A

Report on

Study of New InverteR

Drive
IN PLTCM
Under the Guidance of

Mr. Nirbhay Kumar Gupta

(Maintenance Expert Group)

Submitted by
ABHISHEK DAS
AKSHAY
NEHA SAMEEN

B.Tech 4th year

Electronics and Telecommunication Engineering

ORISSA ENGINEERING COLLEGE,BHUBANESHWAR

CERTIFICATE
This is to certify that the project report entitled STUDY OF NEW
INVERTER DRIVES-PLTCM, being submitted by NehaSameen,
Akshay and Abhishek Das of Orissa Engineering College,
Bhubaneswar to TATA STEEL, as a part of summer training course
of B.Tech curriculum is a bonafide record of work carried out by
them under my supervision and guidance. The sincerity and
sense of dedication shown by them during the project is
commendable.

Mr. Nirbhay Kumar Gupta

Sr. Technologist, Jamshedpur
Maintenance Expert Group
TATA STEEL, limited

CONTENTS
1.

Acknowledgment

2.

Action plan

3.

Introduction to TATA STEEL

4.
5.

Steel making process

Overview of PLTCM
5.1 Entry section
5.2 Pickle section
5.3 Tandem cold reduction section

6.

5.4 Exit inspection section

Tandem cold mills

7.

Drives
7.1 Dc drives
7.2 Ac drives
7.3 Comparison

between ac and dc drives

8 . Speed and frequency control for drives

9 . Drives used in PLTCM
9.1 Cyclo converter
9.2 Voltage source inverter
9.2.1. Two level inverter
9.2.2. Three level inverter
9.3 . Difference between Cyclo converter and VSI
10 . CRM PLTCM mill stand DRIVE database
11 .Conclusion

1.ACKNOWLEDGEMENT
With a great pleasure we would like to express our deep sense of gratitude to
Mr. Ajit Kar, Chief, MEG; Mr. Arghay Deb, Head, MEG and to our guide and
training co-ordinator Mr. Nirbhay Kumar Gupta, Sr.Technologist, MEG, TATA
STEEL Limited, for their valuable instructions, guidance and illuminating
criticism throughout our project. Without their involvement and supervision we
could not have been able to complete this project.
We would like to express our sincere thanks to Mr. GAURAV, Sr. Engineer, in
PLTCM; Mr. V.G. Rao, Consultant, MEG; Mr. O.P. Gupta, MEG and so many
other countless people of TATA STEEL Limited, Jamshedpur for helping us in our
project during our entire internship.
We would also like to thanks Mrs. MitrabindaNayak, head of Training and
Placement Department, OEC, Bhubaneswar for providing us with the
opportunity of undertaking our training at TATA STEEL Limited, Jamshedpur.
Last but not the least we would like to thank all of our friends and the
employees of Maintenance Expert Group for their sincere co-operation and
help throughout our training. Thanks to everybody and to almighty for giving us
this opportunity in our lifetime.

ABHISHEK DAS (VT201301174)

AKSHAY (VT201301661)
NEHA SAMEEN (VT20130210)
B.Tech 4th year

ORISSA ENGINEERING COLLEGE

2.ACTION PLAN
WEEKS

WORK PLAN

WEEK 1

Study of documents on TATA STEEL and introduction of safety.

WEEK 2

Study of motor and visit of Electrical Repair shop.

WEEK 3

Study of document on drive. Visit to CRM-PLTCM.

WEEK 4

PROJECT WORK

3.INTRODUCTION TO TATA STEEL

Type

Public

Traded as

NSE: TATA STEEL, BSE: 500470

(BSE SENSEX Constituent)

Industry

Steel

Founded

1907

Founder(s)

Dorabji Tata
[1]

Headquarters

Mumbai, Maharashtra, India

Area served

Worldwide

Key people

Cyrus Pallonji Mistry

(Chairman)
Hemant M. Nerurkar
(Managing Director)

Products

Steel, flat steel products, long steel

products, wire products, plates

Tata Iron and Steel Company was established by Dorabji Tata on

August 26, 1907, as part of his father Jamsetji'sTata Group. By 1939 it
operated the largest steel plant in the British Empire. The company
launched a major modernization and expansion program in 1951. Later,
the program was upgraded to 2 MTPA project. In 1990, it started
expansion plan and established its subsidiary Tata Inc. in New York. The
company changed its name from TISCO to TATA STEEL in 2005.
In August 2004, TATA STEEL agreed to acquire the steelmaking
operations of the Singapore-based NatSteel for S$486.4 million in cash.
The acquisition was completed in February 2005.
In 2005, TATA STEEL acquired a 40% stake in the Thailand-based
steelmaker Millennium Steel for $130 million from Siam Cement.
On 20 October 2006, TATA STEEL signed a deal with Anglo-Dutch
company, Corus. On 19 November 2006, the Brazilian steel company
CompanhiaSiderrgicaNacional (CSN) launched a counter offer for
Corus at 475 pence per share, valuing it at 4.5 billion. On 11 December
2006, Tata preemptively upped its offer to 500 pence per share, which was
within hours trumped by CSN's offer of 515 pence per share, valuing the
deal at 4.9 billion. The Corus board promptly recommended both the
revised offers to its shareholders. On 31 January 2007 TATA STEEL won
their bid for Corus after offering 608 pence per share, valuing Corus at
6.7 billion.
In 2007 TATA STEEL through its wholly owned Singapore subsidiary,
NatSteel Asia Pte Ltd acquired controlling stake in two rolling mills: SSE
Steel Ltd, Vinausteel Ltd located in Vietna.
The TataGroup of Companies has business operations (114 companies and
subsidiaries) in seven defined sectors Materials, Engineering,
Information
Technology and Communications, Energy, Services,
Consumer Products and Chemicals.TATA STEEL with its acquisition of
Corus has secured a place among the top ten steel manufacturers in the
world and it is the Tata Groups flagship Company. Other Group
Companies in the different sectors are Tata Motors, Tata Consultancy
Services(TCS),Tata Communications,Tata Power, Indian Hotels, Tata
Global Beverages and Tata Chemicals.

Tata Motors is Indias largest automobile company by revenue

and is among the top five commercial vehicle manufacturers
in the world. Jaguar andLandrover are
now part of Tata
Motor s portfolio.
Tata
Consultancy
Services)
is
an
integrated
software
solutions provider with delivery centres in more than 18 countries.
It ranked fifth overall, and topped the list for IT services, in
Bloomberg Business week's 12th annual 'Tech 100', a ranking of
the world's best performing tech companies.
Tata Power has pioneered hydro-power generation in India and is the
largest power generator(production capacity of 2300 MW) in India in the
private sector.
Indian Hotels Company(Taj Hotels, resorts and palaces)
happens to be the leading chain of hotels in India and one of the
largest hospitality groups in Asia. It has a presence in 12 countries in 5
continents.
Tata
Global
Beverages
(formerly
Tata tea) its
major
acquisitions like Tetley and Good. Earth is at present the second
largest global branded tea operation.
TATA STEEL is headquartered in Mumbai, Maharashtra, India and
has its marketing headquarters at the Tata Centre in Kolkata, West
Bengal It has a presence in around 50 countries with manufacturing ope
rations in 26 countries including: India, Malaysia, Vietnam Thailand,
Dubai, Daggaron, Ivory Coast, Mozambique, South Africa, Australia,
United Kingdom The Netherlands, France and Canada.
TATA STEEL primarily serves customers in the automotive, construction,
consumer goods engineering, packaging, lifting and excavating, energy
and power, aerospace, shipbuilding, rail and defense and security sectors
TATA STEEL has set a target of achieving an annual production capacity
of 100 million tons by 2015; ; it is planning for capacity expansion to be
balanced roughly 50:50 between greenfield developments and
acquisitions. Overseas acquisitions have already added an additional 21.4
million tons of capacity, including Corus (18.2 million tons), NatSteel (2
million tons) and
8

Millennium Steel (1.2 million tons). Tata plans to add another 29 million
tons of capacity through acquisitions.
Major greenfield steel plant expansion projects planned by TATA STEEL
include:-

A 6 million ton per annum capacity plant in Kalinganagar,

Odisha, India
An expansion of the capacity of its plant in Jharkhand, India
from 6.8 to 10 million tons per annum.
A 5 million ton per annum capacity plant in Chhattisgarh, India
(TATA STEEL signed a memorandum of understanding with
the Chhattisgarh government in 2005; the plant is facing strong
protest from tribal people).
A 3 million ton per annum capacity plant in Iran;
A 2.4 million ton per annum capacity plant in Bangladesh;
A 10.5 million ton per annum capacity plant in Vietnam
(feasibility studies are underway);

A 6 million ton per annum capacity plant in Haveri, Karnataka

4.STEEL MAKING PROCESS

Iron ore fines are not suitable

for use in the Blast Furnace.
Hence, the iron ore fines
areagglomerated into larger
porous lumps, which is
suitable for use in the Blast
Furnace. A greenmix of
carefully proportioned iron
ore fines, fluxes and coke
breeze is prepared in granular
formin
Mixers.
Heat
generated through combustion
within the mass itself produces
large lumps ofhot Sinter. This
Sinter is cooled, sized and
stored for use in the blast
furnace.Iron ore fines are
recycled to make sinter, to
help produce hot metal of
predictable
andstandard
quality in the Blast Furnace.
Naturally found coal contains
Fixed Carbon (FC), Volatile
matter (VM), Ash, Moisture
and otherimpurities. Its poor
crushing strength and the volatile matter content makes it unsuitable foruse in
Blast Furnace. Hence, naturally found coal is converted into coke in the coke
oven for usein Blast Furnaces.Heating coal in the absence of air carbonizing it to
form a hard porous mass, devoid of volatilematter produces coke. Coal after
carbonization, which gives blast furnace quality coke, is called metallurgical
coal. Coal is graded as prime, medium and bendable, based on its
cokingproperties. Blending of different grades of coal is necessary in order to
conserve metallurgicalcoal, yet ensure uniform coking properties. Currently,
there are 6 batteries of coke ovensupplying coke to the blast furnaces.
The coke plant blends coal from different sources, converts coal to coke and cuts
to the correctsize for use in the blast furnace.

10

The Blast Furnace is a ceramic refractory lined tall reactor, used for the
production of liquidiron called Hot Metal. Iron oxide, present in the iron bearing
raw materials, is reduced insidethe reactor by coke and carbon monoxide.
Coke is used for combustion to attain the high temperatures required for
reduction. Coke oncombustion generates carbon monoxide, which acts as the
reducing agent and converts theiron oxides into molten iron. Fluxes are used to
make low melting slag and control the quality ofHot Metal.
Hot Metal and Slag are collected in the hearth and tapped periodically. Blast
Furnaces A, B, C, D,E and F together produce 2.8 million tons of hot metal,
annually. G-Blast Furnace produces 1.30million tons of hot metal annually. Blast
Furnace F has been rebuilt in 2002 to enlarge itscapacity to 1 million tons.Blast
Furnaces are used for producing Hot Metal.
Hot Liquid Iron (commonly called Hot Metal in TATA STEEL) is converted to
Steel in the SteelMelting Shops. Hot Metal from the Blast Furnace is stored in
Mixers in LD#1 shop. The HotMetal is converted to Steel in the LD converters
by removing its carbon, silicon, sulphur andphosphorous contents.
The liquid steel from the converter is converted to billets using Continuous
Casting machine. Asmall portion of steel is teemed into ingots through Bogie
Bottom Poring process using cast ironmoulds. The liquid steel is treated in On
Line purging, Ladle Refining Furnace or Argon Rinsingstation before continuous
casting. Special grades of steel, which are cast as ingots, areprocessed in On-line
purging, followed by the Vacuum Arc degassing & refining unit.The Steel
Melting Shop requires an Oxygen Plant to cater to the requirement of oxygen for
steelmaking. The Lime Calcining Plant and the Tar Dolo Plant are auxiliary units
required for themanufacture of Steel.
Hot metal is converted to Steel and cast into Billets.
The LD#2 Shop has three Converters of 140 tons capacity each, producing 2.6
million tons ofcrude steel per annum. Hot Metal is brought from A, D, E, F and G
Blast Furnaces in Torpedoladles. The metal from the Torpedo ladle is taken into
the Hot Metal for Desulphurization. It isthen charged into the vessel.Primary
refining of steel is done in the Ladle Furnace (LF) and RH Degasser (RH) to make
cleanersteel of different value added grades.LD 2 makes superior & cleaner
grades of steel required to process Flat products of world-classstandards.

11

5.Overview of PLTCM
Cold rolling mills are used for deforming various metals by passing
them through rollers at a temperature below its re-crystallization
temperature. This process of rolling increases the yield strength and
hardness of a metal by introducing defects into the metal's crystal
structure. These defects prevent further slip and also reduces the
grain size of the metal.Cold Rolling mills are used to obtain desired
level of thickness reduction.
Basically Pickle Line Tandem Cold Mill consists of four sections:
1.Entry Section
2.Pickle(cleaning) Section
3.Tandem Cold Reduction Section
4.Exit Section
5.1Entry Section:
Its basic operation is divided into two parts:
1.CALL TRANSFER:-This system
optimizes logistics and transport
from the hot strip mill,reducing the
potential for damage to the bands that
can occur prior totheir arrival at the
PLTCM. Additionally, a horizontal
storage positionallows for better heat
transfer for faster processing time.
2.COIL TRACKING SYSTEM:-A sophisticated tracking system uses smart cranes to
track themovement of the steel between the hot strip mill and the PLTCM.Automatic band
identification is made based on weight, width and barcodeto guarantee that the correct
coils are delivered to the customer.
There are four parts in this section:-

Automated Coil Preparation Station:- The automated strap

removal and crop shearprocess not only assures operator
safety, butoptimizes product yield by cutting off only
theportions determined by the band quality data.
SMS Siemag Coil Handling:-Built by
SMS Siemag, this system uses
automatedmotion to move and lift the product,reducing the risk
of product mixing and damage.
12

Miebach HSL 19 Laser Welder:- In order to roll AHSS

grades, this laser weldercan join high-alloy coils with absolutely
minimalstrip breaks. The result is superior weld qualityand
increased reliability and on-time delivery.
Tension Leveler in Pickle Section:-The
tension leveler removes scale to provideuniform surface quality
regardless of producttype and flattens the strip.
5.2Pickle(Cleaning) Section:-The PLTCM uses a four-tank,
cascading type hydrochloric acid pickling section with surface agitation to
remove iron fines. This, coupled with afour-stage rinse section utilizing a
demineralized water final rinse spray before drying, ensures a perfectly clean and

dry strip.

It basically has two parts:1. Mitsubishi-Hitachi

Immersion
BoxTurbulent
Pickling:-This system uses strip motion to achieveoptimum
fluid turbulence and minimized pickling time. No moving
parts assure effective scale removal and guarantee superior
reliability.

2. Automated Turret Side Trimmer:-This fully

automated system provides precisewidths and ideal trim
quality. Optional
automatic set-up for gap and overlap leadsto improved edge
trim quality while allowingfor optimized product yield.

13

5.3 Tandem Cold Reduction Section:It basically consists of two parts:1. Independent Main Mill Motots:-Five independent
motors, inconjunction with two tension reelmotors, provide
the capability to processa full range of current and future
productrequirements,
and
allow
maximum
coldreductioncapability.
2. Automated Roll change equipment:- All work rolls
and intermediate rolls can bechanged without stopping the
strip in the pickleline, optimizing surface quality. Rolls
aredelivered directly into the roll shop to bereconditioned
for further use.

Apart from that it has Five stand, six high universal crown mill.

By incorporating smaller diameter work rolls, the millcan realize heavy reduction
rolling and provide a widerrange of product thickness, width and hardness.
Thisallows us to produce products from ultra low carbonto advanced high
strength steel. Since the mill utilizesa straight roll at the number five stand, we are
able toprovide significant improvement in shape control.The five-stand, six-high
universal crown mill is theperfect partner to the pickle line. Together, they
areredefining the shape of todays steel solutions.The Universal Crown Mills
cylindricalrolls create a more consistent relationship between strip speed and roll
speed, improving texture consistency across the width.
5.4 Exit Inspection Section:This section has three parts:-

14

1. Carousel Tension Reel:-The twin-exit reel system

insures a constantthread position and single mode of
operationfor greater consistency and
uninterruptedproduction from coil to coil.

2. Strip-Surface Inspection Station:-This station

provides an optimal view of thestrip-surface quality
and enables comprehensivesurface inspection under
tension withoutdisrupting processing.

3. SMS Siemag Exit Coil Handling System:-Utilizing

a system very similar to the entrycoil handling system, this
automated exit coilhandling system allows for the
automaticdelivery of finished product. After weighingand
strapping to safely restrain the coil, thesystem
automatically marks, and applies barcode tags to the
finished coils.

6.Tandem Cold Mills

The main advantages of Tandem Cold Mills are:-

15

Reduced material loss can be attributed to thefollowing:

Thick ends eliminated by continuous operation
Coil handling damage reduced due to less handling
Minimized off gauge lengths as a result of constantprocess conditions.
Yield increased by 1.52.0%

Improved product quality is attained due to thefollowing criteria:

Constant process conditions result in higher quality and
more consistent products
Reduced strip-edge damage due to less coil handling
Higher proportion of coil with stable operatingconditions
Surface finish flexibility
Flatness tolerance: below 15 I-Units (thickness- andwidth-dependent)
Gauge tolerance: standard tolerance (DIN standard)
Surface quality: roughness, cleanness improvements

Reduced operating cost is reached due to:

Continuous, compact plant requires fewer operators
40% longer roll service life because of less damage dueto reduced threading
and tailing outReduction in energy consumption of 10% by anoptimized
process due to fewer acceleration anddeceleration operations
Reduced roll oil consumption by 3240%
Reduced maintenance costs due to constant operating
conditions and less threading and tailing-out operations
Mill Power:-Since mill speed had to be increased to meet the capacitytargets, a
power upgrade of the existing mill drives from
10,800 kW to 22,100 kW was necessary. The optimizationof the speed cone
required an adaptation of the gearratios and hence new gears.
Mill Stand:-The 5th stand uses smaller work-rolls than stand no. 14which is
required to obtain the aimed maximum reduction
of approximately 6% in particular for rolling of stronghardening, high strength
materials down to the minimumthickness of 0.3 mm. Since the maximum total
reductionfrom hot gauge to cold gauge can reach 84%, the materialhardening is
significantly high. The required reductionson the last stand could therefore not be
performed withconventional work-roll diameters. To compensate forthe decrease
in flexural stiffness of the work-/back-uproll assembly due to the smaller
work-roll diameters, thediameter of the back-up rolls was increased accordingly.

16

Working Principle of Tandem Cold Mill:Application of the UCM-MILL makes possible

to roll all products with straight rolls, which
straight rolls, which allow to get rapid start up.
The operator derives most stable rolling and
shape controllability. Thanks to horizontal
rigidity created by shifting of intermediate roll,
the user can control strip thickness deviation
without jeopardizing the shape of the strip.
The mill is equipped with high response
Hydraulic
Roll
Position
Device
(HYROP-F).Laser Doppler type speed
measuring device and X-ray type thickness
gauge meters. By using these equipment, high
performance up-to-date Automatic Gauge
Control (AGC) system, which includes the
mass flow control, can obtain the higher standard of the finished thickness. At the
exit of the mill , a modern designed shape measuring sensor and Automatic Shape
Control (ASC) system is installed. They can guarantee the required flatness of the
finished coil and the qualified products can be produced.

Technical specification of Motors Used in Tandem Mills:Stand

#No
1.

2.

Type

Power

Synchronous 2300KW

Induction

Current Voltage
1565A

5000KW

Speed

Stator
Rotor
Insulation Insulation

900V

132/600RPM CLASS F CLASS H

3000V

440/1200RPM

3.

Synchronous 3500KW

1551A

1350V

201/600RPM CLASS F CLASS H

4.

Synchronous 3500KW

1551A

1350V

201/600RPM CLASS F CLASS H

5.

Synchronous 3500KW

1551A

1350V

201/600RPM CLASS F CLASS H

17

7.DRIVES
Whenever the term electric motor or generator is used, we tend to think
that the speed of rotation of these machines are totally controlled only by
the applied voltage and frequency of the source current. But the speed of
rotation of an electrical machine can be controlled precisely also by
implementing the concept of drive. The main advantage of this concept
is, the motion control is easily optimized with the help of drive. In very
simple words, the systems which controls the motion of the electrical
machines, are known as electrical drives. A typical drive system is
assembled with a electric motor (may be several) and a sophisticated
control system that controls the rotation of the motor shaft. Now a days,
this control can be be done easily with the help of software. So, the
controlling becomes more and more accurate and this concept of drive
also provides the ease of use. This drive system is widely used in large
number of industrial and domestic applications like factories,
transportation systems, textile mills, fans, pumps, motors, robots etc.
Drives are employed as prime movers for diesel or petrol engines, gas or
steam turbines, hydraulic motors and electric motors.

Types of Drives:
DC Drives
AC Drives
7.1 DC DRIVE CONTROL SYSTEM:
A basic DC drive
control
system
generally contains a
drive controller and
DC motor as shown
inthe figure given
below:
The controls allow
the operator to start,
stop, and change
direction and speed of the motor byturning potentiometers or other operator
devices. These controls may be an integral part of thecontroller or may be
remotely mounted.The drive controller converts a 3-phase AC voltage to an
adjustable DC voltage, which is thenapplied to a DC motor armature.

18

The DC motor converts power from the adjustable DC voltage source to rotating
mechanicalforce. Motor shaft rotation and direction are proportional to the
magnitude and polarity of theDC voltage applied to the motorThe tachometer
(feedback device) shown in Figure converts actual speed to an electrical
signalthat is summed with the desired reference signal. The output of the
summing junction providesan error signal to the controller and a speed correction
is made.
FEATURES:
Field orientation via mechanical commutator.
Controlling variables are Armature Current and Field Current, measured
DIRECTLY from themotor.
Torque control is direct.
OPERATION:
The magnetic field is created by the current through the field winding in the
stator. This field is always at right angles to the field created by the armature
winding. This condition, known asfield orientation, is needed to generate
maximum torque. The commutator-brush assemblyensures this condition is
maintained regardless of the rotor position.Once field orientation is achieved, the
DC motors torque is easily controlled by varying thearmature current and by
keeping the magnetizing current constant. Torque is the inner control
loop and speed is the outer control loop
TYPES OF DC DRIVES:
Armature and Field Controlled DC Drives
The motor is armature voltage controlled for constant torque-variable HP
operation up to basespeed. Above base speed the motor is transferred to field
current control for constant HPreduced torque operation up to maximum speed.

19

APPLICATIONS:
DC drives were used for VARIABLE SPEED CONTROL DRIVES
because they could easily achieve a good torque and speed
response with high accuracy.
Variable Speed Control Drive:
Basic function of a variable speed drive (VSD) is to control the flow of energy
from the mains tothe process. Energy is supplied to the process through the motor
shaft. Two physical quantitiesdescribe the state of the shaft: torque and speed. To
control the flow of energy we musttherefore, ultimately, control these quantities.
In practice, either one of them is controlled andwe speak of torque control or
speed control. When the VSD operates in torque controlmode, the speed is
determined by the load. Likewise, when operated in speed control, thetorque is
determined by the load.
ADVANTAGES:
Accurate and fast torque control
High dynamic speed response
Simple to control
DRAWBACKS:
Reduced motor reliability: the fact that brushes and commutators wear downand
needs regular servicing.
Regular maintenance
Motor costly to purchase
Needs encoder for feedback.

20

7.2 AC DRIVES
AC drives provide a very efficient and direct method of controlling the speed of
the most rugged and reliable of prime movers, the squirrel cage motor. AC drives
provide many economic and performance advantages in a wide variety of
adjustable speed drive applications.
The following are some of the benefits provided:
1. High efficiency and low operating cost.
2. Minimal motor maintenance.
3. Controlled linear acceleration and deceleration provide soft.
4. Starting and stopping and smooth speed changes.
5. Multiple motor operations are easily accomplished.
6. Current limit provides for quick and accurate torque control.
7. Adjustable speed operation can be accomplished with existing AC motors.
8. Improved speed regulation can be accomplished by slip compensation.
9. AC motors are available in a wide variety of mechanical configurations.
10. Flexibility of machine design due to the light weight and compact size of AC
motors.
11. IR compensation provides high starting torque easily and economically.
12. AC motors are available in enclosures suitable for hazardous or corrosive
environments.
13. Fewer spare motors are required since the same motor can be used for both
adjustablespeed and constant speed operations.
14. Cutler-Hammer rugged and reliable designs ensure minimum downtime
expense.
15. High speed operation can be economically accomplished using extended
frequencyoperation.
16. Reverse operation is accomplished electronically without the need for a
reversingstarter.
ADJUSTABLE FREQUENCY AC DRIVE SYSTEM
INTRODUCTION
An adjustable frequency AC drive system consists of an ordinary three-phase
induction motor,an adjustable frequency drive to control the speed of the motor and
an operator's controlstation.The most common motor used with an AF drive system is
a standard NEMA design B squirrelcage induction motor, rated for 230 or 460 volt,
3-phase, 60 Hz operation. The adjustablefrequency controller is a solid-state power
conversion unit. It receives 240 or 480 volt, 3-phase,60 Hz power and converts it to a
variable frequency supply which can be steplessly adjustedbetween 0 and 60 Hz. The
controller also adjusts the output voltage in proportion to thefrequency to provide a
nominally constant ratio of voltage to frequency as required by thecharacteristics of
the motor. The operator's station provides the operator with the necessary controls for
starting and stopping the motor and varying the motor speed. These functions canalso
be performed by a wide variety of automatic control systems. There are
severalclassifications of adjustable frequency AC drives. Some common types of
drives are VariableInput (VVI) sometimes called Six Step drives, current source input
(CSI), pulse widthmodulated (PWM) drives, Sensorless Vector drives, Field Oriented
drives and Closed LoopVector drives.

- 21 -

PRINCIPLES OF ADJUSTABLE FREQUENCY MOTOR OPERATION

The operating speed of an AC induction motor can be determined by the
frequency of theapplied power and the number of poles created by the stator
windings. Synchronous speed isthe speed of the magnetic field created in the
stator windings. It is given by:
N = 120f /P
Where:
n = speed in RPM
f = operating frequency
P = number of poles
When the frequency is changed, the voltage must also be changed, based on the
formula forreactance and Ohms Law.
XL = 2fL
Where L = inductance
XL = reactance
V = voltage
Im = magnetizing current
Im = V/XL
Combining the above equations yields:
Im = (V/f).(1/2fL)
For steady-state operation, a constant volts per hertz ratio must be maintained.
This is equal tothe motor rated voltage divided by the rated frequency.
For the magnetizing current to remain constant, the V/f ratio, or the volts per hertz
ratio, mustremain constant. Therefore, the voltage must increase and decrease as
the frequency increasesand decreases.
INDUCTION MOTOR SPEED CONTROL
Standard induction motors (NEMA design B) have approximately 3% slip at full
load.If the drive only controls the output frequency, the motor speed will deviate from
the set speeddue to slip. For many fan and pump applications, precise speed control is
not needed.
Vector controlled drives need speed feedback of the rotor. For Sensorless Vector, the
rotorspeed is calculated based on a model of the motor stored in the drive. For Closed
Loop Vector,a digital encoder is added to the motor to provide actual rotor speed.

- 22 -

VOLTS PER HERTZ REGULATION

In order to operate the motor with the desired speed/torque curve, we must apply
the propervoltage to the motor at each frequency. As we have already seen, it is
necessary to regulatemotor voltage in proportion to the frequency at a constant
ratio. In reality, this requirement forconstant volts/hertz does not apply to the
motor terminals, but to a hypothetical point insidethe motor. The voltage at this
point is called the air gap voltage. The difference between air gapvoltage and
motor terminal voltage is the IR voltage drop.
AC DRIVE APPLICATIONS
MATCHING THE AC DRIVE TO THE MOTOR
PWM and Vector AC Drives are designed for use with any standard squirrel cage
motor. Sizingthe drive is a simple matter of matching the drive output voltage,
frequency and current ratingsto the motor ratings.
OUTPUT VOLTAGE AND FREQUENCY
Most modern AC Drives are designed for use with various voltages and
frequencies. Byadjusting the V/Hz properly, almost any 3-phase motor can be
used.
OUTPUT CURRENT
AC drive full load currents are matched to typical full load motor current ratings.
Usually an ACdrive can be matched to an AC motor by their hp ratings; however,
actual motor currentrequired under operating conditions is the determining factor.
If the motor will be run at fullload, the drive current rating must be at least as high
as the motor current rating. If the drive isto be used with multiple motors, the sum
of all the full load current ratings must be used, andadding up the hp ratings of the
motors will usually not provide an accurate estimate of thedrive needed.
MOTOR PROTECTION
Motor overload protection must be provided as required by the applicable codes.
Motorprotection is not automatically provided as part of all AC drives. It may be
provided as astandard feature on one model or it may be an optional feature on
another. The best means ofmotor protection is a direct winding over temperature
protection such as an over temperatureswitch imbedded in the motor windings.
Direct over temperature protection is preferredbecause overheating can occur at
normal operating currents at low speeds. Most AC drives areequipped with
electronic overcurrent protection, such as I2t protection, similar to a
conventionoverload.
In multiple motor applications, individual motor overload protection must be
provided evenwhere electronic protection is provided by the drive. In some cases,
short circuit protectionmay be required.
MOTOR WINDING DAMAGE
The voltage output of AC drives contains voltage steps. In modern PWM drives,
the dV/dt of amotor causes can cause very large voltage spikes. Voltage spikes of
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1500 volts or more aretypical for a 460 volt motor. This can cause the end
windings of a Non-Inverter Duty or standardinduction motor to fail. This problem
gets worse as the cable length from the drive to the motorgets longer. Corrective
action is normally required for cables longer than 150 feet. Load sidereactors,
installed at the drive output terminals, will reduce the voltage spikes at the
motorterminals. Most drive manufacturers have load side reactors available as an
option.
7.3 COMPARISON BETWEEN AC DRIVES AND DC DRIVES

1. The Dc motor is complicated and requires a lot of maintenance, which makes it

expensiveto run; it also has a lower degree of protection. The AC motor, on the
other hand, is simpleand sturdy, does not need much maintenance, is therefore
less expensive, and possesses ahigher degree of protection into the bargain.
2. In contrast to the AC standard motor with fixed basic speeds (synchronous
speeds of 3000/1500/1000/... rpm at 50 Hz), the DC motor's basic speed can be
designed from approx. 300 rpmto about 4000 rpm for each working point.
3. Power limitation is caused by the breakdown torque of AC motor decreasing as
the square ofspeed (1/n2).
Power limitation is caused by the commutation of DC motor.

8. Speed and Frequency control for Drives:Both voltage and frequency

reference are fed into a
modulatorwhich simulates an
AC sine wave and feeds this to
the motorsstator windings. This
technique is called Pulse
WidthModulation (PWM) and
utilises the fact that there is a

- 24 -

dioderectifier towards the mains and the intermediate DC voltageis kept constant.
The inverter controls the motor in the formof a PWM pulse train dictating both
the voltage and frequency.
Significantly, this method does not use a feedback devicewhich takes speed or
position measurements from the motorsshaft and feeds these back into the
control loop.Such an arrangement, without a feedback device, is calledan
open-loop drive.
To emulate the magnetic
operating conditions of a DC
motor,i.e. to perform the field
orientation process, the
flux-vectordrive needs to
know the spatial angular
position of the rotorflux
inside the AC induction
motor.With flux vector PWM drives, field orientation is achieved byelectronic
means rather than the mechanical commutator/brush assembly of the DC
motor.Firstly, information about the rotor status is obtained by feedingback rotor
speed and angular position relative to the statorfield by means of a pulse encoder.
A drive that uses speedencoders is referred to as a closed-loop drive.
Also the motors electrical characteristics are mathematicallymodelled with
microprocessors used to process the data.The electronic controller of a
flux-vector drive creates electricalquantities such as voltage, current and
frequency, which arethe controlling variables, and feeds these through a
modulatorto the AC induction motor. Torque, therefore, is controlled indirectly.

9. Drives used in PLTCM

In PLTCM basically two types of drives are used,they are cycloconverter and
Hitachi VSI drives.
9.1 CYCLO CONVERTER:-Cycloconverter isnothing but basically a
Variable Speed drive.This type of VSD makes a direct conversion from
constant frequency, constant voltage to variable frequency,
variablevoltage in one stage, without resorting to an intermediate DC
linkwith energy storage. By supplying each phase of the motor winding
from a reversibleconverter, a low frequency AC drive system is formed,
as shown in Figure 1.16. Although thisVSD is complex, cycloconveters
use a large number of thyristor switches but they do notrequire forced
commutation circuits and thus can use relatively inexpensive,
converter-gradethyristors. The generated structure of cycloconverters
presented in Figure 1.16a, shows a largenumber of power switches and
the need for a special three-phase secondary transformer.

- 25 -

 A cycloconverter is a device that converts alternating current, or AC, power

at one frequency into AC power of an adjustable but lower frequency without
any direct current, or DC, stage in between. It can also be considered as a
static frequency changer and typically contains silicon-controlled rectifiers.
The device consists of an array containing back-to-back, parallel, connected
switches, which are used to fabricate the desired output AC waveforms. It's
possible to control the frequency of these output AC waveforms by opening
and closing the switches in a controlled fashion.
This converter converts single-phase or three-phase AC power to
single-phase or three-phase power having a variable frequency and
magnitude. Typically, the output frequency of the AC power is lower than
the input frequency. A cycloconverter has the capacity to operate with loads
of variable power factors and also allows bidirectional power flow. They can
be broadly classified into two types phase-controlled cycloconverters and
envelope cycloconverters. In the former, control of the firing angle is
accomplished through adjustable gate impulses, while in the latter, the
switches remain in an on state and conduct in consecutive half cycles.
They are mostly used to control the speed of drives and for converting
variable input frequency power into constant frequency output, such as in
very high-power applications, including driving synchronous motors and
induction motors. Some of the places where cycloconverters are employed
include cement mill drives, mine winders, and ore grinding mills. They are
also utilized in ship propulsion drives, scherbius drives, and rolling mill
drives.
Offering many advantages, a cycloconverter can be used in quite a few
low-speed applications and is also a compact system. Its ability to directly
affect the frequency conversion of power without any intermediate stage
involving DC power is another huge advantage. If the cycloconverter
experiences a commutation failure, the results are minimal, such as the
blowing off of individual fuses.
It also has the capacity of regeneration, covering the total range of speeds.
Another huge advantage of the cycloconverter is its ability to deliver a
sinusoidal waveform at a lower output frequency. This advantage comes
from its ability synthesize the output waveform using a large number of
segments of the input waveform.
This technology does have some disadvantages, though. Firstly, the
frequency of the output power is around one third or less of the input
frequency. It's possible to improve the quality of
the output waveform if a larger number
of switching
devices are
employed.
A
cycloconverter requires quite a complex control
mechanism and also uses a large quantity of
thyristors. Its use is also limited by severe
harmonics and the low-output frequency range.

- 26 -

Cycloconverters are used for high power machines (above 1MW) with low
frequency operation(e.g. rolling mills, cement kilns). The output frequency is
typically below 25Hz since thequality of the voltage waveforms degrades as the
output frequency increases. They can operatedown to zero speed and they can be
used both with induction and synchronous motors. Themain disadvantages are
the complex circuit design and the low power factor at low speed.
9.2 VSI DRIVES:-With fast switching semiconductor devices like the insulated
gate bipolar transistors (IGBT) it is possible to build inverter based high voltage
power supplies for electrostatic precipitators. Comparing conventional SCR
(Silicon controlled rectifier) based technology the average corona power can be
increased significantly to improve the precipitator efficiency. Additionally,
during flashovers the fast current control of IGBT power inverters improves the
precipitator performance due to fast voltage recovery resulting in further
increasing of the peak and average precipitator voltage. In a new approach, the
advantages of higher distances up to 400 mm between the discharge and
collecting electrodes could be addressed by a voltage up to 150 kV applied to the
precipitator. Due to the exact voltage control of the IGBT inverter a smooth DC
voltage can be generated and therefore, the overvoltage capability of the system is
much lower than it would have to be with a conventional thyristor based high
voltage generation system. Thus, the IGBT inverter solution becomes more
economical or less expensive to operate than the conventional supply. With the
availability of the latest generation of integrated IGBT modules a very compact
IGBT inverter has been developed to meet the design requirements by operating
at a frequency up to 10 kHz. The new IGBT types have lower saturation voltages
than the previous modules resulting in lower power losses. The HV-transformer
has been designed with the required rating and stray inductance.
The three-phase voltage source inverter (VSI) is used to control AC-motors in the
lower andmedium power ranges, from small high dynamic performance servo
drives with speed andposition control capability (<10kW) to most auxiliary
drives in industry, ranging up to several hundred kW. The VSI is suitable for
supplying induction, as well as synchronous motors. Figure 1.10 shows a
simplified diagram of the basic three-phase voltage source inverter. Theinput
rectifier serves to produce a DC supply, and the relatively large electrolytic
capacitor isinserted to filter ("stiffen") the DC voltage which feeds the inverter.
Typically, the capacitor of2 to 20 milifarads, is a mayor cost item in the system.
Additionally, it is usual to insert areactance between the rectifier and the AC
supply to limit the fault current and to reduce theharmonic distortion produced by
the rectifier. The inverter module converts the DC voltage to avariable frequency,
variable voltage output.
The variable voltage inverter (VVI) uses an SCR converterbridge to convert the
incoming AC voltage into DC. The SCRsprovide a means of controlling the value
of the rectified DC voltage from 0 to approximately 600 VDC. The L1 choke
And C1 capacitor(s) make up the DC link section and smooththe converted DC
voltage. The inverter section consists ofsix switching devices. Various devices
- 27 -

can be used such as thyristors, bipolar transistors, MOSFETS, and IGBTs.

Thefollowing schematic shows an inverter that utilizes bipolartransistors. Control
logic (not shown) uses a microprocessorto switch the transistors on and off
providing a variable voltageand frequency to the motor.

This type of switching is often referred

to as six-step becauseit takes six 60
steps to complete one 360 cycle.
Although themotor prefers a smooth
sine wave, a six-step output can
besatisfactorily used. The main
disadvantage is torque pulsationwhich
occurs each time a switching device,
such as a bipolartransistor, is switched.
The pulsations can be noticeable at
lowspeeds as speed variations in the motor. These speed variationsare sometimes
referred to as cogging. The non-sinusoidalcurrent waveform causes extra heating
in the motor requiring amotor derating.

Classification of Voltage Source Inverter:Voltage source inverters can be

classified according to different
criterions. They can be classified
according to number of phases
they output. Accordingly there
are single-phase or three-phase
inverters depending on whether
they output single or three-phase voltages. It is also possible to have inverters
with two or five or any other number of output phases. Inverters can also be
classified according to their ability in controlling the magnitude of output
parameters like, frequency, voltage, harmonic content etc. Some inverters can
output only fixed magnitude (though variable frequency) voltages whereas some
others are capable of both variable voltage, variable frequency (VVVF) output.
Output of some voltage source inverters is corrupted by significant amount of
rd
th
th
th
th
many low order harmonics like 3 , 5 , 7 , 11 , 13 order of the desired
(fundamental) frequency voltage. Some other inverters may be free from low
order harmonics but may still be corrupted by
some high order harmonics. Inverters used for ac motor drive applications are
expected to have less of low order harmonics in the output voltage waveform,
even if it is at the cost of increased high order harmonics. Higher order harmonic

- 28 -

voltage distortions are, in most ac motor loads, filtered away by the inductive
nature of the load itself.
Inverters may also be classified according to their topologies. Some inverter
topologies are suitable for low and medium voltage ratings whereas some others
are more suitable for higher voltage applications. The inverters shown in Figs.
33.3(c), 33.4(a) and 33.4(b) are two level inverters as the pole voltages may
acquire either positive dc bus or negative dc bus potential. For higher voltage
applications it may not be uncommon to have three level or five level inverters.
In VSI drives Very High Voltage control and very Fast Switching Device is
required ,henceIGBT is used in VSI Drives.
Insulated Gate Bipolar Transistor (IGBT):It is a Power transisitor employed in the power conversion master circuit.This
system uses 33.3kV,1200 A IGBTdevices.IGBT has the characteristics of both
bipolar transisitor and MOSFET.In other words, it is characterized with
comparatively high withstand voltage and high current capacity by means of
bipolar action, high-speed switching by MOS gate, and easy gate drive at low ON
voltage as ideal requirements. Since this device provides a self arc extinguishing
function, it does not require any forced commutation circuit to ensure compact
design of device.

Block Diagram of Hitachi VSI :There are two types of inverter main circuit used.
They are: 3 level type circuit
2 level type circuit

9.2.1--2 Level type Circuit:-The IGBT drive

employs a 2-level system conversion circuit.This
conversion circuit connects 2 serial switching
devices between P bus and N bus.
- 29 -

9.2.2--3 level type Circuit:-The IGBT converter employs a 3-level system

conversion circuit. This 3-level system conversion circuit divides the DC power
voltage into 2 parts via the neutral point,and connects serial switching devices to
the positive bus-neutral point and the neutral point-N bus as a feature.

From the figure when switch QP and QPC is ON the the output voltage is
+Edc,when the switch QPC is ON but QP is OFF then the output voltage is zero.
Similarly when the switch QNC and QN is ON then
the output voltage is Edc, when the switch QN is
OFF but QNC is ON then the output voltage is zero.

In this circuit when the switch QP is ON then the

output voltage is +E/2 and when the switch QN is ON
then the outut voltage is E/2.

9.3 Difference between CYCLOCONVERTER and VSI

CYCLOCONVERTER

VSI

1. It uses tyristor switch.

1. It uses IGBT switches.

2. It converts constant ac to
variable ac directly.

2. It converter contact ac to dc
then to variable ac.

3. It is complex device used large

number of components.

3. It is less complex.
4. Power factor is nearly unity.

4. Power factor is less then unity.

5. It operates in frequency of less
than 25HZ.
6. It is used to operate motors of
higher power range.

5. It can be operate up to
frequency of 200HZ.
6. It is used to operate motors of
lower and medium power ranges.

- 30 -

10. Crm-PLTCM mill stand drive database

MAKE

MODEL NO.

QTY.

AC/DC

ANALOGUE/

KVA

VOLTAGE

APPLICATION

YEAR OF
INSTALLING

DIGITAL

HITACHI HIVECTOL
-VSI-M

AC

DIGITAL

800

DC
1200V

MILL
ENTRY #4
BRIDLE
ROLL

1999

HITACHI HIVECTOL
-VSI-M

AC

DIGITAL

200

DC 600V

MILL
ENTRY
BRIDLE
ROLL

1999

HITACHI HIVECTOL
-VSI-M

AC

DIGITAL

400

DC 600V

MILL
ENTRY
BRIDLE
ROLL

1999

HITACHI HIVECTOL
-VSI-M

AC

DIGITAL

75

DC 600V MILL EXIT

PINCH
ROLL

HITACHI HIVECTOL
-VSI-S

AC

DIGITAL

AC1074

HITACHI HIVECTOL
-CYC

AC

DIGITAL

AC 1645 #2~5 MILL

STAND

1999

TOSHIB TOSVERT
A

AC

DIGITAL

AC 415

1999

- 31 -

#1 MILL
STAND

X-RAY

1999

1999

11. CONCLUSION
Drive is a device which gives us the power to control the motor speed
from distance. It gives the technology to control the torque-speed of
motor. In todays world dc drive is totally replaced with ac drive. In
TATA STEEL there are total 2365 no of drive from which 2060 is ac
and only 305 is dc. Because ac drive is more efficient and gives more
features then dc.PLTCM has a total of 123 drives of which 117 are AC
while the rest 6 are DC . Of the total 9 are analogue while 114 are digital.
In PLTCM, we mainly went throughcycloconverter drive and VSI based
IGBT drive system. By examining and working with this drive we found
that the new one IGBT drive is more efficient and has many more features
compared to cycloconverter. IGBT drive has power factor nearly equal to
unity, it is less complex then cycloconverter. Now a days in TATA
STEEL induction motor are driven by IGBT drive and synchronous
motor are driven by cycloconverter. Also the operating frequencies of
IGBT drives are much more higher than that of cycloconverters.
Therefore, in TATA STEELIGBT drive system has been adopted to go
with new technology.
At last, we would like to thank all officer of meg dept and all employee of
TATA STEEL who helped us directly or indirectly to complete this
project.

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