CONTENT

1. INDUSTRY PROFILE 2. PRIDE OF PLACE 3. PRODUCT OF COMPANY 3.1 4. SPECIALITY OF TECHNOLOGY 5. IMPORTED EQUIPMENT 6. PROCESS 7. COLD ROLLING PROCESS OF CRCA MATERIAL 7.1 H.R. SLITTING 7.2 Pickling 7.3 Flat Rolling Mill 7.4 Electro Cleaning Line 7.5 Annealing 7.6 Skin Pass 7.7 Slitting 7.8 Packing 8. APPLICATIONS OF CRCA 9. GALVANIZATION PROCESS 10. PROGRAMMABLE LOGIC CONTROL 11. DRIVES 12. MOTOR 13. MOTOR CONTROL CENTRE 14. POWER CONTROL CENTRE

PRIDE OF PLACE
The company Products continue to be a favourite with all quality conscious users of Automobiles & White Goods/Domestic Appliances & General Engineering Industries. We take great pride in maintaining the highest standards of quality which our customers expect and it is no wonder that eminent corporate like Maruti Udyog, Honda Siel Cars, Telco, Hindustan Motors , General Motor, Hyundai Motors, Ford Motors, Mahindra & Mahindra, Eicher Tractors, Ashok Leyland, LG Electronics, Whirlpool, Videocon, Daikin Shriram, National Matsushita, Samsung Electronics, Godrej, Voltas, IFB, Fedders Lloyd, Carrier Refrigeration, Electrolux Group, Hitachi Airconditioners, SKF Bearing, Crompton Greaves, Philips India, BHEL, Alstom Limited, L&T,BPL,GE Motors, Jhonson Lift, Kone Elevator, Lucas TVS,NRB Bearing, Harsha Engineers Limited, Bundy India Limited, Tecumesh., Bajaj Auto, Honda Motorcycle, Yamaha, Bajaj Tempo and so many such big organizations continue their unbounded trust on us and in regularly sourcing our products.

PRODUCT OF COMPANY
COLD ROLLED STEEL COILS : Thickness (mm) Width (mm) Coil Weight (MT) Surface Finish Grades 0.10 to 4.00 10 to 1700 (Max) Up to 30 MT (7 to 18 kg/mm width) Super Bright, Bright, Dull & Matte. Super EDD/DD/D (SPCX, SPCEN, SPCD, SPCC)

Fig3.1-cold Rolled Steel Coils COLD ROLLED STEEL SHEETS : Thickness (mm) Width (mm) Coil Weight (MT) Surface Finish Grades 0.10 t0 4.00 10 to 1700 (Max) Up to 30 MT (7 to 18 kg/mm width) Super Bright, Bright, Dull & Matte. Super EDD/EDD/DD/D (SPCX, SPCEN, SPCD, SPCC)

Fig3.2-cold Rolled Steel Sheet

 Galvanized Plain Coil : PLAIN SKIN PASSED CORRUGA TED HILGP PETROL /FUEL TANK Thick ness (mm) Width (mm) upto 1350 upto 1350 602, 762, 800, 900, 1050 200 to 1350 100 to 1350 100 to 1350 0.10 to 2.50 0.30 to 2.50 0.12 to 1.60 0.30 to 2.50 0.40 to 1.20 0.60 to 1.60 FGP FAN BLADE GPC BUSES/CO ACHES

Surfa ce Finish

Regula r& mim.sp angle

Matte with zero/min. spangle

Regular Spangle

Matte, Bright Finish, No spangle

Matte finish, No spangle

Matte, Bright finish, No spangle

Coati ng Mass (gms/ m2) Grade s

80 to 300 80 to 300 80 to 300

20 to 80

60 to 90

60 to 80

Soft/Lo ck formin g

EDD, DD,D, SPCEN, SPCD,SP CC

Roofing

EDD, DD,D, SPCEN, SPCD,SP CC

SPCD,S PCC

SPCEN, SPCD,SPC C

 Galvanized Plain Sheet : PLAIN SKIN PASSE D CORRUGA TED HILGP PETROL/ FUEL TANK Thick ness (mm) Width (mm) upto 1350 upto 1350 602,7 62,80 0, 900,1050 200 to 1350 0.10 to 2.50 0.30 to 2.50 0.12 to 1.60 0.30 to 2.50 0.40 to 1.20 100 to 1350 100 to 1350 0.60 to 1.60 FGP FAN BLADE GPC BUSES/CO ACHES

Surfac e Finish

Regular & mim.spa ngle

Matte with zero/mi n. spangle

Regular Spangle

Matte, Bright Finish, No spangle

Matte finish, No spangle

Matte, Bright finish, No spangle

Coatin g Mass (gms/ m2) Grade s

80 to 300 80 to 300 80 to 300

20 to 80

60 to 90

60 to 80

Soft/Lo ck forming

EDD, DD,D, SPCEN, SPCD,S PCC

Roofing

EDD, DD,D, SPCEN, SPCD,SP CC

SPCD,S PCC

SPCEN, SPCD,SPCC

Cut to Lengt h (mm)

upto 4500

upto 4500

upto 4500

upto 4500

upto 4500

upto 4500

SPECIALITY OF TECHNOLOGY
Auto shape control on both sides of the mill. Mill clean system with syntactic to avoid the coolant mark on the strip. Latest sophisticated ETD machine. Online tension for better flatness and control elongation. Computerised inventory control management. Electrolytic cleaning line to remove irons fines from strips. Electrostatic rust preventive oil spray system for control oil & coating on CRCA surface. Excellent mechanical properties.

IMPORTED EQUIPMENT
EDT machine from valdrich siegen, GERMANY Hydrogen annealing furnace from Ebner, AUSTRIA X-Ray thickness from DMC, USA X-Ray scanner from DMC ,USA Shimless tooling from GERMANY Emission spectrometer from Hilger, ENGLAND Microhardness tester from Zwick , GERMANY Draw ability tester from Olsen,USA Ionometer from Orion, USA Surface finish tester from Mitutoyo, JAPAN Cold rolling mil from Hitachi, JAPAN Skin pass mill from Clecin, FRANCE Cut to length from GERMANY

PROCESS
Raw material is in the form of hot rolled (HR) coils these are of different sizes, thickness and width maximum is 1600 mm. In this plant raw material is taken from Ghaziabad stockyard. Firstly the properties of the materials are checked at P.P.C then it is passed through pickling process so as to remove the rust then cooled by water and dried by the dry air. Then it is passed through rollers (6Hi &20Hi) for changing the thickness of the sheet as per the customer requirement. After this they are passed through annealing process if required (customers requirement), then galvanized and at last skin passed. To overcome the increasing in hardness, micro-structure elongation skin passing is done. After this the sheet is cut in different sizes as customer requirement and then packed.

Fig6-Process Route Of CRCA Material

COLD ROLLING PROCESS OF CRCA MATERIAL

7.1 H.R.Slitting:
In HR slitting, the hot rolled coil is slitted to remove extra part from coil. The activity involved in HR slitting are Loading of coil Slitting Recoiling

7.2 Pickling:
Pickling is required in order to get a neat & clean surface. The HR coil is recoiled and passed through three successive tanks containing Different concentrations of HCL Acid(0.6%,7-11%,12-8%).The temperature of tanks are maintained about 6085celcius.the flow chart of pickling is-

Fig7.2-Pickling Process

7.3 Flat Rolling Mill:

Cold rolling is the mechanical operation of reducing the thickness of coil without any operation of temp. The reduction is given in different number of passes depending upon the input/output size, the grade of material, type of equipment and application. In this process coil is rolled LTR (Left Tension Reel) to the RTR (Right Tension Reel) by taking many passes for the required dimension as per customers requirement. The flow chart of rolling process is

Fig7.3-Flat Rolling Mill Process

7.4 Electro Cleaning Line:

This is a combination of hot pickling & electrolyte cleaning apart from the mechanical cleaning. This operation ensures the coil reaching at the annealing furnace is clean and oil free conduction. In this process rolled coil is loaded on uncoiler by coil car, the strip is fed up to the seam welder using pinch roll, And the head end of new coil is welded with the tail end of the preceding coil. Then pre-cleaning is done by hot alkali solution, then in electro-cleaning the strip passes through two set of electrode having max. Current of 8000 AMP. Now the strip is passing through brush rolls & hot water is sprayed on the strip then coil is recoiling and unloading. The flowchart of ECL is

Fig7.4-Electro Cleaning Line Process

7.5 Annealing:
The coil from ECL is annealed in order to reduce the hardness & improving the mechanical properties of material. In this the world class EBNER_AUSTRIA Furnace is used. Annealing, in metallurgy and materials science, is a heat treatment wherein a material is altered, causing changes in its properties such as strength and hardness. It is a process that produces conditions by heating to above the recrystallization temperature, maintaining a suitable temperature, and then cooling. Annealing is used to induce ductility, soften material, relieve internal stresses, refine the structure by making it homogeneous, and improve cold working properties. In the cases of copper, steel, silver, and brass, this process is performed by substantially heating the material (generally until glowing) for a while and allowing it to cool. Unlike ferrous metalswhich must be cooled slowly to annealcopper, silver and brass can be cooled slowly in air or quickly by quenching in water. In this fashion the metal is softened and prepared for further work such as shaping, stamping, or forming.

There are three stages in the annealing process, with the first being the recovery phase, which results in softening of the metal through removal of crystal defects (the primary type of which is the linear defect called a dislocation) and the internal stresses which they cause. Recovery phase covers all annealing phenomena that occur before the appearance of new strain-free grains. The second phase is recrystallization, where new strain-free grains nucleate and grow to replace those deformed by internal stresses. If annealing is allowed to continue once recrystallization has been completed, grai growth will occur, in which the microstructure starts to coarsen and may cause the metal to have less than satisfactory mechanical properties.

Fig7.5-AnnealingProcess

7.6 Skin Pass:

After cold rolling the metallurgical as well as mechanical properties of coil tend to change. The changes are increasing in hardness micro-structure elongation, yield point elongation. So to overcome from these drawbacks skin passing is done.

Fig7.6-Skin Pass Process

7.7Slitting:
Roll slitting, also known as log slitting, is a shearing operation that cuts a large roll of material into narrower rolls. For harder materials, such as sheet metal, blades cannot be used. Instead a modified form of shearing is used. Two cylindrical rolls with matching ribs and grooves are used to cut a large roll into multiple narrower rolls. This continuous production process is very economical yet precise; usually more precise than most other cutting processes. However, the occurrence of rough or irregular edges known as burrs are commonplace on slit edges. Also, the geometry of these rolls is determined by specific tolerances in addition to the type of material and work piece thickness. The splitter consists of three main parts, "an uncoiler, splitter, and recoiler "[4] the material is fed from the uncoiler, through the nip between the two circular cutting wheels (one on top and another underneath) and then re-wound in slit pieces on the recoiler.

7.8Packing:
After slitting the packing is done of the product and load in to the trucks.

8.APPLICATIONS OF CRCA
Automobiles Electrical panels Furniture Transformers Oil Barrels & Drums

GALVANIZATION PROCESS
Galvanization (or galvanisation) is the process of applying a protective metallic coating to an underlying piece of metal, in order to prevent rusting. The term is derived from the name of Italian scientist Luigi Galvani. The most common method in current use is a process called hot-dip galvanization. The protective layer can also be achieved using electrochemical and electrodeposition processes. In current use, the term refers to the coating of steel or iron with zinc. This is done to prevent galvanic corrosion (specifically rusting) of the ferrous item. The value of galvanising stems from the relative corrosion resistance of zinc, which, under most service conditions, is considerably less than those of iron and steel. The effect of this is that the zinc is consumed first as a sacrificial anode, so that it catholically protects exposed steel. This means that in case of scratches through the zinc coating, the exposed steel will be catholically protected by the surrounding zinc coating, unlike an item which is painted with no prior galvanising, where a scratched surface would rust. Furthermore, galvanising for protection of iron and steel is favoured because of its low cost, the ease of application, and the extended maintenance-free service that it provides. The term galvanizing, while correctly referring to the application of the zinc coating by the use of a galvanic cell (also known as electroplating), sometimes is also used to refer to hot dip zinc coating (commonly incorrectly referred to as hot dip galvanizing). The practical difference is that hot dip zinc coating produces a much thicker, durable coating, whereas genuine galvanizing (electroplating) produces a very thin coating. Another difference, which makes it possible to determine visually which process has been used if an item is described as 'galvanized', is that electroplating produces a nice, shiny surface, whereas hot dip zinc coating produces a matte, grey surface. The thin coating produced by electroplating is much more quickly consumed, after which corrosion turns to the steel or iron itself. This makes electroplating unsuitable for outdoor applications, except in very dry climates. For example, nails for indoor use are electroplated (shiny), while nails for outdoor use are hot dip zinc coated (matte grey). However, electroplating and subsequent painting is a durable combination because the paint slows down the consumption of the zinc. Car bodies of some premium makes are corrosion protected using this combination.

Nonetheless, electroplating is used on its own for many outdoor applications because it is cheaper than hot dip zinc coating and looks good when new. Another reason not to use hot dip zinc coating is that for bolts and nuts size M10 or smaller, the thick hot-dipped coating uses up too much of the threads, which reduces strength (because the dimension of the steel prior to coating must be reduced for the fasteners to fit together). This means that for cars, bicycles and many other 'light' mechanical products, the alternative to electroplating bolts and nuts is not hot dip zinc coating but making the bolts and nuts from stainless steel (known by the corrosion grades A4 and A2). Electroplated steel is visually indistinguishable from stainless steel when new. To determine whether a part is electroplated or stainless steel, apply a magnet. The most common stainless steel alloys (including those used for bolts and nuts) are not magnetic or only very slightly attracted to a magnet. Zinc coatings prevent corrosion of the protected metal by forming a physical barrier, and by acting as a sacrificial anode if this barrier is damaged. When exposed to the atmosphere, zinc reacts with oxygen to form zinc oxide, which further reacts with water molecules in the air to form zinc hydroxide. Finally zinc hydroxide reacts with carbon dioxide in the atmosphere to yield a thin, impermeable, tenacious and quite insoluble dull gray layer of zinc carbonate which adheres extremely well to the underlying zinc, so protecting it from further corrosion, in a way similar to the protection afforded to aluminium and stainless steels by their oxide layers.

Fig9- Process Route Of Galvanized Sheet & Coil

PROGRAMMABLE LOGIC CONTROL

A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or lighting fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in batterybacked or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.

10.1 Features:
Control panel with PLC (grey elements in the centre). The unit consists of separate elements, from left to right; power supply, controller, relay units for in- and output The main difference from other computers is that PLCs are armored for severe conditions (such as dust, moisture, heat, cold) and have the facility for extensive input/output (I/O) arrangements. These connect the PLC to sensors and actuators. PLCs read limit switches, analog process variables (such as temperature and pressure), and the positions of complex positioning systems. Some use machine vision. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays, solenoids, or analog outputs. The input/output arrangements may be built into a simple PLC, or the PLC may have external I/O modules attached to a computer network that plugs into the PLC.

10.2 Scan time:

A PLC program is generally executed repeatedly as long as the controlled system is running. The status of physical input points is copied to an area of memory accessible to the processor, sometimes called the "I/O Image Table". The program is then run from its first instruction run down to the last rung. It takes some time for the processor of the PLC to evaluate all the ladders and update the I/O image table with the status of outputs. This scan

time may be a few milliseconds for a small program or on a fast processor, but older PLCs running very large programs could take much longer to execute the program. If the scan time was too long, the response of the PLC to process conditions would be too slow to be useful.

10.3 System scale:

A small PLC will have a fixed number of connections built in for inputs and outputs. Typically, expansions are available if the base model has insufficient I/O. Modular PLCs have a chassis into which are placed modules with different functions. The processor and selection of I/O modules is customised for the particular application. Several racks can be administered by a single processor, and may have thousands of inputs and outputs. A special high speed serial I/O link is used so that racks can be distributed away from the processor, reducing the wiring costs for large plants.

10.4 Communications:
PLCs have built in communications ports, usually 9-pin RS-232, but optionally EIA-485 or Ethernet. Modbus, BACnet or DF1 is usually included as one of the communications protocols. Other options include various field buses such as DeviceNet or Profibus. Other communications protocols that may be used are listed in the List of automation protocols. Most modern PLCs can communicate over a network to some other system, such as a computer running a SCADA (Supervisory Control and Data Acquisition) system or web browser. PLCs used in larger I/O systems may have peer-to-peer communication between processors. This allows separate parts of a complex process to have individual control while allowing the subsystems to co-ordinate over the communication link. These communication links are also often used for HMI devices such as keypads or PC-type workstations.

10.5 Programming:
PLC programs are typically written in a special application on a personal computer, then downloaded by a direct-connection cable or over a network to the PLC. The program is

stored in the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a single PLC can be programmed to replace thousands of relays. Under the IEC 61131-3 standard, PLCs can be programmed using standards-based programming languages. A graphical programming notation called Sequential Function Charts is available on certain programmable controllers. Initially most PLCs utilized Ladder Logic Diagram Programming, a model which emulated electromechanical control panel devices (such as the contact and coils of relays) which PLCs replaced. This model remains common today. IEC 61131-3 currently defines five programming languages for programmable control systems: FBD (Function block diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal programming language), IL (Instruction list, similar to assembly language) and SFC (Sequential function chart). These techniques emphasize logical organization of operations

DRIVES
A motor controller is a device or group of devices that serves to govern in some predetermined manner the performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation,

selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and faults.

11.1 Types of drives:

There are three general categories of electric drives: DC motor drives, eddy current drives and AC motor drives. Each of these general types can be further divided into numerous variations. Electric drives generally include both an electric motor and a speed control unit or system. The term drive is often applied to the controller without the motor. In the early days of electric drive technology, electromechanical control systems were used. Later, electronic controllers were designed using various types of vacuum tubes. As suitable solid state electronic components became available, new controller designs incorporated the latest electronic technology.

11.1.1 DC drivesDC drives are DC motor speed control systems. Since the speed of a DC motor is directly proportional to armature voltage and inversely proportional to motor flux (which is a function of field current), either armature voltage or field current can be used to control speed. Several types of DC motors are described in the electric motor article. The electric motor article also describes electronic speed controls used with various types of DC motors. Rating (9kW to 18MW)

11.1.2 AC drivesAC drives are AC motor speed control systems. Slip controlled drives control the speed of an induction motor by increasing a motor's slip, either by reducing the voltage applied to the motor, or increasing the resistance of the rotor windings. Because they are generally less efficient than other types of drives, slip controlled drives have lost popularity and have recently been used only in special situations. See eddy current drives above. In larger ratings (more than a few kilowatts), a wound-rotor motor has its rotor connected to a converter that returns energy to the power system, converting it from low slip frequency to the line frequency. This reclaims the energy that would otherwise be wasted in rotor circuit

resistors. These are called "slip energy recovery drives" and are used on such applications as forced-draft blowers for boilers. Rating Low voltage AC Derive: 0.1 to 5600 KW

Medium voltage AC Derive: 315 Kw to 100KW High voltage AC Derive: few 100s KW to 10s of MW

Fig11.1.2- Block Diagram Of Drive

11.2 Application of AC Derives:

Steelmills Paper textile mills Printing machines Servo Cementmills Mine Winder etc.

MOTOR
An electric motor converts electrical energy into mechanical energy. Most electric motors operate through the interaction of magnetic fields and current-carrying conductors to generate force. The reverse process, producing electrical energy from mechanical energy, is done by generators such as an alternator or a dynamo; some electric motors can also be used as generators, for example, a traction motor on a vehicle may perform both tasks. Electric motors and generators are commonly referred to as electric machines. Electric motors are found in applications as diverse as industrial fans, blowers and pumps, machine tools, household appliances, power tools, and disk drives.

12.1 Types of Motor:

AC motors DC motors

12.1.1 Three Phase Induction MotorGenerally 3-phase induction motor are the most commonly used AC motor in industry because they have simple construction, low cost, high efficiency, reasonably , good power factor, self-starting torque and required low maintenance. Almost more than 90% of mechanical power used in industry is provided by three phase induction motor.

Fig12.1.1- Three Phase Induation Motor

Basic construction: The AC induction motor comprises 2 electromagnetic parts: Stationary part called the stator Rotating part called the rotor, supported at each end on bearings The stator and the rotor are each made up of: An electric circuit, usually made of insulated copper or aluminum, to carry current A magnetic circuit, usually made from laminated steel, to carry magnetic flux

The stator The stator is the outer stationary part of the motor, which consists of: The outer cylindrical frame of the motor, which is made either of welded sheets steel, cast iron or cast aluminium alloy. This may include feet or a flange for mounting. The magnetic path, which comprises a set of slotted steel laminations pressed into the cylindrical space inside the outer frame. The magnetic path is laminated to reduce eddy currents, lower losses and lower heating.

A set of insulated electrical windings, which are placed inside the slots of the laminated magnetic path. The cross-sectional area of these windings must be large enough for the power rating of the motor. For a 3-phase motor, 3 sets of windings are required, one for each phase.

Fig12.1.2- Stator And Rotor Lamination

The rotor This is the rotating part of the motor. As with the stator above, the rotor consists of a set of slotted steel laminations pressed together in the form of a cylindrical magnetic path and the electrical circuit. The electrical circuit of the rotor can be either: Wound rotor type, which comprises 3 sets of insulated windings with connections brought out to 3 sliprings mounted on the shaft. The external connections to the rotating part are made via brushes onto the sliprings. Consequently, this type of motor is often referred to as a slipring motor. Squirrel cage rotor type, which comprises a set of copper or aluminium bars installed into the slots, which are connected to an end-ring at each end of the rotor. The

construction of these rotor windings resembles a squirrel cage. Aluminium rotor bars are usually die-cast into the rotor slots, which results in a very rugged construction. Even though the aluminium rotor bars are in direct contact with the steel laminations, practically all the rotor current flows through the aluminium bars and not in the laminations.

The other parts

which are required to complete the induction motor, are: Two end-flanges to support the two bearings, one at the drive-end (DE) and the other at the non drive-end (NDE) Two bearings to support the rotating shaft, at DE and NDE Steel shaft for transmitting the torque to the load Cooling fan located at the NDE to provide forced cooling for the stator and rotor Terminal box on top or either side to receive the external electrical connections.

Fig12.1.3- Assembly Details Of AC Induction Motor

Principle and working When 3 phase supply is given to the motor, the resulting current generates a magnetic flux . Due to the switching sequence of 3 phase current in R, Y and B, the generated flux rotates around the rotor conductor. According to Faradays law which states that an emf induced in any closed circuit is due to the rate of change of magnetic flux through the circuit. Emf is induced in the Copper bar and due to this, current flows in the rotor. The direction of rotor can be given by Lenz law which states that the direction of induced current will be in the opposite of the motion causing it Here the relative velocity between the rotating flux and static rotor conductor is the cause of current generation; hence the rotor will rotate in the same direction to reduce the cause i.e. the relative velocity, thus rotating the rotor of the induction motor. 12.2.1 Types of DC MotorThere are three basic types of dc motors: (1) Series motors (2) shunt motors, and (3) compound motors. They differ largely in the method in which their field and armature coils are connected. Series DC Motor

In the series motor, the field windings, consisting of a relatively few turns of heavy wire, are connected in series with the armature winding. Both a diagrammatic and a schematic illustration of a series motor is shown in figure 9-75. The same current flowing through the field winding also flows through the armature winding. Any increase in current, therefore, strengthens the magnetism of both the field and the armature.

Fig12.2.1- Series DC Motor

Because of the low resistance in the windings, the series motor is able to draw a large current in starting. This starting current, in passing through both the field and armature windings, produces a high starting torque, which is the series motor's principal advantage. The speed of a series motor is dependent upon the load. Any change in load is accompanied by a substantial change in speed. A series motor will run at high speed when it has a light load and at low speed with a heavy load. If the load is removed entirely, the motor may operate at such a high speed that the armature will fly apart. If high starting torque is needed under heavy load conditions, series motors have many applications. Series motors are often used in aircraft as engine starters and for raising and lowering landing gears, cowl flaps, and wing flaps. Shunt DC Motor

In the shunt motor the field winding is connected in parallel or in shunt with the armature winding. (See figure 9-76) The resistance in the field winding is high. Since the field winding is connected directly across the power supply, the current through the field is constant. The field current does not vary with motor speed, as in the series motor and, therefore, the torque of the shunt motor will vary only with the current through the armature. The torque developed at starting is less than that developed by a series motor of equal size.

Fig12.2.1- Shunt DC Motor

The speed of the shunt motor varies very little with changes in load. When all loads are removed, it assumes a speed slightly higher than the loaded speed. This motor is particularly suitable for use when constant speed is desired and when high starting torque is not needed. Compound DC Motor

The compound motor is a combination of the series and shunt motors. There are two windings in the field: a shunt winding and a series winding. A schematic of a compound motor is shown in figure 9-77. The shunt winding is composed of many turns of fine wire and is connected in parallel with the armature winding. The series winding consists of a few turns of large wire and is connected in series with the armature winding. The starting torque is higher than in the shunt motor but lower than in the series motor. Variation of speed with load is less than in a series wound motor but greater than in a shunt motor. The compound motor is used whenever the combined characteristics of the series and shunt motors are desired. Like the compound generator, the compound motor has both series and shunt field windings. The series winding may either aid the shunt wind (cumulative compound) or oppose the shunt winding (differential compound). The starting and load characteristics of the cumulative compound motor are somewhere between those of the series and those of the shunt motor.

MOTOR CONTROL CENTRE

The motor control centre contains the main switch that supplies the power to entire annealing facility. In an emergency, all Electrical equipment can be powered down with this main switch. The MCC also supplies power to common equipment such as hydraulic pump. The MCC also house-

 The incoming main circuit breaker and metering equipment for voltage, total current and kilo-watt hours. Control voltage transfer for generate facilities and work base pair programmable logic controller (PLC). Motor starter for hydraulic power unit. Variable frequency drives for workbace fans.

13.1 Component of MCC:

13.1.1 RelayA relay is an electrically operated switch. Many relays use an electromagnet to operate a switching mechanism mechanically, but other operating principles are also used. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal.

Fig13.3.1- Relay Wiring Guide

Relay Types-

Ratchet relay This is again a clapper type relay which does not need continuous current through its coil to retain its operation.

Contactor relay A contactor is a very heavy-duty relay used for switching electric motors and lighting loads, although contactors are not generally called relays. Continuous current ratings for common contactors range from 10 amps to several hundred amps.

Solid-state relay A solid state relay (SSR) is a solid state electronic component that provides a similar function to an electromechanical relay but does not have any moving components, increasing long-term reliability.

Solid state contactor relay A solid state contactor is a heavy-duty solid state relay, including the necessary heat sink, used for switching electric heaters, small electric motors and lighting loads; where frequent on/off cycles are required. There are no moving parts to wear out and there is no contact bounce due to vibration.

Buchholz relay A Buchholz relay is a safety device sensing the accumulation of gas in large oil-filled transformers, which will alarm on slow accumulation of gas or shut down the transformer if gas is produced rapidly in the transformer oil.

Forced-guided contacts relay A forced-guided contacts relay has relay contacts that are mechanically linked together, so that when the relay coil is energized or de-energized, all of the linked contacts move together. If one set of contacts in the relay becomes immobilized, no other contact of the same relay will be able to move.

Overload protection relay Electric motors need over current protection to prevent damage from over-loading the motor, or to protect against short circuits in connecting cables or internal faults in the motor windings

13.1.2 ContactorA contactor is an electrically controlled switch used for switching a power circuit, similar to a relay except with higher current ratings. A contactor is controlled by a circuit which has a much lower power level than the switched circuit. Contactors come in many forms with varying capacities and features. Unlike a circuit breaker, a contactor is not intended to interrupt a short circuit current. Contactors range from those having a breaking current of several amps and 24 V DC to thousands of amps and many kilovolts. The physical size of contactors ranges from a device small enough to pick up with one hand, to large devices approximately a meter (yard) on a side. Contactors are used to control electric motors, lighting, heating, capacitor banks, and other electrical loads.

Fig12.2.1- Contactor
IEC The current rating of the contactor depends on utilization category. For example IEC categories are described as: AC1 - Non-inductive or slightly inductive loads AC2 - Starting of slip-ring motors AC3 - Starting of squirrel-cage motors and switching off only after the motor is up to speed. (Make Locked Rotor Amps (LRA), Break Full Load Amps (FLA)) AC4 - Starting of squirrel-cage motors with inching and plugging duty. AC11 - Auxiliary (control) circuits

Rating-

NEMA The current rating of smaller NEMA contactors or their auxiliaries are defined by NEMA ICS 5: Industrial Control and Systems, Control Circuit and Pilot Devices standard.[4] The nomenclature is a letter followed by a three digit number, the letter designates the current rating of the contacts and the current type (i.e., AC or DC) and the number designates the maximum voltage design values.Some examples are listed below: A150 A300 A600 13.1.3 BusbarIn electrical power distribution, a busbar is a strip of copper or aluminium that conducts electricity within a switchboard, distribution board, substation or other electrical apparatus. The size of the busbar determines the maximum amount of current that can be safely carried. Busbars can have a cross-sectional area of as little as 10 mm but electrical substations may use metal tubes of 50 mm in diameter (1,963 mm) or more as busbars, and

an aluminum smelter will have very large busbars used to carry tens of thousands of amperes to the electrochemical cells that produce aluminium from molten salts.

Fig13.1.3- Bus Bar

POWER CONTROL CENTRE

It includes the following components 1. Air Circuit Breaker 2. Transformer

14.1 Air Circuit Breaker:

A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city. 14.1.2 Types Low voltage circuit breakers

Low voltage (less than 1000 VAC) types are common in domestic, commercial and industrial application, and include: MCB (Miniature Circuit Breaker) rated current not more than 100 A. Trip characteristics normally not adjustable. Thermal or thermal-magnetic operation. Breakers illustrated above are in this category. MCCB (Molded Case Circuit Breaker)rated current up to 2500 A. Thermal or thermal-magnetic operation. Trip current may be adjustable in larger ratings. Low voltage power circuit breakers can be mounted in multi-tiers in low-voltage switchboards or switchgear cabinets. Magnetic circuit breaker Thermal magnetic circuit breaker Medium-voltage circuit breakers Medium-voltage circuit breakers rated between 1 and 72 kV. Common trip breakers High-voltage circuit breakers

14.2Transformer:
A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductorsthe transformer's coils. A varying current in the first or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force (EMF), or "voltage", in the secondary winding. This effect is called mutual induction. If a load is connected to the secondary, an electric current will flow in the secondary winding and electrical energy will be transferred from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary voltage (Vp), and is given by the ratio of the number of turns in the secondary (Ns) to the number of turns in the primary (Np) as follows:

14.2.1 Construction-

An elementary transformer consists of a soft iron or silicon steel core and two windings, placed on it. The windings are insulated from both the core and each other. The core is built up of thin soft iron or low reluctance to the magnetic flux. The winding connected to the magnetic flux. The winding connected to the supply main is called the primary and the winding connected to the load circuit is called the secondary. Although in the actual construction the two windings are usually wound one over the other, for the sake of simplicity, the figures for analyzing transformer theory show the windings on opposite sides of the core, as shown below.

Fig14.2.1- Transformer

14.2.2 WorkingWhen the primary winding is connected to an ac supply mains, current flows through it. Since this winding links with an iron core, so current flowing through this winding produces an alternating flux in the core. Since this flux is alternating and links with the secondary winding also, so induces an emf in the secondary winding. The frequency of induced emf in secondary winding is the same as that of the flux or that of the s supply voltage. The induced emf in the secondary winding enables it to deliver current to an external load connected across it. Thus the energy is transformed from primary winding to the secondary winding by means of electro-magnetic induction without any change in frequency. The flux of the iron core links not only with the secondary winding but also with the primary winding, so produces selfinduced emf in the primary winding: This induced in the primary winding opposes the applied voltage and therefore sometimes it is known as back emf of the primary. In fact the induced emf in the primary winding limits the primary current in much the same way that the back emf in a dc motor limits the armature current.

14.2.3 Types-

Step Down-

Step down transformers are designed to reduce electrical voltage. Their primary voltage is greater than their secondary voltage. This kind of transformer "steps down" the voltage applied to it. Step down transformers are made from two or more coils of insulated wire wound around a core made of iron. When voltage is applied to one coil (frequently called the primary or input) it magnetizes the iron core, which induces a voltage in the other coil, (frequently called the secondary or output). The turns ratio of the two sets of windings determines the amount of voltage transformation.

Fig14.2.3.1-Step Down Transformer

Step UpStep-Up Transformers are based on the same formulas that other transformers are, but the key element is that they convert voltages to higher volumes while reducing amperage and effects of resistance. This makes Step-Up Transformers ideal in longdistance power transmission use; by stepping up voltage and reducing amperage little energy is lost to resistance.

Fig14.2.3.2- Step UpTransformer