CHAPTER 1 INTRODUCTION 1.1 REQUIREMENT OF PRACTICAL TRANING: Engineering profession is full of practical challenges as every engineer has to confront various problems in his/her professional career. Therefore an engineer must be aware of practical challenges right from the college level. Sometimes it becomes essential to find the solutions to the problems practically, and then comes the need to implement the theoretical knowledge gained during study life into the practical environment. This practical implementation not only requires thorough knowledge of the subject but also the skill and real time decision making so that the task can be performed with full efficiency and accuracy. This skill and decision making power comes only when one should be aware of the live processing and working of an industry, therefore every Engineer has to 1
Engineering profession is full of practical challenges as every engineer has to confront various problems in his/her professional career. Therefore an engineer must be aware of practical challenges right from the college level. Sometimes it becomes essential to find the solutions to the problems practically, and then comes the need to implement the theoretical knowledge gained during study life into the practical environment. This p
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Transcript
CHAPTER 1
INTRODUCTION
1.1 REQUIREMENT OF PRACTICAL TRANING:
Engineering profession is full of practical challenges as every engineer has to
confront various problems in his/her professional career. Therefore an engineer
must be aware of practical challenges right from the college level. Sometimes
it becomes essential to find the solutions to the problems practically, and then
comes the need to implement the theoretical knowledge gained during study
life into the practical environment.
This practical implementation not only requires thorough knowledge of
the subject but also the skill and real time decision making so that the task can
be performed with full efficiency and accuracy. This skill and decision making
power comes only when one should be aware of the live processing and
working of an industry, therefore every Engineer has to undergo a practical
summer internship in an organization so that he can practically visualize the
working, management, and various techniques of the industry and can simulate
on real machines and gadgets with his own hands.
Therefore Rajasthan Technical University, Kota has prescribed 30 days
practical summer training for every Engineer after the completion of the VIth
Semester to enhance one’s practical approach and also the application of the
theoretical knowledge.
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1.2 ROLE OF INDUSTRIAL AUTOMATION:
Life has become simpler and luxurious after the development of science and
engineering. Everything has become automatic and can be operated by just one
click or one press of a button. This has led to revolution in current scenario. It
has reduced labor and has increased efficiency and accuracy as the tasks
considered too difficult and impossible for human being can now be
accomplished with the help of automatic machines. This requires low
manpower and can save a lot time.
Automation in industries play a major role as everyday, the
requirements are increasing and accordingly the production needs to be
increased to earn maximum profits. Today every production industry rely on
heavy machinery which works automatically and saves both power and
money with least risk to human life. Thus automation is a necessary tool for
the increment in production as well as profit for an organization. Therefore it
is both essential and beneficial to learn the role of automation as it requires
core Electronics & Instrumentation along with Computer applications.
1.3 AUTOMATION AT HZL:
Hindustan Zinc Limited is a world renowned organization producing millions
of tons of Zinc (Zn) and Lead (Pb) every year. It requires a lot of sophisticated
machinery and equipments, costing millions of rupees to produce such a huge
amount of concentrate. Therefore skilled labor and proper conditioning is very
essential. Every task on this level cannot be performed by human being for
such huge quantities with proper accuracy and efficiency in the given time
slot, here comes the role of automation. Each equipment works automatically
under the prescribed measurements and norms with complete human
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supervision. Various sensors, transducers, motors, pumps run automatically
24x7 for zinc and lead production. The working of these equipments is
monitored by Programmable Logic control which fetches each and every
information of equipment connected in the stream. It visualizes the functioning
of the plant on a computer screen which is supervised by an Engineer.
Automation system comes under the supervision of Electronics and
Instrumentation department which is responsible for proper functioning of
Smelters. The company profile and training report is accommodated in
forthcoming chapters.
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CHAPTER 2
ORGANIZATION PROFILE
2.1 HISTORY:
Hindustan Zinc Limited, a Vedanta Group Organization the only integrated
Zinc manufacturer in India and is the world`s second largest and India`s largest
integrated Zinc producer and also one of the lowest cost Zinc producer in the
world, with a global share of 6% in Zinc. The company has four mines & four
smelting operations, captive mines are located at Rampura Agucha (Bhilwara),
Rajpura Dariba (Udaipur), Sindesar Khurd and Zawar (Udaipur) with smelters
at Chanderiya, Debari and Dariba located in Rajasthan & Vizag (Andhra
Pradesh).
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Fig .1 HZL Distributions in India
Chanderiya Smelting Complex is located 110kms from north of
Udaipur in the State of Rajasthan,India.It was commissioned in year 1991 with
an initial production capacity of 70,000 tonnes of per annum Zinc & 35,000
tonnes of Lead per annum.
It is basically the single largest Zinc Smelting Complex in the world.
Now the metal production capacity is 610,000 tonnes per annum.With a talent
pool of over 6400 employees and about 16% women employees in the fresh
intake, HZL is emerging as one of the most preferred employer in the industry.
The company has tried to maintain and upkeep the quality of life of its
employees.
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Fig 2. Chanderiya Lead Zinc Smelter
2.2 EXCELLENCE AT HZL:
You set a vision and you build a road map to achieve it, Hindustan Zinc was
no different, but the most important was the approach to excel- to make
Hindustan Zinc Ltd a world class company that is focused to achieve
excellence and set global benchmark. This is what lies in the working culture
at HZL, and this is best reflected in their mission and vision.
MISSION: Be a world class company, creating value, leveraging mineral
resources and related core competencies.
VISION: To be a global lowest cost Zinc producer, maintaining market
leadership with a million tonne Zinc-Lead metal capacity by 2012 by
innovating, customer oriented and eco-friendly environment and maximizing
stake-holder value.
QUALITY POLICY: Ensure involvement, participation and motivation of
employees and contractor employees in implementation of our environment,
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health and safety management systems through training, awareness and
continual competence building.
2.3 IMPORTANT KEY FEATUERS:
In the past 3 decades, Chanderiya Smelting Complex has continuously made
progress in terms of production, cost and consumer satisfaction, it has made
several milestones in this period. To count a few Key facts are: