A

Project Report
On
STUDY OF THE DIGITIZATION OF CRANE AT STEEL MELTING SHOP AT TATA
STEELS

Submitted By
RUCHI JAIN
COLLEGE OF ENGINEERING,
TEERTHANKAR MAHAVEER UNIVERSITY,
MORADABAD (U.P)
INDUSTRIAL TRAINING REPORT
 CERTIFICATE
To Whom It May Concern

This is to certify that this Project report entitled “STUDY OF THE DIGITIZATION OF CRANES AT
STEEL MELTING SHOP AT TATA STEELS” is a bonafide work done by RUCHI JAIN,student
Electronics& Communication Engineering at COLLEGE OF ENGINEERING,TMU during the
industrial training at TATA STEEL,Jamshedpur during the period of 19TH JUNE 2018 to
I found her sincere and her performance was excellent. She attended the training programme
sincerely and his conduct was good throughout the duration of the training.
I wish her all success in her future endeavors.

RUCHI JAIN
ACKNOWLEDGEMENT
With profound respect & gratitude I take the opportunity to convey my regards to all the
Tata Steel staff that helped me out in completing the required training at PROJECT CENTER
at Tata Steel, Jamshedpur.

First of all I would like to convey my gratitude to my project guide Mr NAVEEN Kumar
UPADHYAY (SENIOR MANAGER,PROJECT CENTER DIVISION) for his continuous support
during my project. He has been a constant source of encouragement during the entire
project. He provided us valuable information as well as knowledge regarding my project. I
would also like to thank Mr. MOHIT RANJAN BHATTA (HEAD OF PROJECTS ELECTRICAL) for
his valuable guidance that I was fortunate to receive.

I am indebted to all those who encouraged and helped me to study the project,“
Study of the DIGITIZATION OF CRANES AT STEEL MELTING SHOP AT TATA STEELS”.I would
also like to thank the foremen of the IEM Shift Office for their able guidance, patience
,support and insight without which the study of the project would have been incomplete.
TABLE OF CONTENT:
 CERTIFICATE
 ACKNOWLEDGEMENT
 INTRODUCTION (TO THE ORGANISATION)

 INTRODUCTION (to the topic)

 A) Digitization (digitalization)
 B) Conventional cranes
 C) Digitalize of cranes (basic idea)

 USER REQUIREMENT
 SIMOCRANE ,as discussed in introduction.
 SENSORS (introduction, variety of sensors)

 .OBJECTIVE
 Scope of work
 SCOPE OF WORK
 An Introduction
to the organisation...
Tata Steel
Jamshedpur, Jharkhand
Company Profile

Company Logo:

Type: Public

Industry: Steel

Founded: 1907

Founder: Jamsetji Nusserwanji Tata (production started by Sir Dorabji Tata)

Headquarters: Mumbai, Maharashtra, India

Area served: Worldwide

Chairman: Mr. Natarajan Chandrasekaran

Vice-Chairman: Mr.Balasubramanian Muthuraman

Managing Director: Mr. T. V. Narendran

Products: Hot &cold rolled coils & sheets
Wires & Rods
Construction Bars
Pipes
Structural& forging quality steel

Revenue: $22.741 billion (2010)

Tata Steel formerly known as TISCO and Tata Iron and Steel Company Limited,
was founded in 1907 by Sri Jamsetji Nusserwanji Tata,and brought into operation
by Sir Dorabji Tata. Currently it is the world's seventh largest steel company, with
an annual crude steel capacity of 31 million tonnes. It is the largest private sector
steel company in India in terms of domestic production. Currently ranked
410thon Fortune Global 500, it is basedin Jamshedpur,Jharkhand, India. It is part
of Tata Groupof companies. Tata Steel is also India's second-largest and second-
most profitable company in private sector with consolidated revenues of
132,110 crore(US$29.46 billion) and net profit of over 12,350 crore (US$2.75
billion) during the year ended March 31, 2008. Tata Steel is the 8th most
valuable brand according to an annual survey conducted by Brand Finance and
The Economic Times in 2010.Its main plant is located in Jamshedpur, Jharkhand. With its recent
acquisitions, the company has become a multinational with operations in various countries.The registered
office of Tata Steel is in Mumbai. The company was also recognized as the world's best steel producer by
World Steel Dynamics in 2005. The company is listed on Bombay Stock Exchange and National Stock
Exchange of India, and employs about 34,101 people (as of 2010).

Post its globalization initiatives that established its presence in Europe and South
East Asia, Tata Steel is the world’s second-most geographically-diversified steel
Strategic Business Units

Bearings Division: Manufactures ball bearings, double row self- aligning

bearings, magneto bearings, clutch release bearings and tapered roller for two
wheelers, fans, water pumps, and now the Tata Nano car.

Ferro Alloys and Minerals: operates chrome mines and has units for making
ferro chrome and ferro manganese. It is one of the largest players in the global
ferro chrome market

Agrico Division: Tata Agrico is the first organised manufacturer in India of hand
tools and implements for application in agriculture, mining and construction.

Tata Growth Shop: Has designed,

developed, manufactured, erected
and commissioned thousands of
equipment ranging from overhead
cranes to high precision
components, including a rocket
The Group’s vision is to be the world’s steel industry benchmark in “Value
Creation” and “Corporate Citizenship” through the excellence of its people, its
innovative approach and overall conduct. Underpinning this vision is a
performance culture committed to aspirational targets, safety and social
responsibility, continuous improvement, openness and transparency. In 2008,
Tata Steel India became the first integrated steel plant in the world, outside
Japan, to be awarded the Deming application Prize 2008 for excellence in Total
Quality Management.

Capacity Expansion

Tata Steel has set an ambitious target to achieve a capacity of 100 million
tonne by 2015. Vice Chairman B. Muthuraman stated that of the 100 million
tonne, Tata Steel is planning a 50-50 balance between greenfield facilities and
acquisitions.

Overseas acquisitions have already added up to 21.4 million tonne, which

includes Corus production at 18.2 million tonne, Natsteel production at two
million tonne and Millennium Steel production at 1.2 million tonne. Tata is
looking to add another 29 million tonnes through the acquisition route.

Tata Steel has lined up a series of greenfield projects in India and outside
which includes

 6 million tonne plant in Orissa (India)

 6.8 million tonne in Jharkhand (India)(2.9 million tonne will be added by
dec, 2011)
 5 million tonne in Chhattisgarh (India)
 3-million tonne plant in Iran
 2.4-million tonne plant in Bangladesh
 5 million tonne capacity expansion at Jamshedpur (India)
 4.5 million tonne plant in Vietnam (feasibility studies underway)
Steel Production: A brief Overview
The steps in which the iron ore from the mines takes the shape of different
kind of steel products is depicted below. To better understand what this
project is all about one must be slightly acquainted with how steel is produced.
Before going into details we can see the procedure in form of a small flowchart

Finished
Product

Blast furnace takes in coke, limestone, iron ore and sinter as its input and
produces cast iron or pig iron which contains high percentage of carbon. This
renders it the property to become brittle. Thus to reduce its carbon content,
the hot metal produce from blast furnace is sent to LD1 & LD2 via torpedoes.
There oxygen is passed through the metal to oxidise carbon first to CO and
then to CO2. The produce of LD1 & LD2 is termed as steel and contains very
less amount of carbon. This produce is then casted in forms of slabs(to make
sheets) or billets(to make wires, rods or re-bars) and sent to finishing shops. At
the finishing shops the desired steel product is formed as asked by the
customer.
Sinter, which is one of the inputs of the blast furnace is an agglomeration
of iron ore fines, coke and limestone. It is a ready charge and needs no
treatment. It can be produced as desired by the blast furnace. Sinter is
OVERVIEW OF TATA STEEL,Jamshedpur
The various divisions present inside the plant compound of TATA Steel are

1.RAW MATERIALS AND IRON MAKING GROUP

 Sinter Plant #1
 Sinter Plant #2
 Sinter Plant #3
 Sinter Plant #4
 Blast Furnace A-F
 G blast Furnace
 H Blast Furnace
 I Blast Furnace
 Coke Plant

2.LONG PRODUCTS GROUP

 LD Shop No.1
 Wire Rod Mill
 Merchant Mill

3.FLAT PRODUCTS GROUP

 LD#2 AND Slab Caster

 Hot Strip Mill
 Cold Rolling Mill

4.OTHER PRODUCTION DEPTS.

 Growth Shop,Adityapur
 Tubes division
 Lime Plant

 Metal recovery and Slag processing Plant

DIGITALIZATION OF STEEL MELTING SHOP
CRANES AT TATA STEELS

GUIDE : Mr. Naveen K

Upadhyay
Senior Manager ,Projects
Electrics Environment Projects,
Central Project Engineering
Division.
TRAFFIC LIGHT INDICATION

Fault
Alarm
Healthy

Crane – Ladle Preparation -1 (JK1)

 Let us know about the word ‘digitalization’ it is the process of
converting information into digital (i.e. computer readable) format in
which the information is organized into bits . The result is the
1) representation
INTRODUCTION: of an object image , sound , document ,signal
(generally an analog signal) by generating a series of numbers that
describe a discrete set of its points or samples . This result is called
digital representation . In modern practice, the digitized data is in
he form of binary numbers (i.e. 0 & 1)
 Digitization is of crucial importance
to data processing , storage and transmission ,because it “allows
information of all kinds in all formats to be carried with the same
efficiency and also intermingled”
 Digitization (digitalization) occurs mainly in two parts:
 A) QUANTIZATION : Samples are rounded to a fixed set of numbers
such as integers(say), hence this process is known as quantization .
 B) DISCRETIZATION :The reading of an analog signal A, and at
regular time intervals (frequency), sampling the value of the signal
at a point . Each such reading is called a sample and may be
considered as infinite precision at this stage.
 In general, these can occur at same time , despite being conceptually
 NOW LET US UNDERSTAND ABOUT
CONVENTIONAL CRANES:
A crane is a type of machine, generally equipped with a hoist rope, wire
ropes or chain, an sheaves ,that can be used both to lift an lower
materials and o move them horizontally .It is mainly used for lifting
heavy things and transporting them to other placs. The device uses one
or more simple machines to create mechanical advantage and thus move
loads beyond the normal capability of a human. Cranes are commonly
employed in the transport industry for the loading and unloading of
freight in the construction industry for the movement of materials and in
the manufacturing industry for assembly of heavy equipment.
The first known construction cranes were
invented by the ancient greeks and were powered by men. These cranes
were used for the construction of tall buildings . Larger cranes were
developed ,employing the use of human treadwheels , permitting the
lifting of heavier weights.
For many centuries, power was supplied by
physical exerction of men or animals although hoists in watermills and
windmills could be driven by the harnessed natural power. The first
mechanical power was provided by steam engines , the earliest steam
cranes being being introduced in the 18th or 19th century , with many
remaining in use well into the late 20th century .MODERN CRANES
usually use internal combustion engines or electric motors and hydraulic
systems to provide a musch greater lifting capapbility than was
DIGITALIZATION OF CRANES
(BASIC IDEA)
 CRANE AUTOMATION IS IN FULL SWING. The high level of automation is causing a
lot of change of automation is causing a lot of change : an automated container terminal
means more more efficiency ,greater productivity and in particular , more safety . The
operator digitally operates the crane from a safe distance.
 HIGH LEVEL OF AUTOMATION:
 SIMOCRANE stands for productivity ,safety and efficiency,and is therefore your first
choice when every millimeter counts .And top speed .The higher level of crane
automation in container terminals means more efficiency , greater productivity and in
particular more safety,
 The operator controls the crane from his remote control operator station.(RCOS).He can
view the entire crane operating range on his monitor.
 SIMOCRANE modules are scalable technology modules in crane automation covering
the requirements for cranes in ports, the steel and paper industries ,ship building and a
large range of other indutrial applications.
 The benefits of SIMOCRNE at a glance:
 Minimum commissioning time an easy maintenance.
 Optimized crane performance.
 Safety for personnal during commissioning and operation.
 Fully complint with all norms and quality standads.
USER REQUIREMENT:
Growth Shop who is the principal supplier of cranes
having design, supply, erection & commissioning and
maintenance capability can take up the task to integrate
following different activities to a common plat form and
derive common strategies to benefit organization
1. Maintenance 2. Spare management 3. Management of
lazy capital 4. Crane revamping. 5. Standardization,
Technical up gradation and validation of design 6. Crane
safety 7. Archiving of drawings 8. Consolidation of best
practices 9. Statutory compliance
To integrate the above activities the big challenge is how
to collect, archive and analyze the data, The best way to
overcome this challenge is to digitize the crane.
The bigger prospective is TGS to be service provider for
the crane ,either it is supplied by TGS or by other crane
manufacturer.

APPROACH:
The data can be collected either manual or sensor.
 VARIOUS SENSORS:
Let us understand about sensors first, A sensor is a device ,module or
subsystem whose purpose is to detect change(s) or event(s) in
environment and send that information to other electronics devices.
Sensors are used in every day objects
such as for eg. A touch button in elevator (say). Also sensors are used
in innumerable devices which people are not even aware of. Uses
ofsensors have been expanded from traditional field from
temperature, pressure and flow measuement to applications included
manufacturing and machinery, airplanes and aerospace, cars,
medicines, robotics, and many other aspects of our day to day life.
Thus a sensor’s sensitivity indicates that how much the sensor’s output
changes when the input quautity being measured changes.
So a good sensor obeys the following rules:
1) It is sensitive to the measured property,
2) It is insensitive to any other property likely t be encountered in its
applications,
3) It does not influence the measured property,
 VARIOUS LIST OF SENSORS CAN BE
GIVEN AS:
1) Acoustic , sound vibration. (microphone , sound locator)
2) Automotive transportation (engine coolant temp. sensor, air flow
meter)
3) Chemical (electronic noise , carbondioxide sensor , holographic
sensor , hydrogen sensor , nitrogen sensor , oxygen ,ozone , smoke
detector , ozone monitor)
4) Electric current , electric potential , magnetic , radio (current
sensor,, galvanometer , magnetometer , metal detector , voltage
detector)
5) Environment , weather , moisture, humidity (actinometer
,electrochemical gas sensor, gas detector ,rain gauge, soil moisture
sensor, snow gauge)
6) Proximity sensor (alarm ,motion detector ,proximity sensor, touch
switch,)
7) Optical , light imaging ,photon (LED, infra red, flame detector,
colorimeter, photodetector, photodiode, phototransistor,
photoswitch)
8) Thermal , heat , temperatue (calorimeter, flame detection , quartz
thermometer ,temperature gauge, thermistor, thermometer,
pyrometer)
These are few examples of types of sensors and their further
classifications. There are 1000’s of sensors availble in the market.
 SENSORS USED FOR DIGITIZATION OF
CRANES:

There are numerous numbers of sensors that have been used in

the digitalization of cranes. Few of which of them under my
knowledge are as follows:
1) Gear box vibration monitoring used for alarm generation.

2) Feedback of all brakes proximity used for planning of brake

maintenance & fault diagnosis.
3) All safety limit switch and emergency limit switch status which
will improve safety status.
4) Lubrication condition (continous monitoring of lubriction
status in crane).
5) Fire alarm , if any fire alerts generates it will communicated to
ground level staff.
NOTE:
Since a crane is divided into further subsection so in order to
make every section work the company has its own criteria and
procedures and high quality sensors to make it more accurate
and there fore there are many sensors required and used which
we as a student has not been acknowledged about. So we’ll only
see the sensors which have been given above as they are been
in our knowledge.
OBJETIVE:
The idea behind digitization of cranes for TGS is to deliver value that
goes beyond supplying equipment to their customer. Post
deployment, TGS can offer services to monitor and manage cranes or
equipment’s for their customers. TGS can offer these services from a
central site (Jamshedpur)- using a Digital Service Delivery
platform, allowing it to scale easily as their customer bases grows.
Based on user requirements the objective of Automation is derived as to
deliver TGS with most advance system to Monitor crane condition
monitoring of Equipment’s and perform condition based maintenance
based on the input of equipment condition monitoring parameters.
The solution should offer following value to TGS as equipment
supplier:
• Enable service delivery platform for TGS
• Help in optimization of operation on costs
• Provide increased visibility into the usage of the cranes/products,
which can be used in developing and improving future versions.
• Asset Management
• Standardization and safety.
 SCOPE OF WORK:
 This section describes the automation scope of work under under following
categories:
 IT INFRASTRUCTURE
 SYSTEM FUNCTIONALITY
 APPLICATION SOFTWARE
 INSTALLAION AND COMMISIONING,

i. In IT INFRASTRUCTURE , for remote monitoring of cranes health and

providing the maintenance support for the customers of TGS who are
located at different places , the basic IT infrastructure with necessary
control center need to be established at TGS main center at Jamshedpur.
The following architecture will serve the purpose of TGS even if they
want to provide service support to new customer in future with some add
on IT hardware.
ii. In SYSTEM FUNCTIONALITY, the requirement o user will be fulfilled
by the functionalities of the following three modules:
• First level fault detection
• Second level fault detection
• Time based maintenance module,
IN CONTINUATION WITH THE PREVIOUS PAGE:

iii. IN APPLICATION SOFTWARE, an system architecture has been

designed has been designed by the company which as not be
published and used in any type of work, hence it is confidential
data.

iv. INSTALLATION AND COMMISSIONING for successful

implementation of crane condition monitoring system includes the
following activities:
- IT hardware at Jamshedpur & Kalinga automation center
- Networking at both the places
- Application software.
FUCTIONAL SPECIFICATION OF
CRANE:
1.4 Description of the Module.
The Crane digitization will consist of following main modules; brief description of each
module is mentioned here
1.4.1 Condition Based Maintenance
This Module will provide condition monitoring of crane equipments, the module is based
on Daily management practices followed in Maintenance; based on the alarm and alerts
identified by this module; it will provide input to TBM module and there by Maintenance
manager to take prompt action for maintenance. It will have following sub modules
1. Equipment Health Monitoring
2. Crane Safety Monitoring
3. Process visualization and reporting
4. Life cycle management
1.4.2 Time Based Maintenance
Preventive maintenance schedule are planned as per annual maintenance plan, this
plan
are divided into maintenance schedules. This module will provide Maintenance
manager to
schedule maintenance of crane based on Condition monitoring alerts. This Module
will
have following sub modules
1. Maintenance Schedules
2. Maintenance Practices
 1.5 Impact of the Module
Condition based maintenance: This module will provide traffic light alert
from equipment
health monitoring and will facilitate maintenance expert to take prompt action for
maintenance.
Time based maintenance: The time based maintenance will optimizes
maintenance
resources efficiently and maintenance planning can be done as per the requirement
of
maintenance of equipment’s.
The Concept of crane digitization is to provide service delivery for cranes from
central
location. Since the central location will be remotely located from crane, It is
important to
develop such a service delivery platform that application shall have following key
features:
· Machine self-learning capability.
· Provide alarms and alert to the analyst well in advance to mobilize the service
team
at site for maintenance.
· Optimize the resources used in maintenance.
This can be achieved by following the daily management and maintenance best
practices
such as TQM principle. The below mentioned figure explains the concept to design
 THE BELOW MENTIONED FIGURE EXPLAINS THE CONCEPT TO DESIGN
APPLICATION OF CRANE DIGITIZATION:

TIME BASED
MAINTENANCE

PREDICTIVE CONDITION
BASED MAINTENANCE BASED MAINTENANCE
CONDITION BASED MONITORING:
Crane Health Monitoring:
The Crane Equipment would be classified into sub- equipment’s, The equipment’s sensors
data will be displayed on real time, The data would consist of Analog signals such as:
Current, temperatures and digital signals such as: motor running status, brake operations
etc. Apart from real time trends, Equipment Health conditions would be visible to user.
The KPI will be set for each parameter and if the KPI are within the control limit then
equipment will be considered as healthy otherwise alarm will be raised if the KPI exceeds
the specified control limit. Based on the severity of Alarm, the Alarm will be translated in
healthy OK (green), Alert (yellow) and Fault (red). This would help in improve equipment
availability
1.2.2 Crane Safety Monitoring
The Crane operations are equipped with safety interlocks, most of which are hardware
component driven due to high risk potentiality of crane operation. In order to monitors
safe operations of cranes, the signals would be derived from existing sensors and Operating
status of safety devices will be displayed on real time along with past record. It will also
draw inference for life cycle of limit switches. Following major safety features would be
monitored.
1. Load monitoring status of MH (MAIN HOST)
2. Anti-collision device status
3. Over speed of MH, AH (MAIN HOST & AUXILIARY HOST)
4. x, y, z positions
5. Status of control limit switches
 LIFE CYCLE ESTIMATION AND TIME BASED MAINTENANCE
Life cycle Estimation
The feedback of operations of crane equipment’s like Motors, brakes and rotary limit
switches will be captured, archived and available on real time. Based on these data
maintenance engineer can perform spare planning, predict the life cycle of equipment and
tentative replacement time
Some of the operating events shall be captured are
1. No. of operations of brakes
2. Running hours of Motors
3. Running hours of wheels
4. No. of operations contactors
5. Motor Insulation life through current signature analysis
1.3 Time Based Maintenance
Preventive maintenance schedule are planned as per annual maintenance plan, the time
based maintenance is one of the objective of it. To enhance this objective in cranes, this
module will have following features:
1.3.1 Maintenance Schedules
The Equipment wise maintenance schedule would be available for Maintenance personnel,
The schedule alert would also be raised prior to scheduled maintenance of equipment’s, In
case, if any fault is identified on the equipment then based on fault severity the pre
schedule alert will be raised to the maintenance team. The User will have option of manual
entry of maintenance activity performed in the equipment’s; this record will be archived in
the system for future reference in case of any breakdown occurred in the Equipment.
CRANE DIGITIZATION SYSYTEM
 SOME CLCULATIONS REGARDING THE CRANE SPECIFICATION:

Quality is calculated as:

Quality = Good Count / Total Count
This is the same as taking the ratio of Fully Productive Time (only Good Parts
manufactured as fast as possible with no Stop Time) to Net Run Time (all parts
manufactured as fast as possible with no stop time).
MTTR means Medium Time To Repair, thus the medium until having repaired
the failure
and MTBF means Medium Time Between Failures. MTBF is the medium time
between
each failure within a process, or in other words, the frequency of each failure.
MTTR = total hours of downtime caused by system failures/number of failures
MTBF= total time of correct operation in a period/number of failures
Availability = uptime = MTBF/(MTBF + MTTR)
MTBF tells us the most frequent failures within a process and MTTR tells us
which the most
serious failures are.
MTBDE = MTBF + MTTR (Mean Time to Repair)
DIFFERENTIATING BETWEEN FAILURE METRICS

TIME BETWEEN FAILURE

TIME TO REPAIR TIME TOFAILURE

RESUME NORMAL
OPERATONS

SYSTEM FAILURE
 Pd.M. Target = 15% Diagnostic +
Potential 35% Corrective work = 50% Total OEE losses &
for cost to Repair
Failure is Ultra
introduced sonic Vibration
waves Infrared ₹ X 10

Oil
The Equipment will tell Analysis
us that it is having Can
Problem before final failure , Hear it
if we are listening P.M. Target =
Can 15% Diagnostic +
Smell it 15% Corrective work
= 30% Total

Temptation to avoid :
Using Pd.M. and P.M.s ₹X5
Processes but then optimizing Can
a run to failure philosophy See it
₹X1
Failure Target =
occurs < 20% Total
Plenty of time for Little or no time
Excellent planning Time from P to F for proper planning
and scheduling (can be in weeks, days ,hours or minutes) and scheduling
(Unplanned-Unscheduled R&M work is 7 times more expensive than planned-scheduled work)
Asset Health and the Potential for Failure Curve
ASSET HEALTH AND POTENTIAL FOR FAILURE CURVE:

As in the graph shown ,we can see different lines and

, the main point of this is we have to repair the fault
before it increases.
THANK YOU
RUCHI JAIN