BHANWAR LALELECTRONICS AND COMMUNICATION

THIRD YEAR (B.E.)2011-2012

MAHARANA PRATAP UNIVERSITY OF AGRICULTURE & TECHNOLOGYCOLLEGE OF TECHNOLOGY AND ENGINEERING, UDAIPUR

DEPARTMENT OFELECTRONICS AND COMMUNICATION ENGINEERING

A INDUSTRIAL TRAINING REPORTTAKEN AT: J.K.LAXMI CEMENT LTD. ( SIROHI)

COMPONY OVER VIEW

Singhania group of industriesJk-paper, Jk-tyres, Jk-cement, Jk-agro., Jk-power plant.Last year gross income 1519 cr.Share price Rs 5 (equality share)

Energy Conservation Award 2011" Energy Conservation Award", Certificate

of MeritBest Employer Award” 3rd time in a rowGreen Manufacturing Excellence Award

2011

AWARD AND ACHIEVMENT

Cement is a mixture of limestone, clay, silica and gypsum. It is a fine powder which when mixed with water sets to a hard mass as a result of hydration of the constituent compounds and can join different components or members together to give a mechanically strong structure .

Definition

MiningCrushingGrindingCalcinationMixing of gypsum and fly-ash.Packing of cement.

Process of cement manufacturing

STEP:1 (mining)

STEP :1.2

STEP:2.1 (crushing)

STEP:2.2

STEP:2.3

STEP:2.4

STEP:2.5

STEP:3.1 (grinding)

STEP:3.2

STEP:4.1 (calcination)

STEP:4.2

STEP:4.3

STEP:4.4

STEP:4.5

STEP:5 (mixing & grinding)

STEP:6.1 (packaging)

STEP:6.2

CENTRAL CONTROL ROOM

1. QUALITY CONTROL ROOM

2. MONITORING ROOM

3. DISTIBUTED CONTROL SYSTEM ROOM

4. ELECTRONIC LAB

QUALITY CONTROL ROOM1.CHEMICAL LAB

In this lab chemist checks the chemical composition of cement in every half hour by using chemical reactions.A. The lab has standard specimen of cement, coal, lime

stone and other useful raw and manufactured cement.

B. These specimen are used to compare the manufactured cement

2.ONLINE LAB.It uses three types of analyzer.C. X-RAY MACHINE.D. CROSS BELT ANALYSER.E. COMPUTER APPLICATION.

In this lab damaged devices and faulted circuits are repaired.

ELECRONIC LABORATORY

In this room the engineer monitors the process and devices.

For monitoring they uses four cctv camera and eight computer.

These computers are connected with DCS.

MONITORING ROOM

HPM (High Performance Manager) It uses powerful multiprocessor dedicated to perform

specific tasks. It consists of HPMM & I/0 sub-system.Redundant HPMM card files. HPMM consists of communication processor and

modem, I/0 link interface processor and control processor.

Filed termination assembly. The I/0 sub-system consists of redundant I/0 link and

the I/0 processor. These I/0 processors handle all fields I/0 for both data acquisition and control functions.

Power system.

DCS ROOM

(A). Safety instruments (B). Measuring instruments

(C). Quality checking instruments

(D). Other instruments

INSTRUMENTATION

Belt sway switch

Pull cord switch

Boot level Switch

Zero Speed Switch

Safety instrument

X-ray analyzerCross belt analyzer

Quality checking

Temperature

level

weight

speed

sound

vibration

Pressure

MEASURING INSTRUMENT

(1) RTD

(2) THERMOC

OUPLE

(3) PYROMET

ER

(4) SHELL SCANNER

Temperature MeasurementTemperature Measurement

RTDs are manufactured from metals whose resistance increases with temperature:

RT = RO[1+a(t-to)]

 Where, Rt = Resistance at temperature t

Ro= Resistance at standard temperature t

α = temperature coefficient

A thermocouple circuit is formed when two dissimilar metals are joined at both ends.Thomas Seebeck

RTD

THEMOCOUPLE

A pyrometer has an optical system and a detector. The optical system focuses the thermal radiation onto the detector. The output signal of the detector (temperature T) is related to the thermal radiation or irradiance j* of the target object through the stefan-boltzmann law, the constant of proportionality σ, called the stefan-boltzmann constant and the emissivity ε of the object.

PYROMETER

The KILNSCAN infrared line scanner is used for rotary kiln shell temperature monitoring. This system enables to prevent risks of hot spot formation on the shell, to early detect refractory brick fall, to determine coating thickness and to evaluate the kiln thermal warp amplitude

SHELL SCANNER

PRESSURE MEASURMENT Pressure transmitterDifferential pressure transmitter

It is used to measure the difference between two pressure.

Also used to measure the simple pressure.

Analog o/p: 4-20mACapacitive type

Differential pressure transmitter

Vibration sensorVibration sensor system

Vibration measurement

AC signal from sensor

AMPLIFIERDC O/P OF 0-10 vlt OR 4-

20mAALARM

Default alarm value limits of 4,5 mm/s- Stainless steel sensor- Analog output 4 ... 20 mA- With digital display- Measurement range: 0 ... 25,4 mm/s

Vibration sensor

Weigh feederLoss in weigh feederSolid flow meterLoad cell

WEIGHT MEASURENT

Level measurement

LEVEL SENSOR

CAPACITIVE TYPE

ROTATING PADDEL

TYPE

NLG

Level measurement

SPEED MEASUREMENT

Tacho-generator Tachometer

Speed measurement

Tacho-generator

tachometer is connected to the machine whose speed is to be measured. When armature revolves in the field of permanent magnet emf proportional to the speed is generated. This can be measured directly or after suitable conversions to find the speed of the machine.

Tacho-meter

It’s a digital form of tacho-generator. It gives reading in digit and also measure the speed.

GAS ANALYZER

OPACITY SCANNER

CCTV CAMERA

LOAD CELLSOLENOID VALVE

SPRS

AC DRIVE (VFD)

DC DRIVE

OTHER PURPOSE INSTRUMENTS

CEMENT PACKING MACHINE

Thank you