1.

0 Objectives
Industrial visits are an integral part of Engineering and
acknowledgment of technological improvement. The purpose of
industrial visit for students is to provide technical knowledge with the
technological development in the industry and to understand the gap
between the theoretical and practical knowledge that could be
helpful in future. This experience can help students to provide
information regarding functioning of various industries and
associated problems and limitations.

Interfacing with the industry also provide a chance to build

networks and hone their communication skills. Moreover, the
participating organizations also gain by getting refined students from
the respective institute which could also help in improving their
economy.

This project was based on the implementation of electrical

machines in industrial purpose. Our objective was to gather practical
knowledge over the EE 3108 course about induction motors, DC
motors, universal motors, synchronization of alternators, capacitor
motors and maintenance of machines, power factor improvement,
cost analysis etc.

2.0 Introduction
All types of industries are invariably required to install different types
of electrical motors as prime mover for driving process equipment
participating in their respective production line up. The continuous
process of technical development has resulted into availability of
highly diversified types of electric motors.

The characteristics of motors vary widely with the nature of their

application and the type of duty they are expected to perform. For
example, the applications like constant speed, constant torque,
 variable speed, continuous/intermittent duty, steep/sudden starts,
frequent start/stops, etc. should be taken into consideration carefully
when deciding for the type of a motor for that specific application.

To perform this attachment we went to visit The Crescent Jute Mills

Co. Ltd. which is located in Khalishpur, Khulna, Bangladesh. As jute is
called the golden fiber of Bangladesh, there are a lot of jute mills here
and there. So we chose a jute mill to complete our task.

Raw jute in the form of bales are processed in jute mills to produce
hessian, sacking, jute yarn, bags and other useful products. Raw jute
bales from jute fields or suppliers, carried by trucks are unloaded and
stac . To produce jute goods we need to
produce jute threads from raw jute. The procedure involves the
following steps:

To perform these steps we need three phase induction motors with

different ratings such as:

In the selection process, raw jute bales are opened to find out any defect
and to remove the defective portion from the morah by experienced
workers. The bales are assorted according to spin like Hessian weft, Sacking
wrap, Sacking weft etc. After selection, jute are carried to softning section.
In this softening process jute becomes soft and pileable and suitable for
carding.
2.2 Carding
Carding is a combining operation where jute reeds are splitted and
extraneous matters are removed. Jute fibres are formed into ribbon
called "sliver". There are three different carding sections:
1.breaker carding
2.inter carding
3.finisher carding

The Rolls made in Breaker Carding are of different qaulities. These rolls
are brought together to inter carding machine for re-processing .This
will also enhance the regularity Finisher carding machine make the
sliver more uniform and regular in length and weight obtained from the
Breaker carding machine .

The slivers obtained from finisher carding machine is fed on to the first
drawing machine. The first drawing machines makes blending, equalising
the sliver and doubling two or more slivers, level and provide quality and
color. The Second Drawing machine makes more uniform sliver and reduce
the jute into a suitable size for third drawing The Third Drawing machine is
of high speed makes the sliver more crimpled and suitable for spinning.
In the spinning process slivers are elongated and fibres are twisted into
yarn to impart strength. spun yarns in the spinning process are wound onto
Bobbins.

Winding is a process which provides yarn as spools and cops for the
requirement of beaming and weaving operations. There are two types of
winding:
(i) Spool Winding (ii) Cop Winding
Beaming process follows after spool winding. In Beaming operation yarn
from spool is wounded over a beam of proper width and correct number of
ends to weave jute cloth.

Weaving is a process of interlacement of two series of threads called "wrap"

and "weft" yarns to produce the fabric of desired quality. There are
separate looms for hessian and sacking in weaving section. The Hessian
looms, shuttle which contents cops (weft yarn) is manually/ automatically
changed. The sacking looms are equipped with eco-loader to load a cop
automatically into the shuttle.
Damping is the process in which the rolled woven cloth is unrolled and water
is sprinkled on it continuously to provide desired moisture.

Calendering is a process similar to ironing of fabric. After damping the

damped fabric passes through pairs of heavy rollers rendering threads in
fabric flattened and improve the quality and appearance.

Lapping is the process in which Hessian fabrics are folded into the required
size used in "Bale press" operation on the lapping machine.
Cutting is the process where the sacking cloth is cut to the required length
for making bags for different size such as A-Twill bags ,B-twill bags ,etc.

In Hemming process, the raw edges of sacking cloth cut pieces are shown by
folding it with sewing machine. In Herackle sewing the sides of sacking cloth
cut pieces are sown to make a complete bag. In Safety sewing, the sides of
sacking which was sown at the time of Herackle Sewing is again stiched to
enhace the strength of the Bags edge.This kind of stiching is generally done
on FCI bags.
Bags or Bale processing cloths are pressed compactly according to buyers
need.

3.0 Machines and Load Calculations

4.0 Power Flow

5.0 Capacitor Bank and Transformer

6.0 Calculation of required Capacitor Bank

Here,
power factor obtain at a certain time through power factor
meter, cosՓ1= 0.86
Power factor desired, cosՓ2 = 0.99
Required KVAR to improve power factor from 0.86 to 0.99 is
= P × (tanՓ1-tanՓ2)
= P × 0.45
= 2261.46 × 0.45
= 1017.66 KVAR
where, P is the total machines power of manufacturing process

Capacitor Bank available in the substation of this industry is = 1050

KVAR
Capacitor Bank available in the factory section = 362 KVAR
⸫ Total Capacitor Bank available in this industry = 1412 KVAR

7.0 Cost Calculation

Rated Capacity of the transformer = 1500 KVA

In this industry, transformer was loaded at efficiency of 80% ,power
factor = 0.86
∴Peak connectable load capacity of the transformer
= 1500KVA × 0.86 × 0.8
= 1.032 MW

Again,
Maximum efficiency of each induction motor is nearly 75% and
designed to run at 55% of their rated load
 So, actual real power consumed = 2.26 MW × 0.55 × 0.75
= 932.84 KW

Taking per unit price =10.03 taka(at peak hours 5pm-11pm)

= 7.56 taka(at off-peak hour 11pm-5pm)

Industry runs from 8am to 11pm =15 hours everyday and runs 26 days
per month
So, total electricity cost of this industry
= (932.84 × 9 × 26 × 0.75) +(932.84 × 6 × 26 × 0.75)
=31,78,223.2 taka

8.0 Main liabilities of this Industry

 No back-up generator .
 No industrial layout sheet available .
 Control system is manually operated .

 Makes high level of noise pollution .

9.0 Discussion
This project was based on the implementation of electrical machines
in industrial purpose. At first, the process flow of the jute mill industry
was described. Induction motors were applied to operate the
machines. Motor input current, real power, reactive power and
capacitor bank rating for power factor improvement was calculated.
Monthly cost of the industry was calculated. Power flow and circuit
breaker arrangement was discussed. That gives us the total view of
this industry production and maintenance chain. The main liabilities of
this industry involves ; the deficiency of a backup generator, diagram
of the industry was missing , some name plates were burned out
,heavy noise pollution and hunting. This is how we covered this
presentation.