Submitted By:

VISHESH VIJAY 7th SEM. ECE

ORGANISATION PROFILE
Founded Founder Headquarter s Products 1962 MIKE JOHNSON U.S.A. Copper Tubes , 95/5 CuNi

&Cunifer Tubes 90/10 CuNi Tubes 70/30 CuNi Tubes Revenue US $2.210 billion Income US$ 154 million Employees 3012 (2010)

STEPS FOR MANUFACTURING INDUSTRIAL COPPER

Uncoiling of CRFH Coil at uncoiler Welding Degreasing Annealing in furnace

Cooling section

Entry looper

Pickling

Exit looper

Skin pass mill

Recoiling of CRFH coil at exit

Creep looper

Tension leveler

WELDING SECTION
Type -Guild Model QMM 125-54, Quick lap Seam Welder Material 200,300,400 CRSS Max. Strip Width 1300mm Min. Strip Width 600 mm Max. Strip Thickness 3.0mm Min. Strip Thickness 0.3mm Electrics 415/3/50 Weld Process Continuous Seam

Degreasing section
(i) First degreasing stage -

machine (ii) Second degreasing stage Chemical scrub brush (iii) Rinsing section 3 Stage cascade rinsing (iv) Length of degreasing section 18.15 meters (approx)

Spray degreasing

ANNEALING FURNACE
Annealing is done to: 1. To regain grain structure 2. To increase malleability and ductility. 3. To attain mechanical properties. ANNEALING STAGES 1. Recovery 2. Recrystallization 3. Grain growth

Cooling Furnace section

Length of Section is 135 m 10 Air Jet Cooling Chamber 2nd & 9th Jet Cooling chamber is having

Mist cooling also to assist avoiding carbide precipitation.. Length of Cooling Section 52.5 m 6 burner control Zone

Jet cooling section

PICKLING
The function of pickling is
to dissolve/ remove/ peel off oxide layer on surface

of strip. Such oxide layers are formed during hot rolling and in case of cold rolled strip during annealing operation. Pickling is done in three sections:-

Neolyte electrolytic pickling section Nitric Electrolytic Pickling Section Mixed Acid Pickling Section

COIL AFTER PICKLING

Skin Pass Mill

Skin passing is done to

1. To improve strip shape. 2. To impart the desired surface finish to steel. 3. To produce desired mechanical properties. 4. To eliminate minor surface blemishes. 5. Masking of yield point

Tension Leveler
The purpose of tension leveling is to bring all the fibers

in the metal to equal length To achieve Desired strip elongation(0-2%) and strip flatness Tension leveler consists of Entry bridle, Tension leveler wet type process, Exit bridles Type wet type. Design One set of bending roll cartridge Two sets of anti cross bow roll cartridge 350 KN (max.)

Tension

Tension leveler

Distributed Control System

A distributed control system (DCS) refers

to a control system usually of a manufacturing system process any kind of dynamic system, in which the contrller elements are not central in location (like the brain)but are distributed throughout the system with each component subsystem controlled by one or more controllers.

DCS Hardware
Controller card Input cards (4-20mA,

Thermocouple, RTD ,Digital,SOE). Output cards(4-20 mA ,digital) Power supply module.

Benefits of DCS are:

High reliability. Improved response time. Improve operator interface to plant. Improve accessibility of plant data to

engineering & management personals. Historical storage and retrieval system.

Programmable logic controller

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.

Features
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 battery-backed or nonvolatile memory.

Difference b/w DCS and PLCs

DCS PLCs

Wide Range of

Does not have wide

communication. Used for the entire plant It is redundant Response time is higher Settings can be change

range of communication Used for particular unit Not redundant Very less response time Only vendor can change the setting

SCADA
SCADA stands for Supervisory Control And Data Acquisition. It generally refers to industrial control systems: computer systems that monitor and control Industrial infrastructure or facility-based processes, include those of manufacturing, production, power generation,Fabrication and refining.

General view of SCADA

Transducers
Installed in furnaces to measure, monitor and regulate the temperature There are so many type of transducers: Temperature transducer Pressure transducer Flow transducer etc.

Resistive Temperature Detector

RTD: Probably the most common temperature sensor is the metal RTD or Resistive Temperature Detector, which responds to heat by increasing its resistance to electric current. The freezing temperature of water is used as the reference temperature. R = R0 (1+T) for +ve temp coeff. R = R0 (1-T) for -ve temp coeff.

Characteristic curve of RTD

Characteristic curve of Thermocouple

SENSORS:

PROXIMITY SENSOR a) INDUCTIVE PROXIMITY SENSOR b) CAPACITIVE PROXIMITY SENSOR c) OPTICAL PROXIMITY SENSOR INFRARED SENSOR

3. Strain gauges:
strain gauges are sensors that measure deformation due to pressure. the strain gauge is stretched; the conductor reduces its cross-sectional area and thus can carry less current. the change in resistance is small and so requires a reference resistance and compensating circuitry to compensate for other sources of resistance changes (such as temp.)

RECRUITMENT
All the information of vacancy is given on the respective site:www.multimetals.in Student placed as a GET in the payscale of 3.2-4.0 lakh per annum