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SANTOSH BHARADWAJ REDDY
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INDEX
Contents :
induction motor
4. Project Introduction
5. Project Details
7. Conclusion
Visakhapatnam is popularly called as the Steel City of India and credit was
because of the Vizag Steel Plant – a venture of Ispat Nigam. VSP is the first
destiny. VSP has an installed capacity of 3 million Tones per annum of liquid
steel and 2.656 million tones of saleable steel. VSP products meet exalting
VSP has the distinction to be the first integrated steel plant in India to become
VSP successfully installing and operating efficiently Rs. 460 crores worth of
pollution control and environment control equipment and converting the barren
land scape by planting more than 3 million plants has made the steel plant, steel
Middle East, USA & South East Asia (Pig Iron). RINL VSP was awarded “State
Besides these a captive power plant with a capacity of 247.5 MW, Oxygen
facilities, form part of facilities available at VSP. VSP has sufficient infrastructure
to expand the plant to 10 Million tones per annum of liquid steel capacity.
Steel Melt Shop with three L.D.> Converters of 150T capacities each and 6
Light and medium merchant mills of 710, 000 tones per year capacity.
Medium Merchant and Structural Mill of 850,000 tones per year capacity.
MAJOR DEPARTMENT
VSP annually requires quality raw materials viz. irion ore, fluxes,
coking and non-coking coals etc. to the tune of 12-13 Million tones for
producing 3 million tones of liquid steel to handle such large volume of
incoming raw materials received from different source and to ensure timely
support of consistent quality of feed materials to different VSP consumers,
raw material handling plant serves a vital function. The unit is provided with
elaborate unloading, blending, stacking & reclaiming facilities viz.,
Wagon Tripplers, ground & track Hoppers, Stock Yards crushing plants,
vibrating screens, single / twin boom stackers, weal in boom Blenser
recliners.
In VSP peripheral unloading has been adopted for the first time in the
country.
Number of ovens built in series one after other from a coke oven battery. At
VSP there are 3 coke oven batteries, 7m tall and having 67 ovens each.
Each oven is having a volume of 41.6 cum and can hold upto 31.6 tones of
dry coal charge. The carbonization takes places at 1000-15000C in absence
of air for 16-18 hours.
Red hot coke is pushed out of the oven and sent to coke dry cooling plant
for cooling to avoid its combustion. There are 3 coke dry cooling plants each
having 4 cooling chambers. Heat capacity of each cooling chamber is 50-52
THP. Nitrogen gas is used as cooling medium. Generating steam and
expanding to pressure turbines to produce 75MW power each to the heat
recovery from nitrogen.
The Coal chemicals such as henzole, Tar, Ammonium sulphate etc., are
extracted in the coal chemical plant from Co Gas. After recovering the coal
chemical the gas is used as a by product fuel by mixing it with gases such
as BF, LD etc. A mechanical, biological & chemical plant takes care of the
effluents.
Sinter Plant :
Sinter is a hard & porous ferrous material obtained by agglomeration of
iron ore fines, coke breeze, lime stone fines metallurgical wastes
Vizianagaram., mill scale D slag etc.
Sinter is done 2 nos of 312 sq. m Sinter machines of Dwight Lloyd type
by heating the prepared feed on a continuous metallic belt made of pallets at
1200- 13000 C.
Blast Furnaces:
Hot metal is produced in blast furnace, which are tall vertical furnaces.
The furnace as 1 is run with blast at high pressure & temp. Raw materials
such as sinter/ iron ore lumps, fluxes and coke are charged from the top and
blast at 11000C – 13000C and 5.75 KSCH pressure is blown almost from the
bottom. The furnaces are designated for 80% sinter in the burden.
VSP has two 300 Cu.m blast furnaces equipped with Paul worth Bell
less top equipment with conveyor charging. Rightly named as “Godavari” &
“Krishna”, the furnaces will help VSP in bring the prosperity to the state the
two furnaces with their noval circular cast house and 4 tap holes each are
capable of producing 9720 tones of hot metal daily or 3.4 million tones of
sulphur not metal annually.
Steel is an alloy of iron with carbon upto 1.8%. Hot metal produced in
blast furnaces contains impurities such as carbon, silicon, manganese,
sulphur and phosphorus is not suitable as a common engineering material to
improve the quality the impurities are to be eliminated or decreased by
oxidation process.
Facilities at a continuous casting include a lift and turn table for ladles
copper mould oscillating system tundish, primary & secondary cooling
arrangement to cool the steel bloom. Gas cutting machines for cutting the
blooms in required length.
Rolling Mills :
Blooms produced in sms-ccd do not find much applications as such
and are required to be shaped into products such as Billets, rounds, squares,
angles, channels, I-PE beams, HE-beams, wire rods and reinforcement bars
by rolling them in, there sophisticated high capacity, high speed, fully
automated rolling mills, namely light & medium merchants mills (LMMM), wire
rod mill (WRM) and medium merchant and structural mill (MMSM).
LMMM comprises of two units. In the Billet 250 x 320 mm size blooms
are rolled into billets of 125x125 mm size after heating them in two numbers
of walking beam furnaces of 200 tons/hr capacity each. This unit comprises of
7 stands and 5 alternating vertical & horizontal stands (730x1100 mm &
630x1000mm) billets are supplied from this mill to bar mill of LMMM & WRM.
Wire Rod Mill is a 5 stands fully automated and sophisticated mill. The
mill has a four zone combination type reheating furnace of 2000 TPH capacity
for heating the billets received from billet mill of LMMM to rolling temp of
12000C.
The heated billets are rolled in 4 strand no twist continuous mill having
a capacity of 850,000 tones of wire rod coils and having the following
configuration.
The mill produces rounds in 5.5-12mm range and rebars in 8-12mm range.
The torque at any value of slip varies as the square of the applied
voltage as indicated using this property a family of speed torque curves as
shown below can be computed for the machine when it operates at different
voltage.
A change in the frequency of the power supply for induction motor will
result in a corresponding change in the synchronous speed and some change
in the motor characteristics in the order to maintain the air gap flux at its
normal value, it is necessary to keep E1/f constant to very the magnitude of
the applied voltage in the same ration frequency, thus keeping V1/f constant
and hence the flux approximately constant.
induction motor will modify the speed torque characteristics as shown in fig.
this is a method by which any operating aped between zero and synchronous
speed can be obtained. From equa. It may be observes that the speed at
plotted quite accurately by noting eqs above which indicates that at a given
value of torque the ration of Rs. 2/- is constant, i.e., for a given torque the slip
value of torque, the slip increase (or the speed decreases), with increase in
these curves. While, initially with increase in rotor resistance, starting torque
value if starting torque due to the enormous decrease in the value of the
starting current.
irrespective of other operating conditions of the motor. The induced emf in the
rotor, when the motor runs with a slip S has magnitude SE2, where Es is the
induced emf in the rotor at standstill conditions of the rotor. The magnitude of
12=SE2/sqrt (R2^+(SX2)^2)
phase to E2s, is injected into the rotor circuit. Initially when the speed cannot
change due to the inertia of the rotor, the net emf in the rotor circuit reduces
to a value (SE2-EJ), as a result of which the rotor current 12 and, hence the
torque developed decreases. But, since the load torque remains constant, the
(increases in slip) continuous till the rotor induced EMF increases to circulate
enough current in the rotor to develop the desired torque. Current in the rotor
Let Sj be the new value of the slip and SjE2, the corresponding new of
the rotor DMF, once study state conditions have reached after the injection of
This must be equal to the original rotor current, since both flux and developed
(Sj*E2-Ej/R2=(S*E2/R2)
Sj=S+(EjE2)
That is when the EMF injected is in phase opposition to the rotor induced
with the rotor induced EMF, the slip decreases or the speed if the motor
Sj+S-(Ej/E2)
If EJ/E2>S, the new slip Sj becomes negative, that is the machine runs at a
speed greater than the synchronous speed, maintaining its motor operation.
With the shifting of the technology from dc to ac in the 60’s slip ring
motor became the traditional work horse for hoisting and traveling gears such
as been the mind set and comfort level of the user and maintenance people,
vice versa. The basic control slip ring motors uses contactors for the external
rotor resistance circuit. The early control circuits used timers for the switching
the operating speeds. This resulted in a stressed motor with huge current and
during that time, which used speed dependant switching. The contractors in
the resistance circuit were switched on depending on the actual motor speed.
The analog speed controllers were subsequently introduced in the early 80’s
• Changing the motor voltage with the aid of stator phase angle control.
resistance.
control of slip ring motors, apart from its ruggedness, is the fact that it can be
used for retrofit solutions on existing cranes which are still running with
available with cranes running with dc motors, slip ring motors and cage
motors. The drives may have been retrofitted with digital versions in affect
which can be used for either on any of the drives. With the advancement of
were found to be suitable for hoisting applications with better control and
dynamics. The limitations of the slip ring motors compare to the cage motor
• Slip ring motor have higher weight and rotor inertia compared to cage
motors. The higher rotor inertia calls for higher acceleration torque and
selection of higher motor frame size. The weight of the motor and there by the
contractors.
arrangement.
CAGE MOTORS :
conductor devices in the last 10 years. C VEDs has become the most reliable
bus and the Inverter section. The combination of the field vector control and
the latest IGBT devices, is the optimal control of the cage motor and it even
exceeds the performance of DC drives. The control of the flux and torque
this section we will discuss the various effects of VFDs on cage motors, the
latest motor technology available and selection of the right drive configuration
the standard cage motors with the VFD’s, the transistor based VFDs uses
high impulse frequencies which gives rise to a very high dv/dt stress on the
The peak values of the voltage impulses are always considerably higher that
the normal voltage. It takes some time for impulse to propagate through the
windings of coil, and so the voltages between the turns of a coil or between
The life time and reliability of a motor mainly depends on the insulation
has to ensure reliable motor operation for many years. All components of the
insulation system, for example the turn insulation, the coil insulation, the
gradient tapes or the resin, and also the process parameters have to be
In case of inverter feed, the motor terminal voltages and thus the
The effects of the PWM operation on the lifetime of the bearing of the
motors “explain the degradation of the bearings, especially for larger motors
for hoists.
Mr. Barkar explains – “The issue of induces shaft voltages and attendant
bearing current has been well known for over 70 years in mains fed motors
machines (including DC) potentially suffer from this phenomenon. The main
mains frequency alternating flux component around the shaft, which induces
a current in the loop end shields frame bearings shaft. The problem increases
with the motor frame size and is traditionally controlled by insulating one
current pulses through the bearing depends on the inverter pulse frequency.
frame leakage capacitance. Research has shown that for motor frame sizes
less than – 280, the larger motors, this problem is traditionally controlled by
using good motor design with rigorous installation techniques along with a
single insulated bearing normally located at the non – drive end (NDE)’.
The crane OEMs have their own method for the selection of the
motors. The basic hoisting & travel calculations are the same from the basic
physics. However the service factor, which differ with the particular type of
AC squirrel cage motors, for Hoisting & Travel applications, when operated
with VFDs.
The two main criteria while selecting the motors for crane applications are :-
• Checking the rated power of the motor or in other words, the thermal
The rated power or output from the motor is influenced by the motor
temperature. The thermal loading of the motor is a function of the duty cycle.
The nameplate power rating of a standard motor is usually the SI duty rating.
The same motor rating can differ, when used for other duty cycles, i.e., - short
assumes that the starting current does not have any significant effect on the
motor temperature rise. Duty class S4 takes the starting and braking into
consideration.
and braking were always accounted, when rating the motor for intermittent
of one start. The starting classes are typically defined as 75,150,300 and 600
C = de + 0.25 dj + 0.8f
The motors available in the market for operation with VFT are provided
version, we can provide a selection of options that allows you to use these
conditions.
solution.
Brief overview
No. of poles : 4
Typical applications :
• Pumps
• Compressors
• Fans
• Blowers
• Extruders
• Conveyor systems
solid shaft
The 1PH7 motors are induction motors with compact dimensions. The motors
have a high power – density at low construction volume. The 1PH7 motors
are available in a broad power, speed and option range. The motors have
transverse forces.
1PH7 induction motors – the compact motors with high
degree of protection
• Require very little space.
power* : kW
Rated 22 – 2,480
torque* : Nm
etc.)
external forces such as wind and non-vertical lift. External forces are not so
predominant for indoor cranes. A skilled operated can remove sway using a
properly timed change in the suspension point to place it directly over the load
at a time when the is stopped, at the end of swing “Catching” the load in this
t = 2π √ l/g
Since the steel plant cranes are not affected by wind factor, the basic
algorithm developed in the sway controller works in a open loop. The Master
controller signal comes to the sway controller and the set point to the drive
Up to a certain extent, the sway control can be limited by adjusting the drive
ramp up curve.
PROJECT INTRODUCTION
2. Stator Current : 78 A
3. Rotor Current : 61 A
2. Construction :
The cubicles are divided into a number of function modules, some of which
are basic modules (marking up the basic version) and a few other are
accessory modules.
The modules are arranged on module plates or are in the form of Oombifiex
3. Data :
The inputs for the actual speed value (tachometer voltage) are matched to the
3.4 Efficiency :
The efficiency is abouyt 99% at full output for all sizes of YOTH.
controller (4c) is supplied with two main signals; the speed reference U ur and
an approiat level. Since the polarities of the signals are always opposed, the
As this shows, the difference can be of either polarity, meaning that the speed
The output of the speed control system tries to make Undev as small as
possible, i.e.,, to make Uur to make Uur ~– Un .this is done by allowing Undev to
control the magnitude and direction of the motor torque, i.e., Umr = K1. Undev
The sign of Undev controls the direction of the output torque of the motor via the
/ M / + K 2l2
The equations are valid for any speed. Consequently, to obtain a linear
system, the reference value Ulr for the following current control must be
Or
Umr is determined and the root obtained in the reversing modules (4d) by
inverting circuit and diode networks. The single Ulr thus obtained, which is
always negative, is summated with the current signal, Ul from the current
a always positive, the difference Undev = Ul – Ulr is produced at this point, and
controls the current controller. The control system make this difference as
small as possible, i.e., it makes Ul ~ Ulr this is done by using the output signal
of the current controller as the control voltage (Us) of the trigger pulse
module.
This control voltage alters the phase position of trigger pulses relative to the
phase of the main voltage, thus varying the firing time of the thyristors within
the period, i.e., varying their control angle. This principle is known as phase
control : the output voltage (=motor stator voltage) is given as rms value.
Determined by the control voltage, and a chopped wave – from When the
regulator is operating at less tan full output. At full output the waveforms is
completely sinusoidal.
3.1 Applications:
3.2 Design :
The OP1S can store parameter sets for easy downloading to other
devices.
Two additional thyristor modules in the shunt arm of the power section
facilitate the torque switchover and thus the 4Q operation of the drive.
Using the auto-reversing stage, the phase sequence on the converter
output is electronically reversed. Depending on the load conditions, the
converter functions in plug braking mode (braking) or it drives the
machine in the other direction of rotation (driving). A driving cycle that
is both highly dynamic and gentle is possible because the conventional
stator contractor is no longer required.
The thyristors are controlled by the gating unit. This generates line-
synchronous firing pulses. The control electronics are separated from
the line potentional by ignition transducers. The operating states are
displayed on the unit via the 7-setment display and LEDs or via the
optional OP1S operator control panel.
All converter settings (e.g. controller parameters, limit values, etc) are
saved in non-volatile memory in the converter. The adjustment is made
digitally via the converter control panel or via the optional OP1S control
panel. The values can therefore be easily reproduced at any time.
This means that at a specific load torque ML, the various constant
speeds n2, n3 or n4 can be set. If the load changes, the speed
increases as well.
3.3.4 Method of operation of electronic phase reversal with plug braking.
The drive starts up with the positive speed and stabilizes at point a. A
constant load profile is assumed during this process. If a lower setpoint
or a setpoint with the opposite polarity is connected when in this state,
the SIMOTRAS HD will be switched to counter-torque operation. The
rhyristors that are currently conducting for the clockwise rotating field
are fist blocked. The thyristors for the anti-clockwise rotating field are
then fired. This changes the phase sequence on the output terminals
to produce a new direction of rotation, point b.
The motor then starts plug braking and reduces its speed.
0
Upper limit temperature with C 55 50
current rating
Cooling air requirement M3/h - 100
Sound pressure level dBA - 40
0
Storage and transport C -25 to +70
temperature
Installation altitude above sea level < 1000m at rated current max 3500m with
voltage 4 current reduction
Environmental class DIN IEC 721-3-3 3K3
Degree of protection DIN40050 IEC IP00
144
Dimensions Sec dimensional changings
Weights (approx) kg 16 16 16 16 17 17
The control functions can be entered via the terminals of PROFIBUS (SINEC
L2 DP). If a T300 technology board and / or a CBP board is inserted, the
control functions are automatically entered from the T300 or from PROFIBUS.
Are shown on sheets K4 and K5.
The following diagram shows the arrangement of the pre limit switches and
the limit switches, together with the direction of the travel command as
required for operating the crane control.
PRACTICAL READINGS :
CONCLUSION
The drive system plays a key role in determining the reliability and efficiency
Conservative attitude in the industry still leads to a preference for slip motors
and thyristor controllers. It has been shown that slip ring motors do have their
developments.
the slip ring motors. At the same time, the correct configuration of AC drive
has to be selected based on the requirements of the cranes and the user.
With all the relevant aspects taken care of AC drive systems will offer a
It can be concluded that the AC drive technology is the future of steel plant
arena.