PROJECT REPORT ON

REFERENCE GENERATION FOR MOULD

AND WITHDRAW ROLLS BY USING RVG
CARD

Prepared by
A. UDAYKUMAR
M.S.V. SANTOSHKUMAR
S.V. SUSHIL PRABHAKAR
T. HAREESH

Under the guidance of

SRI A.S.V.GOPALARAO
Dy. Chief Manager(E)
SMS/CCD/E

VISAKHAPATNAM STEEL PLANT

VISAKHAPATNAM
 ACKNOWLEDGEMENT

I take this movement to convey our sincere thanks to my project guide SHRI

A.S.V. GOPALA RAO, Chief Manager (E), SMS/CCD, for his valuable suggestions

and supervision in making this project.

I wish to express my sense of gratitude to SHRI P.N. RAO, D.G.M., (steel),

our HOD for the support to implementing the project.

I am very much thankful to SHRI A. MADHUSUDHAN BABU, J.O(E) whose

valuable guidance for making this report helped a lot.

I am very much thankful to SHRI J.PRABHAKARA RAO Jr manager (trg) for

giving us this opportunity.

A.Udaykumar
M.S.V.SantoshKumar
S.V.SushilPrabhakar
T.Hareesh
 DECLARATION

I hereby declare that this project report “REFERENCES VOLTAGE

GENERATION USING RVG CARD”, submitted by us as a part of the project

training. It is the project done by us with the support of the members in your

organization.

A.Udaykumar
M.S.V.SantoshKumar
S.V.SushilPrabhakar
T.Hareesh

CERTIFICATE
 This is to certify that the project report entitled “REFERENCE VOLTAGE

GENERATION USING RVG CARD”, that is being submitted by A.UDAYKUMAR,

M.S.V.SANTOSHKUMAR, S.V.SUSHILPRABHAKAR & T.HAREESH is a original

record of bonafide work carried out by them under my guidance and supervision.

A.S.V.GOPALA RAO
Dy. Chief Manager(E)
SMS/CCD/E
 INDEX
1. Introduction

2. Brief about project

3. Reference generation of casting mode for thyristor drive

4. Working of the thyristor drives (51AU1 and 52AU2)

5. Advantages of project

6. Circuit diagram before modification

7. Circuit diagram after modification

8. Conclusion
 INTRODUCTION

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 a

mould 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withdrawn at the same rate at which the liquid steel is teamed in the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.

 BRIEF DESCRIPTION OF THE PROJECT

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 51AS1 is 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. And

existing 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 trouble

shooting. Existing sealed relays are rep-laced with normal relays with

indication of ON\OFF for knowing the working status of relay.

In earlier scheme minimum oscillations for mould is also set on

51AS1 panel. 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.

We made 51AU1, 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 os

smooth 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 in

M\c 4 Std 3 whole 51AS1 circuit as been replaced with new modified

circuit. Necessary modification to MOM also done in the same panel.

 REFERENCE GENERATION IN CASTING
MODE 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 51AU1 and 52AU1 drives. Hence the separate power supply

cards also provided for both 51AU1 and 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.

 ADVANTAGES OF THE PROJECT

 Original Russian system occupies more space. New system occupies almost

one-third of old one.

 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 cwn 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.

 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.
 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 51AU1 or 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. Two thyristor bridges

(3-Φ 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 u1 and 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 and

S402A) 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 TM1 and 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 card

N210. The output from the current regulator is given to a phase angle control

card in which min and max values of α 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. Now the output of this is

given to the amplifier cards (TM1 and TM2). Based on whether the thyristor

has to be forward or reversed the corresponding card generates a high signal

and gives to the thyristor panel through isolators from the thyristor panel to

the thyristor panel the motors are driven.

CIRCUIT DIAGRAM BEFORE
MODIFICATION
CIRCUIT DIAGRAM AFTER
MODIFICATION
CIRCUIT DIAGRAM OF RVG
CARD