TRAINING

ADANI PORT & SEZ LTD., MUNDRA

DEPT : ES-MHS

Guided by:

Mr. DHARMENDRA PATEL

AGM. ES-MHS DEPARTMENT

SUBMITTED BY:

VIPUL M.PATIL

B.E.MECHNICAL at SAL INSTITUTE

OF TECHNOLOGY & ENGINEERING

RESEARCH, AHMEDABAD

MUNDRA PORT VISION

“A globally competitive, India fo-cused, technology driven, Port

Company, offering cost effective logistics solutions to the delight of customers and stakeholders.”

INDEX

SR.NO CONTENT PAGE NO.

1. INTRODUCTION1.1 Adani Group of Companies1.2 Strength of Mundra Port1.3 Location of Mundra Port

1

2. Preface3. Acknowledgement4. Conveyer System

4.1 Introduction4.2 Conveyer System Line Diagram4.3 Equipment of the conveyer system4.4 PCS & ZSS.4.5 Belt Design4.6 Belt Joining Process

5.

6.

Import Conveyer System of COAL, FCC & FRMControl room

7. Cargo Handling facilities8.9.

Goliath:Maint- MHSConclution

DATE TIME SCHEDULE/LOCATION

18.06.2012 9.00 TO 1.00 PM 2.00 TO 4.00 PM 4.00 TO 7.15 PM

ADANI House(Mr.Gaurav Pujari)ES-Dept.(Mr.Dharmendra Patel) MHS-Dept.(Mr.Kalpesh Panchal)

19.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

MHS-Dept.(Mr.Kalpesh Panchal)FCC-Dept.(Mr.Jitendra Zala)

20.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

FCC-Dept.(Mr.Jitendra Zala)FRM-Dept.(Mr.Jitendra Zala)

21.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

MHS-Dept.(Mr.Kalpesh Panchal)CONTROL ROOM(Mr.Ashwin DherIya)

22.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

CONTROL ROOM(Mr.Dinesh )MHS-Dept.(Mr.Harsh)

25.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

Begging(Mr.Gohil Kaka)

26.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

MHS-Dept.(Mr.Kiran Patel)Goliath (Mr.Divyam Suthar)

27.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

Goliath (Mr.Pratik Goswami)

28.06.2012 9.00 TO 1.00 PM 2.00 TO 6.00 PM

Goliath(Mr.Tivari)Goliath (Mr.Divyam Suthar)

29.06.2012 9.00 TO 4.00 PM

Completed my report work At MHS-Dept.

1.INTRODUCTION:

Adani Ports and Special Economic Zone Limited (APSEZ), India's largest private port and special economic zone, was incorporated as Gujarat Adani Port Limited (GAPL) in 1998 to develop a private port at Mundra, on the west coast of India. The company commenced commercial operations in October 2001. Mundra Special Economic Zone Limited (MSEZL) was incorporated in November 2003, to set up an SEZ at Mundra. MSEZL was merged with GAPL in April 2006 and the company was renamed as Mundra Port and Special Eco-nomic Zone Limited, to reflect the nature of business. The board of MPSEZL on Nov 21,2011 has approved a proposal to change the company's name to Adani Ports and Special Economic Zone Ltd. and this change in name from MPSEZL to APSEZL has come into effect from Jan.6,2012.

WE WERE INCORPORATED AS GUJARAT ADANI PORT LIMITED ON MAY 26, 1998, AND COMMENCED PHASED OPERATIONS AT MUNDRA PORT IN OCTOBER 1998 WITH COMMERCIAL OPERATIONS BEGINNING IN OCTOBER 2001. WE WERE INITIALLY PROMOTED BY ADANI PORT LIMITED AND GUJARAT PORT INFRASTRUCTURE DEVELOPMENT COMPANY LIMITED, AN UNDERTAKING OF THE GOVERNMENT OF GUJARAT.

1.1 ADANI GROUP OF COMPNIES:

The various companies under the group are:

1. Adani Gas Limited2. Adani Enterprises3. Adani Power4. Adani Retail5. Adani Wilmar6. Adani Mining7. Gujarat Adani Port8. iCall India9. Adani Ports & SEZ Limited10.Adani Agri Logistics11.Adani Agri Fresh12.Adani Properties13.Adani Welspun

1.2 STRENTH OF MUNDRA PORT

Long water front & no maintenance dredging.

One of the closest Port to the entire and well developed northern hinterland with pipe-line connectivity passing through sparsely populated areas, no problems in Row.

Mundra Port is committed to sustainable development with all efforts towards mainte-nance and improvement of ecological balance.

Port is already playing a catalytic role for the socio-economic growth of the Kutchh re-gion of Gujarat.

Mundra Port and Special Economic Zone Ltd has informed that the Board of Directors of the Company at its meeting held on May 20, 2009, inter alia, has appointed Dr. Malay Mahadevia as an Additional Director and Whole Time Director on the Board of the Company with immediate effect.

1.3 LOCATION OF MUNDRA PORT:

2. PREFACE:

Training is one of the most enriching opportunities, which the engineering students get to upgrade their skill and apply the theoretical knowledge attained in the class room in the practical world. Trainings are an occasion to learn and experiment with the theoretical input that one has gained in the course of class room participation. Hence, Trainings are one’s knowledge and information to the fullest capabilities.

Training on “ES-MHS Department” is the most important in its respect and regarding the whole maintenance. The experience at ADANI PORT & SEZ. Ltd. ,Mundra was very fruitful and it has added an extra feather to our career for the days ahead.

3. ACKNOWLEDEMENT:

It’s a great pleasure to acknowledge those people who have contributed to the successful completion of my training project. The proposed training on “ES-MHS” has been made possible through the direct & indirect co-operation of various people, towards whom I would like to express my application and heartfelt gratitude.

I extremely thankful to the management of ADANI PORT & SPECIAL ECONOMIC ZONE Ltd. , Mundra(APSEZ) foe giving me the opportunity to undergo my organization.

I would like to express my sincere thank to my training guide Mr.Dharmendra Patel for permitting me to training to undergo training in his department. His guidance and inspiration from time to time is invaluable advice and faithful suggestion at crucial stages of the training, enable to successful competition of my training and let me learn a lot.

At last but not the least I expressed my heartfelt gratitude towards all fitter grades & foreman grades employees of MHS-Department, who in spite of their busy and stressful schedule gave me their valuable time, which went a long way in the proper completion of my training.

3. CONVEYER SYSTEM:

4.1 INTRODUCTION:

A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another.

Conveyors are especially useful in applications involving the transporta-tion of heavy or bulky materials.

Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries.

4.2 CONVEYER SYSTEM LINE DIAGRAM:

Mr.Kalpesh Panchal is explained me the whole conveyer system work at port. These system has been divided into three parts like COAL, FCC & FRM. Mr.Panchal is also explained me to see the different part with neat sketch.

ES buildin

g

TT8A

TT7TT4

TT5TT6

TT3

TT8

TT8B

L : 916 Mtr BC

6I

BC F2

BC 5I

BC 8I

BC 2

I

BC 3I

BC 4

IBC

F3

BC F

4

FC 3

I

L : 388 Mtr

L : 2484 Mtr

L : 938 Mtr

L : 690 Mtr

L : 1500 Mtr

L : 1330 Mtr

L : 1330 Mtr

L : 540 Mtr

L : 230 Mtr

Coal Yard

L : 160 Mtr

BC

C2

4.3 EQUIPMENT OF THE CONVEYER SYSTEM:

There are different equipment of the use in the conveyer system. Here we have used the belt conveyer system.

Naturally, these equipments are generally used in belt conveyer system: MOTOR FRICTION COUPLING GEAR BOX GEAR COUPLING DRI PULLEY SNUB PULLY BAND PULLY TAKE UP PULLY PCS ZSS SCRAPER CHUTE etc.

4.4 PCS & ZSS:

PCS (PULL CROSS SWITCH):

Generally these switches are used in plant for safety purpose. When the belt conveyer are in working condition at the plant, thus there are in any problem of equipment or in the case of the any accident in the plant. So, when these switch is on the whole plant is a offline means that there are in stop of all the works.

ZSS (ZERO SPACE SWITCH):

The zero space switch is used for measuring the rpm of the tail roller in the plant. These plant there a two roller head and tail roller. The head pulley mounted with the motor. When the motor runs then the motion is transmitted on the head pulley. The head pulley is also transmitted the motion through the belt on the tail pulley. If the tail pulley is not run at the same rpm of the head pulley thus these became a big accident or breakdown the system. So, these equipment is also used for safety purpose.

4.4 BELT DESIGN:

The fig. shows the various layer are used made of the belt. The capacity of these belt is used in the plant is 1500 TPH.

4.6 BELT JOINT PROCESS:

There are the two types of belt joint process:

• HOT JOINT PROCEDURE :

Belt tension release from take up 2)Do the write angle belt3) Do the tapper mark & cutting on belt 22 degree with three steps. ( steps depend on beltlayer )

4) Solution used for joint Thejo T4451 Black Three times cording on belt.

5)Insulation compound laying on joint area

6) Belt over lap after solution condition ready,

7) Belt Rolling or Hammering start from joint area

8)Channel filling.

9) Use machine for joint water jacket pressures adjust up to 6 kg/cm2

10) Machine temperature increase up to 145 degree & temperature maintain ( 1mm belt thick = 3 min )

COLD JOINT PROCEDURE:

1) Belt tension release from take up2) Do the right angle belt3) Do the tapper mark & cutting on belt 26 degree with three steps. ( steps depend on belt )

250 TO 300 MM

22 degree

4) Solution used for joint Thejo TC-310 Three times cording on belt. [Thick, low, v. low) (check for expire date.)

5) Belt over lap after solution condition ready.

6) Belt Hammering start from joint area

7) Wait 1.5 hrs for better joint (currying time)

5. IMPORT CONVEYER SYSTEM OF THE COAL, FCC and FRM:

IMPORT CONVEYOR SYSTEM - COAL

26 degree

350 TO 400 MM

-

BC-BELT CONVEYER

TT-TRANSFER TOWER

COV-VEYOR

LENGTH (M)C/C

DIST.

NOR-MALCAP. TPH

BELT WIDTH (MM)

SPEED

( M /SEC )

MOTOR RATING ( KW )

MATERIAL HALDLED

JETTY

TT-4

TT-5TT-6

TT-7

BC – 6I 189 1500 1400 3.0 75 LT COAL

BC – 5I 1237 1500 1400 3.0 2x200 HT

COAL

BC – 4I 461 1500 1400 3.0 160 HT COAL

BC- C2 6.0 1500 1400 3.0 22 LT COAL

BC – C1 70 1500 1400 3.0 75 LT COAL

MATERIAL HANDLING SYSTEM FOR IMPORT – COAL

IMPORT CONVEYOR SYSTEM - FRM

FR

M – 1 , 2 &

3

BC

- Belt C

onveyor .

TT

- Tran

sfer Tow

er .

FR

M - F

ertilizer Raw

Material .

FC BC 3I

FEEDIN

G

HO

PPER

TT

-10T

T-8

TT

-3

TT

-4

MATERIAL HANDLING SYSTEM FOR IMPORT - FERTILIZER

COV-VEYOR

LENGTH (M)C/C

DIST.

NOR-MALCAP. TPH

BELT WIDT

H (MM)

SPEED

( M /SEC )

MOTOR RATING ( KW )

MATE-RIAL

HALDLED

BC – 6I 189 1500 1400 3.0 75 LT FRM

BC – 5I 1237 1500 1400 3.0 2x200 HT

FRM

BC – 4I 461 1500 1400 3.0 160 HT FRM

BC – 3I 453 1500 1400 3.0 132 LT FRM

BC- 2I 340 1500 1400 3.0 200 HT FRM

BC – 8I 353 1500 1400 3.0 2x110 LT

FRM

IMPORT CONVEYOR SYSTEM - FCC

FEEDING HOPPER

BCF3BC F4

BC F1

FC BC 3I

BC 3I

BC F2

TT-8A

TT-8B

TT-8

TT-3TT-4

OVER VIEW OF THE FACILITY:

Export Conveyor System .

JETTY

FRM - 1

BC - Belt Conveyor .

TT - Transfer Tower .

CG

- 1

0RC - Raddler Conveyor.

PC - Portable Conveyor .

Diverter Gate at TT-2 to divert Cargo inside CG-10 when

there is no Vessel.

The system is integrated with existing Import Conveyor system at TT-8. The system is going to integrate with Ground hopper system at OSY-2 by newly installa-

tion of F1 Conveyor from OSY-2 to TT-8A. (Phase-2). The existing system of 2I belt conveyor has been modified for the installation of V-

plough feeder which feeds the material to newly constructed F2 conveyor as well as 8I Conveyor. The V-plough is working on 0% and 100% basis in Auto mode. i.e. either 100% material diverts to F2 conveyor and 0% material on 8I conveyor or 0 % to F2 and 100% to 8I conveyor. This V-plough can be manually adjusted to any range 0-100% for feeding to F2 conveyor. However performances need to be evaluated.

The F2 conveyor is equipped with Belt weigher which can give indications of flow rate on F2 conveyor.

6. CONTROL ROOM:

In control room, Mr. Ashwin Dheriya and Mr. Dinesh is explained me the how we can handle the operation philosophy of the FCC. This is fully computerized system. Thus we can use the program the screen is known as the SCADA.There are three mode of the operation:1. Auto mode2. Manual or Semi auto mode3. Local mode

1. Auto mode:In auto mode you have to satisfy following condition before starting the conveyer in AUTO MODE.a) Hopper feeding values.b) Conveyer checks.c) Motor feeder status.d) Field discussed healthy checks.e) Initial setting to start with AUTO MODE.

2. Manual Mode:In manual mode we can run individual conveyer with their individual safety. So first of all check the initial status(SAFETY STATUS) of the safety from Home Screen.

3. Local Mode:In local mode we can run the individual conveyer from the LCS panel from the field.There are two buttons at each LCS panel Start and Emergency switch.

7. CARGO HANDLING FACILITIES:

Model HMK 300E – 2 Nos.

Commissioned in 2000

Model HMK 330EG – 2 Nos.Commissioned in 2005

MOBILE HARBOR CRANE SPECIFICATION

o Length of chassis with stabilizer pads : 22 Mo Width of chassis without stabilizer Pads : 8.7 Mo Boom length : 50.5 Mo Max. Out Reach : 50 Mo Min. Out Reach : 11 Mo Lifting height above quay : 33 M at 11~45 M Radius

22 M at 50 M radiuso Lifting height below quay : -12 Mo Total Weight of Crane : 430 Tono Main Drive : Diesel - Electrico Diesel engine : Cummins-QST-30

970 KW at 1500 RPM o Heavy lift capacity : 100 Tono Grab operation : 50 Ton ALLIED ATTACHMENT TO MHC FOR HANDLING DIFFERENT CARGO

GRAB

2 Nos. CAMSHELL , CAPACITY – 27M3 FOR BULK CARGO

2 Nos. CAMSHELL , CAPACITY – 35M3 FOR BULK CARGO

2 Nos. ORANGE PEEL , CAPACITY -21M3 FOR BREAK BULK CARGO

BALANCED ‘C’ HOOK

CAPACITY – 32 MT. FOR HANDLING HRCOILS.

DIFFERENT TYPE OF SPREADERS

FOR HANDLING 20 FT & 40 FT CONTAINER , MS PLATES, MS PIPE & JUMBO BAGS

RAIL MOUNTED MOBILE HOPPERS 02 NOS.

o To Suit the MHC Loading & connectivity to Importo Conveyor Systemo Hopper Capacity - 95M3o Grab Loading cycle - 1.3 Min/Cycle to 2.0 Min/Cycleo Material Handled - Steam coal/Coking coal / Fertilizero Feeding Capacity - 750 MT/HR

MOBILE HOPPERS EQUIPPED WITH:

o ROAD GATE : To control Feed of Materialo VIBRATORY MOTORS : 4 Nos. unbalanced weight typeo BELT FEEDER : To Receive Material from Hopper & Feed to Shuttle conveyor.o SHUTTLE CONVEYOR : To Receive Material from Belt feeder & Feed to Import Con-

veyor System. o All Electrically operated safety switches like Zero Speed , Over load , Pull cord Switch &

Belt sway Switches

ELECTRICAL & INSTRUMENTATION SYSTEM FOR

MATERIAL HANDLING SYSTEM

1. IMPORT SYSTEM: UNLOADING CARGO LIKE COAL, FERTILIZER, COILS,PIPES,

BULK, ETC. WITH HELP OF 4 GOTTWALD GERMANY MAKE

CRANES.

2. EXPORT SYSTEM : HANDLING WHEAT, SBM, ETC CARGO THRU’ EXPORT

CONVEYING SYSTEM WITH HELP OF SHIPLOADER AT JETTY INTO VESSEL

3. FOR BULK CARGO LIKE COAL & FERTILIZER, DISCHARGING

MATERIAL THRU’ CRANES, UNLOADING IN MOBILE HOPPER WHICH FINALLY

CONVEYED TO RESPECTIVE LOCATION BY CONVEYORS.

4. CONVEYING SYSTEM IS BEING OPERATED CENTRALLY FROM

CONTROL ROOM & START SEQUENTIALLY THRU’ PROGRAMMABLE

LOGIC CONTROLLER SYSTEM.

5. CONVEYORS / SHIPLOADER ARE RUNNING IN INTERLOCKS & HAVE PROTECTION

WITH SAFETY SWITCHES LIKE PULL CORD, BELT SWAY, ZERO SPEED.

FOR GOTTWALD CRANES ALSO, WE HAVE SOPHISTICATED PLC SYSTEM

SUPPLIED BY SIEMENS.CRANES ARE OPERATING THRU’ D G SET.

7. TO UNLOAD VARIOUS FERTILIZERS IN GO-DOWN TRIPPER SYSTEM IS

INSTALLED AT DICHARGE CONVEYOR IN GO-DOWN.

8. TO KNOW THE RATE OF DISCHARGE & TOTAL QTY UNLOADED, BELT

WEIGHER IS INSTALLED. BOTH READINGS ARE AVAILABLE IN CENTRAL

CONTROL ROOM.

8. GOLIATH MAIN.(MHS):

In goliath, the in charge engineer is Mr. Diva Suthar. He has a 11 years experience of these field. He has a good knowledge about his field. He has work by daily planning, this is spatiality I like most.

He has explain the introduction of the equipments are used in his field. His assistant Mr. Prate Goswami is a diploma mech-engeer. He is explain me the operation procedure of cargo handling techniques.

Mr.Suthar Sir has also detail about the material handling:

a) Cranesb) Fore liftc) Rich stackerd) Mobile hopperse) Jetty fenderf) Earthmover type crane(KALMAR)

9. CONCLUTION:

The purpose of these training is the how we can work the actual in the induries.. As a part of curriculum I have take these training. In these ten days I have a getting idea abut in-dustries as well field. I really enjoy the every moment of these days.

And last thank to all of you who has in spite me for completed my training report. I also thanks those people who has giving me knowledge about the whole system.