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  • Corporate Presentation India

    1. 1. Welcomes You All Control Techniques India
    2. 2. Founded in 1973 CT is a world leader in the Design, Manufacture, Marketing and Application of…. AC & DC Drives, Servo Drives Systems
    3. 3. Every Electric Motor is a Potential Application for Control Techniques products
    4. 4. Control Techniques - a 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 2002 Introduces world’s first “Solutions Platform” AC drive 2005 Introduces world’s first “knowledge” AC drive in small rating (Commander SK)
    5. 5. Control Techniques India <ul><li>CT India started in 1993 </li></ul><ul><li>CT India is a fully owned subsidiary of CT-Worldwide (CT - UK) </li></ul><ul><li>CT-Worldwide is a fully owned company of the US Electrical conglomerate Emerson Electric </li></ul>
    6. 7. <ul><li>$20 Billion Fortune 500 Company </li></ul><ul><li>Global product/market leadership </li></ul><ul><li>Recognized for outstanding management practices </li></ul><ul><li>Strong International presence </li></ul><ul><li>Solid financial position </li></ul>
    7. 8. Sales by Business Group $20 Billion Total Appliance & Tools 23% Electronics & Telecommunications 15% Process Control 21% HVAC 17% Industrial Automation 24%
    8. 9. Expectations from Customers Today…For Plant Automation Floor Level Floor Level Plant Level Motors / Alternators & Power Products Single Point Source Drives & Automation Distributed Control
    9. 10. Distributed Control Motors / Alternators Products Drives & Automation
    10. 11. United Kingdom Newtown, Wales London Headquarters R&D Manufacturing Plant
    11. 12. <ul><li>Situated in Newtown, Mid Wales country, UK </li></ul><ul><li>The most advanced facility of its kind </li></ul><ul><li>Robotic Assembly of Drive modules </li></ul><ul><li>800 Drives per day </li></ul>Control Techniques World Class Drive Manufacturing Facilities
    12. 13. Product Portfolio General Purpose AC Drives DC Drives Cabinet Free AC Drives Energy Saving Drive High Performance AC Drives Motion Controller
    13. 14. Product Portfolio Networking And Software Products OPERATOR INTERFACE Soft Starters Servo Motors CTIU 200
    14. 15. Digital DC / AC Drives Mentor : Digital DC 7.5 Kw to 750 Kw Commander SK : Simple ,Knowledge 0.25 Kw to 110Kw Unidrive SP : Solution Platform 0.75 Kw to 1.0 MW PV /EV - Fans & Pumps 5.5 Kw to 280 Kw
    15. 16. Other Products MC 204/216 - Motion Controller 4 to 16Axes CT START - Soft Starters 4 to 800 Kw Unimotor - AC Servo 1 to 70 Nm LSMV - Inverter Grade AC Motors 0.75 to 132 Kw Sincrovert - AC Spindle Motors 0.75 to 110 Kw
    16. 17. Worldwide Operations EUROPE ASIA PACIFIC AMERICAS
    17. 18. Drive Centres in North America Chicago Toronto Providence Charlotte Cleveland Distributors S.America Minneapolis (Head Office) Dallas
    18. 19. Drive Centres in Asia Pacific South Africa Australia Thailand India S. Korea China Indonesia (distributor) Malaysia Singapore Hong Kong Taiwan Vietnam (distributor)
    19. 20. New Delhi Application Center Kolkata Application Center Drive/Application Centers Indian Operations Ahmedabad Sales Office Pune Application Center Chennai Drive Center Nagpur Sales Office Hyderabad Sales Office
    20. 21. Control Techniques India Manufacturing & Support Facilities <ul><ul><li>12,000 Sq. ft. Purpose built factory </li></ul></ul><ul><ul><li>45 People ( of which 20 are Engineers) at Chennai </li></ul></ul><ul><ul><li>15 People (of which 10 are Engineers) in Branch Offices </li></ul></ul><ul><ul><li>Extensive Systems Capability </li></ul></ul><ul><ul><li>Over 150 Domestic Projects </li></ul></ul><ul><ul><li>Over 50 Export Projects </li></ul></ul><ul><ul><li>Complete Manufacturing facilities with Test Set Up </li></ul></ul>Facilities / Expertise Testing Facilities <ul><li>Test Jigs for PCB’s (PC Based) </li></ul><ul><li>PROM Programmer </li></ul><ul><li>DC Motors , AC Motors Test Beds </li></ul><ul><li>High Current Low Voltage Source for Load Test </li></ul><ul><li>Insulation Tester, High Voltage Break Down Tester </li></ul>Training / Repair <ul><ul><li>CT Approved Training Centre </li></ul></ul><ul><ul><li>CT Approved Repair Centre </li></ul></ul><ul><ul><li>Component Level Repair Facility </li></ul></ul>
    22. 35. Digital DC Drives Mentor II - Flexible Systems Drive - 25 to 1850A Single & Four Quadrant 6-pulse Fully Digital 7.5 -75kW 100-300kW 300 – 750kW
    23. 36. Mentor Family Range 0.75-75KW H-370 mm W-250 mm D-195mm 300-750KW H-1355 mm W-450 mm D-510 mm 100-300KW H-423 mm W-450 mm D- 280 mm
    24. 37. MENTOR INPUT SPECS Voltage 220-480 V +/- 10% Suitable for Global Power Supplies NO Tap Selections Voltage 525 V and 660 V (Optional) Frequency 47-62 Hz. Wide tracking Range for PLL Temperature 40 Deg C for Power Derating upto 55 Deg C Electronics upo 55 Deg C
    25. 38. MENTOR features Phase Sequence Insensitive to Supply Phase Sequence Field Control Controlled Field Field weakening Inbuilt and Programmable Field Control Inbuilt (8 A) upto 210 A 20 A External
    26. 39. MENTOR I/O Analog Inputs 6 Nos. 4 No. Programmable (Volt) 1 No. Dedicated (Volt/Current Selectable) 1 No. Dedicated for Motor Thermistor Analog Outputs 4 Nos. 3 No. Programmable (0-10 Volt) 1 No. Dedicated (10Volt=200%Current ) Digital Inputs 10 Nos 2 Dedicated 8 Programmable Digital Outputs 7 Nos 1 Dedicated Relay 1 Programmable Relay 5 Programmable (Open Collector Type)
    27. 40. The most versatile DC systems drive in the world More than 3000 drives in India More than 125,000 drives in use world-wide
    28. 41. The most versatile DC systems drive in the world Control Techniques also Brand Labels Digital DC Drives for.. CGEE ALSTOM (FRANCE)
    29. 42. Unidrive Unified AC Drive with Solution Platform
    30. 43. Full Torque upto Standstill Excellent Speed, Current & Position Loop Very good Dynamic responses Servo Servo Applications Full Torque upto Standstill Excellent Speed & Current Loop Very good Dynamic responses Closed Loop Flux Vector Cranes / Hoists Process Lines Sectional Drives Full Torque to 1 Hz No Speed Loop Good Current Loop Mostly O/L Vector Constant Torque Load Fan/Pump / Conveyors Application Open Loop No Speed Loop No Current Loop V/f What you get… Type of Control
    31. 44. UniSP – The Universal Drive With Solution Platform 5 Modes of Operation: OL ( Open Loop V/f) OLV(Open Loop Vector) CLV(Closed Loop Vector) Servo Regen High Performance Powerful Flexible
    32. 45. The UniSP Advantage <ul><li>Single Drive from Simple to Complex applications </li></ul><ul><li>Can be adapted to any mode of operation by simple parameterisation </li></ul><ul><li>Single Learning Curve for End-user </li></ul><ul><li>Single Control module for all sizes </li></ul><ul><li>Minimum Inventory </li></ul><ul><li>Integral Braking module for all sizes </li></ul>
    33. 46. <ul><li>200/240V 3ph, 50/60Hz </li></ul><ul><li>380/480V 3ph, 50/60Hz </li></ul><ul><li>500/600V 3ph, 50/60Hz </li></ul><ul><li>500/690V 3ph, 50/60Hz - </li></ul>Global power supplies
    34. 47. 6 (//) 5 4 3 2 1 7 (//) 22 LV 48 / 96Vdc 45 75 132 160 37 55 90 132 45 75 <ul><li>- Servo, Closed loop </li></ul><ul><li>Open loop, V/F </li></ul><ul><li>- Open loop, V/F,Servo, Regen </li></ul>110 160 690V 110% 150% 175% KW O/L Volts *8 575V 400V 220V 15 11 22 11 4.0 5.5 2.2
    35. 48. UNISP SPECS Input Voltage 380-480 V +/- 10% NO Tap Selections Output Frequency 0-3000 Hz Suitable for High Frequency Spindle Input Frequency 47-62 Hz. Switching Frequency 3/4/6/8/12/16 KHz Quiter Operation Reduced Harmonics
    36. 49. Environmental Specs Ambient 40 Deg C 1 % per Deg C deration for 40- 50 Deg C Module IP rating IP 20 Nema 1 Special Cooling Fans Suitable for IP54 Extended IP rating IP54 Nema 12
    37. 50. 48V DC supply input <ul><li>Ideally suitable for </li></ul><ul><li>Emergency battery operation for lift rescue </li></ul><ul><li>Limited speed set up for Machine Tool robot cells </li></ul><ul><li>Jog Operation in Extruders in case Of Power failure </li></ul>
    38. 51. 24V DC Auxiliary Power <ul><li>External 24V / 2A input for control backup </li></ul><ul><li>Encoder position retained </li></ul><ul><li>Fieldbus stays live </li></ul><ul><li>Safe programming of drive </li></ul><ul><li>Additional means of Maintaining control </li></ul>
    39. 52. Intelligent Options for AC Drives… <ul><ul><li>Palm-sized Second Processor </li></ul></ul><ul><ul><li>Intel i960 32-bit RISC processor </li></ul></ul><ul><ul><li>With High-speed Fieldbus Connectivity </li></ul></ul><ul><ul><li>Programming in Ladder / Function Blocks or Script </li></ul></ul><ul><ul><li>Connects to Remote I/O Blocks </li></ul></ul><ul><ul><li>Distributes Real Time Control </li></ul></ul>Zero Space PLC Plugs into Drive module Calculate Logic Connect Systems Connect I/O
    40. 53. <ul><li>Customisation at point of uses </li></ul><ul><li>3 options,X million number of combinations </li></ul>SM-I/O Plus SM- PROFIBUS-DP SM-Applications SM-Universal Encoder Plus SM-CANopen SM- DeviceNet SM-INTERBUS SM-Applications Lite SM-Resolver SM- Encoder Plus SM-CAN SM-Ethernet SM-SLM SM-SERCOS
    41. 54. 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
    42. 55. Option Module Assembly <ul><li>Application Module (incl CTNet) </li></ul><ul><li>Profibus DP </li></ul><ul><li>Devicenet </li></ul><ul><li>Interbus S </li></ul><ul><li>CANopen </li></ul><ul><li>Ethernet </li></ul><ul><li>SERCOS </li></ul><ul><li>Extra I/O </li></ul><ul><li>2nd Encoder </li></ul><ul><li>Resolver </li></ul><ul><li>SLM </li></ul><ul><li>“ Easy Motion” PowerTools </li></ul>Designed to Empower Applications Engineers 
    43. 56. UniDrive SP Field Bus Gateway Smart Card Facility - As standard <ul><li>Hot pluggable </li></ul><ul><li>Auto backup of parameters </li></ul><ul><li>Fast low cost cloning </li></ul><ul><li>Fast Network Start-Up’s </li></ul><ul><li>Up to 4 full parameter sets </li></ul><ul><li>Supplied as standard with UniDrive SP </li></ul>
    44. 57. Field Bus Connectivity <ul><li>Modules are available for </li></ul><ul><li>Modbus RTU </li></ul><ul><li>Profibus </li></ul><ul><li>DeviceNet </li></ul><ul><li>CANopen </li></ul><ul><li>Interbus S </li></ul><ul><li>Sercos </li></ul><ul><li>Ethernet </li></ul><ul><li>CTNet, </li></ul>RS485 Port Modbus (RTU or ASCII) Johnson Controls (Metasys) CSI
    45. 58. PLC FUNCTIONALITY IN UNISP Level – 1 Addl. Hardware – Nil Memory - 4k Exe Prog. Software – SyPT Lite Level – 2 Addl. Hardware – SM Appln Lite (Option) Memory - 10 k Exe Prog. Software – SyPT Lite Level – 4 Addl. Hardware – SM Appln+ CT Net (Option) Memory – 384k Exe, 80k RAM Prog. Software – SyPT Pro (Option) Level – 3 Addl. Hardware – SM Appln Lite (Option) Memory - 100k Exe, 20k RAM Prog. Software – SyPT Pro (Option)
    47. 60. Application Programming <ul><li>SyPT PRO </li></ul><ul><li>Industrial Networking </li></ul><ul><li>Realtime Multitasking </li></ul><ul><li>Confirms to IEC 61131-3 </li></ul>
    48. 61. Programming Tool
    49. 62. SYPT Overview <ul><li>Main Areas </li></ul><ul><ul><li>Configuration </li></ul></ul><ul><ul><li>Programming </li></ul></ul><ul><ul><li>DPL Editor </li></ul></ul><ul><ul><li>Function Block Editor </li></ul></ul><ul><ul><li>Quick Ladder Editor </li></ul></ul><ul><ul><li>Watch Window </li></ul></ul><ul><ul><li>Function Blocks </li></ul></ul><ul><ul><ul><li>Standard Library </li></ul></ul></ul><ul><ul><ul><li>User Define </li></ul></ul></ul>
    50. 63. Configuration Editor <ul><li>Project Oriented. </li></ul><ul><li>Configuration of:- </li></ul><ul><ul><li>Distributed CTNet Systems </li></ul></ul><ul><ul><li>OPC Server available . </li></ul></ul>
    51. 64. DPL Editor <ul><li>Drive Prog Language(Quick Basic) </li></ul><ul><li>Standard constructs like IF, THEN,ELSE as well as Loops </li></ul>
    52. 65. Quick Ladder Editor <ul><li>Compliant to -61131 </li></ul><ul><li>Quick development of boolean and function block ladder diagrams. </li></ul>
    53. 66. Function Block Editor <ul><li>Compliant to -61131 </li></ul><ul><li>Library of more than 256 Function Blocks. </li></ul><ul><li>Can create additional Function Blocks </li></ul>
    54. 67. Function Blocks <ul><li>Standard Library </li></ul><ul><ul><li>Floating Point & Integer Types. </li></ul></ul><ul><ul><li>DPL commands, std PLC functions , Motion & communication types. </li></ul></ul><ul><ul><li>Maintained by SSPD. </li></ul></ul><ul><ul><li>Powerful:- </li></ul></ul><ul><ul><ul><li>Development. </li></ul></ul></ul><ul><ul><ul><li>Modular </li></ul></ul></ul><ul><ul><ul><li>Easy to Understand </li></ul></ul></ul><ul><ul><ul><li>Common standard block </li></ul></ul></ul>
    55. 68. Allows you to Monitor the Drives Parameters and Program Variables. Immediate Window Allows you to Set the Drive Parameters or Program Variables and Monitor status.
    56. 69. Help files SyPTPro Includes a comprehensive help file and the manuals for all related products.
    57. 71. CT Net Distributed Control System Remote I/O CTNet @ 5Mbps Ethernet <ul><li>CT-Net System: </li></ul><ul><li>CT Digital Drives </li></ul><ul><li>SCADA - CT32 </li></ul><ul><li>CTIU user interface </li></ul><ul><li>for Local Monitoring </li></ul><ul><li>CTNet I/O </li></ul><ul><li>Repeaters/Hubs </li></ul>Repeater Remote I/O CTIU CTIU CTIU CTIU Hub R SCADA MMI - CT32 Programming Diag. Tools PC Gateway
    58. 72. Cranes Fans & Pumps Food and Drink Material Handling Metals & Metal Forming Paper Printing Rubber & Tyre Stage Scenery Textiles Wire Drawing Industrial Sector Focus Plastic Oil & Gas
    59. 73. Control Techniques are the preferred Suppliers to…
    60. 74. Control Techniques India is Preferred Supplier to <ul><li>TISCO </li></ul><ul><li>TELCO </li></ul><ul><li>TUBE PRODUCTS </li></ul><ul><li>STEELCO GUJRAT </li></ul><ul><li>ESSAR </li></ul><ul><li>FLAT PRODUCTS </li></ul><ul><li>MULTIFORM </li></ul><ul><li>NESTLE </li></ul><ul><li>BALKRISHNA TYRES </li></ul><ul><li>BALLARPUR INDUSTRIES </li></ul><ul><li>SHESASAYEE PAPER AND BOARDS </li></ul><ul><li>LUCAS TVS </li></ul><ul><li>BRAKES INDIA </li></ul><ul><li>KOHLI INDUSTRIES </li></ul><ul><li>and ……… on </li></ul>
    61. 75. CT India Sample References Automation Solutions for Metal Industry <ul><li>Over 40 Customers Served till date </li></ul><ul><li>Major Repeat References include: </li></ul><ul><ul><li>TISCO (Over 35 projects till date) </li></ul></ul><ul><ul><li>Salem Steel </li></ul></ul><ul><ul><li>Flat Products Equipment (Process Line OEM) – Over 20 Export Projects </li></ul></ul><ul><ul><li>Multiform Machinery (Process Line OEM) – Over 10 Projects </li></ul></ul><ul><ul><li>Visakhapatnam Steel Plant </li></ul></ul><ul><ul><li>Metastrips </li></ul></ul><ul><ul><li>ITW Signode </li></ul></ul><ul><ul><li>PHP Steel - Bangladesh </li></ul></ul><ul><ul><li>Karnafully Steel - Bangladesh </li></ul></ul><ul><ul><li>Tube Product of India </li></ul></ul><ul><ul><li>Pennar Steel </li></ul></ul><ul><ul><li>Ispat Industries </li></ul></ul><ul><ul><li>SteelCo Gujarat </li></ul></ul><ul><ul><li>Shree Pre-Coated Steels </li></ul></ul><ul><li>Applications Expertise in: </li></ul><ul><ul><li>Rolling Mills </li></ul></ul><ul><ul><li>Skin Pass Rolling </li></ul></ul><ul><ul><li>Continuous Galvanizing Line </li></ul></ul><ul><ul><li>Cut-To-Length Line </li></ul></ul><ul><ul><li>Pickling & Slitting Lines </li></ul></ul><ul><ul><li>Rewinding & Electro-Cleaning Line </li></ul></ul><ul><ul><li>Color Coating Line </li></ul></ul><ul><ul><li>Partial Line Upgrades + Retrofits </li></ul></ul><ul><ul><li>Fan & Pumps </li></ul></ul><ul><ul><li>Flying Shears </li></ul></ul><ul><li>Supplies include Drive Systems + SCADA + PLC Automation + Motors + MCC’s </li></ul>
    62. 76. Galvanising Lines <ul><li>Karnafully Steel - Bangladesh (Thru, MAS ) </li></ul><ul><li>Rajesh Metals - Nepal (Thru, MAS ) </li></ul><ul><li>PHP Steel, Bangladesh </li></ul><ul><li>PT Essar Indonesia </li></ul><ul><li>Kandil Steels,Egypt </li></ul><ul><li>Yung Kong Steel , Malaysia </li></ul><ul><li>( PCC+MCC+Drives( AC ) + LINE PLC + FURNACE PLC + </li></ul><ul><li>SCADA +UPS) </li></ul>
    63. 77. Galvanising Lines <ul><li>Cheman Ispat, Bangladesh (Thru’ Multiform) </li></ul><ul><li>PHP Steel, Bangladesh </li></ul><ul><li>YESU STEEL, ETHIOPIA </li></ul><ul><li>VARDHAMAN STEELS, AMBALA(DC ) </li></ul><ul><li>Kandil Steels, Egypt </li></ul><ul><li>Midgal, Nigeria </li></ul><ul><li>Doo Won Steel, Korea </li></ul>PCC+MCC+Drives( DC ) + LINE PLC + FURNACE PLC + SCADA +UPS
    64. 78. Steel Industry Cold Rolling Mills <ul><li>Tube Products of India( 4 Hi) </li></ul><ul><li>Shamon Ispat Ltd( 4 Hi) </li></ul><ul><li>Meta Strips(4 Hi) </li></ul><ul><li>Kandil Steels, Egypt( 4 Hi) </li></ul><ul><li>Karnafully, Bangladesh(4 Hi and 20 Hi) </li></ul>
    65. 79. Steel Industry Skin Pass Mill <ul><li>Essar Steel, Indonesia </li></ul><ul><li>Kandil Steels, Egypt </li></ul><ul><li>KYCR Steel, Bangladesh </li></ul><ul><li>SPSL, Pune </li></ul><ul><li>Balco(Slab) </li></ul>
    66. 80. Steel Industry Slitting Line <ul><li>Raymonds Ltd (3 Lines) </li></ul><ul><li>Meta Strips </li></ul><ul><li>Pennar Steel </li></ul><ul><li>SPSL,Pune </li></ul><ul><li>TATA SSL,Navsari-C.R.Slitter (thro. Metpro) </li></ul><ul><li>TATA SSL,Navsari-H.R.Slitter (thro. Hollow Block) </li></ul><ul><li>Tube Products Of India </li></ul>
    67. 81. Steel Industry C UT TO LENGTH LINE <ul><li>Tube Products of India-3 Lines </li></ul><ul><li>TATA SSL </li></ul><ul><li>Dass Nagar (A/c.Galsheet , Kenya) </li></ul><ul><li>Flat Products (A/c. Uttam Steel revamping) </li></ul><ul><li>Flat Products (A/c.PHP Steels) </li></ul><ul><li>Flat Products (A/c.Apollo Steels) </li></ul><ul><li>Flat Products (A/c.R.M. Steels) </li></ul><ul><li>T.K.Steels </li></ul>
    68. 82. Steel Industry Pickling Line / Cleaning Line <ul><li>Jai Corp </li></ul><ul><li>Meta Strips </li></ul><ul><li>S Alam , Bangladesh </li></ul><ul><li>Lloyds Steel </li></ul><ul><li>Essar, Hazira </li></ul>
    69. 83. Steel Industry Pickling Line / Cleaning Line <ul><li>Flat Products </li></ul><ul><li>Kandil Steel Steel,Egypt. </li></ul><ul><li>R.M.Steel Bangladesh </li></ul><ul><li>Yung kong Steels, Malaysia </li></ul><ul><li>Yesu Steel, Ethiopia </li></ul><ul><li>Mobati Steel,Kenya </li></ul>
    70. 84. Steel Industry Rewinding Line <ul><li>Flat Products: </li></ul><ul><li>R.M. Steels,Bangladesh </li></ul><ul><li>Yesu Steel, Ethiopia </li></ul><ul><li>PHP Steel,Bangladesh </li></ul><ul><li>Apollo Steels, Bangladesh </li></ul><ul><li>Jindal Steel, Kolkata </li></ul><ul><li>Uttam Steel, Khopoli </li></ul>
    71. 85. Steel Industry Rewinding Line <ul><li>PT Essar, Indonesia </li></ul><ul><li>SPSL,Pune </li></ul><ul><li>S ALAM, Bangladesh(Thru’ Multiform) </li></ul>
    72. 86. Steel Industry TLL <ul><li>PT Essar, Indonesia </li></ul><ul><li>SPSL,Pune </li></ul><ul><li>Jai Corp, Nanded </li></ul><ul><li>Mobati Steels, Kenya </li></ul><ul><li>Multiform(at Malaysia) </li></ul>
    73. 87. TISCO <ul><li>ROLLER TABLE DRIVE SYSTEM – 315 KW * 8 SETS (Getting upgraded to 480 Kw) </li></ul><ul><li>GAS BOOSTER FANS – 450 KW – 5 NOS </li></ul><ul><li>THYRISTOR CONVERTERS FOR HSM- 16 SETS </li></ul><ul><li>VARIOUS UPGRADES </li></ul><ul><li>MORE THAN 500 Modules of Various Ratings </li></ul>
    74. 88. Wire Rod Mills <ul><li>TAMILNADU STEEL, ARAKONAM </li></ul><ul><li>NATIONAL ENGG, CHENNAI </li></ul><ul><li>SUMANGALA STEEL, BHUVANGIRI </li></ul><ul><li>INDO BAZHA , INDONESIA ETC </li></ul>DC Drives (Stand ,Coilers) + PLC + AUTOMATION
    75. 89. CRANES <ul><li>SALEM STEEL PLANT </li></ul><ul><li>TATA STEEL </li></ul><ul><li>TATA MOTORS , PUNE </li></ul><ul><li>RANK CRANES, HYDERABAD ETC </li></ul>
    76. 90. Additionally <ul><li>Wagon Tippler Drives in VSP </li></ul><ul><li>Static Excitation for Generators </li></ul><ul><li>Double Column Planing Machine Controls Retrofit for BHEL ,with Active Front end </li></ul><ul><li>12 Pulse Converters for Banbury Mixers </li></ul>
    77. 91. Steel Industry Cold Rolling Mills <ul><li>Tube Products of India </li></ul><ul><li>Shamon Ispat Ltd </li></ul><ul><li>Meta Strips </li></ul>
    78. 92. Steel Industry- Cold Rolling Mills Tube Products of India Highlights <ul><li>Supplied & Commissioned in 1993 /1994 </li></ul><ul><li>Uncoiler : 2 x 75 HP / 250 V DC </li></ul><ul><li>Main Mill : 300 HP </li></ul><ul><li>Coiler : 2 x 75 HP / 250 V DC </li></ul><ul><li>PLC : S 135 </li></ul><ul><li>MMI : Intellution </li></ul>
    79. 93. Steel Industry- Cold Rolling Mills Tube Products of India Highlights <ul><li>Supplied & Commissioned in 2005 </li></ul><ul><li>Uncoiler : L&T Stack with Mentor Electronics </li></ul><ul><li>Main Mill : 375 Kw/ 575 V(New) </li></ul><ul><li>Coiler : L&T Stack with Mentor Electronics </li></ul><ul><li>PLC : S-7/400 </li></ul><ul><li>MMI : Win CC </li></ul>
    80. 94. Steel Industry- Tube Mills for China Tube Products of India Highlights <ul><li>Supplied & Commissioned in 2006 </li></ul><ul><li>Forming/Fin Pass/ Sizing: 150 Kw DC </li></ul><ul><li>Accumulator: 55 Kw AC </li></ul><ul><li>Pinch Rool:30 Kw AC </li></ul><ul><li>Shear: 55 Kw AC </li></ul><ul><li>Carriage : 60 Nm Servo </li></ul>
    81. 95. Steel Industry- Cold Rolling Mills Shamon Ispat Ltd – Haldia Highlights <ul><li>Supplied & Commissioned in 1998 / 1999 </li></ul><ul><li>Uncoiler : 500 HP / 600V </li></ul><ul><li>Main Mill :1500 HP /600V </li></ul><ul><li>Exit Coiler : 500 HP / 600V </li></ul><ul><li>Screw Down : 50 HP / 250V each near /far </li></ul><ul><li>PLC : GE Fanuc </li></ul><ul><li>MMI : Intellution </li></ul>
    82. 96. Steel Industry- Cold Rolling Mills Shamon Ispat Ltd A/c. Karnafully Steels- 4 Hi Mills <ul><li>Supplied in 1999 & Commissioning under progress </li></ul><ul><li>Payoff : 60 HP / 250V </li></ul><ul><li>Entry Coiler : 500 HP / 600V </li></ul><ul><li>Mill Drive : 1500 HP / 600V </li></ul><ul><li>Exit Coiler : 500 HP / 600V </li></ul><ul><li>Screw down : 50 HP /250V each far/near </li></ul><ul><li>PLC : GE Fanuc </li></ul><ul><li>MMI : Intellution </li></ul>
    83. 97. Steel Industry- Cold Rolling Mills Karnafully Steels- 20 Hi Mills <ul><li>Supplied in 2003 & Commissioned in 2004 </li></ul><ul><li>Payoff : 100 HP / 400V </li></ul><ul><li>Entry Coiler : 2*950 HP/350V(Series) </li></ul><ul><li>Mill Drive : 2*1800 HP/ 750V(Tandem) </li></ul><ul><li>Exit Coiler : 2*950 HP/350V(Series) </li></ul><ul><li>Screw down : 50 HP /250V each far/near </li></ul><ul><li>PLC : GE Fanuc </li></ul><ul><li>MMI : Intellution </li></ul>
    84. 98. Steel Industry- Cold Rolling Mills Meta Strips Highlights <ul><li>Supplied & Commissioned in 1999/ 2000 </li></ul><ul><li>Pay Off : 50 Kw </li></ul><ul><li>Uncoiler : 230 Kw </li></ul><ul><li>Main Mill : 600 Kw </li></ul><ul><li>Coiler : 230 Kw </li></ul><ul><li>PLC : S7 300 </li></ul><ul><li>MMI : PCIM </li></ul>
    85. 99. Steel Industry Hot Mills Sumangala Steel <ul><li>Supplied & Commissioned in 1995 /1996 </li></ul><ul><li>Main stand : 6 x 200 Kw </li></ul><ul><li>Coiler : 2 x 15 Kw </li></ul><ul><li>Pinch Roll : 2 x 15 KW </li></ul><ul><li>PLC : S 135 </li></ul><ul><li>MMI : Intellution </li></ul>
    86. 100. Steel Industry Hot Mills Indo Baja - Indonesia <ul><li>Supplied & Commissioned in 1997 /1998 </li></ul><ul><li>Main stand : 3 x 400 Kw </li></ul><ul><li>PLC : S 135 </li></ul><ul><li>MMI : Intellution </li></ul>
    87. 101. How have we been sustaining this Success – Year after Year?
    88. 102. The Driving Force behind our success…. <ul><li>Application Specific Engineered Systems – We have the Experience! </li></ul><ul><li>Able to obtain the latest technology in Automation – No Compromises </li></ul><ul><li>Product Leadership position </li></ul><ul><li>Getting the most-up-to-date engineering design – Due to our Shared Resource Network </li></ul><ul><li>All our Drive products carry a Product Warranty for 2 Years & your nearest Support Centre will honour all Warranty Commitments for supplies made to you </li></ul><ul><li>Excellent and prompt after sales service support </li></ul>
    90. 104. Intelligence in Drives <ul><li>Modern System Requirements </li></ul><ul><li>High Resolution Speed Ref(Master Speed) </li></ul><ul><li>Draw Calculations(Section Draws) </li></ul><ul><li>Diameter Calculations and TensionReference Generation(Uncoilers) </li></ul><ul><li>Length Computations </li></ul><ul><li>Logical Decision Makings </li></ul>
    91. 105. INTELLIGENCE IN Drives <ul><li>All these require quite a good amount of Computing Power and hence need of Additional Processor. </li></ul><ul><li>While selecting the control system,other parameters also need consideration </li></ul><ul><li>Updates need to be periodic & deterministic (Data must arrive at regular guaranteed time intervals) </li></ul><ul><li>The period or cycle of updates should be synchronized with the digital control loops in the drive / controller to eliminate any undesirable “beating” effects </li></ul>
    92. 106. INTELLIGENCE IN DRIVES <ul><li>In addition to these critical parameters, Non-Time critical access to network should also be supported (e.g. Operator interaction / Drive set-up / Downloading application software / Diagnostics / Data logging) </li></ul><ul><li>Implementation can be by Centralized Intelligence or Distributed Intelligence approach </li></ul>
    93. 107. Configuration Possibilities Central Intelligence <ul><li>All System Control Functions can be located in the Central Controller & transfer Demands + Feedbacks cyclically over the network. This is a typical Centralized Intelligence system Most PLC manufacturers prefer this approach even for Drive digital control for obvious reasons!! </li></ul>
    94. 108. How about the Control Techniques Approach?
    95. 109. INTELLIGENCE IN DRIVES C.T. Approach <ul><li>C.T.uses Distributed Control and pioneered use of an additional Microcomputer Board fitted on the Drive. </li></ul><ul><li>This function board is called MD29 and uses a 32 bit 2 nd Processor for onboard maths and logics </li></ul><ul><li>All Drive related functions and calculations reside as preprogrammed Macros and the user has just to enter certain system data </li></ul><ul><li>The 2 nd Processor will communicate with the processor in the Drive and execute the additional functions with timings synchronised with Drive Processor </li></ul>
    96. 110. Distributed Architecture Benefits <ul><li>With Distributed architecture, the load on the network is reduced to a large extent </li></ul><ul><li>Peer-To-Peer communications is possible. This allows data to be shared easily between the nodes without reducing network speeds . </li></ul><ul><li>The dynamic performance of the system is better handled by distributed systems. </li></ul>
    97. 111. INTELLIGENCE IN DRIVES C.T. Approach Add-On Co-Processor Card for Mentor II
    98. 112. Intelligent Options for AC Drives… <ul><ul><li>Palm-sized Second Processor </li></ul></ul><ul><ul><li>Intel i960 32-bit RISC processor </li></ul></ul><ul><ul><li>With High-speed Fieldbus Connectivity </li></ul></ul><ul><ul><li>Programming in Ladder / Function Blocks or Script </li></ul></ul><ul><ul><li>Connects to Remote I/O Blocks </li></ul></ul><ul><ul><li>Distributes Real Time Control </li></ul></ul>Zero Space PLC Plugs into Drive module Calculate Logic Connect Systems Connect I/O
    99. 113. The 1986 Industrial Revolution. <ul><li>In 1986 Control Techniques launches MD21. </li></ul><ul><ul><li>The birth of the intelligent drive. </li></ul></ul>
    100. 114. From revolution to evolution
    101. 115. Hardware Evolution 1 st Generation 2 nd Generation 3 rd Generation MD21 MD29 UD70 MD29AN UD75 SM-Applications
    102. 116. Software Evolution 1 st Generation 2 nd Generation 4 th Generation 3 rd Generation Terminal Window DPL Toolkit SyPT V1
    103. 117. Functionality Evolution 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
    104. 118. Functionality Evolution 100% 90% 90% <1% Execution Speed Hitachi SH2 (28kHz) I960 (16kHz) I960 (16kHz) Intel Basic Interpreter Processor Yes Yes Yes No Multi-Tasking 80Kb 44Kb 8Kb Variable Memory 384Kb 256Kb 96Kb 32Kb Program Memory SM-Apps UD70 MD29 MD21
    105. 119. Example Line Configuration
    106. 122. <ul><li>Line Automation Features </li></ul><ul><li>Feature </li></ul><ul><li>Master Reference Generation </li></ul><ul><li>A Basic Programme is written in MD29AN card simulating up-down counter operation </li></ul><ul><li>Accuracy is 1 in 64000 </li></ul><ul><li>Increase and Decrease in adjustable steps (Ramp adjustable) </li></ul><ul><li>Reference is transmitted in Digital form to other sections along CT Net bus </li></ul><ul><li>Please note PLC is not used for Master ref generation </li></ul>
    107. 123. <ul><li>Line Automation Features </li></ul><ul><li>Feature </li></ul><ul><li>Tension Control for Uncoiler </li></ul><ul><li>MD 29AN is provided with Centre wind Software </li></ul><ul><li>Dia is calculated in MD29AN </li></ul><ul><li>Inertia compensation, Friction compensation etc. are inbuilt in MD29 </li></ul><ul><li>Taper tension, Stall tension, dia hold, strip breakage protection etc. are standard inbuilt facilities in MD29AN </li></ul><ul><li>Please note PLC is not used for Tension Control </li></ul>
    108. 124. <ul><li>Line Automation Features </li></ul><ul><li>Feature </li></ul><ul><li>Loop Pit Control </li></ul><ul><li>2 No. Encoders will be mounted, (one on delivery side and another on entry side) for each loop </li></ul><ul><li>MD29AN is used for Counting and comparing the pulses from both Encoders and the differential is a measure of Loop. </li></ul><ul><li>Depending upon required Loop,the speed of the concerned DC Pinch Roll Units are modified such that Process speed remains constant. </li></ul><ul><li>Please note PLC is not used for Loop Control </li></ul>
    109. 125. <ul><li>Line Automation Features </li></ul><ul><li>Feature </li></ul><ul><li>Squeeze Roll Control </li></ul><ul><li>The Encoder mounted on the delivery side of Loop Pit (in the Process Section ) is used to measure the length of strip (initiated after Head indexing) </li></ul><ul><li>Length counting is done in MD29 AN and passed to PLC on BUS. </li></ul><ul><li>PLC will initiate commands to squeeze rolls to lift whenever welding is passing and after certain time, rolls would be lowered. </li></ul>
    110. 126. <ul><li>Line Automation Features </li></ul><ul><li>Feature </li></ul><ul><li>Acid Dozing Control </li></ul><ul><li>The length calculated is used on different scale </li></ul><ul><li>Acid pumps can be switched ON/OFF automatically after certain length of material is passed thru’ Process Section. </li></ul>
    111. 127. <ul><li>Line Automation Features </li></ul><ul><li>Feature </li></ul><ul><li>Coil weight Measurement </li></ul><ul><li>The existing weighing control system will be connected to PLC System on the Bus. </li></ul>
    112. 128. <ul><li>Line Automation </li></ul><ul><li>Drives (Network #1) </li></ul><ul><li>All Drives connected on Hi-speed CT Net </li></ul><ul><li>Data Transfer at 5MB/S (Large amount of data Transmitted quickly) </li></ul><ul><li>Peer to Peer System and no Master PLC Controller required </li></ul><ul><li>Each node takes control of network on its turn to communicate directly with other Network nodes. </li></ul>
    113. 129. <ul><li>Line Automation </li></ul><ul><li>Drives (Network #1) …… </li></ul><ul><li>Each Drive fitted with MD 29 AN Application cum Fieldbus Module with CT Net connectivity </li></ul><ul><li>All Line specific controls like Tension control, Loop Control etc.are set up in Application Module,located within drive module itself. This frees PLC from doing Maths functions related to Drive systems. </li></ul><ul><li>Fast real time control of equipment is achieved. </li></ul>
    114. 130. <ul><li>Line Automation </li></ul><ul><li>PLC’s in MCC/Main/Remote Racks </li></ul><ul><li>(Network #2) </li></ul><ul><li>All I/O’s are connected on fast Profi-bus Network </li></ul><ul><li>Remote stations are located to minimize cabling </li></ul><ul><li>PC in ECR Room is loaded with PLC programme and Sypt </li></ul>
    115. 131. <ul><li>Line Automation </li></ul><ul><li>Interfacing between Two Bus Systems </li></ul><ul><li>An UniSP Drive is used </li></ul><ul><li>One Addon Slot is fitted with CTNet Module </li></ul><ul><li>Relevant FieldBus (Profibus/ Modbus / DeviceNet) Module from UniSP family is put in the 2 nd Slot </li></ul><ul><li>Application Programme for Register to Register Transfer is written by SyPT </li></ul>
    116. 132. Control Techniques India <ul><li>Scope of Supply: </li></ul><ul><li>Drives, PLC & Scada system </li></ul><ul><li>Mill Specification: </li></ul><ul><li>Max. Speed: 300 MPM </li></ul><ul><li>Material Thickness: 0.2mm to 2.00mm </li></ul><ul><li>Material Width: 600mm to 1320mm </li></ul><ul><li>Maximum Roll Force: 3500 kN </li></ul>Process Line : 4 Hi Non Reversible Skin Pass Mill Customer : Flat products Limited, India End User : PT Essar Dhananjaya, Indonesia Contract value : US $ 180,000 Project Team : Ganesh + Satish
    117. 137. Control Techniques India Application Module : MD29AN PLC : Siemens, S7 - 400 Gateway Module : UniSP + SM Application + SM Profibus Scada System : WinCC V 5.1 Process Line : 4 Hi Non Reversible Skin Pass Mill End User : PT Essar Dhananjaya, Indonesia Project Team : Ganesh + Satish M1850R 325kw Recoiler M550R 90kw Exit Bridle Roll – M2 M550R 140kw Exit Bridle Roll – M1 M1850R 250kw Mill Stand M550R 140kw Entry Bridle Roll – M2 M550R 90kw Entry Bridle Roll – M1 M 1850R 225kw Uncoiler Drive Rating Motor Rating Application
    118. 138. Control Techniques India <ul><li>Time taken for commissioning </li></ul>Process Line : 4 Hi Non Reversible Skin Pass Mill End User : PT Essar Dhananjaya, Indonesia Project Manager: B. Ganesh + Satish 5 Mandays Post Commissioning Observation/Tuning 3 Mandays Commissioning 2 mandays SCADA Modification 1 Manday Interaction withAEC Panel Check 1 Manday Drive Software Simulation Test 3 Mandays Operation from CD with interlock 2 Mandays No Load motor Test 5 Mandays I/O Checking
    119. 139. Drives & Automation System Of Continuous Galvanizing Line PT.Essar, Indonesia.
    120. 140. <ul><li>End-Customer: M/s PT.Essar, Indonesia </li></ul><ul><li>Application: Continuous Galvanizing Line </li></ul><ul><li>(Non-OX Furnace) </li></ul><ul><li>OEM: M/s Flat Products Equipment (I) Ltd </li></ul><ul><li>Mumbai, India </li></ul><ul><li>Contract Date: 26th August 2003 </li></ul><ul><li>Contract Value: US $ 652,000 </li></ul><ul><li>Scope of Supply: Drives, PLC & SCADA Systems </li></ul><ul><li>Commissioned on: October 2004 </li></ul>Project Details
    121. 141. <ul><li>The CR coils directly from 6 Hi/4 Hi mills are transferred to CGL lines.  </li></ul><ul><li>The Strip passes through various processes to remove defects, etc. </li></ul>CGL Process ( 1 of 3) <ul><li>CGL being a continuous line, the coils passed through Looper. </li></ul><ul><li>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.   </li></ul>
    122. 142. <ul><li>Then the coil is passed through Zinc pot where Zinc coating is carried out . </li></ul><ul><li>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. </li></ul>CGL Process ( 2 of 3) <ul><li>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 . </li></ul><ul><li>The Zinc Coating weight is controlled by the Air Knife Blowers </li></ul>
    123. 143. <ul><li>Zinc coated coils thus passed through Chromate solution provides safe guard to the coils from white rusting and other atmospheric reaction. </li></ul><ul><li>The chromic acid concentration shall be 20 to 25 gm/ltr with a temperature of 40 to 45 C.  </li></ul><ul><li>In addition, the strip passes through Tension Leveler & 4-Hi Skin Pass Mill to improve the shape of product and give perfect flatness.  </li></ul><ul><li>At the exit, strip is coiled.  </li></ul>CGL Process ( 3 of 3)
    124. 144. <ul><li>Max Machine Speed: </li></ul><ul><ul><li>Entry Section: 190 MPM </li></ul></ul><ul><ul><li>Process Section: 150 MPM </li></ul></ul><ul><ul><li>Exit Section: 190 MPM </li></ul></ul><ul><li>Material Thickness Range: </li></ul><ul><ul><li>Min: 0.16 mm </li></ul></ul><ul><ul><li>Max: 2.00 mm </li></ul></ul><ul><li>Material Width Range: </li></ul><ul><ul><li>Min: 600 mm </li></ul></ul><ul><ul><li>Max: 1320 mm </li></ul></ul><ul><li>Max Furnace Capacity: </li></ul><ul><ul><li>25 Tons / Hour </li></ul></ul><ul><li>Other Specialties: </li></ul><ul><ul><li>Online 4-Hi Skin Pass Mill </li></ul></ul><ul><ul><li>Online Tension Leveling Line </li></ul></ul><ul><ul><li>Online Chemical Coater </li></ul></ul>Line Specifications
    125. 145. <ul><li>There are 33 Nos. of Unidrive Classic and the Range of the Motors from 5.5 KW to 400 KW. </li></ul><ul><li>All the Line Drives are connected on COMMON DC BUS. </li></ul><ul><li>One no. of 2000 Amps Uncontrolled Diode bridge is there to provide the DC Supply. </li></ul><ul><li>Also, there are 19 Nos. of Auxiliary Drives (5 Nos. Unidrive Classic for higher rating and Commander SE Drives for the remaining). </li></ul><ul><li>Further,there are some emergency Drives, which are related to the furnace system </li></ul><ul><li>3 Nos. of Siliconics Soft Starters used for Heater Controls. </li></ul>Drive System Details
    126. 146. Single Line Diagram (Line Drives)
    127. 147. Drive Details (Line Drives) Entry Section Drives UD75 UNI 4401 45.0 Entry Accumulator 7 UD75 UNI 3403 18.5 Bridle # 1D 6 ~ UNI 3403 18.5 Bridle # 1C 5 UD75 UNI 3401 15.0 Bridle # 1B 4 ~ UNI 3401 15.0 Bridle # 1A 3 UD75 UNI 4402 110.0 Payoff # 2 2 UD75 UNI 4404 110.0 Payoff # 1 1 Apps. Module Drive Rating Motor Rating Description Sr.No
    128. 148. Drive Details (Line Drives) Process Section Drives (1 of 2) ~ UNI 5401 160.0 Backup Roll-Top 18 UD75 UNI 5401 160.0 Backup Roll-Bot 17 ~ UNI 4402 55.0 Bridle # 4B 16 UD75 UNI 4401 45.0 Bridle # 4A 15 ~ UNI 3405 37.0 Bridle # 3B 14 UD75 UNI 3405 37.0 Bridle # 3A 13 UD75 UNI 3404 30.0 Furnace Bridle C 12 ~ UNI 3403 18.5 Furnace Bridle B 11 ~ UNI 2402 5.5 Furnace Bridle A 10 ~ UNI 3404 30.0 Bridle # 2B 9 UD75 UNI 3404 30.0 Bridle # 2A 8 Apps. Module Drive Rating Motor Rating Description Sr.No
    129. 149. Drive Details (Line Drives) Process Section Drives (2 of 2) ~ UNI 4402 55.0 Bridle # 7B 29 UD75 UNI 4403 75.0 Bridle # 7A 28 ~ UNI 3402 18.5 KW Chromate Coater#4 27 UD75 UNI 3402 18.5 KW Chromate Coater#3 26 ~ UNI 3402 18.5 KW Chromate Coater#2 25 UD75 UNI 3402 18.5 KW Chromate Coater#1 24 ~ UNI 5402 132.0 Bridle # 6B 23 UD75 UNI 5401 200.0 Bridle # 6A 22 UD75 UNI 4404 90.0 Bridle # 5C 21 ~ UNI 5401 132.0 Bridle # 5B 20 UD75 UNI 4403 75.0 Bridle # 5A 19 Apps. Module Drive Rating Motor Rating Description Sr.No
    130. 150. Drive Details (Line Drives) Exit Section Drives UD75 UNI 5403 400.0 Recoiler 33 UD75 UNI 4402 55.0 Bridle # 8B 32 ~ UNI 3405 37.0 Bridle # 8A 31 UD75 UNI 4402 55.0 Exit Accumulator 30 Apps. Module Drive Rating Motor Rating Description Sr.No
    131. 151. Single Line Diagram (Aux. Drives)
    132. 152. Drive Details (Aux. Drives) 18.5 KW - SE 7 x 2.2 KW Hearth Roll Drive # 2 19 18.5 KW - SE 7 x 2.2 KW Hearth Roll Drive # 1 18 11 KW - SE 5.5 KW Entry Seal Roll 17 7.5 KW - SE 5.5 KW Boot Roll 16 1.1 KW - SE 0.83 HP Jet Act In/ Out # 4 15 1.1 KW - SE 0.83 HP Jet Act In/ Out # 3 14 1.1 KW - SE 0.83 HP Jet Act In/ Out # 2 13 1.1 KW - SE 0.83 HP Jet Act In/ Out # 1 12 4 KW - SE 2.2 KW Jet Act Up/ Down # 2 11 4 KW - SE 2.2 KW Jet Act Up/ Down # 1 10 UNI 5402 110 KW Air Knife Blower # 2 9 UNI 5402 110 KW Air Knife Blower # 1 8 UNI 4404 55 KW Cooling Tower Blower # 3 7 UNI 4403 55 KW Cooling Tower Blower # 2 6 UNI 4404 90 KW Cooling Tower Blower # 1 5 37 KW - SE 37 KW NOF flue Exhaust Blower 4 37 KW - SE 22 KW Jet Cool Fan # 3 3 37 KW - SE 22 KW Jet Cool Fan # 2 2 37 KW - SE 22 KW Jet Cool Fan # 1 1
    133. 153. <ul><li>All the Line Drives are connected through CT-Net. </li></ul><ul><li>The Auxiliary Drives & Soft starters are hard-wired to PLC. </li></ul><ul><li>Automation (PLC) Part is segregated into two parts. One is Line controls & other is Furnace Controls. </li></ul><ul><li>Siemens Step-7 PLC is used. </li></ul><ul><li>S7 – 400 for Line Operations & S7 – 300 for Furnace Operations. </li></ul><ul><li>There are 14 Nos. of Remote I/O Stations and all are connected through Profibus- DP. </li></ul><ul><li>S7-400 & S7-300 Data exchange is done by Global Data Communication. </li></ul><ul><li>Unidrive SP + SM-Apps + SM-Profibus are used as the communication gateway between drive system & PLC system </li></ul>Automation Details
    134. 154. Line Specifications Communication 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
    135. 155. Profibus Routing
    136. 156. CT-Net Routing
    137. 157. <ul><li>There are 2 sets of 1024 Power tags SCADA Stations, One for Line Operations and other is dedicated for Furnace Operations. </li></ul><ul><li>Siemens WinCC SCADA Package is used. </li></ul><ul><li>SCADA is connected to PLC System through Profibus-DP. </li></ul><ul><li>In addition, there are 4 Nos. of Operator Interface units (OP170B), which are fitted on the Control Desks. </li></ul>SCADA – Overview
    138. 158. SCADA – Line Overview
    139. 159. SCADA – Entry Section
    140. 160. SCADA – Process Section
    141. 161. SCADA – Exit Section
    142. 162. SCADA – Furnace Section
    143. 163. SCADA – PHF Burner Controls
    144. 164. SCADA – PHF PID Settings
    145. 165. SCADA – Pot Furnace
    146. 166. Control Techniques India Process Line : Continuous Galvanising Line Customer : Flat Products Limited, India End User : PT Essar Dhananjaya, Indonesia Contract value : US $ 630,000 Project Team : Bhanuprakash + Ganesh + Satish <ul><li>Process </li></ul><ul><li>1. Strip is Acid cleaned, passed through various parts of furnace to burn out oxygen </li></ul><ul><li>2. Temp. taken to 700 deg. and brought down to 400 deg for softening Strip and matching the Zinc temp. </li></ul><ul><li>3. Strip dipped in molten zinc </li></ul><ul><li>4. During process, important to maintain strip tension regulation to maintain Metallurgical characteristics of the strip </li></ul>
    147. 167. Control Techniques India <ul><li>Scope of Supply: </li></ul><ul><li>Drives, PLC & SCADA system </li></ul><ul><li>Mill Specification: </li></ul><ul><li>Max. Speed: Entry & Exit : 190MPM Process: 160MPM </li></ul><ul><li>Material Thickness Range : 0.16mm to 2.00mm </li></ul><ul><li>Material Width Range : 600mm to 1320mm </li></ul><ul><li>Furnace Capacity: 25 Tons/ Hour </li></ul>Process Line : Continuous Galvanising Line Customer : Flat Products Limited, India End User : PT Essar Dhananjaya, Indonesia Contract value : US $ 630,000 Project Team : Bhanuprakash + Ganesh + Satish
    148. 172. Jet Act Up/Down # 2 4 kw - SE Exit Accumulator 55kw – Uni 4402 Bridle # 4A 45kw – Uni 4401 LINE DRIVES Jet Act Up/Down # 1 4 kw - SE Bridle # 7B 55 kw – Uni 4402 Bridle # 3B 37kw – Uni 3405 SCADA – 2 sets 1024 tags Win CC Version 6.0 Air Knife blower # 2 110kw – Uni 5402 Bridle # 7A 75 kw – Uni 4403 Bridle # 3A 37kw – Uni 3405 Gate way Module – 3 sets UniSP + SM Application + SM Profibus Air Knife blower # 1 110kw – Uni 5402 Chromate Coater # 4 18.5kw – Uni 3402 Furnace Bridle C 30 kw – Uni 3404 PLC : Siemens S 7 - 400 S7 - 300 Cooling Tower Blower # 1 55kw – Uni 4403 Chromate Coater # 3 18.5kw – Uni 3402 Furnace Bridle B 18.5kw – Uni 3403 Total Drives – 38 Uni Drives – 14 SE Drives Cooling Tower Blower # 1 55 kw – Uni 4403 Chromate Coater # 2 18.5kw – Uni 3402 Furnace Bridle A 5.5kw – Uni 2402 Cooling Tower Blower # 1 90 kw – Uni 4404 Chromate Coater # 1 18.5kw – Uni 3402 Bridle # 2B 30kw – Uni3404 Hearth Roll Drive # 2 18.5kw - SE NOF Flue Exhaust Blower 37 kw – SE Bridle # 6B 132 kw – Uni 5402 Bridle # 2A 30kw – Uni3404 Hearth Roll Drive # 1 18.5kw - SE Jet Cool Fan # 1 37 kw - SE Bridle # 6A 200 kw – Uni 5401 Entry Accululator 45kw – Uni4401 Entry Seal Roll 11kw – SE Jet Cool Fan # 1 37 kw - SE Bridle # 5C 90 kw – Uni 4404 Bridle # 1D 18.5 kw - Uni 3403 Boot Roll 7.5kw – SE Jet Cool Fan # 1 37 kw - SE Bridle # 5B 132 kw – Uni 5403 Bridle # 1C 18.5 kw - Uni 3403 Jet Act In/Out # 4 1.1kw SE FURNACE DRIVES Bridle # 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
    149. 173. Textile Industry Customers <ul><li>TEXMACO, CALCUTTA </li></ul><ul><li>SUSSEN ASIA, PUNE </li></ul><ul><li>RAJASTHAN TEXTILE, BILWARA </li></ul><ul><li>MOTEX ENGG. AHMEDABAD </li></ul><ul><li>SANMARCO TEXMAC, COIMBATORE </li></ul><ul><li>OSWAL CHEMICALS </li></ul><ul><li>DRIVES UNIDRIVE & GP DRIVES </li></ul><ul><li>DIGITAX DRIVES,UNIMOTORS </li></ul>
    150. 174. Material Handling Industry Customers <ul><li>CONVEYORS Salem Steel Plant </li></ul><ul><ul><ul><ul><ul><li>Webb India </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>TISCO, Jamshedpur </li></ul></ul></ul></ul></ul><ul><li>HOIST & CRANES Salem Steel Plant TISCO, Jamshedpur </li></ul><ul><li> Telco, Pune </li></ul><ul><li> Rain Calcining, Vizag </li></ul><ul><li>DRDL </li></ul><ul><li>DRIVES UNIDRIVES </li></ul>
    151. 175. Food & Beverages Industry Customers <ul><li>COCA COLA </li></ul><ul><li>PEPSICO </li></ul><ul><li>PARLE INDUSTRIES </li></ul><ul><li>MOHAN MEAKINS </li></ul><ul><li>CADBURY INDIA </li></ul><ul><li>NESTLE </li></ul><ul><li>INDIAN DAIRY (AMUL) </li></ul>
    152. 176. Fiber Industry Customers <ul><li>Application PFY & PSF Plants </li></ul><ul><li>Customers Terene Fibres Ltd </li></ul><ul><li>Reliance Industries Indian Acrylics IPCL </li></ul><ul><ul><ul><ul><ul><li>Orissa Synthetics </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>Shreeram Fibre </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li> Grasim Industries </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li> Indian Organic Chemicals </li></ul></ul></ul></ul></ul><ul><li>Drives Digital DC / AC Drives Systems </li></ul>
    153. 177. Tyre Industry Customers <ul><li>Customer BALKRISHNA TYRES,AURANGABAD </li></ul><ul><li>Applications 6’’ EXTRUDER LINE(8 DRIVES) </li></ul><ul><li>8’’ EXTRUDER LINE(8 DRIVES) </li></ul><ul><li>CALENDER LINE (9 DRIVES) </li></ul><ul><ul><ul><ul><ul><li> TYRE BUILDING M/C DRIVES </li></ul></ul></ul></ul></ul><ul><li>Drives Digital DC / AC Drives Systems </li></ul>
    154. 178. Tyre Industry Customers <ul><li>Customer GOVIND RUBBER, DELHI </li></ul><ul><li>Applications 6’’ EXTRUDER LINE(8 DRIVES) </li></ul><ul><li>8’’ EXTRUDER LINE(8 DRIVES) </li></ul><ul><li>MIXER-170 LITRES </li></ul><ul><ul><ul><ul><ul><li> MIXER-210 LITRE </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>BIAS CUTTERS </li></ul></ul></ul></ul></ul><ul><li>Drives Digital DC / Servo Drives Systems </li></ul>
    155. 179. Tyre Industry Customers <ul><li>Customer CORNELL INTERNATIONAL,MUMBAI </li></ul><ul><li>Applications 210 LITRE MIXER FOR </li></ul><ul><li>ELASTOMERIC ,SRILANKA </li></ul><ul><li>Drives Digital DC / Servo Drives Systems </li></ul>
    156. 180. Proven Flux Vector Technology Sample CT References
    157. 181. CT India References High Performance Crane / MH Drive systems – Sample List <ul><li>Salem Steel Plant – Outdoor Gantry Crane </li></ul><ul><ul><ul><ul><li>- Hoist - 75kW with Regen + LT – 75kW + CT – 15kW + Radio Remote </li></ul></ul></ul></ul><ul><li>Rain Calcining, Vizag – Outdoor Gantry Crane </li></ul><ul><ul><ul><ul><li>- Hoist 30kW + Aux. Hoist – 15kW + LT – 7.5kW + CT – 4kW + Radio Remote </li></ul></ul></ul></ul><ul><li>L&T-ECC Highway Construction Cranes </li></ul><ul><li>Neyveli Lignite – Rotary Kiln application </li></ul><ul><ul><ul><ul><li>37kW Drive + Inv. Grade Motors </li></ul></ul></ul></ul><ul><li>Chennai Port Trust – Wagon Tippler, Feeder & Conveyor Drives </li></ul><ul><ul><ul><ul><ul><li>Upto 200kW regen </li></ul></ul></ul></ul></ul><ul><li>TISCO - EOT Cranes </li></ul><ul><li>Mahindra – Synchronized Hoists for Scorpio Manufacturing Line </li></ul><ul><ul><ul><ul><ul><li>– 32 Nos. UNiDrive SP with Position Control Loop </li></ul></ul></ul></ul></ul><ul><li>TELCO – Synchronized Hoists for Indica Manufacturing Line </li></ul><ul><ul><ul><ul><ul><li>– 32 Nos. UNiDrives with Position Control Loop </li></ul></ul></ul></ul></ul>
    158. 182. CT India Sample References High Performance Drive Systems <ul><li>BHEL Trichy – 3-Axis Servo system for Double Column Planing machine </li></ul><ul><li>BHEL Bhopal – 4-Axes FNC Controller for Milling Machine Retrofit </li></ul><ul><li>BHEL Hyderabad - 4-Axes FNC Controller for Milling Machine Retrofit </li></ul><ul><li>BHEL Hardwar – Vertical Lathe Servo upgrade </li></ul><ul><li>HAL Koraput– 528kW AC Drive – Motor system for Sukhoi Engine Test Jig </li></ul><ul><li>HAL Engine Division – 5-Axis Controller for Sunstrand machine </li></ul><ul><li>HAL Helicopter Division – 4 Axes Controller for Spiramatic Jig Mill </li></ul><ul><li>NAL – 120kW Low Speed Wind Tunnel for Boeing components (4 nos.) </li></ul><ul><li>Triveni Engineering – 750kW DC Drive System for High Speed Gear Box Testing </li></ul><ul><li>Cornell Industries, Sri Lanka - 750kW, 12 pulse for Rubber Mixer Automation </li></ul>
    159. 183. CT India Retrofit Business <ul><li>Binjirajka Steel, Hyderabad – 13 Section Rolling Mill Mentor Retrofit (Upto 1200kW) </li></ul><ul><li>Ballarpur Industries – Yamunanagar – 21-section L&T Sectional Drive System Retrofit with Hi-Speed CT Net </li></ul><ul><li>Servall Board Project – 21 Section Asea Retrofit with Mentor II & MD-29 </li></ul><ul><li>SPB, Erode – Rewinder-cum-Unwinder Brake Generator Retrofit of Stromberg DC System with Automation </li></ul><ul><li>Pennar Industries, Hyderabad: Over 8 projects (Slitter / Mill / Cut-To-Length with Automation) </li></ul>
    160. 184. 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 Example
    161. 185. CT India Sample References High Performance Drive systems <ul><li>Sugar Industry </li></ul><ul><li>160kW Centrifuge Systems ( 350 nos. supplied/commissioned in India ) </li></ul><ul><li>Automotives </li></ul><ul><li>MICO High Performance Testing – Over 500 Nos. AC Drives </li></ul><ul><li>Lucas TVS– over 50 High Performance AC Drive – Motor systems for SPM’s </li></ul><ul><li>Ford India </li></ul><ul><li>Hyundai Motor Industries </li></ul><ul><li>Mahindra </li></ul><ul><li>TELCO </li></ul><ul><li>Escorts </li></ul><ul><li>Goetze </li></ul><ul><li>Delphi TVS </li></ul><ul><li>Visteon </li></ul>
    162. 190. Understanding the Common DC Bus Concept For AC Drive Systems
    163. 191. Drive System Configuration CT-Net Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R R R Brake Chopper Resistor 2000A
    164. 192. Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor Rectifier Unit 6-Pulse Full wave Rectifier Low Input Harmonics Power Factor > 0.95 12-pulse configuration can be offered as optional 2000A R
    165. 193. Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor 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 . R
    166. 194. Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor 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. R
    167. 195. Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor UniDrive Fully Digital IGBT Controlled Micro-processor based On-Board 2 nd 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 2 nd processor Master Line Speed generation within the Drive System R
    168. 196. Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor 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 R
    169. 197. Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R R Regenerative Drive Trafo Elevatore 400V/660V Alternative DC Bus Configuration 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 R
    170. 198. Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R R Alternative DC Bus Configuration 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 Y   IPT R
    171. 199. Major Approvals <ul><li>MECON </li></ul><ul><li>HEC, RANCHI </li></ul><ul><li>TATA STEEL (TISCO, JAMSHEDPUR) </li></ul><ul><li>NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LTD. </li></ul><ul><li>ERCOM ENGINEERS PRIVATE LIMITED NEW DELHI. </li></ul>
    172. 200. <ul><li>We have Technology </li></ul><ul><li>We have Products </li></ul><ul><li>We have Financial Strength </li></ul><ul><li>We have Experience </li></ul><ul><li>We have Application Expertise </li></ul><ul><li>We can deliver large Systems in stipulated time limits </li></ul><ul><li>We can commission Systems very fast </li></ul><ul><li>It will be a privilege for Control Techniques India to have continued association with TATA </li></ul>Summary
    175. 203. Thank You for your Kind Attention