documents
-
view
223 -
download
0
Transcript of Electrical Training Report
-
7/29/2019 Electrical Training Report
1/73
TRAINING REPORT
ON
ELECTRICAL
IN PARTIAL FULFILLMENT FOR THE DEGREE
OF ELECTRICAL ENGINEERING
AT
BALLARPUR INDUSTRIES LIMITED
Unit Shree Gopal, Yamuna Nagar
Under Supervision Of: Submitted By:-
Mr. SANJEEV VOHRA Dheeraj Chopra
Submitted To:- 2208713
Electrical Dept. ELECTRICAL(3rd Year)
1
-
7/29/2019 Electrical Training Report
2/73
PREFACE
Practical training is an important part of theoretical studies. Itcovers all that remains uncovered in the classroom. It offers
the student to exposure an invaluable treasure of
experience. It offers an exposure to real practical of
instruments in the industries.
As we know that practical training plays an important role in future
building of an individual. One can easily overcome the fear from
that life in which he has to join a member after some time.
Just theoretical knowledge is not sufficient for the success of an
individual so one should have practical knowledge about eachtheory general life. The training greatly enhance our knowledge
and provide good opportunities to blend our theoretical as well as
trainees get familiar with certain aspect of industries like shop floor
management, production, process and industrial relation etc.
I feel proud to get training at BALLARPUR INDUSTRIES LTD,
YAMUNANAGAR that is one of the tops most paper
manufacturing industries in India.
2
-
7/29/2019 Electrical Training Report
3/73
ACKNOWLEDGEMENT
This report conveys my heartiest thanks to all those officers and
employees of THAPAR GROUP who have given me their full co-
operation and devoted their valuable time, for rendering me their
needy services, guidelines during the course of imparting me
practical training and with those sincere and precious help I have
been able to complete my practical training successfully.
I wish to express my sincere gratitude to
Mr. SANJEEV.VOHRA for providing me the training facility.
I also like to thank Mr.MUKHERJEE and Mr. PRAKASH
SHARMA (HR DEPTT) for their valuable support.
3
-
7/29/2019 Electrical Training Report
4/73
INDEX
1)Introduction
2)Infrastucture
3)Departments
4)Power House
5)Coating Plant
6)Process Of Power House
7)Speciality Plant
8)Chipper House
9)Programable Logical Control(PLC)
10)Distributed Control System(DCS)
11)Conclusion
4
-
7/29/2019 Electrical Training Report
5/73
INTRODUCTION TO BILT
BALLARPUR INDUSTRIES LIMITED, popularly knownas BILT is efficiently managed, financially sound, and self
sufficient and self made company is
The flagship of the covetedTHAPARGROUPS.
The ThaparGroup is one of the leading business houses in India. It hasa turn over of Rest 5000/- Crores BILT is one of the leading
companies with in the Thapar Group.
The Thapar Group has a wide range of activities like paper,
engineering, electronics, textiles, chemicals, glass,
telecommunications, biotechnology, leather etc.
There are 54 companies and 84 plants under this group. Some of the
main companies under this group are Crompton Greaves, K.C.T &
Bros. Limited, JCT Limited, BILT.
Ballarpur Industries Ltd. (BILT) promoted by LM Thapar, isthe leader in Indian paper industry with an annual production capacity
of 460000 MT spread over in five manufacturing facilities produces
ordinary and superior varieties of writing, printing and specialty papersetc. The company is also backwardly integrated with its
Caustisoda/Chlorine manufacturing facility, which is a vital material
consumed in the production process of paper.
5
-
7/29/2019 Electrical Training Report
6/73
BILT, which is originally incorporated in 1945 as Ballarpur Straw
Board Mills, has changed its name in March 1946 to Ballarpur
Paper and Straw Board Mills and again it was changed to the
present name in Oct. 1975. Since then the company has grown tobe a leader in paper industry by continuous expansion andmodernization of its capacity and plant and strategic acquisitions. In
1969 the company has merged Shree Gopal Paper Mills with
itself and the company which has acquired the Sinar Mass Pulp
and Paper (India) Ltd. (now BILT Graphic Papers Ltd.)
The company which was one of the most diversified companies in thepre-liberalization era of industrial licensing with interests in Paper,
Chemicals has decided to focus on its core competence that is inpaper and exit from its non-core businesses. First major steps on theselines were initiated in the year 1994-95 with hiving off the glass
business. Thereafter the company sold its vanaspati and edible oils
business in 1996-97. And in 1998, the chemical division of thecompany with its plant at Karwar, Karnataka and which has interests
in Phosphates, Chlor Alkali and Bromine and Bromine Chemicals was
spun of into a separate company that is Ballarpur Chemicals Ltd (nowSolaris ChemTech Ltd). To complement its Restructuring and to enable
it to emerge as a stronger and more competitive organization, thecompany is implementing a project involving modernization and
expansion of capacity at its Units in Shree gopal, Ballarpur and
Sewa by 105000 TPA. The Project will be implemented in twophases.
In the first phase, the capacity expansion of 35000 TPA and 28000TPA is planned over a two-year period from 2000-01 to 2002-03 for
Units Sewa and Shree Gopal. In the second phase 42000 TPA
of capacity is expected to come on stream at Unit Ballarpur by 2003-04. During the year 2001-02, the company has completed the upgradation of pulp mill at unit Sewa resulting in increase in capacity by
37 tones from the earlier 125 tones of unbleached pulp per day. The
company has also completed the installation of a 2.4 meter wide
blade coater at Unit Shree Gopal in FY2001-02. BILT enteredinto strategic alliance with Hansol of South Korea to provide world
6
-
7/29/2019 Electrical Training Report
7/73
class blade coated paper to the Indian customer. it is the first company
in the world to commercially exploit the fractionation of bamboo andhas applied for the world patent for this process. It has also entered
into direct retail distribution with the launch of A4 size, 100-sheet
pack of Royal Executive Bond
Mr. Gautam Thapar, Managing Director of BILT, has beenassociated with BILT since 1986 when joined the company as Shop
floor Management Apprentice-Paper Mills and was instrumental inturning around BILT in the late 1990s.
Thapar Paper Group Consists Of Five Units:
1. Ballarpur Unit, Distt. Chandrapur, Maharastra.
2. Shree Gopal , Yamuna Nagar, Haryana.
3. Ashti, Maharastra.
4. Bhigwan, Maharashtra
5. Sewa, Orissa
7
-
7/29/2019 Electrical Training Report
8/73
INFRASTRUCTURE
Founder - Late Lala Karam Chand Thapar (1900-1962)
Consist of major industries such as paper, chemicals, glass,
pulp, china clay, electronics etc.
Lala Karam Chand acquired Shree Gopal Paper Mill in 1936 ashe already established himself as a coal king.
Shree Gopal Paper Mill earlier know as M/S Panjab Plup and
Paper Company which was initially promoted by Foundation
Company England, the mill was laid shut for 6 month andwas ultimately auctioned.
This unit consists of:
Six paper machine machines.
Two coating plants.
Three finishing houses.
Two power houses. One caustic soda plant.
New pulp mill.
CHSR.
At present Unit - Shree Gopal is producing around 250 TPD ofpaper.
Total Area - 206 Acers.
Factory Area - 155 Acers. Colony Area - 51 Acers.
Turnover - Rs 24-26 Crores / month.
Manpower -:
Managerial staff 230
Permanent workers 1560Casual workers 740
8
-
7/29/2019 Electrical Training Report
9/73
Clerical 146
DEPARTMENTS
The departments are categorized as
Administrative department
PDC People development and communication.
Accounts Department.
Material Department.
Sales Department.
Raw material Department.
Traffic Department.
Process Department Mill
1. Pulp Mill2. Machine House.
3. Coating Plant.
Engineering Department
a. Electrical engineering.
b. Mechanical Engineeringc. Civil Engine
d. Instrumentation Engineering
e. Power House.
9
-
7/29/2019 Electrical Training Report
10/73
POWER HOUSE
This section of workshop undertakes the maintenance of: -
1. High pressure boilers No. 1,2 and 3(steam pr 85Kg/cm2)
2. ABL Recovery Boiler No. 4
3. JMW Recovery Boiler No. 5
4. Low Pr. Boiler No. 6 and 7
5. T.G Turbine
6. BTH Turbine
7. Black Liquor Evaporation Section
8. Chemical House
1
-
7/29/2019 Electrical Training Report
11/73
COATING PLANT
This section workshop undertakes the maintenance of: -
1. Colour Kitchen
2. Coating Machine
3 Super Calendar
4 Rewinder
5 Laminating Machine No.1.2 and 3
6 Cutter 1&2
7 Wrapmatic Machine
8 Bundling Machine
1
-
7/29/2019 Electrical Training Report
12/73
DIFFERENT SECTION
1)SPECIALITY SECTION
This section of workshop undertakes the maintenance of: -
1 Paper Machine No. 5,6 and 7
2 Effluent Treatment Plant
2) PULP MILL SECTION
This section of workshop undertakes the maintenance of: -
1. New Pulp Mill
2. New Chipper House
CLO2 PLANT
1. CLO2 section
2. O2 section
3. SO2 section
4. Vapourizer section
1
-
7/29/2019 Electrical Training Report
13/73
PROCESS OF POWER PLANT
POWER HOUSE
In the Power House, electric power is generated to meet the
demand of electrical energy for running the plant. The powerhouse
can be divided into the following main sections:-
1. Water Treatment Plant (D.M Plant)
2. Coal fired boilers section
3. Recovery boilers section
4. Turbines section
The detailed description of these sections is as follows: -
1,Water Treatment Plant:
In this plant, water is purified so as to make it usable for the
boilers. The water, which comes from the pump house, has
the hardness of approximately 200-250 and conductivity
around 300-600 mho. This water with the help of feed
pumps is fed to the reaction tank where it reacts with lime to
remove the hardness of water. The reaction-taking place is: -
Ca (HCO3) 2 + Ca (OH) 2 CaCO3 + H2O
1
-
7/29/2019 Electrical Training Report
14/73
Precipitates settle down and water is collected from overflow
in some adjacent tank. Now, the water is sent to the pressure
filter, where calcium carbonate is taken as filter medium.
After pressure filter, the hardness of water decreases to 50-
60. Now, this water is passed through the cation exchanger.
In the cation exchanger, cationic impurities are removed.
Cationic exchanger is charged with HCL every twenty-four
hours. Then, the water flows to the De-gasser. Here, water is
showered from the upper side and air is pumped fromdownwards. When the air strikes with water droplets, it takes
the gas along with it. After this, the water goes to the weak
Base Anion Exchanger, where strong anionic impurities are
removed. The next is the Primary mixed bed, where the
remaining cationic ND anionic impurities are removed. This
water is now stored in the D.M tank. The condensates of
steam are also brought to the same tank after passing through
charcoal and iron filters. To ensure the required standard of
de-mineralized water, the water is taken to the secondary
mixed bed. Ammonia is dozed in this water so as to increase
the pH to about 6.8-6.9. Now, this water is sent to the boilersfor steam production.
1
-
7/29/2019 Electrical Training Report
15/73
( OverView Of Steam Turbine)
2.Boiler section: -
The boiler section has two main parts: -
1. Coal fired boilers
2. Recovery boilers
2.1.Coal fired boilers
The coal-fired boilers are of two types:
a) High pressure
b) Medium pressure boilers
1
-
7/29/2019 Electrical Training Report
16/73
Out of total seven boilers, Boiler No 1,2 and 3 are H.P. Boilers;
Boiler No. 6 & 7 is M.P boilers and ABIL & JMW are the two
recovery boilers.
In the boiler, the steam is produced in the following manner.
Water comes to the steam drum from the P.D.M tank. This tank is
surrounded by steam line due to which inlet water temperature is
approximately 48C. Here, morphine is dozed in the water, so as to
laminate the pipes internally to increase the life of pipelines. The
water is then taken to the Derator Tank. In the Derator Tank, wateris showered from the upper side and steam is taken from the
bottom side. This steam removes the air and increases the
temperature of the feed-water. In the Derator Tank, hydrazine is
dozed for the reaction with oxygen in the air. The reaction-taking
place is: -
N2H4 + O2 N2 +2H2O
The outlet temperature of water in the Dearator Tank is around
110C + 5C. From the Dearator Tank, water goes to the
economizer. In the economizer, the heat of outgoing flue gases is
used to increase the temperature of water from 105C to 235C
(approx). The water from the economizer goes to the steam drum,where Na2PO4 is added to water so as to remove the silica left (if
any) from the water. From steam drum, water through section lines
goes to the mud drum. Precipitates of Na2PO4 and silica settle
1
-
7/29/2019 Electrical Training Report
17/73
down and are drained off from the mud drum using CBD. Water
from mud drum through sections lines goes to the furnace. In the
furnace the temperature is around 1200-1400 deg C. This steam
then goes to super heaterzone.
In this zone, there are two super heaters primary and secondary, an
temperature is connected in between the primary and secondary
super heater to control the temperature of out going steam by
spraying pressurized water droplets. The steam produced is then
connected in the header and then it is sent to the turbine section.
1
-
7/29/2019 Electrical Training Report
18/73
2.2.Recovery boilers
The process of producing steam is same in recovery boiler as in the
coal feed boilers. The difference lies in the combustion. In
recovery boilers, the heat energy is recovered in boilers; heat
energy is recovered from the wastage. The conc. black liquor from,
evaporate section is taken and sprayed into the furnace by a nozzle
of black liquor gun. As the black liquor falls into furnace at its
ignition temp. The organic part of it i.e.-lignin burns to give heatenergy and inorganic part i.e.- sodium salts are collected as smelt
when dissolved in water is called weak white liquor or green
liquor.
1
-
7/29/2019 Electrical Training Report
19/73
Three Element Control Loop in
The Boiler
Feed water flow
This control loop is used to control the feed water flow. The feed
water control systems, maintains the drum level at a manually set
value by using both feed forward and feed backward control. The
feed for a signal is the steam flow measurement, which
manipulates the set point of feed water flow controller and
therefore, manipulates the feed water flow to equal the rate of
steam being withdrawn from the drum. The bias of the summing
unit is such that during steady state conditions the output of the
drum level controller does not affect the set point of the feed water
flow controller. Since the liquid level process is subject to rapid
load changes and is not self-regulating, feedback must be applied
to eliminate drift. The feed back path is formed by the drum level
signal from the drum level controller. This controller trims out the
change in error during a load change or other transient variations in
drum level.
1
-
7/29/2019 Electrical Training Report
20/73
Air Flow Control Loop
The next very important control loop is the Air Flow Control Loop.
It is required because in deficiency of air, there will not be proper
burning of coal and in case, the air is present in excess, we have the
heat loss. Thus in both cases there is an economical loss. So we
have a control loop for air also.
General Data of Boilers
1) H.P Boilers (no. 1, 2 & 3)
Steam Pressure at output-86 kg/cm2
Steam Temperature at output-490deg celc.Steam producing capacity- 35-tones/ hr
2) Recovery boilers (ABIL & JMW)
Steam pressure at output -46 kg/cm2
Steam temperature at output-400 deg celc.
Steam producing capacity - 35-tones/ hr
4. Turbine section
2
-
7/29/2019 Electrical Training Report
21/73
There are two turbines of capacity 18 MW & 6 MW respectively
(namely TG and BTH). Both the turbines are steam driven. The TG
turbine uses steam at a pressure of 86 kg / cm2
And the BTH turbine uses the steam at the pressure of 46 kg/cm2.
Generally, 4 tones of steam is used for the production of 1 MW of
electrical energy as per approximate value. The process of
producing electricity is same in both the turbines. The rotary blade
of the turbine is set to motion by the steam pressure and hence the
shaft of the turbine, which is coupled with the generator, rotatesand produces electrical energy.
Genral Data of Turbine:-
Inlet Steam Pressure: -86Kg/cm2
Inlet Steam Temp. :-( 490 +5deg.C) or (490 5deg.C)
Steam pressure at first extraction: - 10Kg/cm2
Steam temp.at first extraction: - 270deg.C
Steam pressure at second extraction: - 3Kg/cm2
Steam temp. At second extraction: -150deg.C-170deg.C
Input RPM to gearbox: -8000
Output RPM to gearbox: -1500
For BTH Turbine: -Inlet steam Pressure: -46Kg/cm2
Inlet Steam temp: - (490 + 5deg.C) or (490-5deg.C)
Input RPM to gearbox: - 1500
2
-
7/29/2019 Electrical Training Report
22/73
PULP MILL SECTION
Raw Materials & specifications
Paper is made of pulp and pulp is made of fibers, which is obtained
from various materials like grass, bagasse, wood & bamboo. Any
material for pulp is selected on the basis of: -
1. Ample supply
2. Available to pulp mill throughout the year.
3. High yield of quality fiber.
4. Should not deteriorate in storage.
5. Capable of being collected & stored in small area and
transported, if necessary, at low cost
6. Cost of conversion to paper must be low.
7. Cellulose fiber must be of suitable size and character.
8. Location of paper mill must be close to the location of the
raw material.
9. It must make paper of sufficient quality to be competitive in
the international market.
10. It must be cheap.
11. Must give good printability.
2
-
7/29/2019 Electrical Training Report
23/73
The ideal fiber for high-grade paper should be high in cellulose
content and low in lignin content. The raw materials used in the
paper industry are of two types: -
1. AGRO BASED
These are the short fibers.
1. Bagasse
2. Khal
3. Khar
4. Sabai grass2. WOOD BASED
1. Bamboo
2. Eucalyptus
3.Veneer waste
2
-
7/29/2019 Electrical Training Report
24/73
Different Views Of Paper Making Process
At Different Machines
2
-
7/29/2019 Electrical Training Report
25/73
DRIVES
Different Drives Used In Paper Making Process And Also
In Power Generation Process
1) AC DRIVES
2) DC DRIVES
2
-
7/29/2019 Electrical Training Report
26/73
Overview Of DC DRIVE System:-
2
-
7/29/2019 Electrical Training Report
27/73
Chipper House
Introduction
It is necessary to reduce the wood to chips for pulp manufacture in
order that the cooking liquor may penetrate the wood quickly,
completely easy to transport pneumatically or on belt conveyers,
and to store. This operation is known as chipping and the machine
used for cutting the wood into chips is known as chipper. Thus,
chipping is a necessary operation but is also a drastic action, which
caused fiber damage and effects pulp quality. Damage is caused
when wood is subjected to compressive strain as a result of
bending, twisting or compression.
Screening Size
The size of the acceptable chips after screening varies
considerably. In sulphite process, the aim is to have an average
chip length of about 20 mm but chips are present ranging from less
than 10mm to over 35mm long. Shortening of the chip length tends
to give better impregnation of the chips, it is not suitable to
decrease the chip length too much, as a big number if the fibers
will be shortened and thus the strength pf pulp decreases. Short
2
-
7/29/2019 Electrical Training Report
28/73
chips also mean more fines and saw dust, higher power costs in
chipping, a smaller percentage of long fibers in the pulp and
reduced pulp yield.
New Pulp Mill
Introduction
The New Pulp Mill has been set up recently to produce the
indigenous pulp for paper machines of the unit. The setup of the
mill was aimed at fulfilling the needs of paper machines numbers
4,5, and 7. New pulp mill has helped in becoming self-dependent
in terms of pulp requirement. Chief raw materials used are
eucalyptus, bamboo, wood scrap and poplar etc. The raw material
is first chipped in the chipper house with the help of two venoclain
drum type chippers, the wood/raw material is converted into small
chips of size 1 * *1/4. After chipping operation the chips are
cooked in the digesters where indirect heating of digesters is done
with the help of white liquor and black liquor mixer. After proper
cooking the cooked slurry is washed. At the brown stock we are
using four washing stages working in counter current fashion.
After adequate washing the pulp is bleached at four bleaching
section the desired brightness of the pulp is obtained without
degrading the quality of the pulp.
2
-
7/29/2019 Electrical Training Report
29/73
Finally the pulp after cleaning operation through centri cleaners is
stored in bleached high-density towers. This final pulp can be sent
to corresponding paper machineries. Important steps in cooking or
digesters control operations.
Liquid Penetration
To ensure reaction, it is important that all the fibers in the wood get
their proper share of chemicals and heat. Now charging of liquor
starts. First of all we start white liquor pump (white liquor contains
NaOH+Na2S) and charge white liquor as per need when requiredquantity is charged, we close the respective liquor charging pump
and charge the black liquor as per the required quantity.
Digester Heating
After this, digester cooking commences. It takes place in two ways:
-
1. Direct heating
2. Indirect heating
The digesters in the NEW PULP MILL are indirectly heated.
Indirect heating involves the circulation of cooking liquor through
external heat exchangers with the aid of circulation pumps, which
draw off cooking liquor through strainers in the digester walls and
deliever, the heated cooking liquor at appropriate inlets. The
following are the advantages of the indirect cooking system: -
1.Uniformity of circulation through out the digester.
2.Uniformity of quality.
3.Increased yield.
2
-
7/29/2019 Electrical Training Report
30/73
4. Increased pulp strength.
5.Steam saving.
For ideal cooking the following parameters should be checked:
1.Proper temperature - 165 deg. C
2.Cooking time - 90 Min (at 165 deg. C)(Total time 260 min.)
3. Pressure - 8Kg/cm2
Digester Blowing
During the blowing of the pulp and black liquor go to the blow
tank and blow condensed steam vapors to the accumulator tank
having primary and secondary condensers, which are in operationtill blow is finished. From accumulator tank condensed steam goes
to heat exchanger through fiber filter to arrest any fibers going with
the condensed vapors.
In heat exchanger warm water is pumped from warm water tank
and hot water goes to hot water tank, which is used in brown stock
washing and bleaching stages.
Brown Stock Washing
It is the process in which the dissolved organic and in organic
materials are removed from pulp by filtreation. Our objective
should be to obtain most efficient washing by using minimum
amount of water. For this purpose we have four washing stages
operating in counter current fashion.
A low consistency suspension pulp (1-2%)is spread into vat which
contains rotating drum filter vaccum created is applied to drum
which cause the slurry to thicken as the liquor filtrates through the
3
-
7/29/2019 Electrical Training Report
31/73
surface of the drum, as drum cylinder rotates a sheet of pulp is
formed on the pulp surface which passes through spray wash zone
and then drying zone and finally it is discharged.
Consistency
Vaccum drum filter operates with 1% feed consistency and 11 14
% discharge consistency.
Bleaching
The unbleached pulp contain a large amount of lignin and some
other impurities which have been left behind after cooking and it is
essential to bleached these pulps to obtain brighter pulps without
degradation of cellulose fibers. Thus the main aim of bleaching of
pulps can be summarized as follows:
1.Removal of residual lignin left after cooking and destruction and
solubilization of coloring matters.
2.Removal of objectional dirt particles in form of five specks inpulp.
3.Retention of strength properties of the unbleached pulp.
4.To obtain greater brightness at low cost.
The following various types of chemical may be employed for the
bleaching of pulp: -
1. ClO2, Cl2
2. H2O2, Na2O2
3. So2, NaHSO34. O2
3
-
7/29/2019 Electrical Training Report
32/73
Washing
Again washing is done to remove the liquid chlorine from the pulp.
RefinerThe pulp is refined in the refiner. We have to refine the pulp to
make short fibered.
Mixing Chest
In the mixing chest pulp is mixed with Rosin, Alum, Ranipal and
filler like Carbon black as per requirement of the paper.
Machine Chest
After mixing the pulp is transferred into machine chest where its
consistency is maintained.
The fibrous pulp from machine chest is taken into the head box; normally
the consistency pf pulp at this stage is kept 1.5 to 2 percent .now the pulp
is make to pass on through the wire pat where the considerable amount of
water is taken out of the fibers and paper web moves ahead to the press
part .At these stage web is pressed in between the press rolls to reduce the
moisture contents of fiber .The press section has two parts:
The first press
The second press.
Now the paper is taken on to the dryers for drying purpose.
After passing through predryers an intermediate stage comes known as thesize press where the sizing chemicals such as starch are added. Then after
passing through the post dryers section paper goes towards the
calendar .A calendar is to smooth and shine the paper .Now the paper is
wrapped on the drum reel .At the final stage the paper contains moisture
contents about 5-6%.
3
-
7/29/2019 Electrical Training Report
33/73
SPECIALITY PLANT
After this the pulp is transferred to Specialty Departmentwhere required quality paper is made from this pulp.
In paper industry a raw material (pulp) is then brought into paper
plant, technically called Specialty Paper Plant. The Specialty
paper machines installed here make Executive bond, Sunlightbond and other high quality paper.
Machine No. 5: -The pulp turns into a paper of required thickness after passing
through a number of stages and number of sections: -
1. Hydra Pulper:-It is the main chamber of pulp. Here raw
material rotates with the help of rotor. Here the backwater of
process is added because it contains chemicals. If we want to
change the color or quality from superior to inferior or vice
versa, then fresh water is used.
2. Dump Chest: - The pulp comes into dump chest from hydra
pulper. Here pulp is beaten accurately.
3. Circulation Chest: - The function of this chest is to reduce
pulp into smaller particles.
3
-
7/29/2019 Electrical Training Report
34/73
4. Stock Refinery: - It removes impurities from the pulp and
beat the pulp.
5. Mixing Chest: - The mixing and machine chest further beat
the pulp.
6. Machine Refiner: - They remove remaining dust from the
pulp.
7. Constant Level Box: - It consists of two chambers, which
give the level of the erkensater. Its level remains constant
always.
8. Open Screen: - It consists of a hollow type roller, which is
covered by an iron net having equal no. of holes. It removes
heavy dust particles.
9. Head Box: - In this we detect weight of paper. In this
fresh water, are mixed highly purified pulp and their
ratio depend upon weight of paper.
10. Wire Section: - In this the pulp moves on belt in the
form of sheet.
11. Press Section: - In this section vaccum pressure is
applied on the sheet of paper to reduce the moisture content.
12. Dryers: - Here heated steam dryers absorb almost
100% of the moisture.
13. Size Press: - In this section we smoothen the paper we
smoothen the paper with the help of roller.
14. Drum Roll: - Final Bond paper rolls over this roll.
3
-
7/29/2019 Electrical Training Report
35/73
View Of Speciality Plant Paper Machine
3
-
7/29/2019 Electrical Training Report
36/73
COATING PLANT
In This Plant we increase the shininess & Strength of a Paper.
Colour Kitchen:
Firstly, The coating material is made in a colour kitchen at suitable
concentration of different chemicals.This Preperation is called
Recipe and this can be made by Kaddy Mill. Chemicals Include
Starch,Latex,Calcium Carbonate & several other resins which are
imported from MALAYSIA & BRAZIL.
Coaters:
This Material goes to the three Coaters which coat this material on
a paper at three stages. At each stage we find its moisture
contents,thickness etc. by scanner.
Super Calendar:
From coater this paper reels goto Super Calendar to increase its
Shinning by continuous rolling a Reel in a cylinders.
Rewinder:
After this paper goes to Rewinder where reel is packed more
efficiently.
Lamination Machine:
If we want to make a laminated paper then we send the paper to
lamination Machine in this two reels of paper from different ends
3
-
7/29/2019 Electrical Training Report
37/73
are joined with a help of glue which is made of starch. If we need a
paper for playing cards we put black die in glue so that we cant
see what is written on opposite side.
Now this laminated paper is dried by steam cylinders which are on
a above side of lamination Machine.
Cutters:
After this paper goes to 2 Cutters to make a sheets of proper size.
These paper reels are cut in form of sheets by pneumatic cutter
which are carrying circular knife.
Wrapmatic machine
These sheets are go to Wrapmatic machine for bundling. This is
specially designed Machine in which we have three grippers .
We feed the paper in it either automatically or manually,which are
picked by jaws like structure and through belt it pulled back where
it is picked by gripper 1,we use cylinders for each gripper.
Gripper1 forward this bundle of paper to gripper2 then gripper2
send it to gripper3 but before gripper 3 this bundle is covered by
outer cover which comes here with the help of reel this is
straighten by vaccum when bundlr reach near it ,this outer cover is
cutted by a cutter.gripper3 picked this bundle one rodless cylinder
is use to apply glue .it is pneumatic cylinder. We use brushes to
increase smoothness in gluing .Then this bundle goes under the
another glue nozzle to glue the sides.this glue is maintained on
high temperature so that our glue not solidifythis is maintained by
head & hose.this bundle move to different lifts the location of liftsis controlled by gate which in turn is controlled by cylinder.
From there we move a paper to Finishing House.
3
-
7/29/2019 Electrical Training Report
38/73
PARAMETERS OF INSTRUMENTATION
1). Pressure
2). Temperature
3). Level
4). Flow
5). Consistency
6) . PH
3
-
7/29/2019 Electrical Training Report
39/73
761 CONTROLLER(Bells make)
The single station controller used in BILT is the 761 series station
controller .The 761 station controllers is self contained microprocessor
based controller having the standard proportional integral and derivatives
function .The exact tuning method used in it does not use any arbitrary
process model .Instead it takes microprocessor technology. To make
controller adjustments based on the actual current process dynamics. The
controller is equipped with an RS485 serial communication port. This
controller has got all the configuration and operating parameters being
stored in a non-volatile memory .During a power failure essential
controller settings and last operating condition are saved indefinitely andno batteries are required for it.
The input signals for the controller are:
Current input:
The controller can have up to four currents inputs .the input standard
range is 4-20 ma into 240 ohm input range can changed to 1-5v dc by
changing input.
Thermocouple converter input:
One 4-20 mA measurement signal from temperature transistor or
equivalent using thermocouple is provided to
the controller.
RTD input:
It is used for one input from 100 ohm platinum RTD for direct
temperature measurement or two elements RTD for direct temperature
measurement or two elements RTD for temperature difference input.
Discrete input :
The controller can have up to two contact or transistor switch input 5V
DC nominal open circuit voltage 1mA maximum current.
3
-
7/29/2019 Electrical Training Report
40/73
The output signal for the controller are:
Control output signal:
4-20 mA DC into 500 ohm maximum standard non isolated output.
Auxiliary Out put signal:
It can be configured to transmit the measurement, setpoint, condition
input or output 1 signal as a 1-5 V DC output signal into 2K Ohm
minimum.
Discrete input:
The controller has two non isolated open collector transistor switch output.switch reading are 50 V DC maximum and 250 mA maximum.
Transistor power :
The standard controller can provide 25 V DC nominal field power to two
4-20 mA transmitters .power supply has 250 ohm limiting resistors at
each transmitter connection.
Its operating limit in terms of temperature is 5 and 50 C. The relative
humidity limits are 5,95%.the supply voltage required is
A.C supply voltage :
110V, 220V, 50 Hz.
D.C supply voltage :
24 V ,1 mA
The resolution of the display is +-0.1% of the upper range value. The
resolution of the bar graph is 2% of upper range value.
4
-
7/29/2019 Electrical Training Report
41/73
Segmented graphic display indicates the set point, measurement and
controller output .Each segment represents an incremental reading of 2%
of span the set point is indicated by illumination of the single segment in
the set point display. For measurement and controller output reading the
segment illuminates to form a bar graph .The desired reading is selectedby a selector key the function being displayed is identified by an
illuminated dot located above the corresponding bar graph.
The controller operates in one of the three following modes: NORMAL
,READ OR SET . In NORMAL operation the controller performs the
usual controller function READ mode the operator can read the value or
status of various control parameters . In SET mode the operator can
change these parameters and can adjust them according to theirrequirement .
The description of various keys of the controller is given below
W/P :
Depending on the configuration it permits the controller to be
used either as a workstation or panel controller.
R/L :
Depending on the configuration it permits the user to select
remote or local set point .
A/M
Depending on the configuration it permits the operator to select
automatic or manual controller.
TAG
Used to go from normal to read mode and to return from any
point in read or set mode to normal mode.
4
-
7/29/2019 Electrical Training Report
42/73
In normal operation used to change local set point ,output etc. in read
or set mode used to change configuration settings and to sequence through
parameters categories.
ACKIn normal mode used to acknowledge an alarm condition .in read
or set mode used to step sequential through every parameter in
structure
SEL
In normal mode used to move the bar graph identifier dot .in
read or set mode returns display in minor incremental back
through program structure.
4
-
7/29/2019 Electrical Training Report
43/73
PROGRAMMABLE LOGIC CONTROL (PLC)
The P.L.C stands for Programmable logic control .It is an industrial
computer based system which performs discrete and continuous
control function for a plant or factory automation .The first P.L.C
was designed in 1968.
Some of the points describing how a P.L.C is different from a
computer are as follows:
Real Time Operation :
The P.L.C is a real time operation system.
Environmental design :
The P.L.C is much more suitable for the environmental
conditions like heat, dust moisture electrical noise,
interference etc.
Programming language :
The programming done in P.L.C is relay logic programming
and also sometimes blocks oriented language.
Maintenance and troubleshooting :
The P.L.C has got modular design and inbuilt diagnostic
software due to which the maintenance and problem
emerging are dealt with very easily.
The various P.L.C components are as follow:
C.P.U
Power supply
I/O System
4
-
7/29/2019 Electrical Training Report
44/73
Programming Unit
Peripheral Devices
A brief description of these elements is given below:
4
-
7/29/2019 Electrical Training Report
45/73
C.P.U:
It stands for the central processing unit .It contains the processor
which performs all the work required to be done for the process
control .It act as the brain of the P.L.C it performs function whichare given below:
Logical operation:
It performs the logical operations like AND, OR, NOT.
Timers:
The C.P.U can also provided the functions of a timer .It can
provided on delay (the output will be produced after a certain delay
pf applying the input),off delay (the switching off occurs after a
delay of applying the switch off command .Pulse (high output
when input is high and low output when input is low)
and extended pulse (it has the same output as for the pulse but it
completes its pulse time even when the input signal goes low.
Counters:
This function of C.P.U is used to count up as well as down.
Flip-Flop:
It is used to latch the signal.
Power supply:
4
-
7/29/2019 Electrical Training Report
46/73
It is used to charge the various units (I/O system, peripherals &
C.P.U) connected together to make a P.L.C it supplies the power at
various levels as required by the units.
I/O System:The input module is used to convert the various input signals
which are in the form of 24V DC, 220V AC, which are understood
by the C.P.U the output module does the work opposite to that of
the input module it converts the 5V DC signal given by the C.P.U
to 24 V DC 220 AC as realized by the other devices in the field.
Programming Unit:
The programming unit provide an inter face between the P.L.C and
the user during the program development start-up and trouble
shooting.
The programming of P.L.C can inform by three ways:
STL statement list
Ladder logic diagram
Control system flow
The tools need are :
Programmer
Software
The connector used for the purpose of connecting programmer &
P.L.C is RS 232 it is 9 pin used for serial communication.
Peripherals:
The peripherals include communication cards and memory. The
communication cards are used by C.P.U to send and receive the
4
-
7/29/2019 Electrical Training Report
47/73
signal to and from various ends respectively. The memories used
are ROM and RAM. To store the application and the executives
program.
Types:
The P.L.C are of two types:
Modular
Non-Modular
The modular type of P.L.C have each and every components fitted
in such a way that it can be checked by taking it out but the nonmodular type of P.L.C have every thing fitted within & it can't be
taken out in any way .
Companies:
There is a wide variety of P.L.C available in the market but most
common trade names in P.L.C are :
Siemens
Messung
Bhartiya Cutler Hammer
Allen Bradely
Telemecanique
Cegelec
Crompton Greaves
4
-
7/29/2019 Electrical Training Report
48/73
Factors:
The factors which are kept in mind while selecting a P.L.C:
1Number of inputs and outputs
2.Cost
3.Space available
4.Speed and scan time
How P.L.C Works
The functionality of P.LC includes the following:
Input updating
Program execution
Output updating
The functioning of the P.L.C include firstly input updating it
checks every input &updates the input value if it gas changed.
Then it executes the program feed in already and then according to
the values generated for a output it gives the output .The time taken
in performing the above three functions is called the scan time.
4
-
7/29/2019 Electrical Training Report
49/73
DISTRIBUTED CONTROL SYSTEM (DCS)
D.C.S stands for distributed control system. It is the dominant form
of instrumentation used in industrial process control.
Features
The features of the D.C.S can be summarized as below:
1. The control system is distributed across the plant.
2. The complete plant data is integrated with the other plant and
management information system.
3. It involves high speed networks for data transmission at various
levels.
4. The D.C.S system is expanded and flexible.
5. The basic principal of distributed control system is functional
and structural integration.
Functional integration:
The term functional integration means that the same system is used
for logic, regularity, supervisory control.
Structural integration:-
The term structural integration stands means that all station from
small controllers to advent operator station for control are part of a
4
-
7/29/2019 Electrical Training Report
50/73
system which expands step by step from small scale to wide plant
automation.
DIFFERENT COMPONENT VIEW OF DCS SYSTEM
5
-
7/29/2019 Electrical Training Report
51/73
Components
5
-
7/29/2019 Electrical Training Report
52/73
The various components of a distributed control system are:
Process controllers.
Operator station.
Engineering station.
Information management station.
Gateways.
Networks and protocols.
A brief description of the components is given below:
Process controllers:
These are a part of level one control. These include single loopcontrollers, multiloop controllers, P.L.C etc
Operator station:
This is a part of level two controllers it include both low and high
end man machine interface. The man machine interface equipment
includes simple panel mounted displays and push buttons
monochrome video terminal, supports of standard Guts etc.
Engineering station:
It includes the process controllers configuration it uses ladder
logic, block oriented programming language and other high level
languages support for control configuration. It uses for plant data
documentation.
Information management station :
It provides facility for process decision making bythe management.It has extensive reporting facility also.
Gateways:
5
-
7/29/2019 Electrical Training Report
53/73
It is a part of three components. It provides a data transparency
between various networks like control network to control network,
control network to plant network.
Networks and ProtocolsThe networks are used for high speed data communication for level
one and two components. The various topologies used for
networking are:
Bus Topology
Ring Topology
Star Topology
Bus Topology
The bus topology uses CSMA principle that is carrier sense
multiple access. Direct mutual communication between two nodes
or stations is possible in this topology .These type of topology has
no master on the network. In this topology any station that needs to
transmit can be provided no other station is doing so. If two station
start simultaneously, both will stop and the higher priority station
begins after waiting a period of time.
Ring Topology
The ring topology uses token passing principle .communication
takes place from one node to other in a sequence till the required
node is reached.
Star Topology
The star topology uses central node that handles all exchange of
data .The communication is point to point between central nodeand peripheral node .It not a very popular topology.
Functional Units:
5
-
7/29/2019 Electrical Training Report
54/73
Brief explanation of the blocks connected along with the D.C.S is:
Local control units :
The process input /output signals are connected to the local controlunits, which can be of various levels of cost and reliability .The
most critical loops, are usually placed in dedicated card controllers
rest of the control loops ate placed in unit operation controllers,
and the monitoring and alarm functions are connected to local
multiplexer. The briefings of the above mentioned devices are
given below:
Dedicated card controllers:The input /output for the most critical loops the one which should
continue functioning even if the central processor or the data
highways fails. This is the most expensive but also the most
reliable method of PID implementation in a D.C.S system. Each
D.C.S supplier offers a wide variety of card controllers having
from one to four analog output, four to twenty analog input and
two to eight digital input and outputs. There execution speed
generally ranges from four to ten executions per second . the
individual card controllers are connected to the data highway of
D.C.S. If the central processing unit of D.C.S fail or if data
highway spoils,only the communication link is lost to the card
Controllers, the control loop itself continues functioning.
Unit operation controllers:
A unit operation controller is dedicated to a unit operation of the
process, such as a chemicals or a distillation column, and therefore
all the input /output associated with that unit operation is connectedto that unit operating station. If this level of reliability is selected,
the process will remain under control as long as the unit operation
controllers are functioning, even if the central processor of the
D.C.S fails. Inversely, if the unit operation controllers fails, that
failure will interrupt the controls of only one unit operations, while
5
-
7/29/2019 Electrical Training Report
55/73
the rest of the plant remains unaffected .Therefore the number of
loops at risk equals the number of loops servicing the particular
unit operation.
Local multiplexer:The proper local control unit choice for the type of input/output
which serves monitoring functions but not control functions is the
local multiplexer .This type of local control unit does not execute
any control functions it only transmit input/output to form the
central processor.
Data highway:
The data highway is communication device that allows adistributed control system to live up to its a name, permitting
distribution of controlling function through out large plant area.
Data highways vary in length as a function of traffic capability and
speed of transmission .Highways lengths can be in excess of 5
miles. The most popular medium is coaxial cable. Several suppliers
supply highways made of Twin ax cable, a twisted and shielded
coax. Shorter highways may be constructed of a pair of twisted and
shielded copper wires. The most recent addition is the fiber glass
cable, making of fiber optics .Fiber optics is attractive for use as adata highway because it eliminate of electromagnetic and radios
frequency interference, ground loops, and common mode voltages.
It is safe in explosive or flammable environments. et can carry
more information then can copper conductors. It is inert to most
chemicals and it is lighter and easier to handle than coaxial cable.
5
-
7/29/2019 Electrical Training Report
56/73
Functioning of D.C.S
The solid state electronics portion of the locally mounted
equipment is a special purpose minicomputer, programmed toperform the control functions for which the distributed control
system is being used. It has an input section and an output section,
but the major portion of circuitry is made up of the central
processing unit (CPU), read only memory (ROM), random access
memory (RAM),and registers and buses that are characteristics of
microprocessor base devises .The CPU operates with a clock to
repeat a sequence of programmed subroutines over a time period
,typically half a second. This period is divided into a number of
segments of time slots, in each of which other subroutines specific
to a control operation are carried out .The subroutines ate called
algorithm they are a program of instructions designed to perform a
specific function. Depending on the configuration practices of a
particular supplier ,time slots may me of equal length ,with one
algorithm per slot ,or they have variable lengths, with a series of
algorithms used to accomplish the control action the electronic
circuitry associated with a module controlling a number if loops is
contained on several complex printed circuit cards ,frequently withthree or four layers of foil in one card .The cards are usually
plugged into a back plane containing buses that provide
communication between these.
Each time slot of this controller file has a 1/32 of a second period,
and there are 16 times slots. Accordingly, all operation are repeated
every half second .At a beginning of the half period, all the inputs
are scanned by a multiplexing circuits, and the analog signals arechanged to digital values, which are then stored in registers as
binary numbers. The transition from analog to digital is performed
by a 13 bit analog to digitals converter circuits.
5
-
7/29/2019 Electrical Training Report
57/73
All the information about 16 time slots such as inputs & outputs
value is stored in a data base .Functional subroutines (algorithm)
are stored in ROM .When 1/32 of a second period begins, the
information for that particular time slot is brought from the database into a section of RAM. The configuration is checked to
ascertain which algorithms are to be used. An output value is
computed and sent to an output register. The updated function
information is returned to the data base, and the time period is
completed, to be followed by the next 1/32 of a second operation.
The output register in this case is one of eight (the controller file
services eight control loops).The binary value of each output ischanged in a separate conversion circuit to a frequency which is in
turn converted to a 4-20mA output signal ,updated every 1.2 s.
Some of the advantage that a distributed control system has in
comparisons to the computer systems is:
Distributed control system requires less installation cost because
less wiring is required when information is transmitted serially
across the two wires on a data highways, rather than in parallel
over many pairs of wires. Panel space is also reduced and so is the
room size required to house it. The cost of the distributed control
system is greater on a hardware basis than its equivalent analog
controller ,but the overall cost including installation is lower.
From the point of view of the operator,the interface with the
process is improved. The group display provides a means of
viewing a combination of control loops that has meaning in termsof process association.
The distributed control system can be called a computer, but it is
no longer a single mainframe. Instead, many small computers are
5
-
7/29/2019 Electrical Training Report
58/73
distributed throughout the remote area installation, sharing the
work that the mainframe had to do alone.
The distributed control system is also flexible and relatively easy to
expand.
The programming effort required for the mainframe computer
system is also eliminated. The system programming that directs the
operation of the remote controller electronics, the central station
and the communication links is furnished as part of the distributed
control package .Furthermore, the programming required to tailor
the system to the needs of the individual process to which it is
applied can be done without knowing a high level programminglanguage.
A most common type of backup available from most of the
suppliers is in form of manual stations. These are specific to a
single control output and allow a local operator to take over from
the automatically generated signal at any time.
The availability of a system is defined as the ratio of mean time
between failures (MTBF) and mean time between failures and
mean time to repair (MTBF +MTBR).
It is clear that a system will be most available when it is very
reliable (high MTBF) and can be quickly repaired (low MTTR)
.Since distributed control equipment is highly modular and
contains many printed circuit cards, time to repair can be very short
if sufficient spare parts are available.
5
-
7/29/2019 Electrical Training Report
59/73
INSTRUMENTS USED IN BILT
1. Conductivity measuring instruments used in D.M. Plant.
2. pH measuring instruments used in D.M. Plant .
3. Flow measuring instruments installed at PDM tank, super
heater, water inlet in steam drum and in turbine section.
4. Pressure measuring instruments installed at ID fan, FD fan,
main steam pipe, derator tank and turbine section.
5. Temperature measuring instruments used in main steam
line, derator tank, steam drum, furnaces and also in turbinesection.
6. Level measuring instruments used in various drums and
tanks used in this section.
7. Control valves are installed at different places in the whole
powerhouse.
8. Speed measurement of rotational speed of shaft in turbine
section.
9. 761 controller is used in every section of powerhouse.
5
-
7/29/2019 Electrical Training Report
60/73
Control Valve
A control valve is a final control element in a running process.
The change in the position or condition of the control valve
varies with process parameters. In level, pressure, flow and
temperature applications control valve can control the process
according to the requirement .It consists of three parts: -
1. ACTUATOR: It is a part of control valve, which apply
the force on valve for controlling the process. It looks likepiston, which can move up and down according to the
requirement. The actuator is based upon the concept of pressure.
F = (P1 - P2) x A
Where, P1-P2= Pressure differenceA= Diaphragm area
F= Force applied
2. VALVE: It is a part of control valve, which can be operated
with the actuators manually, and an actuator operates valve. It
has many types : -
a) Butterfly valves
b) Pilot valves
c) Plug type valve
3. POSITIONER: These are fast responding precision
calibrated, force balance instrument providing accurate valve
positioning.
6
-
7/29/2019 Electrical Training Report
61/73
Flow Measurment
Flow Measurements are also important parameters to be
measured. The flow rate of the flowing pulp gives an idea of the
consistency of the pulp. The various flow meters, which are
used in BILT, are: -
1. ROTAMETER: - It consists of a vertical tube with a tapered
cone in which a float assumes a vertical position
corresponding to each flow rate through the tube. The tube is
made up of steel and float is of brass. It works on equation: -
Qv = CEA2/Zgpd
-------
e
If Pd = Pressure is held constant then volume flow rate is
directly proportional to orifice area.
2. ORIFICE METER: - It consists of an orifice plate inserted
in a pipeline cases an increase in flow velocity and a
corresponding decrease in pressure. The Flow pattern shows
an effective decrease in cross of flow beyond the orifice plate
with the maximum velocity and minimum pressure. The plate
may be concentric, eccentric or segmented.
3. VENTURI METER: - The basic design of a venturi tube
comprises three sections viz the converging conical section at
the upstream, cylindrical throat, diverging recovery outlet cone
at the downstream. The inlet cone tapers down from the pipearea to the throat section of a smaller area to produce the
necessary increase in velocity and decrease inpressure. The
throat provides a point of the measurement of this decrease in
pressure where flow rate is steady.
6
-
7/29/2019 Electrical Training Report
62/73
Magnetic Flow Meter
The transmitter is based upon the principle of Faradays law ofEMI according to which, when a conductor is moved in a magnetic
field, a voltage is induced in the conductor.During the
electromagnetic flow measurement, the fluid passes through a
magnetic field applied normally perpendicular to the direction of
liquid flow. The movement of liquid induces and electric voltage
which is proportional to the average field velocity and therefore to
the volume of flow.
In the case of electromagnetic flow transmitter:
U = K x B x D x V
Where, K = Instruments constant
B = Strength of magnetic field
V = Average velocity
D = Pipe diameter
6
-
7/29/2019 Electrical Training Report
63/73
Pneumatic Current to Pressure converterThe main principle behind this type of I/P converter is that a core
is wounded by coil, which receives a standard input signal of 4-20
mA, and it converts this electrical signal into a pneumatic signal.
According to Faradays Law when a coil is carrying a current, a
strong magnetic field is produced around the coil. This magnetic
field is used to attract the soft iron core, to which is attached a
flapper and nozzle.
The nozzle opening is governed by the amount of current through
the coil. A strong signal, i.e. large current would bring the flapper
closer to the nozzle and this is provided to a pneumatic relay
which produces an output in range of 3-15 PSI which are linear
with 4-20 mA input signal. This output is capable to operate the
control valve.
I/P transmitter is also known as current to pressure converter
since it converts or transmits current signals into pressure signal.
In control loops where control valves are used I/P converter areused to operate the control valve.
The transmission of signal to current is required since controllers
in control loops are current controlled. The controlled valve open
and close according to a set point. The signal from the controller
is electrical but nature of control valve is pneumatic. So I/P
converters render the signal, which is suitable for control valve
operation.
6
-
7/29/2019 Electrical Training Report
64/73
Temperature Measuring Instruments
(A)Thermocouple:- Thermocouple is made up of two dissimilarwires joined at their measuring and forming the measuring
junction and hot junction.
A small voltage known as sees back voltage creates at another
junction.i.e.cold junction. This voltage change in accordance withthe temperature. The controller or monitor measures the small
voltage and converts it into a temperature signal and controls the
temperature of loop and tank.
(B) Resistance Temperature Detector (RTD): - RTDs areusually platinum wire, wound on a glass or a ceramic babbin and
sealed with a coating of ceramic or glass. They can also be made
by depositing platinum as a film .The electric resistance of RTD
changes as a function of temperature.
The circuit is similar to a wheat stone bridge .A constant current
into the bridge produces an output voltage that varies with
temperature.
RTDs are generally more accurate and more stable over time than
thermocouple.
6
-
7/29/2019 Electrical Training Report
65/73
pH meter
pH Meter :
It is a device which measures the pH of any liquid such as acid
alkalies and water.
Introduction about pH :
pH is a chemical factor which denotes the acidity or alkalinity
of a solution . The degree of acidity or alkalinity of an aqueoussolution is determined by relative concentration of hydrogen and
hydroxyl ions in that solution. When the hydrogen ion
predominates the solution is acidic and when hydroxyl ion
dominates it is alkaline .
Working of pH Meter:
Hydrogen ion concentration is measured on scale that ranges from
0-14. When the value on scale is 7.0 hydrogen ions and hydroxyl
ions balance each other as in case of distilled water.
When the pH value is more than 7.0 solution is alkaline and when
the value is less than 7.0 the solution is acidic.
The measurement is done by immersing a cell (pair of electrodes)into the solution to be measured and measuring the voltage
developed across them .In the pH cell one of the electrode is
reference electrode is at a potential regardless of the pH value of
solution under test. The potential of the other electrode called
measuring electrode is determined by pH value of solution. Thus
6
-
7/29/2019 Electrical Training Report
66/73
the potential difference between the two electrodes depend upon
the pH value of the solution.
Now a days combination electrode is used thus eliminating the
need of two electrodes .The combnation electrode is a delicatechemical transducer to be handled very carefully .The pH
combination electrode generates the potential difference which is a
function of the pH value of the solution being tested. This is
amplified and calibrated and fed to digital voltmeter which is again
suitably calibrated to read directly in pH.
6
-
7/29/2019 Electrical Training Report
67/73
Differential Pressure Transmitter
Pressure Measurement:
The differential transmitter may be used for measuring liquid flow,
level or other applications requiring accurate measurement of
differential .The quality of measurement depends to a great extent
on proper installation of the transmitter.
Construction of Differential Pressure Transmitter
A pressure transmitter consists of sensor element two metal pieces
are separated by sensor element seal as a diaphragm .It has two
states low and high oil is filled in it and this system is covered with
an insulator. When we apply the pressure on its low or high side
then the pressure flows through the middle diaphragm and the
middle diaphragm offers capacitance effect due to two plates
separated by an insulator.
In this system insulator is diaphragm and conductive surface is the
metal piece when oil is linked with the diaphragm.
When pressure is applied then capacitance C2 increases and C1
decreases .It flows from high level than voltage will be developed
across to terminals, which is differential pressure, so it called as
differential pressure transmitter.
The pressure transmitter has a variable capacitance-sensing
element the - cell. The differential capacitance between the
sensing diaphragm and capacitor plate is converted electronically
to a two wire 4 20 mA DC signal.
6
-
7/29/2019 Electrical Training Report
68/73
P = K1 x C1 - C2
-------------C1 + C2
P = Process pressure
K1 = Constant
C1 = Capacitance b/w high pressure side and sensing diaphragm
C2 = Capacitance b/w low pressure side and sensing diaphragm
6
-
7/29/2019 Electrical Training Report
69/73
Liquid Level Measurement
Differential pressure transmitter used for liquid level application
measures hydrostatic pressure.
The pressure is equal to liquid height above the tab multiplied by
the specific gravity of the liquid. Pressure depends upon volume or
vessel shape.
Open Vessel:
A pressure transmitter mounted near a tank bottom measure thepressure of liquid above. Make connections of the high-pressure
side of the transmitter went the low.
Closed Vessel (Wet Leg Condition):
Pressure above a fluid affects the pressure measure at the bottom of
a closed vessel.
The liquid specific gravity multiplied by the liquid height plus the
vessel pressure equals to the pressure at bottom of the vessel.
To measure true level the vessel pressure must be subtracted from
the vessel bottom pressure. To do this, make pressure tab at the top
of the vessel and connect this to the low side of a differential
pressure transmitter.
Vessel pressure is equally applied to both the high and low side of
transmitter. The resulting differential pressure is directly
proportional to liquid height multiplied by liquid specific gravity.
I/P Transmitter
6
-
7/29/2019 Electrical Training Report
70/73
Current to pressure transmitter accepts the electrical inputs signals
and converts it into proportional pneumatic output. Typically 4 to
20 Ma is converted to 3 to 15 pounds per square inch (Psi).the most
common application of this transmitter is to receive electrical
signal from a controller and to produce a pneumatic output foroperating a control valve positioner .
It has a solid state pressure sensor that moniters the output
pressure and is a part of electronic feedback network.
The final assembly of a transmitter contains the electronic circuit
board, pilot/actuator assembly and booster stage.
Electronic circuitThe input current signal is received by electronic circuit and
compared to the output pressure from booster stage .a solid state
pressure sensor used strain gauge this film technology. It can
withstand loops of pressure w/o damage.
7
Mag actuator Pilot stage Booster Valve
Solid state press sensor
Elec stage
-
7/29/2019 Electrical Training Report
71/73
Magnetic actuatorThe electronic circuit control the level of current flowing through
the actuator coil which is located in the pilot /actuator assembly. A
change to the level of coil current is to made by electronic circuitwhen it senses a discrepancy between the pressure measured by the
sensor and pressure required by the input signal. The actuator
performs the task of converting electrical energy to motion.
Pilot stageIt contains two opposed fixed nozzle. It also contains the deflector
which is moving element. The supply nozzle is connected to the
supply air stream. The receiver nozzle captures the air stream andconverts it back to pressure . the receiver nozzle pressure is the
output pressure of the pilot stage. In order to vary the pilot output
pressure the velocity stream is diverted away from the receiver
nozzle. This accomplished by the deflector which is cylindrical
aerodynamic body located between the two nozzle.
In response to a change in actuator coil current, the deflector is
repositioned between the nozzle. There is a linear relationship
between the coil current and the pilot stage output pressure . thepower of f or fail safe , the position of the top of the deflector is
near to the centre of stream and results in zero pilot output
pressure. As the coil is energized , the deflector is drawn out of the
stream. maximum pilot output pressure results when the deflector
has moved completely out of the stream.
The deflector material is tungsten carbide and nozzle are 316
stainless steel. The nozzle has a large bore of 0.016 inches whichprovides good resistance to plugging.
7
-
7/29/2019 Electrical Training Report
72/73
Booster stageThe receiver nozzle pressure controls the booster stage which has a
poppet valve design. An increase in the transducer output signal.
A decrease in the receiver nozzle pressure positions the valving inthe booster stage to allow the exhaust to occur, decreasing the
output signal.
7
-
7/29/2019 Electrical Training Report
73/73
CONCLUSIONIt can be concluded that BILT is a modernized and well-equipped
industry form every aspect whether it is manufacturing process or
finishing process. During my training period, I got valuable
knowledge regarding the most modern techniques used in
Electronics & Instrumentation trade that is P.L.C & D.C.S .My
training also made me familiar with many machines & instruments
used in industry. The management & employees are very helpful. I
hope that the valuable knowledge I have gain here will help me infuture.