corporate presentation india

Drive Centre Vicenza

Welcomes You All Welcomes You All

Control Techniques IndiaControl Techniques India


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


Every Electric Motor is a Every Electric Motor is a Potential Application for Potential Application for

Control Techniques Control Techniques productsproducts


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)



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


• $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


Sales by Business GroupSales by Business Group$20 Billion Total$20 Billion Total

Appliance & Tools23%

Electronics & Telecommunications

15%

Process Control21%

HVAC17%

Industrial Automation24%


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


Distributed Control

Motors / Alternators Products

Drives & Automation


United KingdomUnited KingdomNewtown, WalesNewtown, Wales

London

Headquarters R&D

Manufacturing Plant


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


Product PortfolioProduct Portfolio

General Purpose AC DrivesDC Drives

Cabinet Free AC Drives

Energy Saving Drive

High Performance AC Drives Motion Motion

ControllerController


Product PortfolioProduct Portfolio

Networking And SoftwareProducts

Soft StartersSoft Starters Servo MotorsServo Motors

CTIU 200

OPERATOR INTERFACE


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


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


Worldwide Operations

EUROPEEUROPE

ASIA PACIFICASIA PACIFIC

AMERICASAMERICAS


Drive Centres in North AmericaDrive Centres in North America

Chicago

Toronto

Providence

Charlotte

Cleveland

Distributors S.America

Minneapolis (Head Office)

Dallas


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)


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


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


HIGHHIGH

PERFORMANCEPERFORMANCE

INTELLIGENT DRIVESINTELLIGENT DRIVES

FORFOR

SYSTEMSSYSTEMS


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


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


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


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


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)


The most versatile DC systems drive in the world

More than 3000 drives in India

More than 125,000 drives in use world-wide


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)


UnidriveUnidrive

Unified AC Drive with Solution PlatformUnified AC Drive with Solution Platform


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


UniSP – The Universal Drive With Solution PlatformUniSP – The Universal Drive With Solution Platform


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


• 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


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


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


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


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


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


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


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


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


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


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


Field Bus ConnectivityField Bus Connectivity

Modules are available for

Modbus RTU ProfibusDeviceNetCANopenInterbus SSercos EthernetCTNet,

RS485 PortModbus (RTU or ASCII)

Johnson Controls (Metasys)CSI


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)


DRIVE PROGRAMMINGDRIVE PROGRAMMING


Application ProgrammingApplication Programming

SyPT PROSyPT PRO

• Industrial NetworkingIndustrial Networking

• Realtime MultitaskingRealtime Multitasking

• Confirms to IEC 61131-3Confirms to IEC 61131-3


Programming ToolProgramming Tool


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


Configuration EditorConfiguration Editor

• Project Oriented.

• Configuration of:-– Distributed CTNet SystemsDistributed CTNet Systems

OPC Server availableOPC Server available..


DPL EditorDPL Editor

• Drive Prog Language(Quick Basic)

• Standard constructs like IF, THEN,ELSE as well as Loops


Quick Ladder EditorQuick Ladder Editor

• Compliant to -61131

• Quick development of boolean and function block ladder diagrams.


Function Block EditorFunction Block Editor

• Compliant to -61131

• Library of more than 256 Function Blocks.

• Can create additional Function Blocks


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


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.


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.


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


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


Control Techniques are the Control Techniques are the preferred Suppliers to…preferred Suppliers to…


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


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


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)


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


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)


Steel IndustrySteel IndustrySkin Pass MillSkin Pass Mill

• Essar Steel, Indonesia

• Kandil Steels, Egypt

• KYCR Steel, Bangladesh

• SPSL, Pune

• Balco(Slab)


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


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


Steel IndustrySteel IndustryPickling Line / Cleaning LinePickling Line / Cleaning Line

• Jai Corp

• Meta Strips

• S Alam , Bangladesh

• Lloyds Steel

• Essar, Hazira


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


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


Steel Industry Steel Industry Rewinding Line Rewinding Line

PT Essar, Indonesia

SPSL,Pune

S ALAM, Bangladesh(Thru’ Multiform)


Steel Industry Steel Industry TLL TLL

PT Essar, Indonesia

SPSL,Pune

Jai Corp, Nanded

Mobati Steels, Kenya

Multiform(at Malaysia)


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


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


CRANES CRANES

• SALEM STEEL PLANT

• TATA STEEL

• TATA MOTORS , PUNE

• RANK CRANES, HYDERABAD ETC


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


Steel IndustrySteel IndustryCold Rolling MillsCold Rolling Mills

• Tube Products of India

• Shamon Ispat Ltd

• Meta Strips


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


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


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


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



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



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



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


Steel Industry Hot Mills Steel Industry Hot Mills Sumangala Steel Sumangala Steel


• Main stand : 6 x 200 Kw

• Coiler : 2 x 15 Kw

• Pinch Roll : 2 x 15 KW

• PLC : S 135



Steel Industry Hot MillsSteel Industry Hot MillsIndo Baja - Indonesia Indo Baja - Indonesia


• Main stand : 3 x 400 Kw

• PLC : S 135



How have we been sustaining this Success –How have we been sustaining this Success – Year after Year?Year after Year?


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


INTELLIGENCE INTELLIGENCE

IN IN

DRIVESDRIVES


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


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


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


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!!


How about the Control Techniques How about the Control Techniques Approach?Approach?


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


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.


INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVESC.T. ApproachC.T. Approach

Add-On Co-Processor Add-On Co-Processor Card for Mentor IICard for Mentor II


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


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.


From revolution to evolutionFrom revolution to evolution


Hardware EvolutionHardware Evolution

MD21

MD29

UD70

MD29AN

UD75SM-Applications

1st Generation 2nd Generation 3rd Generation


Software EvolutionSoftware Evolution

Terminal Window DPL Toolkit

SyPT V1

1st Generation 2nd Generation 4th Generation3rd Generation


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


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


Example Line Configuration Example Line Configuration


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


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



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


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


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.



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.



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.


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.



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.



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



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



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


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


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 )


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 )


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



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



• 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


• 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


• 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.


• 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.


• 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


• 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.



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


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.


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


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


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


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


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


F U

K M 1 K M 2

L C 1

B R2 0 0 0 A


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



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 340430.0Furnace Bridle C12

~UNI 340318.5Furnace Bridle B11

~UNI 24025.5Furnace Bridle A10

~UNI 340430.0Bridle # 2B9


Apps. Module

Drive Rating

Motor RatingDescriptionSr.No



~UNI 440255.0Bridle # 7B29


~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 440490.0Bridle # 5C21

~UNI 5401132.0Bridle # 5B20


Apps.Module

Drive Rating

MotorRatingDescriptionSr.No

Process Section Drives (2 of 2)



UD75UNI 5403400.0Recoiler33

UD75UNI 440255.0Bridle # 8B32

~UNI 340537.0Bridle # 8A31

UD75UNI 440255.0Exit Accumulator30

Apps.Module

Drive Rating

MotorRatingDescriptionSr.No

Exit Section Drives


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


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




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



37 KW - SE37 KWNOF flue Exhaust Blower4

37 KW - SE22 KWJet Cool Fan # 33




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


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


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


A 1 B 1 S B 2A 2

E N T R Y C DR S # 7



A 1 B 1 S B 2A 2

E N T R Y F I E L DR S # 1 2 ( 1 / 1 )



A 1 B 1 S B 2A 2

E N T R Y F I E L DR S # 1 2 ( 0 / 1 )



A 1 B 1 S B 2A 2

E N T R Y M C CR S # 4



A 1 B 1 S B 2A 2

P R O C E S S M C CR S # 5



A 1 B 1 S B 2A 2

F U R N A C E P L CR A C K # 4 / 4



A 1 B 1 S B 2A 2




A 1 B 1 S B 2A 2




A 1 B 1 S B 2A 2




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


A 1 B 1 S B 2A 2

M P IA D D R E S S : 5


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


A 1 B 1 S B 2A 2

M P I A D D R E S S : 2


A 1 B 1 S B 2A 2

E N T R Y D R I V E SR S # 1



A 1 B 1 S B 2A 2

A U X D R I V E SR S # 3 ( 0 / 2 )



A 1 B 1 S B 2A 2

A U X D R I V E SR S # 3 ( 1 / 2 )



A 1 B 1 S B 2A 2

A U X D R I V E SR S # 3 ( 2 / 2 )



A 1 B 1 S B 2A 2

P U L P I T C DR S # 8



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 )



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 )


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


A 1 B 1 S B 2A 2

S P M C DR S # 9



A 1 B 1 S B 2A 2

S P M C D - E S A



A 1 B 1 S B 2A 2

T L L C DR S # 1 0



A 1 B 1 S B 2A 2

T L L C D - E S A



A 1 B 1 S B 2A 2

E X I T M C CR S # 6



A 1 B 1 S B 2A 2

E X I T D R I V E SR S # 2



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


A 1 B 1 S B 2A 2

G A T E W A Y( P R O C E S S )



A 1 B 1 S B 2A 2

G A T E W A Y( E N T R Y )



A 1 B 1 S B 2A 2

E X I T F I E L DR S # 1 4



A 1 B 1 S B 2A 2

E X I T C DR S # 1 1



A 1 B 1 S B 2A 2

E X I T C D - E S A


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


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



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


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.


SCADA – Line Overview


SCADA – Entry Section


SCADA – Process Section


SCADA – Exit Section


SCADA – Furnace Section


SCADA – PHF Burner Controls


SCADA – PHF PID Settings


SCADA – Pot Furnace



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



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



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



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 )


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 )


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 )


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




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


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 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


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


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


55 kw – Uni 4403

Chromate Coater # 2

18.5kw – Uni 3402

Furnace Bridle A

5.5kw – Uni 2402


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


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


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


Food & Beverages IndustryCustomers

•COCA COLA

•PEPSICO

•PARLE INDUSTRIES

•MOHAN MEAKINS

•CADBURY INDIA

•NESTLE

•INDIAN DAIRY (AMUL)


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


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



• 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



• Customer CORNELL INTERNATIONAL,MUMBAI

• Applications 210 LITRE MIXER FOR

ELASTOMERIC ,SRILANKA

• Drives Digital DC / Servo Drives Systems


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


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


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


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)


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


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


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


Understanding the Understanding the Common DC Bus ConceptCommon DC Bus Concept

For AC Drive SystemsFor AC Drive Systems


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



COMMON DC-BUS 560V

RRR

DC Bus ConfigurationDC Bus Configuration

R

Brake


Rectifier Unit

6-Pulse Full wave Rectifier

Low Input Harmonics

Power Factor > 0.95

12-pulse configuration can be offered as optional

2000A



COMMON DC-BUS 560V

RRR


R

Brake


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.



COMMON DC-BUS 560V

RRR


R

Brake


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.



COMMON DC-BUS 560V

RRR


R

Brake


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



COMMON DC-BUS 560V

RRR


R

Brake


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



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



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


Major Approvals Major Approvals

• MECON

• HEC, RANCHI

• TATA STEEL (TISCO, JAMSHEDPUR)

• NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LTD.

• ERCOM ENGINEERS PRIVATE LIMITED NEW DELHI.


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


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


PUSH SPEED

THREAD SPEED

THREAD END

FAST ACCELERATION

HOME

SPEED PROFILE FOR PUSH BENCH DRIVE

HOME

RETURN POINT

6 Meters / Sec

30 Meters


Thank You for your Kind Thank You for your Kind AttentionAttention

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