A PROJECT REPORT ON BELT WATCH SYSTEM FOR

1. A PROJECT REPORT ON BELT WATCH SYSTEM FOR CONVEYOR APPLICATIONS SUBMITED BY SURYAKANT TRIPATHI NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR

2. CERTIFICATE This is to certify that SURYAKANT TRIPATHI of NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR has successfully completed his project on BELT WATCH SYSTEM FOR CONVEYOR APPLICATION under my supervision from 21 st May 2015 to 23 rd June 2014.I wish all the best for his future. Mr. AMIT ROY(guide) RMM DEPARTMENT , ELECTRICAL MAINTENANCE TATA STEEL JAMSHEDPUR CHARU KHULLAR In- charge Vocational raining Tata Steel Ltd

3. ACKNOLEDGEMENT I FEEL PRIDE TO EXPRESS SINCERE AND INDEBTEDNESS TO MY GUIDE MR. AMIT ROY MANAGER OF RMM DEPARTMENT IN COAL SECTION , TATA STEEL ,JAMSHEDPUR, FOR PROVIDING THE NECESSARY FACILITIES AND ENCOURAGEMENT DURING THE COURSE OF PROJECT WORK. I’M THANKFUL TO HIM FOR HIS SUGGESTIONS AND CONSTANT ENCOURAGEMENT FOR MAKING THE REALM OF DREAM INTO A SUCCES LAST BUT NOT THE LEAST,WE WOULD LIKE TO THANK FOR OUR COLLEGE ADMINISTRATION FOR PROVIDING US THIS GOLDEN OPPORTUNITY TO UNDERGO TRAINING IN SUCH A PRESTIGIOUS INDUSTRY OF INDIA,TATA STEEL,JAMSHEDPUR. SURYAKANT TRIPATH STUDENT, DEPARTMENT OF ELECTRICAL ENGINEERING NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR VT20151032

4. CONTENTS 1. OVERVIEW OF TATA STEEL 2. RAW MATERIAL MANAGEMENT 3. CUSTOMER OF RMM 4. BLAST FURNACE & COKE PLANT 5. THE BELT WATCH SYSTEM 6. CONCLUSION 7. REFRENCES

5. OVERVIEW OF TATA STEEL Tata Steel Limited (formerly Tata Iron and Steel Company Limited (TISCO)) is an Indian multinational steel-making company headquartered in Mumbai, Maharashtra, India, TISCO is a worldwide steel industry founded in 1907 by Dorabji Tata.. TISCO stands for Tata Iron and Steel Company Limited. Tata Iron and Steel Company was established by Dorabji Tata on August 25, 1907, as part of his father Jamsetji's Tata Group. On February 12, 2012 Tata Steel completed 100 years of steel making in India.

6. OVERVIEW OF TATA STEEL It was the 12th largest steel producing company in the world in 2012. with an annual crude steel capacity of 23.8 million tones, and the second largest private-sector steel company in India (measured by domestic production) with an annual capacity of 9.7 million tones after SAIL. Tata Steel has manufacturing operations in 26 countries, including Australia, China, India, the Netherlands, Singapore, Thailand and the United Kingdom, and employs around 80,500 people.

7. OVERVIEW OF TATA STEEL Its largest plant is located in Jamshedpur, Jharkhand Tata Steel acquired the UK-based steel maker Corus which was the largest international acquisition by an Indian company till that date. The company changed its name from TISCO to Tata Steel in 2005. Tata Steel primarily serves customers in the automotive, construction, consumer goods, engineering, packaging, lifting and excavating, energy and power, aerospace, shipbuilding, rail and defence and security sectors.

8. RAW MATERIAL MANAGEMENT Raw material handling department is a part of raw material and iron making group. The department is the prime feeder of bulk raw material to iron making & steel making production departments. The department is basically bridging the gap between the supplier and the consumers.

9. THE BELT WATCH SYSTEM The mission is to ensure right type of raw materials in right quantity at right place with minimum service charge so that production department could run their plant at optimal level. The department’s role is to coordinate with the suppliers & the service providers like Railways & transporters in such a way to avoid production loss on account of Raw Materials the minimum Inventory of raw Materials inside the works.

10. CUSTOMERS OF RMM 1. Blast furnaces A-F blast furnace G blast furnace H blast furnace I blast furnace 2. Coke plant Battery 8,9 Battery 5,6,7 Battery 10 & 11

11. THE BELT WATCH SYSTEM Generally any industrial work consists of a bulk transfer of products from one place to other. These products can’t be transferred by crane or luggage trucks as there is continuous requirement of the product. A steel factory require coal as a fuel for continuous ignition purposes.

12. THE BELT WATCH SYSTEM Hence for the continuous transfer of raw materials in steel industry like coal, coke cynter etc are transferred from one place to another via CONVEYOR BELTS. These belts are totally based on the principle of conversion of rotational kinetic energy to translational kinetic energy.

13. THE BELT WATCH SYSTEM

14. THE BELT WATCH SYSTEM The conveyor system consists of 1. Pulleys 2. Belts 3. Motors 4. Rollers(for generate pulses) 5. Protection switches like pull chord switch, belt snap switch, belt snap switch etc. 6. A display board to indicate the status of the protective switches. 7. Sensor module and termination module 8. A PPI panel which receives the trip signal and give a logic signal to PLC.

15. THE BELT WATCH SYSTEM

16. THE BELT WATCH SYSTEM 1. The pulleys act as a medium to convert rotational K.E to translational K.E. 2. Belts are used to transfer raw materials or the required products from one place to other.

17. THE BELT WATCH SYSTEM 3. Motor’s shaft is coupled with the pulleys axis with certain gear arrangement to provide require speed and torque Generally induction motors of high slip is used for this purpose since the running and starting characteristics of the motor is influenced by the load. High slip motors also improve the load sharing among directly coupled motors and reduce the effect of belt stretching.

18. THE BELT WATCH SYSTEM Adequate power supply must be fed to the motors so that the stretch to slip ratio must not cross beyond certain limits. The gearing system with the motors will change depending upon the type of applications. For high speed belts with low weight of raw materials per foot a large gear coupled with the motor shaft whose teeth is connected with the teeth of small gear attached directly with the axis of pulley. For high torque applications with heavy weight of raw materials per foot a small gear coupled with the motor’s shaft. It’s teeth connected with the teeth of large gear which is attached directly to the axis of the pulley.

19. THE BELT WATCH SYSTEM 4. Rollers are used as a sensing element to detect appropriate speed and if the speed reach beyond permissible limits it will send inappropriate signals(pulses) to the controller which will detect the over and under speed conditions makes the whole system to switch off. Under normal conditions since 4 plates are attached to the roller wheels it will send 4 pulses per revolution. If the speed go beyond permissible limits it’ll not send 4 pulses to the controller and in this way the controller will understand the fault.

20. THE BELT WATCH SYSTEM There is a proximity sensor which act as a switch when one blade pass through it and there is a setting in PLC that it receives a fixed amount of pulses in a given interval of time(NTD). It is approximately 6 seconds overall. 1 sec in field and 5 seconds form PLC. If the pulse is not given in this time the conveyor is turned off

21. THE BELT WATCH SYSTEM There is a controller board for zero speed switch which contain a red led when glows means there is a fault(reduction in speed), the yellow led flashes at the same frequency as that of sending of pulse by the proximity switch. The green led has the necessarily to glow or the conveyor has to be shut off.

22. THE BELT WATCH SYSTEM There is a transformer also inside the controller board which converts the incoming 220 volts to 110 volts to the conveyor. ITD(initial time delay):- For the first 5 seconds the motor must be in running position so as to make up speed and can’t be stopped during this time NTD(normal time delay):- After 70 percent reach of speed a normal time delay is set in PLC so that it will get exactly one pulse during this time period under normal running conditions.

23. THE BELT WATCH SYSTEM The permissible range of speed is 70 to 100 percent of the rated speed of the motor. In case of starting conditions the raw material is fed into the belt above 70 percent of the rated speed. If the speed go beyond that level, there is ZSS(zero speed switch) which operates makes the conveyor to shut down immediately.

24. THE BELT WATCH SYSTEM Generally what happens there is some amount of metal involved in raw materials(which need to be filtered out after a certain number of steps) these traces of metals are responsible for the wear and tear of belt due to which most of the raw materials fall in ground led to heavy loss. The rollers also provide a protection to these type of problems. Yet there is another solution for this problem there is a BELT SNAP switch which operates when some material fall due to torn of belt on a rope provided below the belt.

25. THE BELT WATCH SYSTEM 5. Protection switches are used to make protection of belt from wear & tear and inappropriate positioning. Generally there are two types of protection switches mainly in conveyor system. Automatic protection which involves Belt Sway Switch(BWS) which operates automatically when there is an inappropriate positioning of belt Manual protection involves Pull Chord Switch(PCS) which is operated manually. When somebody sees any inappropriate positioning of belt he can operate that switch and the conveyor system goes turn off.

26. THE BELT WATCH SYSTEM

27. THE BELT WATCH SYSTEM

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29. THE BELT WATCH SYSTEM 6. The display board of the protection panel involves three 7 segment displays which represent the status of the protection switches. The representation is just like:- P AC pull card loop healthy. B AC belt sway loop healthy. P SC pull card loop cable shorted. B SC belt sway loop cable shorted.

30. The display board works on the principle of digital logic. A seven segment decoder gives the logic output in the seven segment display module.4 pins (14,15) and (43,44) pin no are taken out for controlling purposes by PLC THE BELT WATCH SYSTEM

31. THE BELT WATCH SYSTEM 7. The sensor module(BW7011C) senses the action taken with the pull chord(when somebody pulls it, then senses) and sends the display board a signal about it’s pull chord no and the display board display the pull chord number being operated. The information which it gives to the display unit depend on the pulse width modulation

32. THE BELT WATCH SYSTEM What is pulse width modulation ? Output signal alternates between on and off within specified period Controls power received by a device The voltage seen by the load is directly proportional to the source voltage.

33. THE BELT WATCH SYSTEM Duty Cycle: on-time / period V low is often zero Definitions

34. THE BELT WATCH SYSTEM Types of Pulse Width Leading edge fixed, tailing edge modulated Pulse center fixed, edges modulated Tailing edge fixed, leading edge modulated Pulse Width constant, period modulated

35. THE BELT WATCH SYSTEM

36. THE BELT WATCH SYSTEM Pull Cord Switch with Sensor module The red wire is the main supply wire(+ve) The black wire is neutral(grounded) The green wire is one of the wires included in NC contacts of sensor module

37. THE BELT WATCH SYSTEM With Termination module Consist of red and black wire (+ve and neutral)

38. THE BELT WATCH SYSTEM 8. About PPI panel Pull cord positioning indicator unit located in the control room and one Sensor Module(JP202) per Pull Cord switch in the field. The Sensor Module is fitted across the normally closed (NC) switch inside the switch housing.  Emergency lines with up to ninety-nine pull cord switches can use PPI-202 for indication. The two-core cable in the pull cord circuit is used to transmit the position of the operated switch electrically nearest to the indicator. The indicator displays the switch number.

39. THE BELT WATCH SYSTEM The transmitter unit also automatically detects the resetting of the operated switch and outputs the position numbers of next nearest operated switch if multiple switches are operated. If no operated pull cord switch is detected it outputs the “Healthy Loop signal”.

40. THE BELT WATCH SYSTEM PPI panel outlook MODE BUS COMMUNICATION TB PULL CHORD TB BELT SWAY TB

41. THE BELT WATCH SYSTEM MODE BUS B1- FOR RS485 TEST KEY SPARE +VE 24 VDC -VE 24 VDC EARTH SPARE 5V GROUND FOR RS485 A1+ FOR RS485

42. THE BELT WATCH SYSTEM BELT SWAY BLACK WIRE OF BELT SWAY SWITCH FROM FIELD RED WIRE OF BELT SWAY SWITCH FROM FIELD -VE 24 VDC FOR BELT SWAY TRIP SPARE TRIP CONTACT FOR PULL CORD SWITCH +VE 24 VDC FOR BELT SWAY TRIP

43. THE BELT WATCH SYSTEM SMPS(110/24V) 110 V 24 Vdc

44. THE BELT WATCH SYSTEM MCBs MCB 110 v

45. THE BELT WATCH SYSTEM RELAYs BSS RELAY PCS RELAY

46. THE BELT WATCH SYSTEM CIRCUIT DIGRAM FOR BELT WATCH

47. THE BELT WATCH SYSTEM Display blank Check 230/110 Vac at input of SMPS mounted on back plate of panel Check 24 Vdc at output of SMPS Check 24 Vdc at terminal no 11,12 of indicator unit Display shows p.00 or b.00 Cable may be open between BWS panel and first field switch Two core connecting field switches from conveyor to BWS panel may get interchanged Display shows p sc or b sc Two core connecting field switches may get shorted in between TYPES OF FAULTS

48. THE BELT WATCH SYSTEM Display shows wrong number of actuated switch at field Check switch connection , if any dust & water inside switch for all switches Indicator malfunctions Follow procedure Emergency by-pass

49. THE BELT WATCH SYSTEM SOLUTION Display Blank If not check corresponding MCB – replace if required If not replace SMPS If ok repair indicator Display shows p.00 or b.00 Do the proper connection & check system performance Correct the polarity of wires as explain in point 4 of installation guide Display shows p sc or b sc Power off Indicator ,wait 1-2 minute ,power on Indicator ,if still display remains as it is follow the procedure detect cable short

50. THE BELT WATCH SYSTEM Display shows wrong number of actuated switch at field Clean the switches & check system performance b. If still problem remains ,follow procedure Detect cable short

51. THE BELT WATCH SYSTEM Procedure to detect cable short / cable fault / switch fault :- Switch off power for master unit Operate known switch from field (say switch no 5,10,15,20,25,30 & so on) Switch on power for master unit As feature of master unit ,it start displaying operated switch nos. in cyclic fashion Suppose cable short is at switch no 17 Master unit will indicated switch no 5,10,15 and then instead of 20 it will show sc It mean cable is shorted in between switch no.15 &20 Now reset all operated switches ,operated from 15 to 20 Repeat step no c to f This time master unit will indicate operated switch no 15,16;sc as short is at switch no17 Resolve the problem at switch no 17 Switch off master unit Check performance for any operated switch

52. THE BELT WATCH SYSTEM Emergency by-pass feature :- If belt watch indication having malfunction for local indication or plc communication . Remove top connector marked for 1-13 terminals from back side of belt watch indicator Keep power to this particular indicator in ON state

53. CONCLUSIONS Belt watch is a bulk material handling system .It uses belt for carrying raw materials from one place to another. Pull cord and belt sway switches are installed along the conveyor to provide safety against malfunctioning. The main components of the system are: Master cum display unit located in central control panel. Sensor module located in each pull cord/belt sway switch. Termination module located in the last pull cord/belt sway switch. We have learned the entire process in part by part method. we also learned how automation is done in the control panel; which helped me a lot to understand how automation is done in mass production of industry. Because The belt watch system and its checking procedure is based on automation.

54. REFRENCES WWW.WICKIPEDIA.COM WWW.NPTEL.ORG WWW.ELECTRICALFORU.COM WWW.JAYSHREEELECTRONICS.COM