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AN OVERVIEW OF VSP:
Visakhapatnam Steel plant, the first coastal based steel plant of India
per annum of liquid steel and 2.656 million tones of saleable steel.
VSP exports quality pig iron & steel products to Sri Lanka, Myanmar,
Nepal, Middle East, USA and south East Asia (Rig iron).
productivity of 265 tone per man year of liquid steel which it the best in the
MAJOR DEPARTMENTS:
VSP annually required quality saw material Viz. iron ore, fluxel
(limestone, Dolomite) coking and non coking coke etc. to the tune of 12-13
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million tones far producing 3 million tones of liquid steel. To handle such a
large volume of incoming raw material received from different source and to
consumers, Raw material handling plant served a vital function. This unit is
facilities viz. wagon tippers, ground and track hoppers, stock yards crushing
In VSP peripheral unloading has been adopted for the first time in the
country.
Blast furnaces the mother units of any steel plant require huge
quantities of strong, hard and porous solid fuel in the form of hard
metallurgical coke for supplying necessary heat for carrying out the
coke oven comprises of two hollow chambers namely coal chamber and
heating chamber. In the heating chamber gaseous fuel such at Blast furnace
gas, coke oven gas etc is burnt. The heat so generated is conducted through
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the common wall to heat and carbonize the coking coal placed in the
adjacent coal chamber. Number of ovens built in series one after the other
form a coke oven battery. At VSP there are 3 coke oven batteries, 7 meter
tall and having 67 ovens each. Each oven is having a volume of 41.6 cm
and can hold upto 31.6 tonnes of dry coal charge. The carbonization takes
The coal chemicals such as Benzole (& etc products, far landsite
SINTER PLANT:
agglomeration of iron use fines, coke breeze, lime stone fined, metallurgical
wastes viz. Flue dust mill scales, LD slag etc. Sinter is a better feed material
to Blast Furnace in composition to iron are lumps and its usage in Blast arc
and its usage in Blast furnace help in increasing productivity, decreasing the
pallets at 1200-13000C.
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BLAST FURNACES:
Steel is an alloy of iron with carbon upto 1.8% Hot metal produced in
oxidation process.
the mould.
ROLLING MILL:
and are required to be shaped into products such as Billets, rounds, squared,
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angles, channels, I-PE beams, ME beams wire rods and reinforcements bars
by rolling them in, three sophisticated high capacity, high speed, fully
automated rolling mills, namely light & medium merchant mills (LMMM),
wire Rod mill (WRM) and Medium Merchant and structural Mills
(MMSM).
5 alternating vertical and horizontal strands. Billets are supplied from this
finished products such as sounds, refer square flats, angles, channels besides
mill has a four zone combination type reheating furnace of 200TPH capacity
for heating the billets received from billet mill of LMMM to rolling temp of
12000C.
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MEDIUM MERCHANT & STRUCTURAL MILL (MMSM):
assigned in 3 trains.
products.
units of VSP when operating the full capacity will be 221 MW. The
of A.P.
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3. Traffic Department: A Steel plant of the size of VSP has to handle
departments.
Calcining plant & Brick plant. In Calcining plant limestone & dolomite
are calcined for producing lime calcined dolomite which are used for
refining of steel in the converters. The brick plant has two LAE is 1600
Tonne presses & a tampering kiln (upto 3000C temperature) for making
bricks.
7. Roll shop & Repair shop (RS &RS): Roll shop and Repair shop is in
roll assemblies guides few maintenance spares and roll pass design.
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8. Field Machinery Department (FMD): Field Machinery is meant for
coupling.
ensured.
11. Electrical Repair Shop (ERS): Electrical Repair shop is provided for
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Blast One furnace of One furnace of 1700 3400
furnace 3200 cum useful 3200 cum
volume useful volume
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3-Φ INDUCTION MOTOR
rugged, require less maintenance, and are less expensive than D.C. motors of
equal kilo-watt and speed ratings. Induction motors are manufactured both
for 1-phase and 3-phase operation. Three-phase induction motors are widely
used for industrial applications such as in lifts, cranes, pumps, line shafts,
exhaust fans, lathes etc., where as 1-phase induction motors are mainly for
machines etc.
CONUSTRUCTIONAL FEATURES:
An induction motor is a rotating machine which converts the
Of course the induction motor also has few disadvantages like its
d.c.shunt motor.
(i)Stator and
(ii)Rotor
STATOR:
inner periphery. The insulated conductors are placed in the stator slots and
circuit or all the six terminals of the 3-phase winding are brought out to
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terminal box so that operator can connect the motor as per the requirement
the 3-phase stator winding is wound for a definite number of poles as per
the requirement of speed . Greater the number of poles lesser the speed and
is produced this rotating magnetic field flux induces an e.m.f. in the rotor by
The sturdy construction and the ample provision for air circulation and
output.
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ROTOR:
It is the rotating part of the motor. There are two general types of
SQUIRREL-CAGE ROTOR:
because this type of rotor has the simplest and most rugged construction and
squirrel-cage is to place the assembled core in a mould and then force the
molten conducting material aluminum or copper into the slots. The rotor
conductors need not be insulated from the core, since the current flow
through the least resistance path i.e. conductors. The rotor bars are short-
circuited at both ends by end rings. The rotor slots are not made parallel to
the rotor shaft axis, they are skewed at a certain angle to reduce magnetic
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noise during working, to produce a more uniform torque, and to prevent
possible magnetic locking also called as cogging of the rotor with the stator.
In some cases the heavy conductor bars (not wire) are driven into the
slots with a tight fit and project a short distance from each end of the core.
Enb rings, with holes lining up with projecting conductors, are then forced
over the latter, after which conductors and end rings are soldered or welded
together. The fig 1.3 shows the construction of the squirrel rotor.
to the rotor slots similar to stator winding. The rotor is wound for as many
poles as the number of stator poles and is always wound for 3-phase, even
the stator is wound for two-phase. The three-phase are starred internally, the
other three winding terminals are brought out and connected to three
insulated slip-rings mounted on the same shaft with brushes resting on them.
each phase of the rotor circuit during the starting period for increasing
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starting torque. Under normal running conditions, the slip-rings are
along the shaft and connects all the slop tings together. Then the rotor is
automatically to reduce friction, wear and tear. Fig. 1.2 shows the
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WORKING PRINCIPLE:
mentioned earlier are stationary part knows as stator and rotating part as
known rotor. When 3-phase stator winding is fed from 3-phase supply, a
Ns=129f/p speed is produced. This rotating flux passes through the air gap
and cuts the stationary rotor conductors. Due to the relative speed between
of the induced e.m.f. is same as the supply and proportional to the relative
speed between the flux and the rotor conductors and its direction is given by
Fleming’s Right-hand rule. Since the rotor conductors form a closed circuit
and has no external path to the induced current, whose direction as given by
Lenz’s Law, such as to oppose the very cause producing it. In this case the
cause which producing it is the relative speed. Hence, to reduce the relative
speed the rotor starts rotating in the same direction as that of stator flux and
tries to catch it, but it never do so. (Suppose if the rotor catches the stator
field or rotates at synchronous speed, the relative speed increases and again
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the rotor picks up the speed. Likewise the rotor tries to catch the
The working principle or the torque developed in the rotor can also be
explained as below:
direction as shown in Fig. 1.5(a). Consider the instant when the rotor is
stationary; the relative motion of the rotor with respect to the stator is anti-
1.5(b). Now, by combining the two fields, the flux strengthens on left and
to travel in straight line. Due to this property the flux try to travel in straight
. Its magnitude is clock wise direction. Hence the rotor is set into rotation in
the same direction as that of the stator rotating flux as shown in fig. 1.5(c)
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From the above discussion it is clear that an induction motor is a self-
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CHARACTERISTICS:
TORQUE/SPEED CHARACTERISTICS:
on its speed but the relation between the two cannot be represented by a
(fig. 1.9(a)). In this diagram, T represents the nominal full-load torque of the
motor. As seen, the starting torque (at N=0) is 1.5T and the maximum torque
increases, motor speed decreases till the motor torque again becomes equal
to the load torque. As long as the two torques are in balance, the motor will
run at constant (but lower) speed. However, if the load torque exceeds 2.5 t,
TORQUE/SLIP CHARACTERISTICS:
For this range of slip, the load resistance in the circuit model of fig 1.9(b) is
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(b) The torque has a maximum value, called the breakdown
(d) The normal operating point is located well below TBD. The
load resistance is negative in the circuit model of fig 1.9(b) which means
that mechanical power must be put in while electrical power is put out at the
machine terminals.
The motor runs in opposite direction to the rotating field (i.e. n is negative),
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INTRODUCTION TO AC DRIVES
increasing due to the need for better equipment Control and for energy
saving where partial power is required drive systems are widely used in
industries for all application such as pumps, fans, paper and textile
mills, steel and cement mills etc. The electrical machine, that converts
in a drive system.
AC DRIVES FEATURES:
No commutator / brushes
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AC motors offer more flexible motor enclosure
As the frequency is increases the air gap flux and rotor current
Similarly the frequency is decreases the air gap flux tends to saturate and
causes excessive stator current, the machine behaves like a dc series motor.
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Variable Voltage and Variable Frequency drives:
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VARIABLE FREQUENCY DRIVE CONCEPT
OPERATING PRINCIPLE :
motor:
Ns = 120 F / P
F = frequency ( cps )
A small variable
frequency
drive(VFD) is
shown in figure
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P = no . of poles. The number of poles of a particular motor is
set in its design and manufacture. The adjustable frequency system controls
ratio to the motor at any speed. This provides maximum motor capability
throughout the speed range. The frequency output of the control is infinitely
adjustable over the speed range and therefore the speed of the motor is
infinitely adjustable.
BLOCK DIAGRAM:
1) A Rectifier
2) Filter
3) Inverter
All the three i.e. the rectifier, filter and the inverter are connected in cascade.
Three phase a.c. supply is given to the rectifier this rectifier converts the
applied three phase a.c. voltage to d.c. voltage .This d.c.output voltage is
given as input to the filter, this filter filters the waveform and gives the pure
d.c. voltage .this d.c.voltage is given as input to the inverter .this inverter
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converts the applied d.c.voltage into a.c. voltage with variable frequency
V/F ratio should be kept constant to maintain air gap flux constant.
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The air gap flux of the machine is kept constant to get higher starting torque.
Τ=ΚΦΙa*sin (d)
In order that the magnetic flux is kept constant for any frequency the
DC
frequency i.e. the ratio of applied voltage over frequency should be constant.
The inverter frees the I.M. from its inherent limitation of single speed.
IaIa If
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Z Z
Voltage has to be boosted before it is given to the v/f drive.
In low frequency region the air gap flux is reduced by the stator
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VFD system
VFD motor :
Some types of single-phase motors can be used, but three-phase motors are
some situations, but induction motors are suitable for most purposes and are
generally the most economical choice. Motors that are designed for fixed-
speed mains voltage operation are often used, but certain enhancements to
the standard motor designs offer higher reliability and better VFD
performance.
VFD controller:
rectifier circuits are also used. Since incoming power is converted to DC,
must be rerated when using single phase input as only part of the rectifier
460 volts at 60 Hz, the applied voltage must be reduced to 230 volts when
the frequency is reduced to 30 Hz. Thus the ratio of volts per hertz must be
regulated to a constant value (460/60 = 7.67 V/Hz in this case). For optimum
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performance, some further voltage adjustment may be necessary, but
nominally constant volts per hertz are the general rule. This ratio can be
The usual method used for adjusting the motor voltage is pulse
width modulation PWM. With PWM voltage control, the inverter switches
Example, a 100 Hp, 460V, 60Hz, 1775 rpm (4 pole) motor supplied with
460V, 75Hz (6.134 V/Hz), would be limited to 60/75 = 80% torque at 125%
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programming and parameter adjustment is usually provided so that the user
can customize the VFD controller to suit specific motor and driven
equipment requirements.
between VFDs and motors can vary by a factor of 2.5:1. The longer cables
distances are allowed at the lower Carrier Switching Frequencies of 2.5 kHz.
The lower Carrier Switching Frequencies can produce audible noise at the
motors. The 2.5 kHz and 5 kHz Carrier Switching Frequencies cause less
stop the motor and adjust the operating speed. Additional operator control
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the drive. An operator interface keypad and display unit is often provided on
the front of the VFD controller as shown in the photograph above. The
from the VFD controller. Most are also provided with input and output (I/O)
VFD Operation :
Starting at such a low frequency avoids the high inrush current that occurs
turning on a switch. When a VFD starts, the applied frequency and voltage
develop 150% of its rated torque while drawing only 50% of its rated
draws at least 300% of its rated current while producing less than 50% of its
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rated torque. As the load accelerates, the available torque usually drops a
little and then rises to a peak while the current remains very high until the
150% starting torque from standstill right up to full speed while drawing
starting sequence. The frequency and voltage applied to the motor are
ramped down at a controlled rate. When the frequency approaches zero, the
decelerate the load a little faster than it would stop if the motor were simply
switched off and allowed to coast. Additional braking torque can be obtained
power source.
ratings to match the majority of 3-phase motors that are manufactured for
110 volts to 690 volts are often classified as low voltage units. Low voltage
units are typically designed for use with motors rated to deliver 0.2kW or
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1/4 horsepower (Hp) up to at least 750kW or 1000Hp. Medium voltage VFD
placed between a low voltage drive and a medium voltage load. Medium
voltage units are typically designed for use with motors rated to deliver
375kW or 500Hp and above. Medium voltage drives rated above 7kV and
off) designs.
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CONCLUSION
operation of slip ring induction motor using variable frequency drive control
in the plant is clearly studied. Variable frequency speed control drives are
These drives have special features than the other drives. Those are
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