Talon Garikayi C056634k-Work Related Learning Report For Simbi Plantwith Cover Page

CHINHOYI UNIVERSITY OF TECHNOLOGY
FACULTY OF ENGINEERING
DEPARTMENT OF MECHATRONICS ENGINEERING
ATTACHMENT REPORT
FOR
TALON GARIKAYI
REG NO: CO56634K
AT
S.I.M.B.I. PVT. LTD

(STEELMAKERS ZIM PVT LTD GROUP OF COMPANIES)
MASVINGO BRANCH
________________________________________________________________ 1
Talon Garikayi B.Eng Honours Degree in Mechatronic Engineering, Chinhoyi
University of Technology- Attachment Report.
TITLE: A WORK RELATED LEARNING REPORT AT STEELMAKERS (PVT)
LTD –SPONGE IRON PRODUCTION DIVISION (SIMBI BRANCH) BY TALON
GARIKAYI (C056634K).
A REPORT SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS
OF A BACHELOR OF ENGINEERING HONOURS DEGREE IN MECHATRONIC
ENGINEERING TO THE DEPARTMENT OF MECHATRONIC ENGINEERING,
CHINHOYI UNIVERSITY OF TECHNOLOGY UNIVERSITY (2008).
__________________________________
INDUSTRIAL SUPERVISOR’S SIGNATURE
MR I. MUCHIMWE
GROUP INSTRUMENTS ENGINEER
CONTENTS PAGE
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Contents Pages
Acknowledgements i
Summary of report ii
Job offer letter iii
Letter of recommendation iv
Chapter One
1.1 Introduction 1
1.2 Plant Operations 2
Chapter Two
2.0 Instrumentation and Control department 5
2.1Introduction and objectives of the department 5
2.2 SCADA and Automation as applied to Sponge Iron Production 8
2.3 The Drive overview 12
2.4 The VersaMax PLC 13
2.5 Inputs and Outputs signals of the PLC 17
2.6 CPU Details 18
2.7 The Communication protocol 22
Chapter Three
3.0 The Control Phylosophy 29
3.1 PLC Programming 30
3.2 Plant Control loop drawings 36
3.3 The transformer Theory 37
3.4 Variable Speed Drives 39
3.5 General structure of a Drive 43
3.6 Programming a Drive 46
Chapter Four
4.0 Activities and tasks Carried out in the Instruments department 48
4.1 Thermocouple movements 48
4.2 Cleaning Slip Rings 50
4.3 Cleaning Belt Conveyor Tail pulley Sensor-ZSS 50
4.4 Replacing a ZSS 51
4.5 Cleaning weighfeeders 51
4.6 Calibration of Weighfeeders 52
Chapter Five
5.0Field Instruments 53
5.1 Kayblower 54
5.2 Air Compressor 54
5.3 Schematic representation of valves 56
5.4 Pressure regulator 56
5.5 Uninterrupted Power Supply 58
5.6 Kiln main Drive 58
5.7VFD Parameter setting 59
5.8 Weighfeeder Controller 60
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Chapter Six
6.0 Sensors 62
6.1 Water level sensor 63
6.2 Water flow sensor 64
6.3 Zero Speed Sensor 65
6.4 Gate Valve-Actuator 65
6.5 Thermocouples 66
6.6 Temperature Transmitter 67
6.7 Pressure Transmitter 70
6.8 Weighfeeder control loop 75
6.9 Junction Boxes and Weighbridge 77
Chapter Seven
7.1 Information and Technology 80
Chapter Eight
8.0 Telecommunication System 82
Chapter Nine
9.1 Workshop Practices and Processes 84

9.2 Machining Operations 86
9.3 Basic machining processes 88
9.4 Other Types of machining operations 88
9.5 The Centre Lathe Machine 89
9.6 The Cutting Tool 90
9.7 The Cutting Conditions 91
9.8 The Cutting Fluid 92
9.9 Turning, Milling and Grinding 95
Chapter Ten
10.0 Maintenance Work at the Mechanical Engineering Dept. 114

10.1 Conveyors 115
10.2 The Rotary Kiln Section 116
10.3 The Rotary Cooler Section 117
10.4 Wet Scrapper Section 118
10.5 Gearboxes 119
10.6 Water Pumps 120
10.7 The Crusher 121
10.8 Electric Motors 121
Chapter Eleven
11.0 Screen maintenance 122

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11.1 Double Pendulum Valves (DPV) 122
11.2 Welding Process 123
11.3 Oxy-Acetylene Welding 124
11.4 Acetylene Cylinders 126
11.5 Oxygen Cylinders 126
11.6 Gas Welding 127
11.7 Manual Metal Arc Welding 127
Chapter Twelve
12.0 Introduction to Electrical Engineering Department 128

12.1 Safety precautions 131
12.2 The 33KV/11KV and 11KV/415V 131
12.3 The Motor Control Center 133
Chapter Thirteen:
12.0 Recommendations to the Company 143

12.1 Recommendations to the University 144
Chapter Fourteen: Conclusion 145

APPENDIX 146
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Summary of report
The Bachelor of Engineering Honours Degree in Mechatronic Engineering is a four

and half year full-time programme. The programme focuses on Mechanical
Engineering, Electronics, Control Engineering and Computer Science. The
programme also links Applied Science with entrepreneurship. This Degree
programme was new to most industries, thus most companies were not comfortable to
engage us, as they believe it will take months to come up with a training programme.
I did my Attachment at two different locations i.e. the branches of Steelmakers
Zimbabwe. I did my Workshop practices and processes at Steelmakers Kwekwe
branch and finally plant maintenance at Steelmakers (SIMBI)-Sponge Iron Division
in Masvingo as part of Mechanical Engineering Internship.
After finishing Mechanical Engineering training programme I was attached to the

Information and Technology (IT) Department at Kwekwe HQ for four weeks
where I was taught Networking, Programming (C, C++ and Visual basic
programming), hardware and software engineering this improved my computer skills.
As soon as I finished IT I was transferred to SIMBI-Masvingo for my Electrical and

Electronics Engineering internship where I was trained on substation installation,
general plant electrical maintenance and, AC and DC motor installation as D.O.L
motors.
Later on I joined the Instrumentation and Control Engineering Department,
where I was trained on SCADA, PLC, sensors, controllers, transmitters, engineering
design and innovation, telecommunication system and ladder logic programming. It
is during this period I managed to a greater extent prove to the Company Directors
that Mechatronics is a total engineering package for all engineering problems and that
a Mechatronic Engineer is a must at any Automated Industry. I displayed a broader
knowledge base in Mechanical and Control Engineering such that I was promoted to a
Technician Level with all company benefits, the position I still hold.
To a greater extent this report covers all areas that I was trained on.
CHAPTER 1
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1.1 Introduction
SIMBI is an acronym, which stands for Sponge Iron Mining Beneficiation Industry
and is a subsidiary of Steel makers Group of companies. It is located in Westview
industrial site in Masvingo along Bulawayo road. SIMBI is currently the only
company in the country involved in the production of SPONGE IRON which is a
metallic product formed when iron ore is directly reduced below the melting point of
iron. The iron ore pellets are reduced directly in the solid state without the material
changing its physical state. SIMBI is capable of producing 100 tones per day of
sponge iron.
The organization is headed by the Managing director who currently resides in Kenya.
On the local scene the top official is the GGM-Group General Manager.
In essence we are a part of the process industry because our final product is used as a
raw material in the fabrication industry for instance where sponge iron is mixed with
various materials to make steel and other alloys.
1.2 Plant Operation

1.2.2 Process overview
The raw materials in sponge iron manufacture are coal, iron ore and limestone. The
coal is a reducing agent and also heats up the raw materials.
Limestone is for desulphurization i.e.: it acts as a fluxing agent.
Iron ore is the main raw material for the production of sponge iron.
These raw materials are conveyed to the SCREEN HOUSE by means of two conveyor
belts. Each of the conveyor belts is driven by electric motors. Proximity sensors are
mounted to monitor the movement of each belt.
At the screen house the raw materials are screened, oversized coal particles are
conveyed back to the CRUSHER where they are crushed to desirable sizes. Fine coal is
conveyed to the INJECTION HUSE where it is used to Aid ignition in the kiln.
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Fine coal is discarded from the process because there is a danger of fusion at high
temperatures which causes ACCREATIONS in the kiln.
Limestone is fed into the system using the same belt of that of iron ore.
 Recommended Particle Size
Feed coal 3mm to 15mm

Injection coal Less than 3mm
Iron ore 5mm to 18mm
Limestone 1mm to4mm
1.2.3 Storage Bins
Raw materials are later stored in storage bins from the raw material section. This
enables a continuous supply of raw materials since the rate of consumption in the kiln
is not the same with the rate of which the raw material are supplied. There are four
different storage bins, which are
 Feed coal bin
 Charcoal bin
 Iron ore bin
 Limestone bin
At the storage bin there are weigh feeders for feed-coal, iron and charcoal and one
volumetric feeder for limestone. The weigh-feeders are used to control the tonnage
per hour fed into the kiln using the principle of load cells and the tachometer to
measure the speed of the belt using the formula below.
WEIGHT = LOAD CELL VALUE X SPEED OF BELT

1.2.4 Kiln Section
The Kiln is the heart of the plant and is the site of all chemical reactions involving
sponge iron manufacture. The Kiln is 42m and has an internal shell of 2,6m diameter
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and external diameter of 3,0m.The kiln in inclined at 15º to facilitate movement. The
retention time is the time taken to flow the material from the feed to the discharge
end. The lining of the kiln is of refractory thickness 250mm. At the various sections
of the kiln are thermocouples to measure the temperatures in the kiln.
The kiln is divided into two zones, which are the pre-heating zone and the reduction
zone.
(a) Preheating Zone
Raw materials are heated using fee gases to the reaction temperatures and several
reactions take pace such as drying of iron ore and coal.
Free gases heat raw materials to a reaction temperature which result in:
 Calcinations because of limestone / dolomite.
 Drying of Iron ore and Coal.
 Release of volatile matter from coal.
(b) Reduction Zone
As temperatures of the charge exceed the carbon gasification of the boundary reaction
becomes available for the reduction reactions. Temperatures of the order 900 to 1000
degrees are maintained in the kiln.
The reaction:
3Fe2O (s) + CO(g) 2Fe3 O4(s) + Co 2(g)
Fe3 O4(s) + CO(g) 3FeO(s) + CO2(g)
FeO(s) + CO(g) Fe(s) + CO2(g)

1.2.5 Cooler section
The kiln discharge temperature is around 900-1000. The discharge should be cooled
down to 150-200 degrees before being discharged hence the need for cooler.
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The cooler section consists of a steel cylinder of 2.2m diameter and length 12.262m
and rotates at 4rpm. The cooler shell is cooled by circulating cold water around it.
The product is not cooled directly because it can easily reoxidise when it gets in
contact with water.
1.2.6 Product section
The product is transported via a conveyer belt to the intermediate bin where it is
blended (when necessary) with older stock. The product is then sent to the product
house via another belt. In the product house there are magnetic separators which
separate the product into four types:
+ 4mm magnetic Direct reduced Iron

+ 4mm nonmagnetic Charcoal
- 4mm magnetic Direct reduced iron fines
- 4mm non-magnetic Ash
These materials are collected in four different bins and are sent to different markets
around the region.
STOCK PILE 3
STOCK PILE 1 COAL SHADE
STOCK PILE 2
LIMESTONE
IRON ORE
DUST
EXTRACTOR
GROUND HOOPER
VIBRO FEEDER 1 VIBRO FEEDER 2
CONE CRUSHER IMPACTOR

LIMESTONE HOOPER
DOUBLE DECK
SCREEN
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University of Technology- Attachment Report. PRIMARY SCREEN
COARSE NON- FINE NON-

ELBOW
CAP
STACK ESP GCT LUMP SPONGE ROTARY ROTARY
COOLER KILN
SECONDARY
DOUBLE DECK
FINE SCREEN
SCREEN
SPONGE
MAGNETIC MAGNETIC
DUCT I-FAN
CHIMNEY COARSE
MAGNETIC
IRON BIN FRACTION
SEPERATOR IRON BIN
MAGNET
CHAR BIN LIMESTONE BIN IRON ORE BIN FEED COAL BIN
STOCK HOUSE
WEIGHFEEDERS AND LIMESTONE-VOLUMETRICFEEDER
INJECTION
COAL BIN
A DCS I-BIN
B
C
DUST EXT
PRODUCT HOUSE
FINE FRACTION
MAGNETIC SEPERATOR
CHAPTER 2
2.0Instrumentation and Control Engineering Department
2.1Introduction
This Department is headed by Mr. I. Muchimwe a well known Instruments and

Control Engineer in Masvingo and the Low-veld area of Chiredzi and Triangle. There
are 3 Technicians and six Assistants that is for every shift there is a Technician and an
Assistant. SIMBI is a fully automated plant that uses SCADA and PLC.
Instrumentation is a collective term used to describe the equipment that is used for
measurement, control, data storage, and display of process variables such as:
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temperature, pressure, pH, humidity, weight, speed, distance, level, flow, position,
conductivity, turbidity e.t.c. Instrumentation equipment can be installed in the field,
control room and marshalling rooms depending on the purpose and type of
Instrument.
Instrumentation department is there to ensure quality production of Sponge Iron and
the associated byproducts by installation and maintenance of the appropriate
measurement and control instruments in an economic, safe and efficient manner.
Instrumentation department is there to ensure quality production of Sponge Iron and

the associated byproducts by installation and maintenance of the appropriate
measurement and control instruments in an economic, safe and efficient manner.
The main objective of this report is to focus on:
• Variable speed drives
• PLC programming
• Appreciate drive programming keypad operation.
• Design a drive programme for a motor for a specified operation.
• Appreciate analogue and digital I/O wiring.
• Be able to read a ladder logic programme
• Use ladder logic on fault finding,
• PLC hardware trouble shooting
• Procedures for connecting HMI to SCADA
• Appreciate SCADA and associated software
• Design control logic in ladder language.
• Practice loading ladder logic programmes in PC.
• Improve production, easy maintenance and cost effective.
• Identification of the entire field instrumentation and control room
Instrumentation
• The principal of operation and control loops of each instrument.
NB: PLC and AC drive programming dealt in depth at this point.
2.1.1Objectives/Roles of Instrumentation Department
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 Instrumentation department is there to ensure quality production of sponge
Iron and the associated by products by installation and maintenance of the
appropriate measurement and control instruments in an economic, safe and
efficient manner.
 Ensures plant and equipment availability at all times by carrying out planned
and preventive maintenance of instruments and attending to breakdowns.
 Carry out equipment calibration and checks as per planned schedules or as the
need arises so as to ensure safe and accurate measurement and control of
variables.
 To ensure that equipment is user safe bay carrying out appropriate and
standard installations and checks/tests of measurement, safety and other
instrumentation
 Interaction with other departments (Engineering, SHE, Administration and
Processing) to form a strong and reliable sponge ion production team.
 Offer appropriate training to unskilled workforce and other trainee in order for
them to be a useful asset in the instrumentation field.
 Make plans, recommendations and provisions for further plant expansion in
future.
2.1.2Safety Precautions
 Next to the Kiln Slip rings for shell thermocouples, there are power rings for
shell air fans and these have very high and dangerous voltages, so extra care
must be taken not to temper around the rings. As a safety measure, any one
entering this area should have company.
 Before carrying out any work on proximity, sensors make user the belt has
stopped unless carrying out level 3 maintenance (i.e. cleaning or inspection)
taking care not to interfere with the moving parts of the conveyor.
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 Avoid putting hands or any other body parts underneath the moving machinery
of weigh feeders.
 Make sure power supply is switched off before disconnecting power supply to
the transmitter and sensors. If there is need for power to the transmitter caution
must be taken not to short circuit the power cables.
 AC Drives and Weigh feeder Panels have very high and dangerous voltages,
therefore no work is to be carried out on these equipment when energized. If
need arises that work ought to be carried out when energized, caution must be
taken not to interfere with the live parts.
 The main kiln temperatures are very high and dangerous, thus when carrying
out thermocouple movements and QRT readings, always wear hand gloves,
apron and safety goggles.
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2.2SCADA and Automation as applied to SIMBI
Monitoring the Plant using the SCADA
Fig 1
2.2.1SCADA
SCADA simply means Supervisory Control and Data Acquisition the terms refer to
large-scale distributed measurement and control system. The bulk of the site control is
actually performed automatically by a Remote Terminal Unit or PLC as for SIMBI
most of the control functions are restricted to basic plant override or supervisory level
capability. It includes all HMI controllers, I/O devices; networks and software
(Cimplicity as for SIMBI). It implements a distributed database, which contains data
elements called points.
 Hard point representative of actual O&I connected to the system.
 Soft point result of mathematical \operations applied to hard and soft points.
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The main SCADA Screen of SIMBI Plant
Fig 2
2.2.2Automation
Is the automatic processes done by machines with minimum to no human

interference.
As the name indicates, it is not a full control system, but rather focuses on the
supervisory level. As such it is a purely software package that is positioned on top of
hardware to which it is interfaced, via PLCs. The system collects data from various
sensors in the plant and then sends this data to a central computer that then manages
and controls the data. The plant control logic resides in the PLC and it does all the
logic decisions.
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Roles
• Aid humans
• Increase production
• Control management
• Increase precision.
Characteristics
• System must be safe
• System must be comprehensive
• System must have minimum human interference.
• Improve production, easy maintenance and cost effective.
2.2.3Supervisory Control Architecture
INTERFACE
SUPERVISORY
DISPLAY CONTROL
SYSTEM
COMPUTER
HUMAN
INTERVENTION
CONTROL
SENSOR
Control engineering is the engineering discipline that focuses on the modelling of a

diverse range of dynamic systems (e.g.mechanical systems) and the design of
controlers that will cause these systems to behave in the desired manner. Although
________________________________________________________________ 17
such controllers need not be electrical many are and hence control engineering is
often viewed as a subfield of electrical engineering.
Electrical circuits, digital signal processors and microcontrollers can all be used to
implement control system. Control engineering has a wide range of applications from
the flight and propulsion systems of commercial airliners to the production of sponge
iron at SIMBI.
Control engineers often utilize feedback when designingcontrol system. For example,
in temperature is continuously monitored and fed back to the system which adjusts the
motor’s speed accordingly. Where there is regular feedback, control theory can be
used to determine how the system responds to such feedback. In practically all such
systems stability is important and control theory can help ensure stability is achieved.
Although feedback is an important aspect of control engineering, control engineers

may also work on the control of systems without feedback. This is known as open
loop control. A classic example of open loop control is a temperature control at
SIMBI that use K type thermocouples on the KILN SECTION.
Other functions of SCADA are:

• To generate trends and reports of the plant parameters.
• To generate alarms.
• To have graphical views of the whole plant.
• To provide troubleshooting guides.
So many SCADA packages are currently in use throughout the world. Some of the
most common ones are:
- Wonder ware
- Cites
- Genesis
- RS View
- Cimplicity
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At SIMBI, we use CIMPLICITY SCADA. It is important to note that SCADA is not a
controller but simply interfacing software between the controller and the operator’s
panel, the computer.
2.3The Drive
2.3.1Human Machine Interface (HMI)
Fig 4
A SCADA system includes a user interface usually controls where the individual can
interface with the SCADA system. The SCADA system communicates with PLCs
throughout the system network and processes information that is easily disseminated
by HMI
At SIMBI we use two computers the Engineering PC and the Station manager PC for
our SCADA system. Also for TUC-4 HMI for communicating with our weigh feeder
TUC-4 controller.
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2.4PLC (VersaMax)
2.41Introduction
I was trained on how to do fault finding and appreciate the need for a controller in the
processing industry so I compiled the information in this chapter with great caution
since any wrong information could lead to a disastrous future in the control
engineering field. Most of the literature was researched after practicals with the
Instruments engineer. This was one of the most challenging topics of my attachment
since it strongly requires good background of control engineering. Emphasis was on
understanding the principle factors under industrial measurement and control.
The appearance of the PLC at SIMBI Plant
Fig 5
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2.4.2Schematic representation o f the PLC
Mains supply
Digital Input and

Power Supply
Fig 6 Output Modules
2.4.3General Structure of a PLC consists of the
Detachable
• CPU, Processor
Programming device CPU
• Output and Input modules,
• Power supply Analogy Input and
Output Modules
• Detachable programming device
• Expansion transmitter modules
Memory unit
The GE Fanuc* PLC system consist of Ethernet based control processing unit and
total programming for monitoring and controlling the various equipment pertaining to
the plant.
A PLC is a microcomputer based controller that uses stored instructions in
programmable memory to implement logic, sequencing, timing, counting and
arithmetic functions through digital or analogue I/O module for controlling machines
and processes.
The microprocessor is used for automatic distribution of real world process but
designed for an extended temperature ranges dirty or dusty conditions. It is immune to
electrical noise, mechanically more rugged and resistant to vibrations.
2.4.4 Processor
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It is the CPU of the programmable controller. It executes the various logic and
sequencing functions by operating on the PLC inputs to determine the appropriate
output signals. It consists of one or more microprocessors designed to facilitate I/O
transmissions. The GE Fanuc* PLC like all PLCs, it has inbuilt facilities like timers
counters, PID loops and parameters like memory bits registers, global bits, temporary
bits, and system bits that can be configured as per plant requirements through
programming software for the better monitoring and control of the plant.
The VersaMax solution is a single control product that may be used as I/O, as a PLC,
and/or as distributed control for up to 256 I/O points. With its modular and scaleable
architecture, intuitive features and ease of use, it saves initial costs for machine
builders and life-cycle costs for end users. VersaMax provides reliability and
increased uptime because of its Six Sigma design, intuitive diagnostics, and hot I/O
module insertion. Its broad family offers 34 different I/O modules, powerful PLC
CPU, open networking, and multiple wiring options. Its combination of feature-rich
I/O and powerful CPU provides the performance to meet any industry need
2.4.5 Memory unit
It is connected to the CPU; it contains the programs of logic sequencing and I/O
operations. It also holds data files associated with these programs including I/O status
bits, counter and timer constants, other variables and parameter values. This memory
unit is referred to as the user or application memory because it s contents are entered
by the user. In addition the processor has a system that directs the execution of the
control program and coordinates I/O operations. The contents of the system memory
are entered by the manufacturer and cannot be accessed or altered by the user.
2.4.6 Power supply
A power supply of typically 120VAC is used to drive the PLC some 230VAC .It
converts AC to DC of 5V. It often includes a battery back up that switches on
automatically in he event of an external power source failure. At SIMBI a UPS is
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connected in series and there is a 230AC transformer of equal voltage on Primary and
Secondary winding responsible for smoothening the 230ACV. A number of breakers
are installed in the PLC panel for different inputs. These are:
• Transformer
• PC
• Digital output signals
• Digital input signals
• Analogue signals
NB: swichedmode power supply units are the ones in use.
2.4.7 Input/ Output Module
Provides the connectors to the backplane and process that is to be controlled. Inputs to
the controllers are signals from he sensors and other ON/OFF devices. Outputs from
the controller are ON/OFF signals to operate actuators and other devices required to
activate. Many PLCs are capable of accepting continuous signals from analogue
sensors and operate signals suitable for actuators.
2.4.8 Programming device
The PLC is programmed by means of a special programming device. It is detachable

from he PLC cabinet so that it can be shared among the controllers. A PC (as for
SIMBI) can be used, but usually remain connected to serve a process monitoring or
supervision functions related to the process.
2.4.9 Expansion transmitter modules
These modules are responsible for communication between the processor and the
input/output modules. There is a main ETM and is the one responsible for direct
communication and the rest of the ERMs behave as parasites.
2.5.0 Inputs and Output Signals

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• Digital Inputs
These are real discrete inputs from the field e.g. limit switches, level switches, flow
switches, push buttons, and contactors, overload relays.
Digital input modules are configured to accept these inputs, which are connected to
the same power supply from the CPU.
The switching mode for digital inputs can either be source mode or sink mode and are
activated on by either a 24 VDC, 110 VAC at 220VAC. The most common are the
source mode, which has a switching signal at the (+) positive.
For sink mode, the switching mode is (-) negative; therefore, the PLC will sink
(switching a mental OV). At SIMBI there are 32 input modules with a 24 VDC
switching voltage (source mode).
2.5.1 Digital Output
Give out a voltage usually 24 VDC to field devices such as relays, contractors,
transistors depending on the type of PLC. Usually the output is a low current, which is
used to switch a higher current.
2.5.2 Analog Output
Gives output commands to field devices such as control valves, transistors, indicators
etc. The signal current operates the current to pneumatic converter.
2.5.3Analogy Inputs
Receives signals from real world analog transducers and transmitters. Most common
type of inputs are: 0 – 20mA; 0,-5V; 0,-10V; 1 – 5V, 1 – 10V and 4 – 20mA. At
SIMBI, the most widely used analog input is the 4 – 20 mA.
Input module/card
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Source voltage +
-CH1
24VDC
+
- CH2
+
TRANSMITER - CH3
+
- CHn
SENSOR
Fig 7
NB: The wiring of digital inputs is different from that of analogue inputs. If the 4 – 20
mA is coming from a transmitter, a power supply, in our case, of 24VDC is required.
2.6The CPU (Details)
The CPU at SIMBI is as shown below.
ETM – Expansion Transmitter Module

µp ETM Ethernet µp-processor
POWER card
SUPPLY
The VersaMax's powerful processor with 12K of memory for application programs,
floating point math, real-time clock, subroutines, PID, Flash memory, and bumpless
run mode provides a powerhouse of versatility in a small package. It includes
automatic I/O addressing - extensive diagnostics with an internal fault table and LEDs
that indicate system faults and I/O forces - freeing up the operator to concentrate on
maintaining the highest quality
The Input and Output modules are connected onto a Backplane; the general structure
is shown below. The Output and Input modules are fitted on the female connectors to
________________________________________________________________ 25
enable communication with the CPU, which is also placed on the back plane. The
power supply of the back plane is to supply some modules with power.
NB: Not all output and input modules get their supply from the power supply in the
PLC, but some input/output modules are supplied from the back plane.
Each back plane accommodates a specific number of modules and if the required
modules in a plant exceed the maximum number accommodated by a back plane,
there is need for an Expansion Transmitter Module which will enable the CPU on a
certain back plane to communicate with Input and Output Module in another back
plane.
NB: All other modules which are connected on a different back plane from the one
with the CPU need an Expansion Receiver Module (ERM) which receives
instructions or signals from the Expansion Module (ETM). See diagram below.
All Analog Output Modules are powered from the back plane with a 5V supply.
Digital Output sends output to the relays, which will enable switching on of high
currents. There are two types of relays in use, NO (normally open) and NC (normally
closed) Each relay has one digital output from the PLC.
2.6.1The VersaMax PLC Panel
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Fig 7
2.6.2Hardware Configuration
When assembling a PLC you carry out hardware configuration first i.e.
 Choosing the correct type of CPU

 Choosing the correct digital input card (32 port)
 Selecting the type of mode (SIMBI uses source mode)
 Correctly, use slot number and rack number for the PLC to correctly identify
the Input/Output signals.
2.6.3Back Plane
This is the plane where digital/analog modules are mounted. At SIMBI, the back
plane can support up to 9 modules. Some of the output modules take their supply
voltage from the back plane, however at SIMBI most of the output modules are not
supplied from the back plane.
2.6.4Expansion Transmitter Module (MDL 650)
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It is the main transmitter from the CPU to the output modules. All other ERMs
depend on the ETMs thus; they behave in a parasite manner. For every backplane, we
have the ERM. In addition, when changing modules one should take note of the
codes.
Digital outputs and inputs can be slotted on the same back plane but it is wise for
uniformity to separate them that is using different back planes.
At SIMBI, there are 7 digital output modules, which translate to 7 x 32 output signals
from the PLC. In addition, there are also 17 digital input modules, which translate to
17 x 32 input signals.
NB: Analog Output Modules uses 24VDC from SMPS and Input Modules use 5VDC
from the back plane.
 Relays
SIMBI uses 24VDC relays and they are high current rating relays. These are of two
types, Normally Open (NO) and Normally Closed (NC). Each digital output uses one
relay.
 LED
The LED ON, on the Modules only signal whether the signal from the instrument is
reaching the PLC. These LEDs are helpful during trouble shooting of an instrument.
Digital outputs have only 2 LEDs for power supply.
 Terminal Block Side (TBS)
The blocks are used to connect the cables from the field to the PLC. This reduces the
number of cables into the PLC panel and provides SMART installation. Terminal
________________________________________________________________ 28
blocks on the terminal side also help a lot during troubleshooting. The cables are
given addresses for easy identification e.g.
Analog Outputs AQ0001 (Blue Cable)
Analog Inputs AI 0001
Digital Outputs R0001 (Blue cable)
Digital Q000I(Yellow cable)
NB: Take note that after expansion of the plant, some of the cables are not labeled
and the terminal side has changed a lot and is not yet updated.
2.7.0 The Communication Protocol

Checking the Ethernet LEDs IC200CPUE05.
For more information about the IC200CPUE05 Ethernet Interface, refer to the next
chapter of VersaMax® PLC User’s Manual – GFK-1503D.
After configuring the Interface, follow the steps below to verify that the Ethernet
Interface is operating correctly.
1. Turn power OFF to the PLC for 3–5 seconds, and then turn the power back ON.
This starts a series of diagnostic tests. During powerup diagnostics, after a brief delay
the STAT LED on the Ethernet side of the CPU module blinks. Both the LAN and
PORT1 LEDs are off. If a fatal diagnostic failure occurs, the failure is indicated by a
two-digit pattern in amber on the STAT LED.
2. After successful power-up, all three LEDs on the Ethernet side turn on briefly. Then
the STAT and LAN LEDs should be green. The LAN LED blinks when there is
traffic.
3. If the STAT LED is amber, check the PLC Fault Table. With the Station Manager
feature, you can also use the LOG command as explained in GFK- 1876, The
VersaMax PLC Ethernet Station Manager Manual.
If a problem occurs during power-up, the Ethernet interface may not begin operating.
Check the Ethernet LEDs, as explained below.
________________________________________________________________ 29
 Ethernet LEDs
LAN Off
STAT Off
PORT 1 Off
Actions
-Make sure the PLC has power
-Look in the PLC Fault Table for problems
-Recheck configuration
-Check module installation
-If the problem persists, replace PLC CPU
 Ethernet LEDs
LAN Off
STAT Fast blink green
PORT 1 Off
Indications
Performing powerup diagnostics
Actions
No action necessary; diagnostics will complete within 3 to 10 seconds.
 Ethernet LEDs
LAN Off
STAT Blinking amber
PORT 1 Off
Indications
Hardware failure mode.
Actions
STAT: Blinks 2-digit error code:
1 – 2, unexpected interrupt
1 – 3, timer failure
1 – 4, DMA failure
________________________________________________________________ 30
2 – 1, RAM failure
2 – 2, stack error
2 – 3, shared memory interface error
2 – 4, firmware CRC error
3 – 1, unidentified instruction, or divide by 0
3 – 2, unexpected SWI interrupt
3 – 3, prefetch abort error
3 – 4, data abort error
3 – 5, unexpected IRQ request
3 – 6, unexpected FIQ interrupt
3 – 7, reserved exception error
4 – 1, fatal operating system startup or EEPROM error
Actions
-Note error code
-Power cycle or restart Ethernet interface
-If problem persists, replace the PLC hardware.
 Ethernet LEDs
LAN Off
STAT Slow blink Green
PORT 1 Off
Indications
Waiting for Ethernet configuration data from CPU.
PORT 1: PLC CPU is controlling Port 1.
Actions
-Use the PLC programmer to update the configuration, then store the configuration to
the PLC.
-Power cycle the PLC.
-Clear faults and press the Restart pushbutton for less than 5 seconds to restart the
Ethernet interface.
________________________________________________________________ 31
 Ethernet LEDs
LAN Green / flickering
STAT Slow blink green
PORT 1 Off
Indications
Waiting for IP Address, IP address has not been configured, or has been configured as
0.0.0.0 .
LAN: Ethernet interface is online. Flickers during activity.
STAT: IP Address has not been configured.
 Ethernet LEDs
PORT 1 Amber
Waiting for IP Address
Indications
0.0.0.0 .
PORT 1: Available for Station Manager use
 Ethernet LEDs
LAN Amber
PORT 1 Amber
Indications
________________________________________________________________ 32
0.0.0.0 .
LAN: Ethernet interface is offline. Attempting to recover if possible.
 Ethernet LEDs
LAN Amber
PORT 1 Amber
Indications
0.0.0.0 .
PORT 1: Available for Station Manager use
Actions
Use the PLC programmer to configure a non-zero IP address.
 Ethernet LEDs
STAT Green
PORT 1 Off
Indications
Operational
STAT: No “exception” detected
________________________________________________________________ 33
 Ethernet LEDs
STAT Green
PORT 1 Amber
Indications
Operational
PORT 1: Forced to Station Manager use
 Ethernet LEDs
LAN Amber
STAT Green
PORT 1 Off
Indications
Operational
 Ethernet LEDs
LAN Amber
STAT Green
PORT 1 Amber
Indications
Operational
________________________________________________________________ 34
PORT 1: Forced to Station Manager use
Actions
If LAN is off, the problem may be:
-Network cable not connected either at the PLC or at the hub.
-Hub disconnected/failed.
-Network cable not properly terminated.
If STAT is amber, an “exception” condition has occurred.
 Ethernet LEDs
LAN Slow blink green, all LEDS blink in unison
STAT Slow blink green, all LEDS blink in unison
PORT 1 Slow blink green, all LEDS blink in unison
Indications
Software Load
Loading new firmware (via CPU serial port)
Actions
No action necessary; the Ethernet interface restarts automatically after loading
________________________________________________________________ 35
CHAPTER 3
3.0The Control Philosophy

As an abstract, the plant has been divided into four major segments.
i) Kiln and Cooler Section

ii) Waste Gas Section
iii) Product Separation Section
iv) Raw material handling section
The corresponding signal from every individual section has been connected to the
PLC system through the corresponding Input and Output modules. The CPU is
continuously processing the data as per the program logic and communicating the
SCADA – Graphical interface terminals for equipment status, monitoring and control.
The proposed PLC is user friendly and during the operation, in case of any fault due
to malfunction of any input address, the same can be reset by assigning some other
address from the spare block for ensuring the smooth functioning of the plant.
The necessary interlocks have been incorporated for every equipment to safe guard
from any eventualities and ensuring the smooth operation of the plant.
The system is designed to operate in 3 modes:
i) Manual
ii) Auto
iii) DE INT
________________________________________________________________ 36
 Manual Mode
In this mode, the system can be started/stopped through SCADA i.e. from computer.
Here we can start all drives as well as conveyers by clicking the respective icons. All
interlocks are applicable in this mode.
 Auto Mode
Generally, the system is operated in this mode. Here the system is designed in such a
way that the entire plant can be started with one click or individual major sections can
be started one by one.
 DE INT Mode
In this mode, all the drives can be started/stopped independently irrespective of the
interlocks and is generally used for maintenance purposes.
The selection of the control of the plant is achieved by selecting LOCAL/REMOTE

positions in the MCC. To operate the plant in Auto mode all the selector switches
should be in REMOTE mode. When the system is in Auto mode, if any of the selector
switches in a particular group changes to LOCAL mode, then the whole group trips
along with down stream groups.
NB; In case it is necessary to keep one or few drives out of the total sequence of
operation, this is achieved by putting them in DE INT mode.
3.1PLC Programming
Introduction
________________________________________________________________ 37
A program is a set of instructions to execute a certain function. The instructions to be
performed during each scan are coded and inserted into memory with the programs.
Programming is carried out using a programming unit, which provides an interface
between the PLC and the user during program development, start up and trouble
shooting.
What makes a PLC special? PLC's are used to automate machinery in assembly lines.
For our (plant) project, we use the computer link feature that allows a PLC to take
commands and communicate with a host computer. If something goes wrong with the
computer link, the PLC still functions and protecting valuable equipment. This PLC
and most others use a language called relay ladder logic programming. Normally in a
programming language things happen in order. The command or line of code on top is
executed before the command on the bottom until you hit the end of a loop. This is
not so in ladder logic. Everything happens at the same time.
So what is ladder logic programming really like? Ladder logic programming looks,
well, like a ladder. It's more like a flow chart than a program. There are two vertical
lines coming down the programming environment, one on the left and one on the
right. Then, you have rungs of conditionals on the left that lead to outputs on the right.
The things you will probably use the most writing Ladder Logic are the relay
conditionals --| |-- ---|/|--- and the output coils --- ( ) ---. These three things basically
make up a kind of IF THEN statement.
Ladder logic is a method of drawing electrical logic schematics. It is now a graphical

language very popular for programming PLCs. It was originally invented to describe
logic made from relays. The name is based on the observation that programs in this
language resemble ladders, with two vertical "rails" and a series of horizontal "rungs"
between them.
A program in ladder logic, also called a ladder diagram, is similar to a schematic for
a set of relay circuits. An argument that aided the initial adoption of ladder logic was
that a wide variety of engineers and technicians would be able to understand and use
it without much additional training, because of the resemblance to familiar hardware
systems. (This argument has become less relevant given that most ladder logic
________________________________________________________________ 38
programmers have a software background in more conventional programming
language, and in practice implementations of ladder logic have characteristics — such
as sequential execution and support for control flow features — that make the analogy
to hardware somewhat imprecise.)
Ladder logic is widely used to program PLCs, where sequential control of a process
or manufacturing operation is required. Ladder logic is useful for simple but critical
control systems, or for reworking old hardwired relay circuits. As programmable logic
controllers became more sophisticated it has also been used in very complex
automation systems.
Manufacturers of programmable logic controllers generally also provide associated
ladder logic programming systems. Typically, the ladder logic languages from two
manufacturers will not be completely compatible; ladder logic is better thought of as a
set of closely related programming languages rather than one language (the
IEC61131-3 standard has helped to reduce unnecessary differences, but translating
programs between systems still requires significant work). Even different models of
programmable controller within the same family may have different ladder notation
such that programs cannot be seamlessly interchanged between models.
Ladder logic can be thought of as a rule-based language, rather than a procedural. A
"rung" in the ladder represents a rule. When implemented with relays and other
electromechanical devices, the various rules "execute" simultaneously and
immediately. When implemented in a programmable logic controller, the rules are
typically executed sequentially by software, in a loop. By executing the loop fast
enough, typically many times per second, the effect of simultaneous and immediate
execution is obtained. In this way it is similar to other rule-based languages, like
spreadsheet. However, proper use of programmable controllers requires understanding
the limitations of the execution order of rungs.
Hence a program is a set of instructions to execute a certain function. The instructions

to be performed during each scan are coded and inserted into memory with the
programs. Programming is carried out using a programming unit, which provides an
interface between the PLC and the user during program development, start up and
trouble shooting.
________________________________________________________________ 39
• There are four types of programming units
i) Hand held Unit

ii) Video/System programming unit
iii) Graphic programming unit
iv) Personal computers.
Where computers are used the manufacturer supply a program for the P.C that usually
allow the computer to, interface with serial input/output module installed in the PLC,
peripheral devices, programming aids and computer interface devices.
• Symbols
This --| |-- means closed if energized while --|/|-- means closed if not energized. The
output coil -- ( ) -- basically means then energize this. So the first rung of example one
means that if input 1 is energized and input 2 is not then energize output 1. You should
note that on the T1, the number of a particular input or output is written on the case of
the PLC but for T2's and for some other more advanced PLC's this is not necessarily
the case. To find out what the addresses of your inputs and outputs are you should
refer to the documentation that came with your PLC. Also, in most ladder logic
programming environments you have to specify the address of each of your inputs
and outputs before it will even let you start programming. [The T series can auto
configure]
For example
x0001 x0002 Y0001

|---| |-----|/|---------( )-----|
| |
| |
| x0001 Y002 |
|---| |--[01000 TON T012]--( )--|
| |
| |
| R001 |
|--[D0140 = 0001]--------( )--|
________________________________________________________________ 40
| |
| R001 Y004 |
|--| |---------------------( )--|
| |
|-{END}-------------------------|
In Ladder logic programming you do not have variables, you have registers. There
are four kinds of registers: X's that are inputs, Y's that are outputs, D's that are data
that can form integer, hex and real numbers, and finally R's that are internal relays.
X's and Y's are pointers to the actual terminal strip connectors (what you use a screw
driver on to connect wires) on the PLC. If you energize an input, let's say 5, then
X0005 will have an on status; also if you give Y0023 an on status then relay 23 will
flick on.
R's are just about the same as X's and Y's except that they don't point to any hardware.
They just hold an on or off value inside of the PLC's memory. R's can be useful. X's
Y's and R's can even hold data besides their on and off states on many PLC's, but
personally I don't recommend it. For data like integers and hexadecimal numbers D's
are used as their addresses.
• Delay timer
What this means is that after a specified amount of time after x0001 turns on, y0002
will turn on. You should note that because of the nature of ladder logic you can not
simply put a timer attached directly to the left hand side without a relay conditional
between it. Remember, everything is happening at the same time. PLC's are meant to
run on their own for long periods of time, so you can't just tell it that 10 seconds after
it's first plugged in it should activate something. You have to tell it to start timing after
something in the outside world has occurred, like the energizing or de-energizing of
an input.
In the code --[01000 TON T012]-- there is the parameter 01000 that tells the timer to
wait 1000*10ms or 10 seconds, and the parameter T012 tells the PLC which internal
timer you want to use. Some of the more advanced PLC's have timers with different
accuracy. Most measure time in 10ms intervals but others measure time in single
milliseconds. You should check the documentation on your PLC to see if any of it's
________________________________________________________________ 41
timers measure time in different units than the others. Also you should not use the
same timer for more than one thing.
On rung three of the ladder we have a conditional statement. If the number stored in
D0140 is equal to 1 then energize R001. If you look at the entire circuit you'll note
that there is no where else in it where D0140 is mentioned and you should know that
all data registers are set to 0 at default. You may think that D0140 will never actually
reach the value of 1 and that R001 will never be activated and that rung three and four
are useless garbage code. It's true that during the normal operation of the PLC D0140
will never change from zero and the last two rungs before end would be useless.
However, this is where the computer link function comes in. All Toshiba PLC's have a
computer link protocol built into them. This allows a host computer, such as any sort
of DOS, Linux based PC or even a Unix administrator with an RS232 serial port to
send commands to the PLC while it's running and read or write values into its
registers. This includes data, inputs, outputs, and relays.
Suppose that Y004 was attached to equipment that you wanted to turn it on or off at
your pleasure. Suppose it was an air conditioner or maybe some strange contraption
that brought you a coke from the fridge to your seat at a computer. If you can write a
program at your own specialized system that can send ASCII characters with 8 data
bits 1 start bit 1 stop bit and 9600 baud rate with odd parity, then you can manipulate
the registers in the VersaMax PLC 's and toggle d0140 between 1 and zero or 1 and
any other value.
The final rung on the ladder the - {END} - is basically what it says. It's the end
statement. It doesn't really do anything except to say, well, your done programming.
However, no program will work without an end statement and the PLC will ignore
any code put in after an end statement. This shouldn't be a problem for small
programs, just look at the screen and make sure the end is in there and at the bottom.
If you happen to be making a very large and a very complicated relay circuit your
editor will likely force you to write it in separate blocks.
Before attempting to write a very large program you should go to the very last
programming block available to you and put the end statement there and no where
________________________________________________________________ 42
else. The end statement can be used in debugging by ending the program early and
disabling commands that fall after the end statement.
NB: Most of the time on has to draw wiring diagram as shown below so that you can
come up with the Ladder Diagram.
3.2 Plant Control Loop drawings

All Drawings had been drawn using AUTOCAD2004 by Talon Garikayi for the
company with the immense help of the Instruments Engineer- Mr. I Muchimwe
• Belt Conveyor Control Loop
JB201
PLC
+24VDC
DIGITAL INPUT +24VDC
MODULE
CH1 SIGNAL
SIGNAL
24VDC SMPS -24VDC

-24VDC
L
220VAC
+
N
-
PE
COMPANY NAME: SIMBI Pvt Ltd
TITTLE:BC101 CONVEYOR BELTSLIP CNTRL LOOP
DATE:28-05-2008
• Gas Conditioning Tower water level Control Loop
________________________________________________________________ 43
JB202
PLC
PROXIMITY SENSOR
+24VDC
DIGITAL INPUT +24VDC
MODULE
CH1
+24VDC SIGNAL
24VDC SMPS -24VDC -24VDC
L
220VAC
+
N
-
PE
COMPANY NAME: SIMBI Pvt Ltd
TITTLE:GCT TANK WATER LEVEL LOOP
DATE:28-05-2008
Fig 8
• Ladder Logic/Diagram
NB: In ladder logic a rung is a complete ladder, and the complete circuit when
represented in ladder diagram is called a Project. Every input and output is assigned
an address and at SIMBI, inputs are addressed as % IQ0001
All inputs with the same status as the output are given an address similar to that of the
output.
3.3Basic Induction and Transformer Theory
“Since I had encountered circuits which include Transformers on most power supply
units I decided to include this section.”
When an electric current is applied to a conductor a magnetic field builds around that
conductor. If another conductor is in close proximity so that the building magnet field
"cuts" through that conductor, a current of equal potential is produced with flow in the
opposite direction of the original current. This conductor is called the secondary
circuit and the principal is called induction.
________________________________________________________________ 44
If the number of conductors in the secondary are increased the output potential is
increased in direct proportion. The inverse is also true. This is called transformer
action. It is because of transformer action that a current is created in the rotor
(secondary circuit) of an AC induction motor and a resulting magnetic force, within
and around the rotor, is also created.
If the magnetic field reaches maximum strength and quits growing, the current flow in
the secondary returns to zero regardless of the level of current flow in the primary. In
other words, there is a secondary current generated only when the magnetic field is
changing state.
Magnetism and electricity are the same way. We have some well-accepted theories
that we can use to explain how magnets can move our load but no one really knows
what magnetism and electricity are (regardless of what they say). When it comes to
using magnetic force to move our load, how it works just doesn't matter. We do know
that it works. We have even noticed a few peculiar things.
We have noticed that when you wrap a coil of wire around a piece of iron and apply
electric current the piece of iron becomes magnetic. We call this an electro-magnet.
We have noticed a lot of things about electro-magnets that are very important to the
drive application wizard:
• After we apply the electric current, the magnet field grows at a finite rate to a
finite size.
• After voltage is applied and full current is reached, which always takes a little
time, the field quits growing and becomes a constant size. If we increase the
applied voltage the field grows and becomes stronger, decrease the voltage
and the field weakens and shrinks.
• When we remove electric power to the coil the field does not just disappear. It
just decreases in size until it does disappear. It collapses over time so to speak.
• The more current our coil draws (which we can force by increasing the applied
voltage level) the stronger and larger our magnetic field becomes. I know I
said it twice. It's that important.
________________________________________________________________ 45
• When we increase voltage to our electro-magnet, current will increase directly
proportional up to a point. After that point current increases exponentially.
THIS IS IMPORTANT! Generally accepted theory says that the iron core or
any material, can only conduct a limited amount of magnetic flux. Once that
point is reached current can become very high with a very small increase in
voltage. This is called magnetic saturation and is sometimes seen in motor
applications. Motor life becomes very short when the core reaches saturation -
about 15 seconds in some cases. We will look at this and some of the causes
later.
• Some energy is consumed by simply magnetizing the iron core. Different
materials consume different amounts of energy. This is usually considered an
energy loss.
• Some energy is converted into heat within the iron core. Different materials
convert different amounts of energy. This is also usually considered an energy
loss.
• Once a core is magnetized, demagnetization and reverse polarity re-
magnetization consumes more energy and takes quite a long time, relatively
speaking. (Remember, an existing field has to collapse over time.) The amount
of this loss is proportional to the frequency of polarization reversals. This
happens 120 times per second when operating an AC motor at 60 hertz. We
will touch on the importance of this later. (Are you beginning to see where all
this is going?)
3.4Variable Speed AC Drives
________________________________________________________________ 46
Fig 9
The word "drive" is used loosely in the industry. It seems that people involved
primarily in the world of gear boxes and pulleys refer to any collection of mechanical
and electro-mechanical components, which when connected together will move a
load, as a "drive". When speaking to these people, an AC drive may be considered by
them as the variable frequency inverter and motor combination. It may even include
the motor's pulley .
People in the electrical field and electrical suppliers usually refer to a variable
frequency inverter unit alone as the "drive" and the motor as the "motor".
Manufacturers of variable frequency drives (VFD) used to refer to the drive as just
that, a "variable frequency drive". More manufacturers are referring to their drive as
an "adjustable speed AC drive". To make matters worse when a motor is included in
the package it may be referred to as an "adjustable speed AC drive system".
________________________________________________________________ 47
A variable frequency drive is an adjustable speed drive. Adjustable speed drives
include all types; mechanical and electrical. Now is it clear? Don't worry about it. It's
not clear to anyone. As you read on, when I refer to the "drive" I am referring to the
variable frequency inverter alone.
3.9 A little about AC drives
 Outside the drive panels
Fig 10
The main power components of an AC drive have to be able to supply the required
level of current and voltage in a form the motor can use. The controls have to be able
to provide the user with necessary adjustments such as minimum and maximum speed
settings, so that the drive can be adapted to the user's process.
Spare parts have to be available and the repair manual has to be readable. It's nice if
the drive can shut itself down when detecting either an internal or an external
________________________________________________________________ 48
problem. It's also nice if the drive components are all packaged in a single enclosure
to aid in installation but that's about it
 Ambiguous Motor Theory
The real action in an AC variable frequency drive system is in the motor. This is really
where it all happens.
To be an AC drive application Wizard one must understand how motors use electric
power. It is essential. I cannot emphasize the importance of this.
All loads moved by electric motors are really moved by magnetism. The purpose of
every component in a motor is to help harness, control, and use magnetic force. When
applying an AC drive system it helps to remember you are actually applying magnets
to move a load.
To move a load fast does not require more magnets, you just move the magnets fast.
To move a heavier load or to decrease acceleration time (accelerate faster) more
magnets (more torque) are needed. This is the basis for all motor applications.
Fig 11
________________________________________________________________ 49
Motors are designed so that the electro-magnets are made as strong as possible with
acceptable risk of core saturation. This will maximize the torque capability of the
motor but also means that during normal operation every motor may at some point,
operate close to saturation. How close a motor runs to saturation depends upon the
amount and type of core material used. So naturally, this point varies from
manufacturer to manufacturer. There really is a difference in motors and you get what
you pay for.
When the voltage applied to a motor is increased current to the electro-magnets

increases resulting in higher field strength and increased motor torque output. This is
a commonly used technique, especially in AC drive applications. It is a very good way
to gain torque capability when needed. This technique can cause higher than normal
motor heating resulting in reduced motor life. Close monitoring of the motor is
required. Avoid saturating the core.
3.5General Structure
 Inside the AC drive Panel
________________________________________________________________ 50
Fig 12
AC drives consists of two sections namely.
i) Rectifier section which converts AC to DC

ii) Inverter section which converts DC to AC
 Rectifier Section
This consist of three sections namely
a) AC Choke/Inductor – this is put on the supply side of the drive to
correct/reduce harmonics.
b) Charging circuit – it consist of capacitors which smoothens the charging
voltage. It also helps to reduce the amount of current from the drive phase,
which may damage the capacitors.
iii) Rectifier Bridge – usually made of thyristors or a combination of thyristors

and diodes.
________________________________________________________________ 51
NB: Between the rectifier and inverter there is a DC link, which consist of capacitors
and resistors. Capacitors smoothen the voltages and resistors discharge capacitors
 Inverter section
Depending on the type of drive, some employ any of the following.
i) Thyristors
ii) Diacs
iii) Triacs
iv) IGBT – This is the one used at SIMBI to drive the AC motors. These
devices either can be individual units or integrated.
Also on the inverter side there are clamping capacitors which clamp (keep it constant)
output voltage at a required level, i.e. setting voltage to a certain load.
For the charging circuit, some use a diode with a resistor . Since during initial
charging of capacitors, they draw a high current, this is also very dangerous when 3
lines are used so voltage is tapped from one phase and used to charge the capacitors
and when fully charged the 3Ф voltage can now pass through. The resistors in parallel
with the capacitors are used during discharging of capacitors. The DC voltage is later
converted to variable AC voltage, which is required by the AC motors.
Rectifier Bridge – It is made of Thyristor only or combination of Thyristor and

diodes.
 Standard Six Thyristor Bridge
For the set up above where only a resistor is used and no diode but relay B, the
standard six diodes are used. During the operation, current passes through the resistor
charging the capacitor. When the capacitor is fully charged, a signal is send to relay B
and energizes it. The relay then closes the switch.
 The Six Diodes

AC Drive Control of AC is divided into various circuitries namely :
________________________________________________________________ 52
i) Main Control Board
ii) Input/Output Board
iii) Gate Pulse Board
iv) Interface Board
These can be incorporated into one unit or set as individual units.
• How to vary frequency
The rate and mode of switching ON/OFF determines the frequency (varying
frequency).
Variable Frequency Drive Operation Parameter Setting that can be set on an AC

Drive. The following example illustrates how to carry an Operation Parameter Setting
when the drive is in REMOTE, LOCAL OR DUAL mode for RPM and ON/OFF
sequence.
• General Schematic Representation of the Drive Structure
Analog/ Digital
External Analog Signals in
Input/Output Card
Analog Signals to external devices
Digital Inputs
Interface Board
Links with the outside world
Communication with other devices
Motor Control
Board (Program
Gate Driver
Board
IGBT
TRIACS
Drives Electric Motor at SIMBI
0 THYROSTOS
- 415V
0 TRANSISTORS
– 50Hz
Application
RESISTORS
i) Main Control Board – It is microprocessor based. It is used for the
program and memory of the control system of the drive.
________________________________________________________________ 53
ii) Input/Output Board – It is an interface between the drive and the outside
world (analog and digital signal parts)
iii) Gate Pulse Board – It gives pulses to the thyristors, IGBT, TRIACS, and
DIACS etc to activate the whole system.
iv) Interface Board – It receives all measured signals as they are send to the
board e.g. supply voltage and current, output current, output voltage,
frequency.
3.6Programming an AC Drive
To program an AC Drive needs a user programme which is in the application control

board. A good example is when you want to run an AC motor using Variable
Frequency Drive (VFD) the following parameters should be considered.
 Parameters for AC motor application
i) Motor Parameters
ii) Control Method Parameters
iii) Input/Output Parameters
iv) Preprogrammed Parameters
 Motor Parameters
The following are considered:

i) Supply Voltage
ii) Motor Power
iii) Motor Current
iv) Motor Speed
v) Motor Frequency
vi) Power factor correction (Cos Ф)
 Control Method Parameters
________________________________________________________________ 54
Consider the following
i) Variable frequency
ii) Variable torque
iii) Constant torque
iv) Constant frequency
v) Direct Torque Control (DTC)
 Input/Output Parameters
a) Input Parameters are subdivided into two groups.

i) Process Inputs – Includes such factors as speed, flow level.
ii) Digital Inputs: Consider factors like
- Start command
- Stop command
- Reverse/forward command
- Auto/Manual selection command
- Selecting the control method
 Output Parameters
i) Analog Output – These are signals representing measured parameters

inside/outside change. Inside parameters include factors such as Output
torque, frequency, current, voltage input signals.
ii) Digital Outputs – these show status of the drive

- Running status
- Power status
- Direction
- Auto/Manual selection
- Control method selection
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CHAPTER 4
4.0Activities and Tasks in the Instrumentation Department
4.1Thermocouple Movements
4.1.1Reasons for carrying out the task.
The thermocouple (Tc) is housed in a stainless steel protector tube, which is in turn
housed in a thermowell (Tw).
Tc movements are done after every 4 hours during production, when the casted
material in the kiln inner lining is heated; the Tw gained a lot of heat and expands.
The protector tube also expands but due to di8fference in coefficient of expansion of
the two different materials the protector tube tends to stick to the Tw thus Tc
movements are done to create the much-needed clearance.
To a greater extent excretion build up at the tip of the Tw thereby blocking the tip of
the protector tube, which will be exposed to the process/product in the kiln. During Tc
movements these build ups are displaced and the protector tube will be exposed to the
process/product.
Therefore Tc movements are important and technicians are advised to closely monitor
this routine work.
4.1.2 Risk and Possible Dangers.

During Tc movements Technicians and their Assistants are exposed to highly
dangerous temperatures with the central burning area T6 and T7 recording an average
of 3600C and 4870C respectively hence T1 is always greater than 550C hence being
the lowest temperature at the Kiln area. Thus during Tc movements employees are
advised to spend the shortest possible time on this area. Research I had carried out
revealed that the shortest possible time one could spend whilst properly caring out this
task is &minutes. After Tc movements one is advised to drink at least to glasses of
water to compensate for dehydration that could have occurred so as to avoid
unexpected headaches.
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4.1.3 Safe work procedure
Before leaving the Instruments Workshop one should put on the following safety
clothing:
 Leather gloves, which are able to cover up to the elbow.
 Safety goggles, which are heat resistant and can avoid dust particles from
entering from the top of the goggles.
 A helmet to prevent any falling objects to directly harm you.
 Safety shoes and proper clothing.
On moving T1, T2 and T3 ensure that the stand you will be using is properly
positioned; caution has to be taken since the Kiln will be rotating and shell air fans
can easily harm you.
Do not totally remove the Thermocouple since the process can easily have access to
get yet it will be red-hot.
Company is a must when one is carrying out this exercise.
4.1.4 Removing Thermocouple

Do not remove Tc during production if there are other alternatives, Technicians are
advised to seek clearance from the Instruments Engineer or otherwise wait for
shutdown.
Do not add water into the thermowell, this can cause a sudden contraction and may
result on the thermowell cracking. Thus decreasing unnecessarily clearance for the
protector tube thereby causing the thermocouple to stick.
If force is required you are advised not to over apply it on one side since this can
cause the thermocouple to be deformed.
Proper documentation is to be done during this exercise taking note of all serial
numbers.
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4.2.0 Cleaning slip rings
4.2.1 Reasons for carrying out the task.
The compensation cables from the respective thermocouples are all connected to the
slip rings. These slip rings are also important because if they are dirty we will not be
able to get the correct input mV to the transmitter.
Slip rings for shell thermocouples and QRT signals need regular cleaning
4.2.2 Risk and Possible Dangers

Technicians should note that next to the temperature signal cables there are power
cables for shell air fans and these have very high voltage so extra care must be taken
not to temper around these slip ring cables.
4.2.3 Safe procedure

• Always use fine sand paper and dry cotton when cleaning the slip rings.
• Under what circumstance do not apply water on the slip rings.
• Do not clean the slip rings for shell air fans.
4.3.0 Belt conveyor tail pulley sensors

The status of a belt drive on the SCADA is attained by the status of a Zero Speed
Sensor (ZSS), which is mounted at the tail pulley of the belt conveyor. Most ZSS are
of the Ale Bradley make and model ID18 3005NA.

The maintenance work carried out on these sensors is done when the belt is moving so
the assistants are advised not to interfere with the rotating crossbar. Since company is
not a must when one is doing routine work on these sensors, you are advised to clean
the sensors only.
4.3.3 Safe work procedure
 Do not interfere with any moving parts on the tail pulley.
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 Remove the fuse for the respective sensor before tempering with power supply
cables.
 Do not apply oil on the shank or threads of the sensor, this will cause dust
particles to stick on the sensor.
 Routine check on the ZSS has to e done during the start of every shift and at
the end of every shift.
 Documentation on the status of every sensor has to be done on every shift.
 The tags on the shank of the sensors or power cables are not suppose to be
removed or exchanged without the Engineer’s approval.
 Do not remove the housing of the sensor or exchange them.
4.4.1 Replacing a ZSS-Proximity sensor.

ZSS are in the START/STOP circuit of nearly all conveyor belts, caution has to be
exercised when carrying out any maintenance work while the plant is running.
Remove the fuse before tempering with the power cables of the ZSS, or any
replacement is done.
One has to remember when setting the ID sensor it is not all about lighting the LED
but also setting the correct Sn.
All Technicians must be in a position to interpret the model of every ZSS in the field.
Consider ID18 3005NA
 05-is the Sn –detecting distance. Which is 5mm.
 ID- means it is an inductive sensor.
 18- means the diameter of the sensor is 18mm.
 30-means the power supply should be greater than 6V but less than
30V.
 N- means its an NPN logic.
 A- means its Normally open circuit.
4.5.0 Weighfeeders
4.5.1 Cleaning of weighfeeders
As the name suggest, these instruments are used to feed the measured quantities of the
raw materials into the main conveyor belt BC7 into the kiln. They are 4 weighfeeders
________________________________________________________________ 59
at SIMBI and mostly 3 are always running except for one for feed coal which had
developed some drive faults lately, but we are doing everything in our capacity to
reprograme it in the long run.
Normally no work is expected to be carried out on moving machinery unless you are
carrying out level 3 maintenance.
4.5.3 Cleaning Safe working procedure

 Do not lean or sit on the weighfeeders.
 Do not open the load cell box during cleaning.
 Avoid disturbing the limit switches during cleaning.
 Always use a blower when cleaning since compressed air can penetrate the
awkward positions of the weighfeeders.
NB: When cleaning the weighfeeders do not use wet material, there are electronic
components.
4.5.4 Safe working procedure for general maintenance work
 First know the level of your maintenance work (level 1,2 or 3)
 Get clearance from the Instruments Engineer.
 Put the machinery on LOCAL so as to avoid the situation whereby someone
can run the machinery from REMOTE.
 Notify other relevant departments e.g. Electrical and Mechanical about the
breakdown.
4.6.0 Calibration of weighfeeders.
Calibration is always done if and only if:
 The process value deviates from the expected value.
 The plant is about to be RUN after shutdown jobs are done.
 When the Process Operator requested for the procedure.
4.6.2 Procedure
 Switch ON the WF.
 Clear all errors if any is flagged
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 Check WF Date/month/year
 Press ESC then CL
 The word “password” will be flagged. (Calculate the password as 10-
(date+month) if the sum of (date+month) is less than 10. or 20-
(date+month) if the sum of (date+month) is greater than 10.
 Press as ENTER.
 Press to select CALIBRATION.
 Press to ZERO the WF.
 Press to select SPAN.
 Press for SPAN CALIBRATION
 TYPE 1800d (1800 are counts) for SPAN after you have confirmed
hat the test weight has been placed.
 Press ESC then CL to escape from calibration

mode.
 Press BB twice so as ton verify whether the counts are
in the 90% range.
 Press after selecting the main program.
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CHAPTER 5
5.0 Field Instruments
5.1 Kayblower
A Kayblower is a positive displacement, constant volume machine that operates

against varying pressure. The Two “8” shaped impellers (involute design) which are
mounted on parallel shafts, rotate in opposite direction and with every movement of
the impeller across the compressor inlet, a definite volume of air is trapped and
carried across the casing to the compressor outlet where this air is discharged.
Design
 This allows operation without the need for lubrication inside the air casing.
 The compact, sturdy design is engineered for continuous service when operated in
accordance with speed and pressure ratings.
 Kayblower Compressor has computer calculated impeller profiles and is precision
machined on the latest CNC equipments assuring close tolerances between the
impellers, casing and side
Diagram
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Fig 14
Pipe Sizes
Position INSIDE DIAMETER OUTSIDE DIAMETER
mm Inches mm Inches
Kayblower 150 6 160 6.4
CB Fans 150 6 160 6.4
5.2Air compressor
At SIMBI, we use a Centrifugal air compressor -a vane rotating disk or impeller in a

shaped housing forces the gas to the rim of impeller increasing the velocity of the gas.
A diffuser (divergent duct) section converts the velocity energy to pressure energy.
These are used for continuous, heavy industrial uses and are usually stationary.
Their application can be from 100 hp (75 kW) to thousands of horsepower. With
multiple staging, they can achieve extremely high output pressures greater than
10,000 lbf/in² (69 MPa).
I am going to design a pressure control system that will improve productivity and
safety. Fluid-handling devices are not concerned with the modulation of power, but
only with the movement of fluid.
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Choosing a fluid-handling valve used to be easy, because each one had its own area of
utility. For on off, full, or no-flow requirements, ball and gate valves were favored;
where tight shutoff was not required, butterfly and slide valves were used.
As a result, beliefs were formed which may inhibit the selection of the best valve for
my design.
5.3Schematic representation of the valves
The present set up of the valves
Fig 15
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5.4Pressure Regulators
The first pressure regulator has to allow a constant air pressure supply of 140Kpa
(21psi) to be used as an input to the Current-to-Pneumatic converter.
The second pressure regulator has to allow a constant air pressure supply of 140Kpa
(21psi) to be used as an input to the Valve Positioner.
The pressure regulator is a normally open valve and is installed at the START of a
system or before pressure sensitive equipment to regulate or reduce undesirable
higher upstream pressure. Too often, a pressure regulator is installed. In this case, the
pressure regulator will simply stay wide open and just send liquid straight into the
tank without maintaining upstream pressure...just a very expensive fitting.
Where an obstruction will benefit everything after the valve, a pressure regulator
should be used so that not all the equipment after it will have excessive pressure. Used
where it should be that is at the beginning of a process, the pressure regulator will
ensure safe downstream pressure. The combination of a pressure regulator at the
beginning of a system, and a backpressure regulator at the end of a system, will
ensure balanced pressure throughout the system. This is a simplification, of course,
and the specifics within any given system can vary greatly.
Calculations.
Using the equation of continuity
A1 v1 = A2 v 2
Assumption: The flow rate at any point of the system obeys this equation
By varying the area of the opening at the outlet of the regulator we can regulate the
outlet pressure.
Applying Bernoulli Principle, under steady state flow, well developed flow conditions
the total energy of a unit volume of material must be constant at every part of the
system.
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P1 v2 P v2
H1 + + 1 = H2 + 2 + 2
ρg 2 g ρg 2 g
P1 v12 v22
P2 =( H 1 + + −H 2 − ) ρg
ρg 2g 2g
By increasing A2 we decrease v 2 and increase the pressure P2 thereby regulating

pressure.
5.5 Uninterrupted Power Supply (UPS)
The Power Supply is made up of 20,12v batteries. It uses IGBT for inverting and is
used to supply the panels with power when, the main supply is down. It uses the
concept of switched mode power supply (SMPS)
5.6 The Kiln Main Drive
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SCADA SETPOINT
OPERATOR PC
PLC
DRIVE
CONTROLLER
TACHO METER
MOTOR
Fig 16
At SIMBI, from the Drive Output the signal is going straight to SCADA via RS 485.
5.8 Variable Frequency Drive Operation Parameter setting that can be set on an
AC Drive.
The following example illustrates how to carry an Operation Parameter Setting when
the drive is in REMOTE, LOCAL OR DUAL mode for RPM and ON/OFF sequence.
1. To operate the Drive in REMOTE MODE

Parameter to set Set Parameter to Operation
Value to set to
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b1 – 01 0 RPM setting from
screen
on the system.
b1 – 02 0 ON/OFF sequence from
the Screen on the system
2. To operate the Drive in LOCAL MODE
Parameter to set Set parameters to; Operation
b1 – 01 0 RPM setting from
digital
Operator on drive panel.
b1 – 02 0 ON/OFF Sequence
from the screen on the system.
3. To operate the Drive in DUAL MODE
Parameter to set Set parameters t Operation
B1 -01 0 RPM setting from the

digital Operator on the drive panel.
B1 -02 1 ON/OFF sequence from
the Screen on the system.
4. To increase/decrease the RPM from digital operator on the drive in running

mode.
i) Check the display is in rpm or frequency mode.

ii) The drive LED on the digital operator should be stable if the above
conditions are satisfied, then press: DATA/ENTER. At this point the
Display in Operator Panel starts blinking. By scrolling the Up, Down,
________________________________________________________________ 68
Reset arrow keys on the operator panel, set the required RPM. Then press
ENTER and then ESC.
5.8 Weigh feeder Controllers
There are four weigh feeder controllers in the control room, each for.
i) Feed coal
ii) Iron ore
iii) Charcoal
iv) Injection coal
NB: Weigh feeder controllers are constructed in the same way as AC Drives, thus
most of the information has been covered.
 Weigh feeder Control Panel
During programming of the control panel controller, a statement list is used. The
tonnage set point is set from the SCADA. The Digital and Analog Input/Output cards
are used for interfacing with the controller. The control panel shows the status of the
belt. Serial communication is used on control panels and drives.
VFD (telemechanics-it implies hard wired circuit)
________________________________________________________________ 69
Fig17
FIELD DISPLAY
4-20mA DIGITAL
SCADA
SERIAL PLC A/I CARD CONTROLLER
RS485
DRIVE COMMAND
A/I..O
Fig 18
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CHAPTER 6
6.0Sensors
Introduction
A transducer is a device that is able to convert one form of energy to another. The
signal from a transducer will require undergoing the process of conditioning and
conversion. Transducers can be classified as either passive or active.
i) Active- is one that generates electrical energy directly e.g. moving coil
microphone, since it uses the principle of electromagnetic induction
ii) Passive – require an electrical supply which is then modified in some way
(modules) so as to develop an output e.g. a potentiometer is supplied with
a voltage, a portion of which appears at the wiper according to its position,
thus the output voltage is directly related to the angular or lower position
of the wiper.
 Proximity sensors, level sensors and flow sensors
At SIMBI, proximity sensors (ZSS) are used mostly to confirm belt status, ie
running or not running (the, RUN/STOP MODE). The most common type of
proximity sensors in use is the inductive sensor. Again, the same inductive sensors
are used as level sensors (for checking the water level) at the wet scrapper tank
and as flow sensor in the supply pipes at the cooler section.
 Inductive sensor principle of operation

The sensors operate on the principle of an inductor producing a wave like output
signal of graphical means, which is used for ON/OFF of an LED at the rear of the
sensor. When a metal is passed near the inductive sensor 9within a detecting distance)
the LED switches on. Thus, the sensors are mounted in such a way that will signal the
presence of a metal within their operating distance.
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 Coding of Inductive Sensors
The most common type of inductive sensors at SIMBI are cylindrical in shape and the
markings are at the rear unthreaded section. Inductive sensors come in different
diameters and each chosen depending on its mode of exploitation. An example of such
a sensor marked as follows:
ID 18 – 3005NA, where
ID – Inductive.
18 – diameter in mm
30 – 6 – 36VDC
05 – Detecting distance
N- NPN
A – Normally Open
6.1Proximity sensor as Water level sensor
High Sensor
Metal bar
Floater
Fig 19
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6.2 Proximity sensor as a water flow sensor
The Proximity sensor is also used as a water flow sensor after including a mechanical
design on the flow sensing system. The Kayblower is water-cooled and if there is no
signal indicating the flow of water it automatically stop. The Kayblower water flow
sensor is in the start /stop circuit of the injection coal circuit so this will mean the
whole circuit will trip.
This clearly indicates the importance of the water flow sensor; therefore, care must be
taken when dealing with the water flow sensor.
o Common faults
The water flow sensor is positioned in a wet environment hence there is no proper
housing provided so it usually turn off due to obstruction.
There is a fuse in the junction box, which is usually loosely held, and during cleaning
of JB box by Assistants it is often disturbed.
o Diagram
Fig 20
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6.3Proximity sensor as a Zero Speed Sensor (ZSS)
During this operation the inductive sensors are used as ZSS, thus they signal the status
of the belt as RUN/STOP. There is a cross bar protruding from the pulley center (non-
drive section of the belt. The sensor is then positioned at a determined detecting
distance away from the cross bar.
At this position, it will be able to detect the presence of the metal and sent an impulse
signal to the PLC on the status of the belt. An LED will be either ON or OFF
depending on the presence of the metal. When the belt is moving it will be ON/OFF
on equal intervals, depending on the metal position.
o Detecting RUN/STOP MODE of a belt
Inductive Sensor Nuts

Led cable
Belt Pulley Mounting bracket

Rotating Bars
Fig 21
6.4 Gate valves (actuator)
Include wedge and double-disc valves. Both are typically used in a fully open or fully
closed position because close regulation of flow is not possible.
A gate valve can be used for throttling only when the valve is in an almost shut
position, where most of the flow reduction occurs. The small, crescent-shaped
aperture causes a high flow velocity that can erode seat faces. Repeated movement of
the disc near the point of closure against upstream pressure can create drag between
the seats on the downstream side and may gall or score the seat faces. In addition, the
high-velocity flowing liquid impinging against a partially open disc or wedge
produces vibration that can damage seating surfaces and score the downstream side.
________________________________________________________________ 74
Nevertheless, a gate valve is excellent for service that requires either full or no flow. It
has essentially no flow restriction when fully open. The flow area at the point of
control is equal to the full cross-sectional area of the line. Because flow is straight
through the line, pressure drop across a gate valve is only about 1/50 that of a globe
valve of comparable size.
6.5Thermocouples
These are temperature devices, which utilizes the set back effect. They are designed
by joining two dissimilar metals to form two junctions. One junction called a hot
junction is placed at the point where the temperature is to be measured. This junction
is a permanent one, usually formed by welding the two metals together.
The cold junction, since in use has outside controlled environment and is closed by a
load across it where a thermo – electric is developed by the flow of a thermoelectric
current through it. This results from the temperature difference between the two
junctions.
NB; Different materials are used for making various types and each make is
differentiated by useful temperature ranges and tolerances.
At SIMBI thermocouples are used to measure the temperature of the rotary Kiln ABC
and cooler outlet, T/Cs gives out, put in mV, which is converted into mA by a
temperature transmitter. The mA are then send to the PLC for conversion into Celsius.
6.5.1Resistance Temperature Detectors

Those are wire wound and thin film devices that measure temperature because of the
physical principle of the positive temperature coefficient of electrical resistance of
metals. The hotter they are the higher the value of their electrical resistance.
PTs and PT 100 are the most popular RTD type nearly linear over a wide range of
temperatures. Some are small enough to have response times of a fraction of second.
They are the most precise temperature sensors available with resolution and
________________________________________________________________ 75
measurement unattainable of 10C or better. Usually RTDs are provided encapsulated
in probes for temperatures sensing and measurement with an external indicator,
controller or transmitter or is enclosed inside other devices where they measure
temperature as a part of the device function such as temperature controller or
precision thermostat.
6.5.2 Temperature Control System

There are 7 thermocouples at the kiln section. These thermocouples are connected to
the slip rings and one 2 wire transmitter. The transmitter is positioned under the main
kiln. The thermocouples measure or detect mV which are transmitted to the
transmitted to the transmitter and the transmitter gives an output 4 – 20 mA. The PLC
will have an input of 4 -20mA, which will be used for control calculation to have an
output temperature in degrees Celsius showing in SCADA.
6.5.3 The Temperature Loop
Process (Kiln) (Sensor) Temperature

Thermocouples 2 Wire Transmitters
mV TT 209
4– 20 mA
SCADA PLC Junction Box

Indicator Controller (JB 201)
Fig 22
The regulation of temperature at the kiln is achieved by the STACK CAP use, i.e.
opening and closing and INDUCED DRAFT FAN (although it is not in use at the
moment)
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6.6 Temperature Transmitters (Type K)
Temperature sensors at SIMBI show their reading in mV. However the PLC does not
read signals, which are in mV (unless it is a stand alone controller), hence there is
need to convert the mV into mA, which the controller can read. Thus, a temperature
transmitter is used to convert mV into mA. The mA (4-20 mA) is converted into
degrees Celsius and send as a digital signal to the indicator.(PC).
The XTR108 is a "smart", programmable, 4-20mA, two-wire transmitter designed

for temperature and bridge sensors. Zero, span, and linearization errors in the analog
signal path can be calibrated via a standard digital serial interface, eliminating
manual trimming. Non-volatile external EEPROM stores calibration settings.
The all-analog signal path contains an input multiplexer, auto-zeroed programmable-

gain instrumentation amplifier, dual programmable current sources, linearization
circuit, voltage reference, sub-regulator, internal oscillator, control logic, and an
output current amplifier. Programmable level shifting compensates for sensor DC
offsets. Selectable upscale and downscale output indicates out-of-range and burnout
per NAMUR NE43. Automatic reset is initiated when supply is lost.
6.7.1Calibration of Temperature Transmitter

Sometimes the temperature transmitter gives false readings, hence there is need to
carry out a calibration procedure in order to set it to within operating range
 Transmitter Calibration Procedure (Type k Input type
Range: 0 - 1200ºC
Input; 0 - 47,836 mV which corresponds to 4 – 20 mA
For cold junction compensation, adjust to 0mV. For input adjust transmitter to 4,33A
which equals 25ºC.
NB: For 0mV input, the Input channel has to be shorted.
When calibrating always check zero calibration first followed by span calibration and
then the mid ranges.
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24VDC Millimeter
Power Supply (PLC)
+ Temperature
Transmitter
+
-
+ -
Calibrator
(Thermocouple)
Fig 23
 Procedure for calibration

i) Connect the components as shown above
ii) Put the Read/Feed switch to feed.
iii) Switch on your 24VDC
iv) Switch on your calibrator
v) Adjust the coarse/fine mV switches to read zero
vi) Millimeter should indicate 4,33A if not adjust the zero adjustment,
millimeter to indicate 4,33A.
vii) Adjust the coarse/fine mV switches to 47,836mV.
viii) Multimeter should indicate 20mA, if not adjust for span.
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 Other Mid-Range Adjustments
When calibrating the mid-ranges, 1mV must be subtracted from each value for
temperature compensation.
mV Input m A Output Corresponding
Temperature
0 4,33 25ºC
11,210 8,0 300ºc
25,90 12 600ºC
36,33 16 900ºC
47,830 20 1200ºc
NB: After mid range calibration always check that zero and span have not been offset
Pressure Control System for the kiln section

There is pressure build up in the kiln due to gases formed during the production
process. In addition, the volume of air blown in by the Kay Blower and Central
Burner (CB) fan increases the volume of gases in the kiln. If pressure is not regulated,
it results in temperature increase, which can lead to changes in the dimensions of the
kiln.
6.7.0The pressure transmitter
The pressure control system is open loop. The opening and closing of the STACK
CAP is based on operator’s decision and is not programmed.
NB; It is advisable to take note that even when the control loop for pressure (and
temperature) is open, their output will be used to actuate most of the machinery within
the plant such as ID fan, stack cap, kiln rotation speed and Kay blower speed.
6.7.1Functional Principle
The transmitter is ready for operation immediately after installation. The settable
measuring span corresponds to the specification on the rating plate. If customized
setting is made at the factor, the start of scale are specified o the measuring pate .If
________________________________________________________________ 79
necessary, the parameters can also be changed during commissioning by simple
operating procedures.
6.7.2 Design
 The device consists of different components depending on what the

customer has specified in the order. The possible variants will be listed
in the operating manual.
 The rating plate with the order number is on the side of the housing.
One can determine the optional constructional details and the possible
measuring range (physical properties of the built –in sensor element)
with the specified number and specifications.
6.7.3 Installation
We must not overlook the possibility of condensate freezing in impulse lines to
transmitters measuring gas pressure. Although these components could be heated
similar to water and steam applications, the simplest and best approach is to install
transmitters so that they are self draining. This means that the impulse lines are
connected to the lowest point in the transmitter meter body and the piping is sloped
downward at least one inch per foot. If the transmitter is located below the process
taps, piping must still run downward from the transmitter to the point and then to the
process as shown on the next page.
________________________________________________________________ 80
Functional Block Diagram for Transmitter
________________________________________________________________ 81
Fig 24
When the transmitter is in its DE mode, the process variable is available for
monitoring and control purposes; and the meter body temperature is also available as
a secondary variable for monitoring purposes only.
6.7.4Effects of pressure on the STACK CAP
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START KILN
KILN
ROTATING
IS
ABOVE RANGE PRESSURE BELOW RANGE
WITHIN
RANGE
ID FAN SPEED
INCREASED ID FAN SPEED
DECREAED
STACK CAP
STACK CAP
OPENING
OPENING
INCREASED
DECRESED
FINISH
Fig 25
It is also called the Differential Pressure Transmitter since it utilizes the principle of
difference in pressure. Other types of pressure transmitters are:
i) Differential capacitor
ii) Piezoelectric
iii) Linear Variable Differential Transformer (LVDT)
iv) Servo Motor
6.7.5 Principle of Operation
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The differential pressure is directly proportional to the flow rate,
- Differential pressure
- Flow rate
The differential capacitor is used to achieve the differential pressure due to decrease
or deformation of the diaphragm, which reduces the dielectric field thereby changing
the mV and inducing a new value of capacitance. The mV are then changed to mA (4-
20mA) which is then transmitted to the PLC. A defining equation then changes the
mA to a pressure value, which is then shown on SCADA.
Parallel plate
low pressure High pressure
Using the equation of capacitance we can deduce that any slight change on D, or D2
will cause a change in voltage. Atmospheric pressure D1 = D2, hence the differential
pressure = 0
During calibration O K Pa (when expressed to atmospheric pressure) = 4mA.

A pressure simulation is used to achieve the differential pressure, span = 20mA.
During installation note that P = * so that the height in 8 on which the high pressure
pipe and low pressure pipe are connected must be equal to avoid the creation of
vacuum i.e.
6.7.6 Important facts about Pressure Transmitter
i) When zeroing always make sure you open the equalizing valve so that P1
= P2 and open the two isolation valves
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ii) When trying to position the pressure transmitter, take note that the
equalizing valve is closed and the isolation valves open.
iii) Drainpipes should be open for flushing.
iv) Always reset transmitter to zero.
NB: If one side of the transmitter is exposed to high pressure, a condition known
as warping results which lead to a permanent deformation of the parallel plate.
High pressure on one side is usually due to a blockage in one of the impulse lines.
6.8.0Weigh feeders
 Weigh frames
These mechanical components make up a weigh feeder control system. It is that

position where the load is placed during weighing and there are mechanical links
to the load cells. During calibration of a weigh feeder controller, the desired
weight (test weight) is placed directly on the weigh frame. The weigh frame also
comprises an adjustable bolt and nut mechanism.
6.8.1Weigh feeder Control Loop
Weigh feeders are used for the raw material feed into the kiln to maintain a fixed ratio
which is ideal for optimum reduction of iron ore into sponge iron. Iron ore charcoal,
feed coal and injection coal are the main raw materials used.
SCADA OPERATOR
SET POINT
PLC
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PROCESS WEIGHFEEDR FIELD
CONTROLLER INDICATOR
LOAD
CELL TACHOGEN
SERIAL COMMUNICATION
AC MOTOR VARIABLE
SPEED DRIVE
Fig 26
To get the material flow rate, the controller multiplies the load on the weigh frame
(Kg/m) by the speed of the conveyor (m/s) i.e. **/m X m/s = k*/s (also expressed
in tons/hr). The flow rate is then compared to the operator set point and a control
output send to the VFL.
NB: There are only 3 control loops at SIMBI

i) Weigh feeder control loop
ii) Temperature system at the kiln section
iii) Control valve at the high-pressure tank. These valves do not use the PLC
but has a standalone controller, which is in the MCC.
6.8.2 Limit Switches and Push buttons
Limit switches at SIMBI show discrete from the position of individual components.
They are powered by a24VDC. This limit switches indicate
i) belt sway
ii) gate valve position (open or close)
iii) Position of the stack cap as it opens and closes
Push buttons also give two states ie ON or OFF. They are used for switching field
electrical and instrumentation machines.
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6.9 Junction Boxes
There are 3 junction boxes within the plant. These are used to connect wires from the
field with those from/to the PLC i.e. a junction box provides termination of field
wires, where signals can easily be traced. It also provides a 24VDC supply to the
individual sensors using the loop system.
One junction box is within the Screen House area and it caters for ZSS (BC1 – BC7),
charcoal, feed coal and iron ore weigh feeders, dust extractor solenoid valves, limit
switches and loud speaker within the area.
The second one is at the elbow of the ABC near the kiln inlet. It has terminations for
the ABC temperatures, wet scrapper temperature and level sensor, kiln inlet pressure
and the ESP area.
The last one is at the kiln outlet, just close to the Central Burner fans and it caters for
the ZSS (BC9 – BC 11), dust extraction solenoid valves for cooler area and product
section, kiln thermocouples, kiln outlet pressure, flow sensor at the cooler, coolant
pressure and cooler discharge temperatures.
It is important to note that there are Analog and Digital sensor signals at the junction
box. There also have different 24V supply lines and do not share common ground
When checking voltage across a fuse, always connect the voltmeter at OV and any
point on the field side. When checking for current, always connect the ammeter in
series with the measured.
NB: Disconnect the fuse before attempting to work on transmitter and check for 24V
supply. On this junction boxes, blue is negative.
Junction boxes are an important termination point for troubleshooting.
• The Weighbridge
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At SIMBI we have a weighbridge, which is used to measure all the raw materials to
be used at the plant and also the products of SIMBI before distribution to the
respective customers. It consists of 8 load cells all wired to respective corner boxes.
We have two corner boxes each with 4 load cells. The excitation voltage is 9V and the
output voltage range is 0 to 18mV. The actual mV is the average of the 8 load cells.
Sometimes the colour coding printed on the PCB do not coincide with the polarity of
the load cell so during trouble shooting one has to recheck the wiring. Considering the
weighbridge at SIMBI when measuring the mV we use the Red and White cables at
the corner boxes.
A password is required during calibration. A digital display for HMI with weighbridge
is the L215 but there are different models for specific applications in the industry.
The weighbridge schematic diagram
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LOADCELL LOADCELL
8 7
CORNER BOX LOADCELL

LOADCELL
5
6
2
CORNER BOX LOADCELL

LOADCELL
3
4
1
LOADCELL LOADCELL
2 1
L215
COMPUTER
Fig 27
CHAPTER 7
Information and Technology Department

7.1 Introduction
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This department is based mainly at our company Headquarters in Kwekwe. The main
objective of this department is to maintain the Information System at Group level of
all other branches nationwide. At each branch there are Technicians responsible for
the day-to-day business of the department. I was trained at Kwekwe HQ then worked
at SIMBI Masvingo for all my practicals. Together with the Hardware Engineer we
did the Network System currently being used at SIMBI Branch in Masvingo.
I also did Basic Software Engineering at an advanced stage. It is from this Department
where I was trained on Telecommunication system with the help of Digital Dynamic
System Pvt Ltd and Commaf as external service providers. I carried out proper
maintenance of all the Computers at the plant up to date, this include System
Administration of the new Broadband network system provided by Ecoweb.
 The Network Project

We started this project on 13 May 2008 and finished on 24 May 2008.This was
my first time to take part in a project concerning the IT-Department but I managed
to work well with the whole team.
• Constructing a communication cable.
Generally there are two main types of communication cables used in
Networking, i.e. Straight-through and the cross-over cable using RJ45
pins.
The cross-over cable is used when connecting two computers without the
use of a hub. This cable is constructed by using the T568A on one side and
T568B wiring scheme on the other end.
Straight-through cable is used during LAN, whereby the T568A wiring
scheme of CAT 5E is implemented on both ends of the cable.
• Important colours.
Orange and green are the main colours hence the other colours are for
voice.
• Wiring scheme for CAT 5E as T568A.
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1-orange/white
2-orange
3-green/white
4-blue
5-blue/white
6-green
7-brown/white
8-brown
• Wiring scheme for CAT 5E as T568B.
1-green/white
2-green
3-orange/white
4-blue
5-blue/white
6-orange
7-brown/white
8-brown
• Panel components
 24 Port CISCO catalyst 2950 series switch
 Patch panel- for interfacing with cables so as to avoid direct
conection.
 CISCO 1841 Router
 Bridge
 Radio
CHAPTER 8
Telecommunication Systems
Overview
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I did telecommunication systems practices with an external service provider called
Digital Dynamic Systems based in Masvingo which is responsible for the
maintenances of telecommunication system at Steelmakers Branches country wide.
I was under the guidance of Mr. J Mbirima a Telecommunication Technician with the
same company. I did several types of PABXs at different locations, which include the
following types:
 Samsung 24/72
 Jupiter 8/48
 Siemens 20/84
Connectors
o RJ11- has two wires inside the connector head.
o RJ45- has 4four wires inside and can also have 8 wires for LAN networking.
o BT- for Betacom and also for BT handsets which are an old model.
Communication cards
These cards are categorized using the colour on their handles.
 WHITE means two direct lines and two extensions and no executive line.
 BLUE you can connect two extensions and one can connect a switchboard or
executive line.
 BROWN has only four extensions.
 BLACK one direct line, 2 extensions and one executive.
 GREEN is the control card or main control board. It controls all the
communication system between peripheral interface, supervises all resources
in the system and control the gain adjustment of PCM signal, generates
stantenous and manage all processes of the system
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PIN CONFIGURATIONS
1 2 3 45 1 2 3 4 5
6 7 8 9 6 7 8 9
OPTION A OPTION B
COMPUTER
PABX
TELONE
JUNCTION BOX
EXTENSIONS AND
DIRECT LINES
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CHAPTER 9
Mechanical Engineering Department
9.1 Workshop practices and processes at SIMBI

I want to thank Mr. D Wakasemwa for the encouragement he gave me so that I can
also concentrate on practicals during my Workshop practices and processes at C.U.T.
He was my Lecturer for that Course i never had problems in the Workshop at SIMBI
as I was even a step further during Welding processes as I produced door frames,
window frames and did maintenance work in the plant at a good speed and accuracy
thereby producing attractive work.
The workshop at SIMBI has fully assembled and running lathe machines, heavy duty
milling machines and drilling machines. I had access to all the machines and I was
trained on turning, milling and drilling operations. We had the following machines to
name but a few:
• Lathe machine
• Milling machine
• Drilling machine
• Electric grinders (Grinding wheels)
• Saw Cutters
• Sheet metal cutters
• Welding machines (Gas & Electric Arc Welding)
First, I was taught the precautions necessary to take before working on any of these
machines and dangers associated with running machines.
I gained good knowledge and experience to an extent that our company assigned me
to do some external jobs from other nearby companies which include mines, garages
and foundry companies. I did all my workshop operations under the guidance of Mr.
B. Bvunde who is the Workshop Foreman and his Artisan Mr. M Chapukira a well
known lathe operator.
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On 25 April 2008 the main driving shaft at the Kiln broke and a technical team was
set up to investigate the cause, write a report, design the shaft and machine it. I was
tasked to come up with the AUTOCAD drawings also during research i was made the
team leader that also involved Paul a student on attachment from Production
Engineering-C.U.T currently at Steelmakers Kwekwe branch. We managed to come
up with the shaft, which is 120cm in diameter and 160cm in length consisting of 3-
gear system. We did this project at our Steelmakers Kwekwe Branch.
Safety precautions
(a) Never to start the machines unless I know how to stop them.
(b) Any electrical fault to be reported to qualified personnel.
(c) Avoid spilling oil and grease or placing any obstacle within the working area.
(d) Horseplay within the working area to be avoided.
(e) To use the correct tool for the right job always.
(f) When I’m not sure of what to do on any particular job, I should ask qualified
experienced personnel first.
(g) To carry out regular house keeping and to put on goggles when grinding &
welding hat during welding.
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Fig 28
9.2 Machining operations
The three principal machining processes are classified as turning, drilling and milling.
Other operations falling into miscellaneous categories include shaping, planing,
broaching and sawing.
• Turning operations are operations that rotate the workpiece as the primary
method of moving metal against the cutting tool. Lathe is the principal
machine tool used in turning.
• Milling operations are operations in which the cutting tool rotates to bring
cutting edges to bear against the workpiece. Milling machines are the
principal machine tool used in milling.
• Drilling operations are operations in which holes are produced or refined by
bringing a rotating cutter with cutting edges at the lower extremity into
contact with the workpiece. Drilling operations are done primarily in drill
presses but not uncommon on the lathes or mills.
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• Miscellaneous operations are operations that strictly speaking may not be
machining operations in that they may not be chip producing operations but
these operations are performed at a typical machine tool. Burnishing is an
example of a miscellaneous operation. Burnishing produces no chips but can
be performed at a lathe, mill, or drill press.
An unfinished workpiece requiring machining will need to have some material cut
away to create a finished product. A finished product would be a workpiece that meets
the specifications set out for that workpiece by engineering drawings or blueprints.
For example, a workpiece may be required to have a specific outside diameter.
 A lathe is a machine tool that can be used to create that
diameter by rotating a metal workpiece, so that a cutting tool
can cut metal away, creating a smooth, round surface matching
the required diameter and surface finish.
 A drill can be used to remove metal in the shape of a
cylindrical hole. Other tools that may be used for various types
of metal removal are milling machines, saws, and grinding
tools. Many of these same techniques are used in
woodworking.
More recent, advanced machining techniques include electrical discharge machine

(EDM), electro-chemical erosion, laser, or water jet cutting to shape metal workpiece.
As a commercial venture, machining is generally performed in a machine shop, which
consists of one or more workrooms containing major machine tools. Although a
machine shop can be a stand alone operation, many businesses maintain internal
machine shops which support specialized needs of the business.
Machining requires attention to many details for a workpiece to meet the
specifications set out in the engineering drawings or blueprints. Beside the obvious
problems related to correct dimensions, there is the problem of achieving the correct
finish or surface smoothness on the workpiece. The inferior finish found on the
machined surface of a workpiece may be caused by incorrect clamping, dull tool, or
inappropriate presentation of a tool. Frequently, this poor surface finish, known as
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chatter, is evident by an undulating or irregular finish, and the appearance of waves on
the machined surfaces of the workpiece.
9.3Basic machining process.

Machining is not just one process; it is a group of processes. The common feature is
the use of a cutting tool to form a chip that is removed from the workpart. To perform
the operation, relative motion is required between the tool and work. This relative
motion is achieved in most machining operation by means of a primary motion, called
cutting speed and a secondary motion called feed. The shape of the tool and its
penetration into the work surface, combined with these motions, produce the desired
shape of the resulting work surface.
9.4Types of machining operation

There are many kinds of machining operations, each of which is capable of generating
a certain part geometry and surface texture.
 Turning, a cutting tool with a single cutting edge is used to remove material
from a rotating workpiece to generate a cylindrical shape. The speed motion in
turning is provided by the rotating workpart, and the feed motion is achieved
by the cutting tool moving slowly in a direction parallel to the axis of rotation
of the workpiece.
 Drilling is used to create a round hole. It is accomplished by a rotating tool

that is typically has two cutting edges. The tool is fed in a direction parallel to
its axis of rotation into the workpart to form the round hole.
In boring, the tool is used to enlarge an already available hole. It is a fine
finishing operation used in the final stages of product manufacture.
 Milling, a rotating tool with multiple cutting edges is moved slowly relative
to the material to generate a plane or straight surface. The direction of the feed
motion is perpendicular to the tool's axis of rotation. The speed motion is
provided by the rotating milling cutter.
The two basic forms of milling are:
 Peripheral milling
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 Face milling
Other conventional machining operations include shaping, planing, broaching and
sawing. Also, grinding and similar abrasive operations are often included within the
category of machining.
9.5The Center Lathe

A lathe is a machine tool used principally for shaping pieces of metal, sometimes
wood, or other materials by causing the workpiece to be held and rotated by the lathe
while a tool bit is advanced into the work causing the cutting action. Lathes can be
divided into three types for easy identification: engine lathe, turret lathe, and special
purpose lathes. Some smaller ones are bench mounted and semi-portable. The larger
lathes are floor mounted and may require special transportation if they must be
moved. Field and maintenance shops generally use a lathe that can be adapted to
many operations and that is not too large to be moved from one work site to another.
The Lathe is the most versatile of all machine tools in the workshop. Its main
operations are:
 Sliding
 Surfacing
 Screw cutting
 Drilling
 Running
 Boring
 Tapping
 Knulling
The Lathe size is given by the distance from the center of the headstock to the lathe
bed or by its overall length. The bed is made from high-grade cast iron. Mounted on
the bed is the headstock, which contains a clutch and the gears, which enable the
correct cutting speeds and feeds to be selected and obtained. The main spindle is
either screwed or flanged to take a chuck or face plate and is hollow to allow for long
bars. The center is tapered to accommodate other centers (live centre, dead centre,
half centre and bell centre for larger diameters).
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The Tailstock on the machine can be moved to any position on the bed and has a
clapping lever. A hand wheel moves the barrel in or out and the barrel has a nose
tapper to allow for centers, drills and runners.
The carriage comprises the saddle, apron, cross-slide, compound or topside and the
tool post. The saddle rests on the slide of the bed and the apron carries the automatic
controls for moving the cross- slide and for engaging the lead screw. On top of the
cross slide is the compound slide, which can be manually operated and rotated
through 1800 and is useful for boring and tapper turning. Also mounted on the
compound slide is the tool post.
The Lead Shaft enables threads to be cut to desired pitch and the feed shaft enables
the carriage to be engaged automatically for uniform movement of the tool, thus
saving the operator from fatigue.
All Lathe machine have chucks. These can be either 3 –jaw chucks which have jaws
that move together from a single adjusting point and they are self centering. 4 –jaw
chucks are independent and can handle irregular work. Also included is the Face
Plate, which is used to hold work, which cannot be held between centers or in the
chuck.
The engine lathe is ideally suited for this purpose. A trained operator can accomplish
more machining jobs with the engine lathe than with any other machine tool. Turret
lathe and special purpose lathes are usually used in production or job shops for mass
production or specialized parts, while basic engine lathes are usually used for any type
of lathe work.
9.6The cutting tool

A cutting tool has one or more sharp cutting edgesand is made of a material that
harder than the work material. The cutting edge serves to separate chip from the
parent work material. Connected to the cutting edge are the two surfaces of the tool:
 The rake face; and
 The flank.
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The rake face which directs the flow of newly formed chip, is oriented at a certain
angle is called the rake angle "α". It is measured relative to the plane perpendicular to
the work surface. The rake angle can be positive or negative. The flank of the tool
provides a clearance between the tool and the newly formed work surface, thus
protecting the surface from abrasion, which would degrade the finish. This angle
between the work surface and the flank surface is called the relief angle.
There are two basic types of cutting tools:
 Single point tool; and
 Multiple-cutting-edge tool.
 Single point tool has one cutting edge and is used for turning. During
machining, the point of the tool penetrates below the original work surface of
the workpart. The point is easily rounded to a certain radius, called the nose
radius.
 Multiple-cutting-edge tools have more than one cutting edge and usually
achieve their motion relative to the workpart by rotating. Drilling and milling
uses rotating multiple-cutting-edge tools. Although the shapes of these tools
are different from a single-point tool, many elements of tool geometry are
similar.
9.7Cutting conditions
Relative motion is required between the tool and work to perform a machining
operation. The primary motion is accomplished at a certain cutting speed. In addition,
the tool must be moved laterally across the work. This is a much slower motion,
called the feed. The remaining dimension of the cut is the penetration of the cutting
tool below the original work surface, called the depth of cut. Collectively, speed, feed,
and depth of cut are called the cutting conditions. They form the three dimensions of
the machining process, and for certain operations, their product can be used to obtain
the material removal rate for the process.
Where:
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• The material removal rate in mm3/s, (in3/s),
• The cutting speed in m/s, (ft/min),
• The feed in mm, (in),
• The depth of cut in mm, (in).
Machining operations usually divide into two categories, distinguished by purpose

and cutting conditions:
 Roughing cuts, and
 Finishing cuts.
o Roughing
These cuts are used to remove large amount of material from the starting workpart as
rapidly as possible, in order to produce a shape close to the desired form, but leaving
some material on the piece for a subsequent finishing operation.
o Finishing
These cuts are used to complete the part and achieve the final dimension, tolerances,
and surface finish. In production machining jobs, one or more roughing cuts are
usually performed on the work, followed by one or two finishing cuts. Roughing
operations are done at high feeds and depths — feeds of .04-1.25 mm/rev (0.015-
0.050 in/rev) and depths of 2.5-20 mm (0.100-0.750 in) are typical. Finishing
operations are carried out at low feeds and depths - feeds of 0.125-0.4 mm/rev (0.005-
0.015 in/rev) and depths of 0.75-2.0 mm (0.030-0.075 in) are typical. Cutting speeds
are lower in roughing than in finishing.
9.8.1Cutting fluid
A cutting fluid is often applied to the machining operation to cool and lubricate the
cutting tool. Determining whether a cutting fluid should be used, and, if so, choosing
the proper cutting fluid, is usually included within the scope of cutting condition.
 Lubrication for cutting tools

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When machining a lot of heat is generated between the tool and the machined
component. If not properly cooled, the cutting tool becomes blunt. The most common
cutting lubricants are
i. Soluble oil and water

ii. Pure oil
iii. Paraffin
The advantages of using lubricant are:
(a) A tool and work are cooled ad higher cutting speeds maybe used.
(b) It helps the rubbing action between the chip and the tip of the tool,
which saves power, lasts longer and promotes a better finishing.
(c) It helps wash away the chips and keeps the cutting point clear
 Material and their lubricants
 Cast Iron – dry

 Brass, Bronze & Aluminum – dry or little paraffin
 Steel – Soluble oil and water.
 Stages in metal cutting
Roughing cuts are used to remove large amount of material from the starting workpart
as rapidly as possible, in order to produce a shape close to the desired form, but
leaving some material on the piece for a subsequent finishing operation.
Finishing cuts are used to complete the part and achieve the final dimension,
tolerances, and surface finish. In production machining jobs, one or more roughing
cuts are usually performed on the work, followed by one or two finishing cuts.
Roughing operations are done at high feeds and depths — feeds of .04-1.25 mm/rev
(0.015-0.050 in/rev) and depths of 2.5-20 mm (0.100-0.750 in) are typical.
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Finishing operations are carried out at low feeds and depths - feeds of 0.125-0.4
mm/rev (0.005-0.015 in/rev) and depths of 0.75-2.0 mm (0.030-0.075 in) are typical.
Cutting speeds are lower in roughing than in finishing.
A cutting fluid is often applied to the machining operation to cool and lubricate the
cutting tool. Determining whether a cutting fluid should be used, and, if so, choosing
the proper cutting fluid, is usually included within the scope of cutting condition.
 Tool Geometry
The various angles in a single-point cutting tool have importance functions in
machining operations. Different types of angle such as rake angle, side rake angle,
cutting-edge angle, relief angle, nose radius exist and may be different with respect to
the workpiece.
 Cutting Tool Selection

An important aspect in lathe machining is the selection on of cutting tools. The
following factors should be considered when choosing a cutting tool.
i. The tool should have a high core of fraction (hardness)
ii. Bending strength must be high.
iii. Should have high compressive strength.
iv. Should have high impact strength.
v. The tool should have the ability to work at elevated temperatures without
loosing its hardness properties (red hardness)
vi. Tool should be able to resist wear (abrasion resistance)
Thus the cutting tool should not be used under the following conditions:
i. High pressure
ii. High friction force
iii. High heat generation
The type of cutting tool material in common use is:

(a) Carbon steel and steels – for machine thread taps and core drills and
for making files.
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(b) Alloy Tool Steels – for making files, core drills & taps
(c) High speed steels
(d) Cemented carbides – twist drills, milling cutters single point tools,
core drills & reamers.
 Overview
Machine tools can be operated manually, or under automatic control. Early machines
used flywheel to stabilize their motion and had complex systems of gears and levers
to control the machine and the piece being worked on. Soon after World War 2, the
NC, or numerical control, machine was developed. NC machines used a series of
numbers punched on paper tape or punch cards to control their motion. In the1960,
computers were added to give even more flexibility to the process. Such machines
became known as CNC, or computerized numerical control, machines. NC and CNC
machines could precisely repeat sequences over and over, and could produce much
more complex pieces than even the most skilled tool operators.
Before long, the machines could automatically change the specific cutting and
shaping tools that were being used. For example, a drilling machine might contain a
magazine with a variety of drill bits for producing holes of various sizes. Previously,
either machine operators would usually have to manually change the bit or move the
work piece to another station to perform these different operations. The next logical
step was to combine several different machine tools together, all under computer
control. These are known as machining centers, and have dramatically changed the
way parts are made.
From the simplest to the most complex, most machine tools are capable of at least
partial self-replication since they are machines, and produce machine parts as their
primary function.
 Material
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Aluminium, copper alloys, steels, stainless steels, high-temperature alloys, refractory
alloys, titanium alloys, cast irons, thermoplastics, thermosets, etc… are examples of
different type of materials used.
9.9 Turning
Turning is the process whereby a centre lathe is used to produce "solids of

revolution". It can be done manually, in a traditional form of lathe, which frequently
requires continuous supervision by the operator, or by using a computer controlled
and automated lathe which does not. This type of machine tool is referred to as
computer numerical control, better known as C.N.C. and is commonly used with
many other types of machine tool besides the lathe.
When turning, a piece of material (wood, metal, plastic even stone) is rotated and a
cutting tool is traversed along 2 axes of motion to produce precise diameters and
depths. Turning can be either on the outside of the cylinder or on the inside (also
known as boring) to produce tubular components to various geometries. Although
now quite rare, early lathes could even be used to produce complex geometric figures,
even the platonic; although until the advent of C.N.C it had become unusual to use
one for this purpose for the last three quarters of the twentieth century. It is said that
the lathe is the only machine tool that can reproduce itself.
• Facing is part of the turning process. It involves moving the cutting tool
across the face (or end) of the workpiece and is performed by the operation of
the cross-slide, if one is fitted, as distinct from the longitudinal feed (turning).
It is frequently the first operation performed in the production of the
workpiece, and often the last- hence the phrase "ending up".
9.9.1 Turning operations
The turning processes are typically carried out on a lathe, considered to be the oldest
machine tools, and can be of four different types such as straight turning, taper
turning, profiling or external grooving. Those types of turning processes can produce
various shapes of materials such as straight, conical, curved, or grooved workpiece. In
general, turning uses simple single-point cutting tools. Each group of workpiece
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materials has an optimum set of tools angles, which have been developed through the
years.
9.9.2Assigning cutting parameters in turning operations

i. Select the cutting depth, t
ii. Select rate of the feed, s
iii. Select speed, v
NB: Cutting temperature, wear and tool life are influence least by the cutting depth, t
more by the rate of feed, s and most by the cutting speed, v.
The cutting speed should be less than 3 000rpm
Feed rate for roughing: 1,5mm – 25mm/rev or /sec
Feed rate for finishing: 0,5mm – 1mm/rev or/sec
Cutting speed for semi finishing: 500 – 800 rpm
Cutting speed for semi finishing: above 800rpm.
Cutting Tool Clearance
The following are recommended angles or tool rake
Mild steel: 200– 2700
Cast Iron: 10 –800
Brass: 10 – 800
Bronze: 10 –800
Copper: 3000
Aluminum: 4000
 Material removal rate
The material removal rate (MRR) in turning is the volume of material removed per
unit time in mm3/min. For each revolution of the workpiece, a ring-shaped layer of
material is removed.
MRR = pi×Davg×d×f×N where
Davg: Average diameter
N: Rotational speed of the workpiece
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f: Feed
d: Depth of cut
 Turning forces
The forces acting on a cutting in turning are important in the design of machine tools.
The machine tool and its components must be able to withstand these forces without
causing significant deflections, vibrations, or chatter during the operation. There are
three principal forces during a turning process: cutting force, thrust force and radial
force.
• Cutting force acts downward on the tool tip allowing deflection of the
workpiece upward. It supplies the energy required for the cutting operation.
• Thrust force acts in the longitudinal direction. It is also called the feed force
because it is in the feed direction of the tool. This force tends to push the tool
away from the chuck.
• Radial force acts in the radial direction and tends to push the tool away from
the workpiece.
Although it requires less-skilled labor, the engine lathes do need skilled labor and the
production is somewhat slow. Moreover, it can be accelerated by using a turret (In a
turret lathe, a longitudinally feedable, hexagon turret replaces the tailstock. The turret,
on which six tools can be mounted, can be rotated about a vertical axis to bring each
tool into operating position, and the entire unit can be moved longitudinally, either
manually or by power, to provide feed for the tools) and automated machines.
 Elements of the Cutting process in turning operation
In order to machine part by machining blank, definite motions must be imparted to the
blank and cutting tool. These motions are divided in o
i. Working motions (serves the effects of cutting process)
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ii. Auxiliary motions – serves to prepare the machine, work and tool for
cutting process and for completing the operations.
It is important to note that after mounting the blank onto the machines, the speed and
feed should be selected taking into account the type of material to be machined. Thus
hard material e.g. steel requires slow speeds and light feeds while soft material such
as brass require high speeds and feeds.
NB Test running the blank to see if its running true is important before any machining
is carried out. This is done to ensure complete removal of material from the work
piece.
 Setting Speeds on a Lathe (n)
To select speed on a lathe, you place/put one hand on the face plate or chuck and turn
the lathe spindle slowly by hand, while shifting the lever position. This enables the
levers to engage the gear teeth without clashing.
NB: Never change speed when lathe is running.
 Setting Feeds (s)
i. Select the desired feed on the chart.

ii. Move tumbler lever #4 into the hole directly below the selected feed.
iii. Follow the row in which the selected feed is found to the left and set the feed
change levers (No1 &11) to the letter indicated.
iv. Set lever (No111) to disengage the lead screw.
NB: Turn the head stock spindle by hand and see that the feed rod turns to ensure that
all levers are engaged before turning on the lathe.
 Analysis of Cutting Parameters.
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(a) Cutting Speed – is a travel of a point on the cutting edge relative to the surface of
cut in a unit time e.g. let Dmm be the blank diameter, D0 mm be the machined surface
diameter, N rpm be the rotation speed of the spindle.
(b) Rate of feed – is the travel of the cutting edge in the direction of the feed motion
relative to the machined surface in a unit time. The feed can be expressed as
 Distance traveled by the tool in a minute i.e. feed (Sm) = mm/min.
 Distance traveled by the tool in one revolution of the spindle is S =
mm/min.
Relation between Sm and S is given by
S = Sm/N where N = rpm (angular velocity)
 Cutting depth (t) – for external longitudinal turning
Rate of Chip Removal (Q) – this is the volume of chip removed in one minute of
operation.
Q = V.t S cm3/min where s, t&v are expressed in mm, mm/rpm and mm/min
respectively.
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Fig 17
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9.9.3 Milling Machine
A milling machine is a machine tool used for the shaping of metal and other solid
materials. Its basic form is that of a rotating cutter, which rotates about the spindle
axis (similar to a drill), and a table to which the workpiece is affixed. The cutter and
workpiece move relative to each other, generating a toolpath along which material is
removed. The movement is precisely controlled, usually with slides and leadscrew or
analogous technology. Often the movement is achieved by moving the table while the
cutter rotates in one place, but regardless of how the parts of the machine slide, the
result that matters is the relative motion between cutter and workpiece. Milling
machines may be operated manually or by CNC.
Milling machines can perform a vast number of operations, some of them with quite
complex tool paths, such as slot cutting, planing, drilling, diesinking, rebating,
routing, etc.
Cutting fluid is often pumped to the cutting site to cool and lubricate the cut, and to
sluice away the resulting swarf.
There are various types of milling machines available but at SIMBI, the milling
machine is a Knee type generally known as Universal Milling machine. It is called a
knee type because of the overhanging of he cross slide and the table. This machine
can swing in both directions for helical milling and the spindle can turn in both
directions.
Milling is a machine process whereby a surface is generated with a rotating toothed

cutter. Each tooth takes an individual chip to form a uniform profile.
 Milling Machine Parts
• The Spindle – provides the drive to the arbor aid cutters.
• Arbor – drives and holds the cutters in correct position.

• Arbor Support - It fits and clumps to the over atm. Can be secured in any
position to align and support the arbor.
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• Knee – It is fitted to the column and can manually & automatically moves
vertically up and down.
 Dividing Head
An important use of the milling machine is for cutting slots, gloves, teeth and gears
that are to be placed equally around the circumference of a cylinder or disc. A
dividing head is used for such purposes. This unit has a single start worm with a 40:1,
thus the index plate has for a chuck turn.
 Index Plate
The object of this plate is to enable one turn of the rank. In the plate are a number of
holes in a circle, each circle containing a different number.
The crank can be adjusted to a radius that will fit any desired circle of holes.
The sector arms can be adjusted to include any remainder on any number of holes.
9.9.5The shaping Machine
The main function of the machine is the production of flat surfaces, which are
obtained by combined line tool cuts with a perpendicular feed. It is preferred for the
quickness with which the work can be set-up and the good standard of accuracy.
 Shaper Drive
An electric motor is mounted on a platform at the rear and drives the gearbox pulley
and clutch with a V- belt. The gearbox delivers the power to a pinion, which drives
the stroke wheel. Mounted on the face of the stroke wheel is the crankpin, which is
incorporated with a sliding block working in dovetail slide ways, running across the
face of the wheel.
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A link arm connects a stroke wheel to the ran and is pivoted at the bottom of the
machine. The feature for shaping machine is that for every cutting stroke there is an
idle return. The tool is carried on a holding slide of the tool holder which is attached
to the end of the ran through a circular flange which is graduated in degrees. The feed
is activated by a screw from a handle at the top of the slide.
9.9.5. The Principle of he speed of the Stroke
 Quick Return Motion
Although the pivot distance covered in a straight line from A –B is the same from B –
A the peripheral distance is much shorter on the return stroke thereby speeding up the
forward stroke
 Mounting of Cutter
The cutter is carried on the arbor being keyed and is supported between collars. It is
essential that the arbor run through in all places i.e. along its length to make full use
of all teeth on the cutter. Milling cutters are made from Hs, hardened and then
ground.
 Rotation and Feed.
When operating a cut with a milling cutter the normal relation between the direction
and rotation are of importance. These are also called up cut and down cut milling.
NB: Climbed milling should never be used unless the machine is equipped with
backlash elimination or else a cutter will overrun itself (Climb up or dig in)
Care and Operation of the machine
 Cleaning the table after every use.

 Oil and greasing the machine regularly.
 Always use draw bolt to secure arbor.
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 Never loosen or tighten arbor nut without the over –atm support in position
and do not leave spanners on the arbor nut.
 Always clamp up the slides when traversing a cut.
 Do not drop cutters.
 Always clean collar faces before assembly onto the arbor.
 Always note the direction of rotation before engaging automatic.
9.9.6Milling as a process
Milling is the process of cutting away material by feeding a workpiece past a rotating
multiple tooth cutter. The cutting action of the many teeth around the milling cutter
provides a fast method of machining. The machined surface may be flat, angular, or
curved. The surface may also be milled to any combination of shapes. The machine
for holding the workpiece, rotating the cutter, and feeding it is known as the milling
machine.
9.9.7Milling operations
 Slab milling
In peripheral (or slab) milling, the milled surface is generated by teeth located on the
periphery of the cutter body. The axis of cutter rotation is generally in a plane parallel
to the workpiece surface to be machined.
 Face milling
In face milling, the cutter is mounted on a spindle having an axis of rotation

perpendicular to the workpiece surface. The milled surface results from the action of
cutting edges located on the periphery and face of the cutter.
 End milling
The cutter in end milling generally rotates on an axis vertical to the workpiece. It can
be tilted to machine tapered surfaces. Cutting teeth are located on both the end face of
the cutter and the periphery of the cutter body.
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9.9.7.1Methods of Milling
Up milling is also referred to as conventional milling. The direction of the cutter

rotation opposes the feed motion. For example, if the cutter rotates clockwise , the
workpiece is fed to the right in up milling.
• Down milling
Down milling is also referred to as climb milling. The direction of cutter rotation is
same as the feed motion. For example, if the cutter rotates counterclockwise , the
workpiece is fed to the right in down milling.
However the chip formation in down milling is opposite to the chip formation in up
milling. The figure for down milling shows that the cutter tooth is almost parallel to
the top surface of the workpiece. The cutter tooth begins to mill the full chip
thickness. Then the chip thickness gradually decreases.
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PRINCIPLLE MOTIONS OF A MILLING
MACHINE
TOOL
4
1
WORKPIECE
3
WORK TABLE
NAME: TALON REPORT

COMPANY: SIMBI TITLE:PRINCIPLE MOTIONS
9.9.8Grinding Wheel
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Grinding wheels are as important to any mechanical workshop as any other machine.
They are used for grinding shaping and providing a finish to any work piece. Several
factors are considered when grinding. These are
 Material to be ground
 Amount of material to be removed and finish desired
 Arc of contact
 Type of grinding machine
Other influential variable factors in grinding are:
o Wheel speed
o Work speed (speed of work piece)
o Condition of machine
o Skill of workman.
NB: When selecting a grinding wheel for general workshop practice non-ferrous
metals should not be ground on any grinding wheel (material will clog the wheel.
Also important to note is that Green wheel soft wheel should only be used for
grinding tungsten carbide tools.
The following physical properties of material are also important to take into account
when using grinding wheels.
(a) Aluminum oxide grinding wheels should be used for materials of high
tensile strength e.g. carbon steels, alloy steel, Hss, wrought iron and
tungsten.
(b) Silicon carbide grinding wheels are used for materials of low tensile
strength e.g. cast Iron, Chilled Iron, Marble granite, Cementile,
carbides and to a lesser extend non-ferrous groupings.
• Factors affecting Selection of Grit of Wheel
i. Amount of material to be removed, use a course wheel for fast removal.
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ii. Finish desired use a fine wheel for time finish. Physical Property of material, -
use course grain for duck file material and finer grain for hard, dense or brittle
material.
• Factors affecting the selection of the grade of wheel.
i. Physical properties of a material - use hard wheels for soft materials and soft
wheel for hard materials.
ii. Arc of contact – the shorter the contact the harder the wheel should be.
iii. Wheel speed and work speed – the higher the ration of the wheel speed to
work speed the softer the (grinder) grade.
iv. Condition of machines - machine in poor conditions would normally require
hard wheels.
v. Operators Skill – skillful operators can use softer wheels. Every grinding
wheel has two components: Abrasive that does the cutting & Bond that holds
it together.
Cutting efficiency depends largely upon the abrasive and the grade and hardness
depends upon the relative percentage of the bond used. The functions of the bond are:
i. It holds the abrasive grains together.

ii. It provides a factor of safety at running speeds.
iii. It modifies the hardness or strength of the wheel.
• Factors affecting selection of bond on a grinding wheel
i. Dimensions of wheels - wheels subjected to bonding strain should be made

from elastic or rubber bond followed by extremely thin abrasive. NB; Wheels
over 900mm in diameter are usually made from a silicate bond.
ii. Rate of Cutting – for most rapid cutting, use vitrified wheels and rubber
wheels for speeds above 2000rpm.
iii. The finish desired – Use elastic or rubber wheels best finish and silicate for
cutlery.
• Common Abrasive in use

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i. Emmery – confined to abrasive paper and cloth
ii. Silicon Carbide (C) - for grinding tungsten tipped tools
iii. Aluminum Oxide (A)
iv. Crushed Diamond
v. Boron Carbide
• Types of Bonds
i. Vitrified (V) – this is the most common

ii. Silicate (S) – for large wheels
iii. Shellac (Elastic Bond) E – for thin cut off wheels.
iv. Resinoid (B) –for high-speed wheels.
v. Rubber (R) - for thin cut of wheels.
• Grinding wheel marking
The selection of a grinding wheel is affected by these markings.
i. Abrasive type
ii. Grain size
iii. Grade of hardness and strength of bond
iv. Structure o f spacing of grains
v. The kind of bond
vi. Manufacturers’ record
• Mounting of a Grinding Wheel
Before mounting the wheel, it must be checked for cracks. All new wheels should be
run at full speed for I minute before applying work on it, during which time the
operator should stand to one side. Work should never be forced against the cold
wheel but should be applied gradually. Grinding on the flat sides of speed wheels is
often hazardous.
• Balancing the Grinding Wheel
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The procedures when balancing a wheel are:
i. Balancing it
ii. Mounting it on the machine
iii. Truing it (dressing the wheel)
iv. Balancing it once again.
Truing is carried out with a diamond, which has a shearing action on the abrasive
grains and the bond. It trues the wheel face parallel to the axis of the machine.
Dressing is a process of cleaning and opening up of the face using a star wheel
dresser.
NB: Care must be taken not to traverse too fast when dressing or truing a wheel. A
good flow of coolant must be used to prevent overheating of the stone and the dresser.
 Diamond Abrasive Wheels
These are the most common wheels in use and are made from diamond particles
(diamond dust) held in either a Resinoid or Vitrified bond. These are recommended
for cementite tipped tools, glass, ceramic and stone. The recommended surface speed
are 1500 – 2000rpm.
 Rules for Diamond Wheels
i. Mount the wheel so that it turns time.

ii. Keep the wheel in its collect until it is worn out.
iii. Undercut the steel shank on carbide tipped tools.
iv. Lubricate the face of the wheel at all times.
v. Do not dress the wheel with a diamond dresser.
vi. Do not grind or other relatively soft materials.
CHAPTER 10
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10.0 The maintenance work that I carried out in the Plant during my attachment
at Mechanical Engineering Department
The mechanical department concern for the plant is ranges from monitoring the plant
itself as well as the process. The plant is comprised of Static and Dynamic machines
the majority being supported on structural frames.
The most notable dynamic machines are:
i. The conveyor belt system

ii. The rotary Kiln and cooler
iii. Wet scraper
iv. V- belts
Static running (rotating) machines include:
i. Electric motors
ii. Gear boxes
iii. Water pumps
iv. Crusher.
• Conveyor Belts
Conveyor belts are made of a carcass to transmit power and carry tension. Sheet metal
covers from blows, abrasion and keep out moisture protect the carcass. Carcass
consists of plies or layers of rubber impregnated fabric or cord. The rubber compound
on the fabric is called friction skims (thin layer of rubber between plies)
• Belt Support
These are straight beds, which are narrow hang* platforms of wood, plastic or steel.
Mainly used for carrying objects that requires individual handling. Belts run on idlers.
Belt idlers convey bulk material in volume at medium to high speed. They are made
from pressed steel or steel tubings in anti-friction bearing. Their purpose is to shape or
trough the belt to increase it carrying capacity.
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There are 17 conveyor belts at SIMBI plant. A gearbox compiled to an electric motor
drives each. The electric motor here is the source of drive; hence, the size of the
motor used depends on the length of the belt, angle of inclination and the load
carrying capacity of the belt. Thus, the size of the gearbox used is as well differently
proportional to the length of the belt and the load resistance.
BC1 – BC11 are the main conveyor belts and these cover from the raw material
section to the production section. The 11 main conveyor belts are installed in such a
way that they are repairable and adjustable in the unlikely event of a major crack
breaking.
Within the stock house, there is another belt, smaller in size to the main belts which
runs across the storage bins as it transport charcoal to its storage bin
The remaining 5 belts are for the weighing feeders (4) and one (1) used in the
production house.
NB: It is important to note that BC 4 transports both Iron Ore and Limestone into the
storage bins. Within the storage bins, there is a gate valve, which is used to direct
either Iron Ore or Limestone into its proper storage bin. An assistant from the
mechanical department operates this valve. Therefore, a lot of care must be exercised
not to mix the two raw materials in one bin by opening the valve in the wrong
direction. To avoid the operator limit switches are used to indicate the position of the
valve.
10.1Repair and maintenance carried out on conveyors
i. Check the condition of head and tail pulleys. If excessively worn replace with
a new one. Also greasing the bearings on which these pulleys run.
ii. Checking the condition of bearings and replacing when it collapses.
iii. Checking the condition of rollers on which the belts run. If rollers are
excessively worn out replace them.
iv. Checking for cracks on belts. Joining the belts using special glue.
v. Securing frames which support the belts and all covers.
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vi. Checking status of sensors and metal detectors. Adjusting or replacing where
necessary.
10.2 The Rotary Kiln Section
Fig 18
The rotary Kiln acts as a furnace into which the process of coming up with sponge
iron takes place. I is compiled to a gear box which is driven by a variable speed
electric motor but it normally rotates at a constant speed of 1rev 144 sec.
There is also an auxiliary electric motor, which is used to drive the Kiln when the
main electric motor is fault or when carrying out maintenance work.
The Kiln sits on rollers placed at each end. The rollers are supported by ball and
roller bearings, which resist radial and axial loading respectively.
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Around the Kiln shell are 7 air fans with air ducts for air circulation. These fans are
electric motor driven. There are also Thermocouples placed radially along the Kiln
and these are used for temperature measurement.
Just at the middle of the Kiln, there are slip rings for thermocouple and quick response
Thermocouple (QRTs) temperature mill volts readings. There is also another set of
slip rings, which is used for power supply to the shell air fans. The inlet and the outlet
of the Kiln sit and rotate on a brass lining referred to as hood. In these two areas a lot
of heat is generated hence cooling is provided by a continuous supply of air into the
pockets around.
• Repair and Maintenance work carried on the kiln
i. Greasing the hood regularly

ii. Lubricating roller bearings
iii. Cleaning slips rings.
iv. Oiling gearboxes and replacing worn seals and gaskets.
v. Thermocouple movement (this prevents sticking)
vi. Checking the temperature of the electric motors, loose connections, removing
dust and listening to any abnormal noises.
vii. Purging Kiln inlet and outlet pressure impulse lines.
viii. Taking Kiln outside temperature periodically.
ix. Checking for any connections of T/C wires.
10.3 The Cooler
From the Kiln Iron Ore now Sponge Iron goes into the cooler. This is achieved by
free movement due to the angle of inclination. The cooler is constantly supplied with
water, which is speed across the whole surface area. The sponge Iron when it gets
into the cooler has to be cooled from as a high a temperature as 7000c temperatures
below 1200c before it can be transferred to the storage bins.
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The cooler is also driven by a gearbox (smaller as compared to the main Kiln gearbox,
which gets its drive from an electric motor. The water, which is pumped to the cooler,
circulates as the cooling process takes place.
Repair and Maintenance of the Cooler Section
i. Checking the flow rate by observing the flow sensor indicator.

ii. Remove clogging to permit free flow of water.
iii. Welding broken water pipes due to rusting.
iv. Checking electric motor temperature, loose connections and abnormal noises.
v. Changing oil in the gearbox
vi. Checking for oil leaks and level & topping up.
vii. Changing worn oil seals and gaskets.
viii. Lubricating bearings
ix. Checking coition of valve deflector.
10.4 Wet Scrapper Section
During the production process, a lot of dust is extracted and should be disposed off in
ways that are environmentally correct. Also during this extraction period the gases
and dust are very hot such that it is not recommended to dump it as it is hazardous to
both human beings and vegetation. Most of the dust /gases comes out through the
Gas
o Gas Conditioning Tower. The GCT has a constant supply of water, which
mixes with the dust as it tries to escape into the atmosphere. The dust on
mixing with water becomes dense. Instead of going up the tower it goes
down the tower and out through the extraction point. Below this outlet is a
water reservoir where the wet dust settles. Within the water reservoir, there is
a chain link with blades, which is driven at the other end by a gearbox
coupled to an electric motor at a very slow speed. The blades scrap the wet
dust out of the water.
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Repair and Maintenance carried on Water scrapper
i. Checking the status of the water level sensor adjusting sensing distance and
replacing with new one when fault.
ii. Checking condition of floater.
iii. Checking water level, if low opening supply valve. Chain and blades. Replace
worm out blades
iv. Lubricating bearings.
v. Removing scrapped wet material around the area.
10.5 Gearboxes
All gearboxes within the plant were manufactured by Radicon. From my

observations and questioning the gearboxes, seem to be very robust as non has
suffered a breakdown so far.
The gearboxes are used for steeping up or stepping down both speed and torque
depending on the mode of exploitation. At SIMBI, most of the gearboxes are step
down gearboxes the gearboxes are driven by high-speed electric motors, which runs at
speeds ranging between 1000-1300rpm.
The Electra gearboxes have helical gears. Theses offer smooth noise free operation
and can achieve torque without subjecting the gears to high stresses. The bearings,
which support the shafts, are either taper roller or ball bearings. These preferred
because of their ability to sustain high loads and stresses. The gearboxes can be oiled
or greased lubricated.
Repair and Maintenance on gearboxes
i. Checking oil level s and leaks.

ii. Topping oil.
iii. Replacing worn seals and gaskets.
iv. Replace worn rubber compiling between electric motor & gearbox.
v. Checking and changing bearings.
vi. Lubrication of bearings.
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vii. Changing oil
viii. Securing loose mounting bolts.
ix. Checking condition of gear teeth.
10.6 Water pumps
Excluding the ESP, there are currently six water pumps working at plant, and these are
mainly used for cooling purposes. The pumps are:
a) Make up Pumps x 2
b) Cold Water Pumps x 2
c) Hot Water Pumps x 2
The pumps are centrifugal type, single stage (multistage are for the ESA).
* Cold well pumps draw water from a reservoir and supply it under predetermined
pressure to the cooler for cooling purposes of Sponge Iron. Hot Well pumps draw ho
water from another reservoir and pump it to cooling fans where it is cooled before
being pumped again to the cooler.
Make-up pumps are used to cater for shortfalls results from evaporation, leakages,
spillages when the coolants reaches levels below the normal requirements makeup
pumps are opened and pump in water to cover the loss. Each of the above pumps
delivers a volume of 5litres per revolution and has a lead of 6 meters
I carried an installation of one of the make-up pumps. During installation one should
take note of the normal direction of rotation when in use otherwise incorrect
installation will result in no delivered of water at all also to take note of is the type of
coupling used in this case it is a flange type. This is the most preferred because there
are no shock loads involved. The pump does not need any form of lubrication since
bearings are repacked and sealed.
Repair and Maintenance carried on Water Pumps
i. Replacing seal and packing.

ii. Pining the pump after installation
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iii. Checking for misalignment and realigning.
iv. Checking for any bend, crack on section line and repairing as necessary.
v. Checking and removing dirty.
vi. Checking condition of impeter if not damaged.
vii. Checking conditions of bearings and lubricating them.
10.7 Crusher
The coal supplied to SIMBI is sometimes and in most cases large boulders not
suitable for use directly in the production process. It has to be reduced to
recommended size and this is achieved by the use of a jaw crusher. This crusher
consists of fixed jaws and moving jaws. It is driven by an electric motor through V-
belts. During the reciprocal movement of the jaws coal boulders are trapped in
between jaws and are crushed to set size. The crushed coal is taken through screens
where large boulders are returned to the crusher for further reduction.
Repair and Maintenance of Crusher
i. Checking and adjusting belts tension

ii. Replacing worn jaws.
iii. Adjusting jaws gap size.
iv. Lubricating bearing
10.9 Electric Motors
These are the source of drive power to all machines in the plant. Most of the electric
motors in use are the 3 Induction motors.
Repair and Maintenance of Electric Motors
i. Check for any loose connection.

ii. Dedusting.
iii. Covering the motors.
iv. Listening to any abnormal noises
v. Remove and replace worn bearings.
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CHAPTER 11
11.0 Screens
I have mentioned earlier on that raw material are supplied in different sizes and so is
the end product which comes out in different sizes hence some of the material is not
required at all. The unwanted material is separated by means of screening. These
screens are placed at various places within the flow process of raw materials up to the
product house. The screens serve as sieve to select correct sized particles of both raw
materials and sponge iron. These screens are mesh wired and are of different sizes
placed one after the other in accordance to size.
At the screen house there are 2 screens each for coal and iron ore. Dust and unwanted
particles are disposed off through chutes. At the product house there are 4 screens, all
of different sizes and these separate large particles from correct size particles and dust
with the second screen separating the correct size from dust. All the 3 particle sizes
are directed via different chutes.
Repair and Maintenance carried on screens
i. Inspecting whether correct particles size screening is taking place , if not

remove screens.
ii. Check whether screen are damaged if so repair by welding.
iii. Check whether screening is taking place, if not remove clogging.
11.1 Double Pendulum Valves (DPV)
As the process of screening is carried out, a lot of dust is extracted or removed. All
round the plant there are pipes laid to direct dust to a particular point of collection.
Just below, the screens and other ducts (chutes) (toward the outlet) are doubled
Pendulum valves, which opens and close for extraction of dust. These valves are can
operate and the cans are driven by a single phase (1) motors.
Also incorporated within the working mechanism of DPVs are return springs, which
allow closing of the valves.
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 Repair and Maintenance of DPV
i. Check the tension of the spring replaces spring when the tension is weak.
ii. Check cam bearings/ bushings condition. Lubricate if necessary or replace
when worn out.
iii. Check cam if in condition.
iv. Inspect for any loose connections on motor, secure monitoring bolts and listen
to any abnormal noises.
11.2 Welding
During my attachment period at the workshop I was also taught how to weld I did
mainly two types of welding:
o Gas welding
o Arc welding
Having taught that all workshop processes have their specific safety precautions and
safe working procedure to be followed. I was assigned to produce several window
frames and doorframes .I was also made to produce some steel fabricated products
with the guidance of Mr. Neil and Mr. Mugova the senior Boilermaker and Welder
respectively.
Types of joints
Before carrying out any welding, the type of joint best for the job should be
ascertained.
There are 4 types of joints in common use. These are:
o T –joint.
o Butt joins.
o Cuter joint.
o Lap joint.
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T- joint
T – Joint mostly used at a flange to weld junction in late girders, branches attached to
main pipe and stiffness welding to panel.
Butt joint
Used for joint where load is transmitted along common axis.
For joining length of pipes, plates and flanges on bridge girders.
Corner joint
There are normally associated with Box sections
Lap joint
The bond is over a small area of interface as a narrow strip along the length of joint.
Used in sheet fabrications.
11.3 Oxy-Acetylene Welding
An oxygen and acetylene mixture is burnt at the tip of a designed nozzle which is
fitted to a torch body. The welder uses the flame to melt the parent metal to form a
weld pool. Filler metal if required is added separately by manual feeding off a wire
into the bading edge of the welding pool.
Parent Metal Fusion.
To make a weld of good quality the surface of the parent metal has to be melted
before the added electrode or filler metal is allowed to flow into the joints.
Heat input in gas welding
Oxy Acetylene welding depends on a chemical reaction to generate heat which is then
transferred to the work.
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The flame has two zones
1. Inner cone
2. Outer enveloped
 Inner Cone
Acetylene (C2 H2) burns in that emerges from the nozzle to give carbon monoxide
(C0) and oxygen heat,
C2 H 2 + O 2 2CO+H2 + heat
 Outer enveloped
Carbon monoxide and hydrogen burns in atmospheric oxygen giving carbon dioxide,
water and heat.
4C+H2 +3O2 4Co2+2H2O+heat
NB: Total quantity of heat produced depends on the amount of acetylene, which is
burnt. If more heat is required, the flow rate of acetylene is increased and oxygen
supply is adjusted to give the correct type of flame.
Types of flames
 Carburizing flame
Temperature 21000c
Used when welding aluminum or where excess oxygen on metals would cause
oxidation
 Neutral Flame
Temperature –32000c
________________________________________________________________ 135
Used for welding all normal welding on mild steel, cooper and magnesium.
 Oxidizing flame
Temperature-32000c
Used for welding brass and bronze. On an oxidizing flame, temperatures do not
change but due to more oxygen being released, the heat is increased.
 Safety measures when using Gas welding
11.4 Acetylene Cylinders
• The gas is stored together with a solvent acetone in maroon painted cylinders.
Note that the cylinder valves outlet is screw left-handed.
• As the gas is highly inflammable, all joints must be checked for leaks using
soapy water.
• Acetylene cylinders must be stored and used in an upright position and
protected from excessive heat and coldness.
• Acetylene can form explosive compounds in contact with certain metals and
alloys especially copper and silver. Joint fittings made of copper should never
be used.
• The colour of cylinders, valve threads or markings must not be altered or
tempered with in any way.
11.5 Oxygen Cylinders
 The gas is stored in black painted cylinders.

 Never allow oil or grease to come in contact with oxygen fittings
because spontaneous ignition may take place.
 Oxygen must not be used in ease of compressed air.
 Do not allow cylinders to come in contact with electricity.
________________________________________________________________ 136
 Cylinders must not be roughly, knocked or allowed to fall to the
ground.
11.6 Gas Welding
When the direction changes to right ward movement, the torch angle becomes 40o-
50o
NB: When lighting or extinguishing the welding torches the manufacturers

instructions should always be followed.
To clean the nozzle use special nozzle cleaners not steel wire.
11.7 Manual Metal Arc Welding
This has become an efficient and reliable means of welding sheet and metal plate. It
is used for welding the heavier gauge metal plates ranging in thickness from 2mm –
75mm. It is used for either mild steel stainless steel and aluminum metals.
• Principals of Arc Welding
It is based on the principal that intense heat is obtained from an electric current, which
creates an arc between a metal electrode and the plates which are to be welded. The
heat produced will fuse the edges of the plates at the joint forming a small pool of
molten metal. A small addition of molten metal comes from the tip of the electrode
and is deposited into the molten pool. When it solidifies it forms a very strong
welded joint.
• Heat input In Arc Welding
Arc power: Input (watts) (j/s) = Arc Voltage x Arc Current
E.g. Power Input = 20V x 150 A = 3000W.
________________________________________________________________ 137
Input at any given point depends on the travel speed. Hence knowing the energy being
supplied to the arc and travel speed, it is possible to calculate the heat input and to
express it as the amount of heat per unit length of wed run.
NB: Current Range is normally 25-350 Amps
Heat input is normally 0, 5 – 11kj
• Factors governing heat Input
i. Current
ii. Arc voltage
iii. Travel speed
Electrodes To a large extend the degree of success of the welding operation depends
on the coating which is varied to suit different conditions and metals.
• Functions of Coating
i. Stabiles the arc and enable the use of arc welding.

ii. Cleans away an impurities
iii. Speed up the welding operation by increasing the rate of melting.
iv. Prevents oxidation by forming a slag over the weld, slow the rate of cooling of
the weld
• Electrodes identification
The following codings are used:
i. Strength, toughness and coating (STC) code.

ii. Electrode Dimensions and tolerance.
iii. Electrode and bundle identification.
• Essential Factors of Arc welding
i. Correct choice of electrode

ii. Correct arc length
________________________________________________________________ 138
iii. Correct speed of travel
iv. Correct current.
• Welding Accessories
In addition to the welding machines, the following should also be part of the welder
before commencing any work:
i. Electrode holder
ii. Welding earth
iii. Head shield (face screen)
iv. Gloves
v. Leather Aprons
vi. Goggles
vii. Cleaning tools
viii. Welding booth
• Arc Welding Positions
Arc welding operations can be carried out with work in every position but the degree
of skill required of the operator will vary considerably depending on the position of
the joint.
i. Flat (downward position)

ii. Horizontal position
iii. Vertical position
iv. Overhead position
NB: The successful step towards electric arc welding is learning to strike and
maintain the arc and run a straight bead of weld metal
First set the control unit to correct setting specified for the size of electrode being
used. Then bring the electrode in to contact with the plate by either
i. Tapping
ii. Scratching
________________________________________________________________ 139
• Weld Defects: Under – cutting grooves appear in the base metal on
both sides of the bead this results due to high current. Overlapping –
Molten metal fall from the electrode with out fusing with the base
metal. This result when current is set too low.
CHAPTER 12
Electrical Department Internship

12.0 Introduction
The Electrical Engineering Department is one of the production sections which have
its full and committed participation in rendering services in the repair and
maintenance of all electrical faults and machinery at the plant. I however recommend
that most of our courses require more practicals and industrial visits even on-site
learning.
The relationship between Mechatronics and Electrical Engineering has been derived
from the fact that I did the following courses which are a major in the field of
Electrical Engineering:
• Electrical Machines which consist of :
o DC Machines
o Transformers
o AC machines
o Generators
o All types of Electric motor starters
• Electrical Principles and Principles of Electronics which consist of :
o All electrical principles and their application in the industry.
o Most electronic components and their application in Design and in the
industry.
Since industrial internship is mainly applying most theoretical knowledge that you
had from the University, it was an easy period of training in this Department as I had
vast knowledge in Electrical Machines.
________________________________________________________________ 140
Mr. Srihari heads the department and the supervisors are Mr. M. Munyariwa and Mr.
Mahove. There are 5 artisans and 8 assistants all committed to offering first class
service in line with the company’s goals. During my first days at the department I
was taken through a rigorous learning process to ensure that I get well acquainted
with the necessary safety precautions, knowledge and procedure of working on
(handling) high voltage.
12.1 Safety Precautions
i. No unauthorized entry into designated high voltages areas such as 33kv, 11kv
substations and the MCC.
ii. No switching without authority.
iii. When switching, you have to know what you are doing.
iv. When entering into the substation, always leave the gates wide open.
v. Fire extinguishers must be installed on accessible points and should always be
in good working conditions.
vi. Before carrying out any work, you must make sure whether power is ON or
OFF. Isolate power when necessary..
vii. Wear proper safety clothing. When switching always put on rubber shoes.
viii. Put dangers warning signs on main switches and if necessary lock.
ix. Work environment must be clean and free of obstacles.
x. Never put sharp objects in the pocket.
12.2 The 33/11kv and 11kv/415v Transformers

The Electrical department tasks starts at the supply substation from ZESA which is a
33kv. SIMBI substation receives 33kv from ZESA and steps it down to 11kv through
a 10MVA transformer.
From the 10MVA transformer , power is transferred to a second substation which
steps the 11kv to 415v through a 2MVA transformer. The 2MVA substation is located
closer to the plant. The 415v is fed into the MCC (Motor Control Centre) to supply
the whole plant. The 33kv and 11kv are sometimes referred to as outdoor
transformers.
________________________________________________________________ 141
Within the 33kv substation there are switch gears which are used for grounding
residual electrical power when maintenance work is to be carried out. The two
transformers, 10MVA and 2MVA have four banks with tins each for air cooling the oil
used in the transformers. In every shift of 8hours, winding temperatures and cooling
oil temperature readings are recorded twice . the cooling oil temperature should
always be higher than the winding temperature . This ensures that the transformer
windings are not burnt.
________________________________________________________________ 142
ZESA ISOLATOR OIL CIRCUIT
BREAKER
33KV
P
POTENTIAL CURRENT
TRANS- TRANS-
ISOLATOR
33KV/11KV
TRANS-
415V TO MCC
11KV/415V CURRENT
2MVA TRANS- ISOLATOR
P
OIL VACUUM POTENTIAL
CIRCUIT BREAKER TRANS-
 Maintenance Work carried out on outdoor transformers (33/11KV)
________________________________________________________________ 143
i. Checking oil level and topping up if necessary.
ii. Recording winding and oil temperatures twice per every shift.
iii. Checking moisture content by observing colour changes of Silica gel (status of
silica gel: Blue –Ok; Red/Pink – fault).
iv. Checking physical conditions of measuring instruments.
v. Checking condition of arcing horns.
vi. Verify all tapping positions such as Isolators.
vii. General checks.
 Maintenance Work done on Indoor Substation (33kv & 11kv)
i. Taking meter readings twice every shift

ii. Checking the presence of 33kv and 11kv (Voltage & Amperes)
iii. Checking relay status (for tripping)
iv. Checking enunciator status (fault alarm status)
v. Taking energy meter readings twice every shift.
vi. NB: For 11kv, we check energy consumption after every 8hours and this
includes Diesel Generator.
vii. Checking condition of batteries for substation and emergency lights.
12.3The Motor Control Centre (MCC)
The 415 V from the 2MVA transformer is fed into the MCC from where the whole
plant is supplied. All plant electrical circuit starts from the MCC i.e. the MCC is
where all field drives are controlled. The circuits are divided into 12 sections with the
main circuits being MCC 1; MCC 2 and MCC 3. The diagram below starting from
the MCC.
________________________________________________________________ 144
415 SUPPLY DG. INCOMER
1600A 4P
MDO ACD MDO ACB
DG PANEL V V
CT1-3 1/55 A 0-500V

3200/5A 0-500V
A A
0-1600A
0-3200A
630A 630A 630A 630A 630A 250A 250A 250A 125A 125A 125A 1235A
50KVAR CAPACITOR BANK
 Circuit No 1 Power Factor Correction
It is protected by an 800 A circuit breaker and supplies a 300 kVAR capacitor panel.
The panel has six capacitor banks each supply protected by a 125A circuit breaker.
Each bank consists of 3,50kVAR capacitors connected in Delta configuration. The
bank has an automatic power factor control and the number of banks energized
depends on the inductive loads connected at that particular time.
NB: Each bank is supplied through NO contacts and a relay, which are energized,
by a 110v supply.
________________________________________________________________ 145
 MCC 12&3 Circuits
These are the main circuits in the plant. Each circuit is supplied by a 630 A circuit
breaker. The circuits are categorized as:
a) MCC 1 – Raw Material Section
b) MCC – Kiln & Cooler Area
c) MCC3 – Production/ Separation Section
 MCC 1
630A
Supply for Dedusting Solenoid vales-32A Coal Crusher 3 Induction Motor

Power – 37, 5 KW
Supply breaker – 125 A
This circuit has a total of 22 electric motors (Induction Type) mainly for driving
conveyor belts screens weigh feeder belts, crusher and dust fans. Three of them are
star – delta connected and the rest are direct on line. See Appendices 1
 MCC 2
The kiln and cooler are consists of 43 electric motor circuitry. 3 are star – delta
connected, 26 are DOL. In this circuit we have the kiln main drive and cooler main
drive, shell air fans, weigh feeders, all of which are variable speed drives some of
the motor drive DPVs fans Kay Blower dedusting etc. See Appendices 2
 MCC 3
The Product separation section has a total of 36 electric motors (Induction) with five
5 of them star – delta connected and 22 are Dol. The motors drive water pumps;
fans, wet scrapper and ABC pumps see Appendices.
________________________________________________________________ 146
12.4 Motor Starting Circuits
Electric Motors at SIMBI are connected in star – Delta or direct online
configuration. Connecting a motor in star – Delta is done to reduce high starting
currents.
The majority of the motors are DOL due to their small size (1,1kw – 11kww) and
those connected in star - Delta have a power rating of 22kw –55kw.
All the Motors can be switched either in the MCC control room or in plant
depending on the mode selected. In each panel either for DOL or star Delta there is
a selection switch for selecting REMOTE OR LOCAL mode of operation, see
control diagrams for both DOL & S/D REMOTE _ enables starting from Control
room.
LOCAL -enables starting from MCC or plant.
NB: If you select LOCAL or REMOTE, you can only start in the selected mode and
not the other.
13.5 Direct on Line Starter
Electric motors that are bi-directional can run either in forward or reverse direction.
Below is typical Control diagram for a DOL starter circuit at SIMBI. The diagram
also incorporates (show) signals, which go to the controller. These signals show the
selected
i. Mode
ii. Status of motor, whether running or not, whether tripped or not.
iii. Emergency stops, whether tripped or not.
iv. Overload
v. Trip wire (pull cord switches.
Also in this circuit are additional relays KIA (PLA relay and KIB (PLA relay) .
When the drive is running in LOCAL, KIA relay is energized and its NO contacts
will close and NC contacts opens. During this time, when the emergency stop is
disturbed it opens the control circuit and there is no supply to KIA and NO contact
opens, cutting the 24v supply to the PLC. The NO contact KIA supplies J5, which
goes to the PLC.
________________________________________________________________ 147
NB: When running in LOCAL mode one of the KIM No contacts closes to switch
on J3 signal which gives indication to control room that the drive is running in
LOCAL.
When REMOTE is selected, KIB is energized and the indication closes and
switches on J2 and gives an indication for REMOTE selection (PLC input). After
REMOTE selection, the motor can be started from control room. By initiating a
start o the PC in the control room, we are inputting a signal to the PLC. The output
from the PLC wick close the switch indicated PLC O/P in the diagram. This is
achieved by the use of an opt coupler which is in series with the switch.
 Reverse DOL
An additional contactor K2M is incorporated in parallel with KIM. Also included
are inter locks which prevent selecting both directions.NB: KIM and K2M are
interlocks connected in PLC can select mode through an opt coupler.
12.6 Star – Delta Connection

Star – Delta circuit can also be started in either LOCAL OR REMOTE mode.
LOCALLL starting is done in the MCC or field and REMOTE starting is done in
control room. Like any other circuit at SIMBI, the parameters monitored for a star –
Delta circuit are :
i. Mode Selection
ii. Run feedback
iii. Overload trip
iv. Emergency trip
The status of mode selection is monitored by KIB relay through its NO contact.
When LOCAL is selected, simply to the REMOTE terminal is open, thus KIB relay
is off. The NO contact of KIB which is in series with J2 will be open and there is
no 24V signal to J2 going to PLC. Absence of 24v shows that REMOTE is not
selected
When REMOTE is selected, KIB relay is energized closing its NO contact, thereby
supplying 24v to J2
Presence of 24v indicates that REMOTE mode is selected.
________________________________________________________________ 148
The Run feedback is detected by the NO contact of Kim relay, which is the main
(Common) contactor, which supplies the motor. When the motor is running one of
its NO contact, which is in series with J3 closes, thereby supplying 24V to the PLC.
The presence of 24V to the PLC indicates that the motor is running.
When the main contactor is off, its NO contacts opens thereby opening 24v supply
to J3 . Absence of 24v indicates the motor is not running.
NB: This condition is applicable to any mode selected.
Incorporated in this circuit is a timer T1 which closes its NO contracts at the same
time as no contacts at the same time as No contacts for relay K3M closes, switching
on indicating lamp P14. The timer indicates the time it takes for the motor to run in
star before switching to delta.
Overload status is detected by J4, which is connected in series with the NO contact
of the overload (O/L) relay. When the overload trips, its NO contacts closes
supplying 24v to J4. Presence of 24 V indicates to the PLC that O/L trips. When
O/L is not tripped the NO contact is open, hence there is no Supply to J4, which
indicates that the circuit is okay.
Emergency trip is detected by the NO contact of K/A relay. When the machine is
running and the Emergency stop is on, K/A relay is energized closing its NO
contacts, enabling the 24v signal to J5. Presence of 24V indicates that the
Emergency trip is okay and absence of 24v means Emergency trip is off.
NB: The Status of the motor ie emergency trip, on or off can also be seen in the
MCC through indicating lamps.
Control and Power Circuit for Conveyor Belts
The conveyor belts BC1 - BC 11 run at a constant speed and they are connected in
DOL> other belts for weigh feeders vary speed, so they are connected in variable
AC drives.
The diagram for a conveyor belt is similar to any ordinary DOL circuit. What
differs is the control circuit. All the Circuits for conveyors are unidirectional;
hence, they are a forward DOL starter.
________________________________________________________________ 149
Below is a control diagram for conveyor. Like any other circuit at SIMBI, conveyor
belts can also be started in LOCAL or REMOTE mode.
LOCAL – starting in MCC or plant.
REMOTE – starting from the control room.
Conveyor incorporates a safety mechanism in the form of a pull switch. The pull
cord switch runs in tandem with the belt so that at any point along the belt one can
operate it in case of emergency. When the switch is open, the belt cannot be started
in either mode.
The pull cord is wired in series with the coil of KIC relay, which is wired from the
NO contact of KIC J6, which shows the status of the pull cord switch in the PLC.
Thus when the belt is running, KIC relay is energized and its NO contact enabling
24v to go to the PLC via J6. The presence of 24v to PLC indicates that the pull cord
switch is okay.
When the pull cord switch is tripped, supply to the KIC relay is open, reenergizing it
and the NO contact at J 6 opens, thereby opening he 24v line to the PLC.
Therefore, absence of 24v to the PLC shows that the pull cord switch is off.
For conveyor belts, the PLC indicates the following parameters:

i. Run feedback, J 3
ii. Mode selection J2
iii. Emergency stop feedback J5
iv. Overload trip feedback, J 4
v. Status of pull cord switch, J 6
NB: J2-J6 are cables connecting 24v to the PLC input section.
NO contact of the O/L shows the status of the O/L relay under normal operation
conditions, the NC contact of the O/L allows supply of power onto the control
circuit. When the O?L trips, the NO contacts opens whilst NO contact closes. The
trip indicator J4 is wired in series with the NO contact. During this time, the O/L is
tripped. Thus, when there is no 24 V signal, the O/L is not tripped.
________________________________________________________________ 150
12.7 Diesel Generator
The diesel generator supplies the whole plant with electricity when ZESA power is
cut. It is a 600KVA generator driven by a 600 Horsepower Cummins K19 diesel
engine at 1500rpm.It is manually operated. It supplies the whole plant through a
1600A circuit breaker and has an output voltage of 415 V Ac
When ZESA power supply is cut off, an electrical attendant switches the ZESA
circuit off and switches on the diesel generator circuit. Included within this
switching mechanism are mechanical breaker and diesel Generator Supply breakers)
which ensures that only one-breaker switches at a time
 D.G Metering
The DG metering in the MCC shows voltage at 400V and current at 400A when
running at an average speed of 1300rpm.
In the D.G room the following parameters are recorded and at an average speed of
1500rpm,the following readings are obtained:
Current
Voltage
Frequency
Power
KVA
Power Factor
Battery
The source of power for the AC generator is a K19 Cummins engine. This engine
has been chosen because of its problem free and long life span operation. Since the
Kiln is not allowed to stop for more than 15 minutes during the production period, it
is essential that the source of power for the generator does not develop a fault
especially these days when ZESA power cuts are so rampant. As such, the engine is
incorporated with an Electronic Control Panel, which monitors the running
parameters and possible faults for easy identification of a problem. This helps to
ensure the problem is attended, to avoid a major breakdown.
________________________________________________________________ 151
12.8 Electronic Control Panel
Parameter Problem
Engine Speed (rpm) Engine Over speed
Lube Oil Pressure (ban) Low lube Oil Pressure
Coolant Temp (oc) High Coolant Temp
Intake Air Temp High Intake Air Temp
Engine Run Time Low Coolant level
Battery (V) Battery charging Fault
Fuel Actuator Command (%) High Fuel Actuator
Command
ECP Fault Code ECP Fault Code Detected
NB: The D.G is now manually started after it developed a fault in automatic start.
Therefore, during the day it requires those on duty to quickly notice a ZESA power
cut in order to switch the D.G on.
Also within the D.G room there is a boast charger for Batteries which supplies a
voltage of 35 VDC
The batteries are used for power back up to relays.
12.9Maintenance and Repairs
The following meter readings for Electric Motors and Electric parameters are
recorded
33kV voltage
33kV current
11kV current
Relay status (Amps)
Kay Blower Status (Amps)
Cooler Drive (Amps)
Kiln Main Drive Amps)
Shell Air fans (Amps)
________________________________________________________________ 152
I.D Fan (Amps)
Also at 4hour interval the following checks are carried out
Coal crusher
Cold Well Pump1&2
Gas Conditioning Tower
After Burning Chamber 1&2
 Other duties I carried out were
i. Rewiring of emergency lights in MCC & Control room.

ii. Replacement of worn electric motor bearings.
iii. Checking the status of running drives.
iv. Checking the temperature of electric motors
v. Replacement of electric motor covers and securing loose connections.
vi. Listening to any abnormal noises
________________________________________________________________ 153
CHAPTER 13
Recommendations to the Company

I recommend that the instruments department create a library of books so that even
the newly employed Technicians can use during their research. It was difficult to
extract or share knowledge from fellow technicians, as they were new to this plant at
the same time their previous employers were using a different set up from that at
SIMBI.
The Instruments Engineer was too busy trying to train the whole department as both
Technicians and Trainees show their lack of knowledge about instrumentation at a
processing plant like SIMBI so the training programme was long as I tried to catch up
with the Technicians.
Researching using the Internet is slowly becoming expensive hence as trainees we
don’t have a computer specifically for us. I therefore recommend that a computer be
put in place in the Instruments Laboratory/Workshop.
However I enjoyed this phase of my training since I was being exposed to real plant
faults and was the most challenging of them all.
The Mechanical Department is too centralized at the Headquarters with other

branches only focusing on maintenance thus I was transferred to the HQ for my
training in Workshop practices and Processes. I recommend that new well equipped
workshops be constructed at all branches especially at the Glenlivet and Chiredzi Coal
mine. To a greater extent I enjoyed my training with the Mechanical Engineer who by
now has since left the company.
The fact that the IT department only comprises of one Hardware Engineer and one
Software Engineer made my training difficult as these
Engineers had to also meet the Company demands; I recommend that the Company
employ another two Technicians.
________________________________________________________________ 154
Recommendations to the Department of Mechatronics
Firstly I would like to thank our Department Staff Members mainly Mrs. Hondoma
and Mr. D Wakasemwa for their tremendous support as I even bothered them after
working hours. I recommend that Workshop practice and process which is done in the
first year have more practicals and a good relationship be forged by the department
between Mechanical Engineering Diploma Students and Mechatronics Students as
this will help a lot on understanding the mechanical engineering principles as applied
to Mechatronics. I recommend that Practicals had to be done on Electronics so that
students won’t be found too theoretical during attachment period.
I however want to thank the Department Staff for accurately selecting the Course
content of most of the Courses that are covered during our First and Second Year, this
enabled us (feedback from other students) to have an upper hand in the industry since
we were trained among Electronics student and Mechanical Engineering students
from other universities.
AUTOCAD proved to be more helpful during Designing both Electrical diagrams and
Mechanical diagrams, if it is possible I recommend that more time be created for
AUTOCAD i.e. it should be applied to second year.
The Industrial and Automation, Control Engineering and Intelligent controllers and
interfacing were not dealt in depth since the late Mr. T Zhuga was hospitalised yet in
the field of Mechatronics these courses proved to be the driving force behind the
establishment of this Engineering discipline in Zimbabwean industries, I therefore
recommend that students be advised on the need of the 75% attendance during
Lectures as this will give them a cutting edge in the industry.
All in all I do believe corrective measures are to be taken from the department to
include on the site learning even during the semester before attachment.
________________________________________________________________ 155
CHAPTER 14
Conclusion
The work related period of training was quite a good and successful experience,
though there were ups and downs here and there. I had an opportunity to prove the
theoretical aspect in the real practical environment. The attachment period however
did prepare me for becoming a Mechatronic Engineer and I gained vast experience
and requisite skills. It was quite a helpful experience since it developed me in many
aspects of what the working environment entails. The attachment prepared me well
for the industry that waits after completion of studies.
At first life was difficult at the IT-Department as I was trained alongside Computer
Science students who were a step ahead but later on I managed to improve my
programming skills in Visual Basic, C++ and C+ .
I managed to acquire a certificate in Industrial First Aid from Red Cross after being
trained by the S.H.E Department.
I believe I had a very wonderful training from Steelmakers Pvt Ltd, in return of my
hardworking and ability to be an ambassador for Mechatronics at that company I was
offered a job as an Instrumentation and Control Technician up to graduation day.
Many thanks to the Department of Mechatronics at C.U.T. and may the good Lord
guide you and give you more strength to help us during our final year.
________________________________________________________________ 156

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CHINHOYI UNIVERSITY OF TECHNOLOGY

DEPARTMENT OF MECHATRONICS ENGINEERING

REG NO: CO56634K

S.I.M.B.I. PVT. LTD

LTD –SPONGE IRON PRODUCTION DIVISION (SIMBI BRANCH) BY TALON

A REPORT SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS

OF A BACHELOR OF ENGINEERING HONOURS DEGREE IN MECHATRONIC

ENGINEERING TO THE DEPARTMENT OF MECHATRONIC ENGINEERING,

CHINHOYI UNIVERSITY OF TECHNOLOGY UNIVERSITY (2008).

INDUSTRIAL SUPERVISOR’S SIGNATURE

GROUP INSTRUMENTS ENGINEER

7.1 Information and Technology 80

8.0 Telecommunication System 82

9.1 Workshop Practices and Processes 84

10.0 Maintenance Work at the Mechanical Engineering Dept. 114

11.0 Screen maintenance 122

12.0 Introduction to Electrical Engineering Department 128

12.0 Recommendations to the Company 143

Chapter Fourteen: Conclusion 145

The Bachelor of Engineering Honours Degree in Mechatronic Engineering is a four

After finishing Mechanical Engineering training programme I was attached to the

As soon as I finished IT I was transferred to SIMBI-Masvingo for my Electrical and

1.2 Plant Operation

 Recommended Particle Size

Feed coal 3mm to 15mm

1.2.3 Storage Bins

WEIGHT = LOAD CELL VALUE X SPEED OF BELT

(a) Preheating Zone

(b) Reduction Zone

Fe3 O4(s) + CO(g) 3FeO(s) + CO2(g)

FeO(s) + CO(g) Fe(s) + CO2(g)

1.2.6 Product section

+ 4mm magnetic Direct reduced Iron

CONE CRUSHER IMPACTOR

COARSE NON- FINE NON-

WEIGHFEEDERS AND LIMESTONE-VOLUMETRICFEEDER

This Department is headed by Mr. I. Muchimwe a well known Instruments and

Instrumentation department is there to ensure quality production of Sponge Iron and

2.1.1Objectives/Roles of Instrumentation Department

Monitoring the Plant using the SCADA

Is the automatic processes done by machines with minimum to no human

• System must have minimum human interference.

• Improve production, easy maintenance and cost effective.

2.2.3Supervisory Control Architecture

Control engineering is the engineering discipline that focuses on the modelling of a

Although feedback is an important aspect of control engineering, control engineers

Other functions of SCADA are:

The appearance of the PLC at SIMBI Plant

Digital Input and

2.4.5 Memory unit

2.4.6 Power supply

2.4.7 Input/ Output Module

2.4.8 Programming device

The PLC is programmed by means of a special programming device. It is detachable

2.4.9 Expansion transmitter modules

2.5.0 Inputs and Output Signals

2.5.1 Digital Output

2.5.2 Analog Output

2.6The CPU (Details)

The CPU at SIMBI is as shown below.

ETM – Expansion Transmitter Module

2.6.1The VersaMax PLC Panel

 Choosing the correct type of CPU