Fauji Cement Company Limited

(FCCL)

Half Yearly Progress Report

Submitted to:
Mr. Amir Habib
D.G.M Electrical & PG
Submitted by:
Muhammad Rahim Irshad
Trainee Engineer

Electrical
Abstract
This report is based on the six month learning and progress in fauji cement as a
trainee engineer in electrical department The objectives were to become familiar
with the organization and to make an identifiable contribution in the electrical
engineering field; and to gain experience in the non-academic activities of the
company, industry standards, ethical practices, and the interactions with the
industrial environment
During the period I was involved in different activities and learn about
the process of cement manufacturing from raw material, Distribution system,
AC motors working and starting principle and their testing and maintenance,
different types of transformer and their testing, Frequency drives and the
maintenance, Relay testing. I also developed of operating VFD and circuit
breaker and cable sizing for electrical power circuits. Furthermore I gained
experience in operational work, industry practices, and the internal and external
activities of the cement industry.
Table of Contents
1 FAUJI CEMENT...............................................................................................................5
1.1 Production Lines:.........................................................................................................5
1.2 Equipment Suppliers:..................................................................................................5
2 Cement:..............................................................................................................................5
2.1 Types of Cement:........................................................................................................5
2.2 Cement manufacturing Process:..................................................................................6
2.3 Department working in Fauji Cement:........................................................................6
3 ELECTRICAL DEPARTMENT.......................................................................................7
4 Power distribution design of FCCL:..................................................................................7
4.1 Line 1:..........................................................................................................................7
4.2 Line 2:..........................................................................................................................8
5 AC Motors:.........................................................................................................................9
5.1 Medium Voltage (MV motors):...................................................................................9
5.2 List of MV motors:....................................................................................................11
5.3 Low voltage (LV motors):.........................................................................................11
5.4 Motors Maintenance:.................................................................................................12
5.5 Installation of Motor:.................................................................................................12
6 Motor Testing:..................................................................................................................13
6.1 Insulation resistance testing:......................................................................................13
6.2 Vibration testing:.......................................................................................................13
6.3 Polarization Index:.....................................................................................................13
6.4 Dielectric Absorption Ratio (DAR):.........................................................................13
7 ABB ASC 800 Drive:.......................................................................................................14
7.1 How to start-up the drive:..........................................................................................15
7.1.1 Start-up Assistant:..............................................................................................15
7.1.2 Limited Start-up:................................................................................................15
8 Relay testing:....................................................................................................................16
8.1 Following relay function is being tested except MV motor relays:..........................17
8.2 For Slip ring MV motor following function is being tested:.....................................17
8.3 Sample result:............................................................................................................18
9 Energy monitoring system:..............................................................................................18
9.1 Energy Monitoring System Components:.................................................................18
10 Transformer:.....................................................................................................................20
10.1 According to design:..............................................................................................20
10.1.1 Hermetically sealed transformer:.......................................................................20
10.1.2 Conservator tank transformer:............................................................................20
10.2 According to voltage level.....................................................................................20
11 Transformer Testing:........................................................................................................20
11.1 DGA:......................................................................................................................20
11.1.1 Purpose:..............................................................................................................21
11.1.2 Fault gases:.........................................................................................................21
11.1.3 Sampling:...........................................................................................................21
11.2 Break down voltage test:........................................................................................21
12 LV panels:........................................................................................................................22
12.1 Component:............................................................................................................22
12.1.1 MStart:................................................................................................................22
12.1.2 MControl:...........................................................................................................22
12.1.3 MLink:................................................................................................................23
12.1.4 MView:..............................................................................................................23
12.2 Parameterization:...................................................................................................23
12.3 M Start Repairing:.................................................................................................24

TABLE OF FIGURES
FIGURE 1 LINE I DISTRIBUTION SYSTEM.....................................................................................8
FIGURE 2 LINE II DISTRIBUTION SYSTEM...................................................................................9
FIGURE 3 MV SLIP RING MOTOR..............................................................................................10
FIGURE 4 MV MOTOR LIQUID STARTER...................................................................................10
FIGURE 5 LUMPS CRUSHER MOTOR..........................................................................................12
FIGURE 6 ACS 800 DRIVE........................................................................................................14
FIGURE 7 REF 542 PLUS RELAY & RELAY HMI.....................................................................17
FIGURE 8 FIRST MODEL OF COMMUNICATION SYSTEM............................................................18
FIGURE 9SECOND MODEL OF COMMUNICATION SYSTEM.........................................................19
FIGURE 10 OIL SAMPLING FOR DGA........................................................................................21
FIGURE 11 MSTART..................................................................................................................22
FIGURE 12 MCONTROL.............................................................................................................22
FIGURE 13 MLINK....................................................................................................................23
FIGURE 14 MNAVIGATE SOFTWARE.........................................................................................24
FIGURE 15 A01 CARD OF MSTART...........................................................................................24
1 FAUJI CEMENT
FAUJI cement is one of the prestigious cement industry in Pakistan. It is also recognized
worldwide for production jobs high strength cement. It is located at village Jang-Bahtar. Fauji
cement consists of two plants line 1 and line 2.

1.1 Production Lines:

Fauji Cement is operating two lines of Cement Plants, Line 1 and Line 2. Line 1 production
started in 1997. It has a capacity of 3700 tons per day (TPD) of clinker. 2nd production line
erection & commissioning completed and plant started in 2011. It has a capacity of 7200 TPD
of clinker.

1.2 Equipment Suppliers:

The plant technology has been supplied by different companies abroad:
1) FLSMIDTH, Denmark (Line 1)
2) TKIS (Thyssen Krupp Industrial Solutions), POLYSIUS AG (subsidiary),Germany
(Line 2)
3) LOESCHE, Germany (Cement Mills Line 2)
4) HAVER & BOECKER, Germany (Packing Plant)
5) ABB Switzerland (Electrical Equipment & PLC)

2 Cement:
Cement is a binder; substance used for construction that sets hardens and adheres to other
materials to bind them together.
Cements may be classified into two groups: this classification is based upon the manner in
which these cements set and harden. Non-hydraulic cements do not have the ability to set and
harden in water & Hydraulic cements are finely ground materials which when mixed with
water set and harden either in air or in water

2.1 Types of Cement:

Fauji cement manufacture five type of cements:
1) OPC
2) SRC
3) Low Alkali cement
4) Pamir cement
5) Muhafiz cement

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2.2 Cement manufacturing Process:

 Cement manufacturing is a complex process that begins with mining (extraction of

valuable minerals or other geological materials from the earth)
 The most important raw materials for making cement are limestone, clay and marl.
These are extracted from quarries by blasting or by ripping using heavy machinery.
Wheel loaders and dumper trucks transport the raw materials to the crushing
installations.
 Crushing is used to reduce the quarried materials to a size suitable for grinding.
 Grinding raw materials that include limestone and clay, to a fine powder in a mill
called raw mill.
 Fine powder is then heated to a sintering temperature as high as 1450 °C in a kiln and
then it is cooled in cooler and the resultant form is known as clinker
 After burning, the clinker is cooled down and stored in clinker silos. From there the
clinker is conveyed to ball mills or roller presses, in which it is ground down to very
fine cement, with the addition of gypsum and anhydrite, as well as other additives,
depending on the use to which the cement is to be put
 The clinker is grinded to a fine powder in a cement mill and mixed with gypsum to
create cement. 

2.3 Department working in Fauji Cement:

 Administration Department
 Mining Department
 Production Department
 Electrical Department
 Mechanical Department
 Quality Control
 Planning

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3 ELECTRICAL DEPARTMENT
Electrical department also holds a key importance in an industry any because all the
equipment’s are operated with electricity. Installation, maintenance, replacement and
repairing of all electrical instruments/equipment are performed by electrical department.
Electrical department is led by DGM electrical followed by Manager, deputy managers,
assistant managers etc.
There are multiple electrical substations and each substation is led by DM / AM
 Main Substation (Grid)
 Crusher/ Storage Substation
 Raw mill Substation
 Kiln /cooler/ coal Substation
 Cement mill Substation
 Packing Substation

4 Power distribution design of FCCL:

Power distribution system of a cement plant begins with the substation of the grid where
power is received two 132 kV Incoming overhead line from wapda line 1 (Wahfatehjhang
feeder) & line 2 (margalla Feeder) There is a mini grid receiving power from main electricity
grid and also from plant’s captive power plant. They have to work simultaneously and hence
should be synchronized when working in parallel, the voltage, frequency and phase must
match
4.1 Line 1:
 Two 20 MVA (ONAN) transformer having tap changer were installed at line 1
 Line 1 (BAY-1) having load of 4.9 MW
 Line 1 (BAY-2) having load of 8.2 MW

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 Figure 1 Line I distribution system

4.2 Line 2:
 40/50 MVA (ONAN/ONAF) at line 2 which step-down the voltage to 6.3KV
 Line 2 divide into critical (8.7 MW) and non-critical (27.8 MW) load
 Line 2 is synchronizing with WHR (12 MW) and backup is provided by wartsilla
(16.3 MW)
 Solar is connected to line 2 (12.5 MW)

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 Figure 2 Line II distribution system

5 AC Motors:
According to voltage level there are two types of AC motor and used in fauji cement
 Medium voltage motor
 Low voltage motor

5.1 Medium Voltage (MV motors):

There are 12 MV motors installed in fauji cement plant and all are wound rotor or slip ring
type.A slip ring motor is a three-phase induction motor, designed to provide high starting
torque for loads with high inertia, while requiring very low current. Wound rotor motors are
also referred to as slip ring motors. The stator of a wound rotor motor is the same as a typical
induction motor, but the rotor has a three-phase winding, with each of the winding terminals
connected to separate slip rings. The slip rings on the wound rotor motor contain brushes that
form an external, secondary circuit (liquid rotor starter) into which resistance can be inserted.
During starting, this resistance is placed in series with the rotor windings. This added
resistance causes the rotor current to run more in phase with the stator current, which
increases the torque that is developed. But added resistance also decreases the current in the
secondary circuit, so a very high starting torque can be produced with low starting current.

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 Figure 3 MV slip ring motor

Figure 4 MV motor Liquid starter

5.2 List of MV motors:

Table 6.1
Area Rating (KW) Voltage Motors

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 2200 6300 Filter Fan
4150 6300 Vertical mill
Cement Mill 2 2200 6300 Filter Fan
4150 6300 Vertical mill
4150 6300 Mill fan
Raw mill 2
4350 6300 Raw mill

Coal mill 2 730 6300 Coal mill

Limestone/Clay Line
2200 6300 Crusher
2
20000 6300 Raw mill
Raw mill 1 2240 6300 Raw mill fan
6300 6300 cement mill
Cement Mill F 450 6300 cement mill fan

5.3 Low voltage (LV motors):

Low voltage motors were controlled by Motor controlled center (MCC) and most of the LV
motors are three phase induction squirrels cage motors.
A squirrel cage induction motor is a type of three phase induction motor which functions
based on the principle of electromagnetism. It is called a squirrel cage motor because the
rotor inside of it.
Squirrel rotor is a cylinder of steel laminations, with highly conductive metal (embedded into
its surface. When an alternating current is run through the stator windings, a rotating
magnetic field is produced. This induces a current in the rotor winding, which produces its
own magnetic field. The interaction of the magnetic fields produced by the stator and rotor
windings produces a torque on the squirrel cage rotor.
In term of mounting LV motors are of two types:
 Flange mounted
 Foot mounted

5.4 Motors Maintenance:

During shutdowns of plant I saw decoupling of motor and Slip ring motors Maintence in
workshop were they change the Drive End (DE) & Non-Drive End (NDE) bearing due the
vibrations and abnormal conditions of motors motor and closely saw the different parts of
motors:
 Phase wound type rotor

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  RTD’S (Temperature Sensor)
 Space Heater (Used to avoid of moisture when motor power off for long period of
time)
 Vibration Sensor
 Weight (for balancing of shaft)
 Encoder (RPM Measurement device)
 Drive End bearing (Ball bearing or Roller Bearing)
 Non-Drive End bearing (Ball Bearing)
 Grease (shell gadus/ alvania)

5.5 Installation of Motor:

During installation of lumps crusher motors and drive were I learn about the connection &
connection of motor and how emergency system of motor installed and how insulation testing
is done using megger

Figure 5 Lumps crusher motor

6 Motor Testing:
6.1 Insulation resistance testing:
Insulation resistance (IR) test measures the total resistance between any two points separated
by electrical insulation. The test, therefore, determines how effective the dielectric
(insulation) is in resisting the flow of electrical current. Such tests are useful for checking the
quality of insulation the output voltage is typically in the range of 50 to 1000 Volts DC

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6.2 Vibration testing:
It is used for preventative maintenance reducing the chance of breakdowns by analyzing any
change in noises or vibration coming from motors any deviation found can then be used to
diagnose and repair problem that could lead to motor failure

Figure 6Vibro pin for motor vibration measuring

6.3 Polarization Index:

Polarization Index, or PI, is a ratio of the mega ohms after 10 minutes divided
by the mega ohms after 1 minute.PIis conducted on HV electrical machine to determine
service condition of the insulation. PI test is conducted especially to determine the dryness
and cleanliness of the insulation. Megger gives required direct (DC) voltage across the
insulator, and it also shows the resistive value of insulation directly in M – Ω and G – Ω
range. We generally use 500 V, 100V. It is always desired to have polarization index of an
electrical insulator more than 2. It is hazardous to have polarization index less than 1.5

6.4 Dielectric Absorption Ratio (DAR):

DAR measurement is a diagnostic test similar to the Polarization Index (PI), but DAR takes
the ratio of the Insulation Resistance usually measured at 30 sec and 1 min (other time
settings are possible) instead of 1 min and 10 min typically of the PI.DAR measurements are
useful for instance when the PI is 2 or less even for new objects under test. In such cases, a
min DAR value of 1.25 is required

Table 7.1

DAR 1.4 or more 1.25-1.0 1.0 or less

Criteria Best Good Bad

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7 ABB ASC 800 Drive:
A variable frequency drive controls the speed, torque, direction, and the resulting horsepower
of a system of an AC motor by varying the frequency supplied to the motor. The drive also
regulates the output voltage in proportion to the output frequency to provide a relatively
constant ratio of voltage to frequency (V/Hz), as required by the characteristics of the AC
motor to produce adequate torque.
 The first step in this process is to convert the AC supply voltage into DC by the use of
a rectifier.
 DC power contains voltage ripples which are smoothed using filter capacitors. This
section of the VFD is often referred to as the DC link.
 This DC voltage is then converted back into AC. This conversion is typically
achieved through the use of power electronic devices such as IGBT power transistors
using a technique called Pulse Width Modulation (PWM). The output voltage is
turned on and off at a high frequency, with the duration of on-time, or width of the
pulse, controlled to approximate a sinusoidal waveform.

Figure 7 ACS 800 Drive

7.1 How to start-up the drive:

There are two start-up methods between which the user can select:
7.1.1 Start-up Assistant:
 Apply the main power.
 Press the FUNC key
 Select the language
 Follow the instruction display on screen

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7.1.2 Limited Start-up:
1) Apply main power
2) Press PAR to select the Parameter Mode of the panel and enter into parameter number
99.
3) 99.01 –Language (For language selection)
4) 99.02-Select the Application Macro (the default setting is set on factory).Application
macros are preprogrammed parameter sets

Table 8.1

Marcos Application
Factory Ordinary speed control Application where no & multiple speed control
constant is used
Hand/Aut Speed control application where switching between two external device
o is possible
PID Closed loop control system Pressure level & flow control
control
Torque Torque control application Switching b/w torque and speed is possible
control
Sequential Speed control application in which speed seven reference constant &
control two acceleration and ramp possible

5) 99.04-Select the motor control mode.

DTC is suitable in most cases.

 DTC is a method used in variable-frequency drives to control the torque and thus
finally the speed of three-phase AC electric motors

The SCALAR control mode is recommended for:

 multimode drives when the number of the motors connected to the drive is variable
 when the nominal current of the motor is less than 1/6 of the nominal current of the
inverter
 When the inverter is used for test purposes with no motor connected.

6) 99.05- motor nominal voltage

7) 99.06-motor nominal current
8) 99.07-motor nominal frequency
9) 99.08-motor nominal speed
10) 99.09-motor nominal power
11) 99.10-ID Run

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The ID Run (Standard or Reduced) should be selected if:
 The operation point is near zero speed
 Operation at torque range above the motor nominal torque within a wide speed
range and without any measured speed feedback is required. The Reduced ID Run is
to be performed instead of the Standard if it is not possible to disengage the driven
machine from the motor
 If parameter values changed before the ID Run, check that the new settings meet the
following conditions:
o 20.01 MINIMUM SPEED < 0 rpm
o 20.02 MAXIMUM SPEED > 80% of motor rated speed
o 20.03 MAXIMUM CURRENT > 100%
o 20.04 MAXIMUM TORQUE > 50%

8 Relay testing:
This test conducted by prescon on MV panel ABB REF542 relay in fauji cement. The
objective was primarily to focus on the checking the protection scheme or continuity of relays
and circuit breaker tripping mechanisms subjected to electrical faults
The test consist of applying appropriate input to the relay under test and measuring the
performance to determine that relay is operate at the present time delay under fault conditions
while comparing the tripping time of relay with relay tester .
These are required to identify equipment failure and degradation in service so that corrective
action can be taken because a protection scheme operate only in fault condition defects may
not be revealed for a significant period of time, until a fault occur periodic testing assist in
detecting fault that would otherwise remain undetected until a fault occurs
8.1 Following relay function is being tested except MV motor relays:
 Over current high
 Over current low
 Over current instantaneous
 Under voltage
 Gnd.non dir. Low
 IDMT extremely inverse

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8.2 For Slip ring MV motor following function is being tested:
 Over current high
 Over current low
 Over current instantaneous
 Under voltage instantaneous
 Gnd.non dir. Low
 Unbalanced load
 Thermal over load
 Number of starts

Figure 8 REF 542 plus Relay & Relay HMI

8.3 Sample result:

Table 8.3

Relay Preset(relay) Time delay in Injected Tripping time in

Function relay (sec) Relay tester(sec)
O/C inst 2.6 In 0.17 3A 0.162
Gnd 0.05 In 0.2 0.10 A 0.205
O/C high 1 In 0.7 1.2 A 0.7
O/V Inst 1.03 In 1.5 0.90 A 1.5

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9 Energy monitoring system:
We were facing problem of energy consumption data reporting system hanging after week or
two. Which resulted in delay in DPR (daily production report) so we use to reset PLC CP
(communication Processor) to restore data communication for energy monitoring. But for
resetting CP we also have to stop plant to reset PLC communication. Our management
decided to separate energy monitoring system from main PLC to avoid plant stoppage during
trouble shooting of energy monitoring system. Electrical department was given task to
separate the energy monitoring from main PLC communication.
9.1 Energy Monitoring System Components:
1. ABB Ref542 Plus
2. Carlo Gavazzi Energy Meters
3. ABB Rex 640
4. Link 150 (Gateway)
5. USR-DR302 (Gateway)
6. Spider II
7. HUB
8. PC

Figure 9First Model of communication system

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Figure 10Second Model of communication system

10 Transformer:
The working principle of a transformeris very simple. Mutual induction between two or more
windings allows for electrical energy to be transferred between circuits.

10.1 According to design:

Two types of transformer used in distribution system
10.1.1 Hermetically sealed transformer:
Hermetically sealed transformer is a transformer design which has no conservator. Here the
dielectric insulating fluid in the transformer tank is completely sealed and is in zero contact to
the atmosphere. The design avoids air in the transformer tank thereby avoiding oxidation of
the dielectric fluid. Relay used in hermetically sealed transformer is DGPT2 relay (Discharge
gas, pressure, temperature) four different types of protection
DGPT2 SETTING TRIPPING
Alarm 90 C
Tripping 100 C
Pressure 0.10 bar

10.1.2 Conservator tank transformer:

This is a cylindrical tank mounted on supporting structure on the roof the transformer main
tank. The main function of conservatortank of transformer is to provide adequate space for
expansion of oil inside the transformer. This transformer having  Buchholz relay
whose purpose is to give the protection to a transformer from the different faults happening in

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the transformer like the Short circuit, inter-turn, core, incipient, etc. This relay will sense
these faults and shuts the alarm circuit.

10.2 According to voltage level

Transformer step down voltage in two different voltage level

 One transform voltage from 6.3kv to 440V which give supply to LV panels
 VVVF transformer step down voltage from 6.3kv to 725V which give supply to
drives

11 Transformer Testing:
11.1 DGA:
Dissolved gas analysis (DGA) is the identification, measurement, and interpretation of the
gases dissolved in the insulating liquidTransformer mineral oils are mixtures of many
different hydrocarbon molecules, and the decomposition processes for these hydrocarbons in
thermal or electrical faults are complex. The fundamental steps of gas generation are the
breaking of carbon-hydrogen and carbon-carbon bonds. Active hydrogen atoms and
hydrocarbon fragments are formed. These free radicals can combine with each other to form
gases, molecular hydrogen, methane, ethane, etc
11.1.1 Purpose:
The underlying purpose of DGA, in addition to the more obvious purpose of attempting to
detect and identify a possible fault, is to improve safety and equipment reliability while
reducing cost.
11.1.2 Fault gases:
The principal gases used in identification of faults (so-called “fault gases”) are hydrogen
(H2); methane (CH4); ethane (C2H6); ethylene (C2H4); acetylene (C2H2); carbon monoxide
(CO); and carbon dioxide (CO2). Oxygen (O2) and nitrogen (N2) are also measured and used
in the interpretation, although they are not fault by-products
11.1.3 Sampling:
To minimize gas loss and air contamination, a gas-tight glass syringe is the preferred
sampling vessel.

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Figure 11 Oil sampling for DGA

11.2 Break down voltage test:

The dielectric strength of transformer oil is also known as the breakdown voltage (BDV) of
transformer oil. Breakdown voltage is measured by observing at what voltage, sparking
strands between two electrodes immersed in the oil, separated by a specific gap. A low value
of BDV indicates presence of moisture content and conducting substances in the oil. Or
measuring BDV of transformer oil, portable BDV measuring kit is generally available at site.
In this kit, oil is kept in a pot in which one pair of electrodes are fixed with a gap of 2.5 mm
(in some kit it 4mm) between them. Now slowly rising voltage is applied between the
electrodes. The rate of rising voltage is controlled at 2 KV/s and observe the voltage at which
sparking starts between the electrodes Minimum breakdown voltage of transformer oil or
dielectric strength of transformer oil at which this oil can safely be used in transformer, is
considered as 30 KV.

12 LV panels:
Lv panel installed in kiln & cooler/coal mill are of ABB
MNS iSpart of the ABB Low Voltage Switchgear solution uses the well proven ABB
Compact, space-saving design, Easy project and detail engineering through standardized
components Earthquake-, vibration- and shock-proof designs are available, Easy retrofitting
without the need for switchgear de-energizing, Maintenance-free busbar construction,and
High operational reliability and availability Optimum personal protection. The main function
of this panel is to control, monitor, and protection
12.1 Component:
12.1.1 MStart:
The power module MStart / MFeed comprises of the electrical isolator, the short circuit
protection (fuses or circuit breaker), contactor and any electrical control equipment and status
indication. , The sensor module (measuring the electrical values, which are made available to
the process via the Control processor module

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 Figure 12MStart

12.1.2 MControl:
The processor performing all the protection, control functions and monitoring functions. It
sends and receives information to and from the MStart / MFeed via an internal bus. I/O
interface modules providing an interface to external components for both control and
indication

Figure 13 MControl

12.1.3 MLink:
The interface module MLink serves for the serial gateway interface to higher level systems
which communicate through the internal bus to all MControl modules.

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Figure 14 MLink

12.1.4 MView:
A local Human System Interface MView is available to monitor the MNS iS status and
display information for each connected motor / feeder.
12.2 Parameterization:
The Microsoft Windows based software application Navigate can be used to parameterize
MNS iS from a convenient location outside the switch room environment. The PC is
connected via Ethernet network topology to the MLink devices in this network.
Capabilities:
 User settings/ Access control
 Parameterization, Configuration and Download
 Diagnostic function
 Archive/ Restoration/ Reports of project data
 Switchgear Arrangement overview
 Guidance by Online help

Figure 15MNavigate software

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12.3 M Start Repairing:
Mostly MStart A01 and A02 become faulty and module stop working so we change the
MStart module cards and repair this card as well after changing the parameter parameterized
the module and download the application and configure the module and test run the to check
the show any thermal fault or phase balancing after running some time.

Figure 16 A01 card of MStart

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