The document summarizes an industrial visit to a jute mill. It describes the manufacturing process which involves several steps from softening raw jute to final packaging. Electric motors power most machines, including softening, carding, drawing, spinning, winding, and loom machines. Motor specifications like power ratings and quantities are provided for each machine. The document also discusses the overall electrical load, transformer capacity, power factor correction, and monthly electricity costs.

1. PRACTICAL APPEARANCE OF
MACHINES IN INDUSTRY
Course No : EE 3108
Visited Industry Name:
The Crescent Jute Mills Co., Ltd.
Khalishpur,Khulna ,Bangladesh
One of the original Tesla Electric Motors from 1888 which to this day is
the main power generator for industry and household appliances. Credit:
Wikimedia Commons

2. Electrical Machineries in industry
All types of industries are invariably required to install
different types of electrical motors as prime mover for driving process equipment
participating in their respective production line up. The continuous process of technical
development has resulted into availability of highly diversified types of electric motors.
The characteristics of motors vary widely with the nature of their
application and the type of duty they are expected to perform. For example, the
applications like constant speed, constant torque, variable speed, continuous/intermittent
duty, steep/sudden starts, frequent start/stops, etc. should be taken into consideration
carefully when deciding for the type of a motor for that specific application.

3. The Crescent Jute Mills
Raw jute in the form of bales are processed in jute mills to produce hessian, sacking, jute yarn, bags and other useful products. Raw jute
bales from jute fields or suppliers, carried by trucks are unloade & stacked in the jute mills’ godown. To produce jute goods we need to
produce jute threads from raw jute. The procedure involves the following steps:
Softning Pilling Carding
1st
Drawing
2nd
Drawing
Winding Spining
3rd
Drawing
SoftningRaw
Jute
Mill Side
Repair-
ing
Calend-
aring
Cutting Swing
Storing Packing Press
DampingLoom-
ing
Factory Side

4. An Overview of the manufacturing process
1. Softning & Piling :
• Jute get mixed up with a mixture of oil,soap and water produced from
an Emulsion Plant
• jute become soft pile and suitable for carding .
 Induction Motor Rating:
Power: 12.5 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity: 5
2. Carding :
• jute reeds are splitted and overseas are removed
• jute fibers are formed into ribbon called 'sliver'
 Induction Motor Rating:
Power: 10 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:41

5. How motor drives the machines
Rotor connected with gear shaft by belt

6. An Overview of the manufacturing process(contd.)
3. Drawing (1st,2nd,3rd) :
• Makes more uniform sliver
• Reduce the jute into a suitable size called ‘sliver’
 Induction Motor Rating:
Power: 5 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity: 47
4. Spinning :
• processed slivers are formed into small rolls
• slivers are elongated and fibres are twisted into yarn to impart strength.
 Induction Motor Rating:
Power: 15 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:82

7. An Overview of the manufacturing process(contd.)
5. Winding :
• This machine wound the yarn into bigger packages known as 'spool'.
• The Spool are used in making sheets of yarn to form warp portion
used during weaving.
 Induction Motor Rating:
Power: 10 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:12
6. Beaming :
• Spool is wounded over a beam of proper width
• Finally thread is produced which is used to weave sacks, bags
and others .
 Induction Motor Rating:
Power: 5 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:07

8. An Overview of the manufacturing process(contd.)
7. Loom :
• The warp threads are hold under tension to facilitate the interweaving
of the weft threads.
• Sacks are built from the threads.
 Induction Motor Rating:
Power: 1 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:500
8. Damping :
• In the damping section the rolled woven product is unrolled and water is
sprinkled on it continuously to provide desired moisture.
• In the repair section the repair of the final products are performed and
added to the manufacturing process chain.
 Induction Motor Rating:
Power: 5 HP Phase: 3
Cycle: 50Hz Voltage:400V
Quantity:02

9. An Overview of the manufacturing process(contd.)
9. Calendering :
• After damping the damped fabric passes through pairs of heavy
rollers rendering threads in fabric flattened and improve the quality
and appearance.
 Induction Motor Rating:
Power: 15 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:04
10. Cutting :
• The sacking cloth is cut to the required length for making bags
for different size such as A-Twill bags ,B-twill bags ,etc.
 Induction Motor Rating:
Power: 6 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:02

10. An Overview of the manufacturing process(contd.)
11. Swinging :
• The sides of sacking cloth cut pieces are sown to make a complete bag. The
sides of sacking is again stitched to enhance the strength of the Bags edge.
 Induction Motor Rating:
Power: 1 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:32
12. Pressing:
• Processing cloths are then pressed compactly.
• Bags are then moved to the storage
 Induction Motor Rating:
Power: 70 HP
Voltage: 400V
Phase: 3
Cycle: 50Hz
Quantity:02

11. Overall load
SL No. Name of the Machine Motor
Power
Rating in
(KW)
Line current
(A)
Machine
Quantity
Number of
Motors/
Machine
connected
Real Power
in (KW)
Connected
Reactive Power in
(KVAR)
Required
Capacitor Bank
Rating in (KVAR)
1. Softening & piling M/C 9.325 15.15 5 3 139.9 82.96 62.96
2. Carding M/C 7.46 12.52 41 1 305.9 181.4 137.66
3. Drawing M/C(1st,2nd,3rd) 3.73 6.26 47 1 175.3 103.96 78.88
4. Spinning M/C 11.19 18.78 82 1 917.6 544.2 412.92
5. Winding M/C 7.46 12.52 12 1 89.5 53.1 40.27
6. Beaming M/C 3.73 6.26 7 1 26.1 15.48 11.75
7. Weaving M/C 0.746 1.252 500 1 373.0 221.2 167.85
8. Dumping 3.73 6.26 2 1 7.46 4.42 3.36
9. Calendaring M/C 11.19 18.78 4 2 89.5 53.1 40.27
10. Cutting M/C 4.48 7.52 2 1 8.9 5.27 4.0
11. Swing M/C 0.746 1.252 32 1 23.9 14.2 10.76
12. Bailing M/C 52.22 87.64 2 1 104.4 61.91 46.98

12. Calculation of required Capacitor Bank
Here,
power factor obtain at a certain time through power factor meter, cosՓ1= 0.86
Power factor desired, cosՓ2 = 0.99
Required KVAR to improve power factor from 0.86 to 0.99 is
= P × (tanՓ1-
tanՓ2)
= P × 0.45
= 2261.46 × 0.45
= 1017.66 KVAR
where, P is the total machines power of
manufacturing processCapacitor Bank available in the substation of this industry is = 1050
KVAR
Capacitor Bank available in the factory section
= 362 KVAR
⸫Total Capacitor Bank available in this industry = 1462 KVAR

13. Capacitor Bank & Transformer
Capacitor Bank
Transformer
 Capacitor Bank Capacity:
1462 KVAR
 Transformer Rating:
11kV / 400V, 1500 kVA

14. Cost Calculation
Rated Capacity of the transformer = 1500 KVA
In this industry, transformer was loaded at efficiency of 80% ,power factor = 0.86
∴Peak connectable load capacity of the transformer = 1500KVA × 0.86 × 0.8
=
1.032 MW
Again,
Maximum efficiency of each induction motor is nearly 75% and designed to run at
55% of their rated load
So, actual real power consumed = 2.26 MW × 0.55 × 0.75
= 932.84 KW
Taking per unit price =10.03 taka(at peak hours 5pm-11pm)
= 7.56 taka(at off-peak hour 11pm-5pm)
Industry runs from 8am to 11pm =15 hours everyday and runs 26 days per month
So, total electricity cost of this industry = (932.84 × 9 × 26 × 7.56) +(932.84 × 6 ×
26 ×
From BPDB

15. Power Flow
Sub-
Staion
Transformer
Main Control Box
12 High rated C.B
Air Break Switch
Machine Section
Lower Rated C.B
Each MachineInduction Motor
National
Grid
PGCB
WZPDCL
• 33/11K
V
• 11/0.4K
V
• 132/33K
V
• 11/132KV
Power Flow
under this
Sub-station

16. Discussion
This project was based on the implementation of electrical machines in industrial purpose. At first, the process flow
of the jute mill industry was described. Induction motors were applied to operate the machines. Motor input current, real
power, reactive power and capacitor bank rating for power factor improvement was calculated. Monthly cost of the industry
was calculated. Power flow and circuit breaker arrangement was discussed. That gives us the total view of this industry
production and maintenance chain. The main liabilities of this industry involves ; the deficiency of a backup generator,
diagram of the industry was missing , some name plates were burned out ,heavy noise pollution and hunting. This is how we
covered this presentation.

17. Submission info
Submitted To:
-Prof. Dr. Bashudeb Chandra Ghosh
-Dr. Md. Habibullah
Dept. of EEE,KUET
1. Jahedul Morsalin --------------------1503061
2. Md. Sazzadul Islam --------------------1503062
3.Pranto Dip ----------------------------1503063
4. Tasnim Shahriar Prottoy ---------------1503064
5. Md. Rayid Hasan Mojumder -------------1503066
Year : 3rd Semester : 1st Session : 2017-18 Group : ( B1-01 )
Submitted By: