PROJECT TITLE

STUDY OF NEW AC DRIVE

SYSTEM AT PLTCM CRM

Under Guidance: - Mr. ARGHYA DEB

ACKNOWLEDGEMENT
With a great pleasure we would like to express our deep sense of gratitude to Mr. Ajit Kar, Chief, and
MEG;
Mr.Arghay Deb, Head, MEG
And to our guide and training co-coordinator Mr. Nirbhay Kumar Gupta, Sr. Technologist, MEG, TATA
Steel Limited,
For their valuable instructions, guidance and illuminating criticism throughout our project
Without their involvement and supervision we could not have been able to complete this project.
We would like to express our sincere thanks to Mr. K. Paswan, Sr. Manager, and PH-4;
Mr. V.G. Rao, Consultant, MEG; Mr. O.P. Gupta, MEG and so many others countless people of TATA Steel
Limited, Jamshedpur for helping us in our project during our entire internship
We would also like to thank Dr. Mandal Training and Placement

Last but not the least we would like to thank all of our friends and the employees of Maintenance
Expert Group for their sincere co-operation and help throughout our training. Thanks to everybody and
to almighty for giving us this opportunity in our lifetime.

NAME: VIDYA KUMARI

UNIV.ROLL NO.: JSDPRFELTNKSOJUL1100776
REFE NO: VT20131799

CERTIFICATE
This is to certify that the project report entitled
STUDY OF NEW AC DRIVE SYSTEMS,

PLTCM CRM

Being submitted by Ms. VIDYA KUMARI,

JAGDISH Institute of Industrial Technology, Bhubaneswar to TATA Steel, as a
part of summer training course of DIPLOMA in Electronics curriculum is a
bonafide record of work carried out by them under my supervision and
guidance. The sincerity and sense of dedication shown by them during the
project is commendable.
Mr. ARGHYA DEB
HEAD
Maintenance Expert Group
TATA Steel Limited
Jamshedpur
Date:

CONTENTS

COMPANY PROFILE

Tata Steel

PAGE NO.

5-7

-MAINTENANCE EXPERT GROUP

10

ELECTRONICS DEVIVE

11-12

A.C. MOTOR

Types

19
19

INDUCTION MOTOR

Construction

23

Working principle

24

Testing and Inspection parameter

24

OBSERVATION OF MOTORS

25

CONCLUSION

25

BIBLIOGRAPHY

31

THANKING YOU

35
36
36

INTRODUCTION TO TATA STEEL

Tata Steel Limited
4

Type Public
Traded as NSE: TATASTEEL, BSE: 500470 (BSE SENSEX Constituent)
Industry Steel
Founded 1907
Founder(s) Dorabji Tata
Headquarters Mumbai, Maharashtra, India
Area served Worldwide
Key people CYRUS PALLONJI MISTRY (Chairman)
HEMANT M. NERULKAR (Managing Director)
Products
Steel, flat steel products, long steel products, wire products, plates
Tata Iron and Steel Company was established by Dorabji Tata on August 26,
1907,
As part of his father Jamshedji's Tata Group. By 1939 it operated the largest steel
plant in the British Empire.
The company launched a major modernization and expansion program in 1951.
Later, the program was upgraded to 2 MTPA project. In 1990, it started expansion
plan and established its subsidiary Tata Inc. in New York. The company changed its
name from TISCO to TATA Steel in 2005.
Tata Iron and Steel Company was established by Dorabji Tata on August 26,
1907,
As part of his father Jamshedji's Tata Group. By 1939 it operated the largest steel
plant in the British Empire.
The company launched a major modernization and expansion program in 1951.
Later, the program was upgraded to 2 MTPA project. In 1990, it started expansion
plan and established its subsidiary Tata Inc. in New York. The company changed its
name from TISCO to TATA Steel in
2005.

PLANS OF PROJECT

WEEK-1

Visit of electronics repair LAB, LDC Study of

document.

WEEK-2

STUDY OF DOCUMENT AT AC DRIVE

WEEK-3

VISIT ON ELECTRICAL &AC REPAIR SHOP AND

PROJECT WORK

WEEK-4

PROJECT WORK

ELECTRONICS DEVICE

RESISTOR
A resister may be defining as an electronic component which is manufactured with
a specified amount of resistance. Resistor is controls the flow of electric current.

RECTIFIER
A rectifier is a circuit which is used to convert AC voltage in to the pulsating DC
voltage .A rectifier circuit usage one or more diode.

DIODE

It has two terminal cathode (+) and anode (-).

TRANSISTOR
A semiconductor device consisting of a two p-n junction formed by sand witching
either p-type or n-type semiconductor between a pair of opposites type is known as
a Transistor.

THYRISTOR
THYRISTOR is a generic term for a semiconductor device which has four
semiconductor layers and operates as a switch, having stable ON and OFF.

ELECTRICAL REPAIR SHOP

Defective electrical motors come here for repair and rectification and overhauling
It is Asia second biggest electrical repair shop.
ELECTRICAL REPAIR SHOP is one of the most important sections of the M.E.D.
(Electrical) departments.
The job of Electrical Repair Shop is to repair various kinds of electrical motors, main
coolers changing sets and manufacturing panels for cranes .The ERS is divided into several
sections for work efficiency

ERS various sections are as follows:

1. Motor receiving section
2. Opening section
AC motor opening
DC motor opening
3.
4.
5.
6.

Motor washing area

Bearing section
Stripping section
Winding section
AC winding area
DC winding area
Heavy winding area

7. VPI (Vacuum Pressure impregnation) section

8. Assembly part
AC assembly area
DC assembly area
Heavy assembly area
9. Final testing Area
10. Final fitting Area
11. Motor Testing Area

AC MOTOR
With the almost universal adoption of A.C. system of distribution of electrical energy for light
and power,
The field of application of A.C. motors has widened considerably during recent years.
TYPES OF AC MOTORS:

10

INDUCTION MOTOR

10

11

Three phase induction motor is the most popular type of a.c. motor. It is very commonly used for
industrial drives since it is cheap, robust, efficient and reliable. It has good speed regulation and
high starting torque. It requires little maintenance. It has a reasonable overload capacity.
CONSTRUCTION:
A 3- induction motor essentially consists of two parts: the stator and the rotor.
The stator is the stationary part of the motors electromagnetic circuit. The stator core is made up
of many thin metal sheets, called laminations. Laminations are used to reduce energy loses that
would result if a solid core were used. Coils of insulated wire are inserted into slots of the stator
core. When stator windings supplied with 3- currents, produce a magnetic flux which revolves
at constant speed & induces an E.M.F. in the rotor by mutual induction.
Rotor is the rotating part and made up of thin laminations of the
same material as stator.
Squirrel-cage rotor: Motors employing this type of rotor are
knows as squirrel-cage induction motors. Almost 90 percent of
induction motors are squirrel-cage type. The rotor consists of a
cylindrical laminated core with parallel slots but little skewed for
carrying the rotor conductor.

Phase- wound or wound rotor: Motors employing this type of

rotor are variously known as phase wound motors or slip-ring
motors. This type of rotor is provided with 3-, double layer,
distributed winding consisting of coils as used in alternators.

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Working principle of Induction Motor

When three phase supply is given to three

phase stator winding, a rotating magnetic field
is produced. Due to rotating magnetic field,
the flux passes through the air gap between
rotor and stator, sweeps past the rotor surface
and so cuts the rotor conductor. Hence
according

to Faradays

law

of

electromagnetic induction, there would be a

induced current circulating in the closed rotor
conductors. The amount of induced current is
proportional to the rate of change of flux linkage with respect to time. Again this rate of change
of flux linkage is proportional to the relative speed between rotor and rotating magnetic field. As
per Lenz law the rotor will try to reduce the every cause of producing current in it. Hence the
rotor rotates and tries to achieve the speed of rotating magnetic field to reduce the relative speed
between rotor and rotating magnetic field.

TESTING & INSPECTION PARAMETER OF A.C. MOTOR

STATOR:
If the stator is ok in IR test then:

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Step1: BTS: - In BTS (Balance test of stator) the stator is checked for
whether the three phases of the winding are drawing same amount or not.
Step2: Impregnation in Hot Box. Here the stator is inserted into hot box after
varnishing so that moisture and dust are removed.
Step3: storage

ROTOR:
If it is a squirrel cage rotor then it is send to Bearing Removing and checking and if it is a Slip
Ring Rotor first it undergoes IR Test then it is moved to Bearing Removing and checking
From there it is send for Washing .Then if machining is required then it is send to machining
section and then only Slip Ring is send for BTR.
If BTR result is ok
Step 1: Bearing fitting
Step 2: Storage ok Rotor
Assembly:-Both the Rotor and Stator are assembled for no load test in the Test
Bed.

Test in Test Bed: -Here the motor is tested as per the SOP.
MEGGER TEST:Checking of insulation resistance of motor is done this method.
Check MEGGER test leads are proper insulated.
Use 1000V MEGGER for IR test.

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Rotate the MEGGER handle slowly & increases the speed to the slip speed
and note IR.
Insulation resistance is to be measured between phases and also between
phases and ground of stator and rotor winding (in case slip-ring motor).
After meggering discharge the stator/rotor winding by reversing MEGGER
terminal.
Minimum acceptable IR value is as follows:

Voltage rating of M/C

Up to 450V
3KV-11KV

Minimum acceptable value

5.0 M
100 M

BLOCKED ROTOR TEST:

Apply voltage slowly (by regulating the regulator) to the motor so as to
inject rated full load current.
During increasing the voltage watch the reaction of the person holding
the shaft .Whether the person facing any difficulties to hold or not .If
any reaction noticed Immediately bring the regulator to zero position.
If full load current cannot be injected then inject half of full load current
and note the voltage applied.
Acceptable limit of locked rotor test voltage at full load current is 1/8 to
1/4 of rated voltage of motor.

14

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OPEN CIRCUIT TEST (FOR SLIP-RING MOTOR):

Apply full stator voltage slowly to the stator terminal and measure
the rotor voltage (phase to phase) at rotor terminal keeping rotor
winding open. Rotor voltage should be equal to rated voltage.
Note down stator magnetising current, rotor voltage and stator
voltage.
RUN (NO-LOAD) TEST:
The rated voltage at rated frequency is applied to stator slowly (by

Type

15

regulating the regulator) to run the motor.

Run the motor for half an hour at rated voltage, rated frequency.
Note down current reading from ammeter.
All 3 phase current should be balanced
Acceptable range of no load current as follows:

Allowable range

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General purpose motors

20% to 50% of rated current

High torque motors like Withdrawal &

Mudgun motors

60% of rated current

In case of slip-ring motor after doing open circuit test short the rotor and
run the motor as squirrel cage motor as above.
Following reading are taken in run test:
No-load current
No-load speed
Vibration at bearing, body & foundation of body.
Temperature at bearing, shaft, body etc.
Bearing condition by SPM meter.
Sound using stethoscope.
Sparking in case of slip-ring motor

TEMPERATURE MEASUREMENT:
Take temperature reading of bearing, shaft & body by temperature gun .
Maximum acceptable value of temperature after half an hour is as follows:

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Location
Surface temp. of bearing housing

Maximum acceptable temperature

75C

Body temp. class B motor

55C

Body temp. class F motor

70C

Body temp. class H motor

90C

VIBRATION TEST:
Put vibration probe gently on motor driving and no driving end bearing
housing.Body and foundation base in horizontal, vertical & axial direction
and take the reading.
Maximum acceptable value of vibration as follows:

56<H132

132<H225

225<H400

H>400

SL.
No

shaft
height(mm)

Range of
speed

500 to
1500

>15003000

500 to
1500

>15003000

500 to
1500

>1500 3000

5001500

>15003000

N(normal)

1.8

1.8

1.8

2.8

2.8

4.5

2.8

4.5

R(reduced)

0.71

0.71

0.71

1.12

1.8

2.8

S(special)

0.45

0.45

0.45

0.71

1.12

1.8

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SOUND CHECKING:
Put the probe of stethoscope on bearing housing and body and observe any
unsual sound(humming, metallic, etc.) is coming or not.
BEARING CONDITION:
Connect the SPM probe to the instrument(shock pulse tester) and enter the
bearing data in the instrument.
Put the SPM probe on the bearing housing at an angle 45 to the load zone.

SPEED CHECKING:
Hold the Tachometer correctly and measure the speed of the motor.

AC DRIVES
AC drives provide a very efficient and direct method of controlling the speed of the
most rugged and reliable of prime movers, the squirrel cage motor. AC drives

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provide many economic and performance advantages in a wide variety of

adjustable speed drive applications.
The following are some of the benefits provided:
1. High efficiency and low operating cost.
2. Minimal motor maintenance.
3. Controlled linear acceleration and deceleration provide soft.
4. Starting and stopping and smooth speed changes.
5. Multiple motor operations are easily accomplished.
6. Current limit provides for quick and accurate torque control.
7. Adjustable speed operation can be accomplished with existing AC motors.
8. Improved speed regulation can be accomplished by slip compensation.
9. AC motors are available in a wide variety of mechanical configurations.
10. Flexibility of machine design due to the light weight and compact size of AC
motors.
11. IR compensation provides high starting torque easily and economically.
12. AC motors are available in enclosures suitable for hazardous or corrosive
environments.
13. Fewer spare motors are required since the same motor can be used for both
adjustable speed and constant speed operations.
14. Cutler-Hammer rugged and reliable designs ensure minimum downtime
expense.
15. High speed operation can be economically accomplished using extended
frequency operation.
16. Reverse operation is accomplished electronically without the need for a
reversing starter.

ADJUSTABLE FREQUENCY AC DRIVE SYSTEM

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INTRODUCTION
An adjustable frequency AC drive system consists of an ordinary three-phase
induction motor, an adjustable frequency drive to control the speed of the motor
and an operator's control station.
The most common motor used with an AF drive system is a standard NEMA design B
squirrel cage induction motor, rated for 230 or 460 volt, 3-phase, 60 Hz operation.
The adjustable frequency controller is a solid-state power conversion unit. It
receives 240 or 480 volt, 3-phase,
60 Hz power and converts it to a variable frequency supply which can be sleeplessly
adjusted between 0 and 60 Hz. The controller also adjusts the output voltage in
proportion to the frequency to provide a nominally constant ratio of voltage to
frequency as required by the characteristics of the motor. The operator's station
provides the operator with the necessary controls for starting and stopping the
motor and varying the motor speed. These functions can also be performed by a
wide variety of automatic control systems. There are several classifications of
adjustable frequency AC drives. Some common types of drives are Variable
Voltage Input (VVI) sometimes called Six Step drives, current source input (CSI),
pulse width modulated (PWM) drives, Sensor less Vector drives, Field Oriented
drives and Closed Loop
Vector drives.

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PRINCIPLES OF ADJUSTABLE FREQUENCY MOTOR

OPERATION
The operating speed of an AC induction motor can be determined by the frequency
of the applied power and the number of poles created by the stator windings.
Synchronous speed is the speed of the magnetic field created in the stator
windings. It is given by:

N = 120f /P

Where:
n = speed in RPM
f = operating frequency
P = number of poles
When the frequency is changed, the voltage must also be changed, based on
the formula for reactance and Ohms Law.

XL = 2fL

Where L = inductance
XL = reactance
V = voltage
Im = magnetizing current

Im = V/XL

Combining the above equations yields:

Im = (V/f). (1/2fL)
For steady-state operation, constant volts per hertz ratio must be
maintained. This is equal to the motor rated voltage divided by the rated
frequency.
For the magnetizing current to remain constant, the V/f ratio, or the volts per
hertz ratio, must remain constant. Therefore, the voltage must increase and
decrease as the frequency increases and decreases.

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INDUCTION MOTOR
SPEED CONTROL
Standard induction motors (NEMA
design B) have approximately 3%
slip at full load.
If the drive only controls the output
frequency, the motor speed will
deviate from the set speed due to
slip. For many fan and pump
applications, precise speed control
is not needed

CONCLUSION
Motors failure can lead to even higher cost in terms of lost production and efficiency. Industrial
companies need effective motor management strategies to minimize overall motor cost.
The maintenance practices that encompassed excellent reliability of motors are:
Visual inspections
Insulation resistance
Cleaning
Lubrication and/or filters
Vibration analysis
Bearing check/inspection
Temperature checking
Air gap checks

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Alignment
Check/change brushes, as applicable.

* The use of continuous-monitoring systems (i.e., temperature and vibration) and the
application of technologies and maintenance practices that will avoid or detect electrical
and mechanical faults
*The result is about a two-thirds reduction in failure rate and a significant decrease in
production downtime.
*Proper shaft alignment can prolong the life and improve the efficiency of motors and
other integral equipment.

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