Outline

Introduction
Power receiving and distribution system
Electric motors
Starting Methods for Induction motors
Sensors
Transmitter
Uninterrupted Power Supply
Inverter
Programmable Logic Control
Power factor correction
Circuit breaker
 INTRODUCTION

Background of the company

 The company is located in northern part of Ethiopia11km away from

Mekelle the capital city of Tigray regional administrative which is
783 km far from the capital Addis Ababa.
 The company was established in 1993 G.C and it is proposed to
produce a maximum 900,000 tons per year. Currently it produces
about 845,280 tons per year.
 MBMP has two lines line1 and line2 and uses large amount of power
supply from ELPA which is about 132KV (50MW).
 Now a day the campany produce four types of cements these are:
1. OPC-ordinary Portland cement
2. PPC-Portland pozzoland cement

3,PLC-portland limestone cement

4.LHHS-low heat high sulfur
 Power Receiving and distribution system
 As we have seen Messebo cement factory it receives 132 KV from Latchi and
enters to the Messebo Substation and it passes different controlling systems,
like breakers, isolators, ear thing protections and current and voltage
transformers and other matters.
 The 132 kv after passing these controlling systems entering to the step down
transformer and steps down to 6kv and 6.3.

1. Surge Arrestor: - Used for over voltage protection. For instance if the voltage is
above 132KV it detects and makes grounded.
2. Voltage transformer: - It is connected in parallel and uses to send data to
computer for measuring and protection of voltage.
3. Disconnector: - it uses to disconnect the system if problem is occurred.
CONT…
4. Current transformer: - It is connected in series and uses for
measuring and protection of current.
5. SF6 Circuit breaker: - It is a circuit breaker which operates
manually and automatically.
6. Bus Bar: - It is a horizontal bar uses to distribute current
equally.
7. Power transformer: - It contains silage to absorb humidity
and oil for cooling system. Main function of this
transformer is to step down132KV to 6.3KV & 6kv.
8. Earthing transformer: - uses to protect over voltage after the
power transformer step down to required voltage level.
 Electric motor
 An electric motor is an electric machine that
converts electrical energy into mechanical energy.
 motors are broadly classified into two categories
based on the power source as follows:
DC Motors
AC Motors
 DC MOTORS
 DC motors have been used in industrial
applications for years Coupled with a DC drive, DC
motors provide very precise control DC motors can
be used with, kiln.
AC Motors
 are used worldwide in many applications to
transform electrical energy into mechanical energy.
CONT…
There are many types of AC motors, but three phases AC induction motors,
the most common type of motor used in industrial applications. This type of
motor has three main parts.

Rotor
Stator
Enclosure
 The stator and rotor do the work, and the enclosure protects
the stator and rotor.
 According to their construction of rotors three phase motors
can be classified in to two groups:
1. Squirrel cage induction motor
2. Wound rotor motor (slip ring motor)
CONT…
1.Squirrel cage induction motors
 These motors are the most widely used type. It consists of copper or
aluminum bars surrounded in rotor slots; each bar is short circuit by end
rings permanently. Hence it is not possible to add any external resistance
in series with the rotor circuit for starting purpose.
 These types of induction motor are very rugged, durable & almost
maintenance free. Due to these reasons downhill belt conveyor
derived by this type of motor since it uses variable frequency drive
system.
2. Wound rotor motor (slip ring motor)
 wound rotor winding terminates in slip rings mounted on the rotor shaft.
Brushes are riding on slip ring, and during the starting period of the motor
they are connected to a three phase resistance bank .
 Sensor
 A sensor is a device that converts a physical condition into an
electrical signal for use by PLC. Sensors are connected to the inputs
of PLC‟s .A push button is one example of a sensor that the push
button to the PLC indicating the condition (open/closed) of the
push button contacts.
 Type’s sensors that we have seen in the company are as follows:

1.Temperature sensor
 The temp sensor is the “nervous system” of the controller in
the company. The controller uses the sensor signal to decide
whether to turn the heater on or off to maintain the desired
set point temp.
• CONT…
The four categories of trmperature
 Thermo resistor
 It is used for measuring bearing temperature ,for instance in ventilators
and gears ,and the flexible length of the combined cable and sensor
makes it applicable for measuring oil temperature in the oil sump in
symetro gears.
 Thermocouple
 Are by far the most widely used type of sensor in industry. They are very
rugged and can be used from sub-zero temp to 2000 0c.
 Resistance temp device
 Is a sensor whose reseistance changes fairly linearly as temp
change. They are used up to 650 0c.
 Sem scanner (IR sensor)
 It is the kiln shell temperature sensor in which it measures
the T0 using rays.
CONT…
2.Load cell
A Load cell is a type of sensor or transducer which is
used to convert a given force to electrical signal.
3. Sway sensor
Is a type of sensor which is used to prevent the
material appropriately mounted in the conveyor
system.
CONT…
4.Speed monitor
• Speed monitor is used to indicate the health of the conveyor and
sends a signal to central control room or central control system.

5.Rope switch
• This kind of sensor is used to switch off the conveyor system
manually at the emergency case.
6.Level sensor
• This kind of sensor is used to measure the amount of raw material
in the bin. For instance if the bin is full the raw material could be
traveled to another bin.
Transmitter
A roduce an output signal,often in the form of a 4-20 mA
eletrical current signal,although many other options using
volatage,freqency,pressure.
 This signal can be used for informational purposes,or it can
to a PLC,Lab view or other type of computrized
controller ,where it can be interpreted into readable valus
and used to control devices and processes in the system.
 INVERTOR
 Electrical power is usually transmitted and used in the
form of alternating current. An inverter is a power
electronic apparatus which converts DC to AC, allowing the
DC power from these generators to be used with ordinary AC
appliances, and/or mixed with the existing electrical grid.
 DC-AC power inverter is a circuit which modifies an
input varying or noncurrent (DC) to an alternating current
(AC) of a specified voltage and frequency, and a regulated DC
voltage.
 Uninterrupted power supply
 Uninterruptible Power Supplies (UPSs) provide immediate
power back-up to sensitive electronic and electrical
equipments, where an unexpected power loss could lead to
unwanted outcomes.
 They usually bridge the connected equipment between
the utility mains power and other long term back-up
power systems like generators and batteries. Usually
UPSs run off (run away) battery power when the utility
mains power is absent.
CONT…
Features of Uninterrupted Power Supply
 Low THD sinusoidal input current and unity power factor.
 High reliability.
 Electric isolation of the battery, output, and input.
 Low maintenance.
 Low cost
 Programmable Logic Control
 PLC provides ease and flexibility of control based on programming and
executing logic instruction.
 The structure of a PLC can be divided into four parts. They are
input/output modules; central processing unit (CPU), memory and
programming terminal.
 Although PLCs are similar to 'conventional' computers in term of
hardware technology, they have specific features suited for industrial
control:
 Rugged, noise immune equipment;
 Standard input/output connections and signal levels;
 Ease of programming and reprogramming in-plant;
 Capable of communicating with other PLCs, computers and intelligent
devices;
CONT…
1.I/O modules
 The input/output unit of PLCs handles the job of interfacing high power
industrial devices to the low-power electronic circuit that stores and
executes the control program.
2.Memory unit
 is where the program is stored that is to be used for control actions..
3.Programming terminal
 used to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.
4.Central processing unit
an acronym used for the central processing unit of a computer.
CONT…
Advantages of PLC‟s over hard wired control:
 Smaller physical size than hard – wire solutions
 Easier and faster to make changes
 Applications can be immediately documented
 Applications can be duplicated faster and less expensive
CONT…
 Digital input
 A digital input is an input that is either in an ON or OFF
condition.
 Analog input
 Is an input signal that has a continuous signal. Typical analog
inputs may vary from 0 to 20 milliamps, 4 to 20 milliamps or 0 to
10 volts.
 Digital output
 Is an output that is either in an ON or OFF condition.
 Analog output
 Is an output signal that has a continuous signal.
 CIRCUIT BREAKERS

 Circuit breakers are a type of switch designed to disrupt

electrical current when an overload or short occurs.
 HV Circuit-Breakers
 They are designed to use as interrupting devices both
in normal operation and during faults.
 Medium-voltage circuit breakers
1. Vacuum Circuit-Breakers
• vacuum circuit-breakers are predominant in medium
voltage levels • They are also considered as maintenance-
free circuit-breakers due to their simple and reliable design.
CONT…
1.SF6 Circuit-Breakers
• High dielectric withstand characteristic.
• At normal conditions, SF6 is inert, non-flammable, non-
corrosive, odorless and nontoxic.
Low voltage circuit breakers
 circuit breakers are made for DC applications. DC requires
special because the arc is continuous unlike an AC arc.
 POWER FACTOR (PF)
 most ac electric machines draw apparent power in terms of
kilovolt amperes (KVA) which is in excess of the useful power,
measured in kilowatts (KW), required by the machine.
 The ratio of these quantities (KW/KVA) is called the power
factor cosØ and is dependent on the type of machine in use.
POWER FACTOR IMPROVEMENT
• The apparent power (KVA) in a.c. circuit can be resolved into
two components,
1.the in-phase component which supplies the useful power
(KW),
2.wattless component (kVAr) which does no useful work.
CONT…
Advantages of Power Factor Improvement
• Reduction of electricity bills.
• Reduction of voltage drops in long cables.
• Reduced electrical burden on cables and
electrical components.
 Starting Methods for Induction Motors
 There are two types of motors used in the cement factory. The
two types of motors are slip ring and squirrel cage motors. For
the protection of these motors from over current different
starting techniques are used. These starting techniques are based
on the motor status or data.
 The starting techniques are:
• Direct on line
• Star delta
• Frequency converter
• Liquid starter
• Soft starter
• Rotor starter
CONT…
1. Direct on line (DOL)
 The starting equipment consists of only a main contactor and
thermal or electronic overload relay. The disadvantage with
this method is that it gives the highest possible starting
current. This is normally used for small rating squirrel-cage
motors and the most application areas are like compressor,
conveyor belt, centrifugal fan &pump.
2. Star-delta (Ү-∆)
 this is a starting method that reduces the starting current and
starting torque. The device normally consists of three
contactors, an overload relay and a timer for setting the time
in the star-position (starting position).
CONT…
3. Frequency converter
 this is usually called variable frequency drive (VFD).
 The drive consists primarily of two parts, one which converts AC
(50 or 60 Hz) to DC and the second part which converts the DC
back to AC, but now with a variable frequency of 0-250 Hz. It is
used to vary speed of the motors.
4. Rotor starter
 if direct online starting is not permitted because of the high
starting current must be limited and the starting torque with star-
delta starting is too low a slip ring motor may be used.
CONT…
5. Liquid starter
 this type of starting method uses water as a resistance to
minimize the starting current and then it becomes out of the
use after the motor starts to run.
6. Soft starter
 A s soft starter has different characteristics to the other
starting methods. It has thyristors in the main circuit, and
the motor voltage is regulated with a printed circuit board.
 The soft starter makes use of the fact that when the motor
voltage is low during start, the starting current and starting
torque is also low.
•THANK You!