2. Engineering department
Electrical department:
Supervisors: 6
Man power: 24
Motor winding/ health: 4
PLC repair: 2
Team management:
Two teams for shift repairs is distributed in departments:
1) Tyre / mixing
2) Tube
Motor winding team:
Their duty is motor winding, oiling and health of motors. The winding is
done in workshop. The health of motors is checked and oiling etc is
done.
General team:
General tea is for new projects and extra planning. The major issues are
also dealt by them. Project planning and all the management is done by
them.
Power electrical room:
Motor winding is done here. Power related all the equipment is placed
here.
3. Electronics room:
All the electronics are placed here. The electronics are repaired here by
the assigned team.
Procedure for complaint work:
1) The work order is given by the concerned department mentioning
the nature and machine number.
2) The work order is signed and accepted by the department team
3) The concerned team in the department note the down time of
machine and the completion time.
4) This time and the fault is noted in the log book present in
department.
Power distribution:
The power sources in factory are:
1) WAPDA
2) Power house
11KV connection is given by the WAPDA. This is step down to 415 V,
660 V.
HT Along Time office
LT1 Tube department
LT2 Mixing department
LT3 Utility department
LT4 Tyre department
The poles have two set of distribution lines:
1) From WAPDA
2) From power house
4. In LT a changeover panel is made to shift the connection from WAPDA
to power house.
A safety lock is made on changeover panel to do switching between
WAPDA and power house
Two separate transformers two separate panels for WAPDA and power
house.
Inside the panel ACB are used for protection.
Bus bars are made for further distribution.
In every dept. DB is made and further distribution is done from DB to
machines with protections attached.
On LT panel current, voltages, power factors are displayed.
Transformers in factory:
Capacity( KVA) Voltage company
1000 11KV / 415V J and P
1500 11KV / 415V Transformer panel
Lahore
3000 11KV / 415V Bilal Engg.
2000 11KV / 415V China
2000 11KV / 415V Bilal Engg.
3000 415V / 11KV Pel
3000 415V / 11KV Pel
4000 11KV / 415V Bilal Engg.
2000 11KV / 660V Bilal transformer
6. Equipment and details:
AC drive:
AC drive is used to run AC motors. There are different modes inside it.
Scalar control
Vector control
The voltage and frequency is controlled.
Key modules inside:
1) Rectifier
2) Inverter
3) Brake chopper
Parameters:
1) Manual/ guided start up
2) Direction of rotation
3) Analogue inputs
4) Digital inputs
5) Mode selection
6) Limits entry
7) Timers
8) PID
9) Reference set
7. Tube extruder (XJ150):
Screw:
Outer dia: 150 mm
operating length: 665 mm
Max speed: 81rpm
Driving motor:
Model: YJP16OL-4
Power: 55 KW
Speed: 1500rpm
Voltage: 380V
Production: 1050 Kg/hour
Other motors:
Blowers, lubricating pump (1.1KW)
Main motor fan: 0.37KW
Tube extruders motor specs:
Extruder # rpm power current
1 980 55 KW 94.8 A
2 990 75 KW 141 A
3 980 55 KW 94.8 A
4 980 55 KW 94 A
5 1500 55 KW 101 A
8. Tube curing press:
Model: LLN240
Closing time: 16s
Motor Power: 11KW
Rpm: 897rpm
Voltage: 420V
Tube splicer:
Tube thickness: 2-6 mm
Flat fold width of tube: 240mm
Power: 220V
Heater: 400W, 110 V
Current: 15A
Limit switches:
control up down of mold pressing
up down of cutter
emergency stop
9. All well press:
Rickshaw press specs:
Name All-well
Model AW-24-M4
Platen outside diameter 600mm
Mold clamping force 65 to each mold
Mold closing speed 15 sec
Hydraulic pressure 210bar
Shaping pressure max 2.5 bar
Vacuum 100mmHg
Power 380 V, 50 Hz
Limit switches:
LS1: for mold open top position
LS2: for shaping
LS3: low speed mold close
TBM4:
Main motor: 11 KW, 970 rpm
Poke lifting motor: 0.75 KW, 1400 rpm
Power source: 415 V
Total power: 30 KW
10. Tractor press specs:
Name 1900 tire curing press
weight 65 ton
Heating method dome
Max mold opening time <100 sec
Mold closing force 6480 KN
Main motor 400 V, 50 Hz , 3 phase
Power 18.5 KW
Steam pressure for shaping 7 bar
Heat water inner pressure 28 bar
Air pressure 3.5 bar
Hydraulic pressure 28 bar
Temp detectors PT100
Pressure sensor P/I sensor
Tread extruder:
Model: XJ200
Motor power: 110KW
Screw diameter: 200mm
Productivity: 1800 Kg/h
Screw speed: 67rpm
Voltage: 680V
Current: 120A
Compound used: T100
Two warming mills for milling the compound.
1 lubricator tank for extruder
Barrel temp: 73 degree centigrade
Extruder head temp: 100 degree centigrade
11. Batch off unit:
Voltage: 415V
Receiving speed: 5 to 30 m/min
Store capacity: 3 ton (commonly 2 ton)
Total load: 30 KW
Conveyor motor: 3 KW
Main motor: 1250 KW, DC 750 V
In power supply: 660 V, 2000 A
Maintenance:
Hydraulic device oil tank repaired once every yea
Changing dust stop fixed rings
Seal rings of oil cylinder
Main motor 1250 KW DC 750V
High pressure pump 1.5 KW AC 380V
Grease pump 0.25 KW AC 380V
Hydraulic bi pump
motor
55 KW AC 380V
Hydraulic cooling
pump motor
2.2 KW AC 380V
Speed reducer
lubrication
3 KW AC 380V
12. Banbury Mixer 1:
Model: F270
Speed: 49 rpm constant
Product: only butyl tubes are made on it
Type of process:
Only direct final process is done
Temperature dependent process
Operation is manual
Type of rooters:
Tangential rooters are present
Gap between rooters is known as nip.
Capacity:
Its capacity is 240 liters converted to Kg by specific gravity formula.
Batch weight = capacity of mixer x fill factor x specific gravity
Filler factor:
Defined by manufacturer is 0.75
Metal detector:
Controller: DMD-510
Max conveyor speed: 60 m/min
Power: 220 V, 30 W
13. Conveyor speed can be set according to requirement. Metals or any
other magnetic material must not interfere. The alarm is set on
detecting.
Temperature control unit:
Total zones: 7
Each zone:
Heater power: 10 KW
Heat exchange area: 1.3 mm2
Temp sensor: Pt 100, WZP 270(platinum resistance)
Electric control:
Electric control consists of:
Temp control gauge, solid relay, solenoid valve, heater
Pressure of water: 0.2 to 0.4 MPa
14. Duplex extruder:
Max capacity:
250(top): 3500 kg/h
200(lower):2300 Kg/h
Supply:
380 V, 3 phase
Control 220 V, 3 phase
250 extruder:
Diameter: 250mm
DC motor: 500 KW, 440 V
Rpm: 2.6 to 26 rpm
200 extruder:
Diameter: 200mm
DC motor: 315 KW, 440 V
Rpm: 2.8 to 28 rpm
Feeder:
Motor: 1.5 KW
15. Mechanical Workshop:
Equipment:
i. Metal filling machine
ii. Slotting machine
iii. Lathe machine(14 feet)
iv. Lathe machine(12 feet)
v. Lathe machine(8 feet)
vi. Lathe machine(6 feet)
vii. Lathe machine(7 feet)
viii. Lathe machine(7 feet)
ix. Shaping machine
x. Milling machines
xi. Valve repair
xii. Welding and fabrication
xiii. Hydraulic oil
xiv. Gear oil
16. Utilities department:
Compressors:
Atlas capco: screw, centrifugal compressors
Broom and wade: reciprocating compressors
Atlas Capco compressors:
Precautions:
The aspirated air must be free of fumes
Ambient air cool and clean
No external force on air outlet valve
Multiple compressors must have manual valves to isolate them
High temp pipeline must be insulated
Periodically check:
All guards are in place
All hoses/ pipes in good condition
No leaks
All the safeties are working
Introduction:
GA(200) and GR(200) are oil injected screw compressors driven by
electric motor enclosed in sound insulated body work.
GA200 are single stage water cooled compressors. They have less
pressure but greater flow. The pressure is approx. 8 bar. There are 5
compressors present.
GR200 are 2 stage compressors. They have greater pressure but less
flow. The pressure is approx. 18 bar. There are 2 compressors present.
18. Check valve prevents blow back of air
Minimum pressure valve prevents receiver pressure from dropping
below the minimum pressure.
Oil system:
Cooling and condensate system:
Dac (automatic condensate drain)
Dmc(manual condensate drain)
Regulating system:
Electronikon regulator:
This regulator keeps the net pressure within programmable range by
loading and unloading the compressors.
receiver
oil coolers
filters
oil stop valve
compressor elements
19. Unloading: solenoid valve de-energized
Loading: solenoid valve energized
Control panel:
1. Start button
2. Scroll keys
3. Tabulated keys
4. Function keys
5. Stop button
6. LEDs
7. Emergency stop
Recommended difference between warning and shut down level is 10
degrees
Recommended difference between warning and shut down pressure is
0.6 bar
Supply voltage: 400 V
RSI (Ryznar stability index):
It is a parameter for predicting whether water will tend to dissolve
calcium carbonate
Neutral water range:
6.3< RSI <6.8
20. TDS (total dissolved solids):
Calculated from dry residue after evaporation
For an open system TDS< 450mg/l
Fo closed system TDS<3000mg/l
Chlorides:
They cause pitting corrosion on stainless steel.
Closed cooling < 5000ppm
Open cooling < 150 ppm
Oil level indicator must be in green range
Maintenance:
Check readings
Condensate discharge during loading
Oil level check
Drain condensate from air eceiver
Check leaks
Test safety valves
Replace oil filters
Bearings must be replaced after 25000 operating hours
Compressor element 1 outlet
temp.
b/w 80 and 100 ⁰C
Compressor element 2 outlet
temp.
b/w 90 to 110⁰C
Cooling water temp. Below 50 ⁰C
Air inlet temp. 20 ⁰C
21. Cooling water inlet temp. 20⁰C
Max air inlet temp. 40⁰C
Max cooling water inlet temp. 40⁰C
Max cooling water outlet temp 50⁰C
Max cooling water inlet pressure 10 bar
Overload relay 233 A
Circuit braker 1.4 A setting
Max working pressure 20 bar
Motor shaft speed 1487 rpm
Input power 223 KW
Oil capacity 93 litres
Complete maintenance: 40,000 hrs
Oil, filter change: 4000 hrs
Cooling:
Three cooling towers are present,
City pump (75 KW): supply to cooling towers
Feeding pump (75KW): supply to compressors
Chemicals to maintain pH:
NNI-404, BC-1, biogeen 100, H2SO4
Blue pipeline is for air
Green pipeline is for water.
22. Broom and wade compressors:
Model: D91940
They are known as double action compressors. Because they work on
both upper and lower stoke of piston.
Parts:
Inlet
4 suction valve
4 discharge valve
Inter cooler
4 suction valve
4 discharge valve
Header
one low pressure compressor
two high pressure comprsssors
23. Cooling tower:
LRS series
Loss of evaporation calculation:
𝐸 =
𝑄
600
=
𝑡1 − 𝑡2
600
∗ 𝐿
L= circulating water flow
Q=heat load
600= water evaporation heat
T1=inlet water temp
T2=outlet water temp
Types:
Bottle type cooling tower
Rectangular cooling tower
Hot and cold water supply:
Supplying Number of
pumps
power Pressure
(psi)
Cold water 2 75 KW, 75 KW 350
Hot water to rear
tyre
3 75 KW, 75 Kw, 90
KW
320
Hot water to LT 2 90 KW, 90 KW 455
24. Zeolite is used to soften water to avoid scaling
After 4 to 5 days zeolite is refreshed by salt water
At drain hot and cold water combine and come to hot water
storage
The pipes are covered with grass wool to avoid heat loss.
turbine
zeolite
filled tank
hot water
storage
hot water
tank
pumps
to
departent
turbine
zeolite
filled tank
cool
water
storage
cool
water
tank
pumps
to
departent
25. Power house:
Gas generators 3 1064 KW each
Diesel generator 1 1004 KW
Standby rental
generator
1 2 MW
LTs have the changeover panels to supply from WAPDA or power house
Power house and WAPDA both have separate supply lines, protection,
and transformers etc.
The cooling system of the generator is governed by the closed cycle.
The heat is absorbed by the water and supplied to cooling towers for
cooling.
The pH of the cooling tower is maintained and inspected after 1 hour.
Water temp: 60⁰C
Lube oil high temp: 80⁰C
LT number Load Area of supply
1 700- 800KW MC tube green, car
tube green, cooling
towers
2 2500 – 2600
KW(WAPDA)
mixing
3 2400 KW Curing, workshop,
boiler, compressors,
lighting, rim putty
4 700 KW Dupilex extruder, MC
tyre green, calendar
26. Gas generator:
Model: jenbacher IC9222
Cylinders : 20
Main parts of generator:
1. After cooler
2. Heat exchanger
3. Alternator
4. Vibrator
5. Lube oil
Co-generation:
These generators work on co generation i.e. the generators produce
electricity and their heat energy by outgoing gases is used to produce
steam in the mini boiler.
27. Synchronization:
For synchronization the WAPDA is run at 2400 KW. Then three
generators each run at 800 KW. The load is shifted to generators by
MCB.
MCB ( main cct. breaker) is used to synchronize WAPDA and generators
automatically and manually also. But the fluctuation if frequency does
not allow synchronization of MCB automatically. So, it is switched
manually when generators are off.
Boilers:
The boilers are used to produce steam. There are four boilers present:
Boilers Capacity
CFBC 25 ton
Fire tube boiler 1 12 ton
Fire tube boiler 2 13 ton
Fire tube boiler 3 8 ton
Two pressures are used in factory:
High pressure steam
Low pressure steam
28. CFBC (circulating fluidized bed combustion):
Hopper:
The coal is fed to furnace by the hopper set above.
Furnace:
The air coal mixture is burnt in the furnace having water tubes inside it.
Water:
The water is supplied inside the furnace by the water tubes inside. The
condensate from all the departments is also collected and fed.
Cyclone:
In cyclone the solid carbon is caught and fed back to furnace.
Economizer:
29. Economizer is used to increase the efficiency of the system by heating
the supplied air and water to furnace by heat of flue gases.
Scrubbers:
Scrubbers are used to collect solid particles from flue gases.
ID fan:
Induced draft fans are used to suck the gases to the chimney.
FD fan:
Forced draft fan supply the heated air in furnace for burning.
Header:
The whole steam produced is collected in header having safety
attached.
