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PROJECT REPORT ON

REFERENCE GENERATION FOR


MOULD AND WITHDRAW ROLLS BY
USING RVG CARD

PREPARED BY
CH. PRATHIP KUMAR
(09P31A0409)

Under The Guidence of


Sri.A.V.VENU GOPAL,Sr.Manager
VISAKHAPATNAM STEEL PLANT, VISAKHAPATNAM

ACKNOWLEDGEMENT
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I take this movement to convey sincere thanks to my project guide Shri.A.V.VENU GOPAL,
Sr.Manager, SMS/CCD,for this valuable suggestion and supervision in making this project.
I wish to express my sense of gratitude to Shri P.K.RATH,D.G.M,(Steel),HOD for the
support to implementing the project.
I am very much thankful to Shri ASHOK NAIK,DM whose valuable guidance for making
this report which helped a lot.
I am very much thankful to Shri J.PRABHAKARA RAO,Jr manager(Trg) for giving us
this opportunity.

CH. PRATHIP KUMAR (09P31A0409)

DECLERATION
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I here to declare that this project report REFERENCES VOLTAGE GENERATION


USING RVG CARD, submitted by me as a part of project training. It is the project done by me
with the support of the members in your organization.

CH.PRATHIPKUMAR(09P31A04
09)

CERTIFICATE
This is to certify that the project report entitled REFERENCE
VOLTAGE GENERATION USING RVG CARD CARD, that is being submitted by N.Venu
Gopal, CH.Prathip Kumar, CH.Naveen , P.Mahesh Varma and is a original record of
bonafide work carried out by them under my guidance and supervision.
A.V.VENU GOPAL
Sr.Manager

INDEX
1.INTRODUCTION................................6
2.BRIEF ABOUT PROJECT..............................7
3.REFERENCE GENERATION IN CASTING MODE FOR THYRISTOR MODE .....9
4.WORKING OF THE THYRISTOR DRIVES (51AU1AND 52AU2)....17
5.DESCRIPTION OF THYRISTOR .20
6.CIRCUIT DIAGRAM OF RVG CARD..22
7.CIRCUIT DIAGRAM BEFORE MODIFICATION...........24
8.CIRCUIT DIAGRAM AFTER MODIFICATION......25
9.ADVANTAGES26
10.CONCLUSION.............................28

1.INTRODUCTION
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Steel melting shop is the heart of any steel plant where steel making process is
being done. In VSP steel melt shop is equipped with three LD converters and six number of
bloom casters with 100% continuous casting facility.
Continuous casting may be defined as teaming of liquid steel in amould with a
false bottom through which partially solidified ingot\ bar(similar to the shape and cross section
of the mould) is continuously withdrawn at the same rate at which the liquid steel is teamed in
the mould.
At VSP we have six-4 strand continuous casting machines capable of producing
2.82 million tones\year blooms of size 250mm*250mm and 250mm*320mm. Entire quantity
of molten steel produced (100%) is continuously cast in the radial bloom casters which help in
energy conservation as well as production of superior quality products.

2.BRIEF DESCRIPTION OF THE PROJECT


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In a process of continuous casting the speed control of withdraw roles is very much
important in our plant 11kw DC Motors are used for the same. DC Motor is driven by thyristor
converter panels. There are two thyristor panels for speed control of withdraw role motors one is
working panel and another is standby panel.
Analog reference signal generated for these two is from common panel is designated as
51AS1. If there is any failure in this panel for more than one minute causes strand closer during
casting. Of late both the electrics and electronics of the said 51AS1is giving frequent troubles
causing the closure of the strand.
At present there is no supply of spares of 51AS1 panel from original soviet
manufacturer. It is having no.of Analog cards, and also complicated circuit. This will lead to
maximum troubleshoot time and down time.
The most influencing factor to taking of this project is to generate indigenous reference
panel for individual thyristor converters. Another factor is to eliminate electrical schematic
circuit as technology improved such that total reference circuit can be replaced by single RVG
card. Andexisting relays are sealed type, in this physical contacts cannot be seen with naked eyes
and replacement took much time.
As a solution of the problem schematic drawing for this project has been prepared
such that two individual reference circuit will be provided for individual thyristor drives. Circuit
also made simple for easy troubleshooting. Existing sealed relays are rep-laced with normal
relays within dication of ON\OFF for knowing the working status of relay.
In earlier scheme minimum oscillations for mould is also set on51AS1panel. Now in
this project we did modification so that minimum oscillations can be generated in the mould
thyristor panel itself.
For making trail run, we made one prototype working model with single RVG card,
the circuit is connected to M\c 2 Std 4,52AU1, thyristor drive. Now existing Russian reference
panel is connected to only 51AU1.
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We made 5 1AU1,52AU1 working independently. Now 52AU1 thyristor converter is


put into operation continuously to check the compatibility of reference signal to the thyristor
drive. With this new reference circuit we observed the speed control ossmooth and linear.
It is better than the earlier system. We observed it for more than two months no
complications are arised. Now we made a total circuit with the RVG card in a single board for a
reference for both 51AU1 and 52AU1, thyristor converters.
After that inM\c 4 Std 3 whole 51AS1 circuit as been replaced with new modified
circuit. Necessary modification to MOM also done in the same panel.

3. REFERENCE GENERATION IN CASTINGMODE FOR


THYRISTOR DRIVE

In withdrawal rolls casting speed has to vary according to the conditions. This casting
speed will vary through the reference given to thyristor drive. In earlier Russian system one
separate panel (51AS1) was there and in that a lot of cards were there.
This was common reference panel for both 51AU1and 52AU1drives. Hence the
separate power supply cards also provided for both 51AU1and 52AU1. Ultimately total 10
number of cards were put for this system. Now in present market one simple electronic card
(RVG) is available.
With this reference generation can be done and all adjustment pots were provided as
per withdrawal rolls requirement and moreover electronic supply can be tapped from thyristor
drive reference can be given to the same drive.
Hence this isolation cards are not required. In this system we can put two cards for two
drives so that change over facililty will be available in case of failure of one card.

DIGITAL AND ANALOG I/O- The analog and digital inputs and outputs are connected to the
function blocks of the standard program to build up the drive
application.
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DIGITAL INPUTS-

Standard I/O has eight digital inputs (DI1...DI8) which are connected via SDCS-IOB-2x or directly to the Control Board SDCSCON-2.
I/O extension board SDCS-IOE-1 contains seven isolated digital
inputs (DI9...DI15).

DIGITAL OUTPUTS-

There are eight digital outputs and the connections are made to
the SDCS-CON-2 or SDCS-IOB-2x boards.

ANALOG INPUTS-

Maximum number of analog inputs is seven. The first five


channels, AITAC, AI1, AI2, AI3 and AI4, are available with
the

SDCS-CON-2 or SDCS-IOB-3 boards. The last two

channels,AI5 andAI6, are connected by means of the SDCSIOE-1 extension I/Oboard.


Analog inputs are scaled with parameters:
HIGH VALUE (1XX) = value in OUT+ (XXXXX) that
corresponds to
maximum input value (normally +10V or +20 mA).
and
LOW VALUE (1XX) = value in OUT+ (XXXXX) that
corresponds to minimum input value (normally -10V or
+20 mA). If offset balancing is needed, the value of the
HIGH and LOW
VALUE has to be increased or decreased slightly.
Note. The temperature measurements are scaled internally in AI2 and AI3 ( orC). The
parameters HIGH VALUE and LOW VALUE have no significance in that case.
ANALOG OUTPUTS-

There are three analog output channels. Connections


made to either SDCS-CON-2 or SDCS-IOB-3 boards. The
first two outputs (AO1 and AO2) are programmable, and
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the range of the outputs is +10V...-10V. The third output is


an armature current actual measurement from the HWcircuit. For more detailed information, see TECHNICAL
DATA.

ACTUAL SPEED BASED ON E.M.F-The EMF (Electromotive Force) speed actual is based on
the relationship of flux, EMF and actual speed. This
method can be used up to the field weakening point. The
parameter U MOTN V (501) defines the armature
voltage of the motor, which corresponds to the speed
value 20000 in the software. The armature autotuning
function calculates the ARM R (411) and ARM L(410)
parameter values. See paragraph "Autotuning" in this
chapter.
CALCULATION OF SPEED FROM THE EMF Q= 8GF ( 5 * , / * G, / GW )/ )/8;
The resistive voltage drop ARM R (411) is calculated:
ARM R= 22444 * RA[&]*I CONV A (10509 )/U
SUPPLY (507)
where RA [] = armature resistance
The inductive voltage drop ARM L(410) is calculated:
ARM L= LA mH * I CONV A (10509 ) * 245/U
SUPPLY (507) * scantime
where LA [mH] = armature inductance in mH
scan time = 3,33 ms (50 Hz network) or 2,77 ms (60 Hz)

CONSTRUCTION OF FUNCTION BLOCKOnly one of the five constant reference sources can be
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selected at a time by means of inputs [ACT1] (1901),


[ACT2] (1902), [ACT3](1903) or [ACT4] (1904). The
Logic diagram is shown above. If ACT1...ACT4 inputs
are all in zero state, the reference value is set to parameter
DEF (1905). Otherwise the reference value is one of
REF1...REF4.for example, if constant reference REF3
(1908) is used, input [ACT3] (1903) has to be set to
logical state 1 and inputs [ACT1] and [ACT2] must be
set to zero by the application. Normally, if input pin is not
connected at all, its state is zero. Block output OUT
(11901) value is set equal to parameter REF3 (1908).

RAMP GENERATOR FUNCTION BLOCKThe main function of the RAMP GENERATOR function
block is to accelerate and decelerate the motors speed
with selected time constants to the value of [IN] (1701).

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Function of the Ramp Generation function block


LOCAL / REMOTEThere are two switches in front of the ramp block.
The

first

switch

Speed

Reference

is

the

LOCAL/REMOTE selector. When LOCALcontrol


is selected from, for example, the CDP312 control
panel, the speed reference comes from the panel
link. In REMOTE control the reference comes from
the input pin [IN] (1701).The second switch sets the
reference to zero at the input of the ramp by means
of [RES IN] (1702) input pin.

HOLDING OF THE REFERENCEIf the [HOLD] (1703) input is in logical state 1, the
output of the ramp is holding the old value.
RAMP FUNCTION IN EMERGENCY STOP
If emergency stop function is activated by drive
logic EME STOP MODE (907) = 1, then the
deceleration time is read from the parameter
EMESTOP RAMP (1714).

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SELECTING OF THE RAMP FUNCTIONIt is possible to define two different acceleration,


deceleration and smoothing time constants. A
typical application for this feature is
two DC-motors connected to one drive and each
motor is operated separately. The application
program in the drive may also select different ramp
times in different control situations. Selection can
be done by input pin [T1/T2] (1707). If input
[T1/T2](1707) is in logical state 0, then the values
of the parameters ACCEL 1 (1708), DECEL 1
(1709) and SMOOTH 1 (1710) define the ramp
function as seen in figure above. If input [T1/T2] is
in logical state 1 then the values of the parameters ACCEL 2 (1711), DECEL 2 (1712) and
SMOOTH 1 (1713) define the ramp function.
LIMITATION OF THE REFERENCEParameter

SPEEDMAX

(1715)

defines

the

maximum reference value and SPEEDMIN (1716)


the minimum value after the RAMP block

PASSING OF THE RAMP FUNCTIONThe ramp function can be bypassed by setting the
input [FOLLOWIN] (1704) to logical state 1.
OUTPUT FOLLOWS THE SPEED ACTUAL14

The output OUT (11701) can be made to follow the


speed actual by setting the input [FOLL ACT]
(1705) to logical state 1.
RESET THE OUTPUTThe output OUT (11701) can be set to zero by
setting the input [RES OUT] (1706) to logical state
1.
ACCELERATION COMPENSATIONThe output ACCEL COMP (11702) is giving the
additional torque reference which is needed to
compensate inertia of load. The acceleration
compensation mode is selected by parameter ACC
COMP.MODE (1718). The time in which the drive
will accelerate from zero speed to max. speed using
motor nominal torque is set to parameter ACC
COMP.TRMIN (1719).

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4. WORKING OF THE THYRISTOR DRIVES (51AU1 &52AU1)


The thyristor power circuit panel has two independent circuits and the four motors
are connected to this circuit with the help of two knife switches, based on the requirement to
operate either 51AU1or 52AU1 the position of the switches are decided.
In the power circuits a current feedback is connected to card S402A and voltage
feedback is connected to S402.

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MODEL DIAGRAM OF THYRISTOR DRIVE


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Two thyristor bridges (3- bridges) one in the forward direction and the other in the
backward direction are connected as shown between the supply mains and the feedback circuit
whose firing angles are decided from the block diagram as shown.
Initially, signals from 51AS1 are given to the card N404 which is considered to be
casting mode reference generates a reference signal and another card N222 (dummy card mode)
generates the other reference signal which is a fixed one. Now both these reference signals are
given to a ramp generator which has two test points u1and u2.
The ramp generator generates the ramp signal and this is fed to a speed regulator, the
second input required comes from emf generator to which the voltage and current feedback
circuits (S404 andS402A) are given as inputs to this card N205.
The speed regulator provides a smooth regulation of the speed whose output is again
fed to a ramp generator and a logic card N125.
The output from the thyristor panel is given to the thyristor sensor card S118 is fed to
the logic card N125.
The logic card generates the desired logic that to what extent the firing of the
thyristor bridges TM1and TM2 has to be done and is given to the firing card N123A.ramp
generator N205 generates a ramp output and gives to the current regulator where a maximum
value of current is regulated and the other input comes from the current feedback circuit gives
the other input to this cardN210.
The output from the current regulator is given to a phase angle control card in which
min and max values of are fixed to maintain the desired voltage in the thyristor bridges.
The supply to this card comes from the synchronous supply of 415v where it is
stepped down to desired level and is given to the filter card N102,supply is given to the phase
angle control card the output of this is given to the firing card N123A.
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Now the output of this is given to the amplifier cards (TM1and TM2). Based on
whether the thyristor has to be forward or reversed the corresponding card generates a high
signaland gives to the thyristor panel through isolators from the thyristor panel to the thyristor
panel the motors are driven.

5.DESCRIPTION OF THYRISTOR

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For use with the Electrical Machines Teaching System, the Thyristor
Drive System allows students to apply basic thyristor theory to d.c. motor speed control. This
helps them to better understand thyristor speed control. This system works with an optional d.c.
machine and the FH2 test bed. These also allow students to study of the effect of varying the
load and the inertia of the motor.
The main parts of the Thyristor Drive System are:

Thyristor Drive System

A three-term (PID) controller

A diode bridge

Signal generators

A summing junction

A single thyristor drive

A double thyristor drive


The built-in three-term controller has a proportional, integral and

derivative block (PID). This allows students to understand control methods needed to change the
response of a motor, for example from an under-damped oscillatory response to an over-damped
and sluggish response.
The summing junction combines signals from different places to
work with the signal generators. The input signals include feedback from the armature and a
signal from an external source.
The signal generators give a ramp waveform and a trigger
pulse. These work with the summing junction output to create a control (trigger) signal for the
thyristor drives.
The diode bridge gives a rectified output for the shunt field of a d.c.
motor. The double thyristor drive controls the current in the armature of a d.c. motor. Included is

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an extra diode to show the effect of a flywheel diode when using thyristors to control inductive
loads.
The thyristor drives and flywheel diode circuits includes some of the
Transducers to measure current waveforms. For safety, and to avoid mistakes, the control signal
input and output sockets are smaller than the power sockets. Also, the voltage and current
measurement sockets have a different-shaped connector to the power and signal sockets.
NOTE: You need a d.c. motor from the fractional horsepower (FH) machines range to work with
the Thyristor Drive System.
STANDARD FEATURES Supplied with comprehensive user guide
Two-year warranty
Made in accordance with the latest European Union
Directives

6.CIRCUIT DIAGRAM OF RVG CARD

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SIGNAL PRODUCED BY OFFSET VOLTAGE

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OUTPUT SIGNAL PRODUCED BY WITHDRAW ROLLS

7.CIRCUIT DIAGRAM BEFORE MODIFICATION


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8.CIRCUIT DIAGRAM AFTER MODIFICATION


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9.ADVANTAGES OF THE PROJECT

Original Russian system occupies more space. New system occupies almost one-third of
old one.

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In original system terminal blocks were given in front and back side of the panel and it is
different for point to point checking as one terminal is in front and next check point is in
backside.

Whereas in our new system all terminal are provided in front side only and in a same row.

In existing system trouble shooting is very difficult and circuit also very complicated
having more number of cards and sealed relays.

Whereas in our system we used one simple RVG card for reference generation and less
number of relays for easy understanding and troubleshoot.

In sealed relays we cannot find contact or coil problem and it is not possible to see the
relay condition with the naked eye whether the relay is in picked or in dropped.

Whereas in modified system we used the glass relays, by seeing with the eye we can
easily find out the position of the relay and relay contact also.

Spares are also not available for Old Russian system. For new system spares are available
and cheaper.

In earlier system reference generation is common for both the thyristor drives and any

problem in reference generation circuit results in automatically closing of the strand.


Whereas in the new system reference generation circuit is independent for each drive and
any problem in one circuit we can change the reference generation along with the drive
without affecting the casting.

It is difficult to adjust joint mode oscillations during the casting as all individual
adjustment pots were in cards.

Whereas in this new system we can adjust the joint mode oscillations in casting also as
some external pots are provided for adjustments.

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10.CONCLUSION
In the course of doing this project, I have found that it was very interesting,
informative and result oriented. With these type if projects it has lot of benefits to reduce brake
down time, easy for maintenance and above all the satisfaction achieving one of the prime motto
i.e., excellence through innovation.

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REFERENCES
Manuals by staff in Steel Plant.
www.google.com
www.wikipedia.org.

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