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1.HINDALCO AN OVERVIEW:
One of the largest integrated primary producer of aluminium in Asia. With a pan-Indian
presence that encompasses the entire gamut of operations, from bauxite mining, alumina
refining, aluminium smelting to downstream rolling, extrusions and recycling, Hindalco
enjoys a leadership position in aluminium and downstream value-added products in India.
Our Indian aluminium operations are integrated and consist of bauxite mining, alumina
refining, smelting and converting primary metal into value-added products. We have
dedicated sources for critical raw materials such as bauxite, power and coal. We also have
committed supply sources for auxiliary chemicals.
Our finished products include alumina, primary aluminium in the form of ingots, billets and
wire rods, value-added products such as rolled products, extrusions and foils. Metallurgical
alumina is used for our own captive needs. Chemical alumina and hydrates are used in range
of industries including water treatment, fillers in cables and plastics, refractories and
ceramics, glass among others.
Our facilities are in regions close to raw material sources, low cost and available labour and
demand markets. This helps in reducing costs and improving profit margins. The technology
upgrade has resulted in higher utilisation rates at our plants and improved efficiency.
We believe implementation of superior technology not only reduces costs but also provides
superior and customised products, thus, improving our sales.
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Mumbai and Mouda near Nagpur (Maharashtra). Foil rolling facilities are situated at Mouda
near Nagpur (Maharashtra) and Kollur (Telangana) and our extrusion plant at Alupuram
(Kerala).
2.FABRICATION&INSTRUMENT
DEPARTMENT
Instrument plays a big role in industry. Now almost in every industries automation system
introduced. So during running time of plant we have to set some control in input and output
and also during processing. These all are done in auto now a days So we have to measure
some parameters like level, pressure, flow and temperature. While automation system is
running we look all these parameters carefully so that production are not hampered, otherwise
we may face to a big problem or loss.
i. TEMPERATURE:
First we can discuss about temparature measurement. In various industries various
temperature measurements needed. In small industry low temperature measured and in heavy
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industry high temperature measured like in steel plant. For low temperature we use RTD
(Resistance temperature detectors). It may be two or three probe system. The difference
between two wires (one positive and one negative) creates some Voltage and through a
transmitter we can convert it to a digital reading.
ii. PRESSURE:
First we can discuss about temparature measurement. In various industries various
temperature measurements needed. In small industry low temperature measured and in heavy
industry high temperature measured like in steel plant. For low temperature we use RTD
(Resistance temperature detectors). It may be two or three probe system. The difference
between two wires (one positive and one negative) creates some Voltage and through a
transmitter we can convert it to a digital reading.
iii. FLOW:
Flow is also important to measure. How much volume or quantity is needed, the flow
measurement detects it. In industry water is needed, gas, raw materials are also needed. So
we have to measure flow. here also a transmitter is used like pressure measurement. But the
difference is two impulse lines are connected with directly to the line. An orifice or ventury
system is used to create a differential. The amount of differential will vary and we can
measure the flow with the help of Transmitter.
iv. LEVEL:
Level is also an important part which indicates the stock and water level in tank etc. If we
count the stock in number then no problem but how can we say that how much stock is
needed to continue the production automatically. So level measurement is also important.
This measurement is quite tough though different methods are applied to measure. Normally
two lines are tapped and we may say one as low line is connected in the lower part and high
line is connected with open place. Thus a differential is created and the measurement is taken.
One more thing is important that is calibration and maintenance .We need some reference to
measure any thing. So we have to calibrate all instruments and put some range in it.
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3.FABRICATION:
The Fabrication Plant operations span across the entire value chain. The key input for
production to down stream semi-fabricated products commence from integrated Cast
house. Cast house supplies slabs for making flat rolled products, and billets for
extrusions. The Cast house has state of the art Wag staff casting stations for supplying
slabs and billets to take complete care of quality of slabs and billets. This has helped
immensely in producing world class rolled and extruded products.
The Fabrication Plant has an enviable record of producing to its full capacity
consistently. Through a judicious combination of timely investment, process
improvements and revamping, the unit has continuously enhanced the quality and
range of its products to provide customer satisfaction and improve profitability.
The Fabrication Plant plays crucial role in producing value added products to the
extent of 47 percent of total production. The Plant has ensured outstanding capacity
utilization, operational efficiency and consistency. The major manufacturing
equipments have the worlds best Net Running Time (NRT) of more than 22 Hrs/day.
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i. Started in August 1965 with one Hot Mill and one reversible Cold Mill
ii. Beginning of 1000 MT of rolled product in the calendar year 1965
iii. Crossed 14000 MT of annual production during 1975
iv. 26000 MT by 1985 and 38000 MT by 1995
v. Added the world class Pechiney make Caster in 1991
vi. Installation of Davy Cold Rolling Mill during 1994
vii. Major revamping of Bliss Hot Mill and Bliss Cold Mill in 1997
viii. Commissioning of State of art Tension Levelling line in 1999
ix. Commissioning of Bronx cut to length with rotary shear in 2000
x. Reached 58,000 MT mark during 2000
xi. Production of clad products started in 2000
xii. 91,652 MT production in FY 13
4.REMELT SHOP
The Remelt Shop has two sub units. One consists of three Properzi Mills for the
production of properzi rod in coil form and second is DC casting facility to produce
cast slabs/billets for use in rolling mills and extrusion presses respectively.
The electroslag remelting (ESR) process is used to remelt and refine steels and various super-
alloys, resulting in high-quality ingots. This process can be started up through vacuum
induction melting. The ESR process uses the as-cast alloy as a consumable electrode. Electric
current (generally AC) is passed between the electrode and the new ingot, which is formed in
the bottom of a water-cooled copper mold. The new ingot is covered in an engineered slag
that is superheated by the electric current. The electrode tip is slowly melted from contact
with the slag. These metal droplets travel through the slag to the bottom of the water-cooled
mold and slowly freeze as the ingot is directionally solidified upwards from the bottom of the
mold. The slag pool floats above the refined alloy, continuously floating upwards as the alloy
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solidifies. The molten metal is cleaned of impurities that chemically react with the
slag or otherwise float to the top of the molten pool as the molten droplets pass through the
slag.
Electroslag remelting uses highly reactive slags (calcium fluoride, lime, alumina, or other
oxides are usually the main components) to reduce the amount of type-A sulfide present
in biometal alloys. It is a common practice in European industries. ESR reduces other types
of inclusions as well, and is seen as an alternative to the vacuum arc remelting method that is
prevalent in US industries.
Aluminium extrusions are manufactured by the Hot Direct Extrusion process. The logs
are homogenized in the electrical furnaces with fast cooling arrangements. These long
logs are cut in to billets and are used as feedstock for the extrusions.
These billets are heated in an induction heater between 450 to 500 0C depending upon
alloy and then loaded in to electrically heated container. The hot container is sealed
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onto the die assembly of the desired shape and size. Hydraulically powered ram
pushes the hot billet through a dummy block against the die producing the desired
extrusion shape. This is a batch process extruding one billet at a time. The extruded
product is quenched in water / fog / air depending upon the alloy, shape and thickness.
The same is then straightened by stretchers and finished to desired length. Artificial
aging is done in electrically heated PLC controlled furnaces to get the desired temper
& properties. Finally the material is packed and delivered to the warehouse from
where the logistics takes care of dispatches to the customer.
6.CONFORM PROCESS
7.DIE SHOP
The die shop section caters to the needs of Extrusion section & ensures manufacturing
& availability of the desired dies as per the advise of Extrusion Production Planning.
For the manufacturing of the dies, the Die shop is equipped with; latest CNC machine,
a wire EDM machine, Lathe Machine and well supported by the latest AUTOCAD for
the Die Designing. The die shop is also equipped with Profilometer - For measurement
of critical pressure.
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8.ROLLING MILLS
This section of Fabrication plant produces Flat Rolled Products (FRP). The major
equipments include one Hot Rolling Mill, a Continuous Caster, two cold rolling mills
and various finishing lines to meet the customer requirements. The FRP section is
capable of producing 1, 00,000 TPA. The rolling process consists of two stages i.e.
Hot Rolling and Cold Rolling.
Hot Rolling:
The Bliss make Hot Mill is two high, single stand, reversible mill on which the cast
slabs of 305 /330 mm thickness, after preheating in soaking pits are hot rolled into a
coil of thickness 6 to 9 mm as per process requirement. The slab is reversed number of
times giving reduction in each pass and finally converting slab into a coil in about 13
to 21 passes .
Caster:
The caster unit is, state of the art technology from M/S Pechiney of France, which is
capable of converting molten metal in to coils of thickness 5 -7 mm. The advantage of
this process is that, it eliminates all the intermediate process like Casting, Scalping,
Soaking and Hot Rolling etc .
Cold Rolling:
The Cold Mills are Four High, Single stand, non reversible mill, which are capable of
rolling coils of thickness from 6-9 mm into thickness up to 0.18 mm in about 4-5
passes. These mills are equipped with customized software-vantage system supplied
by M/S Siemens. In order to ensure the gauge and shape of the product, these mills are
equipped with non-contact X-Ray meter for gauge measurement and Vidimon shape
meter for on line shape measurement.
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Finishing Lines:
This section converts the cold rolled coils into either rectangular sheets through Cut to
Length Line or a smaller width coils through Slitting Line as per the customers
requirement. This also has Circle Blanking line capable of supplying sheets in circle
form for cookware.
Hindalco is now the worlds largest aluminium rolling company. We are India's
largest manufacturer of the entire range of flat rolled products. Our aluminium sheet is
produced from our own cast slabs or continuous cast coils, rolled down to customised
thickness,gaugeandtolerances.
In India we enjoy a dominant market share. Our plants are equipped with sophisticated
rolling mills and finishing equipment.
Our commitment to quality and service and our extensive infrastructure has made us a
prime source for best-selling brands. We continuously strive to improve our
manufacturing processes, practices and systems to ensure that customers' needs and
expectations are fully met.
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9.CHEMICAL PROCEEDURE
Calcined Alumina: Calcined alumina is widely used in various industries. These alumina are
classified on soda, degree of calcinations, fineness and particle size distribution. These
alumina grades are white crystalline powders that are predominantly alpha alumina of high
chemical purity and consistent physical properties. The specific properties include extreme
hardness, refractoriness, high mechanical strength and resistance to wear abrasion, chemical
attack, and corrosion. Low soda grades provide excellent hot strength to the refractory body.
Reactive Alumina yield a low water demand with very good flow properties when used in
low-cement castables, ULCC and self-flow refractory mixes. Some aluminas have excellent
grindability. They are recommended for usage in grinding media, wear resistant ceramic
components and liners, owing to their superior packing characteristics. Polishing alumina
grades are produced through controlled calcination and processing in order to obtain
consistent particle hardness, shape and size distribution. They provide a choice of oil
absorption values within the product range. These are recommended for use in solid bars,
emulsions and pastes for metal and stone polishing applications. Details of application is
given below
Ceramics
Refractories
Glass
Polishing
Alumina hydrates are classified in based on fineness and particle size distribution. Coarse
Alumina hydrate, a crystalline white powder, is available in both moist and dry forms are
recommended in the manufacture of water treatment chemicals like aluminium sulphate
(alum), PAC (Poly Aluminium Chloride), zeolite, aluminium fluoride, glass, etc. Fine
alumina hydrates are fine white powders are used as fillers in paper and in Sheet Moulding
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Compounds, Dough Moulding Compound etc. They also function as flame retardants and
smoke suppressant in cables, rubbers, plastics, etc. Details of application is given below
Water Treatment (Alum/PAC)
10.PRODUCT RANGE
Producer with low cost base and strong presence across the value chain. Hindalcos diverse
aluminium downstream offerings extrusions, flat-rolled Hindalco ranks among the global
top five aluminium producers based on shipments and is an integrated products, foils, wire
rods, billets, etc. find applications in various industries ranging from automobiles to
packaging and pharmaceuticals.
Hindalco products cater to numerous markets, and provide for all industrial and commercial
requirements like:
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Aluminium is used extensively in the transport industry due to its high strength to weight
ratio and its excellent impact absorption qualities. Western countries use an average of 140kg
of aluminium per vehicle, whereas it stands at 40kg per vehicle in India.
Hindalcos high-quality aluminium is preferred for its superior alloy composition and
metallurgical properties that meet stringent performance parameters. Our expertise is backed
by the superior Wagstaff AirSlip casting technology. From brakes to ignition, transmission to
suspension, cooling and exhaust systems to windows and structurals, ornamentals to
accessories, automobile heat exchangers and registration plates, Hindalcos superior
aluminium material is for making the most precise automobile components.
Hindalco brands:
Maxloader truck bodies are lighter, more environment friendly and fuel efficient.
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high strength-to-weight ratio, corrosion resistance, and ease of recycling, makes it the ideal
material for a wide range of building and construction applications.
Aluminium is used in the construction of windows, doors and facades, and roofing and
cladding. Aluminiums excellent material properties provide the basis for intricate, stable and
lightweight structures. Aluminium allows a high degree of pre-fabrication, with a variety of
finishes.
Our superior Wagstaff Airslip casting technology ensures strength and consistency to meet
the various application requirements of the industry. Hindalco products are used in roofing,
doors and windows, facades, formwork, structural applications, ceilings, grills, hardware,
shutters, ladders, etc.
Defence
Industrial applications
White goods
11.PLC BASIS:
Since the late 1960's, the Programmable Logic Controller (or PLC) has become an essential
aspect of any automated manufacturing process. In recent times there have been contenders
to replace the PLC but the priniciples and popularity of those early PLC's functions and
concepts have continued unabated. It is essential for many people from the technician to the
engineer to understand these essential pieces of equipment.
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PLC Dev has developed this instruction manual "PLC Basics" in hopes it will serve the
beginner to the advanced user. Our goal is to make it comprehensive as possible, providing
not only the generic principles in all PLC, but to give practical examples from many different
PLC manufacturers. To this end you are welcome to comment on each section by registering
as a user and clicking the "add a comment" link at the bottom of the page.
What is a PLC?
A Programmable Logic Controller, or PLC for short, is simply a special computer device
used for industrial control systems. They are used in many industries such as oil refineries,
manufacturing lines, conveyor systems and so on. Where ever there is a need to control
devices the PLC provides a flexible way to "softwire" the components together.
The basic units have a CPU (a computer processor) that is dedicated to run one program that
monitors a series of different inputs and logically manipulates the outputs for the desired
control. They are meant to be very flexible in how they can be programmed while also
providing the advantages of high reliability (no program crashes or mechanical failures),
compact and economical over traditional control systems.
12.PROGRAMMING A PLC:
In these modern times a PC with especially dedicated software from the PLC manufacturer is
used to program a PLC. The most widely used form of programming is called ladder logic.
Ladder logic uses symbols, instead of words, to emulate the real world relay logic control,
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which is a relic from the PLC history. These symbols are interconnected by lines to indicate
the flow of current through relay like contacts and coils. Over the years the number of
symbols has increased to provide a high level of functionality.
The completed program looks like a ladder but in actuality it represents an electrical circuit.
The left and right rails indicate the positive and ground of a power supply. The rungs
represent the wiring between the different components which in the case of a PLC are all in
the virtual world of the CPU. So if you can understand how basic electrical circuits work
then you can understand ladder logic.
In this simplest of examples a digital input (like a button connected to the first position on the
card) when it is pressed turns on an output which energizes an indicator light.
13-SCADA
Supervisory control and data acquisition (SCADA) is a control system architecture that uses
computers, networked data communications and graphical user interfaces for high-level
process supervisory management, but uses other peripheral devices such as programmable
logic controllers and discrete PID controllers to interface to the process plant or machinery.
The operator interfaces which enable monitoring and the issuing of process commands, such
as controller set point changes, are handled through the SCADA supervisory computer
system. However, the real-time control logic or controller calculations are performed by
networked modules which connect to the field sensors and actuators.
The SCADA concept was developed as a universal means of remote access to a variety of
local control modules, which could be from different manufacturers allowing access through
standard automation protocols. In practice, large SCADA systems have grown to become
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very similar to distributed control systems in function, but using multiple means of
interfacing with the plant. They can control large-scale processes that can include multiple
sites, and work over large distances. It is one of the most commonly-used types of industrial
control systems, however there are concerns about SCADA systems being vulnerable to
cyber warfare/cyber terrorism attacks.
The key attribute of a SCADA system is its ability to perform a supervisory operation over a
variety of other proprietary devices.
The accompanying diagram is a general model which shows functional manufacturing levels
using computerised control.
Level 0 contains the field devices such as flow and temperature sensors, and final control
elements, such as control valves.
Level 1 contains the industrialised input/output (I/O) modules, and their associated
distributed electronic processors.
Level 2 contains the supervisory computers, which collate information from processor
nodes on the system, and provide the operator control screens.
Level 3 is the production control level, which does not directly control the process, but is
concerned with monitoring production and targets.
Level 4 is the production scheduling level.
Level 1 contains the programmable logic controllers (PLCs) or remote terminal units (RTUs).
Level 2 contains the SCADA software and computing platform. The SCADA software exists
only at this supervisory level as control actions are performed automatically by RTUs or
PLCs. SCADA control functions are usually restricted to basic overriding or supervisory
level intervention. For example, a PLC may control the flow of cooling water through part of
an industrial process to a set point level, but the SCADA system software will allow
operators to change the set points for the flow. The SCADA also enables alarm conditions,
such as loss of flow or high temperature, to be displayed and recorded. A feedback
control loop is directly controlled by the RTU or PLC, but the SCADA software monitors the
overall performance of the loop.
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Levels 3 and 4 are not strictly process control in the traditional sense, but are where
production control and scheduling takes place.
Data acquisition begins at the RTU or PLC level and includes instrumentation readings and
equipment status reports that are communicated to level 2 SCADA as required. Data is then
compiled and formatted in such a way that a control room operator using the HMI (Human
Machine Interface) can make supervisory decisions to adjust or override normal RTU (PLC)
controls. Data may also be fed to a historian, often built on a commodity database
management system, to allow trending and other analytical auditing.
SCADA systems typically use a tag database, which contains data elements
called tags or points, which relate to specific instrumentation or actuators within the process
system according to such as the Piping and instrumentation diagram. Data is accumulated
against these unique process control equipment tag references.
Both large and small systems can be built using the SCADA concept. These systems can
range from just tens to thousands of process loops, depending on the application. Example
processes include industrial, infrastructure, and facility-based processes, as described below:
However, SCADA systems may have security vulnerabilities, so the systems should be
evaluated to identify risks and solutions implemented to mitigate those risks.
Supervisory computers
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This is the core of the SCADA system, gathering data on the process and sending control
commands to the field connected devices. It refers to the computer and software responsible
for communicating with the field connection controllers, which are RTUs and PLCs, and
includes the HMI software running on operator workstations. In smaller SCADA systems, the
supervisory computer may be composed of a single PC, in which case the HMI is a part of
this computer. In larger SCADA systems, the master station may include several HMIs
hosted on client computers, multiple servers for data acquisition, distributed software
applications, and disaster recovery sites. To increase the integrity of the system the multiple
servers will often be configured in a dual-redundant or hot-standby formation providing
continuous control and monitoring in the event of a server malfunction or breakdown.
Communication infrastructure
This connects the supervisory computer system to the remote terminal units (RTUs) and
PLCs, and may use industry standard or manufacturer proprietary protocols. Both RTUs and
PLCs operate autonomously on the near-real time control of the process, using the last
command given from the supervisory system. Failure of the communications network does
not necessarily stop the plant process controls, and on resumption of communications, the
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operator can continue with monitoring and control. Some critical systems will have dual
redundant data highways, often cabled via diverse routes.
Human-machine interface
The human-machine interface (HMI) is the operator window of the supervisory system. It
presents plant information to the operating personnel graphically in the form of mimic
diagrams, which are a schematic representation of the plant being controlled, and alarm and
event logging pages. The HMI is linked to the SCADA supervisory computer to provide live
data to drive the mimic diagrams, alarm displays and trending graphs. In many installations
the HMI is the graphical user interface for the operator, collects all data from external
devices, creates reports, performs alarming, sends notifications, etc.
Mimic diagrams consist of line graphics and schematic symbols to represent process
elements, or may consist of digital photographs of the process equipment overlain with
animated symbols.
Supervisory operation of the plant is by means of the HMI, with operators issuing commands
using mouse pointers, keyboards and touch screens. For example, a symbol of a pump can
show the operator that the pump is running, and a flow meter symbol can show how much
fluid it is pumping through the pipe. The operator can switch the pump off from the mimic by
a mouse click or screen touch. The HMI will show the flow rate of the fluid in the pipe
decrease in real time.
The HMI package for a SCADA system typically includes a drawing program that the
operators or system maintenance personnel use to change the way these points are
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A "historian", is a software service within the HMI which accumulates time-stamped data,
events, and alarms in a database which can be queried or used to populate graphic trends in
the HMI. The historian is a client that requests data from a data acquisition server.
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REFRENCES:
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