UGANDA PETROLEUM INSTITUTE KIGUMBA

P.O.BOX 50 KIGUMBA, UGANDA

YEAR TWO INDUSTRIAL TRAINING REPORT 2021/2022

PLACEMENT: ROOFINGS ROLLING MILLS LTD

BY: MUTEBI CONERIUS

REG NO: 19/UPIK/DDPO/018G

1
DECLARATION
I MUTEBI CONERIUS declare that this is my own work and was not published or replicated
from any other source. This report is derived from the period I spent at Roofings Rolling Mills
Limited (RRM) where I was working as a trainee in the Maintenance Department- Electrical
section in the factory phase three. It contains both the theoretical work learnt and the practical
work carried out during that period.
Signed,

……………………………………

Mr. MUTEBI CONERIUS

FIELD SUPERVISOR
DDUNGU SHARIFF
Signature………………………....
Date…………………….......

HUMAN RESOURCE MANAGER

Mr. BENARD AKIIKI

Signature…………..

Date:…………………

INSTITUTE SUPERVISOR

Ms. CLARE KATANA

Signature…………………………..

Date……………………………….

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DEDICATION
This report is dedicated to all my family members who have been there and provided their
support whenever I needed it especially Sonko Lawrence, my Aunt, my Father and my Mother. I
am so grateful for your great support.

ACKNOWLEDGEMENT
I thank the Almighty God for having enabled me to train at Roofings Rolling Mills and kept safe
and healthy throughout my internship period in the factory irrespective of all the hazards and
risks involved in the operations. I thank the management of Roofings Rolling Mills for giving me
the opportunity to train with them and gain the necessary skills for working in my field that I
desire.I really appreciate the following people for everything they have done for me and
everyone whom I have interacted with was such a nice experience that I had never passed
through before.Eng. Sharif (My supervisor), Eng.Nankunda Daglous CRM, Eng. Katusiime
Babrah CRM (Overall supervisor),Eng. D(Electrical manager CGL), Eng. MafaabiPatrick (CGL)
and technicians in CRM and CGL, I am so grateful.

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ABSTRACT
This is a report submitted in partial fulfillment of the requirements of the award of Diploma in
Downstream Petroleum Operations. It contains the theoretical work learnt and the practical work
carried out during the training that took place at Roofing Rolling Mills (RRM) Limited between
10th/Jan/2022 and 1st/Mar/2022.
Knowledge of motor starters that is to say, Direct on line, Forward and reverse starter, star Delta,
were attained. Still on motors, I went ahead and worked on different circuit connections
involving the power and control circuits of several starting methods mentioned. Different
trouble-shooting techniques’ concerning the three phase induction motors and their forward and
reverse operation was looked at. Motor installation, capacitor bank and power factor
improvements.
Finally, crane resetting, maintenance of lights, replacing of faulty sensors especially proximity
and thermocouples and so many others were also done practically and all the information has
been detailed in this report.

iii
LIST OF ACRONYMS

ABCDEFGHIJKLMNOPQRSTVUWXYZ

CRM - Cold Rolling Mill

AC - Alternating Currents

ARP - Acid Regeneration Plant

CCL - Continuous Color Coating Line

CGL - Continuous Galvanizing Line

DC - Direct Currents

ELCB - Earth Leakage Circuit Breaker

HV - High Voltage

IGBT - Insulated Gate Bipolar Transistor

KVA - Kilo Volt Amperes

LV - Low Voltage

MCB - Miniature Circuit Breaker

MCCB - Molded Case Circuit Breaker

O/L - Overload

PF - Power Factor

PPPL - Push Pull Pickling Line

SCB - Shunt Capacitor Bank

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TABLE OF FIGURES

Figure 1 COMPANY LOGO ............................................................................................................................. 3

Figure 2 COMPANY STRUCTURE ................................................................................................................... 5
Figure 3 SINGLE LINE CIRCIUT DIAGRAM AT RRM AT PHASE III .................................................................... 5
Figure 4 A photo showing a high voltage panels and step down transformers at RRM main substation for
UMEME incomers. ........................................................................................................................................ 6
Figure 5 10MVA transformer at RRM ........................................................................................................... 7
Figure 6 MODE OF OPERATION OF A TRANSFORMER .................................................................................. 9
Figure 7 BUCHOLZ RELAY AT RRM .............................................................................................................. 11
Figure 8 TYPES OF MOTORS ........................................................................................................................ 14
Figure 9 DIRECT ONLINE STARTER CGL FOR MOTORS ................................................................................ 15
Figure 10 STAR-DELTA STARTER AT CGL ..................................................................................................... 16
Figure 11 FORWARD-REVERSE CONNECTED TO STAR-DELTA STARTER CGL .............................................. 18
Figure 12 INDUSTRIAL INSTRUMENTATION ................................................................................................ 19
Figure 13 PROXIMITY SENSOR AT CRM....................................................................................................... 21
Figure 14 THERMOCOUPLE AT ARP ............................................................................................................ 23
Figure 15 RTD AT CRM ................................................................................................................................ 24
Figure 16 FLOWMETER AT ARP ................................................................................................................... 24
Figure 17 POWER SUPLY FOR PLC AT ARP .................................................................................................. 27
Figure 18 COMMUNICATION MODULE AND PROTOCOL AT ARP ............................................................... 27
Figure 19 CPU MODULE AT ARP.................................................................................................................. 28
Figure 20 I/O MODULE ARP ........................................................................................................................ 28
Figure 21 OVERHEAD CRAINS AT CRM........................................................................................................ 29
Figure 22 MERCURY VAPOR LUMPS AT CGL ............................................................................................... 31
Figure 23 SODIUM VAPOR LUMP AT CGL ................................................................................................... 30
Figure 24 EARTHING AT ARP ....................................................................................................................... 32
Figure 25 CHANGEOVER SWITCH AT CRM .................................................................................................. 33
Figure 26 VACUUM CIRCUIT BREAKER AT MAIN SUBSTATION AT RRM ..................................................... 34
Figure 27 BLOWING DUST FROM MOTORS AT CRM .................................................................................. 36
Figure 28 HEAVY DUTY MOTORS AT CRM................................................................................................... 37
Figure 29 THERMOCOUPLE AT ARP ............................................................................................................ 39
Figure 30 DISMANTLED CONTACTOR.......................................................................................................... 40
Figure 31 RESTORING CONTACTORS AT CGL .............................................................................................. 40
Figure 32 RESETTING A CRAIN .................................................................................................................... 41
Figure 33 MOTOR DRIVE AT THE CRAIN CRM ............................................................................................. 41
Figure 34 INSTALLING A LUMP AT PPPL ...................................................................................................... 43
Figure 35 REPAIRING LIGHTS AT CGL .......................................................................................................... 44

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TABLE OF CONTENTS

Table of Contents
DECLARATION .............................................................................................................................. i
DEDICATION ..................................................................................................................................ii
ACKNOWLEDGEMENT ................................................................................................................ii
ABSTRACT..................................................................................................................................... iii
TABLE OF CONTENTS ..................................................................................................................1
CHAPTER ONE: INTRODUCTION ..........................................................................................................3
Background ....................................................................................................................................3
About Roofings Group ................................................................................................................3
Roofings Rolling Mills (RRM) limited...............................................................................................3
Company vision. .........................................................................................................................4
Company values. ........................................................................................................................4
Company organization structure .................................................................................................4
POWER SUPPLY AT RRM .................................................................................................................5
CHAPTER TWO: LITERATURE REVIEW ..................................................................................................6
Contactors ........................................................................................................................................6
TRANSFORMERS.............................................................................................................................7
COMPONENTS OF A TRANSFORMER............................................................................................8
WORKING PRINCIPAL OF TRANSFORMERS...................................................................................9
TYPES OF TRANSFORMERS ..........................................................................................................9
PROTECTIONOF TRANSFORMERS .............................................................................................. 11
Transformer Cooling Methods................................................................................................... 12
STATCOM..................................................................................................................................... 12
DISTRIBUTION BOARDS ................................................................................................................ 13
Bus Bar ................................................................................................Error! Bookmark not defined.
ELECTRIC MOTORS ....................................................................................................................... 13
PRINCIPAL OF OPERATION ........................................................................................................ 13
TYPES OF MOTORS ................................................................................................................... 13
Construction of induction motor ............................................................................................... 14
Methods of Starting .................................................................................................................. 15

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 Trouble shooting three phase motors ................................................................................................ 18
INDUSTRIAL INSTRUMENTATION............................................................................................................ 19
Structure of Industrial Instrumentation in Real Time Applications .................................................... 19
OVERHEAD CRANES ................................................................................................................................ 29
LIGHTS ..................................................................................................................................................... 29

INDUSTRIAL EARTHING ........................................................................................................................... 31

CHANGE OVER SWITCHES ....................................................................................................................... 32
CHAPTER THREE: PRACTICAL WORK DONE................................................................................................. 33
Introduction ............................................................................................................................................ 34
PREVENTIVE PLANNED PANEL AND MACHINE MAINTENANCE .............................................................. 34
MOTOR MAINTENANCE .......................................................................................................................... 35
Motor testing ...................................................................................................................................... 37
Motor starter wiring ........................................................................................................................... 38
THERMOCOUPLE ..................................................................................................................................... 39
CONTACTORS .......................................................................................................................................... 40
OVERHEAD CRAINS ................................................................................................................................. 41
LIGHTS. ..................................................................................................................................................... 42
Troubleshooting of sodium vapor and Mercury vapor lumps. ........................................................... 44
GENERAL MAINTENANCE ACTIVITIES ..................................................................................................... 45
CHAPTER FOUR: OBSERVATIONS, CONCLUSIONS ANDRECOMMENDATIONS ........................................... 45
Observations ........................................................................................................................................... 46
Conclusion ............................................................................................................................................... 46
Recommendations. ................................................................................................................................. 46
References ................................................................................................................................................... 47

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CHAPTER ONE: INTRODUCTION

Background
This report is derived from the several weeks I spent at Roofings Rolling Mills (RRM) Ltd
where I was working as a trainee in the Electrical department phase III from 10th January
2022 to 21st February 2022.It contains the theoretical work learnt and the practical work
carried out during that period.


About Roofings Group

ROOFINGS GROUP consists of three manufacturing companies; Roofings Limited, Roofings

Rolling Mills Limited and Roofings Manufacturing Rwanda. Roofings Limited is situated about
6km outside Kampala city Centre on Plot 126 Entebbe road, Lubowa. Occupying a 39 acre
expanse of land, Roofings is the leading producer of quality steel products in Uganda, with far
reaching influence across the East African region. Roofings Limited was the first of all three
Roofings Group subsidiary companies to be established.

Roofings Rolling Mills (RRM) limited.

Figure 1 COMPANY LOGO

Roofings Rolling Mills is the state of the art complex in Kampala industrial park, RRM is US
100 million worth of capital investment. Rolling is metal forming process in which metal
material is passed through a pair of rolls. Rolling is classified according to the temperature of the
metal rolled. If the temperature of the metal is above its re-crystallization temperature, then the
process is termed as hot rolling. If the temperature of the metal is below its re-crystallization
temperature, the process is termed as cold rolling.

RRM is established in different production phases:

Phase 1, involved the installation and commissioning of a high-tech wire galvanizing plant. The
highly advanced machinery was manufactured and imported from Canada and applies a patented
high turbulence pickling system with economically friendly processes and the capacity to
produce 12.000 metric tons of galvanized wire per annum.
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Galvanized steel has gone through a chemical process to keep it from corroding/ rusting. The
steel gets coated in layers of zinc because rust won't attack this protective metal. For countless,
domestic and industrial applications, galvanized steel is an essential building component.

Phase 2, commissioned in 2010 is a hot rolling mill with the capacity to produce 72.000 metric
tons of high tensile TMT bars and twisted bars.

Phase 3, commissioned in 2014 is a cold rolling mill with a capacity of 120.000 metric tons per
annum for the production of galvanized sheets (GI) and pre-painted galvanized sheets (PPGI).

Products manufactured at Roofings include; galvanized and pre painted roofing sheets, Eco tiles,
Hollow sections, mild steel plates and open profiles all widely used building for domestic,
commercial, public and industrial purposes.
Roofings mainly engage in cold-forming production with a total installed capacity currently at
160.000 metric tones per annum.

Company vision.

To be the largest manufacturer of steel and plastic building products within the East African
community, through adopting the most modern technology, employing a professionally trained
workforce and complying with the highest international standards to deliver the best quality
products to the market.

Company values.

Roofings Group is established on the values of Integrity, Quality, Customer service and
satisfaction, Creativity and innovation.

To maintain integrity, they strive to root out selfishness from every aspect of their being. Quality
shall be maintained at all times. Process and product policies must always synchronize with set
standards, as must their relations with the individual stakeholders. At Roofings, quality goes
home with you, is reflected in what you say or do, and you pass it on everywhere.

Sustainability is pursued first by applying national and international quality standards for
workplace health/safety and with Roofings, the customer really is a king.

Company organization structure

The company organization structure of RRM limited starting from the highest leader to the
lowest staffs. For example from the chairman to the cleaners is shown in the figure below.

4
Figure 2 COMPANY STRUCTURE

POWER SUPPLY AT RRM

33kv
2MVA Step-down (33/6.6kv)
For other substations inside the factory

6.6/0.415kv6.6/0.415kv 6.6/0.415kv

CGL CCL PPPL MILL AUXILIARIES

A B C D E

Figure 3 SINGLE LINE CIRCIUT DIAGRAM AT RRM AT PHASE III

5
 Figure 4 A photo showing a high voltage panels and step
down transformers at RRM main substation for UMEME
incomers.

Figure 4: A photo showing the high voltage panels and step down transformer at RRM main substation for
UMEME incomers.

CHAPTER TWO: LITERATURE REVIEW

Contactors

A contactor acts as a relay, especially for switching high current electrical power circuits. There
is a control coil that moves the spring loaded armature by magnetic attraction. The moving
contacts are attached to the armature, and either make or break contact with fixed contacts. These
contacts switch the electrical supply. There are a lot of configurations of contactors, such as coil
voltage ranges which can be 110V, 240V, 415V, and so on for alternating voltages (AC), or DC,
the current rating of the contacts. Some are fitted with auxiliary functions like overload sensors,
other contacts to send lamp supervisory signals, test buttons. A contactor is controlled by a
circuit which has a much lower power level than the switched circuit.
Unlike a circuit breaker, a contactor is not intended to interrupt a short circuit current. Contactors
are used to control electric motors, lighting, heating, capacitor banks, and other electrical loads.
A contactor is composed of three different items. The contacts are the current carrying part of the
contactor. This includes power contacts, auxiliary contacts, and contact springs. The
electromagnet provides the driving force to close the contacts.

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TRANSFORMERS

Figure 5 10MVA transformer at RRM

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A transformer is a device that transfers electrical energy from one electrical circuit to another
through mutual (electromagnetic induction) and without change in frequency.

COMPONENTS OF A TRANSFORMER
Core
The core of the transformer is used to support the windings. It is made of soft iron to reduce eddy
current loss and Hysteresis loss, and provides low reluctance path to the flow of magnetic flux.

Windings
Windings consist of several copper coil turns bundled together, each bundle connected to form a
complete winding.

Insulating materials
Insulating materials like papers and card boards are used to isolate primary and secondary
windings from each other as well as the transformer core.

Transformer oil
The transformer oil insulates as well as cools the core and coil assembly. The core and windings
of the transformer must be completely immersed in the oil that normally contains hydrocarbon
mineral oils.

Conservator
The conservator is an airtight metallic cylindrical drum fitted above the transformer that
conserves the transformer oil. It is vented at the top and is filled only half with the oil to allow
expansion and contraction during temperature variations. However the main tank of the
transformer with which the conservator is connected is completely filled with the oil through a
pipeline.

Breather
The breather is a cylindrical container filled with silica gel, which is used to keep the air that
enters the tank moisture-free to prevent the reaction between oil and air that can cause internal
faults.

Tap changer
To balance voltage variations within the transformer, tap changers are used. There are two types
of tap changers – on load and off load. In on load tap changers, tapping can be changed without
isolating transformer from the supply, while in off load, the transformer needs to be disconnected
from the supply.

Cooling tubes
As the name suggests, cooling tubes are used to cool the transformer oil. The circulation of oil
within the transformer may be natural or forced. In the case of natural circulation, when the oil

8
temperature rises, the hot oil naturally moves to the top and cold oil moves down, while in case
of forced circulation, an eternal pump is used.

Buchholz Relay
Buchholz Relay senses the faults occurring within the transformer. It detects the gases emitted
due to decomposition of transformer oil during internal faults.

Explosion vent
The boiling hot oil from the transformer is expelled during internal faults through the explosion
vent to avoid explosion of the transformer. This is generally placed above the level of the
conservatory tank.

WORKING PRINCIPAL OF TRANSFORMERS

Figure 6 MODE OF OPERATION OF A TRANSFORMER

The transformer works on the principle of Faraday’s law of electromagnetic induction and
mutual induction which states that a current will be induced in a conductor which is exposed
to a changing magnetic field. There are usually two coils primary coil and secondary coil on the
transformer core. The core laminations are joined in the form of strips. The two coils have high
mutual inductance. When an alternating current pass through the primary coil it creates a varying
magnetic flux. As per faraday’s law of electromagnetic induction, this change in magnetic flux
induces an emf (electromotive force) in the secondary coil which is linked to the core having a
primary coil. This is mutual induction.

TYPES OF TRANSFORMERS

Step up and Step down Transformer

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Step-up transformer transforms a low voltage, high current AC into a high voltage, low current
AC system.

Step down transformer converts a high primary voltage, low current into a low voltage, high
current.

Power Transformer
The power transformers are used in the transmission networks of higher voltages. They have
high ratings of 400 KV, 200 KV, 110 KV, 66 KV, 33 KV.

Distribution Transformer
This type of transformer has lower ratings like 11 KV, 6.6 KV, 3.3 KV, 440 V and 230 V. They
are used in the distribution network to provide voltage transformation in the power system by
stepping down the voltage level where the electrical energy is distributed and utilized at the
consumer end.

Instrument Transformers
They are generally known as an isolation transformer. The instrument transformer is further
divided into two types:

Current Transformer
The current transformer is used for measuring current and also for the protection.

Potential Transformer
Potential transformer is to measure voltage by stepping down the voltage level to a safe limit or
value.

Single Phase Transformer

A single-phase transformer is a static device, works on the principle of Faraday’s law of mutual
Induction. At a constant level of frequency and variation of voltage level, the transformer
transfers AC power from one circuit to the other circuit.

Three Phase Transformer

Three-phase supply is mainly used for electric power generation, transmission and distribution
for industrial purpose.

Protection Transformers: They are used for component protection purposes. In circuits, some
components must be protected from voltage fluctuation etc. Protection transformers ensure
component protection.

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PROTECTIONOF TRANSFORMERS
Overheating Protection in Transformers
Transformers overheat due to the overloads and short circuit conditions.
This is done by insulating and cooling the windings either with oil or any other method such as
air.

Overcurrent Protection in Transformer

IDMT relays are used to detect overcurrents in the transformer.

Differential Protection of Transformer

The Percentage Biased Current Differential Protection is used to protect power transformers by
measuring current variations across the transformer.

Restricted Earth Fault Protection

A very high fault current can flow when a fault occurs at the transformer bushing. In that case,
the fault needs to be cleared as soon as possible. The reach of a particular protection device
should be only limited to the zone of the transformer, which means if any ground fault occurs in
a different location, the relay allocated for that zone should get triggered, and other relays should
stay the same.
Buchholz (Gas Detection) Relay

Figure 7 BUCHOLZ RELAY AT RRM

The above picture shows a Buchholz relay. It detects internal faults in the transformer detecting
the resolved gas with the help of a float switch and different types of gasses can be produced
depending on the fault condition.

Over-fluxing Protection
To protect the transformer from over-fluxing, the over-fluxing relay is used. The over-fluxing
relay measures the ratio of Voltage / Frequency to calculate the flux density in the core.Over
fluxing causes heating in the core that quickly follows through the other parts of the transformer

11
that leads to overheating of components, thus over flux protection becomes necessary, as it
protects the transformer core.

Transformer Cooling Methods

For the dry type transformers

Air Natural (AN) Cooling

Air Forced (AF) or Air Blast (AB) Cooling

For oil immersed type transformers

 Oil Natural Air Natural (ONAN) Cooling

 Oil Natural Air Forced (ONAF) Cooling
 Oil Forced Air Forced (OFAF) Cooling
 Oil Forced Water Forced (OFWF) Cooling
 Air Natural (AN) Cooling

STATCOM
A static synchronous compensator (STATCOM), also known as a static synchronous condenser
(STATCON) is a regulating device used on alternating current electricity transmission networks.
It is based on a power electronics voltage-source converter and can act as either a source or sink
of reactive AC power to an electricity network. If connected to a source of power it can also
provide active AC power.
Usually a STATCOM is installed to support electricity networks that have a poor power factor
and often poor voltage regulation and thus used for voltage stability.

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DISTRIBUTION BOARDS

A distribution board (or panel board) is a component of an electricity supply system which
divides an electrical power feed into subsidiary circuits, while providing a protective fuse or
circuit breaker for each circuit, in a common enclosure.

ELECTRIC MOTORS

An electric motor is any of a class of devices that convert electrical energy to mechanical energy,
usually by employing electromagnetic phenomena. Most electric motors develop their
mechanical torque by the interaction of conductors carrying current in a direction at right angles
to a magnetic field.

PRINCIPAL OF OPERATION

The basic principle underlying the functioning of an electrical motor is Faraday’s Law of
induction.

That is, that a force is created when an alternating current interacts with a changing magnetic
field.
TYPES OF MOTORS

DC motors
A direct current (DC) motor is a type of electric machine that converts electrical energy into
mechanical energy. DC motors take electrical power through direct current, and convert this
energy into mechanical rotation.

DC motors use magnetic fields that occur from the electrical currents generated, which powers
the movement of a rotor fixed within the output shaft. The output torque and speed depends upon

13
Figure 8 TYPES OF MOTORS

both the electrical input and the design of the motor.

AC MOTORS
Synchronous motors
The synchronous motor, which always runs at synchronous speed. The rotor is an electromagnet
that is magnetically locked with a stator rotating magnetic field and rotates with it. These
machines’ speed is varied by varying the frequency (f) and the number of poles (P), as Ns = 120
f/P.

Induction motors.

These are motors in which the rotating magnetic field cuts the rotor conductors, hence circulating
current induced in these short-circuited rotor conductors. Due to the magnetic field’s interaction
and these circulating currents, the rotor starts to rotate and continues its rotation. runs at speed
less than its synchronous speed, and the rotating torque and speed is governed by varying the
slip, which gives the difference between synchronous speed Ns and rotor speed Nr,It runs

governing the principle of EMF induction due to varying flux density. Hence the name induction
machine comes.

Construction of induction motor

The induction motor essentially consists of two parts: Stator and the Rotor. The supply is
connected to the stator and the rotor receives power by induction caused by the stator rotating
flux, hence the motor obtains its name –induction motor.
The stator consists of a cylindrical laminated & slotted core placed in a frame of rolled or cast
steel. The frame provides mechanical protection and carries the terminal box and the end covers
with bearings. In the slots of a 3-phase winding of insulated copper wire is distributed which can
14
be wound for 2, 4, 6 etc. poles. The rotor consists of a laminated and slotted core tightly pressed
on the shaft. There are two general types of rotors: The squirrel-cage rotor and the wound (or slip
ring) rotor.

Methods of Starting
Direct-on-line starting
The motor is switched on directly to full supply voltage. The initial starting current is large,
normally about 5 to 7 times the rated current but the starting torque is likely to be 0.75 to 2 times
the full load torque. To avoid excessive supply voltage drops because of large starting currents
the method is restricted to small motors only. To decrease the starting current, cage motors of
medium and larger sizes are started at a reduced supply voltage.

Figure 9 DIRECT ONLINE STARTER CGL FOR MOTORS

Figure 10: A practical direct on line starter at RRM factory for pump applications.

The power and control circuit of a DOL starter is as shown below.

Figure 11: Power and control circuit of a direct on line starter

Star-delta starter.
This is applicable to motors designed for delta connection in normal running Conditions. For
starting, the stator windings are connected in star and when the machine is running the switch is

15
thrown quickly to the running position, thus connecting the motor in delta for normal operation.
The phase voltages and the phase currents of the motor in star connection are reduced to 1/3 of
the direct -on -line values in delta. The line current is 1/3 of the value in delta.
A disadvantage of this method is that the starting torque (which is proportional to the square of
the applied voltage) is also reduced to 1/3 of its delta value. Due to the reduced starting torque,
the star-delta-connection is suitable for drives with a high inertia mass but a resistance torque
which is low or only increases with increased speed. It is preferably used for applications where
the drive is only put under a load after run-up, i.e. for presses, centrifuges, pumps, ventilators,
etc.
After motor run-up, in most cases an automatic timing relay controls the switch-over from star to
delta. The run-up using star connection should last until the motor has reached the approximate
operational speed, so that after switching to delta, as little post acceleration as possible is
required. Post-acceleration in delta connection will instigate high currents as seen with direct-on-
line starting. The duration of start in star connection depends on the motor load. During delta
connection, the full mains voltage is applied to the motor windings.
To enable a switch-over from star to delta, the six ends of the motor winding are connected onto
terminals. The contactors of a star-delta starter switch over the windings accordingly.

Figure 10 STAR-DELTA STARTER AT CGL

16
Figure 12: Power circuit of a star delta starter

Starting in star, the main contactor connects the mains to winding endings U1, V1, W1.The star
contactor shorts winding endings U2, V2, W2. After successful run-up, the star contactor
switches itself off and the delta contactor connects terminals U1/V2, V1/W2, W1/U2.

Forward and reverse selection of motor rotation(direct on line)

Electric motors can run in both forward and reverse direction depending on the requirement of
the application where it is to be installed, for example, like the overhead cranes, turn table at the
rolling mill which would require moving in both directions . When such arrangement is
necessary for a certain type of application, then a forward reverse motor controller is applied to
the control circuit of the electric motor to achieve this purpose. Again the device required for the
possibility of this operation is the magnetic contactor.
Reversing motor rotation of 3 phase AC induction motors can be achieved by means of
interchanging the configuration of any two of the three motor terminals U1, V1, W1 with respect
to the reference supply voltage L1, L2, L3.

Figure 14: Forward- Reverse power circuit.

17
From the motor control diagram above, there are two units of magnetic contactors (forward
contactor and reverse contactor) connected in parallel across each other. Notice that the line side
terminals of these two contactors follows a common connection configuration for the supply
voltage L1, L2, L3, while the load side terminals of these two contactors have different
configuration for the motor terminals U1, V1, W1. The forward contactor is connected to make
L1 connect to U1, L2 to V1, L3 to W1 which makes the motor run in the forward direction.
While the reverse contactor is configured with two terminals in the reverse order, with L1
connected to W1 instead of U1, then L3 connected to U1 instead of W1, while maintaining only
L2 connected to V1

Figure 11 FORWARD-REVERSE CONNECTED TO STAR-DELTA STARTER CGL

Figure 16: Practical circuit for Forward –Reverse starter in the control panel at RRM.

Trouble shooting three phase motors

To troubleshoot a three-phase motor, apply the following procedure:

 Using a voltmeter, measure the voltage at the motor terminals. If the voltage is present
and at the correct level on all three phases, the motor must be checked. If the voltage is
not present on all three phases, the incoming power supply cable must be checked. 

 If voltage is present but the motor is not operating, turn the handle of the safety switch or
 combination starter OFF. Lock out and tag the starting mechanism per company policy. 
 Disconnect the motor from the load. 

 After the load is disconnected, turn power ON to try restarting the motor. If the motor
 starts, check the load. 

18
  If the motor does not start, turn it OFF and lock out the power. 
 With an ohmmeter, check the motor windings for any opens or shorts. Take a resistance
reading of the T1-T4 coil. This coil must have a resistance reading. If the reading is zero,
the coil is shorted. If the reading is infinity, the coil is opened. Since the coil winding is
made of wire only, the resistance is low. However, there is resistance on a good coil
winding. The larger the motor, the smaller the resistance reading. 

INDUSTRIAL INSTRUMENTATION
Field instruments: These are device used for measuring and controlling various quantities in
industries which include

Instrumentation is the process in which assembly of several electrical, measuring and control
instruments interconnected for measuring, analyzing and controlling the electrical and non-
electrical physical quantities.

Structure of Industrial Instrumentation in Real Time Applications

This can be easily analyzed with its simple structure as shown below. It majorly consists of
sensors or transducers or input devices, controllers or processors, transmitters and actuators or

Figure 12 INDUSTRIAL INSTRUMENTATION

output devices.

Input instrumentation is used for measuring, regulating physical quantities such as flow, level,
pressure, temperature, humidity, position.

Output instrumentation includes control devices such as valves, regulators, circuit breakers and
relays. These are intended for controlling desired output variable, providing control capabilities
either remotely or automatically.

Three major elements in industrial instrumentation;

19
SENSORS
A sensor is defined as a device or a module that helps to detect any changes in physical quantity
like pressure, force or electrical quantity like current or any other form of energy and sends
detected input to a microcontroller or microprocessor that produces a readable output signal,
which can be either optical, electrical, or any form of signal that corresponds to change in input
signal.

Classification of Sensors
Active and Passive Sensors

Active Sensors (also known as parametric sensors) are sensors that require an external power
source to operate. Examples of active sensors include GPS sensors and radar sensors.

Passive Sensors (also called self-generated sensors) generate their own electric signal and do not
require any external power source. Examples of passive sensors include thermal sensors, electric
field sensing, and metal detecting.

Contact and Non-Contact Sensors

Contact Sensors are those that require physical contact with their stimulus. Familiar examples of
contact sensors are temperature and strain gauge sensors.

Non-Contact Sensors, on the other hand, require no physical contact. These types of sensors
include optical and magnetic sensors, as well as infrared thermometers.

Absolute and Relative Sensors

Absolute Sensors mimic its name by providing an absolute reading of its stimulus. For example,
a thermistor always measures the exact, or absolute, temperature reading.

Relative Sensors provide measurement to a fixed or variable measurement. An example of a

relative sensor would be a thermocouple, where the temperature difference is measured, not the
actual temperature.

Analog and Digital Sensors

Analog Sensors produce continuous analog output signals, proportional to its measurement. A
few examples of analog sensors are: accelerometers, pressure sensors, light, and sound sensors.

Digital Sensors (also known as electronic or electrochemical sensors) convert the data
transmission, digitally. Examples include digital accelerometers, pressure, and temperature
sensors.

Different Types of Sensors

Infrared Sensor(IR Sensor)

Temperature & Thermocouple Sensors

20
Proximity Sensor

Ultrasonic sensor

Accelerometers & Gyroscope Sensor

Pressure Sensor

Hall Effect Sensor

Load cell

Light Sensor

Color Sensor

Touch Sensor

Tilt Sensor

PIR Motion Detector & Vibration Sensor

Metal detector, Water Flow & Heartbeat Sensor

Flow and Level Sensor

Proximity sensors
Proximity sensor is a non-contact sensor that detects the presence of an object (often referred to
as the “target”) when the target enters the sensor’s field.

Types of proximity sensor s

Inductive Proximity Sensor

Figure 13 PROXIMITY SENSOR AT CRM

21
The inductive proximity sensors are useful to detect the metallic object which is present next to
their active side. This sensor operate under the electrical principal of inductance; where a
fluctuating current induces an electromotive force(EMF) in a target object.

2. Optical Proximity Sensor

A complete optical proximity sensors includes a light source, and a sensor that detects the light.
These sensors detect objects directly in front of them by the detecting the sensor’s own
transmitted light reflected back from an object’s surface.

3. Capacitive Proximity Sensor

The capacitive proximity sensors can detect both metallic and non-metallic targets in powder,
granulate, liquid, and solid form. The capacitive proximity sensors use the variance in the
capacitance of the sensor to conclude that an object has been detected.

4. Magnetic Proximity Sensor

Base on the mechanical principle, this sensor only detects the magnetic field(e.g. Permanent
magnet).

5. Ultrasonic Proximity Sensor

22
Ultrasonic sensors emit an ultrasonic pulse which is reflected by objects in its path and the
reflected wave enters the sonic cone. They employ sound waves to detect objects, so color and
transparency do not affect them ( though extreme textures might).

TEMPERATURE SENSOR
The temperature sensor is used to detect the changes in temperature of a particular device or
machine or system and such that gives the signal to the controllers in case of change in
temperature limits. There are different types such as thermistor, thermostat, thermocouple and so
on, specific sensor used based on the application.

Figure 14 THERMOCOUPLE AT ARP

Thermocouple:

A thermocouple is a thermal junction device that functions based on the phenomenon of the
thermoelectric effect, i.e. the direct conversion of temperature differences to an electric voltage.
It works in a temperature range of -200 to +1800(oC).

Thermostat:

23
 A thermostat is a regulating device component which senses the temperature of a physical
system and performs actions so that the system's temperature is maintained near a desired set
point.

Resistance Temperature Detector (RTD):

An RTD, resistance temperature detector, is a passive temperature sensing device that operates
on the principle that the resistance of a metal changes as the temperature changes. The electrical
current that passes through the element or resistor of the sensor creates a resistance value that is
measured by an attached instrument that correlates it to the temperature based on the resistance

Figure 15 RTD AT CRM

characteristics of the RTD sensor and have a temperature range of 0-100(oC).

Figure 16 FLOWMETER AT ARP

Flow meters.
A flow meter (or flow sensor) is an instrument used to measure linear, nonlinear, mass or
volumetric flow rate of a liquid or a gas.

24
PRESSURE SENSOR.
Pressure sensor acts as a transducer and it is used to measure pressure of liquids or gases, it
converts the pressure into electrical signals.

Pressure switch

A pressure switch is a device that operates an electrical contact when a preset fluid pressure is
reached.

A pressure switch monitors the systems fluid pressure and either opens or closes an electrical
connection based on a preset pressure level.

Pressure transducer (Pressure transmitter)

A pressure transducer is a sensor which takes measurement and gives a real-time reading of
pressure. This is different from a pressure switch which reacts to pressure when a limit is
reached.

25
A pressure transducer can measure either absolute, gauge, differential or vacuum pressure
depending on the specifications of the applications and the sensor. They are suitable for complex
applications where the need to monitor exact pressure is required.

Controllers
Most of the controllers or valves are generally implemented using mechanical systems or solid
electronics. But the recent industrial controllers of industrial control systems depends on
computers, which makes ease of implementation of complex control algorithms than using a
mechanical system. Frequently used control systems in instrumentation are PLC, DCS, SCADA
systems.

The Programmable Logic Controller (PLC) is a digital computer frequently used in several

industries and machines for automation of industrial electromechanical processes. The industrial
instruments or machines such as electric motors, pneumatic or hydraulic cylinders, solenoids,
etc. can be operated using PLCs.

Components of a PLC.

Power supply.

26
Figure 17 POWER SUPLY FOR PLC AT ARP

Converts the input AC power to DC power required by the PLC components which is usually
24V DC to run.

Communication interface module.

Figure 18 COMMUNICATION
MODULE AND PROTOCOL AT ARP

27
 The interface modules help to establish interface and communication channels between the PLC
and other components of the control cabinet like servo drive controllers and relays.

Figure 19 CPU MODULE AT ARP

Central Processing Unit (CPU).

This is a static device that processes the input signal from input modules and sends it to actuators
through output modules.

Input/output (I/O) modules.

The I/O section is where status signals are filtered to remove noise, validate voltage levels, and

Figure 20 I/O MODULE ARP

28
CPU decisions are made and put into operation.

Types of PLCs

There are mainly two types of PLCs namely; Rack and compact.

Supervisory Control and Data Acquisition (SCADA)is a type of industrial control system in
which supervisory system is combined with data acquisition system for acquiring information
about the remote instruments or equipment with coded signals over different communication
channels like wireless communication for transferring data to control panel.

Distributed Control System (DCS). It is used to monitor, automate and control various processes
in industries using computerized control system such as nuclear power plants, water management
system, oil refining plants, chemical plants, petrochemical plants.

Actuators
The actuator is used to control the mechanism or system based on the signal given to it by
converting the electrical signal into mechanical energy such as motors, lights, valves, relays,
contactors, and so on.

OVERHEAD CRAIN
An overhead crane, commonly called a bridge crane, is a type of crane found in industrial
environments. An overhead crane consists of two parallel rails seated on longitudinal I-beams
attached to opposite steel columns by means of brackets. The traveling bridge spans the gap. A
hoist, the lifting component of a crane, travels along the bridge.

29
Figure 21 OVERHEAD CRAINS AT CRM
 LIGHTS

Fluorescent lamp: This is a low-pressure mercury-vapor gas-discharge lamp that

uses fluorescence to produce visible light. The diagram below shows the wiring of a
fluorescent lamp

Figure 22: Wiring of a fluorescent lamp

Mercury vapor lump

mercury-vapor lamp is a gas-discharge lamp that uses an electric arc through vaporized mercury
to produce light.

Figure 22 SODIUM VAPOR LUMP AT CGL

30
 Sodium vapor lump
sodium-vapor lamp is a gas-discharge lamp that uses sodium in an excited state to produce light
which is mostly yellow.

Figure 23 MERCURY VAPOR LUMPS AT CGL

31
INDUSTRIAL EARTHING

Figure 24 EARTHING AT ARP

Electrical earthing, or grounding, is the backup safety system for an electrical circuit. The ground
provides a safe path back to the earth. The green or bare wire is commonly the ground
connection in the distribution wiring. This ground is the same whether it is for a residential or
industrial system. The only difference is the size of the grounding conductor and grounding rod
to accommodate the additional amperage.

In electrical engineering, ground or earth can refer to the reference point in an electrical circuit
from which other voltages are measured, or a common return path for electric current, or a direct
physical connection to the Earth.

CHANGE OVER SWITCHES

The Change over switch isolates the entire electrical service panel.
Large industrial transfer switches have an automatic mode that switches the transfer switch and
starts the generator on loss of power and then stops the generator and switches the transfer switch
back when power is restored. They also have "OFF" modes so that the generator will not start
automatically.

32
Figure 25 CHANGEOVER SWITCH AT CRM

33
 CHAPTER THREE: PRACTICAL WORK DONE

Introduction

This chapter covers the procedures, shows the materials, gives the tools etc. of all the activities
that took place during my time of training at RRM.

PREVENTIVE PLANNED PANEL AND MACHINE

MAINTENANCE

Figure 26 VACUUM CIRCUIT BREAKER AT MAIN SUBSTATION AT RRM

Objective: To maintain the good running conditions of all machines in the factory for
continuous running.
Apparatus used
 Adjustable spanner and other sets of different spanners.
 Phase tester.
 An electrical blower. 
  A set of screw drivers. 
 Multi-meter.

34

Procedure for maintaining any electrical panel in RRM

 Removed the air filters of the panels and blown dust out.
 Checked for tightness in the control panel of any given machine under maintenance.
 Checked faulty field instruments for example limit switch, proximity switch, pressure
switch thermocouple and many more.
 Checked the status of all components of the machine under maintenance.

MOTOR MAINTENANCE

Preventive maintenance for motors.

Objective:
To remove dust any other obstacles that can cause malfunctioning of motors by increasing it’s
temperature which is the worst enemy of machines.
Apparatus used:

Adjustable spanner 

Screw drivers 

Multi-meter 
Power supply cables 
Hose pipes
Compressed air
Blowers

PPE used:
Respirator
Multipurpose gloves
Hardhat
Overall
Safety shoes
Clear glasses

Procedure:
Put on appropriate PPE.
Connected hosepipe on to the compressed gas supply.
Held thenosal of the hosepipe gently, opened the gas valve.
Blown the dust on the heavy duty motors ( DTR, Mill master, Follower, ETR, POR).

35
Figure 27 BLOWING DUST FROM MOTORS AT CRM

Cleaned them with cotton waste.

Blown dust from their blower motors and cleaned them too.
Finally, carried out housekeeping after maintenance.

36
Figure 28 HEAVY DUTY MOTORS AT CRM

Motor testing

Objective: To find out whether the motor was in a good working condition.
Apparatus used
  Adjustable spanner 
  Screw drivers 
  Multi-meter 
  Power supply cables 

Procedure 

 Opened the terminal box the motor using and adjustable spanner or a suitable electrical
 screw driver in some cases. 
 Tested for winding resistance of the motor using a multi-meter to ensure the uniform
resistance across the windings. 

 Also tested if there was any leakage by checking for continuity between each of the
windings. 

 Tested for resistance between the coils and the motor body using a Mega meter.( Mega
 test)

37
  After confirmingthat the motor was ok, we connected it in Delta connection.
 Connected the power supply cable (3 phase) after passing the steps above and connected
 a circuit breaker. 
 When power was switched on, the motor was rotating without any interference 
 Used a multi-meter and measured voltage across the motor terminals and found out to be
approximately 415V. 
 We used a clamp meter to determine its running current and everything was ok.

Motor starter wiring

This involved wiring of a motor starter for the motor after it’s maintenance.
We connected Star-delta starter with a timer and gave it three seconds to change from star to
Delta.
 connection circuit was as shown below.
The
 Wiring was done as shown below.
 



Figure 25: Power and control circuit of a direct on line starter .

 The power supply cable to the motor was laid in a cable tray and tied using cable ties 

 Both ends of the power cable were stripped and connected one end to the overload relay
 while the other at the receiving terminals of the motor. 
 The motor was connected in star by short circuiting the remaining terminals (i.e. U2 V2
and W2) 

  The test running was carried out to confirm the direction and it was found working ok.
 Place cleaned after work to make it tidy.


38
THERMOCOUPLE.
Maintenance of thermocouples.

Figure 29 THERMOCOUPLE AT ARP

Objective.
To maintain it so that it senses and measures the correct temperature as it was at the time of
its installation.

Tools used.
Adjustable spanner
Phase tester
Screwdriver
PPE used.
Coverall
Multipurpose gloves
Hardhat
Clear goggles
Safety shoes
Insulating tape
Procedure:
Put on PPE.
Opened the nut using adjustable spanner.
Gently, removed the thermocouple from the pipe.
Checked for any damages by looking at its physical appearance and it’s cover had been
damaged by acid.
The cover was taken to the welders and added another shield resistant to the acid.
Opened the thermocoupleinside using a screwdriver and measured it’s resistance using
multimeter, and it was corresponding with the manufacture's figure.
The transmitter was still fine.

39
Replaced it inside its cover and placed it back to the pipe.
Checked on the HMI in the control room and it was displaying correct flow rate.

CONTACTORS.
Maintenance of a contactor.

Figure 30 DISMANTLED CONTACTOR

Figure 31 RESTORING CONTACTORS AT CGL

Objective.
To maintain it and make sure it stops humming.
Tools used.
Spanners
Spanner holders
Phase testers
Screwdriver
Wire stripper
Sand paper
PPE used.
Electric gloves
Hardhat
Overall
Safety shoes

40
 Procedure.
Made sure that the main breaker supplying power to the control panel was off.
Opened the panel.
Tested for presence of voltage using a phase tester in the panel but was off.
Disconnected all the auxiliary contacts from the contactor using a screwdriver.
Removed the contactor using spanners by opening the nuts.
Disassembled it and found out that there was iron rust between the coil and the armature.
Using sand paper, we removed the rust and reassembled it.
Tested the coil on single phase line and it was ok.
Replaced the contactor in the panel using spanners and screwdrivers.
Finally, carried out housekeeping.

OVERHEAD CRAINS

Figure 33 RESETTING A CRAIN Figure 32 MOTOR DRIVE AT THE CRAIN CRM

Resetting of a tripped crane.

Objective.
To rest it so that it operates normally after power fluctuations.
Apparatus.
Body harness.
Electric gloves
Safety shoes
Overall
Hardhat.

Procedure.
Climbed to the crane using ladders.
Tied ourselves with body harnesses on the support.

41
Opened the control panel.
Placed rest on the driver buttons and then auto button and the operation is done.
Carefully, slop down using ladders.

LIGHTS.
Carried out repairs on the fluorescent fittings/lamps; this was done by carrying out the testing of
the choke, the starter, and fluorescent tube using a multi-meter to confirm whether they were still
in good working condition. For the choke, the resistance across its terminals was tested and for
found to be low for some tubes and infinite for others.
Carried out continuity test for the fluorescent tubes and halogen tubes; after the confirmatory
tests were done, the following work was done depending on the test;
 Replacing the blown fluorescent tubes, chokes and starters for the case of the fluorescent
 fittings. 
 Replacing the blown pin bulbs 
The choke was replaced as according to the following diagram.

Figure 26: Wiring of a fluorescent lamp

42
Figure 34 INSTALLING A LUMP AT PPPL

43
Fig. 28Replacing of a fluorescent light in the PPPL panel room.

Troubleshooting of sodium vapor and Mercury vapor lumps.

Steps taken:
We put on PPE.
We opened the interior of the lumps.
We tested the continuity of the ballast but it was faulty because the
multimeter wasn’t sounding the signal for continuity.
We replaced the faulty ballast with the new one.
We tested the bulb in another lump but it was also faulty.
We replaced a new one and reassembled the lump and gave light.

Figure 27: Lights that were repaired

44
Figure 35 REPAIRING LIGHTS AT CGL
GENERAL MAINTENANCE ACTIVITIES
General maintenance activities were done each time the raw material was over because
production could not continue. The activities carried out during such periods include;
 Preventive maintenance of panels ( blowing, dusting and check of tightness in panel
 circuits) 
 Preventive maintenance of motors on different lines (blowing, dusting and check of
 tightness in the motor terminals and other electrical equipment on the lines.)
  Lubricating rotating parts of machines and motor bearings. 
  Cleaning of site electronic instruments with cotton waste. 
  Replacement of blown fuses 
  Replacement of blown lamps 
  Replacement of broken sockets 
  Replacement of broken switches such as limit switches and faulty proximity switches. 
  Checking for loose connections and tightening them in the overhead crane panels.
 Maintenance of capacitors in the capacitor banks by simple cleaning and blowing of dust 
 Housekeeping and cleaning of electrical control rooms.
 Maintenance of overhead cranes in the factory.
 Generator maintenance.
  Instrumentation maintenance and calibrations.
  Scheduled maintenance of motors and other electrical equipment. 
  Lubrication of motor bearings. 
  Building of motor starters(Both DOL and star-delta) 
  Wiring/repairing of fluorescent lamps 
 Motor maintenance.

45
CHAPTER FOUR: OBSERVATIONS, CONCLUSIONS
ANDRECOMMENDATIONS

Observations

I would like to thank RRM ( Engineers and Technicians) upon the special care it gives to its
trainees. I am so grateful.

Conclusion

All the above reveals a successful training carried out at RRM. All that is shown above was
physically done by the staff of electrical section RRM and me as part of my training. However, I
was able to acquire skills and knowledge but also faced some few challenges.
Skills and knowledge acquired
  Knowledge of capacitor banks 
  Motor installation 
 Forward-Reverse operation of three phase motors 
  Star-delta connection
  Designing of motor starters 
 Knowledge of the different LV components like MCCBs, insulators, MCBs.

Challenges faced during training 
 The pronunciation of foreign workers for example Indians was a very big trouble for to
handle.
 Restrictions from the Indians to study some equipment for example components in the
control panels.
 Shortage of company working tools

Recommendations.
Indians to improve on their audibility in English.

The company to provide enough working tools to their employees.

46
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48