B
Bharat Bijlee Limited
Over 55 years
in the industry
Over 450 Drives in India & abroad
From 750kg to 1750 kg Basket
• Bharat Bijlee is the first and largest
Indian manufacturer of microprocessor
based Variable Speed Drives for Batch
Centrifugals
• AC Variable Voltage since 1985
– 300 drives at 72 locations
• Analogue DC Drives since 1997
– 150 drives at 65 locations
• Digital DC Drive Nov 2002
BBL serves every corner of Asia
SURAT
Digital DC Drives
a result of in-house R&D
• We have 17 years experience with batch
type centrifugal machines
• We have commissioned 150 Analogue DC
drives - drives developed by our own R&D
• WE COMMISSIONED OUR FIRST DIGITAL
DRIVE IN NOVEMBER 2002
– Fully Digital Control Algorithm
– Integrated Field Controller
– Customised Logic Controller
Minutes of meeting between M/S. Shree Renuks Sugars Ltd and
M/s Bharat Bijlee Ltd. Held on 20th January 2003 at
M/S.Renuka Sugars Ltd. Manoli
Persons Present
M/S SRSL M /S. BBL
1. Mr. C G Mane 1. Mr. S S Sathawane
2. Mr. R Y Huilgol 2. Mr. A B Harshe
3. Mr. G B Kulkarni 3. Mr. N D Shanbaug
4. Mr Lokeshappa H 4. Mr T G Kolambkar
1. As per the SRSL Fax dated 9/1/03 BBL representatives reached
site on 13/01/03 to re-commission the digital DC Drive which was
shifted from M/C No. 4 to M/C. No. 5, as per request of SRSL.
2. The mechanical and the electrical work of above M/C. was
completed on 16/01/03
3. The drive and the M/C. No. 5 was re-commissioned on 18/01/03
4. Earlier this drive system was put on M/C. No. 4 and was working
satisfactorily since end October 02 till 3rd January 03, giving
20 cycles per hour on load and has completed approximately 25,000
cycles so far.
5. M/S. SRSL has expressed their satisfaction about the working
and the performance of the above drive system.
The Digital Advantage
- Reliability
• Software based Controls and Protections
• Protections against Frequency Variations
• Protection against Thyristor Gate Control
malfunction
• Not affected by drift in component values
• Not affected by change in Phase
Sequence
• Fault History - last 32 faults with time
stamp
The Numerical Control Advantage
Keypad is in - Screwdriver is out
• Drive Set up - all parameters input
through keypad
• Linear and S curves for acceleration &
deceleration ramp with adjustable time
constants
• Three levels of Password protections
• Adaptive Control Algorithm for
– lower voltage and current overshoots
– faster response to load and line changes
State of the Art DSP
• Texas Instrument 16 Bit Processor
– Type - TMS 320 F240
• High Execution Speeds - 20 MIPS
– In built hardware multiplier
– single cycle execution
– four stage pipeline architecture
• PROTECTION AGAINST OBSOLESCENCE
– Micro Controllers are being replaced by DSP
V
V A M
Mains L Drive Controller
FSU
Input
C Power supply Armature
L
Controller
SW Control card Speed
Control Supply HMI
T
Field
Power card
Field
A
Snubber card Controller
Bleeder
Transformer
PBS
Customised Logic Controller mimic
Solenoids
Power supply Process & m/c Speed
Logic Control
HMI CPU Card
M/c Proximity
I/O Card Protections A Ia Switches
Single Line Diagram of Drive System
Speed Feed back SET IF
PI CURRENT
ERR. AMP. LIMITER
Eb
Ref +
DC TO CONV.
ACTUAL Eb=Va-Ia Ra
PI END STOP
V TO f
A1 Va
Va M ISOLATION
AMP. +
ERR
AMP
f TO V
A2 CONVERTER
F
400V D.C. =10V.
Ia Ra F1
CT
+
F2
BLOCK SCHEMATIC OF FIELD CONTROL
(
ERR. AMPR. ( DECIDES
REQD. Ia
Ia SLEW
RATE LIMIT
SET. Ia
LIMITER
+
REF
N
N f/b
PI
ERR. AMPR. CONTROLLER END STOP
PROCESSING DC TO CON. 630A
Ia f / b GSMJ
A.C. SIDE
CURRENT A1
M
N f/b
Tg A2
BLOCK SCHEMATIC OF ARMATURE CONTROL
Protections in Drive
- Mains under / over voltage
- Mains under / over frequency
- Phase failure
- Excessive motor winding temperature
- Excessive converter temperature
- Instantaneous armature over current
- Overload ( I.t ) type
- Over speed
Protections in Drive
- continued
- Motor stalling
- Tacho failure
- Field failure
- Armature over voltage
- Thyristor gate control malfunction
- Main contactor failure fault
- Motor fan failure
- Converter fan fault
User Interface for Drive Module
150 PARAMETER DISPLAYS 60 PARAMETER INPUTS
• Speed • Rated values of mains
• Armature Voltage and voltage and frequency
Current • Rated Armature Current
• Field Current and Voltage
• Mains Voltage and • Rated Field current
Frequency • Min. and max. Firing
• Faults with time stamp Angle
• PI controller output • Over current over
• Armature and field firing voltage and over speed
angle limits
• Motor base speed
SPEED
1000 RPM
ARMATURE CURRENT
400 AMPS
E
Customised Logic Controller
• Developed by In House R&D efforts
• Programmable as per customer’s
specification
• HMI provided on control panel for
– setting up process parameters
– display of status of process
– fault indications - stores last 16 faults
• Logic changes after commissioning can be
programmed at BB factory and user can
easily replace EPROM on site
• Command vs feedback compliance feature
Push Button Station
300mm X 550 mm X 150 mm
Drive Panel
1200 mm X 1600 mm X 600 mm
FRONT SIDE OF DRIVE PANEL REAR SIDE OF DRIVE PANEL
DRIVE DETAILS
Future Versions of
Digital DC Drive
• Serial Communications
• Armature Current Reversal
• HMI at operator station
• Process and drive inputs through
same HMI
R&D Direction
• AC Variable frequency 2Q drives for
– ID and FD Fans
– Milling Plant
– Cane Carrier
– Pumps
• AC Variable frequency 4Q drives for
– Batch type Centrifugals
Bharat Bijlee
is Wedded to the
SUGAR INDUSTRY
for
Years
Bharat Bijlee
India’s first & largest
manufacturer of
Microprocessor based Drives for
Sugar Centrifuges
the
Bharat Bijlee
advantage
