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Drive Centre Vicenza
Welcomes You All Welcomes You All
Control Techniques IndiaControl Techniques India
Drive Centre Vicenza
Founded in 1973 Founded in 1973 CT is a world leader in the CT is a world leader in the
Design,Manufacture, Marketing and Application of….
AC & DC Drives, Servo Drives
Systems
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Every Electric Motor is a Every Electric Motor is a Potential Application for Potential Application for
Control Techniques Control Techniques productsproducts
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Control TechniquesControl Techniques -- a history of Firsts & Successa history of Firsts & Success
1986 Launches Mentor - world’s first digital DC drive
1989 Launches first closed loop Flux Vector drive
1995 Introduces the world’s first universal AC drive
1988 Launches world’s first IGBT-based digital AC Drive
We set the Benchmark for Drives We set the Benchmark for Drives
2002 Introduces world’s first “Solutions Platform” AC drive
2005 Introduces world’s first “knowledge” AC drive in small rating (Commander SK)
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Control Techniques IndiaControl Techniques India
CT India started in 1993CT India started in 1993
CT India is a fully owned subsidiary CT India is a fully owned subsidiary of CT-Worldwide (CT - UK)of CT-Worldwide (CT - UK)
CT-Worldwide is a fully owned CT-Worldwide is a fully owned company of the US Electrical company of the US Electrical conglomerate Emerson Electricconglomerate Emerson Electric
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• $20 Billion Fortune 500 $20 Billion Fortune 500 CompanyCompany
• Global product/market Global product/market leadershipleadership
• Recognized for outstanding Recognized for outstanding management practicesmanagement practices
• Strong International presenceStrong International presence
• Solid financial positionSolid financial position
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Sales by Business GroupSales by Business Group$20 Billion Total$20 Billion Total
Appliance & Tools23%
Electronics & Telecommunications
15%
Process Control21%
HVAC17%
Industrial Automation24%
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Expectations from Customers Today…For Plant Expectations from Customers Today…For Plant AutomationAutomation
Motors / Alternators &
Power Products
Single Point Source
Floor LevelFloor Level
Drives & Automation
Floor LevelFloor Level
Distributed Control
Plant LevelPlant Level
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Distributed Control
Motors / Alternators Products
Drives & Automation
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United KingdomUnited KingdomNewtown, WalesNewtown, Wales
London
Headquarters R&D
Manufacturing Plant
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Situated in Newtown, Mid Wales country, UKSituated in Newtown, Mid Wales country, UK
The most advanced facility of its kindThe most advanced facility of its kind
Robotic Assembly of Drive modulesRobotic Assembly of Drive modules
800 Drives per day800 Drives per day
Control TechniquesControl Techniques
World Class Drive Manufacturing World Class Drive Manufacturing FacilitiesFacilities
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Product PortfolioProduct Portfolio
General Purpose AC DrivesDC Drives
Cabinet Free AC Drives
Energy Saving Drive
High Performance AC Drives Motion Motion
ControllerController
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Product PortfolioProduct Portfolio
Networking And SoftwareProducts
Soft StartersSoft Starters Servo MotorsServo Motors
CTIU 200
OPERATOR INTERFACE
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Digital DC / AC DrivesDigital DC / AC Drives
MentorMentor : Digital DC : Digital DC 7.5 Kw to 750 Kw 7.5 Kw to 750 Kw
Commander SK : Simple ,Knowledge 0.25 Kw to 110Kw Commander SK : Simple ,Knowledge 0.25 Kw to 110Kw
Unidrive SP : Solution Platform 0.75 Kw to 1.0 MWUnidrive SP : Solution Platform 0.75 Kw to 1.0 MW
PV /EV - Fans & Pumps 5.5 Kw to 280 KwPV /EV - Fans & Pumps 5.5 Kw to 280 Kw
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Other ProductsOther Products
MC 204/216 - Motion Controller 4 to 16Axes MC 204/216 - Motion Controller 4 to 16Axes
CT START - Soft Starters 4 to 800 Kw CT START - Soft Starters 4 to 800 Kw
Unimotor - AC ServoUnimotor - AC Servo 1 to 70 Nm 1 to 70 Nm
LSMVLSMV - Inverter Grade - Inverter Grade AC MotorsAC Motors 0.75 to 132 Kw 0.75 to 132 Kw
SincrovertSincrovert - - AC Spindle Motors 0.75 to 110 Kw AC Spindle Motors 0.75 to 110 Kw
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Worldwide Operations
EUROPEEUROPE
ASIA PACIFICASIA PACIFIC
AMERICASAMERICAS
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Drive Centres in North AmericaDrive Centres in North America
Chicago
Toronto
Providence
Charlotte
Cleveland
Distributors S.America
Minneapolis (Head Office)
Dallas
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Drive Centres in Asia PacificDrive Centres in Asia Pacific
SouthAfrica
Australia
Thailand
India
S. Korea
China
Indonesia (distributor)
Malaysia
Singapore
Hong Kong
Taiwan
Vietnam (distributor)
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New Delhi Application Center
Kolkata Application Center
Drive/Application Centers Drive/Application Centers
Indian OperationsIndian Operations
AhmedabadSales Office
Pune Application Center Chennai Drive Center
Nagpur Sales Office
Hyderabad Sales Office
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Control Techniques IndiaControl Techniques IndiaManufacturing & Support FacilitiesManufacturing & Support Facilities
Facilities / Expertise Testing Facilities 12,000 Sq. ft. Purpose built factory12,000 Sq. ft. Purpose built factory
45 People ( of which 20 are Engineers) 45 People ( of which 20 are Engineers) at Chennaiat Chennai
15 People (of which 10 are Engineers) 15 People (of which 10 are Engineers) in Branch Officesin Branch Offices
Extensive Systems CapabilityExtensive Systems Capability
Over 150 Domestic Projects Over 150 Domestic Projects
Over 50 Export Projects Over 50 Export Projects
Complete Manufacturing facilities with Complete Manufacturing facilities with Test Set UpTest Set Up
Test Jigs for PCB’s (PC Based)Test Jigs for PCB’s (PC Based)
PROM ProgrammerPROM Programmer
DC Motors , AC Motors Test BedsDC Motors , AC Motors Test Beds
High Current Low Voltage Source for High Current Low Voltage Source for Load TestLoad Test
Insulation Tester, High Voltage Break Insulation Tester, High Voltage Break Down TesterDown Tester
Training / Repair
CT Approved Training CentreCT Approved Training Centre
CT Approved Repair CentreCT Approved Repair Centre
Component Level Repair FacilityComponent Level Repair Facility
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HIGHHIGH
PERFORMANCEPERFORMANCE
INTELLIGENT DRIVESINTELLIGENT DRIVES
FORFOR
SYSTEMSSYSTEMS
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Digital DC DrivesDigital DC DrivesMentor II - Mentor II - Flexible Systems Drive - Flexible Systems Drive - 25 to 1850A25 to 1850A
Single & Four QuadrantSingle & Four Quadrant6-pulse Fully Digital6-pulse Fully Digital
7.5 -75kW100-300kW
300 – 750kW
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Mentor Family RangeMentor Family Range
0.75-75KW
H-370 mmW-250 mmD-195mm
300-750KW
H-1355 mm W-450 mm D-510 mm
100-300KW
H-423 mm W-450 mm D- 280 mm
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VoltageVoltage
220-480 V +/- 10%220-480 V +/- 10%
Suitable for Global Power Suitable for Global Power SuppliesSupplies
NO Tap SelectionsNO Tap Selections
MENTOR INPUT SPECSMENTOR INPUT SPECS
VoltageVoltage
525 V and 660 V525 V and 660 V(Optional)(Optional)
FrequencyFrequency
47-62 Hz.47-62 Hz.
Wide tracking Range for PLLWide tracking Range for PLL
TemperatureTemperature
40 Deg C for Power40 Deg C for PowerDerating upto 55 Deg CDerating upto 55 Deg C
Electronics upo 55 Deg CElectronics upo 55 Deg C
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Phase SequencePhase Sequence
Insensitive to Supply Phase Insensitive to Supply Phase SequenceSequence
MENTOR featuresMENTOR features
Field ControlField Control
Controlled FieldControlled Field
Field weakening Inbuilt Field weakening Inbuilt and Programmableand Programmable
Field ControlField Control
Inbuilt (8 A) upto 210 AInbuilt (8 A) upto 210 A20 A External20 A External
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Analog InputsAnalog Inputs6 Nos.6 Nos.
4 No. Programmable (Volt)4 No. Programmable (Volt)1 No. Dedicated 1 No. Dedicated
(Volt/Current Selectable) (Volt/Current Selectable) 1 No. Dedicated for Motor 1 No. Dedicated for Motor
ThermistorThermistor
MENTOR I/OMENTOR I/O
Analog OutputsAnalog Outputs4 Nos.4 Nos.
3 No. Programmable (0-10 Volt)3 No. Programmable (0-10 Volt)1 No. Dedicated 1 No. Dedicated
(10Volt=200%Current ) (10Volt=200%Current )
Digital InputsDigital Inputs10 Nos10 Nos
2 Dedicated 2 Dedicated
8 Programmable 8 Programmable
Digital OutputsDigital Outputs7 Nos7 Nos
1 Dedicated Relay1 Dedicated Relay1 Programmable Relay1 Programmable Relay
5 Programmable 5 Programmable (Open Collector Type)(Open Collector Type)
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The most versatile DC systems drive in the world
More than 3000 drives in India
More than 125,000 drives in use world-wide
Drive Centre Vicenza
The most versatile DC systems drive in the world
Control Techniques alsoControl Techniques also
Brand LabelsBrand Labels Digital DC Drives for..Digital DC Drives for..
CGEE ALSTOM CGEE ALSTOM (FRANCE)(FRANCE)
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UnidriveUnidrive
Unified AC Drive with Solution PlatformUnified AC Drive with Solution Platform
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Full Torque upto Standstill
Excellent Speed, Current & Position Loop
Very good Dynamic responses
ServoServo Applications
Full Torque upto Standstill
Excellent Speed & Current Loop
Very good Dynamic responses
Closed Loop Flux VectorCranes / Hoists
Process Lines
Sectional Drives
Full Torque to 1 Hz
No Speed Loop
Good Current Loop
Mostly O/L VectorConstant Torque Load
Fan/Pump / Conveyors
Application
Open Loop
No Speed Loop
No Current Loop
V/f
What you get…Type of Control
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UniSP – The Universal Drive With Solution PlatformUniSP – The Universal Drive With Solution Platform
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The The UniSP UniSP Advantage Advantage
Single Drive from Simple to Complex applicationsSingle Drive from Simple to Complex applications
Can be adapted to any mode of operation by Can be adapted to any mode of operation by simple parameterisationsimple parameterisation
Single Learning Curve for End-userSingle Learning Curve for End-user
Single Control module for all sizesSingle Control module for all sizes
Minimum InventoryMinimum Inventory
Integral Braking module for all sizesIntegral Braking module for all sizes
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• 200/240V 3ph, 50/60Hz
• 380/480V 3ph, 50/60Hz
• 500/600V 3ph, 50/60Hz
• 500/690V 3ph, 50/60Hz -
Global power suppliesGlobal power supplies
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6 (//)54321 7(//)
575V
400V
220V
15
11
22114.0
5.52.2 22
LV 48 / 96Vdc
45 75 132 160
37 55 90 132
45 75
- Servo, Closed loop-Open loop, V/F-- Open loop, V/F,Servo, Regen
110 160690V
110%
150%
175%
KW
O/L
Volts
*8
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Input VoltageInput Voltage
380-480 V +/- 10%380-480 V +/- 10%
NO Tap SelectionsNO Tap Selections
UNISP SPECSUNISP SPECS
Output FrequencyOutput Frequency
0-3000 Hz0-3000 Hz
Suitable for Suitable for High Frequency SpindleHigh Frequency Spindle
Input FrequencyInput Frequency
47-62 Hz.47-62 Hz.
Switching FrequencySwitching Frequency
3/4/6/8/12/16 KHz3/4/6/8/12/16 KHz
Quiter OperationQuiter Operation
Reduced HarmonicsReduced Harmonics
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Ambient Ambient
40 Deg C 40 Deg C
1 % per Deg C deration for 40- 1 % per Deg C deration for 40- 50 Deg C 50 Deg C
Environmental Specs Environmental Specs
Module IP ratingModule IP rating
IP 20IP 20
Nema 1Nema 1
Special Cooling FansSpecial Cooling Fans
Suitable for IP54 Suitable for IP54
Extended IP ratingExtended IP rating
IP54 IP54
Nema 12Nema 12
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48V DC supply input48V DC supply input
Ideally suitable for
Emergency battery operation for lift rescue
Limited speed set up for Machine Tool robot cells
Jog Operation in Extruders in case Of Power failure
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24V DC Auxiliary Power 24V DC Auxiliary Power
• External 24V / 2A input for control backup
• Encoder position retained
• Fieldbus stays live
• Safe programming of drive
• Additional means of Maintaining control
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Intelligent Options for AC Drives…Intelligent Options for AC Drives…
– Palm-sized Second ProcessorPalm-sized Second Processor
– Intel i960 32-bit RISC processorIntel i960 32-bit RISC processor
– With High-speed Fieldbus With High-speed Fieldbus ConnectivityConnectivity
– Programming in Ladder / Function Programming in Ladder / Function Blocks or ScriptBlocks or Script
– Connects to Remote I/O BlocksConnects to Remote I/O Blocks
– Distributes Real Time ControlDistributes Real Time Control
Zero Space Zero Space PLCPLC
Plugs into Plugs into Drive Drive modulemodule
CalculateCalculate
LogicLogic
ConnectConnect
SystemsSystems
Connect Connect I/OI/O
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SM-I/O Plus
SM- PROFIBUS-DP
SM-Applications
SM-Universal Encoder Plus
SM-CANopen
SM- DeviceNet
SM-INTERBUS
SM-Applications Lite
SM-ResolverSM- Encoder Plus
SM-CAN
SM-Ethernet
SM-SLM
SM-SERCOS
• Customisation at point of uses
• 3 options,X million number of combinations
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Unidrive SP with all front cover removed
Option module docking bays
Universal encoder connector(will accept 12 different types of encoder)
Control Terminals with safety disable function as standard
AC input power and motor connections
Relay connections
Cable support bracket
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Option Module AssemblyOption Module Assembly
• Application Module (incl CTNet)
• Profibus DP• Devicenet • Interbus S
• CANopen • Ethernet • SERCOS • Extra I/O
• 2nd Encoder
• Resolver• SLM• “Easy Motion”
PowerTools
Designed to Empower
ApplicationsEngineers
E
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UniDrive SP Field Bus GatewayUniDrive SP Field Bus GatewaySmart Card Facility - As standardSmart Card Facility - As standard
• Hot pluggableHot pluggable
• Auto backup of parametersAuto backup of parameters
• Fast low cost cloningFast low cost cloning
• Fast Network Start-Up’sFast Network Start-Up’s
• Up to 4 full parameter sets Up to 4 full parameter sets
• Supplied as standard with Supplied as standard with UniDrive SPUniDrive SP
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Field Bus ConnectivityField Bus Connectivity
Modules are available for
Modbus RTU ProfibusDeviceNetCANopenInterbus SSercos EthernetCTNet,
RS485 PortModbus (RTU or ASCII)
Johnson Controls (Metasys)CSI
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Level – 1Addl. Hardware – NilMemory - 4k ExeProg. Software – SyPT Lite
PLC FUNCTIONALITY IN UNISPPLC FUNCTIONALITY IN UNISP
Level – 2Addl. Hardware – SM Appln Lite (Option)Memory - 10 k ExeProg. Software – SyPT Lite
Level – 4Addl. Hardware – SM Appln+ CT Net (Option)Memory – 384k Exe, 80k RAMProg. Software –
SyPT Pro (Option)
Level – 3Addl. Hardware – SM Appln Lite (Option)Memory - 100k Exe, 20k RAMProg. Software –
SyPT Pro (Option)
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DRIVE PROGRAMMINGDRIVE PROGRAMMING
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Application ProgrammingApplication Programming
SyPT PROSyPT PRO
• Industrial NetworkingIndustrial Networking
• Realtime MultitaskingRealtime Multitasking
• Confirms to IEC 61131-3Confirms to IEC 61131-3
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Programming ToolProgramming Tool
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SYPT OverviewSYPT Overview
• Main Areas– ConfigurationConfiguration– ProgrammingProgramming– DPL EditorDPL Editor– Function Block EditorFunction Block Editor– Quick Ladder EditorQuick Ladder Editor– Watch WindowWatch Window– Function BlocksFunction Blocks
• Standard Library
• User Define
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Configuration EditorConfiguration Editor
• Project Oriented.
• Configuration of:-– Distributed CTNet SystemsDistributed CTNet Systems
OPC Server availableOPC Server available..
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DPL EditorDPL Editor
• Drive Prog Language(Quick Basic)
• Standard constructs like IF, THEN,ELSE as well as Loops
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Quick Ladder EditorQuick Ladder Editor
• Compliant to -61131
• Quick development of boolean and function block ladder diagrams.
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Function Block EditorFunction Block Editor
• Compliant to -61131
• Library of more than 256 Function Blocks.
• Can create additional Function Blocks
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Function BlocksFunction Blocks
• Standard Library– Floating Point & Integer Types.Floating Point & Integer Types.– DPL commands, std DPL commands, std PLC functionsPLC functions, ,
Motion & communication types.Motion & communication types.– Maintained by SSPD.Maintained by SSPD.– Powerful:-Powerful:-
• Development.• Modular• Easy to Understand
• Common standard block
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Allows you to Allows you to Monitor the Drives Monitor the Drives Parameters and Parameters and
Program Variables.Program Variables.
Immediate Window Allows Immediate Window Allows you to Set the Drive you to Set the Drive
Parameters or Program Parameters or Program Variables and Monitor Variables and Monitor
status.status.
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Help filesHelp files
SyPTPro Includes a SyPTPro Includes a comprehensive help file comprehensive help file and the manuals for all and the manuals for all
related products.related products.
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RemoteI/O
CTNet @ 5Mbps
Ethernet
CT-Net System: CT Digital DrivesSCADA - CT32CTIU user interfacefor Local Monitoring CTNet I/ORepeaters/Hubs
Hub
R
Repeater
RemoteI/O
SCADAMMI - CT32
ProgrammingDiag. Tools PC Gateway
CT Net Distributed Control SystemCT Net Distributed Control System
CTIU CTIUCTIU
CTIU
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Cranes
Fans & Pumps
Food and Drink
Material Handling
Metals & Metal FormingPaper
Printing
Rubber & Tyre
Stage Scenery
Textiles Wire Drawing
Industrial Sector FocusIndustrial Sector Focus
Plastic
Oil & Gas
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Control Techniques are the Control Techniques are the preferred Suppliers to…preferred Suppliers to…
Drive Centre Vicenza
Control Techniques India is Preferred Supplier toControl Techniques India is Preferred Supplier to
TISCOTISCO TELCOTELCO TUBE PRODUCTSTUBE PRODUCTS STEELCO GUJRATSTEELCO GUJRAT ESSARESSAR
FLAT PRODUCTSFLAT PRODUCTS MULTIFORMMULTIFORM
NESTLENESTLE BALKRISHNA TYRESBALKRISHNA TYRES
BALLARPUR INDUSTRIESBALLARPUR INDUSTRIES SHESASAYEE PAPER AND BOARDS SHESASAYEE PAPER AND BOARDS
LUCAS TVSLUCAS TVS BRAKES INDIABRAKES INDIA
KOHLI INDUSTRIESKOHLI INDUSTRIES
and ………..so onand ………..so on
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CT India Sample ReferencesCT India Sample ReferencesAutomation Solutions for Metal IndustryAutomation Solutions for Metal Industry
• Over 40 Customers Served till dateOver 40 Customers Served till date• Major Repeat References include:Major Repeat References include:
– TISCO (Over 35 projects till date)– Salem Steel– Flat Products Equipment (Process Line OEM) – Over 20 Export Projects– Multiform Machinery (Process Line OEM) – Over 10 Projects– Visakhapatnam Steel Plant– Metastrips– ITW Signode– PHP Steel - Bangladesh– Karnafully Steel - Bangladesh– Tube Product of India– Pennar Steel– Ispat Industries– SteelCo Gujarat– Shree Pre-Coated Steels
• Applications Expertise in:Applications Expertise in:
– Rolling MillsRolling Mills– Skin Pass RollingSkin Pass Rolling– Continuous Galvanizing LineContinuous Galvanizing Line– Cut-To-Length LineCut-To-Length Line– Pickling & Slitting LinesPickling & Slitting Lines– Rewinding & Electro-Cleaning LineRewinding & Electro-Cleaning Line– Color Coating LineColor Coating Line– Partial Line Upgrades + RetrofitsPartial Line Upgrades + Retrofits– Fan & PumpsFan & Pumps– Flying ShearsFlying Shears
• Supplies include Drive Systems + SCADA + PLC Automation + Motors + MCC’sSupplies include Drive Systems + SCADA + PLC Automation + Motors + MCC’s
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Galvanising Lines Galvanising Lines
• Karnafully Steel - Bangladesh (Thru, MAS )
• Rajesh Metals - Nepal (Thru, MAS )
• PHP Steel, Bangladesh
• PT Essar Indonesia
• Kandil Steels,Egypt
• Yung Kong Steel , Malaysia
(PCC+MCC+Drives( AC ) + LINE PLC + FURNACE PLC + SCADA +UPS)
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Galvanising Lines Galvanising Lines
• Cheman Ispat, Bangladesh (Thru’ Multiform)
• PHP Steel, Bangladesh
• YESU STEEL, ETHIOPIA
• VARDHAMAN STEELS, AMBALA(DC )
• Kandil Steels, Egypt
• Midgal, Nigeria
• Doo Won Steel, Korea
PCC+MCC+Drives( DC ) + LINE PLC + FURNACE PLC + SCADA
+UPS
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Steel IndustrySteel IndustryCold Rolling MillsCold Rolling Mills
• Tube Products of India( 4 Hi)
• Shamon Ispat Ltd( 4 Hi)
• Meta Strips(4 Hi)
• Kandil Steels, Egypt( 4 Hi)
• Karnafully, Bangladesh(4 Hi and 20 Hi)
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Steel IndustrySteel IndustrySkin Pass MillSkin Pass Mill
• Essar Steel, Indonesia
• Kandil Steels, Egypt
• KYCR Steel, Bangladesh
• SPSL, Pune
• Balco(Slab)
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Steel IndustrySteel IndustrySlitting LineSlitting Line
• Raymonds Ltd (3 Lines)• Meta Strips• Pennar Steel• SPSL,Pune• TATA SSL,Navsari-C.R.Slitter (thro. Metpro)• TATA SSL,Navsari-H.R.Slitter (thro. Hollow
Block)• Tube Products Of India
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Steel IndustrySteel IndustryCCUT TO LENGTH LINEUT TO LENGTH LINE
• Tube Products of India-3 Lines• TATA SSL• Dass Nagar (A/c.Galsheet , Kenya)• Flat Products (A/c. Uttam Steel revamping)• Flat Products (A/c.PHP Steels)• Flat Products (A/c.Apollo Steels) • Flat Products (A/c.R.M. Steels)• T.K.Steels
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Steel IndustrySteel IndustryPickling Line / Cleaning LinePickling Line / Cleaning Line
• Jai Corp
• Meta Strips
• S Alam , Bangladesh
• Lloyds Steel
• Essar, Hazira
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Steel IndustrySteel IndustryPickling Line / Cleaning LinePickling Line / Cleaning Line
• Flat ProductsKandil Steel Steel,Egypt.R.M.Steel BangladeshYung kong Steels, MalaysiaYesu Steel, EthiopiaMobati Steel,Kenya
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Steel Industry Steel Industry Rewinding Line Rewinding Line
Flat Products:
R.M. Steels,Bangladesh
Yesu Steel, Ethiopia
PHP Steel,Bangladesh
Apollo Steels, Bangladesh
Jindal Steel, Kolkata
Uttam Steel, Khopoli
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Steel Industry Steel Industry Rewinding Line Rewinding Line
PT Essar, Indonesia
SPSL,Pune
S ALAM, Bangladesh(Thru’ Multiform)
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Steel Industry Steel Industry TLL TLL
PT Essar, Indonesia
SPSL,Pune
Jai Corp, Nanded
Mobati Steels, Kenya
Multiform(at Malaysia)
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TISCO TISCO
• ROLLER TABLE DRIVE SYSTEM – 315 KW * 8 SETS (Getting upgraded to 480 Kw)
• GAS BOOSTER FANS – 450 KW – 5 NOS
• THYRISTOR CONVERTERS FOR HSM- 16 SETS
• VARIOUS UPGRADES
• MORE THAN 500 Modules of Various Ratings
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Wire Rod Mills Wire Rod Mills • TAMILNADU STEEL, ARAKONAM
• NATIONAL ENGG, CHENNAI
• SUMANGALA STEEL, BHUVANGIRI
• INDO BAZHA , INDONESIA ETC
DC Drives (Stand ,Coilers) + PLC + AUTOMATION
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CRANES CRANES
• SALEM STEEL PLANT
• TATA STEEL
• TATA MOTORS , PUNE
• RANK CRANES, HYDERABAD ETC
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Additionally Additionally
• Wagon Tippler Drives in VSP
• Static Excitation for Generators
• Double Column Planing Machine Controls Retrofit for BHEL ,with Active Front end
• 12 Pulse Converters for Banbury Mixers
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Steel IndustrySteel IndustryCold Rolling MillsCold Rolling Mills
• Tube Products of India
• Shamon Ispat Ltd
• Meta Strips
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Tube Products of India HighlightsTube Products of India Highlights
• Supplied & Commissioned in 1993 /1994
• Uncoiler : 2 x 75 HP / 250 V DC
• Main Mill : 300 HP
• Coiler : 2 x 75 HP / 250 V DC
• PLC : S 135
• MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Tube Products of India HighlightsTube Products of India Highlights
• Supplied & Commissioned in 2005
• Uncoiler : L&T Stack with Mentor Electronics
• Main Mill : 375 Kw/ 575 V(New)
• Coiler : L&T Stack with Mentor Electronics
• PLC : S-7/400
• MMI : Win CC
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Steel Industry- Tube Mills for China Steel Industry- Tube Mills for China Tube Products of India HighlightsTube Products of India Highlights
• Supplied & Commissioned in 2006
• Forming/Fin Pass/ Sizing: 150 Kw DC
• Accumulator: 55 Kw AC
• Pinch Rool:30 Kw AC
• Shear: 55 Kw AC
• Carriage : 60 Nm Servo
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Shamon Ispat Ltd – Haldia HighlightsShamon Ispat Ltd – Haldia Highlights
• Supplied & Commissioned in 1998 / 1999
• Uncoiler : 500 HP / 600V
• Main Mill :1500 HP /600V
• Exit Coiler : 500 HP / 600V• Screw Down : 50 HP / 250V each near /far
• PLC : GE Fanuc
• MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Shamon Ispat Ltd A/c. Karnafully Steels- 4 Hi MillsShamon Ispat Ltd A/c. Karnafully Steels- 4 Hi Mills
• Supplied in 1999 & Commissioning under progress
• Payoff : 60 HP / 250V
• Entry Coiler : 500 HP / 600V
• Mill Drive : 1500 HP / 600V
• Exit Coiler : 500 HP / 600V
• Screw down : 50 HP /250V each far/near
• PLC : GE Fanuc
• MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Karnafully Steels- 20 Hi MillsKarnafully Steels- 20 Hi Mills
• Supplied in 2003 & Commissioned in 2004
• Payoff : 100 HP / 400V
• Entry Coiler : 2*950 HP/350V(Series)
• Mill Drive : 2*1800 HP/ 750V(Tandem)
• Exit Coiler : 2*950 HP/350V(Series)
• Screw down : 50 HP /250V each far/near
• PLC : GE Fanuc
• MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling MillsMeta Strips HighlightsMeta Strips Highlights
• Supplied & Commissioned in 1999/ 2000
• Pay Off : 50 Kw
• Uncoiler : 230 Kw
• Main Mill : 600 Kw
• Coiler : 230 Kw
• PLC : S7 300
• MMI : PCIM
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Steel Industry Hot Mills Steel Industry Hot Mills Sumangala Steel Sumangala Steel
• Supplied & Commissioned in 1995 /1996
• Main stand : 6 x 200 Kw
• Coiler : 2 x 15 Kw
• Pinch Roll : 2 x 15 KW
• PLC : S 135
• MMI : Intellution
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Steel Industry Hot MillsSteel Industry Hot MillsIndo Baja - Indonesia Indo Baja - Indonesia
• Supplied & Commissioned in 1997 /1998
• Main stand : 3 x 400 Kw
• PLC : S 135
• MMI : Intellution
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How have we been sustaining this Success –How have we been sustaining this Success – Year after Year?Year after Year?
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The Driving Force behind our success….The Driving Force behind our success….
Application Specific Engineered Systems – We have the Application Specific Engineered Systems – We have the Experience!Experience!
Able to obtain the latest technology in Automation – No Able to obtain the latest technology in Automation – No CompromisesCompromises
Product Leadership positionProduct Leadership position
Getting the most-up-to-date engineering design – Due to Getting the most-up-to-date engineering design – Due to our Shared Resource Networkour Shared Resource Network
All our Drive products carry a Product Warranty for 2 Years All our Drive products carry a Product Warranty for 2 Years & your nearest Support Centre will honour all Warranty & your nearest Support Centre will honour all Warranty Commitments for supplies made to youCommitments for supplies made to you
Excellent and prompt after sales service support Excellent and prompt after sales service support
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INTELLIGENCE INTELLIGENCE
IN IN
DRIVESDRIVES
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Intelligence in DrivesIntelligence in Drives
Modern System RequirementsModern System Requirements
High Resolution Speed Ref(Master Speed)High Resolution Speed Ref(Master Speed)
Draw Calculations(Section Draws)Draw Calculations(Section Draws)
Diameter Calculations and Diameter Calculations and TensionReference Generation(Uncoilers)TensionReference Generation(Uncoilers)
Length ComputationsLength Computations
Logical Decision MakingsLogical Decision Makings
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INTELLIGENCE IN DrivesINTELLIGENCE IN Drives
All these require quite a good amount of All these require quite a good amount of Computing Power and hence need of Additional Computing Power and hence need of Additional Processor.Processor.
While selecting the control system,other While selecting the control system,other parameters also need considerationparameters also need consideration
• Updates need to be periodic & deterministicUpdates need to be periodic & deterministic (Data must arrive at regular guaranteed time (Data must arrive at regular guaranteed time intervals)intervals)
• The period or cycle of updates The period or cycle of updates should be should be synchronizedsynchronized with the digital control loops in the with the digital control loops in the drive / controller to eliminate any undesirable drive / controller to eliminate any undesirable “beating” effects“beating” effects
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INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVES
• In addition to these critical parameters, In addition to these critical parameters, Non-Non-Time critical access to network should also be Time critical access to network should also be supportedsupported (e.g. Operator interaction / Drive set- (e.g. Operator interaction / Drive set-up / Downloading application software / up / Downloading application software / Diagnostics / Data logging)Diagnostics / Data logging)
• Implementation can be by Centralized Implementation can be by Centralized Intelligence or Distributed Intelligence approachIntelligence or Distributed Intelligence approach
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Configuration PossibilitiesConfiguration PossibilitiesCentral IntelligenceCentral Intelligence
• All System Control Functions can be located in All System Control Functions can be located in the Central Controller & transfer Demands + the Central Controller & transfer Demands + Feedbacks cyclically over the network. This is a Feedbacks cyclically over the network. This is a typical typical Centralized Intelligence systemCentralized Intelligence system
Most PLC manufacturers prefer this approach Most PLC manufacturers prefer this approach even for Drive digital control for obvious even for Drive digital control for obvious reasons!!reasons!!
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How about the Control Techniques How about the Control Techniques Approach?Approach?
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INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVESC.T. ApproachC.T. Approach
• C.T.uses Distributed Control and pioneered use C.T.uses Distributed Control and pioneered use of an additional Microcomputer Board fitted on of an additional Microcomputer Board fitted on the Drive.the Drive.
• This function board is called MD29 and uses a 32 This function board is called MD29 and uses a 32 bit 2bit 2ndnd Processor for onboard maths and logics Processor for onboard maths and logics
• All Drive related functions and calculations All Drive related functions and calculations reside as preprogrammed Macros and the user reside as preprogrammed Macros and the user has just to enter certain system datahas just to enter certain system data
• The 2The 2ndnd Processor will communicate with the Processor will communicate with the processor in the Drive and execute the additional processor in the Drive and execute the additional functions with timings synchronised with Drive functions with timings synchronised with Drive ProcessorProcessor
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Distributed Architecture BenefitsDistributed Architecture Benefits
• With Distributed architecture, With Distributed architecture, the load on the load on the networkthe network is reduced to a large extent is reduced to a large extent
• Peer-To-Peer communications is possible. Peer-To-Peer communications is possible. This allows data to be shared easily This allows data to be shared easily between the nodes between the nodes without reducing without reducing network speedsnetwork speeds..
• The The dynamic performance dynamic performance of the system is of the system is better handled by distributed systems.better handled by distributed systems.
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INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVESC.T. ApproachC.T. Approach
Add-On Co-Processor Add-On Co-Processor Card for Mentor IICard for Mentor II
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Intelligent Options for AC Drives…Intelligent Options for AC Drives…
– Palm-sized Second ProcessorPalm-sized Second Processor
– Intel i960 32-bit RISC processorIntel i960 32-bit RISC processor
– With High-speed Fieldbus With High-speed Fieldbus ConnectivityConnectivity
– Programming in Ladder / Function Programming in Ladder / Function Blocks or ScriptBlocks or Script
– Connects to Remote I/O BlocksConnects to Remote I/O Blocks
– Distributes Real Time ControlDistributes Real Time Control
Zero Space Zero Space PLCPLC
Plugs into Plugs into Drive Drive modulemodule
CalculateCalculate
LogicLogic
ConnectConnect
SystemsSystems
Connect Connect I/OI/O
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The 1986 Industrial Revolution.The 1986 Industrial Revolution.
• In 1986 Control Techniques launches MD21.– The birth of the intelligent drive.The birth of the intelligent drive.
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From revolution to evolutionFrom revolution to evolution
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Hardware EvolutionHardware Evolution
MD21
MD29
UD70
MD29AN
UD75SM-Applications
1st Generation 2nd Generation 3rd Generation
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Software EvolutionSoftware Evolution
Terminal Window DPL Toolkit
SyPT V1
1st Generation 2nd Generation 4th Generation3rd Generation
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Functionality Functionality EvolutionEvolution
Intel Basic with Parameter
Access
Winder, Digital Lock, Spindle Orientation, kWh
Software, PID
Advanced Position
Controller added
Winder, Flying Shear and Duty Assist Solutions
PLCOpen Function Blocks
Windows Software, Multi-Tasking Environment, Drive Programming
Language (DPL)
Function Block and Ladder Support, CTNet support.
Constant Function Block Development
Constant Fieldbus Development
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100%90%90%<1%Execution Speed
Hitachi SH2 (28kHz)
I960 (16kHz)I960 (16kHz)Intel Basic Interpreter
Processor
YesYesYesNoMulti-Tasking
80Kb44Kb8KbVariable Memory
384Kb256Kb96Kb32KbProgram Memory
SM-AppsUD70MD29MD21
Functionality Evolution
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Example Line Configuration Example Line Configuration
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ENTRY SECTION
PROCESS SECTION
GENERAL LAYOUT OF CONTINUOUS PICKLING LINE
EXIT SECTION
PROCESS SECTION
PROCESS SECTION
UNCOILER PR. CUM FLATT. EDGE TRIMMER PINCH ROLL
FOR LENGTHCOUNTING
PINCH ROLL RECOILER
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Master Reference GenerationMaster Reference Generation
• A Basic Programme is written in MD29AN card A Basic Programme is written in MD29AN card simulating up-down counter operationsimulating up-down counter operation
• Accuracy is 1 in 64000Accuracy is 1 in 64000• Increase and Decrease in adjustable steps (Ramp Increase and Decrease in adjustable steps (Ramp
adjustable)adjustable)• Reference is transmitted in Digital form to other Reference is transmitted in Digital form to other
sections along CT Net bussections along CT Net bus
Please note PLC is not used for Master ref Please note PLC is not used for Master ref generationgeneration
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Tension Control for UncoilerTension Control for Uncoiler
• MD 29AN is provided with Centre wind SoftwareMD 29AN is provided with Centre wind Software• Dia is calculated in MD29ANDia is calculated in MD29AN• Inertia compensation, Friction compensation etc. are Inertia compensation, Friction compensation etc. are
inbuilt in MD29inbuilt in MD29• Taper tension, Stall tension, dia hold, strip breakage Taper tension, Stall tension, dia hold, strip breakage
protection etc. are standard inbuilt facilities in MD29ANprotection etc. are standard inbuilt facilities in MD29AN
• Please note PLC is not used for Tension Please note PLC is not used for Tension ControlControl
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Line Automation FeaturesLine Automation FeaturesFeatureFeature
• Loop Pit Control Loop Pit Control
• 2 No. Encoders will be mounted, (one on delivery side 2 No. Encoders will be mounted, (one on delivery side and another on entry side) for each loopand another on entry side) for each loop
• MD29AN is used for Counting and comparing the pulses MD29AN is used for Counting and comparing the pulses from both Encoders and the differential is a measure of from both Encoders and the differential is a measure of Loop.Loop.
• Depending upon required Loop,the speed of the Depending upon required Loop,the speed of the concerned DC Pinch Roll Units are modified such that concerned DC Pinch Roll Units are modified such that Process speed remains constant.Process speed remains constant.
Please note PLC is not used for Loop ControlPlease note PLC is not used for Loop Control
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Line Automation FeaturesLine Automation FeaturesFeatureFeature
• Squeeze Roll ControlSqueeze Roll Control
• The Encoder mounted on the delivery side of Loop Pit The Encoder mounted on the delivery side of Loop Pit (in the Process Section ) is used to measure the length (in the Process Section ) is used to measure the length of strip (initiated after Head indexing)of strip (initiated after Head indexing)
• Length counting is done in MD29 AN and passed to PLC Length counting is done in MD29 AN and passed to PLC on BUS.on BUS.
• PLC will initiate commands to squeeze rolls to lift PLC will initiate commands to squeeze rolls to lift whenever welding is passing and after certain time, rolls whenever welding is passing and after certain time, rolls would be lowered.would be lowered.
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Acid Dozing ControlAcid Dozing Control
• The length calculated is used on different scaleThe length calculated is used on different scale
• Acid pumps can be switched ON/OFF automatically after Acid pumps can be switched ON/OFF automatically after certain length of material is passed thru’ Process certain length of material is passed thru’ Process Section.Section.
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Coil weight MeasurementCoil weight Measurement
• The existing weighing control system will be The existing weighing control system will be connected to PLC System on the Bus.connected to PLC System on the Bus.
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Line AutomationLine Automation
Drives (Network #1) Drives (Network #1)
• All Drives connected on Hi-speed CT NetAll Drives connected on Hi-speed CT Net
• Data Transfer at 5MB/S (Large amount of data Data Transfer at 5MB/S (Large amount of data Transmitted quickly)Transmitted quickly)
• Peer to Peer System and no Master PLC Controller Peer to Peer System and no Master PLC Controller requiredrequired
• Each node takes control of network on its turn to Each node takes control of network on its turn to communicate directly with other Network nodes.communicate directly with other Network nodes.
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Line AutomationLine Automation
Drives (Network #1) ……Drives (Network #1) ……
• Each Drive fitted with MD 29 AN Application cum Each Drive fitted with MD 29 AN Application cum Fieldbus Module with CT Net connectivityFieldbus Module with CT Net connectivity
• All Line specific controls like Tension control, Loop All Line specific controls like Tension control, Loop Control etc.are set up in Application Module,located Control etc.are set up in Application Module,located within drive module itself. This frees PLC from doing within drive module itself. This frees PLC from doing Maths functions related to Drive systems.Maths functions related to Drive systems.
• Fast real time control of equipment is achieved.Fast real time control of equipment is achieved.
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Line AutomationLine Automation
PLC’s in MCC/Main/Remote Racks PLC’s in MCC/Main/Remote Racks
(Network #2)(Network #2)
• All I/O’s are connected on fast Profi-bus NetworkAll I/O’s are connected on fast Profi-bus Network
• Remote stations are located to minimize cablingRemote stations are located to minimize cabling
• PC in ECR Room is loaded with PLC programme and PC in ECR Room is loaded with PLC programme and SyptSypt
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Line AutomationLine Automation
Interfacing between Two Bus Systems Interfacing between Two Bus Systems
• An UniSP Drive is usedAn UniSP Drive is used
• One Addon Slot is fitted with CTNet ModuleOne Addon Slot is fitted with CTNet Module
• Relevant FieldBus (Profibus/ Modbus / DeviceNet) Relevant FieldBus (Profibus/ Modbus / DeviceNet) Module from UniSP family is put in the 2Module from UniSP family is put in the 2ndnd Slot Slot
• Application Programme for Register to Register Transfer Application Programme for Register to Register Transfer is written by SyPTis written by SyPT
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Control Techniques IndiaControl Techniques India
Scope of Supply:
Drives, PLC & Scada system
Mill Specification:
Max. Speed: 300 MPM
Material Thickness: 0.2mm to 2.00mm
Material Width: 600mm to 1320mm
Maximum Roll Force: 3500 kN
Process Line : 4 Hi Non Reversible Skin Pass MillCustomer : Flat products Limited, IndiaEnd User : PT Essar Dhananjaya, IndonesiaContract value : US $ 180,000Project Team : Ganesh + Satish
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M 7 0 0 R M 4 2 0 R M 4 2 0 R M 4 2 0 R
E N T . B R I D L ET O P 1 0 0 K W
E N T . B R I D L EB O T . 7 0 K W
E X I T . B R I D L ET O P 1 0 0 K W
E X I T . B R I D L EB O T . 7 0 K W
R E C O I L E R 3 0 0 K W
E N T R Y D E F L E C T O R R O L L E X I T D E F L E C T O R R O L L
L I N E C O N F I G U R A T I O N
L I N E E N C O D E R1 0 2 4 P P R
L I N E E N C O D E R1 0 2 4 P P R
P O R1 5 0 K W
M I L L2 0 0 K W
M 1 2 0 0 RM 4 2 0 R M 8 2 5 R
1 0 2 4 P P R 2 5 0 0 P P R 1 0 2 4 P P R 2 5 0 0 P P R1 0 2 4 P P R
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L I N E D R I V E S ( 7 N o s . )
D C C O N V E R T E R S A N DD C M O T O R S
( 7 N o s . )
M C C A N DF I X E D S P E E D A C
M O T O R S
M C C
A C B2 5 0 0 A
( F I X E D )
M C C B6 3 0 A
D C M O T O R S T O B ES U P P L I E D B Y O T H E R S
F P E
C T I N D I A
F P E
C T I N D I A
I N C O M E R , - 2 5 0 0 AP O R - 1 5 0 K WE N T R Y B R I D L E B O T T O M - 7 0 K WE N T R Y B R I D L E T O P - 1 0 0 K WM I L L S T A N D - 2 0 0 K WE X I T B R I D L E T O P - 1 0 0 K WE X I T B R I D L E B O T T O M - 7 0 K WR E C O I L E R - 3 0 0 K W
F I X E D S P E E D A C M O T O R S T OB E S U P P L I E D B Y O T H E R S
P O W E R S U P P L Y D I S T R I B U T I O N
3 5 0 A
C U S T O M E R
A C B( E D O )
V . S . S
K W H
P V 1
P A 1A
V
F U
A . S . S
F U
4 3 3 V ,2 0 0 0 K V A
A C B3 2 0 0 A( E D O )
P D B
C U S T O M E R
2 1 0 0 A
3 Ø
, 4
Wir
e, 4
15 V
, 50
Hz
3 Ø
, 4
Wir
e, 4
15 V
, 50
Hz
P O W E R S U P P L Y D I S T R I B U T I O N ( S I N G L E L I N E D I A G R A M )
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D PM M I
F I E L D R I O ( R S - 4 )
M A I N P L C
S P M C D ( R S - 2 )
P L C S 7 - 3 0 0
P O R C D ( R S - 1 )
R E C O I L E R C D ( R S - 3 )
P O R E N T . B R I D L ET O P
M I L L E X I T . B R I D L EB O T .
E X I T .B R I D L E T O P
R E C O I L E RE N T . B R I D L EB O T .
U N I S P
G A T E W A Y
M P I A
H U B
C P 5 6 1 1 P C I 2 0C P 5 6 1 1
E N G I N E E R I N G P C
H A R D W A R E : -C P 5 6 1 1 ( D P / M P I )P C I 2 0 ( D R I V E S )
S O F T W A R E : -S T E P 7 ( P L C )S Y P T ( D R I V E S A P P L I C A T I O N )C T - N E T B R O W S E R ( D R I V E P A R A M E T E R )
H M I F O R L I N E
H A R D W A R E : -C P 5 6 1 1 ( D P / M P I )
S O F T W A R E : -W I N C C D E V E L O P M E N T( S C A D A 1 0 2 4 T A G
S Y S T E M C O N F I G U R A T I O N
D R I V E S & M C C ( M A I NP L C )
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S Y S T E M C O N F I G U R A T I O N F O R 4 - H I S P M ( P r o j e c t G E )
M C C P A N E L
M M I
5 6 1 1
F I E L D R I / O
D R I V E P A N E L S
H M I
I N C O M E R , - 3 2 0 0 A
P O R - 1 5 0 K WE N T R Y B R I D L E B O T T O M - 7 0 K WE N T R Y B R I D L E T O P - 1 0 0 K WM I L L S T A N D - 2 0 0 K W
E X I T B R I D L E T O P - 1 0 0 K WE X I T B R I D L E B O T T O M - 7 0 K W
R E C O I L E R - 3 0 0 K W
E N G I N E E R I N G P C ( D R I V E S & P L C )
P O R C D
P C I 2 0
M M I P C
R S - 4
P L C S 7 - 3 0 0D P
D P
U N I S PG A T W A Y
HUB
M A I N P L C
P O R E N T . B R I D L E B O T .
5 6 1 1
E N T . B R I D L E T O P M I L L E X I T . B R I D L E B O T . E X I T . B R I D L E T O P R E C O I L E R I N C O M E R
C O I L E R C D
P C T A B L E
P C T A B L E
S P M C D
R S - 1
0 0
R S - 3 R S - 2
C O N T R O L C A B L E
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Control Techniques IndiaControl Techniques India
M1850R325kwRecoiler
M550R90kwExit Bridle Roll – M2
M550R140kwExit Bridle Roll – M1
M1850R250kwMill Stand
M550R140kwEntry Bridle Roll – M2
M550R90kwEntry Bridle Roll – M1
M 1850R225kwUncoiler
Drive RatingMotor RatingApplication
Application Module : MD29ANPLC : Siemens, S7 - 400Gateway Module : UniSP + SM Application + SM ProfibusScada System : WinCC V 5.1
Process Line : 4 Hi Non Reversible Skin Pass Mill
End User : PT Essar Dhananjaya, Indonesia
Project Team : Ganesh + Satish
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Control Techniques IndiaControl Techniques India
• Time taken for commissioning
5 MandaysPost Commissioning Observation/Tuning
3 MandaysCommissioning
2 mandaysSCADA Modification
1 MandayInteraction withAEC Panel Check
1 MandayDrive Software Simulation Test
3 MandaysOperation from CD with interlock
2 MandaysNo Load motor Test
5 MandaysI/O Checking
Process Line : 4 Hi Non Reversible Skin Pass Mill
End User : PT Essar Dhananjaya, Indonesia
Project Manager: B. Ganesh + Satish
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Drive Centre Vicenza
• End-Customer: M/s PT.Essar, Indonesia
• Application: Continuous Galvanizing Line(Non-OX Furnace)
• OEM: M/s Flat Products Equipment (I) LtdMumbai, India
• Contract Date: 26th August 2003
• Contract Value: US $ 652,000
• Scope of Supply: Drives, PLC & SCADA Systems
• Commissioned on: October 2004
Project Details
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• The CR coils directly from 6 Hi/4 Hi mills are transferred to CGL lines.
• The Strip passes through various processes to remove defects, etc.
CGL Process ( 1 of 3)
• CGL being a continuous line, the coils passed through Looper.
• Continuous annealing of coils takes place in an on line annealing furnace ( to clean the coils and anneal the coil to achieve desired hardness). The temperature of strip in this pre-heating oxidizing furnace would be between 550 and 680 C.
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• Then the coil is passed through Zinc pot where Zinc coating is carried out .
• Zinc and Antimony of highest purity are used for coating sheets in a technologically advanced Hot-dip process. The bath temperature would be around 440 to 460 C. This operation is performed at a precise temperature set up.
CGL Process ( 2 of 3)
• Due care is taken for pretreatment of substrate on which Zinc coating takes place.This consequently increases the life and performance of the galvanized sheets.
• The Zinc Coating weight is controlled by the Air Knife Blowers
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• Zinc coated coils thus passed through Chromate solution provides safe guard to the coils from white rusting and other atmospheric reaction.
• The chromic acid concentration shall be 20 to 25 gm/ltr with a
temperature of 40 to 45 C.
• In addition, the strip passes through Tension Leveler & 4-Hi Skin Pass Mill to improve the shape of product and give perfect flatness.
• At the exit, strip is coiled.
CGL Process ( 3 of 3)
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Line Specifications
• Max Machine Speed: – Entry Section: 190 MPMEntry Section: 190 MPM– Process Section: 150 MPMProcess Section: 150 MPM– Exit Section: 190 MPMExit Section: 190 MPM
• Material Thickness Range: – Min: 0.16 mm Min: 0.16 mm – Max: 2.00 mm Max: 2.00 mm
• Material Width Range:– Min: 600 mm Min: 600 mm – Max: 1320 mm Max: 1320 mm
• Max Furnace Capacity:– 25 Tons / Hour25 Tons / Hour
• Other Specialties:– Online 4-Hi Skin Pass MillOnline 4-Hi Skin Pass Mill– Online Tension Leveling LineOnline Tension Leveling Line– Online Chemical CoaterOnline Chemical Coater
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Drive System Details• There are 33 Nos. of Unidrive Classic and the Range of the Motors from 5.5 KW to 400
KW.
• All the Line Drives are connected on COMMON DC BUS.
• One no. of 2000 Amps Uncontrolled Diode bridge is there to provide the DC Supply.
• Also, there are 19 Nos. of Auxiliary Drives (5 Nos. Unidrive Classic for higher rating and Commander SE Drives for the remaining).
• Further,there are some emergency Drives, which are related to the furnace system
• 3 Nos. of Siliconics Soft Starters used for Heater Controls.
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Single Line Diagram (Line Drives)
E N C O D E R
M
M O T O R
E N .
L C 2
Q S
C h a r g i n gr e s i s t o r
L C 1
5 6 0 V D C B U S
A
C T Q SP A
H LR Y B P H A S E O N
P VQ S
A . S . S
V . S . SF U
V~
~E~
Q F ( A C B )2 0 0 0 A
( M F )
V O L T A G E : 4 1 5 V ± 1 0 % , F R E Q U E N C Y : 5 0 H z ± 3 %3 Ø , 3 W I R E S Y S T E M
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N .
L C 2
Q S
C h a r g i n gr e s i s t o r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N .
L C 2
Q S
C h a r g i n gr e s i s t o r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N .
L C 2
Q S
C h a r g i n gr e s i s t o r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N .
L C 2
Q S
C h a r g i n gr e s i s t o r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N .
L C 2
Q S
C h a r g i n gr e s i s t o r
F U
K M 1 K M 2
L C 1
B R2 0 0 0 A
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Drive Details (Line Drives)
UD75UNI 440145.0Entry Accumulator7
UD75UNI 340318.5Bridle # 1D6
~UNI 340318.5Bridle # 1C5
UD75UNI 340115.0Bridle # 1B4
~UNI 340115.0Bridle # 1A3
UD75UNI 4402110.0Payoff # 22
UD75UNI 4404110.0Payoff # 11
Apps.Module
DriveRating
MotorRatin
gDescriptionSr.No
Entry Section Drives
Drive Centre Vicenza
Drive Details (Line Drives)
Process Section Drives (1 of 2)
~UNI 5401160.0Backup Roll-Top18
UD75UNI 5401160.0Backup Roll-Bot17
~UNI 440255.0Bridle # 4B16
UD75UNI 440145.0Bridle # 4A15
~UNI 340537.0Bridle # 3B14
UD75UNI 340537.0Bridle # 3A13
UD75UNI 340430.0Furnace Bridle C12
~UNI 340318.5Furnace Bridle B11
~UNI 24025.5Furnace Bridle A10
~UNI 340430.0Bridle # 2B9
UD75UNI 340430.0Bridle # 2A8
Apps. Module
Drive Rating
Motor RatingDescriptionSr.No
Drive Centre Vicenza
Drive Details (Line Drives)
~UNI 440255.0Bridle # 7B29
UD75UNI 440375.0Bridle # 7A28
~UNI 340218.5 KWChromate Coater#427
UD75UNI 340218.5 KWChromate Coater#326
~UNI 340218.5 KWChromate Coater#225
UD75UNI 340218.5 KWChromate Coater#124
~UNI 5402132.0Bridle # 6B23
UD75UNI 5401200.0Bridle # 6A22
UD75UNI 440490.0Bridle # 5C21
~UNI 5401132.0Bridle # 5B20
UD75UNI 440375.0Bridle # 5A19
Apps.Module
Drive Rating
MotorRatingDescriptionSr.No
Process Section Drives (2 of 2)
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Drive Details (Line Drives)
UD75UNI 5403400.0Recoiler33
UD75UNI 440255.0Bridle # 8B32
~UNI 340537.0Bridle # 8A31
UD75UNI 440255.0Exit Accumulator30
Apps.Module
Drive Rating
MotorRatingDescriptionSr.No
Exit Section Drives
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Single Line Diagram (Aux. Drives)
V O L T A G E : 4 1 5 V ± 1 0 % , F R E Q U E N C Y : 5 0 H z ± 3 %3 P H A S E , 3 W I R E S Y S T E M
AC TQ S
P A
H LR Y B P H A S E O N
P VQ S
A . S . S
V . S . SF U
V~
~E~
Q F 1 6 0 0 A( A C B )
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
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Drive Details (Aux. Drives)
18.5 KW - SE7 x 2.2 KWHearth Roll Drive # 219
18.5 KW - SE7 x 2.2 KWHearth Roll Drive # 118
11 KW - SE5.5 KWEntry Seal Roll17
7.5 KW - SE5.5 KWBoot Roll16
1.1 KW - SE0.83 HPJet Act In/ Out # 415
1.1 KW - SE0.83 HPJet Act In/ Out # 314
1.1 KW - SE0.83 HPJet Act In/ Out # 213
1.1 KW - SE0.83 HPJet Act In/ Out # 112
4 KW - SE2.2 KWJet Act Up/ Down # 211
4 KW - SE2.2 KWJet Act Up/ Down # 110
UNI 5402110 KWAir Knife Blower # 29
UNI 5402110 KWAir Knife Blower # 18
UNI 440455 KWCooling Tower Blower # 37
UNI 440355 KWCooling Tower Blower # 26
UNI 440490 KWCooling Tower Blower # 15
37 KW - SE37 KWNOF flue Exhaust Blower4
37 KW - SE22 KWJet Cool Fan # 33
37 KW - SE22 KWJet Cool Fan # 22
37 KW - SE22 KWJet Cool Fan # 11
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Automation Details• All the Line Drives are connected through CT-Net.
• The Auxiliary Drives & Soft starters are hard-wired to PLC.
• Automation (PLC) Part is segregated into two parts. One is Line controls & other is Furnace Controls.
• Siemens Step-7 PLC is used.
• S7 – 400 for Line Operations & S7 – 300 for Furnace Operations.
• There are 14 Nos. of Remote I/O Stations and all are connected through Profibus- DP.
• S7-400 & S7-300 Data exchange is done by Global Data Communication.
• Unidrive SP + SM-Apps + SM-Profibus are used as the communication gateway between drive system & PLC system
Drive Centre Vicenza
Line SpecificationsCommunication Schematic
WinCC
scada1
Line PLC
(S7-400)
CTNet
Entry Section Drives
Remote I/O
Operator Interface Units
Process Section Drives Exit Section Drives
Profibus UniSP
As
Comm.
Gateway
UniSP
As
Comm.
Gateway
UniSP
As
Comm.
Gateway
Furnace PLC (S7-300)
Remote I/O
WinCC
scada2
Prog. Station
Drive Centre Vicenza
Profibus Routing
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E N T R Y C DE S A
P R O F I B U SA D D R E S S : 5 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E N T R Y C DR S # 7
P R O F I B U SA D D R E S S : 2 2
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E N T R Y F I E L DR S # 1 2 ( 1 / 1 )
P R O F I B U SA D D R E S S : 2 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E N T R Y F I E L DR S # 1 2 ( 0 / 1 )
P R O F I B U SA D D R E S S : 2 0
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E N T R Y M C CR S # 4
P R O F I B U SA D D R E S S : 1 8
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
P R O C E S S M C CR S # 5
P R O F I B U SA D D R E S S : 1 9
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
F U R N A C E P L CR A C K # 4 / 4
P R O F I B U SA D D R E S S : 1 7
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
F U R N A C E P L CR A C K # 3 / 4
P R O F I B U SA D D R E S S : 1 6
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
F U R N A C E P L CR A C K # 2 / 4
P R O F I B U SA D D R E S S : 1 5
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
F U R N A C E P L CR A C K # 1 / 4
P R O F I B U SA D D R E S S : 1 4
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
F U R N A C E P L C ( C P U S 7 - 3 0 0 )R A C K # 0 / 4
P R O F I B U SA D D R E S S : 5
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
M P IA D D R E S S : 5
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
L I N E P L C ( C P U S 7 - 4 0 0 )R A C K - U R 2
P R O F I B U SA D D R E S S : 2
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
M P I A D D R E S S : 2
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E N T R Y D R I V E SR S # 1
P R O F I B U SA D D R E S S : 1 0
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
A U X D R I V E SR S # 3 ( 0 / 2 )
P R O F I B U SA D D R E S S : 1 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
A U X D R I V E SR S # 3 ( 1 / 2 )
P R O F I B U SA D D R E S S : 1 2
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
A U X D R I V E SR S # 3 ( 2 / 2 )
P R O F I B U SA D D R E S S : 1 3
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
P U L P I T C DR S # 8
P R O F I B U SA D D R E S S : 2 5
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
P R O C E S S F I E L DR S # 1 3 ( 0 / 1 )
P R O F I B U SA D D R E S S : 2 3
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
P R O C E S S F I E L DR S # 1 3 ( 1 / 1 )
P R O F I B U SA D D R E S S : 2 4
M M I P C - 1P R O F I B U S
C O N N E C T O R
A 1 B 1 S B 2A 2
M M I P C - 1P R O F I B U S
C O N N E C T O R
A 1 B 1 S B 2A 2
R E P E A T E R
P R O G P C - 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
S P M C DR S # 9
P R O F I B U SA D D R E S S : 2 6
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
S P M C D - E S A
P R O F I B U SA D D R E S S : 6 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
T L L C DR S # 1 0
P R O F I B U SA D D R E S S : 2 7
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
T L L C D - E S A
P R O F I B U SA D D R E S S : 7 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E X I T M C CR S # 6
P R O F I B U SA D D R E S S : 2 8
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E X I T D R I V E SR S # 2
P R O F I B U SA D D R E S S : 2 9
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
G A T E W A Y( E X I T )
P R O F I B U SA D D R E S S : 1 0 3
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
G A T E W A Y( P R O C E S S )
P R O F I B U SA D D R E S S : 1 0 2
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
G A T E W A Y( E N T R Y )
P R O F I B U SA D D R E S S : 1 0 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E X I T F I E L DR S # 1 4
P R O F I B U SA D D R E S S : 4 1
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E X I T C DR S # 1 1
P R O F I B U SA D D R E S S : 4 0
P R O F I B U SC O N N E C T O R
A 1 B 1 S B 2A 2
E X I T C D - E S A
P R O F I B U SA D D R E S S : 8 1
GL
OB
AL
DA
TA
NE
TW
OR
K
P R O F I B U SA D D : 0
P R O J E C T - J WP R O F I B U S N E T W O R K D E T A I L S
Drive Centre Vicenza
CT-Net Routing
U D 7 5
1 2 3
P A Y O F F # 1P A Y O F F # 2
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
P A Y O F F # 2B R I D L E # 1 AB R I D L E # 1 DE N T A C C U MB R I D L E # 2 A
U D 7 5
1 2 3
H . B R # C
U D 7 5
1 2 3
B R I D L E # 4 AP A Y O F F # 2
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
B R I D L E # 5 AB U R - B O TB R I D L E # 3 AB R I D L E # 5 CG A T W A Y
E N T R Y
U D 7 5
1 2 3
G A T W A Y
P R O C E S S
U D 7 5
1 2 3
G A T W A Y
E X I T
U D 7 5
1 2 3
R E C O I L E RP A Y O F F # 2
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
U D 7 5
1 2 3
B R I D L E # 8 BE X I T A C C U MB R I D L E # 7 AO R G C O A T - 3
U D 7 5
1 2 3
B R I D L E # 6 A O R G C O A T - 1
A D D : 1 1A D D : 1 2A D D : 1 4A D D : 1 3A D D : 1 5A D D : 1 6A D D : 1 7
A D D : 0 3 A D D : 0 2 A D D : 0 1 A D D : 3 1 A D D : 1 8 A D D : 1 9A D D : 2 0 A D D : 2 1
A D D : 2 2 A D D : 2 3 A D D : 2 4 A D D : 2 5 A D D : 2 6 A D D : 2 7 A D D : 2 8
A
S
B
A
S
B
A
S
B
A
S
B
A
S
B
A
S
B
75 OH
MS
75 OH
MS
75 OH
MS
T E R M I N A T I N GR E S I S T O R
T E R M I N A T I N GR E S I S T O R
T E R M I N A T I N GR E S I S T O R
P R O G P C
P C I - 2 0
1 2 3
S Y P TW O R K B E N C H
C T - N E T H U B( R S # 1 )
C T - N E T H U B( R S # 2 )
P R O J E C T - J WC T - N E T C O M M U N I C A T I O N S C H E M A T I C
Drive Centre Vicenza
SCADA – Overview
• There are 2 sets of 1024 Power tags SCADA Stations, One for Line Operations and other is dedicated for Furnace Operations.
• Siemens WinCC SCADA Package is used.
• SCADA is connected to PLC System through Profibus-DP.
• In addition, there are 4 Nos. of Operator Interface units (OP170B), which are fitted on the Control Desks.
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SCADA – Line Overview
Drive Centre Vicenza
SCADA – Entry Section
Drive Centre Vicenza
SCADA – Process Section
Drive Centre Vicenza
SCADA – Exit Section
Drive Centre Vicenza
SCADA – Furnace Section
Drive Centre Vicenza
SCADA – PHF Burner Controls
Drive Centre Vicenza
SCADA – PHF PID Settings
Drive Centre Vicenza
SCADA – Pot Furnace
Drive Centre Vicenza
Control Techniques IndiaControl Techniques India
Process Line : Continuous Galvanising LineCustomer : Flat Products Limited, IndiaEnd User : PT Essar Dhananjaya, IndonesiaContract value : US $ 630,000Project Team : Bhanuprakash + Ganesh + Satish
Process1. Strip is Acid cleaned, passed through
various parts of furnace to burn out oxygen
2. Temp. taken to 700 deg. and brought down to 400 deg for softening Strip and matching the Zinc temp.
3. Strip dipped in molten zinc4. During process, important to maintain
strip tension regulation to maintain Metallurgical characteristics of the strip
Drive Centre Vicenza
Control Techniques IndiaControl Techniques India
Scope of Supply: Drives, PLC & SCADA system
Mill Specification: Max. Speed: Entry & Exit : 190MPM Process: 160MPMMaterial Thickness Range : 0.16mm to 2.00mm
Material Width Range : 600mm to 1320mmFurnace Capacity: 25 Tons/ Hour
Process Line : Continuous Galvanising LineCustomer : Flat Products Limited, IndiaEnd User : PT Essar Dhananjaya, IndonesiaContract value : US $ 630,000Project Team : Bhanuprakash + Ganesh + Satish
Drive Centre Vicenza
P O W E R S U P P L Y D I S T R I B U T I O N
A C B( E D O )
V . S . S
K W H
P V 1
P A 1A
V
F U
A . S . S
F UP D B - 1
3 8 0 V ,2 . 5 M V A
A C B3 2 0 0 A( E D O )
H T P A N E L
A
A C B1 2 0 0 A
( M F )
M C C - 3 ( E X I T M C C )
A C B1 2 0 0 A
( M F )
C T I S C O P E
F P E S C O P E
F I X E D S P E E D A C M O T O R S
A
A C B1 2 5 0 A
( M F )
A
A C B1 0 0 0 A
( M F )
F I X E D S P E E D A C M O T O R S
M C C - 1 ( E N T R Y M C C )
A C B1 2 5 0 A
( M F )
M C C - 2 ( P R O C E S S M C C )
M C C B4 0 0 A
F R O M E M E R G E N C YS O U R C E F O R E M E R G E N C YS U P P L Y
C T I S C O P E
F P E S C O P E
C T I S C O P E
~
~
M C C B6 3 A
1 0 K V A U P SS Y S T E M
C T I S C O P E
U P S S Y S T E MG L O W H E A T E R
( 2 0 N o s . )
G L O W H E A T E RE M E R G E N C Y D R I V E S
E M E R G E N C Y , V A R I A B L ES P E E D A C M O T O R S ( 2 0 N o s . )
E M E R G E N C Y S U P P L Y
M C C B2 5 0 A
S F U6 3 A
F P E S C O P E
F P E S C O P E
A C B1 0 0 0 A
( M F )
M C C B4 0 0 A
C T I S C O P EC T I S C O P E
Drive Centre Vicenza
P O W E R S U P P L Y D I S T R I B U T I O N
V . S . S
K W H
P V 1
P A 1A
V
F U
A . S . S
F UP D B - 3
A C B3 2 0 0 A( E D O )
A C B( E D O )
3 8 0 V ,2 . 5 M V A
H T P A N E L
V E C T O R I N V E R T E R SA N D V A R I A B L E S P E E D
A C M O T O R S ( 1 1 N o s )
A
M C C B6 3 0 A
C T I S C O P E
L I N E D R I V E S - 1 : -
P A Y O F F # 1P A Y O F F # 2B R I D L E # 1 A , 1 B , 1 C & 1 DE N T R Y A C C U .B R I D L E # 2 A , 2 BF U R N A C E B R I D L E # A , B & C
M C C B6 3 0 A
V E C T O R I N V E R T E R SA N D V A R I A B L E S P E E DA C M O T O R S ( 2 2 N o s )
F P E
A C B1 6 0 0 A
( M F )
A
A C B1 6 0 0 A
( M F )
C T I S C O P E
L I N E D R I V E S - 2 : -
B R I D L E # 3 A , 3 BB R I D L E # 4 A , 4 B & 4 CB R I D L E # 5 A & 5 BB R I D L E # 6 A & 6 BE X I T A C C U M .B R I D L E # 7 A & 7 BR E C O I L E R
J E T C O O L E R H E A T E R S ( 3 N o s . ) &E X I T S E C T I O N H E A T E R S ( 3 N o s . )
A
M C C B4 0 0 A
M C C B4 0 0 A
H E A T E RC O N T R O L L E R S
C T I S C O P E
F P E S C O P E
A U X . V A R I A B L ES P E E D A C M O T O R S
A
A C B1 6 0 0 A
( M F )
A C B1 6 0 0 A
( M F )
C T I S C O P E
F P E S C O P E
A U X . D R I V E S : -
J E T A C T U A T I O N I N / O U T ( 4 )J E T A C T U A T I O N U P / D O W N ( 2 )A I R K N I F E B L O W E R ( 1 + 1 )C O O L I N G T O W E R B L O W E R ( 3 )B O O T R O L L E R ( 1 )J E T C O O L F A N ( 3 )O R G A N I C D R Y E RR E C I R C U L A T I O N B L O W E R ( 1 )
Drive Centre Vicenza
H M I F O R F U R N A C E
F I E L D B U S ( C T - N E T )
H A R D W A R E : -C P 5 6 1 1 ( D P / M P I )
S O F T W A R E : -W I N C C - R U N T I M E ( S C A D A )
E N G I N E E R I N G P C
H A R D W A R E : -C P 5 6 1 1 ( D P / M P I )P C I 2 0 ( D R I V E S )
S O F T W A R E : -W I N C C D E V E L O P M E N T ( S C A D A )S T E P 7 ( P L C )S Y P T ( D R I V E S A P P L I C A T I O N )C T - N E T B R O W S E R ( D R I V E P A R A M E T E R )
H U B
H U BF I E L D B U S ( C T - N E T )
F I E L D B U S ( C T - N E T )
D P M P I
P A Y O F F # 1 B R I D L E # 1 A B R I D L E # 1 B E N T R Y A C C . B R I D L E # 2 A B R I D L E # 2 B
B R I D L E # 4 A B R I D L E # 4 B B A C K U PR O L L T O P
B R I D L E # 5 A B R I D L E # 5 B
E X I T A C C . B R I D L E # 8 A B R I D L E # 8 B
B R I D L E # 5 C
B R I D L E # 7 B
H M I F O R L I N E
M P I D P
P A Y O F F # 2
P L C S 7 - 4 0 0 P L C S 7 - 3 0 0
B R I D L E # 7 A
R S - 4E N T R Y M C C
R E C O I L E R - 1
B R I D L E # 1 C B R I D L E # 1 D F U R N A C EB R I D L E # A
B A C K U PR O L L B O T .
B R I D L E # 6 BB R I D L E # 6 A
C H R O M A T EC O A T E RR O L L # 1
C H R O M A T EC O A T E RR O L L # 2
C H R O M A T EC O A T E RR O L L # 3
C H R O M A T EC O A T E RR O L L # 4
F U R N A C EB R I D L E # B
B R I D L E # 3 A B R I D L E # 3 B
R S - 2E X I T L I N E D R I V E S
UN
I S
P G
AT
EW
AY
UN
I S
P G
AT
EW
AY
UN
I S
P G
AT
EW
AY
P R O F I B U S P R O F I B U SP R O F I B U S
P R O F I B U S
P R O F I B U S
P R O F I B U S
PR
OF
I B
US
PR
OF
I B
US
H A R D W A R E : -C P 5 6 1 1 ( D P / M P I )
S O F T W A R E : -W I N C C - R U N T I M E ( S C A D A )
F I E L D B U S ( C T - N E T )
F U R N A C E P L CM A I N P L C + E N T R Y D R I V E S , R S - 1
G L O B A L D A T AC O M M U N I C A T I O N
R S - 6E X I T M C C
R S - 3A U X . D R I V E S
R S - 5P R O C E S S M C C
R S - 7C D # 1
R S - 8C D # 2
R S - 9C D # 3
R S - 1 1E N T R Y V A L V E S T A N D
R S - 1 0C D # 4
R S - 1 2P R O C E S S V A L V E S T A N D
R S - 1 3E X I T V A L V E S T A N D
R E C O I L E R - 2
Drive Centre Vicenza
S Y S T E M C O N F I G U R A T I O N
D E S K # 1 D E S K # 2 D E S K # 4
E N T R Y R I / O
M C C # 1 ( E n t r y )
P R O F I B U S
M
M A I N P L CP L C S 7 - 4 0 0
E N G I N E E R I N G P C( D R I V E S & P L C )
5 6 1 1
P R O C E S S R I / O E X I T R I / O
M P I
P L C S 7 - 3 0 0
D PM P I
M
F U R N A C E P L C
CTIU
20X
CON TR OL
TECHN IQ
UES
Default
Menu
Page
CT IU
20X
CONTROL
TECHNIQ
UES
Default
Menu
Page
D E S K # 3
CTIU
20X
CON TROL
TECHNIQ
UES
Default
Menu
Page
M C C # 3 ( E x i t )
L I N E D R I V E S - 2L I N E D R I V E S - 1
H M I
5 6 1 1
H M I F O RL I N E
A U X I L I A R Y D R I V E S
D P
GLO
BA
L D
ATA
CO
MM
UN
ICA
TIO
N
C T N E T
M C C # 2 ( P r o c e s s )
M
PRO
FIB
US
P R O F I B U S
P R O F I B U S P R O F I B U S
PRO
FIB
US
P R O F I B U S
C P US 7 4 1 4 - 2 D P
P C I 2 0
C T N E T
PRO
FIB
US
R S 4
R S 5 R S 6
R S 1 R S 2
R S 7 R S 8 R S 9 R S 1 0
P A Y O F F # 1P A Y O F F # 2B R I D L E # 1 A , 1 B , 1 C & 1 DE N T R Y A C C U .B R I D L E # 2 A , 2 BF U R N A C E B R I D L E # A , B & C
R S 1 2 R S 1 3R S 1 1
HUB
U N I S PG A T W A Y
PRO
FIB
US
PRO
FIB
US
R S 3
P R O F I B U S
E M E R G E N C Y D R I V E S &G L O W H E A T E R S
H E A T E R C O N T R O L L E R S
M
Drive Centre Vicenza
Jet Act Up/Down # 2
4 kw - SE
Exit Accumulator
55kw – Uni 4402
Bridle # 4A
45kw – Uni 4401
LINE DRIVES
Jet Act Up/Down # 1
4 kw - SE
Bridle # 7B
55 kw – Uni 4402
Bridle # 3B
37kw – Uni 3405
SCADA – 2 sets 1024 tags
Win CC Version 6.0
Air Knife blower # 2
110kw – Uni 5402
Bridle # 7A
75 kw – Uni 4403
Bridle # 3A
37kw – Uni 3405
Gate way Module – 3 sets UniSP + SM Application + SM Profibus
Air Knife blower # 1
110kw – Uni 5402
Chromate Coater # 4
18.5kw – Uni 3402
Furnace Bridle C
30 kw – Uni 3404
PLC : Siemens S 7 - 400
S7 - 300
Cooling Tower Blower # 1
55kw – Uni 4403
Chromate Coater # 3
18.5kw – Uni 3402
Furnace Bridle B
18.5kw – Uni 3403
Total Drives – 38 Uni Drives – 14 SE Drives
Cooling Tower Blower # 1
55 kw – Uni 4403
Chromate Coater # 2
18.5kw – Uni 3402
Furnace Bridle A
5.5kw – Uni 2402
Cooling Tower Blower # 1
90 kw – Uni 4404
Chromate Coater # 1
18.5kw – Uni 3402
Bridle # 2B
30kw – Uni3404
Hearth Roll Drive # 2
18.5kw - SE
NOF Flue Exhaust Blower
37 kw – SE
Bridle # 6B
132 kw – Uni 5402
Bridle # 2A
30kw – Uni3404
Hearth Roll Drive # 1
18.5kw - SE
Jet Cool Fan # 1
37 kw - SE
Bridle # 6A
200 kw – Uni 5401
Entry Accululator
45kw – Uni4401
Entry Seal Roll
11kw – SE
Jet Cool Fan # 1
37 kw - SE
Bridle # 5C
90 kw – Uni 4404
Bridle # 1D
18.5 kw - Uni 3403
Boot Roll
7.5kw – SE
Jet Cool Fan # 1
37 kw - SE
Bridle # 5B
132 kw – Uni 5403
Bridle # 1C
18.5 kw - Uni 3403
Jet Act In/Out # 4
1.1kw SE
FURNACE DRIVESBridle # 5A
75 kw – Uni 4403
Bridle # 1B
15kw - Uni 3401
Jet Act In/Out # 3
1.1kw SE
Recoiler
400kw – Uni 5403
Backup Roll – Top
160kw – Uni 5401
Bridle # 1A
15kw - Uni 3401
Jet Act In/Out # 2
1.1kw SE
Bridle # 8B
55 kw – Uni 4402
Backup Roll-Bot
160kw – Uni 5401
Pay Off # 2
110kw – Uni 4404
Jet Act In/Out # 1
1.1kw SE
Bridle # 8A
37 kw – Uni 3405
Bridle # 4B
55 kw – Uni 4402
Pay Off # 1
110kw – Uni 4404
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Textile IndustryTextile IndustryCustomersCustomers
• TEXMACO, CALCUTTA
• SUSSEN ASIA, PUNE
• RAJASTHAN TEXTILE, BILWARA
• MOTEX ENGG. AHMEDABAD
• SANMARCO TEXMAC, COIMBATORE
• OSWAL CHEMICALS
• DRIVES UNIDRIVE & GP DRIVES DIGITAX DRIVES,UNIMOTORS
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Material Handling IndustryMaterial Handling IndustryCustomersCustomers
• CONVEYORS Salem Steel PlantWebb India
TISCO, Jamshedpur
• HOIST & CRANES Salem Steel Plant
TISCO, Jamshedpur Telco, Pune
Rain Calcining, Vizag DRDL
• DRIVES UNIDRIVES
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Food & Beverages IndustryCustomers
•COCA COLA
•PEPSICO
•PARLE INDUSTRIES
•MOHAN MEAKINS
•CADBURY INDIA
•NESTLE
•INDIAN DAIRY (AMUL)
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Fiber IndustryFiber IndustryCustomersCustomers
• Application PFY & PSF Plants
• Customers Terene Fibres Ltd Reliance Industries
Indian Acrylics IPCL
Orissa SyntheticsShreeram Fibre
Grasim Industries Indian Organic Chemicals
• Drives Digital DC / AC Drives Systems
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Tyre IndustryTyre IndustryCustomersCustomers
• Customer BALKRISHNA TYRES,AURANGABAD
• Applications 6’’ EXTRUDER LINE(8 DRIVES)
8’’ EXTRUDER LINE(8
DRIVES) CALENDER LINE (9
DRIVES) TYRE BUILDING M/C DRIVES
• Drives Digital DC / AC Drives Systems
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Tyre IndustryTyre IndustryCustomersCustomers
• Customer GOVIND RUBBER, DELHI
• Applications 6’’ EXTRUDER LINE(8 DRIVES)
8’’ EXTRUDER LINE(8
DRIVES) MIXER-170 LITRES
MIXER-210 LITRE
» BIAS CUTTERS
• Drives Digital DC / Servo Drives Systems
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Tyre IndustryTyre IndustryCustomersCustomers
• Customer CORNELL INTERNATIONAL,MUMBAI
• Applications 210 LITRE MIXER FOR
ELASTOMERIC ,SRILANKA
• Drives Digital DC / Servo Drives Systems
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Crane Reference ListIndustry Application Description Customer CT System Supplied
Cranes Gantry Cranes Atelier du Loir - Belgium Vector with IN32 ( 11 - 30kW )Cranes Gantry Cranes Tai York Cranes - Taiwan 59 x Vector (22kW)Cranes 50 Ton Harbour Jib Tonsberg Harbour - Norway Vector (2 x 75kw plus Regen) Unidrive (90,45,37kw)Cranes Container Cranes E.C.T - Rotterdams - Netherlands 1x Mentor DC M350R + system : 150kWCranes Container Cranes Dockwise - Rotterdam - Netherlands 6 x Flux Vector inverters V2200.: 22kWCranes Container Cranes Tonsberg Haavnevesen(Tongsberg Hoist:2x 75kW Vector in parallel.
Boom: 75kW Unidrive in closed loop vector.Slewing: 30kW Unidrive in open loop vectorTraverse: 45kW Unidrive in open loop vector
Cranes EOT Gresse Kranbau Wittenberg - Mentor II Vector & CDECranes EOT Krupp Industreitechnik GmbH - VectorCranes EOT Liebherr GmbH - Germany Mentor II & Vector (x10)Cranes Rubber Tyred Gantry Electruck - Sydney, Australia Vector (5 x 150kW) CDE(x10) with MD29Cranes Aluminium Mill Anode Pechiney - Netherlands CD & V2200: 22kWCranes Freighter Winch Drives Canal Marine - USA Mentor II (x 2) with MD21Cranes Barge Handling Winches DeMar Engineering - USA 75kW VectorCranes Hoist, Long Travel, Cross BHP, Kamataka - Wollongong, Unidrive (200kW 4x30kw 2x15kw)Cranes Ocean Cable Laying Dowty Aerospace - Wolverhampton, Mentor II (3 x 100hp)Cranes Container Cranes Australian Electrical Services - Perth, Mentor II &CDECranes Rubber Tyred Gantry Australian Stevedores - NSW, Mentor IICranes Rubber Tyred Gantry Australian Winch & Haulage - NSW, Mentor IICranes Parrachute Drop Australias Wonderland - NSW, Mentor II & VectorCranes Rubber Tyred Gantry CTAL (National Terminals) - NSW, Mentor IICranes Container Cranes Favell Favco - NSW, Australia 30 - 75kW VectorCranes Gantry Cranes Lloyds British - NSW, Australia Mentor IICranes Automated Warehousing Mannesmann Demag - NSW, Mentor IICranes Container Cranes Perini, Scott and Masterman - NSW, Mentor IICranes Special Hoisting Powerlec - NSW, Australia 75kW Vector Cranes Gantry Cranes W & B Engineering - NSW, Australia 30 - 75kW VectorCranes Gantry Cranes W & D Engineering - Victoria, Australia 75kW VectorCranes Hoist and Long Travel The Steel Authority Of India - India Unidrive (2 x 75kW (H) + 1 x 75kW (LT) + 1 x 15kW (CT)Cranes Auto Crane Warehouse Cadbury - Victoria, Australia (via Mentor II with MD21Cranes Auto Crane Warehouse United Distillers - Sydney, Australia Mentor I with MD21Cranes Smelter Lance Controls Elsag Bailey - Burlington - Ontario, 75kW x 2, 150kW x 1 Cranes Mine Hoists Hepburn Engineering Inc. - Ontario, Mentor II with MD29Cranes Container Cranes Zhenhua Port Machinery Co - China Unidrive 5 (3 x Parallel) with UD70 - 400kW * 2 SetsCranes Container Cranes Zhenhua Port Machinery Co - China Unidrive 5 (5 x Parallel) with UD70 with Regen. - 530kW * 9 Sets
Closed Loop Flux Vector
Above List does not include Material Handling , Pick & Place Automation & Automobile Sectors
Proven Flux Vector Technology
Sample CT ReferencesSample CT References
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CT India References High Performance Crane / MH Drive systems – Sample ListCT India References High Performance Crane / MH Drive systems – Sample List
• Salem Steel Plant – Outdoor Gantry Crane Salem Steel Plant – Outdoor Gantry Crane – - Hoist - 75kW with Regen + LT – 75kW + CT – 15kW + Radio Remote- Hoist - 75kW with Regen + LT – 75kW + CT – 15kW + Radio Remote
• Rain Calcining, Vizag – Outdoor Gantry Crane Rain Calcining, Vizag – Outdoor Gantry Crane – - Hoist 30kW + Aux. Hoist – 15kW + LT – 7.5kW + CT – 4kW + Radio Remote- Hoist 30kW + Aux. Hoist – 15kW + LT – 7.5kW + CT – 4kW + Radio Remote
• L&T-ECCL&T-ECC Highway Construction CranesHighway Construction Cranes
• Neyveli Lignite – Rotary Kiln applicationNeyveli Lignite – Rotary Kiln application– 37kW Drive + Inv. Grade Motors37kW Drive + Inv. Grade Motors
• Chennai Port Trust – Wagon Tippler, Feeder & Conveyor Drives Chennai Port Trust – Wagon Tippler, Feeder & Conveyor Drives » Upto 200kW regenUpto 200kW regen
• - EOT Cranes- EOT Cranes
• Mahindra – Synchronized Hoists for Scorpio Manufacturing Line Mahindra – Synchronized Hoists for Scorpio Manufacturing Line » – – 32 Nos. UNiDrive SP with Position Control Loop32 Nos. UNiDrive SP with Position Control Loop
• TELCO – Synchronized Hoists for Indica Manufacturing Line TELCO – Synchronized Hoists for Indica Manufacturing Line » – – 32 Nos. UNiDrives with Position Control Loop32 Nos. UNiDrives with Position Control Loop
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CT India Sample References High Performance Drive SystemsCT India Sample References High Performance Drive Systems
• BHEL Trichy – 3-Axis Servo system for Double Column Planing machineBHEL Trichy – 3-Axis Servo system for Double Column Planing machine
• BHEL Bhopal – 4-Axes FNC Controller for Milling Machine RetrofitBHEL Bhopal – 4-Axes FNC Controller for Milling Machine Retrofit
• BHEL Hyderabad - 4-Axes FNC Controller for Milling Machine RetrofitBHEL Hyderabad - 4-Axes FNC Controller for Milling Machine Retrofit
• BHEL Hardwar – Vertical Lathe Servo upgradeBHEL Hardwar – Vertical Lathe Servo upgrade
• HAL Koraput– HAL Koraput– 528kW AC Drive – Motor system 528kW AC Drive – Motor system for Sukhoi Engine Test Jigfor Sukhoi Engine Test Jig
• HAL Engine Division – 5-Axis Controller for Sunstrand machineHAL Engine Division – 5-Axis Controller for Sunstrand machine
• HAL Helicopter Division – 4 Axes Controller for Spiramatic Jig MillHAL Helicopter Division – 4 Axes Controller for Spiramatic Jig Mill
• NAL – NAL – 120kW 120kW Low Speed Wind Tunnel for Boeing components (4 nos.)Low Speed Wind Tunnel for Boeing components (4 nos.)
• Triveni Engineering – Triveni Engineering – 750kW DC Drive System 750kW DC Drive System for High Speed Gear Box Testingfor High Speed Gear Box Testing
• Cornell Industries, Sri Lanka - Cornell Industries, Sri Lanka - 750kW, 12 pulse 750kW, 12 pulse for Rubber Mixer Automationfor Rubber Mixer Automation
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CT India Retrofit BusinessCT India Retrofit Business
• Binjirajka Steel, Hyderabad – 13 Section Rolling Mill Mentor Retrofit (Upto Binjirajka Steel, Hyderabad – 13 Section Rolling Mill Mentor Retrofit (Upto 1200kW)1200kW)
• Ballarpur Industries – Yamunanagar – 21-section L&T Sectional Drive System Ballarpur Industries – Yamunanagar – 21-section L&T Sectional Drive System Retrofit with Hi-Speed CT NetRetrofit with Hi-Speed CT Net
• Servall Board Project – 21 Section Asea Retrofit with Mentor II & MD-29Servall Board Project – 21 Section Asea Retrofit with Mentor II & MD-29
• SPB, Erode – Rewinder-cum-Unwinder Brake Generator Retrofit of Stromberg SPB, Erode – Rewinder-cum-Unwinder Brake Generator Retrofit of Stromberg DC System with AutomationDC System with Automation
• Pennar Industries, Hyderabad: Over 8 projects (Slitter / Mill / Cut-To-Length Pennar Industries, Hyderabad: Over 8 projects (Slitter / Mill / Cut-To-Length with Automation)with Automation)
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150kW Coiler Analog Drive Power+Controls
(2 Panels + Winder Control thru PLC)
150kW Coiler Digital Drive Power+Controls + Winder Software Loop within Drive
(1 Panel + less components+ less wiring)
DC Drive Retrofit ExampleDC Drive Retrofit Example
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CT India Sample ReferencesCT India Sample ReferencesHigh Performance Drive systemsHigh Performance Drive systems
• Sugar IndustrySugar Industry• 160kW Centrifuge Systems (160kW Centrifuge Systems (350 nos. supplied/commissioned in India350 nos. supplied/commissioned in India))
• AutomotivesAutomotives• MICO High Performance Testing MICO High Performance Testing – Over 500 Nos. AC Drives – Over 500 Nos. AC Drives • Lucas TVS– over 50 High Performance AC Drive – Motor systems for SPM’sLucas TVS– over 50 High Performance AC Drive – Motor systems for SPM’s• Ford IndiaFord India• Hyundai Motor IndustriesHyundai Motor Industries• MahindraMahindra• TELCOTELCO• EscortsEscorts• GoetzeGoetze• Delphi TVSDelphi TVS• VisteonVisteon
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Box Wagon - Fine
0
600
600
600
600
350
350
600
600
0 0
-650
-650
-350
-350
-650
-650
-350
-350
00 9 1818 50 63 70 83
150
150
150
143
70
545045
20
4 00
-700
-500
-300
-100
100
300
500
700
0 10 20 30 40 50 60
Time
An
gle
/ S
peed
Speed Angle
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Understanding the Understanding the Common DC Bus ConceptCommon DC Bus Concept
For AC Drive SystemsFor AC Drive Systems
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Drive System ConfigurationDrive System Configuration
Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR R
Brake
ChopperResistorResistor
2000A
CT-NetCT-Net
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Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Rectifier Unit
6-Pulse Full wave Rectifier
Low Input Harmonics
Power Factor > 0.95
12-pulse configuration can be offered as optional
2000A
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Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Common DC Bus
Connected to the UniDrive this configuration gives best performance in terms of sharing of Energy between the AC Drives
Regenerated / Braking Energy from one drive is re-used by another motoring drive
Motoring Drive draws less power from Mains.
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Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Charging Circuit
Allows re-connection of any inverter to the already running system
This pre-charging is a must. The charging resistor comes into the picture initially, allows the DC Link capacitors within the inverters to reach required potential before the pulses are allowed to fire the IGBTs.
It gets disconnected, once this procedure is safely completed.
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Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
UniDrive
Fully Digital
IGBT Controlled
Micro-processor based
On-Board 2nd processor for Real Time processing of application programs
High Speed Communication
Field-Bus Connectivity
All Real Time calculations like Diameter Computation, Tension Regulation, Accumulator Position control etc in 2nd processor
Master Line Speed generation within the Drive System
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Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Brake Chopper
During the Braking phase, AC Motors give energy to DC Bus.
If DC Bus Voltage exceeds 560V, IGBT-based Chopper gets automatically energized & the DC Bus voltage is kept around 600V
The Brake Chopper has an in-built PI controller, allowing for controlled & smooth braking
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Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR R
Regenerative Drive
Trafo Elevatore 400V/660V
Alternative DC Bus ConfigurationAlternative DC Bus ConfigurationUsing Mentor II Converter
When the DC Bus Voltage increases beyond 600V, the regenerative Mentor II converter is energized.
This returns the regenerated energy to the Mains thru a Step-up Transformer back to Mains.
This configuration will also keep the DC Bus around 600V
Advantages:
No wastage of regenerative energy in the resistor
Disadvantage:
High Cost
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Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR R
Alternative DC Bus ConfigurationAlternative DC Bus ConfigurationUsing 12-Pulse Configuration
Features Double Secondary Transformer, Phase Shifted at Input to Rectifier
Advantages:
Power Factor is near Unity for all load conditions
Very low Harmonics
YYYY
YY
IPTIPT
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Major Approvals Major Approvals
• MECON
• HEC, RANCHI
• TATA STEEL (TISCO, JAMSHEDPUR)
• NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LTD.
• ERCOM ENGINEERS PRIVATE LIMITED NEW DELHI.
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SummarySummary• We have TechnologyWe have Technology
• We have ProductsWe have Products
• We have Financial StrengthWe have Financial Strength
• We have ExperienceWe have Experience
• We have Application ExpertiseWe have Application Expertise
• We can deliver large Systems in stipulated time limitsWe can deliver large Systems in stipulated time limits
• We can commission Systems very fast We can commission Systems very fast
• It will be a privilege for Control Techniques India to It will be a privilege for Control Techniques India to have continued association with TATAhave continued association with TATA
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PULPITROOM
HEAD
FURNACEELOGATION
MACHINE
M E N T O R I IE L E C T R O N I C S
CONVEYOR
RED HOT CYLINDER
RED HOT CYLINDER
RED HOT CYLINDER
RED HOT CYLINDER
RED HOT CYLINDERMANDREL
RED HOT CYLINDER
PUSH BENCH
MOTOR
ENCODER
CAM
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PUSH SPEED
THREAD SPEED
THREAD END
FAST ACCELERATION
HOME
SPEED PROFILE FOR PUSH BENCH DRIVE
HOME
RETURN POINT
6 Meters / Sec
30 Meters
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Thank You for your Kind Thank You for your Kind AttentionAttention
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