B

Bharat Bijlee Limited

Over 55 years
in the industry
 Over 450 Drives in India & abroad
From 750kg to 1750 kg Basket

• Bharat Bijlee is the first and largest

Indian manufacturer of microprocessor
based Variable Speed Drives for Batch
Centrifugals
• AC Variable Voltage since 1985
– 300 drives at 72 locations
• Analogue DC Drives since 1997
– 150 drives at 65 locations
• Digital DC Drive Nov 2002
BBL serves every corner of Asia

SURAT
 Digital DC Drives
a result of in-house R&D
• We have 17 years experience with batch
type centrifugal machines
• We have commissioned 150 Analogue DC
drives - drives developed by our own R&D
• WE COMMISSIONED OUR FIRST DIGITAL
DRIVE IN NOVEMBER 2002
– Fully Digital Control Algorithm
– Integrated Field Controller
– Customised Logic Controller
Minutes of meeting between M/S. Shree Renuks Sugars Ltd and
M/s Bharat Bijlee Ltd. Held on 20th January 2003 at
M/S.Renuka Sugars Ltd. Manoli

Persons Present
M/S SRSL M /S. BBL

1. Mr. C G Mane 1. Mr. S S Sathawane

2. Mr. R Y Huilgol 2. Mr. A B Harshe
3. Mr. G B Kulkarni 3. Mr. N D Shanbaug
4. Mr Lokeshappa H 4. Mr T G Kolambkar

1. As per the SRSL Fax dated 9/1/03 BBL representatives reached

site on 13/01/03 to re-commission the digital DC Drive which was
shifted from M/C No. 4 to M/C. No. 5, as per request of SRSL.

2. The mechanical and the electrical work of above M/C. was

completed on 16/01/03

3. The drive and the M/C. No. 5 was re-commissioned on 18/01/03

4. Earlier this drive system was put on M/C. No. 4 and was working
satisfactorily since end October 02 till 3rd January 03, giving
20 cycles per hour on load and has completed approximately 25,000
cycles so far.

5. M/S. SRSL has expressed their satisfaction about the working

and the performance of the above drive system.
 The Digital Advantage
- Reliability
• Software based Controls and Protections
• Protections against Frequency Variations
• Protection against Thyristor Gate Control
malfunction
• Not affected by drift in component values
• Not affected by change in Phase
Sequence
• Fault History - last 32 faults with time
stamp
The Numerical Control Advantage
Keypad is in - Screwdriver is out

• Drive Set up - all parameters input

through keypad
• Linear and S curves for acceleration &
deceleration ramp with adjustable time
constants
• Three levels of Password protections
• Adaptive Control Algorithm for
– lower voltage and current overshoots
– faster response to load and line changes
 State of the Art DSP
• Texas Instrument 16 Bit Processor
– Type - TMS 320 F240
• High Execution Speeds - 20 MIPS
– In built hardware multiplier
– single cycle execution
– four stage pipeline architecture
• PROTECTION AGAINST OBSOLESCENCE
– Micro Controllers are being replaced by DSP
 V

V A M
Mains L Drive Controller
FSU
Input

C Power supply Armature

L
Controller

SW Control card Speed

Control Supply HMI
T
Field
Power card

Field
A
Snubber card Controller
Bleeder

Transformer
PBS
Customised Logic Controller mimic
Solenoids
Power supply Process & m/c Speed
Logic Control

HMI CPU Card

M/c Proximity
I/O Card Protections A Ia Switches

Single Line Diagram of Drive System

 Speed Feed back SET IF
PI CURRENT
ERR. AMP. LIMITER

Eb
Ref +

DC TO  CONV.
ACTUAL Eb=Va-Ia Ra

PI END STOP
V TO f
A1 Va

Va M ISOLATION
AMP. +
ERR
AMP
f TO V
A2 CONVERTER
F
400V D.C. =10V.
Ia Ra F1

CT
+
F2

BLOCK SCHEMATIC OF FIELD CONTROL

 (
ERR. AMPR. ( DECIDES
REQD. Ia
Ia SLEW
RATE LIMIT
SET. Ia
LIMITER

+
REF
N
N f/b

PI
ERR. AMPR. CONTROLLER END STOP

PROCESSING DC TO  CON. 630A

Ia f / b GSMJ
A.C. SIDE
CURRENT A1

M
N f/b
Tg A2

BLOCK SCHEMATIC OF ARMATURE CONTROL

 Protections in Drive

- Mains under / over voltage

- Mains under / over frequency
- Phase failure
- Excessive motor winding temperature
- Excessive converter temperature
- Instantaneous armature over current
- Overload ( I.t ) type
- Over speed
 Protections in Drive
- continued
- Motor stalling
- Tacho failure
- Field failure
- Armature over voltage
- Thyristor gate control malfunction
- Main contactor failure fault
- Motor fan failure
- Converter fan fault
User Interface for Drive Module
150 PARAMETER DISPLAYS
• Speed
• Armature Voltage and
Current
• Field Current
• Mains Voltage and
Frequency
• Faults with time stamp
• PI controller output
• Armature and field firing
angle
60 PARAMETER INPUTS
• Rated values of mains
voltage and frequency
• Rated Armature Current
and Voltage
• Rated Field current
• Min. and max. Firing
Angle
• Over current over
voltage and over speed
limits
• Motor base speed
SPEED
1000 RPM
ARMATURE CURRENT
400 AMPS

E
 Customised Logic Controller
• Developed by In House R&D efforts
• Programmable as per customer’s
specification
• HMI provided on control panel for
– setting up process parameters
– display of status of process
– fault indications - stores last 16 faults
• Logic changes after commissioning can be
programmed at BB factory and user can
easily replace EPROM on site
• Command vs feedback compliance feature
 Push Button Station
300mm X 550 mm X 150 mm

Drive Panel
1200 mm X 1600 mm X 600 mm
FRONT SIDE OF DRIVE PANEL REAR SIDE OF DRIVE PANEL
DRIVE DETAILS
 Future Versions of
Digital DC Drive
• Serial Communications
• Armature Current Reversal
• HMI at operator station
• Process and drive inputs through
same HMI
 R&D Direction
• AC Variable frequency 2Q drives for
– ID and FD Fans
– Milling Plant
– Cane Carrier
– Pumps
• AC Variable frequency 4Q drives for
– Batch type Centrifugals
Bharat Bijlee
is Wedded to the
SUGAR INDUSTRY
for

Years
 Bharat Bijlee
India’s first & largest
manufacturer of
Microprocessor based Drives for
Sugar Centrifuges
 the
Bharat Bijlee
advantage