This is to certify that SURYAKANT TRIPATHI of

NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR has

successfully completed his project on BELT WATCH
SYSTEM FOR CONVEYOR APPLICATION under my
supervision from 21st May 2015 to 23rd June 2014.I wish all
the best for his future.

Mr. AMIT ROY(guide) CHARU KHULLAR

In- charge
RMM DEPARTMENT ,
Vocational raining
ELECTRICAL MAINTENANCE Tata Steel Ltd
TATA STEEL JAMSHEDPUR
I FEEL PRIDE TO EXPRESS SINCERE AND INDEBTEDNESS TO MY GUIDE
MR. AMIT ROY MANAGER OF RMM DEPARTMENT IN COAL SECTION ,
TATA STEEL ,JAMSHEDPUR, FOR PROVIDING THE NECESSARY FACILITIES
AND ENCOURAGEMENT DURING THE COURSE OF PROJECT WORK.
I’M THANKFUL TO HIM FOR HIS SUGGESTIONS AND CONSTANT
ENCOURAGEMENT FOR MAKING THE REALM OF DREAM INTO A SUCCES
LAST BUT NOT THE LEAST,WE WOULD LIKE TO THANK FOR OUR
COLLEGE ADMINISTRATION FOR PROVIDING US THIS GOLDEN
OPPORTUNITY TO UNDERGO TRAINING IN SUCH A PRESTIGIOUS
INDUSTRY OF INDIA,TATA STEEL,JAMSHEDPUR.
SURYAKANT TRIPATH
STUDENT, DEPARTMENT OF ELECTRICAL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR
VT20151032
1. OVERVIEW OF TATA STEEL
2. RAW MATERIAL MANAGEMENT
3. CUSTOMER OF RMM
4. BLAST FURNACE & COKE PLANT
5. THE BELT WATCH SYSTEM
6. CONCLUSION
7. REFRENCES
• Tata Steel Limited (formerly Tata Iron and Steel
Company Limited (TISCO)) is an Indian
multinational steel-making company headquartered
in Mumbai, Maharashtra, India, TISCO is a
worldwide steel industry founded in 1907 by Dorabji
Tata.. TISCO stands for Tata Iron and Steel
Company Limited.

• Tata Iron and Steel Company was established by

Dorabji Tata on August 25, 1907, as part of his father
Jamsetji's Tata Group. On February 12, 2012 Tata
Steel completed 100 years of steel making in India.
• It was the 12th largest steel producing company in
the world in 2012. with an annual crude steel
capacity of 23.8 million tones, and the second largest
private-sector steel company in India (measured by
domestic production) with an annual capacity of 9.7
million tones after SAIL.

• Tata Steel has manufacturing operations in 26

countries, including Australia, China, India, the
Netherlands, Singapore, Thailand and the United
Kingdom, and employs around 80,500 people.
• Its largest plant is located in Jamshedpur, Jharkhand
Tata Steel acquired the UK-based steel maker Corus
which was the largest international acquisition by an
Indian company till that date.

• The company changed its name from TISCO to Tata

Steel in 2005. Tata Steel primarily serves customers
in the automotive, construction, consumer goods,
engineering, packaging, lifting and excavating,
energy and power, aerospace, shipbuilding, rail and
defence and security sectors.
• Raw material handling department is a part of
raw material and iron making group.

• The department is the prime feeder of bulk raw

material to iron making & steel making
production departments. The department is
basically bridging the gap between the supplier
and the consumers.
• The mission is to ensure right type of raw
materials in right quantity at right place with
minimum service charge so that production
department could run their plant at optimal level.

• The department’s role is to coordinate with the

suppliers & the service providers like Railways
& transporters in such a way to avoid production
loss on account of Raw Materials the minimum
Inventory of raw Materials inside the works.
1. Blast furnaces
A-F blast furnace
G blast furnace
H blast furnace
I blast furnace
2. Coke plant
• Battery 8,9
• Battery 5,6,7
• Battery 10 & 11
Generally any industrial work consists of a
bulk transfer of products from one place
to other.
These products can’t be transferred by
crane or luggage trucks as there is
continuous requirement of the product.
A steel factory require coal as a fuel for
continuous ignition purposes.
Hence for the continuous transfer of raw
materials in steel industry like coal, coke
cynter etc are transferred from one
place to another via CONVEYOR BELTS.
These belts are totally based on the
principle of conversion of rotational
kinetic energy to translational kinetic
energy.
The conveyor system consists of
1. Pulleys
2. Belts
3. Motors
4. Rollers(for generate pulses)
5. Protection switches like pull chord switch, belt
snap switch, belt snap switch etc.
6. A display board to indicate the status of the
protective switches.
7. Sensor module and termination module
8. A PPI panel which receives the trip signal and
give a logic signal to PLC.
1. The pulleys act as a medium to convert
rotational K.E to translational K.E.
2. Belts are used to transfer raw materials or
the required products from one place to
other.
3. Motor’s shaft is coupled with the pulleys
axis with certain gear arrangement to
provide require speed and torque
Generally induction motors of high slip is
used for this purpose since the running
and starting characteristics of the motor
is influenced by the load.
High slip motors also improve the load
sharing among directly coupled motors
and reduce the effect of belt stretching.
Adequate power supply must be fed to the motors so
that the stretch to slip ratio must not cross beyond
certain limits.
The gearing system with the motors will change
depending upon the type of applications.
For high speed belts with low weight of raw materials
per foot a large gear coupled with the motor shaft
whose teeth is connected with the teeth of small
gear attached directly with the axis of pulley.
For high torque applications with heavy weight of raw
materials per foot a small gear coupled with the
motor’s shaft. It’s teeth connected with the teeth of
large gear which is attached directly to the axis of
the pulley.
4. Rollers are used as a sensing element to
detect appropriate speed and if the speed
reach beyond permissible limits it will send
inappropriate signals(pulses) to the
controller which will detect the over and
under speed conditions makes the whole
system to switch off. Under normal
conditions since 4 plates are attached to
the roller wheels it will send 4 pulses per
revolution. If the speed go beyond
permissible limits it’ll not send 4 pulses to
the controller and in this way the controller
will understand the fault.
There is a proximity sensor which act as a
switch when one blade pass through it
and there is a setting in PLC that it
receives a fixed amount of pulses in a
given interval of time(NTD). It is
approximately 6 seconds overall. 1 sec in
field and 5 seconds form PLC. If the pulse
is not given in this time the conveyor is
turned off
 There is a controller board for zero speed
switch which contain a red led when
glows means there is a fault(reduction in
speed), the yellow led flashes at the
same frequency as that of sending of
pulse by the proximity switch. The green
led has the necessarily to glow or the
conveyor has to be shut off.
 There is a transformer also inside the controller
board which converts the incoming 220 volts to
110 volts to the conveyor.
 ITD(initial time delay):- For the first 5 seconds
the motor must be in running position so as to
make up speed and can’t be stopped during
this time
 NTD(normal time delay):- After 70 percent
reach of speed a normal time delay is set in
PLC so that it will get exactly one pulse during
this time period under normal running
conditions.
The permissible range of speed is 70 to 100
percent of the rated speed of the motor.
In case of starting conditions the raw
material is fed into the belt above 70
percent of the rated speed. If the speed
go beyond that level, there is ZSS(zero
speed switch) which operates makes the
conveyor to shut down immediately.
Generally what happens there is some
amount of metal involved in raw
materials(which need to be filtered out
after a certain number of steps) these
traces of metals are responsible for the
wear and tear of belt due to which most of
the raw materials fall in ground led to heavy
loss. The rollers also provide a protection to
these type of problems. Yet there is another
solution for this problem there is a BELT SNAP
switch which operates when some material
fall due to torn of belt on a rope provided
below the belt.
5. Protection switches are used to make protection of
belt from wear & tear and inappropriate
positioning. Generally there are two types of
protection switches mainly in conveyor system.
Automatic protection which involves Belt Sway
Switch(BWS) which operates automatically when
there is an inappropriate positioning of belt
Manual protection involves Pull Chord Switch(PCS)
which is operated manually. When somebody sees
any inappropriate positioning of belt he can
operate that switch and the conveyor system goes
turn off.
6. The display board of the
protection panel involves
three 7 segment displays
which represent the status of
the protection switches. The
representation is just like:-
P AC pull card loop healthy.
B AC belt sway loop healthy.
P SC pull card loop cable
shorted.
B SC belt sway loop cable
shorted.
7. The sensor module(BW7011C) senses the
action taken with the pull chord(when
somebody pulls it, then senses) and
sends the display board a signal about
it’s pull chord no and the display board
display the pull chord number being
operated.
The information which it gives to the
display unit depend on the pulse width
modulation
 What is pulse width modulation ?
• Output signal alternates between on and off within
specified period
• Controls power received by a device
• The voltage seen by the load is directly proportional
to the source voltage.
Definitions
• Duty Cycle: on-time / period
• Vlow is often zero

VAVG  DV HI  (1  D)VLOW
 • Types of Pulse Width
•Leading edge fixed, tailing edge modulated
•Pulse center fixed, edges modulated
•Tailing edge fixed, leading edge modulated
•Pulse Width constant, period modulated
 Pull Cord Switch with
Sensor module
 The red wire is the main
supply wire(+ve)
 The black wire is
neutral(grounded)
 The green wire is one of the
wires included in NC
contacts of sensor module
With Termination
module
Consist of red and
black wire (+ve and
neutral)
8. About PPI panel
• Pull cord positioning indicator unit located in the control
room and one Sensor Module(JP202) per Pull Cord switch in
the field. The Sensor Module is fitted across the normally
closed (NC) switch inside the switch housing. Emergency
lines with up to ninety-nine pull cord switches can use PPI-
202 for indication.

• The two-core cable in the pull cord circuit is used to transmit

the position of the operated switch electrically nearest to the
indicator. The indicator displays the switch number.
• The transmitter unit also automatically detects
the resetting of the operated switch and outputs
the position numbers of next nearest operated
switch if multiple switches are operated. If no
operated pull cord switch is detected it outputs
the “Healthy Loop signal”.
  PPI panel outlook

MODE BUS COMMUNICATION TB

PULL CHORD TB

BELT SWAY TB
 MODE BUS

TEST KEY +VE 24 VDC

SPARE A1+ FOR SPARE
RS485 EARTH

5V GROUND FOR RS485

B1- FOR RS485 -VE 24 VDC
  BELT SWAY

SPARE

-VE 24 VDC FOR BELT SWAY TRIP

TRIP CONTACT FOR PULL CORD SWITCH
+VE 24 VDC FOR BELT SWAY TRIP

RED WIRE OF BELT SWAY SWITCH FROM FIELD

BLACK WIRE OF BELT SWAY SWITCH FROM FIELD

 SMPS(110/24V)

110 V

24 Vdc
 MCBs

110 v

MCB
 RELAYs

BSS RELAY

PCS RELAY
CIRCUIT DIGRAM FOR BELT WATCH
 TYPES OF FAULTS
• Display blank
a. Check 230/110 Vac at input of SMPS mounted on back plate of panel
b. Check 24 Vdc at output of SMPS
c. Check 24 Vdc at terminal no 11,12 of indicator unit
• Display shows p.00 or b.00
a. Cable may be open between BWS panel and first field switch
b. Two core connecting field switches from conveyor to BWS panel
may get interchanged
• Display shows p sc or b sc
a. Two core connecting field switches may get shorted in
between
• Display shows wrong number of actuated switch at field

a. Check switch connection , if any dust & water inside switch for all
switches

• Indicator malfunctions
a. Follow procedure Emergency by-pass
SOLUTION

• Display Blank
a. If not check corresponding MCB – replace if required
b. If not replace SMPS
c. If ok repair indicator

• Display shows p.00 or b.00

a. Do the proper connection & check system performance
b. Correct the polarity of wires as explain in point 4 of installation
guide
• Display shows p sc or b sc
a. Power off Indicator ,wait 1-2 minute ,power on Indicator ,if
still display remains as it is follow the procedure detect cable
short
• Display shows wrong number of actuated switch at field
a. Clean the switches & check system performance

b. If still problem remains ,follow procedure Detect cable short

 Procedure to detect cable short / cable
fault / switch fault :-
a. Switch off power for master unit
b. Operate known switch from field (say switch no 5,10,15,20,25,30 & so on)
c. Switch on power for master unit
d. As feature of master unit ,it start displaying operated switch nos. in cyclic
fashion
e. Suppose cable short is at switch no 17
f. Master unit will indicated switch no 5,10,15 and then instead of 20 it will
show sc
g. It mean cable is shorted in between switch no.15 &20
h. Now reset all operated switches ,operated from 15 to 20
i. Repeat step no c to f
j. This time master unit will indicate operated switch no 15,16;sc as short is at
switch no17
k. Resolve the problem at switch no 17
l. Switch off master unit
m. Check performance for any operated switch
 Emergency by-pass feature :-

If belt watch indication having malfunction for local indication or plc

communication.

• Remove top connector marked for 1-13 terminals from back side of
belt watch indicator
• Keep power to this particular indicator in ON state
 Belt watch is a bulk material handling system .It uses belt for
carrying raw materials from one place to another.
Pull cord and belt sway switches are installed along the
conveyor to provide safety against malfunctioning.
The main components of the system are:
• Master cum display unit located in central control panel.
• Sensor module located in each pull cord/belt sway switch.
• Termination module located in the last pull cord/belt sway
switch.
We have learned the entire process in part by part method. we
also learned how automation is done in the control panel; which
helped me a lot to understand how automation is done in mass
production of industry. Because The belt watch system and its
checking procedure is based on automation.
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