RASHTRIYA ISPAT NIGAM LIMITED

VIZAG STEEL PLANT (VSP), VISHAKAPATNAM

A Project Report on
“INDUSTRIAL APPLICATIONS OF
DRIVES”

Submitted by,

BAKKI. ESTHER DIVYASRUTHI

Roll No.1210512104, 3rd Year B.Tech,
Department of Electrical and Electronics Engineering
GITAM INSTITUTE OF TECHNOLOGY
GITAM UNIVERSITY-VISAKHAPATNAM

Under the guidance of

L.V.RAMESH
Manager
Dept. of Electro Technical Laboratory (ETL)
RINL (VSP) - Vishakapatnam
 ACKNOWLEDGEMENT

I extend my gratitude to The Head of the Department of Electrical and

Electronics Engineering of GIT-VISAKHAPATNAM , Training and Placement
Department of GIT-VISAKHAPATNAM, Training and Develop Centre,
Vishakapatnam Steel Plant for giving me this opportunity to undertake the project.

I express my deep sense of gratitude and indebtedness to Mr.L.V.Ramesh,

Manager, ETL, LMMM, Vizag Steel Plant for his inspiring guidance, untiring efforts
and constant encouragement, support and suggestions for improvement during the course
of my project.

I would like to convey my hearty gratitude to Dr. G.V.K.R. Sastry, Head of the
Department of Electrical and Electronics Engineering for providing all necessary
facilities and helpful suggestions.

I also convey my wholehearted thanks to all in Vizag steel, faculty of our college
and other members who helped in bringing out this project.
Process of Light and Medium Merchant

Mill

BLOOM CHARGING AND DISCHARGING EQUIPMENT

Blooms from the continuous casting department will be received with the help of
16-ton magnet crane for charging on to the charging grids of LMMM. Three charging
grids of capacity 150 tons each are available for receiving the blooms. Defective blooms
can be sorted out and rejected on to two take off grids provided along the charging roller
table. The charging grids are at +800mm. Blooms from the charging grid are fed on to the
charging platform. Blooms so elevated are weighed piece by piece and tilted if necessary
with the help of hook type tilter before feeding into the reheating furnaces. Blooms fed to
the furnaces with the help of furnace approach roller table are electrically stopped at the
proper position in front of the furnace and pushed simultaneously in to rows into the
furnace with the help of hydraulic pushers. Blooms are heated to a temperature of 1100 to
1200deg.cel and discharged by a discharging device on to the furnace delivery roller table
one by one. There are four furnace discharging machines. It will be possible to supply
fully heated blooms once in every 26.5 seconds to the mill, however, normal time being
36 seconds. The blooms are then carried on the mill approach roller table through a
hydraulic de-scalar before feeding to the first stand of the breakdown group. The
charging roller table and the furnace approach roller table are designed with a speed of
1.2mts per second and the solid forged steel rollers are individually drives. Bloom
elevator (with one standby) is of chain type and has a cycle time of 21 seconds.

Hydraulic descaler is designed with a descaling pressure of 186 Kgs. At the end of
furnace delivery roller table an emergency hot bloom reject grid and pusher is provided to
remove defective blooms from the furnace. The defective blooms collected by the mill
crane can be taken back to the bloom storage yard with the help of a transfer car.
Mill equipment
Breakdown group: Breakdown group (billet mill part) has seven continuous
stands, with two horizontal stands followed by 5 alternate vertical and horizontal stands.
The total motor power for the breakdown group is 6,100Kw. The speed of rolling is 1.3
to 1.6 mtr/sec.

An in-line four-crank shear, installed behind the breakdown group is designed to crop
both ends and to cut fixed billet lengths between 5 and 12.0 mts or to perform optimum
yield dividing. Billets fed to the bar mill are only cropped at the front and back ends,
while the billets for sale and for wire rod mill are cut to lengths 5 to 12 mts and 10.4 mts
respectively. When cutting fixed lengths, rest ends upto 1.5 mts are guided into the scrap
bucket and rest ends above 1.5 mts are transported over the closed recoil roller table
sections to a location where they are diverted into a short length disposal cradle.

Billet cooling bed and billet shear : Transfer of billets to the

cooling beds is by feeder screws which, after one full revolution, push the billet moving
on the cooling bed roller table sidewise to a break plate where it comes to rest after a
short braking distance. While the next billet is being delivered the billet resting on the
brake plate is simultaneously transferred through the feeder screw via short chute to the
cooling bed rake system. To ensure discharging of the billets coming in one by one a
lead is produced immediately at the back of the four crank shears to produce the defined
gap between the billets.
During the turnover operation, the moving rakes turn the billets over 90deg in
each stroke, thus moving them on one pitch on the stationary rakes. Each cooling bed is
designed for a capacity of 200tons per hour to cool to approx. 400deg.cel with natural
convection. From the loading grid provided at the end of the cooling bed, billets will be
removed in batches by 16-ton capacity magnet cranes and stored in the intermediate billet
storage area.
 Billets rolled for bar mill are fed in full length to the two-strand roller hearth
furnace before feeding to the bar mill. A switch is arranged in front of the furnace to
guide the full length billets for bar mill, to either of the two strands.
Billets normally arrive at a surface temperature of about 1100deg.cel. at the roller
hearth furnace. In case of two-strand rolling, billets will be heated and soaked to the
discharging temperature of 1150deg.cel. At single strand rolling the billets will be heated
and soaked to a discharging temperature of 1130deg.cel. The temperature of the billets
when entering the first stand of the bar mill will be normally about 1100deg.cel. The
main drive and other connected equipment of the bar mill are, however, designed to roll
billets received at the first stand at a minimum temperature of 1050deg.cel.

Intermediate group: Intermediate group is arranged in multi-line arrangement.

Each line has five stands with four horizontal stands of and one vertical stand .The motor
power for each line is 4.300kw, i.e., a total of 8.600kw for the intermediate group. The
intermediate stands have combined gear box and pinion stands with casing of fabricated
steel. The roll changing is done by complete stand changing with the help of quick stand-
changing arrangement.

Finishing group: The two finishing groups are arranged to roll in single strand
only. Each finishing group has four alternate vertical and horizontal stand. The motor
power for each line is 3,400kw i.e., a total of 6,800 kw for the two finishing groups. The
finishing groups have combined gear box and pinion stands with casing of fabricated
steel.

Mill shear: Shears for cropping and emergency cutting are arranged ahead of the
first roughing stands and up-stream of the intermediate mill. Snap shears are arranged for
emergency cuts ahead of the finishing mills. A pinch roll unit is located adjacent to the
pendulum shear between the furnace and the first roughing stand.

Cooling bed: The double-sided cooling bed is provided with row of axial fans. A
switch is provided ahead of cooling beds permitting both the cooling beds to be fed
simultaneously when rolling in two-strands and the two cooling beds in alternating order
under single-strand rolling conditions.
 The bars entering the cooling beds at rolling temperature will be discharged at
temperatures of about 80deeg.cel. and below for section and about 135deg.cel. and below
for rounds. The first part of the cooling area comprises a straightening plate grid which in
the high temperature area provides additional support to the material and thereby exerts
the material straightening effect by ensuring slow and uniform cooling. On the cold side
of the rake type cooling area an aligning device is provided which consists of
continuously operating driven and idling rollers provided with rake notch profile and
brake shoes which are moved under the action of a pull-rod system.The bars are
transferred to the discharge roller table downstream of the cooling beds.

Cross transfer, piling and bundling: Four cross transfers are provided
after the cold shear for feeding to the piling and bundling equipment.
The bar bundling facilities are provided with counting device, automatic
sorting of under-length and automatic tying of bars into the bundles of 4.5 ton or 10 ton.
The structural products are automatically piled to form square packets in nested
arrangement to make the packets stable enough for being tied and transported. Flats and
squares can also be piled by means of this piler.
Prior to tying, the section packs are compacted by compactors to ensure that the
bindings made thereafter will not become loose even under pack transport conditions.
Tying of packs and bundles is performed by the same tying machines which are shiftable
type.

ELECTRICAL EQUIPMENTS IN LMMM

The mill stands are driven by individual main drive motors. The motors are
separately excited and compensated DC shunt motors in two frame sizes.

The armature circuits of the motors are provided with individual thyristor power
supply systems comprising 11 KV converter transformer, thyristor converter, reactor,
single pole high speed circuit breaker and double pole no-load contactor, in ratings to
match the motor over-loads. Field circuits of the motors are fed by individual thyristor
power supply systems fed from 415v, 3-phase supply source, over isolation transformer.
A modern system of control electronics comprising integrated circuit technology,
standard supply voltages and plug-in cards of analogue modular system has been
provided for speed regulation of the motors, to ensure a steady state speed error and
dynamic speed regulation.
Auxiliary drives which are required to operate in synchronism with main mill
stands or which need regulated speed operation or position control e.g., pinch rolls, flying
shear, braking slides, etc are driven by DC motor.
For the sake of reliability of operation, high overload capacity and
standardization, DC auxiliary drives are provided with mill duty motors. For AC drives
the motors provided are generally squirrel cage type for continuous operation drives and
slip-ring type for intermittent duty drives. Geared motors for individually roller table
drives have also been foreseen. AC motors provided are totally enclosed fan-cooled.
The controls for AC motors in an area are grouped to form motor control
centers(MCC) with incoming isolator, requisite number of outgoing feeders and fully
rated bus bars. Variable frequency motors for roller table drives are fed over variable
voltage-variable frequency (VVVF) supply sources.

OPERATION CONTROL AND MONITORING :

For easy start-up, monitoring and control of electrical equipment of LMMM a set of
control panels, essentially comprising control switches for starting up of mill electrics,
on-off indicating lamps for status indication of the electrical equipment, single-line
mimic diagram of main and important auxiliary drives, chart- recorders for speed and
armature current of each main drive motor, devices for temperature monitoring at
important points of main drive motors and group fault annunciation system, located in
central supervisory control center inside the main control room, have been envisaged.
For operational control of the mill, a total of eighteen(18) pulpits (including one for billet
inspection) have been planned to house the required control desks and switching
cabinets.
Instrument head boards to accommodate indicating instruments, VIDEO display units
and CCTV monitors as required are also housed in the pulpits. The control desks contain
all control devices necessary to operate the equipment within the zone of control. Safety
of men and equipment is important and for this emergency push buttons of lockable
design are provided on the control desks to switch off equipment when required. The
pulpits are provided with package type air-conditioning units. For local control of
equipment during operation and maintenance, control desks and posts have been provided
locally near various group of equipment on the mill-floor.

DC MOTOR SPEED CONTROL

A. Introduction to DC motors
The direct current (DC) motor is one of the first machines devised to convert
electrical power into mechanical power. It converts electrical energy into mechanical
energy through the interaction of two magnetic fields. One field is produced by the
permanent magnetic assembly or field coil energized by dc current, the other field is
produced by an electrical current flowing in the armature windings. When a current
carrying conductor is placed in magnetic field it experiences force. Since in current coil,
current flows in anti parallel direction equal and opposite forces are produced. This equal
and opposite forces produces torque which in turn rotates the current coil (armature). As
the rotor turns, the current in the windings is commutated to produce a continuous torque
output.

B. Speed control
The speed of the motor can be controlled in two ways

1. Armature Control:
By keeping the field flux constant speed can be varied by varying armature
voltage. Here maximum speed that we can achieve applying maximum power
(rated armature voltage) is base speed.

2. Field control:
If we want to operate the motor at speed higher than base speed we go for field
control. Here field flux is varied to achieve required speed. Once the desired
 speed is achieved, the flux is maintained constant. To take care of the torque
requirements, armature current compensation is given by varying the gain of the
speed controller.
Since the torque factor plays a major role in industrial applications, we prefer
separately excited motors for industries. We have better control over torque in
separately excited motor.

C. Speed control system has following sub systems

1.Control supply system.
It consists of automat (breaker) and step-down transformer.
The purpose of control supply system is,
1. Protecting the source from overloading.
2. To obtain regulated power supply (for ±15V).
Automat:
Basically it works as a switch. It is a protective device which protects the source from
overloading. An automat consists of thermal sensitive device. When the overloading
occurs, the current through the thermal sensitive device crosses certain limit and switch
will get open.

2.Synchronous supply system.

This system is used to produce controlled pulses. These pulses are used as gate pulse for
thyristors.
The components of this system are :

1. Synchronous Voltage source.

The supply is of 415/60V, 3ф, 50 Hz and it is stepped down using a transformer. This
voltage has to be in phase with the main incoming supply to the thyristor stack for
proper generation of pulses.
2. Filters.
This consists of LC filters. This unit takes care of harmonics present in the incoming
synchronous supply. These harmonics may affect generation of pulses at proper firing
angle. The filter eliminates such harmonics.

Working of the Speed controller.

The purpose of a motor speed controller is to take a signal representing the
demanded speed, and to drive a motor at that constant speed. The controller may or may
not actually measure the speed of the motor. If it does, it is called a Feedback Speed
Controller or Closed Loop Speed Controller, if not it is called an Open Loop Speed
Controller. Feedback speed control is better, but more complicated, and required for
complex operation.
Our ultimate aim is to rotate the motor at constant speed. If the speed of the motor
comes down then voltage across the armature has to be increased. This is a complex
process in industrial applications. Every time we need to vary the dc magnitude the firing
angle of thyristor has to be varied accordingly. This complex process will be taken care
by speed controller whose block diagram is as shown below.

The speed reference provides a dc voltage, say 10 volts for maximum speed and
zero for stationary. This could be a potentiometer providing any voltage in a range from
zero to +10 volts. The difference amplifier will amplify any difference between its two
input voltages.
 Figure, Block diagram of speed controller
If the motor is stationary, since the tachometer is not rotating and not producing any
tachovoltage (speed feedback=0), there will be a difference in voltages at the two inputs
of the difference amplifier. Therefore there will be a saturated output voltage from the
amplifier. This saturated voltage with the help of current rate of rise limiter, autochange
over, adaptive controller and pulse generator firing pulses will be generated
corresponding to the respective saturated voltage. This new firing angle produces
increased voltage supply to motor. Because of this increased dc power the dc motor
begins to increase its speed of rotation.

This makes the tacho voltage to increases and it will eventually reach the same value as
the speed reference. At this point there will be no output from the difference amplifier
and thyristor bridge. The motor is up to the correct speed. However, since the motor is
no longer powered by the dc amplifier its speed will start to fall. But the tacho voltage
will start to fall, and there will again be a difference between the two input voltages to the
difference amplifier.

This will produce an output from the difference amplifier and thyristor bridge which will
power the motor and correct this drop in speed.
Depending on the mechanical loading conditions, Proportional and Integral gains are set
in the speed controller. Proportional gain is set to take care of the response which is
required for the smoother operation. Integral (time) value is selected to hold the power so
that the system is in equilibrium as long as it is in operation. The output of speed
controller is current reference. So, the limit for current which is to be applied to the motor
is set at the speed controller output. During field weakening operation, additional gain is
given to the speed controller to take care of torque requirement as the field is reduced.
This additional gain varies at various operating field current.

3. Protection and Indication system

Protection and indication system of dc motor has 3 main divisions

1. Protection for transformers

Its aim is to protect transformer from over winding temperature, over insulating oil
temperature. It also aims at protecting transformer from over voltage i.e., overloading the
supply. Its main component is automat. When there is overloading, automatically
disconnects the power supply from secondary of the transformer hence source is not
affected and transformer is protected.
2. Protection for motor.
Motor armature protection:
Its components are
Reactor : When supply is given it protects armature from sudden change in
current.
HSCB(High Speed Circuit breaker): It protects from over current at motor side.
Over voltage: It comes from monitoring flip-flop.

Motor field protection:

Its components are field Instantaneous Over current and field Sustained over

current.
PREVENTIVE MAINTANANCE OF DRIVES

For each drive, below mentioned parameters have to be checked once in a year to ensure
safe and smooth working of drives. These parameters are checked in cards level, to find
whether their values are in the prescribed limit or not. If they show a large deviation from
tolerable value, they will be reset. Main reason for variation in the values of these
parameters is variation in values of resistance and capacitance in cards and drives over a
period.
The parameters are,

1.Current limit.
If there is any small difference between speed reference and speed feedback the output
of the op-amp circuit goes to saturation, i.e., ±15 V.
However, this current limit should be of standard reference (for example 10 V) .This is
checked whether current limit is as set before during commissioning or not. This is done
by injecting a signal at speed controller input.

2. Firing angle.
For a thyristor, firing angle determines the magnitude of output dc voltage. For a drive
application, this firing angle is variable which depends on load. However, this firing
angle should vary within a range. The range is between 30˙and 150˙ with ±10% tolerance
for a 50Hz 3-phase system.

3. Pulse symmetry.
Here the symmetry of pulses generated is checked. There will be 6 pulses generated each
of which is 60˙ phase shifted, i.e., 0˙, 60˙, 120˙, 180˙, 240˙, 300˙. The time period
between two rising edge of each pulse should be 3.34mS.

4. Instantaneous over current (IOC).

When there is over current in armature HSCB should trip. Here we will
compare the current feedback with reference using comparator. Here we will check for
trip signal on applying threshold current feedback. Over current at the controller is acted
when there is bridge short circuit also. As the current is not flowing to the motor, HSCB
may not operate. In such cases, IOC will act.

5. Changeover time.
The current flow in the first bridge is sensed and change over is allowed only when
minimum current is detected. This is called zero current sensing. After sensing the zero
current, changing the bridge for different polarity is allowed. Some amount of safety is
set and after this time the bridge is fired to get other polarity. The time when the first
bridge stops firing to the time when second bridge fires is called change over time. It is
also called dead time because the current in load is zero.

6. Controlled power supply.

Here we will check for magnitude of controlled power supply of ±15V. This value is very
important because the entire speed regulation system is based on the limits and set values
totally depending on the op-amp operating voltages.