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Chittagong Independent University

Live-in Field Experience (LFE)


Presentation
Supervised by:
Mr. MD Morshed Alam
Department of Electrical and Electronic Engineering
Presented by:
Rashid Abul Hashem
15102013
Index
• Part 1 – BSRM Steels mills

• Part 2 – Halishahar 132/33kV grid substation


• Components and their purposes

• Part 3 – CUET
Part 1 – BSRM Steels Mills
Introduction
• Started in 1952
• Produces 3.5 tons of rebar per hour
• European based technology – DANIELI
• Management – 100 staff / 50k- 1.5 lac salary monthly
• Non management – 188 staff / 15k-30k salary monthly
• 5 products
• Xtreme
• Ultima
• Maxima
• Centura
• Xtrong
BSRM Organogram
Production process - Furnace
• Scraps collected, melted and made into
billets.
• Billet is 1.5 ton and max size of
160x160mm2.
• Billets are loaded onto charging unit of
furnace by cranes.
• Furnace is 1200o-1250oC, uses gas for
combustion.
• Heated billets pushed out by discharging
unit.
• Combustion takes place in 1:10 ratio of gas
and air. Waste gas is released through
chimney.
• Hydraulics control the input valves.
• Process is controlled by PLC.
Production Process – Rolling Mill
• The rolling mill is divided into 3 zones each with its own purpose
• 1) Roughing Mill
• 2) Intermediate Mill
• 3) Finishing mill
• Roughing and intermediate mills have both 3 horizontal and 3 vertical stands.
• Both have shears to cut bended head and tail
• Stands have interchangeable heads with grooves to shape the rebar.
• Finishing mill imprints logo, cuts and rolls to standard 16mm diameter.
Production Process – Cooling, cutting and tying
• After the mills, rods are sprayed with water to quench and temper it, hardening
its properties.
• Sent to cooling bed to reduce temperature.
• Once it is ready, it is bundled and sent to a shearing machine to cut to desired
length using wheeling stopper.
• They are then grouped and tied strongly, scaled and moved for storage and
quality check.
Complete Single Line Diagram
AC motor construction
• AC motors consists 2 parts; stator and rotor
• The stator is the stationary part of the motor’s electromagnetic circuit. The stator core is made up of many
thin metal sheets, called laminations. Laminations are used to reduce energy loses that would result if a
solid core were used. Wires are inserted around the core as windings and connected to power directly.
• Rotor is the rotating part of the motor’s electromagnetic circuit. The most common type of rotor used in a
three-phase induction motor is a squirrel cage rotor. By induction, the rotor rotates when power is supplied
either in delta or star connection.
DC motor construction
• Consists of 2 parts; stator and rotor.
• Stator consists of Yoke, Field Winding, Interpoles, Compensating Winding, Brushes and End Cover.
• Rotor consists of armature core, armature winding, commutator and shaft
Workshop – Electrical tools used
• Multimeter
• Pliers
• Spanner
• Screwdriver
• Wrench
• Digital Infrared Thermometer
• Etc
Workshop equipment – CNC machines
• CNC machine is used for making fine grooves for rolling process
• Values are set through program, head is placed and slowly rolled as a
cutter is used to cut through it.
• CNC machine used is called Herkules
• Notching of the bars and logos are also etched on by these machines
PLC basics
• Stands for Programmable Logic Controller.
• Consists of power supply, CPU, communication processor (CP) and interface
modules (IM)
• Interface module has inputs and outputs, receives input and sends it to CPU
through CP.
• CPU process input, sends signal to appropriate output port back through IM.
• Output/input ports have specific addresses. Addresses are arranged by bytes. One
word is 2 bytes. Each byte is 8 bits, therefore one word is 16 bits. Locations of I/O
are located following this algorithm
• Supervisory Control and Data Acquisition (SCADA) interface shows graphically all
information of I/O connected to PLC. Control of all variables is done through this
interface
Pulpits
• Pulpits are like control stations where SCADA
terminals of every process is placed.
• 2 pulpits:
• Main pulpit (Furnace and Rolling mill)
• Finish pulpit (Cutting and tying)
• An operator observes readings of SCADA, if any
issues arise, buttons controlling the mill
machines are available to stop/start them as
well as alarms to notify workers. Some
readings include temperature of furnace,
motor speed etc.
• Continuous reading of power consumption are
logged in these pulpits
Quality Check
• Every 15 min sample is taken from stored batch for testing.
Failing these test results in either retest of same batch or its
complete recycle.
• Three test performed:
• Tensile strength test
• Bending test
• Chemical test
• Tensile strength test
• Universal testing machine is used to pull bar sample from both sides
• Constant readings taken and shown on computer
• Pressure more than 545MPa causes bar to loose elastic property
• At 640MPa, bar breaks off.
• Bend Test
• Machine bends bar to 180o
• After bend, bar is checked for any cracks on the bend.
Quality Check
• Chemical test
• A small sample of bar is taken and placed on spectroscopy.
• Spectroscopy emits high voltage spark on sample, releasing
plasma
• Plasma enters spectrometer and splits into element specific
wavelengths
• Computer reads and compares readings with preset value
and shows concentration of elements
• Microscope Check
• This is usually used to check microscopic cracks formed by
bending test and their cause.
• Grain size is also compared here.
• Usual grain size of good steel is from scale of 7.5 to 9
5s System
• BSRM follows the 5s system during production
• The 5 standards are:
• Sort: Sort through materials, keeping only the
essential items needed to complete tasks
• Set in order: Ensure that all items are organized
and each item has a designated place.
• Shine: Cleaning and maintaining the newly
organized workspace.
• Standardize: Create a set of standards for both
organization and processes.
• Sustain: Sustain new practices and conduct audits
to maintain discipline.
Maintenance types
• Corrective maintenance: Identify, isolate, and rectify a fault so that
the failed equipment, machine or system can be removed or repaired
from the overall system.

• Preventive maintenance: Corrective measures to prevent future


issues from rising.
Safety procedures
• Personal Protective Equipment are provided: helmets, vest, earplugs
etc.
• Specific safe zones and designated walkways for safe passage.
• Communication and signaling between individual and driver is a must
when crossing.
• Fire hydrant and detection system, fire extinguishers etc.
• Proper waste disposal
Fire Hydrant and detection system
• Red water pipes fitted all around the mill with
nearby hoses.
• Smoke/heat detector and bells are also fitted all
around that are controlled by PLC. Can pinpoint
exact location of fire on interface.
• Ideal pressure stays above 7
• 3 pumps are used to keep pressure high
• Jockey Pump (7 bar)
• Main motor pump (5 bar)
• Diesel engine pump (4 bar)
Waste Management
• 5 bins used with different colors. These colors represent:
Color Waste Type Disposal

Yellow Any type of plastic, poly, Biscuit City Corporation Dumping area
packets, cable cover
Green Cloth/pieces of wastage cloth City Corporation Dumping area

Red Sand, Floor dust City Corporation Dumping area

Grey Any small pieces of Metal Re-cycling area for melting


Materials, Iron dust
Blue Used Hand Gloves City Corporation Dumping area
Water treatment Plant
• 2 types of water used: contact (for billets cooling) and non contact
(for cooling machine)
• Solids are filtered from water. Then chemicals are added:
• Micro-biocides to kill insects (for non-contact)
• Anti-coloration to create oil film in pipe
• NaOCl for backwash
• Coagulant 711 to drop heavy particle
• Bio dispersion to remove algae
• After purification, water is stored for reuse and pumped to mill.
Costing and production

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