TO STUDY FEASIBILITY AND IMPLEMENT THRUSTER BRAKES IN LT

MOTOR OF SCP-1 AT BATTERY 5,6,7 COKE PLANT.

Tata steel is Asias first and Indias largest integrated private sector Steel company. It was
established in 1907 by its founder J.N.TATA. Over the years, Tata Steel has emerged as
the thriving , nimble, steel, enterprise due to its ability to transform itself rapidly to meet
the challenges of a highly competitive global economy and commitment to become a
supplier of choice by delighting its customers with services and products. Constant
modernization and introduction of state of-the- art-technology at Tata steel has enabled
it to stay ahead in the industry and successfully meet the exceptions of all the sections of
stake holders. Tata Steels four phases of modernization program in the steel works has
enabled it to acquire the most modern steel making facilities in the world. Recently, Tata
steel commissioned its 1.2 million-ton capacity Cold Rolling Mill complex at global
speed and cost and the H-Blast furnace to further advance itself among the top steel
producers of the world. Its fifth phase of the modernization program leverages the
intellectual capabilities of its employees to generate sustainable value of the stakeholders.
Tata steel is taking better management initiatives to shift focus from creating new
physical assets to utilizing them with ingenuity and study business sense.

TATA STEEL is the world's seventh largest steel company, today said
it has commissioned a new coke oven battery at its Jamshedpur steel
plant, making the unit self-sufficient in coke requirement and in turn
stabilizing operations there.
Built at a production capacity of 700,000 tone, the coke oven battery-11
operates with 88 ovens with stamp charge technology and is the largest
coke oven complex in Jamshedpur Plant.

COAL CARBONIZATION OR COKING
When coking coal heated in the absence of air they become plastic and
soft over a temperature range of 310
0
C to 500
0
C. The coal particle
agglomerate into a coherent mass, which swells and solidifies to form a
porous structure known as coke.
When coal is charged in the hot oven, the temperature of oven
refractory wall being at about 1100
0
C to 1500
0
C, the portion of the coal
in immediate contact with hot wall is heated very rapidly to a high
temperature, a thin layer softens, becomes plastic and melts. This layer
of plastic material travels towards the center of the oven and some of
the gaseous product force their way out of the plastic materials, as the
temperature of the charge is raised. On the wall side, the plastic layer
hardens into a cellar residue and the volatile matter left in the coke is
driven of gradually as the temperature rises during remainder of the
coke period. Thus in an oven, during initial stage of coking, the coal
exists side by side in several phases, e.g. coke, semi coke, a plastic mass
and granular coal.
The phenomenon of conversion of coal to coke may be started in a simplified
way as follows:

Evaporation of the moisture in the temperature range up to 100
0
C.

Release the volatile matters in the temperature range of 200
0
C to 600
0
C, most of the volatile
matter is released between 300
0
C to 600
0
C.

Softening and solidifying zone remains in the temperature range of 300
0
C to 600
0
C.

Plastic zone up to 450
0
C.

Sami coke in the range of 450
0
C to 650
0
C.

Release of hydrocarbons up to 800
0
C.

Above 800
0
C only hydrogen is released and coke cake becomes hard.

Time Duration for Coking

Minimum coking time 19 Hrs. 45 Min.

Maximum coking time 20 Hrs. 45 Min.

Schematic Diagram of COKE Plant

Thruster brake is a device used to retard the speed of
moving machinery and to stop it accurately to the desired
position. The braking force is applied to the brake shoes by a
pre-stressed comprising spring. The shoes press on the
rotating brake drum retarding its speed and finally stop it.
The releasing of the brake drum and compressing of the
spring is done by thruster.


A thruster shoe brake has a pair of cast iron shoes which are lined up with friction
pads. The shoes are hinged on main arm and side arm of the brake, each of them
have a hinge pin fitted in the base. They are connected to each other on top by a tie
rod, which is hinged in the main arm and locked to the swivel block in the side arm,
by a lock nut. A crank lever is hinged on the main arm and the other end is fixed to
the top clevis of the thruster by a hinge pin. A brake spring is fixed on the main
arm and is pre-loaded by a locknut on the lever. The pre-tension in this spring
decides the braking torque. The thruster is fitted on the base by a hinge pin. When
the thruster is not energized, the brake shoes are pressed on the brake drum fitted
on the drive motor shaft and hold it under the effect of braking force provided by
the spring. In such condition, the brake is applied and the drum cannot rotate. As
the piston travels upwards the angle lever turns, pushes the brake rod and
compresses the brake spring. Simultaneously, the brake lever on the other side of
the wheel (Brake Drum) is retracted. When the first lever reaches the stop on the
brake base member the brake lever at the thruster begins to move, releasing the
brake drum.
TYPES OF THRUSTER BRAKE:-
Disk brake Thruster
Double shoe brake Thruster
Electrical Design:-
Motor-

3 ph AC squirrel cage motor, For performance refer to technical data. Insulation
classF.

Modes of Operation-

Continuous operation S1 and intermittent service S3-60 % duty cycle.
>50 C ambient temprature.

Voltages and Frequencies:-

230/400 V, 50 Hz, 3 ph AC
290/500 V, 50 Hz, 3 ph AC
400/690 V, 50 Hz, 3 ph AC
All units are on principle star (Y) connected at delivery. Special windings 110 V - 690
V, 3ph AC at extra charge.
60 Hz design at extra charge.
Single phase versions on request.


Power (switch) Contractor
EOCR
(Generate command)
Break Open
Cable Terminal Field
Motor(pusher )
Single line Diagram of Thruster Brake Connection
FLOW OF EOCR
Mechanical
load
Current of
motor
Detecting
current with LT
sensor
Reducing the
down time of
system
Diagonising the
condition of
machine and
motor
The EOCR(electronic over current relay) are
highly compact and versatile electronic relays
which operates on the basis of current sensing
principle with inbuilt current transformer of
the EOCR.these relays are independent
mounting relays and can be used with any make
of contractor in the equipment. Besides with
independent adjustable time settings for
starting delay time and operating time these
relays find many applications all spheres of the
industry.

EOCR

Pumps
Fans
Single phase motors
Induction motors
Squirrel cage induction motors
Slipring wound motors
APPLICATION OF EOCR
Dust proof double seal
Pressure lug
Piston rod
Piston rod protection tube
Double seal of oil chamber
Oil filter inlet
Piston
Braking spring
Hydraulic cylinder
Centrifugal pump
Oil guide
Motor shaft double seal
3 ph AC squirrel cage motor Terminal box
Fixing lug
Internal Diagram of Thruster
Thruster Versions
Additional Equipment
Lifting or Lowering Valve (H, S, HS)
Built-in lifting (H) and/or lowering (S) valves for stepless prolongation of normal
lifting or lowering times. The adjustable minimum values obtain a level 10-20 times
the standard values. Built-in valves in setting open result in increased lifting and
lowering times for short stroke units of approx. 0.1 to 0.2 seconds and for long
stroke units of approx. 0.2 to 0.4 seconds. The valves are adjusted from the outside.
Braking Spring (c-Spring)
The c-spring generates the braking force. The specified force of the c-spring applies
for 1/3 of the piston rods rated lift stroke or 2/3 of the rated lower stroke.
Re-setting Spring
Operation similar to c-spring, re-setting force is, however, lower (on request).
Damping Spring (d-Spring)
For an aperiodic transient of the brake. This assists the brake to close smoothly.
Only effective in conjunction with a built-in braking spring. No limit switch can be
annexed in his case. There is no alteration in the mounting distance A. When
determining the operating point of the brake the dimension z is to be
considered. Main application: ELDRO-regulated brake.
High-Speed Lowering Circuit
By means of motor capacitors, or by short-circuiting the stator winding and
inserting a contactor. The lowering times are reduced by approx. 15 %.
Heater
For operation below 25 C a heating element must be installed; also to be used as a
stand-by heater. The customer has to provide a separate power supply and
temperature regulator.
Application: aggressive media and/or high relative humidity and the resulting
danger of formation of condensate. Motor: fully vacuum potted stator, applicable
also instead of idling space heater (on request). Special paint: Polyurethane lacquer
(KOR). Primer: one coat Paintfinish: two coats polyurethane varnish. Tint RAL 7022
(umbergrey).
Increased Protection against Corrosion
Limit Switches
For electrical indication of the release or closing positions of the brake, mechanical or
inductive limit switches can be fitted as standard. The appropriate types of switches
are listed in the technical data sheet Limit Switches. All additional equipment is to be
ordered separately at extra charge.
Rated voltage
Code for additional equipment
c Braking spring (c-spring)
d Damping spring (d-spring)
H Lifting valve
S Lowering valve
E Limit switch, mechanical
EB Limit switch, inductive

Code for exchange unit

Stroke in cm

Lifting force x 10 in N

Ed: ELDRO, 3 ph AC version
Ed 121 / 6 . 1 c 230/400 V, 50 Hz
Key to Types
Performance in Service depending on Ambient Temperatures
Temperature range Hydraulic fluid Performance in service
25 C to + 50 C HL 10, DIN 51524, part 1 In the lower range of
ambient temperatures
the lifting times may
increase up to four times
the specified lifting times
when the unit is
operated the first time.
The lowering times
remain unaffected.
over + 50 C special fluid Enquire.
35 C to + 40 C special low temp. fluid Space heater not required.
below 25 C HL 10, DIN 51524, part 1 Space heater required in
unit. Connect up heater
in terminal box using an
additional Pg 16 cable
gland. 230 or 115 volt
connected voltage.
Thermostatic control be
provided by customer.
Method of Operation
Functions
Advance
BRAKEMATIC advance is an electronic control with variable parameter presetting
for generation of controlled brake torque characteristics. In this case an external
reference signal (usually rotation) and a programmed presetting parameter (e.g. time,
rotation) are evaluated and a linear or nonlinear time function is calculated in the
frequency converter. An integral process controller module makes a permanent set
point/actual value comparison of calculated characteristic and the actual values.
Constant brake times for strip guiding systems
Proceeding from the guide signal generated by the controller, the frequency converter
modifies the working frequency at the ELDRO thruster and thus controls the
process of braking operation. Safe adherence to brake time stipulations is the initial
prerequisite for the realization of the shutdown regime of complex belt conveyor
systems. This is the only way to provide protection from surcharges caused by
asynchronous stoppage of conveyors. The application of BRAKEMATIC advance is
excellently suited for this job since it ensures the preset braking times independent of
the conveying direction (up or down) and the loading status.
ABS-System for track bound travelling
Track bound travelling and trolley gears are another field of
application. Due to unfavorable friction (metal to metal contact) in
combination with swaying loads, heavy braking torques, (e.g. caused by
operation of EMERGENCY STOP) or adverse climatic influences it
might occur that wheels are blocked. In those cases the
BRAKEMATIC advance can be used as antilock system.
Using the pedal, the crane operator can actuate the control system. The lifting power
of the ELDRO brake thruster, and thus the braking torque, are changed in
proportion to
the pedal travel. When the pedal is not depressed at all, the full lifting power is applied
to the ELDRO brake thruster, and the brake is being lifted. The more the pedal is
pressed, the lower is the lifting power on the ELDRO brake thruster and the higher
is the braking torque. A special setting allows a long pedal travel for sensitive
variation of the braking torque. In order to avoid full braking, a progressively acting
pull-back spring is incorporated in the pedal. When the crane operator slightly
retracts the pedal, the braking torque is reduced accordingly. Thus, all conditions
required for safety brakes are complied with.
Function of the pedal
Example of pedal control with parking switch
1 ELDRO thruster
2 Control device
3 Pedal
4 Parking switch
Features:-
High reliability.
Long service life with minimum maintenance to low wear operation under
continuous self lubrication.
Soft and smooth operation due to the hydraulic principle.
Fast response (short regulating times).
High switching frequency: up to 2000 cycles per hour.
Reversing operation without restrictions.
Simple installation and dismantling.
No reversing contactors required as the motor may rotate in either direction.
Overloading during operation not possible.
Suitable for adjusting length of stroke from outside as required.
Stepless prolongation of lifting and/or lowering times by the fitting of valves.
Universal applications also in hazardous areas in which there is danger of
occurrence of explosion.
Precaution:-
Cotter pins at pins have to be opened, so they cant fall
out (left). Cotter pins at castellated nuts have to be
opened completely (right)!
RIGHT
WRONG
Lubrication:-
Because of the maintenance-free bushings installed on the brake, no lubrication is
needed.
Cleaning:-
Do not use corrosive or acidic agents to clean the brake. Only use fat
dissolving cleaners (e.g. brake cleaner) and proper cleaning material like
cloth. Never use high pressure cleaners or a wire brush
CONCLUSION
Our curiosity and eagerness were fulfilled with knowledge at Coke Plant. It
was really helpful in knowing about different types of sensor, field
instruments, valves, PLC etc. while practically working in machines, as well as
knowing about maintenance of the plant .

It was very interesting to know that coke plant of TATA STEEL is
continuously for last 12 years and is Steel operating without any Fault where
other industries plant degrade after a 5-6 years of Operation. This was only
possible because the maintenance is regularly and very brilliantly handled at
TATA STEEL
.
This project made us understand the working and function of different field
instruments and the method of their calibration.

While doing this project, we also came to know about the environment norms
that a plant has to follow to allow to avoid pollution.

At last we would like to say that we really enjoyed doing this training and
would like that Tata steel to continue this Vocational Training every year as it
will improve ones knowledge and will give an individual industrial exposure.