ACKNOWLEDGEMENT

First of all I would like to thank Aarti Strips Private Limited for providing me an opportunity to work as an
intern in this industry. I am very grateful towards Department of Electrical Engineering, Aarti Strips Pvt.
Ltd. for identifying me as a right candidate as an intern in this factory. I would like to thank all the staffs
who helped me day and night and provided me data for my study. Without them understanding the
process in plant would be tedious. I would like to thank all the personnel who made me feel like home in
this place.

Specially, I would like to thank Mr. Sushant Kumar Guha, AGM and HOD of electrical department of Aarti
Strips for providing me an opportunity to be part of this organization for a short time. I would also like to
thank Mr. Dibas Nepal, Mr. Satya Prakash Dwivedi, Mr. Rajprakash Dwivedi, Mr. R. K. Pandey, Mr. Deevesh
Singh, Mr. Ishant Aery, Mr. Dilip Singh for coordinating with me.

Lastly, I would like to acknowledge the entire factory members, all of my teachers, friends and family, who
have directly and indirectly helped and supported throughout this training period and providing me
platform to work in a competitive environment.

i
ABSTRACT
The report includes all details of the works assigned and completed during 22 days stay at the Aarti Strips
Private Limited, Tankisinuwari, Morang. During this internship period working of different machines,
instruments, sensors, actuators, etc were seen. Also, the production process is studied thoroughly along
with technical specifications. Different unique observations like production rate of Aarti Strips were done.

This report also includes the study of size and placement of instruments in the factory. Also different
maintenance schedule and process seen in the factory is included in this report. Plant layout of different
lines: Color Coating Line, Continuous Galvanizing Line, Cut to Length, Tubemill were seen in the industry.
The organization structure and discipline is well maintained in Aarti Strips

ii
List of Abbreviations
ASPL: Aarti Strips Pvt. Ltd.
MTPA: Metric Ton Per Annum
PPGI: Color Coated Galvanizing Iron Sheets
CGL: Continuous Galvanizing Line
CCL: Color Coating Line
CTL: Cut to Length
HR: Hard Roll
MS: Mild Steel
HRCTL: Hard Roll Cut to Length
MSCTL: Mild Steel Cut to Length
MPM: Meters per Minute
Hz: Hertz
kHz: Kilo Hertz
IM: Induction Motor
SCADA: Supervisory Control and Data Acquisition System
CR: Cold Roll
CRFH: Cold Roll Full Hard
ACC: Accumulator
NEA: Nepal Electricity Authority
RTD: Resistive Temperature Detector
kW: Kilo Watt
W: Watt
RC: Recirculation Fan
LVDT: Linear Voltage Differential Transformer
BR: Bridle
UNC: Uncoiler
PLC: Programmable Logic Controller
IP: Input
OP: Output
DP: Decentralized Peripherals
LIC: Light Emitter Compact
MCC: Motor Control Center
COC: Cut off Carriage
SMPS: Switch Mode Power Supply
PT: Potential Transformer
VT: Voltage Transformer
CT: Current Transformer
Aux: Auxiliary
DG: Diesel Generator
AVR: Automatic Voltage Regulator
TLL: Tension Leveler

iii
List of Figures
Figure 1 Certification [1] ............................................................................................................................... 2
Figure 2 Organizational Structure ................................................................................................................. 3
Figure 3 SCADA of CGL 1 ............................................................................................................................... 7
Figure 4 Staggering ....................................................................................................................................... 9
Figure 5 SCADA of CGL 2 ............................................................................................................................. 10
Figure 6 Staggering of CGL 2 ....................................................................................................................... 12
Figure 7 SCADA diagram as seen of CCL ..................................................................................................... 13
Figure 8 Staggering of CCL .......................................................................................................................... 15
Figure 9 General Production flow chart...................................................................................................... 17
Figure 10 Production Flowchart Pipes ........................................................................................................ 18
Figure 11. Types of Maintenance................................................................................................................ 19
Figure 12 LIC ................................................................................................................................................ 24
Figure 13 LVDT used as Steering ................................................................................................................. 24

iv
List of Tables
Table 1 Similar Industry in Nepal .................................................................................................................. 5
Table 2 Motor Specification of CCL ............................................................................................................. 21
Table 3 CCL Instruments ............................................................................................................................. 23
Table 4 Load Distribution in CCL ................................................................................................................. 25
Table 5 Problem: Bridle 4B motor gearbox coupling freed ........................................................................ 26
Table 6 Problem: Proximity Sensor Position Displaced of Profile 1’s Uncoiler........................................... 26
Table 7 Problem: Bridle 8B motor gearbox coupling freed ........................................................................ 27
Table 8 Problem: Cleaning Section Hot Air Dryer Temperature Issue ........................................................ 27

v
Table of Contents
ACKNOWLEDGEMENT .................................................................................................................................... i
ABSTRACT...................................................................................................................................................... ii
List of Abbreviations .................................................................................................................................... iii
List of Figures ............................................................................................................................................... iv
List of Tables ................................................................................................................................................. v
1. Introduction .......................................................................................................................................... 2
1.1. History and Objectives .................................................................................................................. 2
1.2. Organizational Structure and Hierarchy ....................................................................................... 3
1.3. Products of the company .............................................................................................................. 4
1.4. Unique observation about Company ............................................................................................ 4
1.5. Similar other Steel industries ........................................................................................................ 5
1.6. Technical Specification of ASPL ..................................................................................................... 6
1.6.1 Plants in ASPS ........................................................................................................................ 6
1.7. Plant Layout and Production Process ........................................................................................... 7
1.7.1 CGL (Continuous Galvanizing Line) 1 .................................................................................... 7
1.7.2 Continuous Galvanizing Line 2 ............................................................................................ 10
1.7.3 CCL (Color Coating Line) ...................................................................................................... 13
1.7.4 Pipe Mill .............................................................................................................................. 16
1.7.5 Profile ......................................................................................................................................... 16
1.8. Production Flow Chart ................................................................................................................ 17
1.8.1 General Production flow chart ............................................................................................ 17
1.8.2 Production Flow chart (Pipes) ............................................................................................. 18
1.9. Maintenance And Management Of Equipment.......................................................................... 19
2. Internship Details ................................................................................................................................ 21
2.1 Training Methodology................................................................................................................. 21
2.2 Work Assigned ............................................................................................................................ 21
2.3 Instruments used in CCL ............................................................................................................. 21
2.3.1 Motors in CCL ............................................................................................................................. 21
2.3.2 PLC Instruments in CCL .............................................................................................................. 22
2.3.3 CCL Instruments ......................................................................................................................... 23
2.4 Instruments used in Profile ......................................................................................................... 25
2.5 Load Distribution in CCL .............................................................................................................. 25
2.6 Diesel Room ................................................................................................................................ 25
2.7 Problems Encountered in ASPL Line during my working period................................................. 26
3. Conclusion and Recommendations..................................................................................................... 28
4. References .......................................................................................................................................... 29
 1. Introduction
1.1. History and Objectives
Aarti Strips Pvt. Ltd. (ASPL) traces its origin in April 2000 with installation of single galvanizing line capacity
of 50,000 MTPA at Tanki Sinwari, Ward No. 1 Biratnagar, district Morang, Nepal. ASPL is promoted by four
Indian promoter companies namely (ASL Investment Ltd., Adhunik Investment Ltd., BIC Investment Ltd.
and ESSENN Investment Ltd.) having equal share holding rights.
Aarti Strips (P) Ltd. located at Tankisinwari, Biratnagar is a fully steel manufacturing company associated
with state of the art of facilities and NS 141, ISO 9001-2008 certified company. With the patronage of
esteemed customers industry are poised for growth and expansion in various other locations, which has
been conceived as future plan.
Vision is to meet the ever-expanding demand of esteemed customers through innovation and constant
up gradation to meet the stringent quality requirements in various segments like automotive, white
goods, PEB & construction, General Engineering, Telecommunication etc.
Since its inception, ASPL provide prime quality products in Nepal market, due to that industry got
tremendous response to products. In 2004 industry expand capacity by 100% i.e. 1, 00,000 MTPA from
50,000 MTPA of Galvanizing Iron Sheets.

Figure 1 Certification [1]

ASPL is young agile and professionally managed company with ISO 9001, BIS, NS certified and it is
constantly expanding its capability to fuel its fairy tale journey. After a valuable and remarkable decade
journey at Nepal market. ASPL spread its wings towards a value added products i.e. Color Coated
Galvanizing Iron Sheets (PPGI) in 2012. The installed capacity of Color Coated Galvanizing Line was
approximate 50,000 MTPA.
Earlier there were only three symbolic colors (Color Coated Galvanizing Products) available at Nepal
Market. But ASPL was first in Nepal's history to produce 26 colors along with multicolors sheets. In 2013
we expand further and started production of M.S Black Pipe and ERW Precision Tube. The installed
capacity of said production line is 50,000 MTPA.

Objectives of the industry are:

1. Customer Satisfaction
2. Improved Productivity
3. Maximize Domestic Sales
4. Speedy Delivery

2
 1.2. Organizational Structure and Hierarchy
ASPL is privately owned industry. Following chart explains the organizational structure of ASPL.

Figure 2 Organizational Structure

3
1.3. Products of the company
The products of the Company are Sheets, Colored Sheets, Tubes, and Shutter Profile. Different
products are manufactured with different length, thickness, diameter, shape and size. TMT Rods
are expected to be produced by December.

1.4. Unique observation about Company

Some of the features of the company’s product is listed below
 Mass Production (150000MTPA)
 Proper balance in Physical and Chemical properties
 Less time required for Production
 Consistency in Quality
 Mostly automatic system are applied
 Less Construction Cost
 National and International market

4
 1.5. Similar other Steel industries
Some of the similar industries related to steel manufacturing are listed below with address:
Table 1 Similar Industry in Nepal

S.N Industry Address

1. Jagadamba Steels Tinkune, Kathmandu

2. Panchakanya Steels Krishna Galli, Kathmandu

3. Hulas Industry Pvt. Ltd. Simra, Bara

4. Ashok Steels Pvt. Ltd. Jitpur, Bara

5. Pathivara Steel Industry Birtamod, Jhapa

Pvt. Ltd.

6. Mainawati Steel Duhabi, Sunsari

Industry Pvt. Ltd.

7. Nepal Steel Pvt. Ltd. Exhibition Road,

Kathmandu

8. Laxmi Steel Pvt. Ltd. Tinkune, Kathmandu

9. Hama Iron & Steel Pvt. Tripureshowor,

Ltd. Kathmandu

10. Siddhartha Steel Lumbini Road, Butwal

11. Ratna Steel Industry Pvt. Birjung

Ltd.

5
 1.6. Technical Specification of ASPL
1.6.1 Plants in ASPS

1. CGL (Continuous Galvanizing Line)

There are two CGL lines in ASPS, which continuously galvanizes the sheets. The sheets come to ASPL
as a coil roll of type COLD ROLL FULL HARD (CRFH) of different lengths. This plant is fully automated
with SCADA and equipment’s from ABB and Siemens. This two lines consumes 12000 to 15000 KWh
each on average per day. CGL is two of three big continuous running line in ASPL.

2. CCL (Color Coating Line)

The galvanized sheets from CGL are coated with desired color in this line. This line uses new
technology and equipment’s installed by Rockwell Automation. This line consumes 20000 to
24000KWh per day on average.

3. Profile Machine
This machines are used for making corrugated sheets of desired length and shape. There are five
profile machines in ASPL which are fully automated.

4. CTL (Cut to Length)

They are used for cutting desired length of sheet. Once the length is set, the machine continuously
cuts the sheets in desired size.

5. HR CTL ( Hard Roll Cut to Length)

HRCTL are used to cut large plain sheet of mild steel in desired length. This differs from CTL as HRCTL
cuts thick steel sheet of mild steel.

6. HR Slitter Machine
This machine cuts the roll in different diameters used for making pipes and shutter profile. A roll of
900mm diameter is cut into 12 pieces of different diameters. This plant uses the biggest IM of the
plant of 275KW rating.

7. Tube Mill
There are two tube mill in ASPL, tube mill 1 is modern and uses new technology of accumulation of
slits. Once the slits are formed in pipe shape, the welding of the slits for making pipes is done by using
High Frequency Welding at frequency of 398KHz and welding speed of 35.4 MPM. The frequency and
speed of welding depends of shape and diameter of Pipe.

6
 1.7. Plant Layout and Production Process

1.7.1 CGL (Continuous Galvanizing Line) 1

The control panel view as seen on SCADA of Continuous Galvanizing Line 1 is shown below:

Figure 3 SCADA of CGL 1

Production Process of CGL 1

For the manufacturing of the GC sheet following steps are performed:

a. Uncoiler-1
CR (cold Rolled) Coil are used as raw materials which is kept on mandrel and allowed to pass away to next
section.

b. Uncoiler-2
CR coil is passed through different section so the process of production remains continuous if Uncoiler-1
has no sheet over there.

c. Seam Welding
When the UNC in any of one section is finished the UNC in other section is passed and Seam welding is
done in order to make production continuous.

d. Bridle
There are 3 Bridle consisting of two motors running in opposite direction used for pulling and pushing the
sheet maintaining a synchronized speed in the plant.

7
e. Steering
They are 3 Steering used in the plant which uses a capacitive sensor and is used to maintaining the sheet
in center position as the sheet is running in the plant.

f. Entry and Exit Accumulator

Accumulators are used for reserving the coil. There are about 11 accumulator roller in Upper and lower
section of Entry Section as well as in Exit section. When a sheet is being loaded or being recoiled, a
significant time takes between changing the metal sleeve. So for continuous running of sheets
accumulators are used to accumulate the sheet for significant time or delay in changing metal sleeves.

g. Tank
Different types of tank are used during production process. Alkali tank, Brush tank, hot-rinse tank, acid
tank and cold drink tank are used. They all are used in different sector which each having different
function.
Alkali tank removes dust, grease
Brush tank uses brush roll removes dirt contain after passed to alkali tank
Hot rinse tank pass hot water with high PH value
Acid tank removes high impurities where HCL is used as acid.
Cold-rinse tank passes cold water to the sheet

h. Pre-heater
Sheet Passes to the pre-heater which is at 900 degree Celsius where moisture content is removed.
Preheater is operated by NEA or DG, and RTD is used to measure the heating temperature.

i. Galvanizing Pot (Zinc Pot)

Sheet is dipped in zinc-solution where it gets galvanized as well sheet will be corrosion resistance,
hardened and shining. A splencer typically an air blower is used for maintaining the thickness of the zinc
solution in the sheet. This air blower motor is the heaviest motor of the line of 175kW.

j. Hot air dryer section

Hot air is passed in order to remove impurities present over the sheet. A RC fan is used to maintain even
temperature in the dryer.

k. Printing
This section is divided into two types. One where the logo of Aarti is printed on the sheet. And other prints
detail of the sheet, its diameter, length, weight, etc. The detail is printed using high speed printer, which
is synchronized to the speed of sheet.

l. Staggering
This is a sensor used to detect the edge of the sheet, thus after every roll like 20 roll on the metal sleeve
it positions the sheet to recoil changing its position.

8
 Figure 4 Staggering

m. Recoiler
The recoiling of the sheet is done on the metal sleeve, after the staggering positions the sheet.

9
1.7.2 Continuous Galvanizing Line 2
The control panel view as seen on SCADA of Continuous Galvanizing Line 2 is shown below:

Figure 5 SCADA of CGL 2

Production Process of CGL 2

For the manufacturing of the GC sheet following steps are performed:

Uncoiler-1
CR (cold Rolled) Coil are used as raw materials which is kept on mandrel and allowed to pass away to next
section.

b. Uncoiler-2
CR coil is passed through different section so the process of production remains continuous if Uncoiler-1
has no sheet over there.

c. Seam Welding
When the UNC in any of one section is finished the UNC in other section is passed and Seam welding is
done in order to make production continuous.

d. Bridle
There are 4 bridles consisting of two motors running in opposite direction used for pulling and pushing
the sheet maintaining a synchronized speed in the plant.

10
e. Steering
They are 4 Steering used in the plant which uses a capacitive sensor and is used to maintaining the sheet
in center position as the sheet is running in the plant.

f. Entry and Exit Accumulator

Accumulators are used for reserving the coil. There are about 11 accumulator roller in Upper and lower
section of Entry Section as well as in Exit section. When a sheet is being loaded or being recoiled, a
significant time takes between changing the metal sleeve. So for continuous running of sheets
accumulators are used to accumulate the sheet for significant time or delay in changing metal sleeves.

g. Tank
Different types of tank are used during production process. Alkali tank, Brush tank, hot-rinse tank, acid
tank and cold drink tank are used. They all are used in different sector which each having different
function.
Alkali tank removes dust, grease
Brush tank uses brush roll removes dirt contain after passed to alkali tank
Hot rinse tank pass hot water with high PH value
Acid tank removes high impurities where HCL is used as acid.
Cold-drink tank passes cold water to the sheet

h. Pre-heater
Sheet Passes to the pre-heater which is at 900 degree Celsius where moisture content is removed.
Preheater is operated by NEA or DG, and RTD is used to measure the heating temperature.

i. Galvanizing Pot (Zinc Pot)

Sheet is dipped in zinc-solution where it gets galvanized as well sheet will be corrosion resistance,
hardened and shining. A splencer typically an air blower is used for maintaining the thickness of the zinc
solution in the sheet. This air blower motor is the heaviest motor of the line of 175kW.

j. Hot air dryer section

Hot air is passed in order to remove impurities present over the sheet. A RC fan is used to maintain even
temperature in the dryer.

k. Printing
This section is divided into two types. One where the logo of Aarti is printed on the sheet. And other prints
detail of the sheet, its diameter, length, weight, etc. The detail is printed using high speed printer, which
is synchronized to the speed of sheet.

l. Staggering
This is a sensor used to detect the edge of the sheet, thus after every roll like 20 roll on the metal sleeve
it positions the sheet to recoil changing its position.

11
 Figure 6 Staggering of CGL 2

m. Recoiler
The recoiling of the sheet is done on the metal sleeve, after the staggering positions the sheet

12
1.7.3 CCL (Color Coating Line)
This line coats the desired color on the sheets continuously. This is the longest line in the factory consisting
of 9 Bridles.
The control panel view as seen on SCADA of Color Coating Line is shown below:

Figure 7 SCADA diagram as seen of CCL

Production Process of CCL

The production process of CCL is given below:

Uncoiler-1
Galvanized Coil are used as raw materials which is kept on mandrel and allowed to pass away to next
section. The control of these uncoiler is done by pneumatic system.

b. Uncoiler-2
Galvanized coil is passed through different section so the process of production remains continuous if
Uncoiler-1 has no sheet over there.

c. Stitching
The coils are stitched together with the previous sheet. A hole is made before the stitches, so that the
hole is detected so that the upcoming instruments does not get damaged with the stitches.

13
d. Entry Accumulator
When a coil is being changed, the production would be halted. SO sheets are loaded in accumulator prior
to changing the sheets for the line to be running smoothly.

e. Pre-Treatment Section
Alkali Treatment- Alkali solution cleans the sheet.
Brush Treatment- Chromium removes the oily substance in the sheet.

f. Chemical Coating
The paint is nonmetallic but the sheet is metallic, so the paint would not stick with the sheet, thus for the
coating to stick smoothly, a chemical named Granodine is coated on the sheet.

g. Hot Air Dryer

A electrical heater is used to dry up the chemical coat before primary coating. This system is powered with
NEA bypassed from the control system, as this system was constantly tripping when powered through the
control panel.

h. Prime Coating
Primer Paint ensures better adhesion of paint to surface. It increases paint durability and additional
protection to the system.

i. Finish Coating
It’s the paint that is the true color of the sheet. Load cell determines the thickness of the paint on the
sheet.

j. Finish Oven
A finish oven dries the paint on the sheet. A heater powered from Burning diesel increases the
temperature of the oven. 4 RC fan is used to maintain the temperature in the oven. 2 exhaust fan and 1
incinerator fan is used to control the oven temperature. Also the air to oil ratio is automatically tuned
using PID controller.

k. Cooling Section (Quenching)

Here water is used to cool down the sheet after coming from the oven.

l. Aarti Logo Print

A running roller is fitted with a Aarti logo. Thus printing the logo on the sheet. The printing is disengaged
when stitch comes. The incoming of sheet is detected by the hole made in the stitching section.

m. Exit Accumulation
When a coil is being fully loaded, an new metal sleeve is to be loaded in the recoiler. During this time, the
production would be halted. So sheets are loaded in accumulator prior to changing the sleeve for the line
to be running smoothly.

14
n. Laminating the sheet
The sheet is laminated with plastic, the edge of the sheet is detected by a steering or LVDT.

n. Staggering
This is a sensor used to detect the edge of the sheet, thus after every roll like 20 roll on the metal sleeve
it positions the sheet to recoil changing its position.

Figure 8 Staggering of CCL

o. Recoiler
The recoiling of the sheet is done on the metal sleeve, after the staggering positions the sheet

15
1.7.4 Pipe Mill
Different process and lines used in Pipe mill are given follow:

a. HR/MS Slitter
Mild Steel slitter is one of the machines used to cut the large mild steel coil into the Small coil section
which is used to manufacture the pipe in required length and thickness.

b. HR Coil
The coil which was cut into the HR slitter is passed into the Pinch roller and safety roller.

c. Accumulator
It contains Series of rollers where the HR coil are reserved over there for continuous operation.

d. Tube mill
It contains series of rollers as Leveler roll, Stamping roll, Side guide roll, Film path, High frequency welder,
Sizing head, Truck head, Damping, End finishing. Function of each have their specific function

 Leveler roller is used to roll the MS Coil.

 Stamping roller is used to stamp the company logo.
 Side guide roller is used to bend the mild steel coil in required Dimension. Rollers may vary
according to the Customers demand of pipe.
 High Frequency welder is used to weld the pipe as per required.
 Sizing Head is used to cut the pipe into the required length.
 Truck Head is used to guide the pipe into the damping section.
 Damping section is the pipe storing section.
 End finishing is surface finishing section where surface is made smooth

1.7.5 Profile
There are 5 profile in Aarti Steels, which is used to cut the sheet in requires size and design. The 5 different
profile can cut the sheet in sizes of 3 feet to 30 feet size. On average the sheets run on conveyer and gets
sheared at a speed of 80MPM. 5 profiles are given name as follow:

 Chirange
 Sameo
 J.S. Engg 1
 J.S. Engg 2
 Profile

16
 1.8. Production Flow Chart
1.8.1 General Production flow chart
Following Flow-chart explains the general flow of the process involved in sheet/pipe manufacturing

Figure 9 General Production flow chart

17
1.8.2 Production Flow chart (Pipes)
There are two pipe lines in ASPL. Tube mill 1 is new one and tube mill 2 is a old one. Tube mill 1 uses a
new type of technology in accumulation, while tube mill 2 uses cage accumulator. Other instruments used
in Tube mill 1 and 2 are identical.

Figure 10 Production Flowchart Pipes

18
 1.9. Maintenance And Management Of Equipment
Maintenance Engineering is the discipline and profession of applying engineering concepts for the
optimization of equipment, procedures, and departmental budgets to achieve better maintainability,
reliability, and availability of equipment.

Figure 11. Types of Maintenance

19
Maintenance is carried out at certain intervals depending on the life of specific equipment. Generally, two
types of maintenance are performed.
a. Corrective Maintenance
b. Preventive Maintenance
Corrective maintenance is performed after the equipment have some failure regarding its working
condition.
Preventive maintenance is performed twice every month.
Maintenance is mainly done on Bridle for its coupling arrangement, also in gearbox where bearing, bushes
are checked, in blower grease and bearing are checked. In this maintenance period all of the connections
of each equipment is checked.
Maintenance engineers ensure that industrial machinery and equipment runs smoothly and reliably.
Maintenance management typically involves:

 Planning and undertaking scheduled maintenance

 Responding to breakdowns
 Diagnosing faults
 Repairing equipment
 Supervising engineering and technical staff
 Obtaining specialist components, fixtures or fittings
 Managing budgets
 Maintaining statistical and financial records
 Ensuring compliance with health and safety legislation
 Creating maintenance procedures
 Managing stocks of supplies and equipment.

20
 2. Internship Details
2.1 Training Methodology
Following methods were followed for training in internship period.

2.2 Work Assigned

Many of the work assigned to me on Internship period were based on literature review of the products,
machinery involved, their arrangement and instruments used. Also placement of sensors and their role
were studied thoroughly of three different lines. First, on the supervision with the Project supervisor
schematic plant diagram was to be made which help me to understand each instruments involved in
production to study in depth.

2.3 Instruments used in CCL

2.3.1 Motors in CCL
The following motors were used in the CCL (Color Coating Line) as of their placement on the line from
start of the line.
Table 2 Motor Specification of CCL

Motor(given name) KW RPM

UNC-1 18.5 730
UNC-2 18.5 730
BR 1A 15 1460

21
 BR 1B 18.5 1475
Entry ACC 22 735
BR 2A 15 1460
BR 2B 22 1480
BR 3A 37 1480
BR 3B 75 1480
BR 4A 65 1480
BR 4B 37 1400
BR 5A 30 1475
BR 5B 18.5 1475
BR 6A 15 1460
BR 6B 15 1460
BR 7A 18.5 1475
BR 7B 18.5 1475
BR 8A 18.5 1475
BR 8B 15 1460
Exit ACC 22 735
BR 9A 15 1460
BR 9B 18.5 1475
Recoiler 37 740

Some other motors out of the line in CCL are given below:

 3 Exhaust fan Motors

- Incinerator Exhaust: 75kW; 1475RPM
- Coater Exhaust: 45kW; 1470RPM
- Oven Exhaust: 75Kw; 1475RPM
 4 Recirculation Fans
- Finish RC Fan 1: 55Kw; 1475rpm
- Finish RC Fan 2: 55Kw; 1475rpm
- Prime RC Fan 1: 55Kw; 1475rpm
- Prime RC Fan 2: 55Kw; 1475rpm

2.3.2 PLC Instruments in CCL

The processor used in PLC is LOGIX 5563. Other instruments in the PLC panel are shown below.

 Profibus Scanner
It is an instrument used to function as a DP (Decentralized Peripherals) is used to operate sensors
and actuators via a centralized controller in production line.
 Ethernet IP Module
 Processor: LOGIX 5563
 Controlnet Module

22
  24V Sink I/P Module
 24V Sink O/P Module
 Isolated Analog I/P Module
 Analog I/P Module
 Analog O/P Module

2.3.3 CCL Instruments

CCL is divided into three parts: Entry, Process and Exit. Different instruments is used for controlled
operation of the line. The Instruments used in CCL and their placement/area of operations are given in
table below.
Table 3 CCL Instruments

Instruments Area of Operation

J-type Temperature Transducer Oven
K-type Temperature Transducer Oven
PT 100 Temperature Transducer Alkali Tank
E/P Transducer Oven
E/P Positioner Alkali
Catenary Sensor Oven
Thermocouple (J type) Incinerator
Thermocouple (K type) Incinerator
Flame Sensor (Controller) Incinerator
Pressure Transmitter Incinerator
Pressure Transmitter Oven
Pressure Switch (Low Oil) Incinerator
Pilot Low Pressure Switch Incinerator
Differential Pressure Transducer Oven
Level Switch Quench Tank
Ignition Transformer Incinerator
Temperature Switch (Oil
Temperature) Incinerator
Solenoid Coil ( Pilot gas inline valve) Incinerator
Temperature Controller Hydraulic Power Pack
Pneumatic Coil Power Pack
Brake Limit Switch Line Motors
Pressure Switch Differential Limit
(PSDL) Oven
Modulation Motor Incinerator
Air Purging Valve Incinerator
Panel View Plus 1000 Control Desk
RTD PT 100 Alkali Tank
Position transducer (Micro Pulse) Tension Leveler
Flame Sensor (UV Sensor) Incinerator
Air Automizing Valve Incinerator
Incremental Encoder Accumulator

23
 Absolute Encoder Accumulator
Braking Chopper AC Drive
Hole Detector Transmitter and
Receiver Line
Used as Protective Layer for sheet as
Guard Film final product

 Entry and Exit MCC

7 Contactors are used in Entry MCC and Exit MCC from 15kW to 160 kW with operating
voltage of 380-415V AC and coil voltage of 110V AC.

 There are 10 spare motors of different rating in CCL.

 LIC ( Light Emitter Compact)
- Linear light emitter
- Used for edge detection

Figure 12 LIC
 Steering
- LVDT
Linear Voltage Differential is used as edge detection of the sheet, and according to its position,
the sheet is positioned to center of the sheet, also known as steering.

Figure 13 LVDT used as Steering

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 2.4 Instruments used in Profile
There are 5 profile in ASPL. The basic instruments used in the profile are:

 Incremental Encoder for detecting length of the sheet

 Proximity Switch for the cutter motion: forward/reverse
 Proximity Switch for Uncoiler Motor speed adjustment
 Servo Motor for powering CUT OFF CARRIAGE forward and reverse.
 Forming Motor for Conveyer belt.

Inside the controller of each profile, it consists of different drivers, transforms and are given below:

 Servo Motor Drive

 Forming Motor Drive
 PLC
 SMPS (Switch Mode Power Supply)
 PT/VT
 CT
 Contactors
 Clock

2.5 Load Distribution in CCL

The Load distribution in CCL is given below:
Table 4 Load Distribution in CCL

Name Amp kW
Entry MCC 297 171.47
Exit MCC 186 107.39
Line Drive 125 72.17
Aux Drive 189 109.122
Incinerator Exhaust 53 30.6
Coater Exhaust 37 21.36
Power Distribution Panel 190 109.69
Heater Panel (Bypassed from NEA) 870 502.3
1947 1124.102

2.6 Diesel Room

There are three diesel generators on the plant. Two of which are of 1700KVA and one of 2000KVA. The
diesel generator consist of 1 AVR (Automatic Voltage Regulator) used for automatically maintaining
generator output terminal voltage at a set value under varying load and operating temperature.
On an average the diesel generator consumes 150 L/hr when operating 1 generator.

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There are 9 compressors in the DG room, currently 6 are in operations and 3 are kept to operate when
new plant of TMT is set up.

2.7 Problems Encountered in ASPL Line during my working period

There were many problems regarding maintenance of the line. Some of the notable problems
encountered during my stay in ASPL are given in table beow.
Table 5 Problem: Bridle 4B motor gearbox coupling freed

Problem: Bridle 4B motor gearbox coupling freed

Date 1st August 2018, 11am

Problem Bridle 4B was not taking any load. When Tension Leveler (TLL) engaged, tension shown
Description in SCADA was in negative.

Works The connection of the motor was opened and problem handled to mechanical
Performed department. When problem solves, the motor supply was connected.

Delay Time 40 Mins

Table 6 Problem: Proximity Sensor Position Displaced of Profile 1’s Uncoiler

Problem: Proximity Sensor Position Displaced of Profile 1’s Uncoiler

Date 4th August 2018, 5pm

Problem Uncoiler was unable to rotate due to its proximity sensor displacement.
Description
Works Position of proximity sensor changed with hit and trial method.
Performed
Delay Time 10 Mins

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Table 7 Problem: Bridle 8B motor gearbox coupling freed

Problem: Bridle 8B motor gearbox coupling freed

Date 13th August 2018, 3pm

Problem Description During line running, at 3pm bridle 8B shows 0 torque with maximum line
speed and minimum current. The problem was

Works Performed The connection of the motor was opened and problem handled to
mechanical department. When problem solves, the motor supply was
connected.

Delay Time 1 hour

Table 8 Problem: Cleaning Section Hot Air Dryer Temperature Issue

Problem: Cleaning Section Hot Air Dryer Temperature Issue

Date 17th August 2018, 2pm

Problem Hot Air Dryer temperature was suddenly unable to show at SCADA.
Description
Works We checked and found its thermocouple was not making proper contact with its end
Performed point. So, the contact point was placed properly and then checked and found working
properly.
Delay Time 20 Mins

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 3. Conclusion and Recommendations
Different types of machines, drives, instruments, sensors were observed and production process were
examined, during my 22 days of internship period. This period made me realize different instruments
studied during my college time in real world. From basic of star delta connection to working of thyristers
and importance of feedback to instruments were seen thoroughly in the factory. ASPL gave me technically
sound and professional knowledge which will be very useful in my carrier life. Also ASPL made me realize
collaboration of mechanical and electrical and other field were very necessary to solve a problem, or
introduce a product.

Me, staying at Aarti Strips had an opportunity to be at maintenance day in this short period of time of 22
days. I noticed that in Aarti Strips Pvt. Ltd. If a problem occurs, there was a conflict between departments
like Electrical or Mechanical or other department to be responsible for problem. So I would recommend
that, when a problem occurs, there must be a mutual coordination between departments and solve the
problem within short period of time.

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4. References

[1] "Aarti Strips (P) Ltd," [Online]. Available:

http://aartistrips.com/index.php/profile. [Accessed 02 09 2018].

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