A

INDUSTRIAL TRAINING REPORT

on

POTROOM MECHANICAL MAINTAINENCE

Completed at

HINDALCO INDUSTRIES LIMITED

RENUKOOT, SONEBHADRA

Submitted
In Partial Fulfillment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
Submitted by

RAGHVENDRA SINGH
1313240128

Duration of Training
18-06-2016 to 18-07-2016 (4 Weeks)

GREATER NOIDA INSTITUTE OF TECHNOLOGY

PLOT NO. 7, K.P. II, GREATER NOIDA, UP-201310
Affiliated to Dr. A.P.J. Abdul Kalam Technical University,
Lucknow
(Formerly known as Uttar Pradesh Technical University,

A
INDUSTRIAL TRAINING REPORT
on

POTROOM MECHANICAL MAINTAINENCE

Completed at

HINDALCO INDUSTRIES LIMITED

RENUKOOT, SONEBHADRA
Submitted
In Partial Fulfillment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
Submitted by

RAGHVENDRA SINGH
1313240128

Duration of Training
18-06-2016 to 18-07-2016 (4 Weeks)

DEPARTMENT OF MECHANICAL ENGINEERING

GREATER NOIDA INSTITUTE OF TECHNOLOGY,

GREATER NOIDA
Affiliated to Dr. A.P.J. Abdul Kalam Technical
University, Lucknow

(Formerly Uttar Pradesh Technical University, Lucknow, U.P.)

August-2016

AKNOWLADGEMENT

I would like to take this opportunity to express my sincere thanks to Hindalco Industries
Limited and special thanks to our respected mentor Mr. R.K. Yadav (senior ManagerPotroom Mechanical Maintenance), for all the guidance and support he provided me
while this training was conducted.
I would like to thanks Mr. Abhineet Singh (Assistant Engineer) for assigning me with the
task and the valuable support he was provided to me.
I would like to thanks Mr. S.K. Das (G.M. Training department Renukoot), and another
staff member for their help, support and guidance they provided to us.
I would like to thanks my father Mr. Arvind Kumar Singh who has suggested me to do
training in the worldwide renowned company HINDALCO.
Last but not least I would like to thanks almighty God who has given me strength to
perform the task given to me. I would also like to thanks my parents, my teachers and
friends and all other member who is directly or indirectly related with this project.

PREFACE

In this era of globalization and liberalization of economy, the technology is changing at a

swift rate and in this process of revolution one need to keep up with the world to strive
for excellence and to meet the global standards.
Giving this due consideration practical training schedules have been inducted in the
curriculum of technical studies as they give a practical exposure to the actual condition,
irrelevant of the field.
In this context I got an opportunity to undergo practical training of 30 days at
HINDALCO INDUSTRIES LIMITED, RENUKOOT, SONEBHADRA(U.P.).
During the training I was asked to study about POTROOM MECHNICAL
MAINTINANCE AT SMELTER PLANT-2 in details and it was a great experience for
me working on this project under the guidance of the professionals.

TABLE OF CONTENT

LIST OF FIGURES

LIST OF TABLES

CHAPTER 1
1.1. INTRODUCTION
HINDALCO INDUSTRIES LIMITED OVERVIEW
A GLIMPSE OF HISTORY
HINDALCO the ADITYA BIRLA GROUP of company is amongst India largest business
house with commanding presence in widely diversified business set up in several
countries.
HINDALCO INDUSTRIES LIMITED, a flagship company of the ADITYA BIRLA
GROUP, is structured into two strategic business aluminum & copper, powerhouse, close
to globe scale, it ranks among Indias top companies in term of market capitalization. In
financial year 2010-11, HINDALCO recorded a turnover of Rs 22313.00 Crore.
It was set up in collaboration with KAISER ALUMINIUM & CHEMICAL
CORPORATION USA, in a record time of 18 months. The plant started its commercial
production in the year 1962 with a capacity of 20000 tons per annum. The company has
grown manifold and is managed by Board of Directors, with Mr. KUMAR
MANGALAM BIRLA as the Chairman of Board of Directors. Day to day affairs of the
company is managed by Professional Executives headed by Sri D.K. Kohli as the Chief
Operations Officer- Aluminum & Power.
The dream of the great visionarys GD Birla to locate an Aluminum plant near Rihand
Power Plant comes true. The late Prime Minister, Pt. Jawaharlal Nehru formally
inaugurated the plant in January 1963. Going around the extensive works, PANDIT Jee
saw his dream of brighter future of India take shape before his eyes. From the modest
beginning in 1962, HINDALCO has now become an industrial giant with a capacity to
produce 345000 tons of aluminum per annum.

1.2.

HINDALCO TODAY

Aluminum has turned out to be the wonder metal of the industrialization world. No other
single metal can do so many jobs, so well, and so economically.
Aluminum growth rate is the highest amongst the major basic metals today. HIDALCO
ranks as the largest aluminum produced in India, whose more than 58% sales are in
value-added products and has more than 40% I total market share. The companys fully
integrated aluminum operations consist of the mining of Bauxite, conversion of Bauxite

into alumina, production of primary aluminum from Alumina by electrolysis and

production like Foil and Wheel at Silvasa. HINDALCOS integrated operations and
operational efficiency have enabled the company to be one of the worlds lowest cost
producers of Aluminum. The company cost efficiency has helped it to record on
outstanding performance in the face of adverse market condition.
HINDALCO also owns a large captive THERMAL POWER PLANT at Renusagar that
meets the power requirement of the company very effectively.
HINDALCO has embarked upon a Rs 18 billion brown field expansion project which
will smelter capacity by 100000MTPA, refining capacity by 210000MTPA, and captive
Power Generated to 769MW in the year 2000, HINDALCO acquired Alcons 54.6
majority stake in another Indian aluminum major Indal. This was followed by public
offer for an additional 20% stake the acquisition makes possible and excellent synergistic
fit Indal. Strength in Aluminum and downstream, products dovetail admirably with
HINDALCO strong presence in metal.
An ISO 9002and 14001 certified company, HINDALCO achieved significant export in
the year 2001-02 & so on, and is registered on the LONDON METAL
EXCHANGE. HINDALCO also has star trading house status. HINDALCO products
range includes Primary aluminum, Ingot, Alloy Ingot, Billets, Cast Slabs, Alloy Wire
Rod, Sheet Products, Extruded Profile, Conform Products, Foil and Alloy.

CHAPTER 2
ALUMINA TRANSFER SYSTEM
2.1.

ALUMINA TRANSPORT TO PRIMARY SILO:

The primary alumina is being feed to each FTP from the existing conveyors through a
diverter valve leading the alumina into air slides (2 airsides / one standby) for filling of
the primary alumina silo (Cap 350 tons).
An emergency airlift is also provided for filling the primary silo.

2.2.

PRIMARY ALUMINA HANDLING:

The primary alumina silo (350 tons) is equipped with two manually operated discharge
valve, one(bypass) leading directly to the distribution box, the other feeding air slide to a
feed box with loss-of-weight control system.
Two blowers are being used to supply fluidizing air to the primary alumina silo and for
the feed & distribution system. From the feed box, the primary alumina is being feed into
the reactors through distribution air slide where it gets reacts with the pot gases.

2.3.

ALUMINA INJECTION & RECIPROCATING:

Adsorption of fluorides take place after the primary alumina has been injected into the
raw gas in the reactor. For more enrichment alumina is recirculated from the screw
conveyer to the same injection point where the primary alumina has injected.
By varying the speed of the screw conveyer we can control the rate of recirculation. All
screw conveyers (6 nos) rotate with the same speed and is being controlled by frequency
converter.

2.4.

ALUMINA TRANSFER SYSTEM:

Alumina produced (Alumina plant) - 1900MT/Day

Alumina transferred to plant-1 400MT/Day
Conveyers
Alumina transferred to plant-2 - 1500MT/Day
Conveyers
Air slide
Air lift
Tankers
Elevators

Figure 1 Air Slide Conveyor

2.5.

FLUORIDE ADSORPTION:

The fresh alumina injected into the reactor serves as an adsorption for the fluorides and it
also helps in creation on the filter bags in the order to collect particles even smaller than
the fabric mesh itself.

2.6.
1.
2.
3.
4.
5.
6.
7.

2.7.

FACTORS AFFECTING THE PRESSURE DROP:

Gas flow per unit of time and filter area
Dust, alumina load and its composition
Pulse cleaning frequency
Valve operating time
Cleaning energy (pulse pressure)
Gas temperature
Gas humidity

CLASSIFICATION OF FANS, BLOWERS AND COMPR:

Fans is used to developed pressure - up to 2 psi
Blower is used
- from 2-10 psi
Compressor is used
- above 10 psi

2.7.1 FANS:
Throughput of centrifugal or axial fans can be changed by varying the inlet or outlet
dampers.
(1) Axial fan is used, where air or gas moves parallel to the direction of rotation of axis
and to move large quantity of air at low pressure.

(2) Centrifugal fan is used, where air or gas moves perpendicular to the axis and for
greater heads.

2.7.2. CENTRIFUGAL FANS:

Radial blade type

Forward curve type
Backward curve and backward inclined type
Air foil centrifugal fans
Tubular centrifugal fans

2.7.3. BLOWERS:
Blowers are generally single stage, high-speed machines or multistage units that operate
at pressure close to or in the range of compressors.
2.8.

SPECIFICATION OF FILTER BAGS:

Diameter

- I.D 127mm

Length

- 6066 mm

No of bags/ lines

- 3240

Top design

-S. S snap band for bag holding. Top open

Longitudinal seam

- Triple stitch with polyester thread

Bottom height

- Bottom closed double bottom unto 100 mm

Fabric used

- Polyester needle felt

Composition

- 100% polyester

Weight

- 550 gm/ mm square

Thickness

- 1.9 mm

Air permeability

- 140 L/dm2/mm at 200 Pa

Air to cloth ratio

- 82 85 m3/m2/hr

Density of fabric

- 0.29 g/cm3

Gas temperature

- 60 to 130 deg. Cen.

Tensile strength

- 1275 N/m

Bursting strength

- 18 Kg/cm2

Max dimensional change

- <1% in hot air at 150 deg. Cen.

Life guarantee

- min 24 month

Performance

- SPM < 8 mg/Nm3

Equipment used for emission measurement: APM 620 supplied by M/S envirotech. New
Delhi

2.9.

ALUMINA (AL2O3) PROPERTIES:

Bulk density 0.9 1.1 g/cm3

Particle density 3.0 3.3 g/cm3
Specific surface 40 80 m2/g
Particle size D50 75 m
- 10 150 m

CHAPTER 3
COMPRESSORS
3.1.

INTRODUCTION:

Compressors are machines designed for compressing air or gas from an initial intake
pressure to a higher discharge pressure.

3.2.

APPLICATIONS:

Compressors are used in wide variety of applications as follows:

For operating instruments

For operating pneumatic tools, gates, damper through
Pneumatic cylinder
It is substitute for steam, electricity in operating tools, drills etc.
For agitation of liquids in tanks
For burner firing through atomization.

3.3.

CLASSIFICATION OF COMPRESSORS:

Type:
1.
2.
3.
4.
5.

Reciprocating
Rotary Vane
Screw
Turbine
Centrifugal

Single acting, Double acting, Single stage, Multi Stage, Two Stage, Single Cylinder,
Multi Cylinder, Water Cooled, Air Cooled, Electrical, Diesel, Gas, and Steam.

3.4. AIR FLOW IN RECIPROCATING COMPRESSOR:

Figure 2 Air flow in Reciprocating compressor

3.5.

MAIN PARTS OF RECIPROCATING COMPRESSORS:

Crank Case: Heavy Duty grain cast iron frame. It also serves as lubricating oil reservoir.
Crank Shaft: Made of forged steel is provided with bolted counter weights.
Connecting Rod: Made of nodular gray iron or forged alloy steel and are provided small and big
end bearing.
Cross Head: Made of nodular gray iron and is designed to ensure true running of piston rod.
Cylinder: Made of graded close grain cast iron. These are provided with water jackets to ensure
efficient cooling of the surface that comes in contact with hot compressed air.
Piston: Made of nodular gray iron or high grade aluminum alloy and having the same weight i.e.
L.P. Piston hollow and H.P. Piston Solid.
Oil Pump: Gear pump is driven from the free end of crank shaft for lubrication of all parts.
Inter Cooler: It is device for removing the Heat of Compression of the air between consecutive
stages of multistage compressors.
After Cooler: These are meant for removing the heat of compression of the air after is
compression is completed. These are also used for removing moisture from compressed air.
Air Receiver: It is used to store the air and help to eliminate pulsation in the discharge line.
Valves: Each cylinder is provided two suction and two delivery valves for the upper and lower
compression. The valve is opened and closed by the means of the pressure difference occurring
in the cylinder.

3.6.

RECIPROCATING COMPRESSOR:
3.6.1. CLEARANCES FOR A TYPICAL RECIPROCATING

COMPRESSOR:
Main Bearing and Crank shaft = 0.66 d to 0.0015 d
Thrust collar and Crank shaft lateral = 0.008 to 0.004
Cross head and guide = 0.006 to 0.016
Cylinder and Piston per 100 mm = 0.004 to 0.012
Piston ring gaps in plates 0.2 to 0.3% dia. Of cylinder or 0.20 to 0.024 per 100 mm dia.
Side gap between rings and piston grooves 0.002 to 0.008
Piston groove depth piston rings thickness 0.01% to 0.2%d
Lateral clearance of big end between connecting rod and crank shaft = 0.008 to 0.025
Piston / Piston rod and outer cover is 1/16 to 3/16
Piston / Piston rod and inner cover is 3/64 to 1/8
Diametrical clearance between big end baring 0.0008 d to 0.0012 d.

3.7.

CENTRIFUGAL COMPRESSORS:

Make: Ingersoll Rand

Type: Centac Integrally Geared, centrifugal air compressors
Model: C 55 MX3
Capacity: 6092 cfm
Speed: 2975 rpm
Discharge pressure (after cooler outlet): 7kg/cm2
Suction pressure (Barometric Pressure): 0.995 kg/cm2
Inlet air temperature: 50-degree c/ 35-degree c

Shaft Power: 828.2 kw / 880.81

Motor BHEL make: 950 kw, 3.3 kV, 3 Ph., 50 Hz, and squirrel cage induction motor.
Specific Power kw/cfm: 0.131/0.144
Cold Water Consumption: 3400 LPM
Suction Filter: 2 no (2stage)
No. Of stage at compressor: 3
Impellers: 3ss impellers mounted on separate pinion
Maximum allowable pressure drops across suction filter: 0.02kg/cm2
Lubricating Oil: Servo prime-32
Oil pressure: 2kg/cm2 max.

3.8.

PRINCIPLE:

The Centac compressor is a dynamic centrifugal type compressor. The air being
compressed enters the compressor through the machine mounted inlet control device and
flows to the first stage where the impeller imparts velocity to air.
The air proceeds through the stationary diffuser that converts velocity to pressure. The
built-in inter cooler removes the heat of compression, which improves efficiency. The air
then passes through a stainless steel moisture separator in a low velocity zone to remove
condensate. Entrained moisture in the air is reduced when the air is forced through
stainless steel moisture separators. This sequence repeats in each succeeding stage until
the compressor archives the desired operating pressure.

3.9.

DESCRIPTION:

The Centac compressor is a centrifugal compressor driven by an electric motor. The

compressor and driver are not directly coupled.
The compressor contains:

A main driver that directly drives a bull gear that is common to all stages.
Compression stages consisting of an impeller mounted on its own shaft, enclosed within a

common cast iron casing.

Rotors consisting of an integral pinon gear driven at its optimum speed by a common bull

gear.
An intercooler that is mounted after stage of compression.
A moisture separator and a moisture removal system are fitted after each cooler to remove
condensate.

3.10. COMPRESSORS PARTS:

Rotor Assemblies

Bearing
Seals
Diffusers
Intercoolers
Moisture Separators
Vibration Probes
Casing
Compressor Driver
Lubrication System
Diffusers: A diffuser, located between each impeller and cooler, converts velocity energy
in pressure energy.
Intercoolers and After coolers: The Coolers are donut types with the water over tubes
and oil in shell.
Moisture Separators: The moisture separator is a SS mesh screen type construction
located at points in the air compressor where air velocities are relatively low permitting
efficient moisture separation.
Vibration Probes: A non-contacting vibration probe is mounted on each stage next to the
plain bearing to measure vibration of each rotor assemblies. Each probe is connected to a
vibration transmitter.
Casing: The gear case consists of a casing and casing cover jointed vertically by bolted
assembly which is opened for servicing the bull gear and its bearings.
Rotor Assemblies: Each rotor consists of an SS impeller and a removable thrust collar
mounted on a helical geared pinion shaft each secured to the shaft by a polygon spline,
eliminating the need of keyways.
Bearings: Each rotor assembly is equipped with a thrust bearing near impeller and a
plain journal bearing, Babbitt lined, near bull gears for radial loads.
Seals: A single cartridge seal is mounted in the plain bearing housing behind each
impeller. Each cartridge consists of three, one piece, fully floating non-contact carbon
rings. One ring is used as an air seal and the remaining two as oil seals. Buffer air is
supplied to the oil a seal assuring that lube oil is not drawn past the seals, thus ensuring
oil free air.

3.11. COMPRESSORS EFFICIENCY:

3.11.1. Factors effecting the compressors efficiency:

Leaky Valve
Too large piston ring gaps
More clearance between cylinder and piston

Leakage at piston rod

Inadequate Inter stage cooling (inter cooler plugged)
High Inlet Air temperature
Low water Pressure
High inlet water temperature
Speed is less (Prime Mover)
Choking of Suction filter
After Cooler ineffective
Moisture separator is not working properly (Moisture in Air)

3.12. AIR CONSERVATION / EFFICIENT AIR SYSTEM:

Inter cooler and after cooler must be perfect and to be cleaned periodically.
Threaded connections are to be avoided in air system.
Tapping in air lines, receiver outlet should be from top to avoid water moisture carry over.
Auto drains are to provide for drain.
Global valves should be used in air system as pressure drop is very high. In 1 gate valve

pressure drop is 1.14ft of used pipe whereas in 1 global valve is 30ft of used pipe.
Hydraulic testing of receiver should be done on every year at 1.5 times the safety of valve

setting.
Flow meters are to provide in air lines to control air consumption.
The color coding of air lines is essential.
Cleaning operation should be done with 30-40 psi air pressure only to save air consumption.

Pressure regulations are to be provided.

pipe releases 308 cfm at 70 psi
pipe releases 200 cfm at 40 psi
Efficiency, flow measurement of compressors.
Ratio of Compression: The rates of initial volume to final volume.
Cylinder Ratio: r = P3/P
Where r = Ratio of Compression
P3 = Absolute discharge pressure in psi
P = Atmospheric pressure in psi
Inter Cooler Pressure: p1 = P*P3/P P
Piston Speed: (2 * Stroke length * rpm)/ 12 ft./min
Displacement: It is volume swept through by the piston with proper deduction for the
piston rod, Unit- CFM

Normal Velocity in compressed air piping = 20 ft. /sec max

Effect of Comparative pressure on power Cost: Cost of air generation is 7% less at 6
kg/cm2 than at 7 kg/cm2

3.13. UNLOADING POWER OF COMPRESSORS IN COMPARISON TO

FULL LOAD:
Unloading Power consumption should be 15% to 18% of full load.

Cost of air generation in Alumina Plant Rs. 5.20 approx. (Calculated)

Intake air temperature decreases 3deg C and due to this increase in volume delivered by 1%.

Figure 3 Centrifugal Supercharger

CHAPTER 4
CRANE
Crane is material handling equipment.

4.1.

TYPES OF CRANE:

1.
2.
3.

Jib crane
Mobile crane
O. h. crane or E.O.T. crane

4.1.1. E.O.T. CRANE (ELECTRICAL OVERHEAD TRAVELING CRANE):

E.O.T. crane travels on a pair of gantry rails mounted on gantry girders, which is turn are
supported on columns on two sides of the bay. The crane consists of bridge girders, end
carriages, platforms, trolley assembly and long travel drive machinery. Machineries for
hoisting motion and trolley travel are mounted on the trolley. The trolley moves on rails fixed
on the top of bridge girders.

4.2.

MAIN PARTS OF CRANE:

1.
2.
3.

Long travel (bridge)

Cross travel (trolley)
Hoist travel (hoist)

4.2.1. ACCORDING TO BRIDGE DRIVE:

1. Single motor drive crane
2. Double motor drive crane

4.3.
1.
2.
3.
4.
5.
6.

POT LINE

MAKE

LINE 1
LINE 2,3
LINE 4
LINE 5
LINE 6 TO 11
B/F#1 TO 3
B/F#4
MAINT. AREA

P&H
P&H
A.C.C.
W.M.I.
MUKAND
W.M.I.
CIMMCO
W.M.I.

CAPACITY
6.0
7.5
7.5
7.5
7.5
6.0
6.0
7.5

M.T.
M.T.
M.T.
M.T.
M.T.
M.T.
M.T.
M.T.

DRIVE
SINGLE DRIVE
SINGLE DRIVE
SINGLE DRIVE
DOUBLE DRIVE
DOUBLE DRIVE
DOUBLE DRIVE
DOUBLE DRIVE
SINGLE DRIVE

BRIDGE UNITS:
Bridge motor (25HP & 960 RPM)
Centre gear box
Long shaft (dia. 2.188 inch, length 188.75 inch)
End gear box (pinion 26 teeth)
Floating wheel (dia. 3 inch, length 7 feet
5/8 inch)
Driving wheel (dia. 17.875 inch)

4.3.1. TROLLEY UNIT:

1. Trolley motor (3 HP)
2. Gear box
3. Driving wheel

4.3.2. HOIST UNIT:

1.
2.
3.
4.

Hoist motor (25 HP 960 RPM)

Floating shaft (dia.2.5 inch; length 30 inch)
Gear box (pinion 24 O.D. 4.4372 inch)
Rope drum (dia. 15 inch, length 4 ft. 11.5 inch, groove 18 nos. L.H. & R.H. & 0.5-inch dia.

Material M.S.)
5.
Equalizer pulley (dia. 9.81)

4.3.3. CRANE HOOK:

(MATERIAL KILLED LOW CARBON STEEL AS PER BS, EN-3 A/IS: 1875 GRADE 2)
1.

Original opening of hook is 78 mm (allowable opening of hook is 10% of the original

opening = 7.8mm. so max. hook opening 85.8 mm is allowable)

2.
Hook thickness is 105 mm (max wear is 10% i.e. 10.5mm allowable)

4.4.

SCOPE IN POT ROOM:

Anode setting, metal tapping, crust breaking, metal pouring, skimming, pot relining and other
material handling jobs.

4.5.

ADVANTAGES OF E.O.T. CRANES:

1.
2.
3.

They eliminate the need for wide passages and do not block any space at ground level.
They cover the entire working area without limiting the layout.
Operating cost are very low, since it needs only one operator, require very little maintenance

and consumes a very little electric power.

4.
These cranes are especially suited for handling unit loads and for such material like hot metal,
explosives, corrosive and dangerous material.

4.6.

FOLLOWING PROBLEMS OCCURRED IN CRANES:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

C.R.P. tripping trouble

Collector shoe out trouble
Bridge jamming trouble
Hoist brake slipping trouble
Foot brake trouble
Wire rope sparking
Hook insulator sparking trouble
Hook jamming trouble
Wire rope broken trouble
Trolley derailment

4.6.1. CAUSE OF C.R.P. TROUBLES:

1.
2.
3.
4.
5.

Collector shoe out

Defective C.R.P. joints
Crossing of crane
Misalignment of pantograph
Defective track rail joints

4.6.2. CAUSE OF C/SHOE OUT:

1.
2.
3.
4.
5.
6.

Crossing of crane
Copper flexible cut
Finger broken
Shoe pin out
Defective C.R.P. joints
Misalignment of pantograph

4.6.3. CAUSE OF CRANE CROSS:

1.
2.
3.
4.
5.
6.
7.

Coupling bolts loose

Wheel housing bolts loose
Excessive play in gear coupling
Unequal diameter of driving wheel
Misalignment of wheels
Jamming of brakes in one side brake unit
Gear loose in gear box

4.6.4. CAUSE OF BRIDGE JAMMING:

1.
2.

Wheel axel broken

Wheel bearing defective or broken

4.6.5. CAUSE OF FOOT BRAKE TROUBLE:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Master cylinder piston broken

Master cylinder cup washer damage
N.R.V. leakage
Valve seat defective
Air in copper tube
Looseness of connector
Wheel cylinder defective
Spiral spring broken
Locating bush broken
Master cylinder paddle slippage
Less oil in master cylinder
Copper tube seat defective
Air breather thread damage
Wheel cylinder hose pipe chocking

4.6.6. CAUSE OF WIRE ROPE SPARKING:

Wire rope touches with pot during tapping.

4.6.7. CAUSE OF HOOK INSULATOR SPARKING TROUBLE:

Hook insulator, insulation defective

4.6.8. CAUSE OF HOOK JAMMING:

Hook insulator thrust Brg. Defective

4.6.9. CAUSE OF WIRE ROPE BROKEN:

Hoist direct during upward direction

Over lifting of hook block due to limit switch not working
Air valve closed during of crust breaker
Overloading due to crust breaker chisel entangle in catwalk

4.6.10.CAUSE OF TROLLEY DERAILMENT:

Trolley movement during crust breaker chisel entangle in catwalk, during shifting of crust
breaker from one pot to another pot.

4.7.

POWER SUPPLY IN CRANE:

415 volts 3 phase

4.7.1. BRAKES:

Bridge: foot operated hydraulic brake

Hoist: D.C. electromagnetic brake
Trolley: nil

4.7.2. POT ROOM CRANES SPEED:

Bridge speed
Trolley speed
Hoist speed

122 MTR/MIN.
58.0 MTR/MIN.
12.8 MTR/MIN.

4.7.3. HOIST MAX. LIFT:

Line 4
Line 5 to 8

5.5 MTR.
5.8 MTR.

Line 9 to 11
B/F# 4

6.1 MTR
4.9 MTR

4.7.4. WIRE ROPE CONSTRUCTION:

16mm dia. 6*19 const; steel
Core; 180 UTS; breaking strength 16500 KGS.

4.7.5. WIRE ROPE MATERIAL UNGALVANIZED STEEL:

Wire rope construction and size:

Line 4
16mm dia. 6*19*38 MTR.
Line 5 to 8
16mm dia. 6*19*42 MTR.
Line 9 to 11
16mm dia. 6*19*48 MTR.
B/F #4
--DOMaintenance area
16mm dia. 6*19*38 MTR.
Hook material
fully killed low carbon steel EN-3AS IS; grade 2

4.8.

CRANE NUMBERING AND LOCATIONS DETAILS:

POT LINES
LINE 4
LINE 5
LINE 6
LINE 7
LINE 8
LINE 9
LINE 10
LINE 11
B/F #4
MAINTENANCE AREA

CRANE NUMBERS
2, 4
6, 8
12, 14
16, 18
20, 22
26, 28
30, 32
34, 36
9(NORTH)
23(NORTH)

4.9. BRIDGE SPAN:

Line 4
Line 5 to 8
Line 9 to 11
Maintenance area
B/F #4

13.056 MTR.
13.970 MTR.
13.900 MTR.
13.970 MTR.
85.0 feet

4.9.1. TROLLEY SPAN:

2.0 MTR.

4.10. GENERAL CHECKING IN PM:

Oil level, oil leakage & base bolt of gear boxes

Brake drum & brake unit of hoist & bridge
Foot brake (master cylinder)
Wheels, bearing and housing
Base & coupling bolt of motor
Coupling & coupling bolts of motor
Rope drum and rope
Bumper block and stopper
Hoist & bridge lever & controller
Coupling & coupling bolts of all shafts

1, 3
5, 7
11, 13
15, 17
19, 21
25, 27
29, 31
33, 35
10(NORTH)
24(NORTH)

Rope drum & rope wire (if 10 wire broken in 01 ft. of 6/19 wire rope) then wire rope should

be changed
Pantograph/shoe & flexible

CHAPTER 5
DRY SCRUBBING SYSTEM:
The dry scrubbing system treats exhaust gas from pots. This treatment of gases is based
on adsorption of gaseous fluoride by means of injection alumina, which is followed by
bag filter where enriched alumina is collected and being sent to pots for alumina feeding.
This plant can also be named as Fume Treatment Plant.
F.T.P. serves the two functions, first it reduces the emission of the HF gas and the dust
particulate into the atmosphere, and secondly it recovers aluminum fluoride, which is an
important input to the pots. This reduces the consumption of ALF3, which we purchase
from outside party.

5.1.

NEED FOR D.S.S./F.T.P.:

During the electrolysis process for producing aluminum, the alumina (AL2O3) liberates
Oxygen and the metal aluminum is produced. The electrolysis process takes place in an
electrolytic bath consisting of aluminum fluoride and some other chemicals. During this
process hazardous gases are emitted (mainly consisting of Hydrogen fluoride and other
fluorides). To prevent these gases to escape into the atmosphere, it is mandatory to install
F.T.P. Since fumes are treated by adsorption of fluorides gases into dry alumina, hence the
system is called Dry Scrubbing System. The F.T.P. treats exhaust gas from aluminum
reduction cells by dry scrubbing process, followed by bag filter to collect fluorinated
(enriched) alumina. F.T.P. reduces the emission of the HF gas and the dust particulate into
the atmosphere.

Figure 4 Process Description

The process description of the F.T.P. is divided into four main sections: 1.
2.
3.
4.

Gas ducting and fan system

Bag filter system
Alumina handling system
Instrumentation and electrical system

Alumina consumed in the pots is transported from the belts conveyors to the primary silo,
through the F.T.P. During this process the primary alumina is mixed with the pot gas in
the reactor and forms the enriched alumina. This enriched (secondary) alumina in turn
transported to the reduction pots where aluminum metal is produced. Other particulates
are collected on the filter bags.

5.2.

GAS DUCTING AND FAN SYSTEM:

The main ductwork is designed in such a way that it gives nearly same velocity
throughout the system. Each individual pot has the branch duct having a manually
adjustable damper. These dampers are set in a fixed position after balancing, so that an
even suction is obtained from each pot.
For the suction of the gas there are three main exhaust fans (Centrifugal type) in each
line. Each fan has inlet and outlet damper. There are 6-filter unit in each FTP and each
filter unit comprises a reactor and a filter compartment.
Each filter unit can be isolated for main jobs by the inlet duct damper and outlet duct
damper.

Figure 5 Duct Connected with Pots

5.3.

CLEANING OF THE FILTER BAGS:

The cleaning od the bags is an accomplished by the pulse jet technique, where a medium
pressure pulse of air is introduced into the open top of each filter bag through nozzle
header through nozzle arranged on a nozzle header. The pulse air enters the nozzle header
through solenoid diaphragm valve installed on pulse tanks. There are 30 rows in each bag
house and each row comprises of 18 bags. The injection of pulse air results in a rapid
expansion of the bags. Alumina and dust having accumulated on the outside of the bags is
dislodged and collected in the hopper.
One row in all the filter unit is cleaned simultaneously. The next row in line is cleaned
after a set time interval has elapsed.
The permeability of a new bag is very high, resulting in a low-pressure drop. Fumes and
alumina in the gas flow will increases the pressure drop through the bags.

5.4.

BAG CLEANING PARAMETER:

The bag cleaning process is controlled by the PLC installed in control room. All filters
are cleaning on-line. This on-line pulsing indicates that one row of bags in each filter unit
is cleaned simultaneously. The gas flow, dust load and gas temperature are normally
given parameters. The pulse cleaning intervals, valve opening time and pulse air pressure
for the bags can be varied within limits for optimal operation of FTP.
The pressure drop affects the power consumption of the fans whereas bag-cleaning
parameters may affect the life of the bags.

5.5.

PULSE SYSTEM:

Figure 6 Pulse System

5.6.

BAG HOUSE:

Figure 7 Pulse - jet Baghouse sketch

CHAPTER 6
CRUST BREAKER

6.1.

EQUIPMENT DESCRIPTION:

The Pot Rooms Crust breaker is comprised of the following principle sub-assemblies:

Upper Frame
Upper Works
Lower Works
Support Bearing Assembly
Hydraulic/Pneumatic System

6.2.

UPPER FRAME:

Connection of the Crust breaker to the crane cross-travel trolley is by means of a crane
adapter frame (Permanently fixed to the trolley framework), and the mating upper frame
of the Crust breaker.
The upper frame incorporates four (4) spring-loaded, pneumatically actuated locking pins
that locate in slotted holes on the crane adopter frame. It is attached to, but insulated
from, the outer frame of the upper structure of the Crust Breaker.

6.3.

UPPER WORKS:

The upper works consist of an inner and outer frame. The inner frame is mounted on
guide bushes that run on four (4) verticals guide bars that are in turn attached to the outer
frame
It is possible to raise and lower the inner frame within an operating range of 400mm to
cater for (1) the variation in pot depth from 14 to 22; an (2) the requirement to lift the
crust breaker over the various arrangement of the sloped bus.

Vertical travel of the inner frame, relative to the outer frame, is achieved by the rising and
lowering of the crane hook is raised, the inner frame is pulled up against two (2)
hydraulic cylinders, which act on the outer frame (and the attached upper frame) against
the crane adapter frame.

These cylinder operate at a constant hydraulic pressure, which is preset via a pressurereducing valve to provide the required preload. A pressure-relieving valve allows the
cylinders to be compressed by the action of the crane raising the inner frame, thereby
maintain the same preset pressure.

If the end of stroke of the hydraulic cylinders is approached (which should not be
necessary)
An Audible indicator will sound to warm the operator.
An additional function of these cylinders is to minimize the risk of the crane hook if an
operator inadvertently allows the crust breaker to bear against a fixed obstacle.
The inner frame also incorporates the hydraulic reservoir, air-over-oil pump, oil filters
and compressed air lubricator.

6.4.

LOWER WORKS:

The lower works of the Crust breaker incorporates the operator controls and the
pneumatic Crust breaker hammer. The moving parts of the lower frame are captured
within replaceable slide-ways and bushes.

The operator controls the motions of the Crust breaker via a joystick. The joystick
controls the following motion:

Rotation to the left and the right (360deg. Slew)

Tilting of the hammer to change the horizontal location of the tip of the chisel relative to the

centerline of the crust breaker.

Extension and retraction of the hammer and activation of the percussion mode of the hammer

Additional controls mounted on the Lower Works include:

A high/low pressures switch to control the force of crust breaking.

6.5.

SUPPORT BEARING ASSEMBLY:

The support bearing assembly is attached to, and insulated from, lower section of the
inner frame. It forms the connection between the upper and lower works and incorporates
the following components:

An outer tube well-meant that is attached to the inner frame and incorporates a fixed ring gear.

A hydraulic motor that acts on the ring gear to provide rotation for the lower structure via the

inner tube weldment.

A telescope air transfer unites that provide transfer of compressed air to the hammer extension

Cylinder and pneumatic Crust breaker hammer.

A rotary union that provide hydraulic and pneumatic connection between the upper works and
the rotary lower structure.

6.6.

HYDRAULIC POWER UNIT:

The crust breaker is serviced by a Hydraulic Power Unit mounted to the inner frame of
the upper works. The Hydraulic Power Unit supplies hydraulic fluid under pressure to a
control valve manifold and joystick where individual valves control the hydraulic
functions of the Crust breaker. The Hydraulic pump is an integrated air over oil piston
pump and supply extra hydraulic capacity during peak demand.

6.7.

CRUST BREAKER OPERATION:

The Pot Rooms Crust breaker breaks the frozen bath (cryolite) crust from the top and
sides of the spent anode by the action of a pneumatic percussion jack hammer.
The jack hammer has three (3) degrees of motion to position the jackhammer pick for
crust breaking. The entire lower works can be rotated without restriction, the jackhammer
move vertically on a sliding carriage, and jackhammer and the carriage, can extend on a
guided scissor mechanism.
Before crust breaking can commences, the following condition must be met:
1. The three safety pins need to be removed, that is the pin that locks the turret rotation, the pin that
lock the scissor linkage from moving, and the pin that holds the jack hammer carriage in the
raised position.

NOTE:
The last two pins may require retraction of the carriage and raising of the jack hammer
under power to alloy easy removal.
2.

The plant air supplied is connected.

The platform operator using the Crust breaking joystick, on the operators panel, controls
the Crust breaking function. To extend the jack hammer (scissor mechanism) the joystick
is pushed forward, the joystick is serviced by the proportional hydraulic valve, therefore
the further forward the joystick is pushed the faster the jack hammer will be extended. To
retract the jack hammer (scissor mechanism) the joystick is pushed backward, pushing

the joystick to the left will rotated the lower works clockwise. Pushing the joystick to the
right will rotate the lower works counter clockwise. Depression the joystick button on the
top of the joystick causes the hammer too lower and the percussion action to commence.
Releasing the joystick button, the hammer causes the hammer to raise and the percussion
action to stop.

CONCLUSION
It was a great privilege to undergo vocational training at Hindalco Industry Limited,
Renukoot. Working in such an encouraging atmosphere with people dealing with latest
technology working in tight schedule, dedicated to help was a privilege. While carrying
out the industrial training, I received tremendous support from all the staffs of the various
departments. Working in different shops provided a real time experience of engineering
and technology being used currently in manufacturing industry. The training helped me in
great deal as I came to know and explore more information and gained invaluable
knowledge about the subject. The training also helped me to gain knowledge about the
industrial environment. This invaluable experience will help me further to adapt quickly
in the environment of the company in future when I will have to join any company.

REFERENCE
BOOKS REFERRED:

Financial Management I.M. Pandey, 9th edition; New Delhi: Vikas

Fundamentals of Financial Management R.P. Rustagi, 3rd edition; New Delhi: Galgotia
Publishing Company; 2002.
Financial Management Prassanna Chandra

MAGAZINE AND JOURNALS:

Annual Report of FY 2010-11, 2011-12 of Hindalco Industries Ltd.

Aditya Kiran
Hindalco Sandesh
Induction Guide (Training Centre)

WEBSITES REFERRED:
www.hindalco.com
www.workingcapital.org
www.investopedia.com
www.adityabirla.com