A PROJECT REPORT ON BELT WATCH SYSTEM FOR CONVEYOR

APPLICATIONS SUBMITED BY

SURYAKANT TRIPATHINATIONAL INSTITUTE OF TECHNOLOGY

RAIPUR

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 21st May 2015 to 23rd June 2014.I wish all the best for his future.

Mr. AMIT ROY(guide) RMM DEPARTMENT , ELECTRICAL MAINTENANCE TATA STEEL JAMSHEDPUR

CHARU KHULLAR

In- chargeVocational raining

Tata Steel Ltd

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

CONTENTS1. OVERVIEW OF TATA STEEL2. RAW MATERIAL MANAGEMENT3. CUSTOMER OF RMM 4. BLAST FURNACE & COKE PLANT 5. THE BELT WATCH SYSTEM 6. CONCLUSION 7. REFRENCES

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.

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.

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.

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.

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.

CUSTOMERS OF RMM1. Blast furnaces A-F blast furnace G blast furnace H blast furnace I blast furnace2. Coke plant• Battery 8,9• Battery 5,6,7• Battery 10 & 11

THE BELT WATCH SYSTEMGenerally 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.

THE BELT WATCH SYSTEMHence 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.

THE BELT WATCH SYSTEM

THE BELT WATCH SYSTEMThe conveyor system consists of 1. Pulleys2. Belts3. Motors4. 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.

THE BELT WATCH SYSTEM

THE BELT WATCH SYSTEM1. 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.

THE BELT WATCH SYSTEM3. 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.

THE BELT WATCH SYSTEMAdequate 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.

THE BELT WATCH SYSTEM4. 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.

THE BELT WATCH SYSTEMThere 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

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.

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.

THE BELT WATCH SYSTEMThe 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.

THE BELT WATCH SYSTEMGenerally 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.

THE BELT WATCH SYSTEM5. 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.

THE BELT WATCH SYSTEM

THE BELT WATCH SYSTEM

THE BELT WATCH SYSTEM

THE BELT WATCH SYSTEM6. 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.

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

THE BELT WATCH SYSTEM7. 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

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.

THE BELT WATCH SYSTEM• Duty Cycle: on-time / period• Vlow is often zero

LOWHIAVG VDDVV )1(

Definitions

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

THE BELT WATCH SYSTEM

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

THE BELT WATCH SYSTEM With Termination

module Consist of red and

black wire (+ve and neutral)

THE BELT WATCH SYSTEM8. 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.

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”.

THE BELT WATCH SYSTEM PPI panel outlook

MODE BUS COMMUNICATION TB

PULL CHORD TB

BELT SWAY TB

THE BELT WATCH SYSTEM MODE BUS

B1- FOR RS485

TEST KEY SPARE +VE 24 VDC

-VE 24 VDC

EARTHSPARE

5V GROUND FOR RS485

A1+ FOR RS485

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

THE BELT WATCH SYSTEM SMPS(110/24V)

110 V

24 Vdc

THE BELT WATCH SYSTEM MCBs

MCB

110 v

THE BELT WATCH SYSTEM RELAYs

BSS RELAY

PCS RELAY

THE BELT WATCH SYSTEMCIRCUIT DIGRAM FOR BELT WATCH

THE BELT WATCH SYSTEM

• Display blanka. Check 230/110 Vac at input of SMPS mounted on back plate of panelb. Check 24 Vdc at output of SMPSc. Check 24 Vdc at terminal no 11,12 of indicator unit

• Display shows p.00 or b.00a. Cable may be open between BWS panel and first field switchb. Two core connecting field switches from conveyor to BWS panel

may get interchanged

• Display shows p sc or b sca. Two core connecting field switches may get

shorted in between

TYPES OF FAULTS

THE BELT WATCH SYSTEM• Display shows wrong number of actuated

switch at fielda. Check switch connection , if any dust & water inside switch for all

switches

• Indicator malfunctions a. Follow procedure Emergency by-pass

THE BELT WATCH SYSTEMSOLUTION

• Display Blanka. If not check corresponding MCB – replace if requiredb. If not replace SMPSc. If ok repair indicator

• Display shows p.00 or b.00a. Do the proper connection & check system performance

b. Correct the polarity of wires as explain in point 4 of installation guide

• Display shows p sc or b sca. Power off Indicator ,wait 1-2 minute ,power on Indicator ,if

still display remains as it is follow the procedure detect cable short

THE BELT WATCH SYSTEM• Display shows wrong number of actuated switch at field

a. Clean the switches & check system performance

b. If still problem remains ,follow procedure Detect cable short

THE BELT WATCH SYSTEM Procedure to detect cable short / cable fault / switch fault :-

a. Switch off power for master unitb. Operate known switch from field (say switch no 5,10,15,20,25,30 & so on)c. Switch on power for master unitd. As feature of master unit ,it start displaying operated switch nos. in cyclic

fashione. Suppose cable short is at switch no 17f. Master unit will indicated switch no 5,10,15 and then instead of 20 it will

show scg. It mean cable is shorted in between switch no.15 &20h. Now reset all operated switches ,operated from 15 to 20i. Repeat step no c to fj. This time master unit will indicate operated switch no 15,16;sc as short is at

switch no17k. Resolve the problem at switch no 17l. Switch off master unitm. Check performance for any operated switch

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

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.

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