3.3kV/VFD/VCB/PLC/Motor commissioned Projects for Centrifugal Pump application in the Under ground coal mine

1. 1
TECHNICAL PRESENTATION OF COMPLETED PROJECT -2022
Presented by Annamalai Rajendran
Contact Number: 9710373057

2. LIST OF PRESENTATION TOPICS
1. 3.3KV/800KW VFD/PLC/MOTOR/DOL FOR PUMP APPLICATION
2. 550V AC/400KW VFD/MOTOR/PLC COMMISSIONED FOR
CONVEYOR APPLICATION IN UNDERGROUND COAL MINES
3. 415V AC / 250KW VFD/MOTOR COMMISSIONED FOR PUMP
APPLICATION IN CEMENT PLANT
4. ROOT CAUSE ANALYSIS
5. SITE COMMISSIONING REPORT
6. SERVICE ENGINEER ESSENTIAL RESPONSIBILITIES AND
REQUIREMENTS

3. 1.3.3KV/800KW VFD/PLC/MOTOR/BYPASS-DOL FOR PUMP APPLICATION
Commissioned Project Details on January-June – 2022 underground coal mines
• Project : 3.3kV/800kW Series Pump synchronization operation
• Industry: Underground coal mines
• Flow: 2500 m3/Hr
• Head : 756 meters ( over all achievable head)
• Liquid : SlurryMine Water with suspended solids
• Motor : 3.3kV ,817 HP – 610kW,4P,VPI,IP55 ( ABB)
• VCB – BYPASS ISOLATOR – 3.3kV/800Amps,CC,TC,aMetering CT
• Drive : Variable Frequency Drive – 3.3kV/800kW/178Amp / 196Amp-110% - 60sec(Fuji electric)
• PLC: 36DI/DO,16AI/AO,26RTD (Fuji MICREX –SX series)
• Pressure sensors – 0-100bar, 24V DC,2-wire,IP-66(Vega)
• Vibration sensors – 0-25mm/sec, 24V DC,2-wire,IP-66( IRD)
• Electro magnetic Flowmeter – 0-2800m3/hr,230VAC,4-20mA,ID200mm(ABB)
• Check Valve – 8inch – DN200mm,Casted Iron,PN40 ( AMCO)
• Gate Valve - 8inch – DN200mm,Casted Iron,PN40 ( AMCO)
Principle of Operation:
We have been commissioned with 3nos centrifugal pumps for the slurry coal mine dewatering process.
Three pumps, coupled with a motor, have been installed in different locations.
The first pump will be a master pump, sucking slurry water from the sump and feeding it to the second pump.
The second pump suction: when the flow has reached the second pump suction pipeline, the pressure sensor
will detect low pressure and feed it back to the PLC, which will then give feedback to the VFD to start the
second pump, and the same procedure will be repeated for the third pump.

4. 2. SYSTEM ARCHITECTURE

5. INSTALLATION PHOTOS OF THE VCB-BYPASS ISOALTOR.

6. INSTALLATION PHOTOS OF THE VFD/PLC PANEL

7. INSTALLATION PHOTOS OF THE PLC PANEL

8. INSTALLATION OF SENSORS PHOTOS

9. VIDEO OF THE COMPLETE INSTALLATION PROJECT

10. 415V AC / 250KW VFD/MOTOR COMMISSIONED
FOR PUMP APPLICATION IN CEMENT PLANT
SCADA & HMI INSTALLED FOR PUMP OPERATIONS BY 24X7
Project Details
• Project : Mine Dewatering at Lime Stone Quarry unit
• Industries : Open cast mines and Cement plant
• Flow: 400 m3/Hr
• Head : 80 -120 meters
• Liquid : Mine Water with suspended solids
• Motor : 400 HP – 300KW,415V AC,4P,IP55(ABB)
• Drive : Variable Frequency Drive – 315KW(ABB)
• IOT – Movicon SCADA: Online Pump Operation Monitoring & Controlling.
Operation:
Successfully commissioned of 300KW Motor,Pontoon Pump,VFD Panel,LCS,JB,FM,PT at Dalmia
Lanjiberena.VFD Panel installed inside Portacabin with 2number of 1ton AC for VFD system maintain
temperature at safe level
Installed UPS 500KVA for VFD,PLC,FM operation and Pump running parameters data backup for 25mins
Operator can monitor and control of Pump live running following the parameters from HMI and SCADA
screen. Which is installed HMI At Portacabin and SCADA system installed at Quarry office.
• PUMP ON
• PUMP OFF
• PUMP SPEED
• FREQUENCY
• VOLTAGE,MOTOR TEMPERATURE
• CURRENT,POWER,TORQUE
• PRESSURE AND FLOW
• PUMP RUUNING HOURS

11. 415V AC / 250KW VFD/MOTOR COMMISSIONED
FOR PUMP APPLICATION IN CEMENT PLANT
SCADA & HMI INSTALLED FOR PUMP OPERATIONS BY 24X7
250kW VFD/Motro control Pump operation and
24 x 7 real time monitoring, vhistorical data & trend monitoring
LCS Installed for Pump Manual control operation.
Pump operators can start the pump easily at Pontoon Pump station.
The benefits of this technological solution are as follows:
• Flexibility to monitor the pumps from any place through laptop or
system
• Reduced operational cost, repair cost and labour.
• Reduced unplanned breakdown and improved process/plant safety &
reliability.
• Increased equipment life and less downtime
• Easily can find Pump working data report Day/Month/Year
• Reminder report to Pump spares maintain list and expire list

12. Found for VFD operation, Power cable size is underrated.
 Successfully commissioned of 250KW Motor,Pontoon Pump,VFD Panel at MOIL site.
 VFD Panel installed at pitbottom, Power cable 3Cx300SqmmxALx1run laid from 11KV substation transformer to
VFD panel and cable distance is 1Km.VFD Panel to motor power cable distance is 25Mtr
 Observed VFD output voltage loss due to power cable weak of insulation and need to increase the cable run.
 After Increased power cable run at VFD input side, found output voltage was increased and VFD parameters
assigned as per the motor details, after start VFD is continuously running at 1580RPM,442VAC ,323Amps
Found voltage 1-Run cable VFD maximum running at1470RPM Found voltage 2-Run cable After VFD running

13. Analytical detailed service report at site

14. Commissioning Report
Follow the procedures that should be mentioned in the commissioning report.
1. Customer order number/Details/Concern technical head details
2. Nature of Job, Commissioning scope of details
3. Product Technical specifications
4. Operation parameters detail of machines like ( VFD,Motor,Sensors,Pump,Fans)
5. Important instructions with machine photos ( To be marked instruction in photos)
6. Critical recommendation points
7. Do’s and Don’t responsibilities
8. Conclusion status.

15. Service Engineer Essential Responsibilities And Requirements
Essential Responsibilities:
1 . Basic troubleshooting, installation, maintenance, and repair on designated
equipment. completing Preventative Maintenance and field modifications.
2. Maintaining tools and test equipment and ensuring they are properly calibrated.
3. Make sure projects meet agreed specifications, budgets, and deadlines.
frequently meet with the client to update them on the progress of the project.
4. Make sure prepare MOM and site report on time once the project is
commissioned and ensure reporting to the management immediately.
Essential Requirements
1. Experience troubleshooting and responding to customer concerns.
Excellent analytical, interpersonal, and communication skills with the ability to communicate
complex technical issues in an easy-to-understand manner.
2. Ability to work in a fast-paced,all kind of environment. strong knowledge about products,
and Always communicate any service-related technical issues to the reporting person.
3. Resourceful, with the ability to work independently. Strong time management
skills

16. Questions?