PROJECT REPORT

ON
TO STUDY DRIVE FAILURE AND
INTERRUPTION IN SCP MACHINES OF
BATTERY 567,COKE PLANT AND SUGGEST
PRACTICES TO REDUCE INTERRUPTION.
CONTENT
TATA STEEL A BRIF INTRODUCTION
INTRODUCTION TO COKE PLANT
COAL CARBONIAZATION OR COKEING
CONVERSION OF COAL TO COKE
SCHEMATIC DIAGRAM OF COKE PLANT
IMPORTANT DIMENSION @ PARAMETERS
BATTERY 8@9
INTRODUCTION TO DRIVE
DRIVE
COMPONENT OF DRIVE
COMPARISON BETWEEN DC & AC DRIVE
SIEMENS MASTERDRIVE
CONCLUSION










TATA STEEL: A Brief Introduction

Established in 1907, Tata Steel is the worlds 6
th
largest steel company
with an existing annual crude steel capacity of 30 million tonnes. Asias
first integrated steel plant and Indias largest integrated private sector
steel company is now the worlds second most geographically diversified
steel producer, with operations in 26 countries and commercial presence
in over 50 countries.

Tata Steel completed 100 glorious years of existence on august 26, 2007
following the ideals and philosophy laid down by its founder, Jamshedji
Nusserwanji Tata. The first private sector steel plant which started with a
production capacity of 1,00,000 tonnes has transformed into a global
giant.


Tata Steel plan to grow and globalise through organic and inorganic
routes. Its 6.8 million tonnes per annum (MTPA) Jamshedpur Works
plan to achieve 10MT capacity by 2010. The Company also has
three Greenfield steel projects in the states of Jharkhand, Orissa
and Chhattisgarh proposed steel making facilities in Vietnam.

Tata Steel is a global player with a balanced presence in developed
European and fast growing Asian market and with a strong position
in the construction, automotive and packaging markets. Its
Jamshedpur steel works produce hot and cold rolled coils and
sheets, galvanized sheets, tubes, wire rods, construction rebars,
rings and bearings. In an attempt to decommodities steel, the
Company has introduced several branded steel products, including
Tata Steelium (the worlds first branded Clod Rolled Steel), Tata
Shaktee (Galvanised Corrugated Sheets), Tata Tiscon (rebars), Tata
Pipes, Tata Bearings, Tata Structura, Tata Agrico (hand tools and
implements) and Tata Wiron (galvanized wire products).
In the financial year 2006-07 revenue from the sale of these
branded steel products was 26% of the companys sales
revenues.
Tata Steels vision is to be the global steel industry benchmark
for Value Creation and Corporate Citizenship.
Tata Steel is one of the few steel companies in the world that
is Economic Value Added (EVA) positive. It was ranked the
"World's Best Steel Maker", for the third time by World Steel
Dynamics in its annual listing in February, 2006. Tata Steel
has been conferred the Prime Minister of India's Trophy for
the Best Integrated Steel Plant five times.


INTRODUCTION TO COKE PLANT

Coke plant converts naturally found coal into coke, which is
suitable for use in the Blast Furnaces. There are six batteries
in operation with a total of 284 nos. Stamp Charged ovens
And 54 nos. of top charged ovens.

KEY ACTIVITIES OF COKE PLANT

BLENDING
COAL PREPARATION
STAMPING OF COAL & CAKE MAKING
CARBONISATION OF COKE (BATTERY # OPERATION)
WHARF MANAGEMENT
SIZING OF COKE
DESPATCHING OF COKE TO BLAST FURNACE


BLENDING
COAL PREPARATION


STAMPING & CHARGING PUSHING
HANDLING OF COKE QUENCHING SYSTEM

WHARF MANAGEMENT SCREENING & SIZING
COKE DESPATCH TO CUSTOMER
COKE PLANT
Coke plant is an essential part of an integrated steel plant. Coking process consist of
heating of coal (pyrolysis) in absence of air at temperature ranging 950
0
C to 1200
0
C in
oven made up of refractory materials for 20 Hrs. The coal undergoes physical and
chemical changes producing volatile chemicals in the form of complex mixture of vapour
and gases. At the end of the process a hard porous mass remains, which is coke.
Quenching with water-cools the lump coke. The coke is further crushed and screened.

During carbonization about 23-25% (by weight) of the initial charges of the coal spews
out as mixed gases and vapours, which pass from oven to collecting mains. Byproducts
are recovered from these gases and vapours.

COAL CARBONIZATION OR COKING

When coking coal heated in the absence of air they become plastic and soft over
a temperature range of 310
0
C to 500
0
C. The coal particle agglomerate into a
coherent mass, which swells and resolidifies to form a porous structure known as
coke.
When coal is charged in the hot oven, the temperature of oven refractory wall
being at about 1100
0
C to 1500
0
C, the portion of the coal in immediate contact
with hot wall is heated very rapidly to a high temperature, a thin layer softens,
becomes plastic and melts. This layer of plastic material travels towards the
centre of the oven and some of the gaseous product force their way out of the
plastic materials, as the temperature of the charge is raised. On the wall side, the
plastic layer hardens into a cellar residue and the volatile matter left in the coke is
driven of gradually as the temperature rises during remainder of the coke period.
Thus in an oven, during initial stage of coking, the coal exists side by side in
several phases, e.g. coke, semicoke, a plastic mass and granular coal.

Schematic Diagram of COKE Plant
Oven:
Length 13760 mm
Height 4570 mm
Average Width 460 mm
(Ram side 450 mm, Middle 460 mm, Coke side 470 mm)
Oven Taper 20 mm
(From Ram side to Oven side)
Oven to Oven Centre Distance 1200 mm
Heating chamber:
Length 13760 mm
Height 4570 mm
Average Width 740 mm
(Ram side 750 mm, Middle 740 mm, Coke side 730 mm)
Thickness of Stretcher Wall 95 mm
(5 mm more that old Batteries)

IMPORTANT DIMENSIONS AND
PARAMETERS

The Battery 8 and 9 of the TATA STEEL is the state of
the art battery with worlds best technology achieving
the quality parameters of the world class coke as well
as meeting 100% of the environmental norms. These
are OTTO DESIGN, Stamp Charge battery with 70
ovens in each battery. Its heating system is twin flue,
under jet firing type, double stage air, and compound
ovens. It can be operated in B.F. (Blast Furnace) Gas or
C.O. (Coke Oven) Gas according to requirement. So it is
called compound ovens. The capacity of both the
batteries combined is one million tons per annum.

BATTERY 8 AND 9
17
POWER DISTRIBUTION IN SCP M/C
Main
Transformer
6.6 KV/ 433 V
General
MCC-1
General
MCC-2
Stamping
MCC
Master
Drive-1
Master
Drive-2
F
r
o
m

H
T

b
r
e
a
k
e
r

* SEPARATE BREAKER FOR MASTER DRIVES IN GNL. MCC-1
18
MAIN TRANSFORMER (SPEC.)
1OOO KVA, Dry Type Resin cast Transformer.
6.6Kv/433, 433v, Dyn5, yn5
Secondary current 666.7, 666.7Amps.
HT side Amps= 87.5
Make: Kirloskar
1U
1V
1W
2U
H T Side
L T Side
3U
3W
3V
To Drives
2V
2W
To General
MCCs
TITLE OF THE PROJECT
TO STUDY DRIVE FAILURE AND
INTERRUPTION IN SCP MACHINES OF
BATTERY 567,COKE PLANT AND SUGGEST
PRACTICES TO REDUCE INTERRUPTION.

INTRODUCTION TO DRIVE
Drives are employed for systems that require motion control e.g. transportation
system, fans,robots, pumps, machine tools, etc. Prime movers are required in drive
systems to provide themovement or motion and energy that is used to provide the
motion can come from varioussources: diesel engines, petrol engines, hydraulic
motors, electric motors etc.
Drives that use electric motors as the prime movers are known as electrical drives

There are several advantages of electrical drives:

a. Flexible control characteristic This is particularly true when power electronic
converters are employed where the dynamic and steady state characteristics of the
motorcan be controlled by controlling the applied voltage or current.
b. Available in wide range of speed, torque and power
c. High efficiency, lower noise, low maintenance requirements and cleaner operation
d. Electric energy is easy to be transported.
DRIVE

AC drives, inverters, and adjustable frequency drives are all terms that are used to
refer to equipment designed to control the speed of an AC motor. The term SIMOVERT
is used by Siemens to identify a SIemens MOtor inVERTer (AC drive).
AC drives receive AC power and convert it to an adjustable frequency, adjustable
voltage output for controlling motor operation. A typical inverter receives 480 VAC,
three-phase, 50 Hz input power and in turn provides the proper voltage and frequency
for a given speed to the motor. The three common inverter types are the variable
voltage inverter (VVI), current source inverter (CSI), and pulse width modulation
(PWM).
Another type of AC drive is a cycloconverter. These are commonly used for very large
motors and will not be described in this course. All AC drives convert AC to DC, and
then through various switching techniques invert the DC into a variable voltage,
variable frequency output.


Variable Voltage Inverter (VVI):
The variable voltage inverter (VVI) uses an SCR converter bridge to convert the
incoming AC voltage into DC. The SCRs provide a means of controlling the value of the
rectified DC voltage from 0 to approximately 600 VDC. The L1 choke and C1
capacitor(s) make up the DC link section and smooth the converted DC voltage. The
inverter section consists of six switching devices. Various devices can be used such as
thyristors, bipolar transistors, MOSFETS, and IGBTs. The following schematic shows an
inverter that utilizes bipolar transistors. Control logic (not shown) uses a
microprocessor to switch the transistors on and off providing a variable voltage and
frequency to the motor.
This type of switching is often referred to as six-step because it takes six 60 steps to
complete one 360 cycle. Although the motor prefers a smooth sine wave, a six-step
output can be satisfactorily used. The main disadvantage is torque pulsation which
occurs each time a switching device, such as a bipolar transistor, is switched. The
pulsations can be noticeable at low speeds as speed variations in the motor. These
speed variations are sometimes referred to as cogging. The non-sinusoidal current
waveform causes extra heating in the motor requiring a motor derating.
Current Source Inverter:
The current source inverter (CSI) uses an SCR input to produce a variable voltage DC
link. The inverter section also uses SCRs for switching the output to the motor. The
current source inverter controls the current in the motor. The motor must be carefully
matched to the drive.
Current spikes, caused by switching, can be seen in the output. At low speeds current
pulses can causes the motor to cog.


Pulse Width Modulation:
Pulse width modulation (PWM) drives, like the Siemens MICROMASTER and
MASTERDRIVE VC, provide a more sinusoidal current output to control frequency
and voltage supplied to an AC motor. PWM drives are more efficient and typically
provide higher levels of performance. A basic PWM drive consists of a converter,
DC link, control logic, and an inverter.

Converter and DC Link:
The converter section consists of a fixed diode bridge rectifier which converts the
three-phase power supply to a DC voltage. The L1 choke and C1 capacitor(s) smooth
the converted DC voltage. The rectified DC value is approximately 1.35 times the line-
to-line value of the supply voltage. The rectified DC value is approximately 650 VDC for
a 480 VAC supply.


Control Logic and Inverter:
Output voltage and frequency to the motor are controlled by the control logic and
inverter section. The inverter section consists of six switching devices. Various devices
can be used such as thyristors, bipolar transistors, MOSFETS and IGBTs. The following
schematic shows an inverter that utilizes IGBTs. The control logic uses a
microprocessor to switch the IGBTs on and off providing a variable voltage and
frequency to the motor.

IGBTs(Insulated Gate Bipolar Transistor):
IGBTs provide a high switching speed necessary for PWM inverter operation. IGBTs are
capable of switching on and off several thousand times a second. An IGBT can turn on
in less than 400 nanoseconds and off in approximately 500 nanoseconds. An IGBT
consists of a gate, collector and an emitter. When a positive voltage (typically +15
VDC) is applied to the gate the IGBT will turn on. This is similar to closing a switch.
Current will flow between the collector and emitter. An IGBT is turned off by removing
the positive voltage from the gate. During the off state the IGBT gate voltage is
normally held at a small negative voltage (-15 VDC) to prevent the device from turning
on.

Using Switching Devices to Develop AC Output:
In the following example, one phase of a three-phase output is used to show how an
AC voltage can be developed. Switches replace the IGBTs. A voltage that alternates
between positive and negative is developed by opening and closing switches in a
specific sequence. For example, during steps one and two A+ and B- are closed. The
output voltage between A and B is positive. During step three A+ and B+ are closed.
The difference of potential from A to B is zero. The output voltage is zero. During step
four A- and B+ are closed. The output voltage from A to B is negative. The voltage is
dependent on the value of the DC voltage and the frequency is dependent on the
speed of the switching. An AC sine wave has been added to the output (A-B) to show
how AC is simulated.
PWM (Pulse Width Modulation) Output:
There are several PWM modulation techniques. It is beyond the scope of this book to
describe them all in detail. The following text and illustrations describe a typical pulse
width modulation method. An IGBT (or other type switching device) can be switched
on connecting the motor to the positive value of DC voltage (650 VDC from the
converter). Current flows in the motor. The IGBT is switched on for a short period of
time, allowing only a small amount of current to build up in the motor and then
switched off. The IGBT is switched on and left on for progressively longer periods of
time, allowing current to build up to higher levels until current in the motor reaches a
peak. The IGBT is then switched on for progressively shorter periods of time,
decreasing current build up in the motor. The negative half of the sine wave is
generated by switching an IGBT connected to the negative value of the converted DC
voltage.

PWM Voltage and Current:
The voltage and frequency is controlled electronically by circuitry within the AC drive.
The fixed DC voltage (650 VDC) is modulated or clipped with this method to provide a
variable voltage and frequency. At low output frequencies a low output voltage is
required. The switching devices are turned on for shorter periods of time. Voltage and
current build up in the motor is low. At high output frequencies a high voltage is
required. The switching devices are turned on for longer periods of time, allowing
voltage and current to build up to higher levels in the motor.
COMPONENT OF DRIVE
The main components of a modern electrical drive are the motors, power
processor, control unitand electrical source. These are briefly discussed below.

a) Motors:

Motors obtain power from electrical sources. They convert energy from
electrical tomechanical - therefore can be regarded as energy converters. In
braking mode, the flow of power is reversed. Depending upon the type of power
converters used, it is also possible for the power to be fed back to the sources rather
than dissipated as heat.
There are several types of motors used in electric drives choice of type used
depends onapplications, cost, environmental factors and also the type of sources
available.. Broadly, they can be classified as either DC or AC motors:


DC motors (wound or permanent magnet).
AC motors:
Induction motors squirrel cage, wound rotor.
Synchronous motors wound field, permanent magnet.
Brushless DC motor require power electronic converters.
Stepper motors require power electronic converters.
Synchronous reluctance motors or switched reluctance motor.

b) Power Processor or Power Modulator:

Since the electrical sources are normally uncontrollable, it is therefore necessary to be
able to control the flow of power to the motor this is achieved using power
processor or power modulator. With controllable sources, the motor can be reversed,
brake or can be operated with variable speed. Conventional methods used, for
example, variable impedance or relays, to shape the voltage or current that is supplied
to the motor these methods however are inflexible and inefficient.
Modern electric drives normally used power electronic converters to shape the
desired voltage or current suppof the motors can be changed at will. Power electronic
converters have several advantages over classical methods of power conversion, such
as:
More efficient since ideally no losses occur in power electronic converters.
Flexible voltage and current can be shaped by simply controlling switching
functions of the power converter.
Compact smaller, compact and higher ratings solidstate power electronic devices
are continuously being developed the prices are getting cheaper.

Converters are used to convert and possibly regulate (i.e. using closed-loop control)
the available sources to suit the load i.e. motors. These converters are efficient
because the switches operate in either cut-off or saturation modes.
Several conversion are possible:
AC to DC
DC to AC
DC to DC
AC to AC


c) Control Unit

The complexity of the control unit depends on the desired drive performance and the
type of motors used. A controller can be as simple as few op-amps and/or a few digital
ICs, or it can be as complex as the combinations of several ASICs and digital signal
processors (DSPs).
The types of the main controllers can be:
Analog - which is noisy, inflexible. However analog circuit ideally has infinite
bandwidth.
Digital immune to noise, configurable. The bandwidth is obviously smaller than the
analog controllers depends on sampling frequency.
DSP/microprocessor flexible, lower bandwidth compared to above. DSPs perform
faster operation than microprocessors (multiplication in single cycle). With
DSP/microp. complex estimations and observers can be easily implemented.
d) Source

Electrical sources or power supplies provide the energy to the electrical motors. For
high efficiency operation, the power obtained from the electrical sources need to be
regulated using power electronic converters.
Power sources can be of AC or DC in nature and normally are uncontrollable, i.e. their
magnitudes or frequencies are fixed or depend on the sources of energy such as solar
or wind. AC source can be either three-phase or single-phase; 3-phase sources are
normally for high power applications.
There can be several factors that affect the selection of different configuration of
electrical drive system such as:
a) Torque and speed profile - determine the ratings of converters and the quadrant of
operation required.
b) Capital and running cost Drive systems will vary in terms of start-up cost and
running cost, e.g. maintenance.
c) Space and weight restrictions.
d) Environment and location.

Comparison Between DC and AC Drives

Motors :

DC require maintenance, heavy, expensive, speed limited by mechanical
construction.
AC less maintenance, light, cheaper, robust, high speed (esp. squirrelcage type).

Control unit:

DC drives: Simple control decoupling torque and flux by mechanical commutator
the controller can be implemented using simple analog circuit even for high
performance torque control cheaper.
AC drives, the types of controllers to be used depend on the required drive
performance obviously, cost increases with performance. Scalar control drives
technique does not require fast processor/DSP whereas in FOC or DTC drives, DSPs or
fast processors are normally employed.

Siemens MASTERDRIVES

The Siemens MASTERDRIVES can be used for variable-speed control on motors rated from 1
to 5000 HP. MASTERDRIVES are available for all major worldwide 3-phase supply voltages:
208-230, 380-460, 500-575, 660-690 volts. The Siemens MASTERDRIVES can also be referred
to by a model series number, 6SE70.

AC - AC (AC - to - AC):
A single inverter can be used with single motor, single motor with a tach, and multimotor
applications. This is referred to as the AC-AC version. Various options allow for analog and
encoder tachometer types.

DC - AC (DC - to - AC):
The Siemens MASTERDRIVES can also be configured so that acommon DC bus supplies
power to several AC inverters. Common DC bus systems also allow single and multimotor
combinations. This is referred to as the DC-AC version.


Braking unit:
In the speed-torque chart there are four quadrants accordingto direction of rotation
and direction of torque. Quadrant I is forward motoring or driving (CW). Quadrant III is
reverse motoring or driving (CCW). Reverse motoring is achieved by reversing the
direction of the rotating magnetic field. The dynamics of certain loads may require
four-quadrant operation. When equipped with an optional braking unit Siemens
MASTERDRIVES are capable of four-quadrant operation. Braking occurs in quadrants II
and IV. Several regenerative rectifier products are also available which return braking
energy to the power source instead of dissipating (wasting) it in resistors.


Compact units:
Compact units require the smallest mounting space. Units canbe DIN-G rail mounted
side-by-side without spacing. There are four sizes: A, B, C, and D. Compact units are
available with ratings from 3 to 50 HP (5.6 to 72 Amps) at 460 VAC.


Chassis Units:
Chassis units can also be mounted side-by-side without spacing. They are easily
mounted on the wall when supplied in an IP20 enclosure. There are four sizes: E, F, G,
and K. Chassis units are available with ratings from 60 to 500 HP (83.7 to 590 Amps) at
460 VAC.

Cabinet Units:
Cabinet units are ready-wired complete units for single and multimotor applications.
All components are accessible from the front of the cabinet. Cabinet units are
available with ratings from 50 to 5000 HP (45 to 4500 KW).

Programming and operating sources:
The MASTERDRIVES can be programmed and operated from the following sources:
Operator Control Panel (OP1S)
Parameterization Unit (PMU)
Terminal strips on the CU board
Serial interface (various)
Digital tachometers:
Digital tachometers (encoders) can be used to measure the actual speed of the motor.
The Digital Tachometer Interface (DTI) is designed to be used with digital tachometers
(encoders) that operate at a voltage other than 11-30 VDC. The DTI is also required if
the following encoders are used:
HTL encoder with inverted channel.
Floating HTL encoder.
TTL encoder.
Encoder with cables greater than 495 feet.

Analog tachometers:
Analog tachometers can also be used to measure the actual motor speed. Analog
tachometers generate a DC voltage which is proportional to the speed. The voltage at
maximum speed is a function of the actual tachometer, and generally lies between 10
V and 300 V. Closed loop speed control with an analog tach can be applied to a speed
range from 1 RPM to 6000 RPM. An analog tach interface (ATI) board is used to
connect an analog tach to the CUVC board.
Applications

When applying an AC drive and motor to an application it is necessary to know the
horsepower, torque, and speed characteristics of the load. The following chart shows
characteristics of various loads.

Loads generally fall into one of three categories:

Constant torque - The load is essentially the same throughout the speed range.
Hoisting gear and belt conveyors are examples.
Variable torque - The load increases as speed increases. Pumps and fans are
examples.
Constant horsepower - The load decreases as speed increases. Winders and rotary
cutting machines are examples.