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Drive Centre Vicenza Welcomes You All Welcomes You All Control Techniques Control Techniques India India

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Page 1: Corporate Presentation India

Drive Centre Vicenza

Welcomes You All Welcomes You All

Control Techniques Control Techniques IndiaIndia

Page 2: Corporate Presentation India

Drive Centre Vicenza

Founded in 1973 Founded in 1973 CT is a world leader CT is a world leader

in the in the Design,

Manufacture, Marketing and Application of….

AC & DC Drives, Servo Drives

Systems

Page 3: Corporate Presentation India

Drive Centre Vicenza

Every Electric Motor is Every Electric Motor is a Potential a Potential

Application for Control Application for Control Techniques productsTechniques products

Page 4: Corporate Presentation India

Drive Centre Vicenza

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 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)

Page 5: Corporate Presentation India

Drive Centre Vicenza

Control Techniques IndiaControl Techniques India

CT India started in 1993CT India started in 1993

CT India is a fully owned subsidiary of CT India is a fully owned subsidiary of CT-Worldwide (CT - UK)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

Page 6: Corporate Presentation India

Drive Centre Vicenza

Page 7: Corporate Presentation India

Drive Centre Vicenza

• $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 Strong International presencepresence

• Solid financial positionSolid financial position

Page 8: Corporate Presentation India

Drive Centre Vicenza

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

Appliance & Tools23%

Electronics & Telecommunications

15%

Process Control21%

HVAC17%

Industrial Automation24%

Page 9: Corporate Presentation India

Drive Centre Vicenza

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

Page 10: Corporate Presentation India

Drive Centre Vicenza

Distributed Control

Motors / Alternators

Products

Drives & Automation

Page 11: Corporate Presentation India

Drive Centre Vicenza

United KingdomUnited KingdomNewtown, WalesNewtown, Wales

London

Headquarters R&D

Manufacturing Plant

Page 12: Corporate Presentation India

Drive Centre Vicenza

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 World Class Drive Manufacturing FacilitiesManufacturing Facilities

Page 13: Corporate Presentation India

Drive Centre Vicenza

Product PortfolioProduct Portfolio

General Purpose AC DrivesDC Drives

Cabinet Free AC Drives

Energy Saving Drive

High Performance AC Drives Motion Motion

ControllerController

Page 14: Corporate Presentation India

Drive Centre Vicenza

Product PortfolioProduct Portfolio

Networking And SoftwareProducts

Soft StartersSoft Starters Servo MotorsServo Motors

CTIU 200

OPERATOR INTERFACE

Page 15: Corporate Presentation India

Drive Centre Vicenza

Digital DC / AC Digital DC / AC DrivesDrives

MentorMentor : Digital DC : Digital DC 7.5 Kw to 750 7.5 Kw to 750 KwKw

Commander SK : Simple ,Knowledge 0.25 Kw to Commander SK : Simple ,Knowledge 0.25 Kw to 110Kw 110Kw

Unidrive SP : Solution Platform 0.75 Kw to Unidrive SP : Solution Platform 0.75 Kw to 1.0 MW1.0 MW

PV /EV - Fans & Pumps 5.5 Kw to PV /EV - Fans & Pumps 5.5 Kw to 280 Kw280 Kw

Page 16: Corporate Presentation India

Drive Centre Vicenza

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 CT START - Soft Starters 4 to 800 Kw Kw

Unimotor - AC ServoUnimotor - AC Servo 1 to 70 1 to 70 NmNm

LSMVLSMV - Inverter Grade - Inverter Grade AC MotorsAC Motors 0.75 to 0.75 to

132 Kw132 Kw

SincrovertSincrovert - - AC Spindle Motors 0.75 to 110 AC Spindle Motors 0.75 to 110 Kw Kw

Page 17: Corporate Presentation India

Drive Centre Vicenza

Worldwide Operations

EUROPEEUROPE

ASIA PACIFICASIA PACIFIC

AMERICASAMERICAS

Page 18: Corporate Presentation India

Drive Centre Vicenza

Drive Centres in North AmericaDrive Centres in North America

Chicago

Toronto

Providence

Charlotte

Cleveland

Distributors S.America

Minneapolis (Head Office)

Dallas

Page 19: Corporate Presentation India

Drive Centre Vicenza

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)

Page 20: Corporate Presentation India

Drive Centre Vicenza

New Delhi Application CenterNew Delhi Application Center

Kolkata Application Center

Kolkata Application Center

Drive/Application Centers Drive/Application Centers

Indian OperationsIndian Operations

AhmedabadSales Office

AhmedabadSales Office

Pune Application CenterPune Application CenterChennai Drive CenterChennai Drive Center

Nagpur Sales OfficeNagpur Sales Office

Hyderabad Sales OfficeHyderabad Sales Office

Page 21: Corporate Presentation India

Drive Centre Vicenza

Control Techniques IndiaControl Techniques IndiaManufacturing & Support FacilitiesManufacturing & Support Facilities

Facilities / ExpertiseFacilities / ExpertiseTesting FacilitiesTesting Facilities

12,000 Sq. ft. Purpose built 12,000 Sq. ft. Purpose built factoryfactory

45 People ( of which 20 are 45 People ( of which 20 are Engineers) at ChennaiEngineers) at Chennai

15 People (of which 10 are 15 People (of which 10 are Engineers) in Branch OfficesEngineers) in 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 Complete Manufacturing facilities with Test Set Upwith Test 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 High Current Low Voltage Source for Load Testfor Load Test

Insulation Tester, High Voltage Insulation Tester, High Voltage Break Down TesterBreak Down Tester

Training / RepairTraining / Repair

CT Approved Training CentreCT Approved Training Centre

CT Approved Repair CentreCT Approved Repair Centre

Component Level Repair FacilityComponent Level Repair Facility

Page 22: Corporate Presentation India

Drive Centre Vicenza

Page 23: Corporate Presentation India

Drive Centre Vicenza

Page 24: Corporate Presentation India

Drive Centre Vicenza

Page 25: Corporate Presentation India

Drive Centre Vicenza

Page 26: Corporate Presentation India

Drive Centre Vicenza

Page 27: Corporate Presentation India

Drive Centre Vicenza

Page 28: Corporate Presentation India

Drive Centre Vicenza

Page 29: Corporate Presentation India

Drive Centre Vicenza

Page 30: Corporate Presentation India

Drive Centre Vicenza

Page 31: Corporate Presentation India

Drive Centre Vicenza

Page 32: Corporate Presentation India

Drive Centre Vicenza

Page 33: Corporate Presentation India

Drive Centre Vicenza

HIGHHIGH

PERFORMANCEPERFORMANCE

INTELLIGENT DRIVESINTELLIGENT DRIVES

FORFOR

SYSTEMSSYSTEMS

Page 34: Corporate Presentation India

Drive Centre Vicenza

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

Page 35: Corporate Presentation India

Drive Centre Vicenza

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

Page 36: Corporate Presentation India

Drive Centre Vicenza

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

Page 37: Corporate Presentation India

Drive Centre Vicenza

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

Page 38: Corporate Presentation India

Drive Centre Vicenza

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)

Page 39: Corporate Presentation India

Drive Centre Vicenza

The most versatile DC systems drive in the world

More than 3000 drives in India

More than 125,000 drives in use world-wide

Page 40: Corporate Presentation India

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)

CGEE ALSTOM CGEE ALSTOM

(FRANCE)(FRANCE)

Page 41: Corporate Presentation India

Drive Centre Vicenza

UnidriveUnidrive

Unified AC Drive with Solution PlatformUnified AC Drive with Solution Platform

Page 42: Corporate Presentation India

Drive Centre Vicenza

Application Type of Control What you get…

Fan/Pump / Conveyors V/f Open Loop

No Speed Loop

No Current Loop

Constant Torque Load Mostly O/L Vector Full Torque to 1 Hz

No Speed Loop

Good Current Loop

Cranes / Hoists

Process Lines

Sectional Drives

Closed Loop Flux Vector Full Torque upto Standstill

Excellent Speed & Current Loop

Very good Dynamic responses

Servo Applications Servo Full Torque upto Standstill

Excellent Speed, Current & Position Loop

Very good Dynamic responses

Page 43: Corporate Presentation India

Drive Centre Vicenza

UniSP – The Universal Drive With Solution UniSP – The Universal Drive With Solution PlatformPlatform

Page 44: Corporate Presentation India

Drive Centre Vicenza

The The UniSP UniSP Advantage Advantage

Single Drive from Simple to Complex Single Drive from Simple to Complex applicationsapplications

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

Page 45: Corporate Presentation India

Drive Centre Vicenza

• 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

Page 46: Corporate Presentation India

Drive Centre Vicenza

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

Page 47: Corporate Presentation India

Drive Centre Vicenza

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

Page 48: Corporate Presentation India

Drive Centre Vicenza

Ambient Ambient

40 Deg C 40 Deg C

1 % per Deg C deration for 1 % per Deg C deration for 40- 50 Deg C 40- 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

Page 49: Corporate Presentation India

Drive Centre Vicenza

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

Page 50: Corporate Presentation India

Drive Centre Vicenza

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

Page 51: Corporate Presentation India

Drive Centre Vicenza

Intelligent Options for AC Drives…Intelligent Options for AC Drives…

– Palm-sized Second ProcessorPalm-sized Second Processor

– Intel i960 32-bit RISC Intel i960 32-bit RISC processorprocessor

– With High-speed Fieldbus With High-speed Fieldbus ConnectivityConnectivity

– Programming in Ladder / Programming in Ladder / Function Blocks or ScriptFunction Blocks or Script

– Connects to Remote I/O BlocksConnects to Remote I/O Blocks

– Distributes Real Time ControlDistributes Real Time Control

Zero Zero Space Space PLCPLC

Plugs into Plugs into Drive Drive modulemodule

CalculatCalculatee

LogicLogic

ConnectConnect

SystemsSystems

Connect Connect I/OI/O

Page 52: Corporate Presentation India

Drive Centre Vicenza

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

Page 53: Corporate Presentation India

Drive Centre Vicenza

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

Page 54: Corporate Presentation India

Drive Centre Vicenza

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

Page 55: Corporate Presentation India

Drive Centre Vicenza

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

Page 56: Corporate Presentation India

Drive Centre Vicenza

Field Bus ConnectivityField Bus Connectivity

Modules are available for

Modbus RTU ProfibusDeviceNetCANopenInterbus SSercos EthernetCTNet,

RS485 PortModbus (RTU or ASCII)

Johnson Controls (Metasys)CSI

Page 57: Corporate Presentation India

Drive Centre Vicenza

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)

Page 58: Corporate Presentation India

Drive Centre Vicenza

DRIVE PROGRAMMINGDRIVE PROGRAMMING

Page 59: Corporate Presentation India

Drive Centre Vicenza

Application ProgrammingApplication Programming

SyPT PROSyPT PRO

• Industrial NetworkingIndustrial Networking

• Realtime MultitaskingRealtime Multitasking

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

Page 60: Corporate Presentation India

Drive Centre Vicenza

Programming ToolProgramming Tool

Page 61: Corporate Presentation India

Drive Centre Vicenza

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

Page 62: Corporate Presentation India

Drive Centre Vicenza

Configuration Configuration EditorEditor

• Project Oriented.

• Configuration of:-– Distributed CTNet SystemsDistributed CTNet Systems

OPC Server availableOPC Server available..

Page 63: Corporate Presentation India

Drive Centre Vicenza

DPL EditorDPL Editor

• Drive Prog Language(Quick Basic)

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

Page 64: Corporate Presentation India

Drive Centre Vicenza

Quick Ladder EditorQuick Ladder Editor

• Compliant to -61131

• Quick development of boolean and function block ladder diagrams.

Page 65: Corporate Presentation India

Drive Centre Vicenza

Function Block EditorFunction Block Editor

• Compliant to -61131

• Library of more than 256 Function Blocks.

• Can create additional Function Blocks

Page 66: Corporate Presentation India

Drive Centre Vicenza

Function BlocksFunction Blocks

• Standard Library– Floating Point & Integer Floating Point & Integer

Types.Types.– DPL commands, std DPL commands, std PLC PLC

functionsfunctions, Motion & , Motion & communication types.communication types.

– Maintained by SSPD.Maintained by SSPD.– Powerful:-Powerful:-

• Development.

• Modular

• Easy to Understand

• Common standard block

Page 67: Corporate Presentation India

Drive Centre Vicenza

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.

Page 68: Corporate Presentation India

Drive Centre Vicenza

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.

Page 69: Corporate Presentation India

Drive Centre Vicenza

Page 70: Corporate Presentation India

Drive Centre Vicenza

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

Page 71: Corporate Presentation India

Drive Centre Vicenza

Cranes

Fans & Pumps

Food and Drink

Material Handling

Metals & Metal FormingPaper

Printing

Rubber & Tyre

Stage Scenery

Textiles Wire Drawing

Industrial Sector Industrial Sector FocusFocus

Plastic

Oil & Gas

Page 72: Corporate Presentation India

Drive Centre Vicenza

Control Techniques are Control Techniques are the preferred Suppliers the preferred Suppliers

to…to…

Page 73: Corporate Presentation India

Drive Centre Vicenza

Control Techniques India is Preferred Control Techniques India is Preferred Supplier toSupplier 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

Page 74: Corporate Presentation India

Drive Centre Vicenza

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

Page 75: Corporate Presentation India

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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)

Page 76: Corporate Presentation India

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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 PCC+MCC+Drives( DC ) + LINE PLC + FURNACE PLC

+ SCADA +UPS + SCADA +UPS

Page 77: Corporate Presentation India

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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)

Page 78: Corporate Presentation India

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Steel IndustrySteel IndustrySkin Pass MillSkin Pass Mill

• Essar Steel, Indonesia

• Kandil Steels, Egypt

• KYCR Steel, Bangladesh

• SPSL, Pune

• Balco(Slab)

Page 79: Corporate Presentation India

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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

Page 80: Corporate Presentation India

Drive Centre Vicenza

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

Page 81: Corporate Presentation India

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Steel IndustrySteel IndustryPickling Line / Cleaning LinePickling Line / Cleaning Line

• Jai Corp

• Meta Strips

• S Alam , Bangladesh

• Lloyds Steel

• Essar, Hazira

Page 82: Corporate Presentation India

Drive Centre Vicenza

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

Page 83: Corporate Presentation India

Drive Centre Vicenza

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

Page 84: Corporate Presentation India

Drive Centre Vicenza

Steel Industry Steel Industry Rewinding Line Rewinding Line

PT Essar, Indonesia

SPSL,Pune

S ALAM, Bangladesh(Thru’ Multiform)

Page 85: Corporate Presentation India

Drive Centre Vicenza

Steel Industry Steel Industry TLL TLL

PT Essar, Indonesia

SPSL,Pune

Jai Corp, Nanded

Mobati Steels, Kenya

Multiform(at Malaysia)

Page 86: Corporate Presentation India

Drive Centre Vicenza

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

Page 87: Corporate Presentation India

Drive Centre Vicenza

Wire Rod Mills Wire Rod Mills • TAMILNADU STEEL, ARAKONAM

• NATIONAL ENGG, CHENNAI

• SUMANGALA STEEL, BHUVANGIRI

• INDO BAZHA , INDONESIA ETC

DC Drives (Stand ,Coilers) + PLC + AUTOMATIONDC Drives (Stand ,Coilers) + PLC + AUTOMATION

Page 88: Corporate Presentation India

Drive Centre Vicenza

CRANES CRANES

• SALEM STEEL PLANT

• TATA STEEL

• TATA MOTORS , PUNE

• RANK CRANES, HYDERABAD ETC

Page 89: Corporate Presentation India

Drive Centre Vicenza

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

Page 90: Corporate Presentation India

Drive Centre Vicenza

Steel IndustrySteel IndustryCold Rolling MillsCold Rolling Mills

• Tube Products of India

• Shamon Ispat Ltd

• Meta Strips

Page 91: Corporate Presentation India

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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

Page 92: Corporate Presentation India

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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

Page 93: Corporate Presentation India

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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

Page 94: Corporate Presentation India

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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

Page 95: Corporate Presentation India

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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Shamon Ispat Ltd A/c. Karnafully Steels- 4 Hi Shamon Ispat Ltd A/c. Karnafully Steels- 4 Hi MillsMills

• 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

Page 96: Corporate Presentation India

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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

Page 97: Corporate Presentation India

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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

Page 98: Corporate Presentation India

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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

Page 99: Corporate Presentation India

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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

Page 100: Corporate Presentation India

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How have we been sustaining this Success How have we been sustaining this Success ––

Year after Year?Year after Year?

Page 101: Corporate Presentation India

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The Driving Force behind our The Driving Force behind our success….success….

Application Specific Engineered Systems – We have Application Specific Engineered Systems – We have the Experience!the Experience!

Able to obtain the latest technology in Automation – Able to obtain the latest technology in Automation – No CompromisesNo Compromises

Product Leadership positionProduct Leadership position

Getting the most-up-to-date engineering design – Getting the most-up-to-date engineering design – Due to our Shared Resource NetworkDue to our Shared Resource Network

All our Drive products carry a Product Warranty for 2 All our Drive products carry a Product Warranty for 2 Years & your nearest Support Centre will honour all Years & your nearest Support Centre will honour all Warranty Commitments for supplies made to youWarranty Commitments for supplies made to you

Excellent and prompt after sales service support Excellent and prompt after sales service support

Page 102: Corporate Presentation India

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INTELLIGENCE INTELLIGENCE

IN IN

DRIVESDRIVES

Page 103: Corporate Presentation India

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Intelligence in DrivesIntelligence in Drives

Modern System RequirementsModern System Requirements

High Resolution Speed Ref(Master High Resolution Speed Ref(Master Speed)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

Page 104: Corporate Presentation India

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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 Computing Power and hence need of Additional Processor.Additional 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 & Updates need to be periodic & deterministicdeterministic (Data must arrive at regular (Data must arrive at regular guaranteed time intervals)guaranteed time intervals)

• The period or cycle of updates The period or cycle of updates should be should be synchronizedsynchronized with the digital control loops with the digital control loops in the drive / controller to eliminate any in the drive / controller to eliminate any undesirable “beating” effectsundesirable “beating” effects

Page 105: Corporate Presentation India

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INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVES

• In addition to these critical parameters, In addition to these critical parameters, Non-Time critical access to network should Non-Time critical access to network should also be supportedalso be supported (e.g. Operator (e.g. Operator interaction / Drive set-up / Downloading interaction / Drive set-up / Downloading application software / Diagnostics / Data application software / Diagnostics / Data logging)logging)

• Implementation can be by Centralized Implementation can be by Centralized Intelligence or Distributed Intelligence Intelligence or Distributed Intelligence approachapproach

Page 106: Corporate Presentation India

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Configuration PossibilitiesConfiguration PossibilitiesCentral IntelligenceCentral Intelligence

• All System Control Functions can be All System Control Functions can be located in the Central Controller & transfer located in the Central Controller & transfer Demands + Feedbacks cyclically over the Demands + Feedbacks cyclically over the network. This is a typical network. This is a typical Centralized Centralized Intelligence systemIntelligence system

Most PLC manufacturers prefer this Most PLC manufacturers prefer this approach even for Drive digital control for approach even for Drive digital control for obvious reasons!!obvious reasons!!

Page 107: Corporate Presentation India

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

• C.T.uses Distributed Control and pioneered C.T.uses Distributed Control and pioneered use of an additional Microcomputer Board use of an additional Microcomputer Board fitted on the Drive.fitted on the Drive.

• This function board is called MD29 and This function board is called MD29 and uses a 32 bit 2uses a 32 bit 2ndnd Processor for onboard Processor for onboard maths and logicsmaths and logics

• All Drive related functions and calculations All Drive related functions and calculations reside as preprogrammed Macros and the reside as preprogrammed Macros and the user has just to enter certain system datauser has just to enter certain system data

• The 2The 2ndnd Processor will communicate with Processor will communicate with the processor in the Drive and execute the the processor in the Drive and execute the additional functions with timings additional functions with timings synchronised with Drive Processorsynchronised with Drive Processor

Page 108: Corporate Presentation India

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Distributed Architecture BenefitsDistributed Architecture Benefits

• With Distributed architecture, With Distributed architecture, the the load on the networkload on the network is reduced to a is reduced to a large extentlarge extent

• Peer-To-Peer communications is Peer-To-Peer communications is possible. This allows data to be possible. This allows data to be shared easily between the nodes shared easily between the nodes without reducing network speedswithout reducing network speeds..

• The The dynamic performance dynamic performance of the of the system is better handled by system is better handled by distributed systems.distributed systems.

Page 109: Corporate Presentation India

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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

Page 110: Corporate Presentation India

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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 Intel i960 32-bit RISC processorprocessor

– With High-speed Fieldbus With High-speed Fieldbus ConnectivityConnectivity

– Programming in Ladder / Programming in Ladder / Function Blocks or ScriptFunction Blocks or Script

– Connects to Remote I/O BlocksConnects to Remote I/O Blocks

– Distributes Real Time ControlDistributes Real Time Control

Zero Zero Space Space PLCPLC

Plugs into Plugs into Drive Drive modulemodule

CalculatCalculatee

LogicLogic

ConnectConnect

SystemsSystems

Connect Connect I/OI/O

Page 111: Corporate Presentation India

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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.

Page 112: Corporate Presentation India

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From revolution to evolutionFrom revolution to evolution

Page 113: Corporate Presentation India

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Hardware EvolutionHardware Evolution

MD21

MD29

UD70

MD29AN

UD75SM-Applications

1st Generation 2nd Generation 3rd Generation

Page 114: Corporate Presentation India

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Software EvolutionSoftware Evolution

Terminal Window DPL Toolkit

SyPT V1

1st Generation 2nd Generation 4th Generation3rd Generation

Page 115: Corporate Presentation India

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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

Page 116: Corporate Presentation India

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MD21 MD29 UD70 SM-Apps

Program Memory

32Kb 96Kb 256Kb 384Kb

Variable Memory

8Kb 44Kb 80Kb

Execution Speed

<1% 90% 90% 100%

Processor Intel Basic Interpreter

I960 (16kHz) I960 (16kHz) Hitachi SH2 (28kHz)

Multi-Tasking

No Yes Yes Yes

Functionality Evolution

Page 117: Corporate Presentation India

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Example Line Configuration Example Line Configuration

Page 118: Corporate Presentation India

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Page 119: Corporate Presentation India

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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

Page 120: Corporate Presentation India

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Line Automation FeaturesLine Automation Features

FeatureFeature

• Master Reference GenerationMaster Reference Generation

• A Basic Programme is written in MD29AN card simulating up-A Basic Programme is written in MD29AN card simulating up-down counter operationdown counter operation

• Accuracy is 1 in 64000Accuracy is 1 in 64000• Increase and Decrease in adjustable steps (Ramp adjustable)Increase and Decrease in adjustable steps (Ramp adjustable)• Reference is transmitted in Digital form to other sections Reference is transmitted in Digital form to other sections

along CT Net busalong CT Net bus

Please note PLC is not used for Master ref Please note PLC is not used for Master ref generationgeneration

Page 121: Corporate Presentation India

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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 inbuilt Inertia compensation, Friction compensation etc. are inbuilt

in MD29in 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 ControlPlease note PLC is not used for Tension Control

Page 122: Corporate Presentation India

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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

Page 123: Corporate Presentation India

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Line Automation FeaturesLine Automation FeaturesFeatureFeature

• Squeeze Roll ControlSqueeze Roll Control

• The Encoder mounted on the delivery side of Loop Pit (in The Encoder mounted on the delivery side of Loop Pit (in the Process Section ) is used to measure the length of strip the Process Section ) is used to measure the length of strip (initiated after Head indexing)(initiated after Head indexing)

• Length counting is done in MD29 AN and passed to PLC on Length counting is done in MD29 AN and passed to PLC on BUS.BUS.

• PLC will initiate commands to squeeze rolls to lift whenever PLC will initiate commands to squeeze rolls to lift whenever welding is passing and after certain time, rolls would be welding is passing and after certain time, rolls would be lowered.lowered.

Page 124: Corporate Presentation India

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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 Acid pumps can be switched ON/OFF automatically after certain length of material is automatically after certain length of material is passed thru’ Process Section.passed thru’ Process Section.

Page 125: Corporate Presentation India

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Line Automation FeaturesLine Automation Features

FeatureFeature

• Coil weight MeasurementCoil weight Measurement

• The existing weighing control system will The existing weighing control system will be connected to PLC System on the Bus.be connected to PLC System on the Bus.

Page 126: Corporate Presentation India

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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 Transmitted Data Transfer at 5MB/S (Large amount of data Transmitted quickly)quickly)

• Peer to Peer System and no Master PLC Controller requiredPeer to Peer System and no Master PLC Controller required

• 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.

Page 127: Corporate Presentation India

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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.

Page 128: Corporate Presentation India

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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

Page 129: Corporate Presentation India

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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) Module Relevant FieldBus (Profibus/ Modbus / DeviceNet) Module from UniSP family is put in the 2from 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

Page 130: Corporate Presentation India

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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

Page 131: Corporate Presentation India

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M 700 R M 420 R M 420 R M 420 R

ENT . BR IDLET O P 100 K W

ENT . BR IDLEBO T . 70 KW

EXIT . BR IDLET O P 100 K W

EXIT . BR IDLEBO T . 70 KW

REC O ILER 300 KW

ENT RY D EFLECT O R RO LL EXIT DEFLECT O R RO LL

L IN E C O N F IG U R A T IO N

LINE ENCO DER1024 PPR

LINE ENCO DER1024 PPR

PO R150 KW

M ILL200 KW

M 1200 RM 420 R M 825 R

1024 PPR 2500 PPR 1024 PPR 2500 PPR1024 PPR

Page 132: Corporate Presentation India

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LINE DRIVES (7 Nos.)

DC CO NVERT ERS ANDDC M O T O RS

(7 Nos.)

M CC ANDFIXED SPEED AC

M O T O RS

M CC

ACB2500 A(F IXED)

M CCB630 A

DC M O T O RS T O BESUPPLIED BY O T HERS

FPE

C T INDIA

FPE

C T INDIA

INCOMER , - 2500 APOR - 150 KWENTRY BRIDLE BOTTOM - 70 KWENTRY BRIDLE TOP - 100 KWMILL STAND - 200 KWEXIT BRIDLE TOP - 100 KWEXIT BRIDLE BOTTOM - 70 KWRECOILER - 300 KW

FIXED SPEED AC M O T O RS T OBE SUPPLIED B Y O T HERS

P O W E R SU P P L Y D IST R IB U T IO N

350 A

C UST OM E R

ACB(EDO )

V.S.S

KWH

PV1

PA1A

V

FU

A.S.S

FU

433 V,2000KVA

ACB3200 A(EDO )

P D B

C UST OM E R

2100 A

3 Ø

, 4

Wir

e, 4

15 V

, 50

Hz

3 Ø

, 4

Wir

e, 4

15 V

, 50

Hz

POW ER SUPPLY DISTRIBUTION (SINGLE LINE DIAGRAM)

Page 133: Corporate Presentation India

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DPM M I

F IE L D R IO (R S - 4 )

M A IN P L C

SPM C D (R S - 2 )

PLC S7-300

PO R C D (R S - 1 )

R E C O IL E R C D(R S - 3)

POR ENT. BRIDLETOP

M ILL EXIT. BRIDLEBOT.

EXIT.BRIDLE TOP

RECOILERENT. BRIDLEBOT.

UNI SP

GATEW AY

M PIA

HUB

CP5611 PCI20CP5611

E NGINE E R ING PC

H AR DWAR E :-C P5611 (DP/ M PI)PC I 20 (DR IVE S)

SOF T WAR E :-ST E P 7 (PL C )SYPT (DR IVE S APPL IC AT IO N)C T -NE T BR O WSE R (DR IVE PAR AM E T E R )

H M I F OR L INE

H AR DWAR E :-C P5611 (DP/ M PI)

SOF T WAR E :-WIN C C DE VE L O PM E NT(SC ADA1024 T AG

SYSTEM CONFIGURATION

DR IVE S & M C C (M AINPL C )

Page 134: Corporate Presentation India

Drive Centre Vicenza

SYSTEM CONFIGURATION FOR 4-HI SPM (Project GE)

MCC PANEL

MMI

5611

FIELD RI/O

DRIVE PANELS

HMI

INCOMER , - 3200 A

POR - 150 KW

ENTRY BRIDLE BOTTOM - 70 KWENTRY BRIDLE TOP - 100 KW

MILL STAND - 200 KW

EXIT BRIDLE TOP - 100 KWEXIT BRIDLE BOTTOM - 70 KW

RECOILER - 300 KW

ENGINEERING PC ( DRIVES & PLC)

POR CD

PCI 20

MMI PC

RS - 4

PLC S7- 300DP

DP

UNI SPGATW AY

HUB

MAIN PLC

POR ENT. BRIDLE BOT.

5611

ENT. BRIDLE TOP MILL EXIT. BRIDLE BOT. EXIT. BRIDLE TOP RECOILER INCOMER

COILER CD

PC TABLE

PC TABLE

SPM CD

RS - 1

0 0

RS - 3 RS - 2

CONTROL CABLE

Page 135: Corporate Presentation India

Drive Centre Vicenza

Control Techniques IndiaControl Techniques India

Application Motor Rating Drive Rating

Uncoiler 225kw M 1850R

Entry Bridle Roll – M1

90kw M550R

Entry Bridle Roll – M2

140kw M550R

Mill Stand 250kw M1850R

Exit Bridle Roll – M1

140kw M550R

Exit Bridle Roll – M2

90kw M550R

Recoiler 325kw M1850R

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

Page 136: Corporate Presentation India

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Control Techniques IndiaControl Techniques India

• Time taken for commissioning

I/O Checking 5 Mandays

No Load motor Test 2 Mandays

Operation from CD with interlock

3 Mandays

Drive Software Simulation Test 1 Manday

Interaction withAEC Panel Check

1 Manday

SCADA Modification 2 mandays

Commissioning 3 Mandays

Post Commissioning Observation/Tuning

5 Mandays

Process Line : 4 Hi Non Reversible Skin Pass Mill

End User : PT Essar Dhananjaya, Indonesia

Project Manager: B. Ganesh + Satish

Page 137: Corporate Presentation India

Drive Centre Vicenza

Page 138: Corporate Presentation India

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

Page 139: Corporate Presentation India

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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

Page 140: Corporate Presentation India

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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.

Page 141: Corporate Presentation India

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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 argin gresisto r

L C 1

560V D C B U S

A

C T Q SP A

H LR Y B P H A SE O N

P VQ S

A.S .S

V .S .SF U

V~

~E~

QF(ACB)2000 A

(MF)

V O L T A G E : 415 V ± 10 % , F R E Q U E N C Y : 50 H z ± 3 %3Ø , 3 W IR E SY ST 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 argin gresisto 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 argin gresisto 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 argin gresisto 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 argin gresisto 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 argin gresisto r

F U

K M 1 K M 2

L C 1

BR2000 A

Page 142: Corporate Presentation India

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Drive Details (Line Drives)

Sr.No DescriptionMotorRatin

g

DriveRating

Apps.Module

1 Payoff # 1 110.0 UNI 4404 UD75

2 Payoff # 2 110.0 UNI 4402 UD75

3 Bridle # 1A 15.0 UNI 3401 ~

4 Bridle # 1B 15.0 UNI 3401 UD75

5 Bridle # 1C 18.5 UNI 3403 ~

6 Bridle # 1D 18.5 UNI 3403 UD75

7 Entry Accumulator 45.0 UNI 4401 UD75

Entry Section Drives

Page 143: Corporate Presentation India

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Drive Details (Line Drives)

Process Section Drives (1 of 2)

Sr.No DescriptionMotor Rating

Drive Rating

Apps. Module

8 Bridle # 2A 30.0 UNI 3404 UD75

9 Bridle # 2B 30.0 UNI 3404 ~

10 Furnace Bridle A 5.5 UNI 2402 ~

11 Furnace Bridle B 18.5 UNI 3403 ~

12 Furnace Bridle C 30.0 UNI 3404 UD75

13 Bridle # 3A 37.0 UNI 3405 UD75

14 Bridle # 3B 37.0 UNI 3405 ~

15 Bridle # 4A 45.0 UNI 4401 UD75

16 Bridle # 4B 55.0 UNI 4402 ~

17 Backup Roll-Bot 160.0 UNI 5401 UD75

18 Backup Roll-Top 160.0 UNI 5401 ~

Page 144: Corporate Presentation India

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Drive Details (Line Drives)

Sr.No DescriptionMotorRating

Drive Rating

Apps.Module

19 Bridle # 5A 75.0 UNI 4403 UD75

20 Bridle # 5B 132.0 UNI 5401 ~

21 Bridle # 5C 90.0 UNI 4404 UD75

22 Bridle # 6A 200.0 UNI 5401 UD75

23 Bridle # 6B 132.0 UNI 5402 ~

24 Chromate Coater#1 18.5 KW UNI 3402 UD75

25 Chromate Coater#2 18.5 KW UNI 3402 ~

26 Chromate Coater#3 18.5 KW UNI 3402 UD75

27 Chromate Coater#4 18.5 KW UNI 3402 ~

28 Bridle # 7A 75.0 UNI 4403 UD75

29 Bridle # 7B 55.0 UNI 4402 ~

Process Section Drives (2 of 2)

Page 145: Corporate Presentation India

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Drive Details (Line Drives)

Sr.No DescriptionMotorRating

Drive Rating

Apps.Module

30 Exit Accumulator 55.0 UNI 4402 UD75

31 Bridle # 8A 37.0 UNI 3405 ~

32 Bridle # 8B 55.0 UNI 4402 UD75

33 Recoiler 400.0 UNI 5403 UD75

Exit Section Drives

Page 146: Corporate Presentation India

Drive Centre Vicenza

Single Line Diagram (Aux. Drives)

V O L T A G E : 415 V ± 10 % , F R E Q U E N C Y : 50 H z ± 3 %3P H A SE , 3 W IR E SY ST E M

AC TQ S

P A

H LR Y B P H A SE O N

P VQ S

A .S .S

V .S .SF U

V~

~E~

Q F 1600 A(ACB)

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

Page 147: Corporate Presentation India

Drive Centre Vicenza

Drive Details (Aux. Drives)1 Jet Cool Fan # 1 22 KW 37 KW - SE

2 Jet Cool Fan # 2 22 KW 37 KW - SE

3 Jet Cool Fan # 3 22 KW 37 KW - SE

4 NOF flue Exhaust Blower 37 KW 37 KW - SE

5 Cooling Tower Blower # 1 90 KW UNI 4404

6 Cooling Tower Blower # 2 55 KW UNI 4403

7 Cooling Tower Blower # 3 55 KW UNI 4404

8 Air Knife Blower # 1 110 KW UNI 5402

9 Air Knife Blower # 2 110 KW UNI 5402

10 Jet Act Up/ Down # 1 2.2 KW 4 KW - SE

11 Jet Act Up/ Down # 2 2.2 KW 4 KW - SE

12 Jet Act In/ Out # 1 0.83 HP 1.1 KW - SE

13 Jet Act In/ Out # 2 0.83 HP 1.1 KW - SE

14 Jet Act In/ Out # 3 0.83 HP 1.1 KW - SE

15 Jet Act In/ Out # 4 0.83 HP 1.1 KW - SE

16 Boot Roll 5.5 KW 7.5 KW - SE

17 Entry Seal Roll 5.5 KW 11 KW - SE

18 Hearth Roll Drive # 1 7 x 2.2 KW 18.5 KW - SE

19 Hearth Roll Drive # 2 7 x 2.2 KW 18.5 KW - SE

Page 148: Corporate Presentation India

Drive Centre Vicenza

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

Page 149: Corporate Presentation India

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

Page 150: Corporate Presentation India

Drive Centre Vicenza

Profibus Routing

PROFIBUSCONNECTOR

A1 B1 S B2A2

ENTRY CDESA

PROFIBUSADDRESS : 51

PROFIBUSCONNECTOR

A1 B1 S B2A2

ENTRY CDRS # 7

PROFIBUSADDRESS : 22

PROFIBUSCONNECTOR

A1 B1 S B2A2

ENTRY FIELDRS # 12 (1/1)

PROFIBUSADDRESS : 21

PROFIBUSCONNECTOR

A1 B1 S B2A2

ENTRY FIELDRS # 12 (0/1)

PROFIBUSADDRESS : 20

PROFIBUSCONNECTOR

A1 B1 S B2A2

ENTRY M CCRS # 4

PROFIBUSADDRESS : 18

PROFIBUSCONNECTOR

A1 B1 S B2A2

PROCESS M CCRS # 5

PROFIBUSADDRESS : 19

PROFIBUSCONNECTOR

A1 B1 S B2A2

FURNACE PLCRACK # 4/4

PROFIBUSADDRESS : 17

PROFIBUSCONNECTOR

A1 B1 S B2A2

FURNACE PLCRACK # 3/4

PROFIBUSADDRESS : 16

PROFIBUSCONNECTOR

A1 B1 S B2A2

FURNACE PLCRACK # 2/4

PROFIBUSADDRESS : 15

PROFIBUSCONNECTOR

A1 B1 S B2A2

FURNACE PLCRACK # 1/4

PROFIBUSADDRESS : 14

PROFIBUSCONNECTOR

A1 B1 S B2A2

FURNACE PLC (CPU S7-300)RACK # 0/4

PROFIBUSADDRESS : 5

PROFIBUSCONNECTOR

A1 B1 S B2A2

M PIADDRESS : 5

PROFIBUSCONNECTOR

A1 B1 S B2A2

LINE PLC (CPU S7-400)RACK - UR2

PROFIBUSADDRESS : 2

PROFIBUSCONNECTOR

A1 B1 S B2A2

M PI ADDRESS : 2

PROFIBUSCONNECTOR

A1 B1 S B2A2

ENTRY DRIVESRS # 1

PROFIBUSADDRESS : 10

PROFIBUSCONNECTOR

A1 B1 S B2A2

AUX DRIVESRS # 3 (0 / 2)

PROFIBUSADDRESS : 11

PROFIBUSCONNECTOR

A1 B1 S B2A2

AUX DRIVESRS # 3 (1 / 2)

PROFIBUSADDRESS : 12

PROFIBUSCONNECTOR

A1 B1 S B2A2

AUX DRIVESRS # 3 (2 / 2)

PROFIBUSADDRESS : 13

PROFIBUSCONNECTOR

A1 B1 S B2A2

PULPIT CDRS # 8

PROFIBUSADDRESS : 25

PROFIBUSCONNECTOR

A1 B1 S B2A2

PROCESS FIELDRS # 13 (0 / 1)

PROFIBUSADDRESS : 23

PROFIBUSCONNECTOR

A1 B1 S B2A2

PROCESS FIELDRS # 13 (1 / 1)

PROFIBUSADDRESS : 24

MMI PC-1PROFIBUS

CONNECTOR

A1 B1 S B2A2

MMI PC-1PROFIBUS

CONNECTOR

A1 B1 S B2A2

REPEATER

PROG PC-1

PROFIBUSCONNECTOR

A1 B1 S B2A2

SPM CDRS # 9

PROFIBUSADDRESS : 26

PROFIBUSCONNECTOR

A1 B1 S B2A2

SPM CD - ESA

PROFIBUSADDRESS : 61

PROFIBUSCONNECTOR

A1 B1 S B2A2

TLL CDRS # 10

PROFIBUSADDRESS : 27

PROFIBUSCONNECTOR

A1 B1 S B2A2

TLL CD - ESA

PROFIBUSADDRESS : 71

PROFIBUSCONNECTOR

A1 B1 S B2A2

EXIT M CCRS # 6

PROFIBUSADDRESS : 28

PROFIBUSCONNECTOR

A1 B1 S B2A2

EXIT DRIVESRS # 2

PROFIBUSADDRESS : 29

PROFIBUSCONNECTOR

A1 B1 S B2A2

GATEW AY(EXIT)

PROFIBUSADDRESS : 103

PROFIBUSCONNECTOR

A1 B1 S B2A2

GATEW AY(PROCESS)

PROFIBUSADDRESS : 102

PROFIBUSCONNECTOR

A1 B1 S B2A2

GATEW AY(ENTRY)

PROFIBUSADDRESS : 101

PROFIBUSCONNECTOR

A1 B1 S B2A2

EXIT FIELDRS # 14

PROFIBUSADDRESS : 41

PROFIBUSCONNECTOR

A1 B1 S B2A2

EXIT CDRS # 11

PROFIBUSADDRESS : 40

PROFIBUSCONNECTOR

A1 B1 S B2A2

EXIT CD - ESA

PROFIBUSADDRESS : 81

GL

OB

AL

DA

TA

NE

TW

OR

K

PRO FIBUSADD : 0

PR OJ E C T - J WPR OF IBUS NE T WOR K DE T AILS

Page 151: Corporate Presentation India

Drive Centre Vicenza

CT-Net Routing

UD75

1 2 3

PAYOFF # 1PAYOFF # 2

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

PAYOFF # 2BRIDLE # 1ABRIDLE # 1DENT ACCUMBRIDLE # 2A

UD75

1 2 3

H.BR # C

UD75

1 2 3

BRIDLE # 4APAYOFF # 2

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

BRIDLE # 5ABUR - BOTBRIDLE # 3ABRIDLE # 5CGATW AYENTRY

UD75

1 2 3

GATW AYPROCESS

UD75

1 2 3

GATW AYEXIT

UD75

1 2 3

RECOILERPAYOFF # 2

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

UD75

1 2 3

BRIDLE # 8BEXIT ACCUMBRIDLE # 7AORG COAT-3

UD75

1 2 3

BRIDLE # 6A ORG COAT-1

ADD: 11ADD: 12ADD: 14ADD: 13ADD: 15ADD: 16ADD: 17

ADD: 03 ADD: 02 ADD: 01 ADD: 31 ADD: 18 ADD: 19ADD: 20 ADD: 21

ADD: 22 ADD: 23 ADD: 24 ADD: 25 ADD: 26 ADD: 27 ADD: 28

A

S

B

A

S

B

A

S

B

A

S

B

A

S

B

A

S

B

75 O

HM

S75

OH

MS

75 O

HM

S

TERM INATINGRESISTO R

TERM INATINGRESISTO R

TERM INATINGRESISTO R

PROG PC

PCI - 20

1 2 3

SYPTW ORKBENCH

CT-NET HUB(RS # 1)

CT-NET HUB(RS # 2)

PROJECT - JWCT-NET COMMUNICATION SCHEMATIC

Page 152: Corporate Presentation India

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.

Page 153: Corporate Presentation India

Drive Centre Vicenza

SCADA – Line Overview

Page 154: Corporate Presentation India

Drive Centre Vicenza

SCADA – Entry Section

Page 155: Corporate Presentation India

Drive Centre Vicenza

SCADA – Process Section

Page 156: Corporate Presentation India

Drive Centre Vicenza

SCADA – Exit Section

Page 157: Corporate Presentation India

Drive Centre Vicenza

SCADA – Furnace Section

Page 158: Corporate Presentation India

Drive Centre Vicenza

SCADA – PHF Burner Controls

Page 159: Corporate Presentation India

Drive Centre Vicenza

SCADA – PHF PID Settings

Page 160: Corporate Presentation India

Drive Centre Vicenza

SCADA – Pot Furnace

Page 161: Corporate Presentation India

Drive Centre Vicenza

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

Page 162: Corporate Presentation India

Drive Centre Vicenza

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

Page 163: Corporate Presentation India

Drive Centre Vicenza

Food & Beverages IndustryCustomers

•COCA COLA

•PEPSICO

•PARLE INDUSTRIES

•MOHAN MEAKINS

•CADBURY INDIA

•NESTLE

•INDIAN DAIRY (AMUL)

Page 164: Corporate Presentation India

Drive Centre Vicenza

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

Page 165: Corporate Presentation India

Drive Centre Vicenza

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

Page 166: Corporate Presentation India

Drive Centre Vicenza

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

Page 167: Corporate Presentation India

Drive Centre Vicenza

Tyre IndustryTyre IndustryCustomersCustomers

• Customer CORNELL INTERNATIONAL,MUMBAI

• Applications 210 LITRE MIXER FOR

ELASTOMERIC ,SRILANKA

• Drives Digital DC / Servo Drives Systems

Page 168: Corporate Presentation India

Drive Centre Vicenza

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 Sample CT ReferencesReferences

Page 169: Corporate Presentation India

Drive Centre Vicenza

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

• TISCOTISCO - 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

Page 170: Corporate Presentation India

Drive Centre Vicenza

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

Page 171: Corporate Presentation India

Drive Centre Vicenza

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)

Page 172: Corporate Presentation India

Drive Centre Vicenza

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

Page 173: Corporate Presentation India

Drive Centre Vicenza

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

Page 174: Corporate Presentation India

Drive Centre Vicenza

Page 175: Corporate Presentation India

Drive Centre Vicenza

Page 176: Corporate Presentation India

Drive Centre Vicenza

Page 177: Corporate Presentation India

Drive Centre Vicenza

Box Wagon - Fine

0

60

0

60

06

00

60

0

35

0

35

0

60

0

60

00 0

-65

0

-65

0

-35

0-3

50

-65

0

-65

0

-35

0-3

50

00 9 18

18 5

0 63 70 83

15

01

50

15

0

14

3

70

54

50

45

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

Page 178: Corporate Presentation India

Drive Centre Vicenza

Understanding the Understanding the Common DC Bus Common DC Bus

ConceptConceptFor AC Drive SystemsFor AC Drive Systems

Page 179: Corporate Presentation India

Drive Centre Vicenza

Drive System Drive System ConfigurationConfiguration

Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors

COMMON DC-BUS 560V

RRR R

Brake

ChopperResistorResistor

2000A

CT-NetCT-Net

Page 180: Corporate Presentation India

Drive Centre Vicenza

Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors

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

Page 181: Corporate Presentation India

Drive Centre Vicenza

Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors

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.

Page 182: Corporate Presentation India

Drive Centre Vicenza

Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors

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.

Page 183: Corporate Presentation India

Drive Centre Vicenza

Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors

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

Page 184: Corporate Presentation India

Drive Centre Vicenza

Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors

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

Page 185: Corporate Presentation India

Drive Centre Vicenza

Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors

COMMON DC-BUS 560V

RRR R

Regenerative Drive

Trafo Elevatore 400V/660V

Alternative DC Bus Alternative DC Bus ConfigurationConfiguration

Using 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

Page 186: Corporate Presentation India

Drive Centre Vicenza

Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors

COMMON DC-BUS 560V

RRR R

Alternative DC Bus Alternative DC Bus ConfigurationConfiguration

Using 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

YY

IPTIPT

Page 187: Corporate Presentation India

Drive Centre Vicenza

Major Approvals Major Approvals

• MECON

• HEC, RANCHI

• TATA STEEL (TISCO, JAMSHEDPUR)

• NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LTD.

• ERCOM ENGINEERS PRIVATE LIMITED NEW DELHI.

Page 188: Corporate Presentation India

Drive Centre Vicenza

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 We can deliver large Systems in stipulated time limitslimits

• We can commission Systems very fast We can commission Systems very fast

• It will be a privilege for Control Techniques India It will be a privilege for Control Techniques India to have continued association with TATAto have continued association with TATA

Page 189: Corporate Presentation India

Drive Centre Vicenza

PULPITROOM

HEAD

FURNACEELOGATION

MACHINE

M EN TO R I IELECTR O N I CS

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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