Training Report

Training Report
Muhammad Yasir Qureshi

Overview of Training
During my tenure at Thatta cement as a Trainee Engineer I have been given a chance to work
with experienced professionals and have gained immense knowledge while working with them
which has helped build my self-confidence and improved my technical skills as well.
I have attended various training programs at the training center, which were very helpful and
informative, not only in regard to Electrical side of industry but also we were given briefings and
lectures by experienced engineers on other important factors of Cement Industry which
includes the fields of Mechanical, Quality Control, Instrumentation and Production.
In addition to the above mentioned training, there were also seminars on different Software
such as Excel, Word and PowerPoint, arranged for employees and trainee engineers so as to
give them some insight into management skills, which I found to be useful.
Over all this training program has been very helpful and I wish to continue my services in such
professional environments so as to advance in my career.
Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Assigned Work Area:
During my training period I was deputed on the following locations.
 EWS.
 Crusher
 Stacker & Reclaimer.
 Raw Mill.
 Pre-heater.
 Kiln.
 Clinker Silo.
 Gypsum Crusher.
 Slag Mill.
 Cement Mill.
 Cement Silos.
 Old Pack House.
 Ventomatic Packer.
 Dispatch.

ELECTRICAL SUMMARY OF PLANT
CRUSHER
The purpose of crusher is to crush down the raw material stones to a size that can be fed and
grinded in Raw Mill.
Total Load of crusher is about 400 KW.
At Thatta Cement we have two crusher.
Primary Crusher:
The job of primary crusher is to crush the raw material stones that are about 500mm to size of
34-40mm irregular. Primary crusher is Hammer type crusher.
The Main Motor of Jaw Crusher is of 130KW, it’s a 50 Hertz Motor.
Volt 400, Amp 230, Sec Volt 530, Sec Amp 135, RPM 980.

Secondary Crusher:
It’s a Jaw type crusher. Its job is to grind raw material to a size of about 20mm.
The Main Motor of Secondary Crusher is of 250KW, it’s a 6000 Volt Motor.
AMP 33, Sec Volt 640, Sec Amp 235, RPM 580.

RAW MILL:
Raw mill is the equipment used to grind raw materials into "raw mix" during the manufacture
of cement. It’s a horizontal ball mill which is used to grind the materials so they can be fed to
Kiln.
Total Load of Raw Mill is about 1.5 MW.
Following are its HT motors.

ESP FAN:
ESP stands for External Static Pressure, This fan is used for Bag House.
The Fan Motor is of 500 KW, Its 690 Volt in star and 400 Volt in Delta Motor and has 520 & 890
Amp respectively.
RPM 993.

MAIN MOTOR:
Raw Mill main motor is an 1100 KW 10 Pole Motor. It’s a 6KV motor.
Amp 133, Sec Volt 1030, Sec Amp 640, RPM 580.

CIRCULATING FAN & IDF:
Raw Mill IDF and Circulating Fan Motor are both of the same specifications as follows:
355 KW, 690 Volt Star and 400 Volt Delta with 373 and 646 Amp respectively.
Both have 933 RPM.
KILN:

Cement kilns are used for the pyro processing stage of manufacture of Portland and other types
of hydraulic cement, in which calcium carbonate reacts with silica-bearing minerals to form a
mixture of calcium silicates. Over a billion tons of cement are made per year, and cement kilns
are the heart of this production process: their capacity usually defines the capacity of the
cement plant. As the main energy-consuming and greenhouse-gas–emitting stage of cement
manufacture, improvement of kiln efficiency has been the central concern of cement
manufacturing technology.
Total load of KILN is about 2 MW.
Kiln Main Drive:
Kiln main drive is of 450 KW it has 744 RPM and a load of 314 RPM.
COAL MILL:

Coal Mill is a vertical mill used to grind Coal into fine powder. Vertical roller mills are a type
of grinder used to grind materials into extremely fine powder for use in mineral dressing
processes, paints, pyrotechnics, cements and ceramics.
Main Drive:
Coal Mill main drive is of 300 kW. It operates on 6.6kV on star connections and has 30 Amp.
Its RPM are 995.
FINISH MILL:

A Finish mill is the equipment used to grind the hard, nodular clinker from the cement kiln into
the fine grey powder that is cement. At our plant we have a Ball Mill type cement mill.
Total load of Finish Mill is 3.2MW-3.5MW.

Finish Mill HT Motors:
Circulating Fan Motor:
Motor kW 190, 6 Pole, 24 Amp. It has 1000 rpm.

IDF (Induced Draft Fan):
Motor kW 170, 6 Pole, Rated Amp 21. It has 1000 rpm.
AIR SEPERATOR FAN MOTOR:

Motor kW 130, 8 Pole, Its rated Ampere are 250/140.
And has rpm 750 and 375.
It’s a VSD driven motor.

Finish Mill Main Motor:
Finish Mill main motor is a twin drive motor. Both the motors are of same specifications as
follows:
1300 KW, 10 Pole, 600 RPM and have rated 155/680 Ampere.
Finish Mill main motor is driven through a CAM Controlled
Starter as it has high starting torque which cause high
secondary voltage and are fed to the resistances to be
eliminated.
SLAG MILL:

Slag mill is also a ball mill and is used to grind clinker into powdered cement.
It has a total load of about 1.3MW.
Slag Mill HT Motors:

IDF (Induced Draft Fan):
It’s a 110 kW Motor, 2 Pole, rpm and has 183 Rated Ampere.
It’s operated through VSD.
Slag Mill Main Motor:

Slag Mill main motor is 1000 kW motor and has 112 primary amp.
It has 740 rpm.

The motor has 1175 Sec Volt and 515 Sec Amp
because of high torque that’s the reason why it
has Liquid Starter connected with it.
WINDIND SHOP:

Winding shop is the area where maintenance of all plant motors (HT & LT) is done which
includes rewinding and repair of motor i.e. replacement of damaged bearing, replacement of
damaged foot mounting , replacement of fan, greasing and lubrication of bearing.
Rewinding of ceiling fans and Kiln shell cooling fans is also done here.
MOTOR WINDING:
We use the following different sizes of winding coil diameter 1.62mm, 1.42mm, 1.21mm,
1.01mm, 0.91mm, 0.81mm, 0.71mm, 0.60mm, 0.55mm, 0.50mm…..0.02mm.
DELTA STAR CONNECTIONS IN MOTORS:

Some motors are specified by the company itself that either it will work on star or delta
connection to give its maximum output efficiency.
Three phase circuit is a multi-phase system where three phases are sent together from the
generator to the load. Each phase has a phase difference of 120° i.e. 120° angle electrically.
In three phase circuit, connections can be given in two types:

1. Star connection
2. Delta connection
Star Connection
In star connection, there are four wires, three wires are for phase and fourth is for neutral
which is taken from the star point. Star connection is preferred for long distance power
transmission because it is having the neutral point.

Star-Delta made for new Blower Motor.
Delta Connection
In delta connection, there are three wires alone and no neutral terminal is taken. Normally
delta connection is preferred for short distance due to the problem of unbalanced current in
the circuit. The figure is shown below for delta connection. In the load station, ground can be
used as neutral path if required. In delta connection, the line voltage is same with that of phase
voltage. And the line current is √3 times of phase current. It is shown as expression below,

Speed of motors according to their number of poles:
2 poles – 3000 rpm
8 poles – 750 rpm
Ceiling fans used have 12 to 14 poles having rpm of 350 while in contrast pedestal fans have 4
poles having rpm of 1500.
EOCR
It is called as electronic over current relay and it used for safety purpose.
Contacts:
A1 and A2 is common
95-96 are normally closed when not energized.
95-98 contacts are normally open when not energized.
Starting time is known as (D-time) while tripping time is known as (O-time).It has different
current ranges.

GRID STATION:
Maximum running load of the cement plant is 10.4 MW.

Grid station is the main part of plant from where the energy is supplied to various sections of
the plant where motors are connected through circuit breakers for achieving miscellaneous
application of Plant accordingly. There are two incoming power supplies for the efficient
working of plant and avoid any power failure resulting into the stoppage of the plant which will
affect our production.
One supply is from the HESCO which is delivered through 132 KV transmission line to the Grid
station. 132 KV power supply is then connected to 15 MVA 132-6.3 Power Transformer. Large
insulators are used for the protection purpose. Potential transformer has large number of
windings on the primary side to bear high voltage which in this case is 132 KV. Isolator switch is
present after potential transformer to make or break contact. The contact is usually broken.
Than these lines carry current transformer for the measurement of the line current. In between
them circuit breaker is installed to avoid any damage / short circuiting. Circuit breakers used
usually in these areas are SF6 circuit breaker. As the Arch quenching medium used between the
contacts is SF6 gas. Gas avoids and suppresses the large sparks produced during the opening /
closing of contacts. Surge arrestors are also installed to avoid any natural lightning effect which
may damage our whole system. Two Energy meters are also installed in series (one is billing
meter and other is backup meter for cross verification) to measure the quantity of unit

consumed from HESCO supply.132 KV is then step down to 6.3 KV through 15 MVA Power
Transformer as the Medium voltage requirement of our plant is 6.3 KV.
Second power supply is from the power plant. DG (diesel engine set) set of 3.6MW and other
small DG set of 200 KVA are also present for the emergency conditions. Power plant was built
with the collaboration of the orient energy system. 7 engines are installed to fulfill our
requirement; Power supply from Power Plant is11KVwhich been further step down to 6.3 KV
through 20 MVA Power Transformer.
Power Transformers connections which has been used are star-delta (Primary / Secondary)
combination.
Grid station has various panels for the different parts of the plant. Firstly we have two panels /
incomers for the measurement of the total power consumed by the plant and its connected
areas. One panel is for HESCO and one for Power Plant. Through the main panel, power supply
been provided through a bus-bar to other panels. Main purpose of the panels is metering and
protection. Separate Meters are installed to indicate the power consumed by each area which
also cross verifies our main metering.
Panels connected to various parts are named as under:
1. Primary and secondary crusher
2. Raw mill
3. Raw mill auxiliaries
4. Colony
5. Kiln
6. Cement mill
7. Slag mill
8. Coal mill
9. Packing plant
We have two kinds of motors in our plant one is HT (high tension) motors and other is LT (low
tension) motors. HT motors are heavy duty motors which operated on 6.3 KV and LT motors
operated on 440 Volt.
Panels contain OCB’s (Oil circuit breaker) within them. They are called so because oil is used
between the contacts to avoid sparking on shifting of load or turning off the area connected to
that panel.

Inspection the motors were carried out to make sure the proper and efficient working of the
motors. We check whether the fans placed at the different position alongside motor are proper.
Vibrations are taken on the driven and non-drive end of the motor with the help of the
instrument. With time bearing wear out so to avoid damage we do so. Vibrations are taken in
three different dimensions named as
1. Horizontal axis
2. Vertical axis
3. Axial axis

INSTRUMENTION AND AUTOMATION:
Instrumentation department is responsible for all the instruments, VSDs, pneumatic cylinders
and automation of systems as per need of the Industry.
Instrumentation is defined as the art and science of measurement and control of process
variables within a production or manufacturing area.
Following are the instruments we have used in our Plant.
TEMPERATURE SENSORS:
1) PT-100:
PT-100 is a resistive temperature detector; it stands for platinum 100 which means it uses
platinum as its resistive component which changes resistance upon change in temperature.
It has output in ohms
General formula for finding temperature is (Resistance-100) *2.6
Platinum resistance thermometers (PRTs) offer excellent accuracy over a wide temperature
range (from –200 to +850 °C). The principle of operation is to measure the resistance of a
platinum element. The most common type (PT100) has a resistance of 100 ohms at 0 °C.
For a PT100 sensor, a 1 °C temperature change will cause a 0.384 ohm change in resistance,
so even a small error in measurement of the resistance (for example, the resistance of the
wires leading to the sensor) can cause a large error in the measurement of the temperature.
For precision work, sensors have four wires- two to carry the sense current, and two to
measure the voltage across the sensor element. It is also possible to obtain three-wire
sensors, although these operate on the (not necessarily valid) assumption that the
resistance of each of the three wires is the same.
2) THERMOCOUPLE:

A thermocouple is a device used extensively for measuring temperature.
A thermocouple is comprised of at least two metals joined together to form two junctions.
One is connected to the body whose temperature is to be measured; this is the hot or
measuring junction. The other junction is connected to a body of known temperature; this is
the cold or reference junction. Therefore, the thermocouple measures unknown
temperature of the body with reference to the known temperature of the other body.
Working Principle
Thermocouple works on seebeck effect.
Seebeck effect: The Seebeck effect states that when two different or unlike metals are
joined together at two junctions, an electromotive force (emf) is generated at the two
junctions. The amount of emf generated is different for different combinations of the
metals.
A Thermocouple is a sensor used to measure temperature. Thermocouples consist of two
wire legs made from different metals. The wires legs are welded together at one end,
creating a junction. This junction is where the temperature is measured. When the junction
experiences a change in temperature, a voltage is created. The voltage can then be
interpreted using thermocouple reference tables to calculate the temperature.
There are many types of thermocouples, each with its own unique characteristics in terms
of temperature range, durability, vibration resistance, chemical resistance, and application
compatibility. Type J, K, T, & E are “Base Metal” thermocouples, the most common types of
thermocouples.
Types of Thermocouples:
A thermocouple is often enclosed in a protective sheath to isolate it from the local
atmosphere. This protective sheath drastically reduces the effects of corrosion.
Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the most common

type of thermocouple. It’s inexpensive, accurate, reliable, and has a wide temperature
range.
Temperature Range:
 Thermocouple grade wire, –454 to 2,300F (–270 to 1260C)
 Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater):

 Standard: +/- 2.2C or +/- .75%
 Special Limits of Error: +/- 1.1C or 0.4%
The formula for finding approximate temperature of K type thermocouple is

mV*2.4
Type J Thermocouple (Iron/Constantan): The type J is also very common. It has a smaller

temperature range and a shorter lifespan at higher temperatures than the Type K. It is
equivalent to the Type K in terms of expense and reliability.
Temperature Range:
 Thermocouple grade wire, -346 to 1,400F (-210 to 760C)

 Standard: +/- 2.2C or +/- .75%
Type T Thermocouple (Copper/Constantan): The Type T is a very stable thermocouple and

is often used in extremely low temperature applications such as cryogenics or ultra-low

freezers.
Temperature Range:
 Thermocouple grade wire, -454 to 700F (-270 to 370C)

 Standard: +/- 1.0C or +/- .75%
Type E Thermocouple (Nickel-Chromium/Constantan): The Type E has a stronger signal &

higher accuracy than the Type K or Type J at moderate temperature ranges of 1,000F and
lower. See temperature chart (linked) for details.
Temperature Range:
 Thermocouple grade wire, -454 to 1600F (-270 to 870C)

 Standard: +/- 1.7C or +/- 0.5%
PADDLE FLOW SWITCH:

Paddle flow switches have NO and NC contacts in them which make or break respectively as
some fluid moves the paddle. There function is similar to that of limit switch.
FLOW METER:
Measuring the flow of liquids is a critical need in many industrial plants. In some operations,
the ability to conduct accurate flow measurements is so important that it can make the
difference between making a profit or taking a loss. In other cases, inaccurate flow
measurements or failure to take measurements can cause serious (or even disastrous)
results.

With most liquid flow measurement instruments, the flow rate is determined inferentially
by measuring the liquid's velocity or the change in kinetic energy. Velocity depends on the
pressure differential that is forcing the liquid through a pipe or conduit. Because the pipe's
cross-sectional area is known and remains constant, the average velocity is an indication of
the flow rate. The basic relationship for determining the liquid's flow rate in such cases is:
Q = V x A
where
Q = liquid flow through the pipe
V = average velocity of the flow
A = cross-sectional area of the pipe
Flow meter gives output in mA and is connected in series with Analog Input Module of PLC.
Other factors that affect liquid flow rate include the liquid's viscosity and density, and the
friction of the liquid in contact with the pipe.
LIMIT SWITCH:
A switch preventing the travel of an object in a mechanism past some predetermined point,
mechanically operated by the motion of the object itself.

Proximity Sensor:
A proximity sensor is a sensor able to detect the presence of nearby objects without any
physical contact.
A proximity sensor often emits an electromagnetic field or
a beam of electromagnetic radiation (infrared, for
instance), and looks for changes in the field or return
signal. The object being sensed is often referred to as the
proximity sensor's target. Different proximity sensor
targets demand different sensors. For example,
a capacitive or photoelectric sensor might be suitable for a
plastic target; an inductive proximity sensor always
requires a metal target.
LOAD CELL:
A load cell is a transducer that is used to create an electrical signal whose magnitude is
directly proportional to the force being measured. The various types of load cells include
hydraulic load cells, pneumatic load cells and strain gauge load cells.
We use mostly strain gauge load cells at our plant, which consist has a mechanical
construction, the force being sensed deforms a strain gauge. The strain gauge measures the
deformation (strain) as a change in electrical resistance, which is a measure of the strain
and hence the applied forces. A load cell usually consists of four strain gauges in
a Wheatstone bridge configuration. Load cells of one strain gauge (Quarter Bridge) or two
strain gauges (half bridge) are also available. The electrical signal output is typically in the
order of a few millivolts.
The cell output is rated in millivolts per volt
(mV/V) of the difference voltage at full rated
mechanical load. So a 2.96 mV/V load cell
will provide 29.6 millivolt signal at full load
when excited with 10 volts.
Typical sensitivity values are 1 to 3 mV/V.
Typical maximum excitation voltage is
around 15 volts.
Given in picture is an S TYPE LOAD CELL.

VIBRATION SENSOR:
A vibration sensor is a device that sense vibration and gives an electrical output.
There are many types of vibration sensor but the generally used are Piezo Electric vibration sensors.
A piezoelectric sensor is a device that uses the piezoelectric effect,

to measure changes in pressure, acceleration, temperature, strain,
or force by converting them to an electrical charge.
The typical voltage output for Piezo Electric Vibration sense is

4mV/mm/sec.
SPEED MONITOR:
A speed monitor is a speed evaluating system that indicates

rotational speed, pulse frequency, linear speed and machine cycles.
They accept pulse train from position sensors and have built-in frequency to current converter.
BELT MISALIGNMENT SWITCHES:

These switches have the same principle in them as limit switches with electrical NO and NC contacts
inside, upon deflection of the paddle cause the electrical circuit to make or break depending up the
wiring, which in return alerts the PLC by giving it a high/low signal about misalignment in belt.
PNEUMATICS:

Pneumatics is a section of technology that deals with the study and application of pressurized gas to
produce mechanical motion.
Pneumatic systems generally have the following parts:
Compressor, Storage Tanks, Regulators, Gauges, Valves and Solenoids, Actuators, Fitting and Tubing
and Cylinders etc.
The Compressor:
Heart of the system.
Converts electrical energy to pneumatic potential.
Contains a relief valve protects compressor and system from overload
AIR DRYER:

The compression process produces a lot of water which is forced out of the compressed air. The
water must be removed using a dryer.
REGULATORS:

Adjust pressure output to working levels for actuators and other Applications
Types:
Relieving and Non- Relieving.
FITTINGS:
Quick release and pipe thread.
Pipe thread requires Teflon tape
VALVES AND SOLENOIDS:

Used to control actuators
Types:
Double Solenoid
Single Solenoid (spring offset)
SOLENOID VALVE:

A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric current
through a solenoid:
CYLINDER:
Also known as a linear actuator.

This is the component that
provides the movement to achieve the machine operation.
EWS (Engineering Work Station):
PLC:
PLC (Programmable logic control) define as a digitally operating apparatus which use a programmable
memory for the internal storage of storage of instruction by implementing specific function such as

logic. Sequencings time, counting & arithmetic to control through digital or analogue I/O modules
various type of machine or processes.
PLC Systems:
Programmable Logic Controllers (PLCs) are most important part of an industry because these devices are
responsible for controlling critical processes in the field. Although not always apparent, these devices
are found in many different industries, including places in which you wouldn’t even expect them to be
found. PLCs have been around for over three decades - one of the first was designed to assist the
automotive manufacturing industry in the 1980s. Today they are used in just about every critical process
your mind can imagine, and they are considered essential to field automation.
Advantages of PLC:
• Less wiring.
• Wiring between devices and relay contacts are done in the PLC program.
• Easier and faster to make changes.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.
RAW MILL:

PYRO PROCESSING:

COAL MILL:
FINISH MILL:

SLAG MILL:
Siemens S7-400 PLC:
The different CPUs are distinguished by, work memory, address

range, number of connections and execution time.
A PLC is especially suitable for data-intensive tasks in the process

industry. High processing speeds and deterministic response
times guarantee short machine cycle times on high-speed
machines in the manufacturing industry.
An S7-400 system basically comprises a rack, power supply, and

central processing unit. It can be installed and expanded in a
modular way. All modules can be positioned freely next to the
power supply plugged in on the left.
An important feature of the S7-400 is its modularity. The powerful backplane bus of the S7-400 and the
DP communication interfaces that can be plugged directly onto the CPU allow the high-performance
operation of many communication lines.

Input Module:
Analog Input
Digital Input
• The I/O interface section of a PLC connects it to external field devices.
• The main purpose of the I/O interface is to condition the various signals received from or sent to
the external input and output devices.
• Input modules converts signals from discrete or analog input devices to logic levels acceptable to
PLC’s processor.
• Output modules converts signal from the processor to levels capable of driving the connected
discrete or analog output devices.
Programming Device
Three way to program

Online programming through Engineering Station
Through PG PC
Through internet
Software:
Simatic Step S7 Version 5.0.4 and Wincc 6.0.
Programming Language
Ladder Logic
FBD (function block diagram)
STL (statement list)
I/O Signal:
Analog Signals
4-20 mA
0-20 mA
0-10 vdc
0-5 vdc
Digital Signals
Contact I/O (on/off)
Loop Diagram (Analog signal)

Digital Output Wire Block Diagram:
VSD (VARIABLE SPEED DRIVES):
VSDs are adjustable speed drives which are connected with electrical machinery to control the speed of
motor.
Many industrial processes such as assembly lines must operate at different speeds for different
products. Where process conditions demand adjustment of flow from a pump or fan, varying the speed
of the drive may save energy compared with other techniques for flow control.
Variable speed drives are needed because many applications are not run at the same speed all of the
time, due to the surrounding conditions. Revolutions per minute (RPM) of the driven shaft need to be
increased or decreased when there are changes in load conditions, application requirements, or other
circumstances.

MONTHLY JOBS:
Training Report for the month of August:
In my first month as a trainee Engineer I was privileged to gain experience from the erection of
new FLSmidth Packing plant. Following are some tasks performed in this month.
ERECTION OF VENTOMATIC
 Control and Power connections were made for manual truck loader.
 Both Manual truck loaders were supplied with three phase supply and A 50 Amp 3-Pole
Terasaki breaker was installed for each Manual Truck loader.
 Control wiring was done according to the drawings provided by FLSmidth.
 A SITOP 24Vdc power supply was installed to provide DC supply to panel.
 A SIEMENS SIRIUS safety module was connected as well to provide electrical safety.

 Earth and Neutral connections were
made for Manual truck loader,
Second Floor and First Floor of
Ventomatic Packing Plant.
 At our plant we have earth and
neutral connected together at the
source end (transformer), but to
provide additional safety a separate
earth was given to Ventomatic
Packing Plant as well.

 PLC Connections for EVO V8
(Rotary Packer) were made.

 Pneumatic
Cylinders for
shutoff gate
were installed
so as to
control the
supply of
cement to the
Ventomatic Packer Bucket Elevator.

 Control wiring for solenoid valves done so as to operate the cylinder from Operator
Control Panel.
 Local box for Air slide blower was also installed under OPC Silo so as to provide the flow
of cement through air slide.

 Ventosort Cube connections were made including all the switches, sensors and belts
into their respective junction boxes according to wiring diagram.

 Earth connections for Ground floor were made.
 Connections of rope pull switches LRS004 from KIEPE ELECTRIK were made.
 Connection of Belt Misalignment Switches VG03/5 from KIEPE ELECTRIK were made.

 Software was installed in
Ventomatic PLC.
 Power cables for manual
truck loaders were laid out.

 Central Processing Unit CPU
040 installed in the 1st spout
board got short circuited.
 Thus a spare one provided
with Ventomatic Spare parts
was replaced and
connections were made.
 As a precautionary measure
another CPU 040 was
indented.
 Evacuation Belt motor of
Ventomatic packer was faulty
due to its burnt out break
thus its break was removed
and motor was operated
normally.

 Cables of Bag filter of Ventomatic Packer were
laid out.
 Two Pulse Timer Card by Classic Electronics
were installed.
 Connections for Pulse Timer Card for
Ventomatic Packing Plant Bag Filter were made
as well.

 Ventomatic Bag Filter consists of 24 valves thus each Pulse Timer card was connected
with 12 solenoid valves.
 Time Delay between each Pulse was set to 3 seconds and Pulse length was set to 0.5
seconds.
 Cable management including

dressing and covering of cable
trays was done.
 Bag discharging motor was
having some issues in operation
due to interlocking in software
which was dealt with by making
few changes in the ladder
diagram.
 Ventomatic packer was
nonoperational because of

elevator belt misalignment which was then reset and packer was brought back into
operation.
 Up gradation of Finish Mill bag filters was brought into process due to which its motors
were dismounted and stored in winding shop.
 The motors included screw conveyor and rotary valve motors for both bag filters.

 The motors were connected back after completion of up gradation job.

VENTOMATIC PACKER SPARES LIST
 Ventomatic Packer spares were submitted into store

and a list of spares was handed over to the joint
manager and manager of the respective departments.
 Manual truck loader contactor was faulty due to dust
which was fixed.
 Diverter belt motor of Ventomatic Packer was being
problematic as the diverter belt was getting stuck and
couldn’t switch between dispatch lines due to high
amperes on belt motor thus its EOCR settings for
tripping were increased as well as belt alignment was
checked and realigned after which diverter was
operating normally.

 Vento check module EWU010 got short
circuit.
 Most of the wiring for the Electronic
Weighing Unit EWU010 was damaged
thus new connections were made
according to the FLSmidth Wiring
Diagram.
 A spare EWU010 unit provided with

Ventomatic Packer was replaced, as a
precautionary measure a spare unit of
EWU010 was indented from M/s FLSmidth.

 Finish mill grinding aid connections were made.

Training Report for the month of September:
In the month of September we mostly worked on preventive and corrective maintenance for
new packer also I was acquiring concepts of how finish mill and slag mill operate.
Following are the tasks performed for the
month of September.
 Finish Mill main motors were

checked, cleaned and inspected
throughout the month.
 Feeding belt motor of Ventomatic
Packer, breaker got tripped due to
overload which was reset.
 As a back up to Bucket elevator for
silos, air lift was put back into
operation by remaking its
electrical connections in the drive
unit as it was out of use for a long
time.
 Bucket Elevator for cement silos
was non operable due to missing
control signals from drive unit and
thus its drive unit was ejected,
faulty relays were replaced and
the connections were made back
again according to drawing thus
elevator was brought back into
operation,

 Power cable of air slide
motor at silo top got burst
thus a new cable was laid out
from silo top to finish mill
MCC room.
 Screw conveyor motor of slag
mill bag filter 1 burned out
due to overload and thus a
new motor was brought in
from winding shop and
 A new cable for lighting was
laid out at the top of OPC
silo.

 A new cable for control signals i.e. availability, remote, run and thermal overload was
laid out for T7TB4-1 because of signal loss.
 For the lighting of new packing plant conduit pipes were welded.
 Bag filter damper motor at the top of cement silo was malfunctioning due to which a
replacement motor was brought in from winding shop and connections were made.
 Lighting at dispatch was burnt out which was then replaced.
 Attended training at training center which covered production side of plant.

 Paper Back cutter from the bag discharge unit of Ventomatic Packer was out of order
due to broken coupling and thus it connections were taken out and it was sent for
repairing.
 Line cable for mosque was burst from dispatch site which was repaired.

 At slag mill the 50 Amp breaker
for BC2 located in MCC was
malfunctioning thus its drive
unit was ejected and breaker
was checked, the breaker
contacts had carbon in it thus it
was opened and all the carbon
from its metal contact was
removed and cleaned, after
which connections were
remade and breaker was
turned on, again it was working
normally.

 All motors present in the winding shop ranging from 0.5 to 7.5 KW were tagged with
their no load ampere, kW, frame number and other details after careful inspection of
each motor.

Training Report for the month of October:
In the month of October I learned about how to manage different ISO certification files and how
to prepare for audit, Lighting for new packing plant was also completed in this month as well as
some regular faults concerning the New packer were dealt with which was a very educational
experience to have.
The task performed in this month are as follows:
 Cable trays at the new packer were

properly maintained, all the loose
cable were properly tied down and
rubber sheets were placed on cable
trays so as to prevent dust.

 Clinker Silo bag filter motors were malfunctioning due to penetration of dust in between
the contacts which were cleaned and resulted in successful operation of bag filter
damper motors.

 Ventomatic PLC’s main breaker
top cover got faulty which as its
clips were broken, so to make
the PLC operable the cover for
breaker was removed and PLC
was brought back into operation.
 The lighting for New Ventomatic
Packer was completed, LED and
mercury bulbs were installed at
each floor.

 BC-1 current load EOCR settings were increased to a safe level of 40 Amp so as the belt
doesn’t trip again and again.

 Ventomatic Packer safety micro
switch was operated which
halted plant operation, it was
reset and the plant was brought
back into operation.
 Telemecamique safety installed
at Ventomatic packing plant
were getting operated falsely
due to their poor resistance to
dust, in order to overcome this
issue most of the switches
where safety isn’t critical were
jumped so as prevent plant
stoppages.

 All the Earth feet around finish mill, slag
mill and gypsum crusher were watered.
 Inspection of complete slag mill and
finish mill motors was done including
their temperatures, vibrations and load
amperes were noted down.
 The Up and Down buttons for manual
truck loader loading belt at Ventomatic
Packer were faulty which were replaced
with new ones.
 Oil cleaning of finish mill Transformer
was done with the help of new oil
cleaning plant.

 The motor brake for loading belt motor of manual truck loader was burnt out and thus
was removed as to make the belt operable back again, an indent for new brake as a
replacement was made as well.

 Due to careless attitude of Labor, main panel of manual truck loader was broker which
was put back together and all the connections were remade.
 Ventomatic Packer feeding belts weren’t running due to fault with their misalignment
switch so as to bring back the plant in operation the misalignment switch was jumped
temporarily.

 USRD parts were stored back in store.
 All the dead light bulbs at Old Pack House were replaced with new mercury bulbs.
 Spout Number 7 of new packer was malfunctioning, hence it was calibrated.
 Attended Training classes at training center, lecture on plant Instruments was given
which proved to be very informative

 Slag mill Rheostat was cleaned complete by removing it top lid.
 FN05 at slag mill had increased vibrations which caused it to be tripped with the
cooperation of mechanical department the vibrations were removed and mill was
brought was back into operation.

Training Report for the month of November:
I found myself to be doing a bit of office work in this month which was very informative as I
got to know how the administrative side of things work, made indent for all the spares for
Packing plant and created a detailed sheet for it in Excel as well. Other than that worked on
some drive units in winding shop which was very helpful in understanding their design and
how each part functions.
 Finish mill circulating fan FA02 had increased temperatures thus cooling fans were
turned on.
 UPS batteries of slag mill were out of charge which caused the PLC to turn off thus it
was connected with direct supply temporarily.

 Sick Transmitter at Vento Check unit got damaged which was fixed temporarily so as
to bring the packer back into operation and request for an indent of new transmitter
was made.
 Documentation and record of winding shop motors was maintained.
 Ventomatic Packer safety gate was faulty due to dust accumulation which was fixed.
 Deposited condemned unserviceable items back to store.
 New lighting for Ventomatic packer was designed which was later installed in
Ventomatic PLC room.
 Bag filter damper motor at silo top was malfunctioning and was replaced with
another 0.2 kW motor which was brought in from winding shop.
 Ventomatic Rotary packer was malfunctioning as it was not filling the bags in one
rotation due to choking thus choking was removed by emptying the impeller and
packer was brought back into operation.

 Connections of new blower motor under silo number 3 were made which was later
brought into operation and checked for normal operation.
 New drive unit for Old air lift motor was prepared and connected with 440V supply.
 35mm (3 core) cable was laid down for old airlift motor of 30 kW under silo number
3.

 Connections of supply cable, EOCR and
current transformer were made in the
drive unit of new 30 kW blower motor
under silo number 3.
 Cleaned and checked all LV and HV panels
of Old Packer MCC room.
 Air leakage in one of the solenoid valves at
Ventomatic Rotary packer was fixed by
putting its seal back into place.
 Air leakage due to the penetration of dust
particles in solenoid valve seal was
removed.
 Added a new selector switch in Ventomatic
PLC panel for manual control of bag filter
purging.

Training Report for the month of December:
In this month got to attend few Seminars and lecture which was a new experience and provided
an insight into the vast variety of technology used in Mega industries other than that got to
learn about Grid side of things how different circuit breakers such as SF6, Vacuum, Oil and Air
breakers work and other electrical instruments installed at Grid.
 Two 3 core cables were laid out from the newly installed grinding aid motors for slag
mill and finish mill stretching all the way to finish mill PLC where drive units for both
motors were installed and PLC connections were made.
 Grinding Aid motor connections of FM-1 and FM-2 were made and was checked and
operated from CCR.

 Selector switch for Ventomatic packer complete lighting was installed beside
Ventomatic HMI panel.
 Screw conveyor 1 at old packing was malfunctioning as it was non operable from its
local box due to faulty contactor in its drive unit located at MCC room which was
replaced with another one.

 Calibration of all spouts of Ventomatic Packer was done multiple times during this
month.
 All the parameters of Ventomatic Packer were set back to their predefined values.
 Regular inspection and cleaning of plant motors was carried out throughout the month
on a weekly basis.
 The loading belt motor of Manual truck loader 2 located at new packing plant was being
operated without a brake which was causing a lot of problems for the labor working
there thus a new brake was indented and was installed back into the motor in a few
days, the model for the new brake installed is BGE 1.5, motor was working normally
after the installation of brake. The air gap between stationary and damping plate of the
same motor was set at 60mm.
 Finish Mill IDF motor couldn’t be operated due to faulty limit switch which was fixed.
 All loose wires at site area were tightened.
 FN08 at slag mill was non operable due to faulty relay in the drive unit hence its drive
unit was ejected and relay was replaced which resulted in the removal of fault from the
drive unit but because of some physical damage on the frame of the motor, it got
burned out. To resolve the issue a new motor of 5.5 kW and 3000 RPM was brought
from winding shop and was replaced, but the motor still is having increased vibration
due to mechanical misalignment which is reported to the concerned authorities.
 Faulty drive units from slag mill were sent to winding shop for repair.

Training Report for the Month of January:
 Finder Relays were replaced with Siemens Relays in Slag mill drive units as finder relays
are usually more efficient then Siemens Sirius contactor type relays which become faulty
over time, are much bigger in size and are very difficult to replace.
 Safety micro switches installed at

Ventomatic Packer became faulty with
time which caused unnecessary delays in
operation due to Ventomatic
programmed interlocking system, to deal
with this fault few of the safety were
bypassed by looping the wires, there
were no safety risks involved as the
safety switch bypassed was not placed at
a safety critical area (Bag cleaning gate).

 A new blower motor was added under Silo Number 3
whose power cables were laid out and its VSD was
installed in the MCC room of old packer which didn’t
work as the VSD was faulty and needed to be repaired
thus a Star-Delta panel was made to replace the VSD,
the Star-Delta panel was moved into MCC room and
connections were made. Later motor was operated
through it and its ampere were checked which were all
normal.
 A training was given on Industrial Pneumatic
Instruments, which gave a fair insight into how
different pneumatics such as cylinders, pressure
transmitters, pressure regulators, solenoid valves and
other pneumatics systems work.
 A flash in FN08 trolley of Slag Mill occurred as the
trolley wasn’t getting energized, after which the trolley
was taken out its breaker of 25 amp was replaced and
the metal grips for connecting the trolley to the bus
bar were changed as well as they were damaged and
were covered in carbon due to flash, after cleaning all
the carbon and putting all the connections back in
order trolley was energized and checked which
operated normally.
 FN08 motor had increased vibrations due to motor
misalignment which were removed by co-operating
with mechanical department, it also had a broken non-
drive end fan due to increased vibrations which was
replaced on site.

 A faulty damper motor at silo top was disconnected and sent to winding shop as it was
overheating and getting stuck, a replacement motor was brought in and its connections
were made after checking it’s no load amperes.
 All the loose wirings on site were retightened and the uncovered cables were also
covered as well as all of the cable trays were checked, cleaned and covered.
 Packing plant transformer was cleaned and its oil was recycled.
 Asynchronous motor for limestone weigh feeder at finish mill was behaving abnormally
and was getting high amperes upon checking it was found that its tachogenerator
bearing was damaged which was replaced after which motor was operated and its
ampere were checked which were normal.
Training Report for the Month of February:

 A solenoid valve was added to the air
compressor tank for drainage purpose,
Ventomatic packer was having troubles in
operation due to sizeable amount of
moisture in the air to deal with the issue a
water tank was installed at the packer, the
solenoid valve was interlocked with
packing plant so that water could be
drained out of the tank for which cables
were laid out from plc room to the water
tank and connections were made.

 A trolley for taking Analog and
Digital Inputs/Outputs was
placed inside packing plant MCC
room, the interface module was
directly connected to finish mill
PLC and for that a profibus was
laid out all the way from Finish
Mill PLC room to Packing Plant
MCC room it was properly
concealed with plastic pipes as
well to reduce any noise. Cables
were laid out and all the
connections AI/DI were made.

 A clogging switch located at bag
cleaning unit of Ventomatic Packer
was non-operational and thus was
disconnected to be inspected at
instrument lab, it was found that
clogging switch was operational
but was disabled from PLC
programming, it was suggested to
enable it from PLC programming or
to hard wire it completely to make
it function though no action was
taken.
 Photocell for bag counter located
at belt BC10 of Ventomatic packing
plant got faulty which was
replaced with a spare.

 An air shutoff solenoid valve was installed at Ventomatic packing plant and was
interlocked with the IDF fan, so as to keep the air shut when packer is not in operation.
This shutoff valve was actually added so as to prevent the build of lumps and choking of
cement due to continuous flow of air.

 Two four core cables caught fire from wielding flames though the fire was quickly
extinguished but it did damage to the Magelis Counter installed at Ventomatic plant, the
burnt cable was replaced and the plant was operational, but the contact for enabling
counter limit wasn’t working, a replacement for the counter has been indented.

 MG-25 blower motor under cement silo became nonoperational due to broken bearing
and motor misalignment, at first it was speculated that motor had vibrations due to
broken bearing only but on careful inspection it was noted that the cement foundation
for blower motor had cracks in it and thus a CPA was made against civil department and
a new foundation was laid down after which motor mounted back on and with the
cooperation of mechanical department its alignment was checked as well after that
connections were made and motor was operated which ran normally. The drive unit for
MG-25 located in Slag mill MCC was also checked and serviced to take care of any
problems might be occurring at MCC side.
Training Report for the Month of March:

 Four local boxes were installed at Manual truck loader of Ventomatic Packer, these four
local boxes were added on each side of Loading belt in order to make it easier for the
labor to operate manual truck loader, a total of four buttons were added to each local
box, two for moving the luffing drive up and down and the other for forward and
reverse movement of manual truck loader.
 T7TB4 5.5 KW motor located at Finish mill had abnormal bearing sound and increased
vibrations thus motor was replaced with another 5.5 KW Siemens Spare motor, the
faulty motor was dismantled at workshop and it was found that motor had damaged
bearings both on drive and non-drive end thus they were replaced and motor was
stored in winding workshop.
 Greasing and Oiling of all critical motors located at Finish and Slag mills was checked and
their lubrication was done accordingly.

 On 15th of March there was a major shut down of Cement Mill as its Main Motor A of
1300 KW was completely out of operation due to a fault with its winding, one of the
conductors of motor winding was short. There were no visible damages found but upon
insulation and continuity tests motor was found to be completely short with its body.
There were some precautionary steps taken as on removing the top body cover of Main
Motor A it was found that the winding heater was out of order and thus it was
speculated that some moisture must exist in motor winding which was responsible for
shorting motor winding thus it was heated for several hours in order to dry out any
moisture left in winding, it was cleaned thoroughly as well with air blowers to remove
any clotted cement. Next motor winding was tested again which still was completely
short with body and thus it was decided to call in SIEMENS officials to inspect motor,
who decided to move motor to the SIEMENS workshop in Karachi thus all of its
connections were disconnected, On 16th March motor was moved to Karachi.

 In the above picture Korean Motor of 1100 KW has been replaced in space of old
SIEMENS Motor.

 A spare for Main Motor A (HICO Korean 1300 KW (1743 HP) 580 RPM) motor was
shifted to Finish Mill area and preparation for coupling the motor were started. Before
moving the motor inside Finish Mill insulation tests were conducted to make sure motor
had no issues, the next step was to make sure RPM for both A and B motors matched as
it is necessary for the operation of Finish mill, an optical tachometer was used to
measure the rpm of both motors which were about the same around 600 rpm. Main
Motor trolley was thoroughly cleaned, filters for the motor to keep the dust out were
made and Motor was cleaned as well from inside by removing its top cover. On
mechanical side of things an extension sleeve for non-drive end of the motor was made
as the non-drive end of the motor was shorter than the previous motor. The air intake
pipes for finish mill main motors were also cut short to move air filters up and keep
them at a distance from ground so that fresh air could be blown inside motor. After all
this motor was coupled after checking it’s no load ampere which were all normal and
motor direction was checked as well after which connections were made and motor was
finally brought into operation on 22nd of March, though motor got trip after a while due
to overload so mill media was emptied and mill was brought in operation again and its
ampere were monitored which were all normal. After which mill media was charged
back again and mill was brought in operation, this time motor didn’t get trip but had
increased temperatures for which a cooling fans were installed on both drive and non-
drive end of the motor which helped to lower down motor temperatures. Motor
vibrations and ampere were noted which were all normal.

Training Report for the Month of April:
 Screw conveyor-1 motor of 5.5 kW under OPC silo had heavily damaged steel
foundation and motor was in no condition to be operated as the vibrations were too
high, thus mechanical department was asked to make a new foundation for the motor
and motor connections were disconnected. Due to increased vibration motor fan had
also got damaged which was replaced. After getting clearance from Mechanical
department motor was mounted back onto the steel frame and connections were
made, motor vibrations and ampere were checked which were all normal.

 Spout number 8 load cell of Ventomatic packer was found to be damaged and was out
of operation and had twisted wire, it was replaced with a spare one. But it couldn’t be
calibrated as the EWU unit parameters were not set. FLSmidth was contacted for
guidelines to set the EWU parameters in response they sent us a list of parameters
which were later updated onto the EWU and spout number 8 was calibrated
accordingly.
 The bag cleaning motor of Ventomatic Packer had high amperes due to the reason that
the replacement belt put on the bag cleaning unit was different in size as compared to
the original one which shifted more load on the motor causing the motor to overload.
Mechanical department were asked to solve this issue.

 Rotary valve motor for feeding
EVO V8 was out of its place as a
bolt holding motor in place was
damaged causing the motor to
turn over. The motor was
brought back in its place and
was retightened with a bolt.
 All the lighting maintenance on
dispatch including installation of
new switch boards and light
cables at dispatch office was
done, new cables were laid out
for street lamps light and were
properly covered in cable trays
as well.

 All the USRD material from winding shop was submitted back into store.
 Finish Mill main motor A had increased temperature thus two cooling fans were
installed to bring the temperature down.
 Main motor A (Korean Motor) which was sent to Siemens Karachi for maintenance was
shipped back after complete maintenance, the motor was moved to finish mill area
where temporary power lines were laid out outside finish mill to power up the motor so
that several tests including insulation, vibration and ampere could be performed on it.
The stator phase to earth reading was 200 mega ohms and for the rotor it was 66 mega
ohms.
Training Report for the Month of May:

I was shifted to Kiln area in the instruments and electrical department under
DM Shahid Malik. I took it as an opportunity to learn more about the instrumentation
side of things, the first month has been very informative and influential in improving my
skills. I am looking forward to learn much more in the coming months.
 Learned about different instruments located on site and their working principle
including solenoid valves, pressure transmitters, level sensors, limit switches,
temperature controllers and load cells etc.
 Learned how the Gas analyzers installed at preheater and coal mill work and how they
are calibrated.
 Reclaimer Kiln side DC motor wasn’t operable on load as it was getting stuck as soon as
some load was applied on it, its bearing were changed and motor was fit back together
but to no avail as motor was still being problematic, it was decided to send the motor to
Karachi for repair. Another spare DC motor which was originally installed at site but had
damaged bearing and needed carbon brushes replacement was fixed up and was
installed at site.
 Have acknowledged the basic idea of how SCADA and CEMAT work.
 Learned how digital and analog signals are taken from site and how we operate different
solenoid valves, VSDs and others instruments through digital and analog outputs.

 Made drive units for vibrators, laid out cables for the Input/output modules for
vibrators and installed relay banks for taking DI and DO.
 Shutoff sliding gates for each weigh feeder hopper were installed except Laterite
hopper.
 Annulling fan damper was installed and solenoid valve connections were made so as to
automatize damper in order to improve process parameters but later it was decided to
remove solenoid valves and control the annulling fan motor through VSD to better
handle process parameters, cable for VSD was laid out and a VSD was installed in Kiln
VSD room where parameters were set and motor was operated in ID run mode to
familiarize motor with VSD, the amperes were noted as well which were all normal.
Training Report for the Month of June &

July:
In the months of June and July, got to learn a
few things from EWS as well as there were a
few lectures given by Arshad Sahib himself
which were very helpful in understanding
how different instruments at site work and
what outputs do each of them have.
 DC motor of 0.5 KW of Reclaimer was
out of operation due to faulty winding
it was getting heat up even though it
showed normal field and armature
resistance the motor failed to operate
during load thus it was sent to Karachi for repair.

 Slag Mill weigh feeder digital indicator panel was moved up from ground to first floor
near the weigh feeders so as to reduce any signal losses due to long distance between
weigh feeders and their digital indicator panel, all the connections were made and
cables were laid out from load cell to Dacell digital indicator panel and from there
output was given to Slag Mill PLC.

 Weigh Bridge located at dispatch was out of order as one of the load cell (Mettler
Toledo 45,000 KGS) was faulty a team was called in to fix the problem and calibrate The
two analog indicators placed at Dispatch office (KING BRO and Cougar 8530), after
replacing the faulty Load Cell the two indicators were calibrated and weigh bridge was
operated normally.

 An air dryer for Housing Gas
Analyzer was installed, and its
 KILN IDF damper from Bernard
Controls was malfunctioning as
its set point was out thus it was
adjusted.
 Several vibrators were installed
at BC5 belt inside tunnel for
every chute, their drive units
were made and were installed
in Raw Mill MCC room.

 I/O modules and DI, DO, AI and AO banks were installed at Raw Mill PLC room for BC5
chute cylinders and vibrators.
 Butterfly Throttle Valve for EVO V8 feed was getting stuck and was unable to open thus
its hopper was emptied and an iron rod was found stuck in between the butterfly valve
thus the rod was removed and also there were some lumps which were resulting in non-
operation of butterfly valve they were removed as well after which valve was operated,
it was working normally.

I got a chance to work at different instruments located at site and how each of them
operate, their looping with PLC and how each of them has their own different use at
plant. There was a major issue with weigh feeders as they gave false reading or RPM at
CCR which resulted in wrong T/H values of raw materials and process was disturbed, the
problem was removed by increasing the depth of each gap between every teeth of the
flywheel plate, which was very effective as it gave accurate results.

PRESENTATION:
FLSmidth Ventomatic Rotary Packer:
KEY FETURES:
1) Modularity and Flexibility

2) Lower Power Consumption about 200 KW (Old was about 338 KW)
3) Easy and Compact Design
4) Easy HMI Interaction
5) Less Manpower Required (Only one person for 8 Nozzles)
6) Efficient (Delivers More bags per Hour as compared to the old Packer7
7) About 120 Tons/Hour
8) Uses Smart PLC System
9) Can Be Monitored From Remote Location (Like CCR)

Operation
FLSmidth Supply and Control Packing Lines
EVO V8 Operation
1) Ventosort EVO V8
2) EVO stands for Electronic,
Versatile and Open Ended.
3) Feeding Header
4) Encoder Group
5) Silo Fluidization And Level
Indicator
6) Throttle Valve Rotary Vane
Feeder
7) Seat
8) Bag Holder
9) Pneumatic Group

PNEUMATIC GROUP FOR SEAT:

Ventosort Cube:

1) Discharge Belt
2) Anti-Obstruction Micro
3) Bag Cleaning Belt
4) Bag Cleaning System
5) Electronic Weighing Unit
6) Bag Rejection Unit
7) Bag Discharge Group
8) Bag Cutting Unit
9) Rotary Screen

Bags Handling System
1) Bags Diverter Belt
2) Left Fixed Chute
3) Manual Truck loaders

Maintenance
1) Simple and Compact Design
2) Easy to be disassembled for inspection
3) Less Components(Minimum number of actuators and wearing parts installed)
4) Less spare parts consumption
5) Lower power consumption
Benefits
1) Power consumption is 200KW including our designed Bag Filter.
2) Less labor is required as compared to old Packer, which needed 4 persons to operate
whereas Ventomatic only needs a single labor person to operate efficiently.
3) Intelligent HMI integration.
4) Capacity of Ventomatic Packer is 125 ton/hour.

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Training Report

Muhammad Yasir Qureshi

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Total load of Finish Mill is 3.2MW-3.5MW.

Motor kW 190, 6 Pole, 24 Amp. It has 1000 rpm.

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Motor kW 170, 6 Pole, Rated Amp 21. It has 1000 rpm.

AIR SEPERATOR FAN MOTOR:

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Slag Mill HT Motors:

Slag Mill Main Motor:

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

It has 740 rpm.

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

In three phase circuit, connections can be given in two types:

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Maximum running load of the cement plant is 10.4 MW.

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the most common

Accuracy (whichever is greater):

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

The formula for finding approximate temperature of K type thermocouple is

Type J Thermocouple (Iron/Constantan): The type J is also very common. It has a smaller

Accuracy (whichever is greater):

Type T Thermocouple (Copper/Constantan): The Type T is a very stable thermocouple and

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Accuracy (whichever is greater):

Type E Thermocouple (Nickel-Chromium/Constantan): The Type E has a stronger signal &

Accuracy (whichever is greater):

PADDLE FLOW SWITCH:

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

A piezoelectric sensor is a device that uses the piezoelectric effect,

The typical voltage output for Piezo Electric Vibration sense is

A speed monitor is a speed evaluating system that indicates

BELT MISALIGNMENT SWITCHES:

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Pneumatic systems generally have the following parts:

Heart of the system.

Converts electrical energy to pneumatic potential.

Contains a relief valve protects compressor and system from overload

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Muhammad Yasir Qureshi Training Report (Electrical & Instrument/Automation Department)

Relieving and Non- Relieving.

Quick release and pipe thread.