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IMPROVEMENT OF SHOPFLOORCOMMUNICATION SYSTEM IN

MMSM

A projet report submitted in partial fulfillment

of

Comprehensive Managerial Course (Visakhapatnam steel plant)

by

S.SRINIVASA RAO

Junior Officer (Telecom)Emp. No. 103140

Under guidance of

Sri. B.KRUPANANDAMSenior manager (Telecom)

VISAKHAPATNAM STEEL PLANT


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CERTIFICATE

This is to certify that the project

work entitled IMPROVEMENT OF

SHOPFLOOR COMMUNICATION SYSTEM IN

MMSM AT ROLLING MILLS being submittedby Mr S.Srinivasa Rao, Empno 103140

Junior Officer (Telecom) works department

in partial fulfillment of comprehensive

managerial course for JOs phase 3 in

Visakhapatnam Steel Plant during 2008-09

is a record of bonafide work carried out by

him under my guidance and supervision.

Place:

PROJECT GUIDE

Date:

B.KRUPANANDAM

Senior Manager(Telecom)


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VISAKHAPATNAM STEEL

PLANT

ACKNOWLEDGEMENT

I take this opportunity to thank Sri

B.KRUPANANDAM Senior

Manager(Telecom) who is my project guide

for his valuable guidance and cooperation.

I also thank Sri S.PRASADA RAO

Deputy General Manager(Telecom) and Sri,

K.IYAPILLAI Deputy General Manager i/c

(Teecom), Head of the department.

My heartiest thanks to Sri DR

MULLAR, Asst. General Manager (Training)

and his team of training & development

centre for giving me this opportunity.


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Dt :(S.Srinivasa Rao)

JuniorOfficer(Telecom)

Emp. No.103140

Declaration

I hereby declare that this project

work entitled IMPROVEMENT OF

SHOPFLOOR COMMUNICATION SYSTEM IN

MMSM AT ROLLING MILLSbeing submittedby me is exclusively done by me as part of

the comprehensive managerial course

phase-III for Junior Officiers in

Visakhapatnam Steel Plant during 2008-09

and is an original work which has not been

submitted to any university or college at

any point of time earlier.


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Place:

S.Srinivasa Rao

Date: Junior Officer(Telecom)

Emp. No.

103140

CONTENTS

INTRODUCTION 01

MODIFICATION02

CORAL EXCHANGE 04


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CARDWISE DESCRIPTION17

BENEFITS23

CONCLUSION

24

INTRODUCTION

The Digital Electronic Exchange

Communication System of modal Coral Flexion 400

equipment is supplied by M/s Tadiran. The people

needs the requirements of Shop floor

Communication for regular operation as well as

maintenance activities in running and shutdown

days of mills. The Digital Exchange Communication

system equipment comprises of Central Processor

Card(MEX), Ringer Power Supply Card(RPS), Per


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feral Power Supply Card(PPS) and Time Switching

Card(SVC) are the Fixed Slots in the Exchange

System. It is having Universal Slots by

interchanging any Slot and inserting any Card of

the following. These are 8 circuits of Shared

Service Card (8DRCM), 8 circuits of Digital Card

(8SFT/SDT), 8 circuits of Co Trunk Card (8TPF) and

Subscribers Card (24SLS).

The Coral FelxiCom system is computer

controlled, and switches both voice and data

signals using Time Division Multiplexing (TDM).

Voice signals encoded using Pulse Coded

Modulation (PCM) and both packet and channelized

data are transmitted through the system over

common highways. This is highlighted and

advanced feature is having HOT LINE

Communication. It is having the interfacing facility

for connecting of MAX Telephone lines and Trunk

lines, call pickup, Call forward and wakeup Call.

MODIFICATION

To meet the requirements of

fast communication HOT LINE is one of the

solutions. A pair of predefined telephone numbers


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can be made as Hot Line. Since neither of the

two telephones in a hot line can communicate to

other telephones except to its counter part the

availability of the system is more. And also no

dialing is required the communication is very fast.

Keeping these benefits in view there was an

extensive demand for this hot line in MMSM. But

unfortunately the ELTEK system does not allow

more than 5 lines. This limitation prompted to go

for modification. System was installed in 90s and

the model was outdated. Hence the spares were no

more in production for the past three years. So,

maintenance of the system becomes difficult which

needed replacement of the ELTEK system.

A system administrator is

required to do some administrative jobs like

extending some of facilities to the subscribers,

making two telephones as hot lines, numbering

plan etc.. These administrative jobs can be carried

out with the help of digital telephones or personnel

computers. This ELTEK exchange cannot support

digital telephones and moreover administration of

this exchange was very complex. The present

Digital Electronic Exchange Communication System

available in the market have many more facilitiesand adoptability to the on going technological

developments. And have facility to maintain and

administer remotely. This remote maintenance


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interface (RMI) was not available with this ELTEK

exchange.

Any system should support

expansion for its future requirements with

minimum hardware addition. The ELTEK system

was a rigid system with no flexibility to expand.

The ELTEK exchange line cards can handle only 8

( eight ) lines comparative with present available

cards which can handle 24 lines. So the present

available systems are compact and can be easily

mounted on wall or table. Conducting conferences

have became regular activity in any organization. If

the conference can be conducted through

telephones, time and other resources can be saved.

But the ELTEK system cannot support for

conducting conferences.

The ELTEK exchange used togive many troubles due to its limitation in

operating temperature. And also the power

consumption was more, the battery backup time

was less in case of power failures.

The demand for number of

normal telephone connections, number of hotlines

and other facilities were increased and the system

was unable to provide them due to its limitations.

So, the ELTEK system needed replacement.


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CORAL FLEXICOM 400AND 400V

The coral FelxiCom 400configuration offers greater capacity and flexibilitythan the Coral FlexiCom 300 cabinet, yet the wallmounted system remains compact and low cost.The system is cost effective for applications of 40

to 300 systems.

Utilizing efficiency, highfrequency, switch mode power supplies the coralFelxiCom 400 can operate directly from a 48V DCpower source, opening up a host of options andapplications, including battery operation wherecontinuous service and maximum reliability arecritical issues. Internal power supplies are availablefor operation from either 48V DC, allowing systemto be operated from a standard, - 48V DC

telecommunications battery plant, or 115 / 230VAC. (AC is not for use in the North Americanmarket.)

The system is ideal for generalbusiness and industrial telephone switchingapplications. When a small stationary plant isadded, the system is an excellent choice forhospitals, campus environments, and municipalgovernment facilities and in vintage central officesto provide Centrexservices.

The Coral FelxiCom 400 iscompetitive with similar sized hybrid and privatebranch exchange systems. The Coral FlexiCom 400delivers more features, more capacity and moreconfiguration flexibility than any other system inits range. In addition, the Coral FlexiCom 400


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expands gracefully into a Coral FlexiCom 5000configuration, utilizing all cabinet except thecabinet.

Requiring only 35 x 22 of wallspace, the Coral FelxiCom 400 demands little morespace than Coral FlexiCom 300, yet provides 50%additional port capacity when powered from ACmains and 150% additional port capacity whenpowered from DC mains. The cabinet contains 16card slots for both peripheral interface and SharedService Cards.

The cabinet is a convection cooled,and includes a wall mount bracket and cover.Peripheral interface system connections are made

via 16 female, 25 pair AMP Champ or Am phenolMicroribbon type connectors. Power and interfacecables exit from the lower left corner.


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TECHNICAL DESCRIPTION:-


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The Coral FelxiCom digitalcommunications switching system employs thelatest advancement in telecommunicationstechnology. The Coral FelxiCom system is computercontrolled, and switches both voice and data

signals using Time Division Multiplexing (TDM).Voice signals encoded using Pulse CodedModulation (PCM) and both packet and channelizeddata are transmitted through the system overcommon highways, ensuring an efficient transfer ofsignals from one port to another.

The Coral FlexiCom is circuitrydivided operationally into two functions Controland Switching. The system also is physically

divided physically into two sections CommonControl and Peripheral. Control functions areperformed throughout the system, while switchingfunctions are performed only in peripheral section.While the peripheral circuitry capacity variessubstantially from one configuration to other in thefamily, the common control circuitry is nearlyidentical in all systems.


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SYSTEM CONTROL:-

Control of the Coral FlexiComsystem operations is distributed among processorthroughout a four level hierarchy within thesystem. The modular control hierarchy ensures thatcontrol resources grow with the system. The openarchitecture ensures continued compatibility withsystems and features yet to be conceived.

The Master Controller (MEX IP)located in the common control section, isresponsible for the supervision of the configuration

database and system wide functions. CardControllers located on each card in the peripheralsection (24SFT, 24SLS, 8TPF) oversee the statusof Shared Service and Peripheral Interface ports.Station Controllers located in all voice stationequipment devices, manage the voice and datafunctions of multi button digital telephone sets andAPA interface modules. Application Processor linkto the master controller through a proprietary datacommunications protocol to provide non-telephonyenhancements to system.

This design offers significantadvantages over other systems built around asingle point of control. The number of controllers inthe Coral FlexiCom system is directly proportionalto systems size. When new features or ports areadded to the system, control power is increased aswell. As a result, the work load on each controllerremains consistent. Regardless of the size of thesystem. And by evenly distributing controlfunctions, the risk of system failure is reduced

dramatically.

The real time functions of portstatus management are handled by Card Controller.Station controllers manage all display, indicator,data switching, and status functions of multi-button electronic telephone sets. Dedicated


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Applications Processors integrate processor-intensive database manipulation and statisticaldata processing capabilities. The master controllerperforms less time critical functions such asmanagement of the system resources and

configuration database, and supervision ofdiagnostic routines.

The Master Controller executes amulti-tasking operating system, which in turnexecutes the Coral FlexiCom operation softwareprogram. The operating software is divided intotask modules, each responsible for a portion of thesystem operation. Various modules include voiceswitching, VoIP, ISDN service, data switching,diagnostics, administrative, programminginterface, etc...

Communications between theCommon Control and Peripheral circuitry isestablished through the Group Controller, throughthe Group Controller is considered neither aCommon Control nor a Peripheral function. The


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Group Controller uses High-Level Data Link Control(HDLC) channels to provide a two way, serial datacommunications link between the Master Controllerand each of the Card Controllers.

Each peripheral shelf has access totwo HDLC channels. While communicationsnormally occurs on the first channel, the systemcan use either or both channels when necessary toensure absolute system reliability.

The Group Controller also providesPeripheral services functions such as generation of

system tones. Peripheral bus timing, diagnosticstesting, and time slot interchange. Each CardController executes a card-specific program tocontinuously monitor the activity of port residingon its card, and act on instructions from the masterController to change a port state. The CardController is responsible for identifying changes inthe status of each of its ports, such as on-hook /off-hook, hook-switch flash, dialing, ringing,incoming call, central office disconnect, etc andreporting these events to the Master Controller.

The Master Controller examines the configurationdatabase, and determines the appropriateresponse to the event, such as assigning orreleasing time slots, returning dial tone, ringing atelephone, or releasing a trunk seizure. The MasterController then instructs the associated CardControllers to take the necessary action in order tocarry out the response. The Station Controlleridentifies the station status, such as on-hook / off-hook, incoming data and key press sequences andpasses this information via a control channel over

twisted pair wiring to the Card Controller. TheStation Controller also interprets control anddisplay information from Master Controller, such asspeaker on / speaker off, display text, illuminateindicator LEDs, enables data, etc and acts on theinformation accordingly.


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Applications processors provideenhanced functions that are not directly related toprocessing calls, such as directory management

and statistical computation. The ApplicationsProcessors are described in more detail in theirrespective product descriptions.


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GROUP CONTROLLER CARDS :-


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The Coral system architecture isdetermined the Group Controller Card used in thesystem.

PERIPHERAL INTERFACE CARDS :-


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Peripheral interface cards providethe Coral FlexiCom system with a wide variety ofinterfaces for interconnecting station, trunk, andancillary equipment and facilities. Each cardincorporates an 8-bit microcontroller as the Card

Controller. Signal gain is adjustable in theconfiguration database for each connection typethrough the system and for each individualPeripheral interface.

All peripheral interface circuits arefully protected against electrical surge andelectromagnetic and radio-frequency interfaces(EMI and RFI) and meets or exceeds allrequirements and specifications of telecommunications and electrical safety

authorities world-wide.

SHARED SERVICE CARDS :-

Shared service cards reside in theperipheral section of the Coral FlexiCom system,and provide community functions such as DTMFtone recognition dial and call progress toneidentification, and multi party conferencing. Eachcard incorporates an 8-bit microcontroller as the

Card Controller.

DIGITAL TRUNK CARDS :-

Digital trunk cards reside in theperipheral section of the Coral FlexiCom system.Each of the Coral FlexiCom digital trunk interfacecards derives a clock signal from the receive datastream of the PSTN. This signal may be used tooperate the Coral FlexiCom system in the slaved

clock (or loop-timed) mode, synchronizing the PCMclock of the Coral FlexiCom with the publicnetwork. Any two digital trunk cards (except thoselocated in CoraLITE remote Peripheral shelves) canbe designated as primary and secondary externalclock source. Thus, with the loss of clock signal


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from the primary card, the system simply switchesto the clock from secondary card.

The Group Controller card contains

the high-precession clock circuitry, whichsynchronizes the Coral FelxiCom system. Thephase-lock circuitry synchronizes the Coral PCMclock to a signal derived from one of two digitaltrunk interface cards, designated the primary andsecondary external clock source. This featureenables the Coral FlexiCom system to integratewith any digital telephone network in the world.

VOICE SWITCHING :-

The Coral FlexiCom voice switchingcircuitry may be further divide into two functions Peripheral interface and Shared service. Individualvoice channels are established through the CoralFlexiCom system between two or more ports,during one of 64 TDM time slots over a PCMhighway. A port may be a shared service such as atone detector circuit or one of the input / outputcircuits of a conference bridge or it may be aPeripheral interface such as a Coral FlexSet or

Single-line station interface, a digital trunkinterface, or a music-on-hold input. The CoralFlexiCom systems Universal Slot design allowsany type of port card to be installed in any order, inany slot in the system.

The analog voice signal at the portis first converted to a series of binary numbers by aPCM Coder/ Decoder circuit, commonly referred ascodec. The codec refers the voice signal 8,000times a second measuring the analog amplitude to

a binary number. This is the essence of the PCMprocess, the international standard for digitalconversion, or digitizing of an analog signal. Oncedigitized, a voice signal can be transmitted to anyother point in a digital network, whether across theroom or across the world, without any signaldistortion or degradation.


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At the same time, the codecreceives a binary number (a digitized sample) fromthe other port in the connection and translates thisto an analog voltage. These voltages, generated by

the codec 8,000 times a second, reconstruct withnear-perfect accuracy, the original voice signalsampled by the other port in the connection. Thecodec is also used for port status processing.Codecs are

Used on most peripheral interface and SharedService cards, which process signals that alreadyare in digital form. Proprietary digital station sets

such as the Coral FlexSet incorporate a codec in thetelephone circuitry to digitize the voice signalwithin the telephone set.

The digitized voice signal from thecodec is applied to a PCM highway via thePeripheral Bus Controller (PBC) circuit, located onthe peripheral interface or Shared service card. ThePBC establishes connections between the codecsand PCM highways. Each PCM highway consists of

transmit and receive bus. The Master Controllerassigns transmit and receive time slots to the portwhen the port requires a voice channel. The PBCoutputs a sample from ports codec onto thetransmit bus during the assigned receive time slotand passes the samples to ports codec.


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Each transmit and receive bus ismultiplexed 64 time slots, which allows 64simultaneous, two way voice channels per PCMhighway. Each Peripheral card has access to twoPCM highways. This enables up to 512 ports to bein use simultaneously in each peripheral shelf.


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CG Make CORAL II TelephoneExchange

CARDWISE DESCRIPTION.

PPS Peripheral Power Supply :- The PPS provides internaloperating voltages for the Coral II switchingsystems. The PPS operates from a normal input of48v DC, typically supplied by an external 48v DC


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rectifier or stationary battery plant. Actual inputmay vary from 42 to 58 volts.

Circuit Description:- The PPS contains three, pulsewidth modulated (PWM), switch mode DC-DCconverters witch convert the 48v DC input power to+5v DC, -5v DC, +12v DC and -12v DC operatingvoltages for the Coral- II internal circuitry. The PPSalso further filters to minimize ripple and noise,current limits the 48v DC input to feed theperipheral cads slots. All outputs except the -48vDC output are regulated. Voltage and current levelmonitoring circuitry check each output of the PPSand produce alarm signaling to the Coral-II systemmain processor in the event of abnormality.Input ----- 48v DC, 20A maxOutput ---- +5v DC, 15A max; -5v DC, 3A max;+12v DC, 8Amax;-12v

DC, 0.15A max; -48v DC, 8A maxIndicators ---- power ON; output voltages test jacks.

Ring Generator Power Supply (RPS):-

The RPS provides high voltage ringgenerator current required by single- linetelephone station ports of the 24SLS cards installedin the Coral-II switching systems. The RPS operatesfrom a nominal input of 48v DC, typically suppliedby an external 48v DC rectifier or stationary


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battery plant. Actual I/p may vary from 42v to 48vDC.

Circuit Description:-

The RPS contains a low frequencyoscillator produces an AC waveforms and powerrectifier which convert the 48v DC input power to75,85 or 105 volts (16,20 or 25 HZ) alternatingcurrent (AC); for use as a ringing message waitingsignal on industrial standard, single line telephone(SLT); and magneto telephone station ports. Theoutput of the oscillator is fed to the poweramplifier. The output of the power amplifier is fedto the output transformer. The output voltage isregulated and adjustable from the front panel.

Voltage monitoring circuitry checks the output ofthe RPS and produces alarm signaling to the Coral-II system main processor in the event ofabnormality.Input ----- 48v DC, 20A maxOutput ----- AC voltage75, 85 or 105vSelectable;

Frequency 16, 20 or 25 HZSelectableIndicators ----- power ON; output voltage test

jacks.


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Control DC Power Supply (CPS):-

The CPS provides the +5voperating voltage for the common control shelf ofswitching system. The CPS operates from a nominalinput of 48v DC, typically supplied by an external48v DC rectifier or stationary battery plant. ActualI/p may vary from 42v to 58v DC.

Circuit Description:-

The CPS contains a pulse widthmodulated (PWM),switch-mode DC-DC converterwhich converts the 48v DC input power regulated+5 volts operating voltage for the Coral commoncircuitry. Voltage and current level monitoringcircuitry checks the output is within the toleranceof the CPS and produces alarm signaling to theCoral-II system main processor in the ofabnormality.

Input ----- 42-58v DC, 6A maxOutput ----- +5v DC.Indicators ----- power ON; output voltage testjacks.

24 SLS ( Single Line Station ) :The system as an S or SH

type. When strapped in the S position, the card isidentical in operation to the S card and identical to

the SH card when strapped in the SH position.When jumper ed as SH the SLS card alsoincorporates a high voltage DC power supplycircuit. Each station circuit also can superimposehigh negative voltage DC on the ring conductor toThe 24 SLS contain twenty-four identical circuits.Each SLS circuit superimposes direct current (DC)talk battery, used to power the telephone set, over


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the same pair of wires which carry voice signals. Tosignal a call to the telephone station, high voltage,low frequency, alternating current (AC) ringgenerator is superimposed on the ring (negative)conductor, to operate a high impedance ringer or

bell at the station.Each SLS card contains an

option strap which instructs the card software toidentify itself to operate a high voltage, neon, gasdischarge lamp; commonly used as a messagewaiting indicator.

Circuit Description: A simplified circuit diagram ofone of the twenty four station circuits. The majorcomponents are relay K1,a precision resistornetwork, the subscriber line interface circuit(SLIC) , and a digital - toanalog converter (orcodec ).

Main Exchange Control Card (MEX):

MEX is the main control card. It is based on an Intel368-EX microprocessor. It integrates the functionsof the MEX, with the following differences:

IMC8 Card and CARD Slot:


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An IMC8 slot is mounted on the MEX board. TheIMC8 contains the code and database and isessential for system operation there must beremoved from its slot during system operation. It

integrates through the main processor, memorymanagement circuitry, local bus interface,programming and maintenance data port, real timeclock, generic feature software memory anddatabase memory. Determine the data send/receiverate in bits per second (bps) for KB0 or RS 232 datainterface ports. Baud rate also determines themodem capability for the modem port.

Front Panel:

There is an IMC8 slot and release button. In thistwo expansion panels for CLA, instead of four. Inthis one no. of KBO connector in 9 pin D-type RS232-E, instead of 25 pin.

Control Card(MEX) status display codes:


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STATUS DISPLAY:- SYSTEM STATUS:-

. Normal System Operation

0 Offline for maintenance

Diagnostics Mode

12

13 Appear During Initialization 14

6 Lithium back up battery low

C Flash memory checking error

E Memory Configuration error

F AC power fail

L Software authorization unitCant be detected

r Ram error

P Protection level error

5 Wait state register error


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BENEFITS

High availability of front-end shop floor

communication.

Provision for expansion of more subscriber lines

and hot lines .

Availability of Remote software changes for group

call , call pickup , call storage, last call memory and

priority calls

Availability of interconnection facility for trunk

lines and MAX lines.

Availability of power backup facility for 8 hours.

Up-gradation facility for hardware and software.

Availability of Seedy dialing facility for all the

subscriber lines.

Standard interfaces like RS 232, LAN etc are

provided for interfacing with other systems and

applications.

Availability of standard interfaces for

interoperability with other systems like central

computer, power plant computer, etc.

Thus Digital Electronic Exchange Communication

system has proven that a better technology

establishment is a one time cost but the fruits we

see from this are continuous and encouraging.


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CONCLUSION Earlier due to lack of

sophisticated equipment is Analog Exchange,

model of ELTEK which is supplied by M/s L&T Ltd is

the first product of communication Systems. It was

very difficult to predict whether the subscriber line

connection is through from exchange to prescribed

destination. It is very difficult to connect theHotline communication between one Control Pulpit

and another Control Pulpit because there is no

provision to club two subscriber lines as a single

Hotline. It is only the way by using of wring and

there is no particular administrative software for

changing the communication requirements. And on

fuse protection for abstraction of higher incoming

power supply. Further it was a very time consuming

process to undo the effect causing the problem. In

the mean time sometimes the quantity production

loss occurred due to non availability of proper

speedy communication in the particular area.

To avoid this burning

problem, finally we have decided to replace the

existing Analog Communication System to Digital

Electronic Exchange Communication system. It is a

very advanced easy software programmable

communication system, which has brought

revolution in the field of fast communication


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systems. It is easy changeable software

programming links between subscriber and

subscriber , group calls , priority calling and normal

subscriber to hotlines. The Digital Electronic

Exchange Communication System over comes all

the above bottlenecks.

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