CAREER
EPISODE 1

 

A)   INTRODUCTION

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CE1.1

In
this first career episode, I wish to describe my experience during a project at
Tarapur wire plant 2 (TWP-2), Wire Division, Tata Steel Ltd which is located at
Tarapur near Boisar, Maharashtra, India. I was internally transferred to Global
Wire Division within Tata steel Ltd on 15th April, 2015 and I
continued to work in this division till 3rd June, 2016. I was
designated as Manager-Electrical in maintenance department.

Dates

May 2015 to
August 2015

Duration

4 Months

Location

Tarapur,
Maharashtra, India

Name of
organization

Tata Steel Ltd

Position title

Manager –
Electrical

Project name

Design,
Installation and Commissioning of 25kg coiler machine

 

B)    BACKGROUND

CE1.2 NATURE OF OVERALL
PROJECT

·       Tata
Steel Ltd is one of the leading Indian Steel-making company in the world. Tata
Steel Global Wire Division is one of the largest steel wire manufacturer in the
world with dominance in India and Thailand. Products manufactured in the plant
where I was working i.e., TWP-2 were LRPC (low relaxation prestressed concrete)
strands used in construction industry, Spring wire used in suspensions and
Galvanized wire used in farming, fencing, etc. This coils are generally coiled
and packed in 1Tor 2T (Ton) packing.

·       The
use of galvanized wire in farming is to support creeper crops. Completion of
this project will introduce altogether new packaging of 25kg coil of galvanized
wire in market and hence, allow direct access to new markets i.e., local grape
growing farmers and other creeper growing farmers.

CE1.3 OBJECTIVES OF THE
PROJECT

Key
objectives of this project associated with my work were:

·       Design,
develop and test circuit for operation of servo motor (part of coiler machine).

·       Design
control panel for the 25kg coiler machine and install all electrical components
in the panel.

·       Erect,
Install, Commission and Test complete electrical work for the 25Kg coiler machine
including cabling, lighting at shop floor, panel wiring, conduiting, etc.

 

CE1.4 NATURE OF MY WORK
AREA

·        Project was implemented in the boundaries of dispatch
department of our plant, just before loading area for finished goods. Due to
frequent loading of finished goods in trucks for final dispatch, there was high
movement of employees, forklifts and cranes in this area. Thus, safety
equipment such as barricades and proximity sensors were installed in this area
to enhance the safety of people working there and moving machines.

·       I
was managing a team of electrical contractors and departmental electricians,
who performed activities such as control panel installation, panel wiring,
cable tray laying, cabling (control and power), providing electrical plug
points, providing lighting in work area, etc. under my directions.

·       As
the project involved other departments (mechanical maintenance dept. and
projects dept.), coordination with those departments for job planning was
essential. Thus, I attended war room meetings which involved other departments
and plant head. Daily targets were set, in terms of work done by each
department, were set in this meeting and I was responsible for achieving
targets in my work area.

·       My
work area also included supervising the ongoing work, training electricians and
giving safety briefing to contactors for every task.

CE1.5
ORGANISATION STRUCTURE

 

 

CE1.6 STATEMENT OF MY
DUTIES

My duties in regards to this
project were as follows:

·       I
was responsible for developing design and implementing the circuit for servo
motor, a part of 25kg coiler machine.

·       I
was responsible for design and layout of control panel including selection of
MCBs, variable frequency drive (VFD), power contactors, relays and other
components.

·       I
was responsible for installation, commissioning and testing of 25Kg coiler
machine.

·       I
was responsible for providing adequate lighting in the project work area and
satisfying electrical needs of other departments working on the project.

·       I
was responsible for daily job allocation to all electricians and supervise them
throughout their work.

·       I
was responsible for raising purchase requisites (in coordination with purchase
department)  for required electrical
materials and consumables for the project.

·       I
was responsible for giving safety briefing to the contractors, enforcing
positive isolation and safe work practices in the work area.

·       I
was responsible for the coordinating planned electrical work with work of other
departments and meet the project timeline requirements.

·       I
was responsible for operation and maintenance of the machine, and developing Standard
operating procedure (SOP) for the operation of the machine after commissioning.

 

C)   PERSONAL WORKPLACE
ACTIVITY

CE1.7 TECHNICAL DETAILS
OF THE WORK

·       The
designed 25kg coiler machine had two motors – 500w servo motor and 1.8kw AC
motor. Servo motor was used to maintain even distribution of product
(galvanized wire) in the coil whereas AC motor was used to drive the main drum
over which the wire was coiled. As the 25Kg coiler machine was completely
developed in-house, the design was kept as simple as possible. From my end, I
developed a relay based logic circuit, to avoid the use of PLC, for operating
servo motor.

·       I
used two Emerson commander sk VFD drives (by control techniques) for operating
the motors. Commander sk 1.5kw was used to drive the servo motor whereas
commander sk 2.2kw was used to drive the AC motor. Speed for both the motors
was controlled/set by changing frequency of the drive.

·       I
developed a layout of control panel for the machine and implemented the same. Various
components such as contractors, drives, relays, MCBs, counter, etc. were
installed by the electrician as per my direction as can be seen in Image-1.1.

·       Electrical
supply to the machine was given from the nearby MCC using 4 core 2.5sqmm
armored cable along the laid cable tray under my supervision. Lighting was
provided in the work area and the supply was given from lighting DB.

·       I
supervised erection of overall machine and control panel. Earthing was provided
to both machine and control panel.

·      

I
commissioned the machine and took the trial run of the machine. Counter was set
as per the thickness of the wire to get 25 kg in one coil.

·       After
successful multiple trial run of the machine, I developed SOP for its operation
and handed the machine over to operations department.

CE1.8 APPLICATION OF MY
ENGINEERING KNOWLEDGE AND SKILLS

1.     I
used my knowledge and understanding of Electrical and Electronics Engineering
to understand various datasheets of the components and could select the
appropriate ones.

2.     I
applied my knowledge of AC motors as well as servo motors while selecting the
drives for those motors.

3.     I
used my learnings of circuit design and relays to develop the relay logic for
operation of servo motor.

4.     I
enforced safe working instructions that were learnt during the course of my
engineering while handling electrical power.

5.     I
used my project management skills, learnt during engineering, to effectively
use resources and man power and adhere to project timeline.

CE1.9 TASKS DELEGATED
TO ME AND THEIR ACCOMPLISHMENTS

1.     After
understanding the datasheets of various components, I could select the
components required for developing control panel and for machine installation.

2.     I
could manage to avoid the use of PLC for servo motor operation by developing
the relay logic circuit, thus could avoid the complexity and cost of PLC .

3.     I
successfully could develop the control panel for machine in-house with the help
of my team of electricians.

4.     Electrical
supply was provided to other departments as and when required.

5.     An
important accomplishment was adherence to project timeline. All the electrical
related work in the project was completed as scheduled.

CE1.10 TECHNICAL
DIFFICULTIES/PROBLEMS AND ITS SOLUTION

·       Problem:
As the machine was handed over to the operation department, operator was
finding it difficult to control the speed of the drum by changing frequency of
the drive.

Solution:
After observing the operator, I realized that changing frequency of the drive
is not convenient for operator and it was taking longer time than expected. To
solve this problem, I used a 10k potentiometer along with the change of mode in
drive for 1.8kw motor. The knob of 10k potentiometer, just by rotating, could
control the input current signal to the drive and hence control the speed of
the motor, hence drum.

CE1.11 STRATEGIES
DEVISED BY ME

·       Procurement
of the electrical equipment and other consumables were done before hand so as
to avoid last stage delays.

·       I
divided the available manpower in electrical department into various groups and
assigned then a particular job to focus on. Multiple groups working on different
jobs helped us attain our time strictly.

·       I
maintained a daily routine of communicating tasks to the groups, delivering
safety briefing to contractors and taking feedback from both after their work.

·       Trail
circuit of relay logic for servo motor was developed in workshop for testing
its operation before the final implementation.

·       Each
component was checked for its rating before installing them in panel and
machine.

CE1.12 WORKING WITH
OTHER TEAM MEMBERS

·       During
the entire project, I worked closely with my electrician team members and
people from other departments.

·       Working
on this project helped me in building qualities for becoming an effective and
efficient team leader.

·       Since
the overall team was cross functional, this project enhanced my knowledge in
other fields such as mechanical engineering, Civil engineering and Operations
management.

·       Daily
war-room meeting helped me to coordinate electrical jobs with other departments
and monitor overall progress of the project.

 

D)   SUMMARY

CE1.13 MY VIEW OF
OVERALL PROJECT

·       As
the overall project team was cross-functional, working on this project improved
my coordination skills, conflict resolution skills and negotiation skills.

·       Hands
on experience of working with VFD (variable frequency drives) enhanced my
confidence in the installation and commissioning of drives and motors.

·       Overall
project enlightened me with the experience which was never experienced while
studying the theory behind the working of various electrical equipment.

CE1.14 HOW PROJECT
FARED IN MEETING GOALS

·       All
war-room meeting during the project commenced as schedule. All the tasks were
almost aligned with the planned project timeline. The project was completed on
time.

·       I
was successful in developing the control panel and relay logic circuit as required
and its implementation in time. Timely delivery of electrical services in the
project was possible because of the commendable support from senior manager,
electricians and contractors

CE1.15 MY PERSONAL
CONTRIBUTION TO THE PROJECT

·       My
earlier experience of working with electrical equipment gave me an added
advantage during successful execution of this project. The overall experience
during the project helped me understand various aspects of project management.
It improved my confidence and enhanced my courage to take up complex electrical
projects in future.