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PROJECT ONTHE STUDY OF DRIVE

COMMUNICATION FAILURE

DEPARTMENT: NEW BAR MILL

By

AMANRAJ SINGH PADANOF

KALINGA INSTITUTE OF INDUSTRIAL TECHNOLOGY

BHUBANESWAR

Guide:

Mr. Sushil Kumar Tripathy

(Senior Manager, IEM)

TATA STEEL LIMITED JAMSHEDPUR

CERTIFICATe

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This is to certify that the summer trainee:

AMANRAJ SINGH PADAN OF KALINGA INSTITUTE OF

INDUSTRIAL TECHNOLOGY OF BHUBANESWAR, ODISHA has

completed his project on the topic:

THE STUDY OF DRIVE COMMUNICATION FAILURE

under the guidance of Mr. SUSHIL KUMAR TRIPATHY,

SENIOR MANAGER (IEM)TATA STEEL, JAMSHEDPUR.

The duration of the training was from 05-05-2015 to 06-06-2015.

ACKNOWLEDGEMENT

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First of all I would like to express our deep sense of gratitude to Mr.

SUSHIL KUMAR TRIPATHY for giving his consent to carry out our

project in Tata Steel.

My sincere thanks to Mr. MANOJIT ROY AND Mr.BIJU ABRAHAM

for his guidance and help which has been very useful in completing this

project.

My Sincere Gratitude to Mr.VINIT SHAH Chief, New Bar Mill.

I am also very thankful to Mrs. NILU KUMARI AND Mr.SURAJ

KUMAR for his valuable support and guidance without which this

project would not have been a successful one.

I would also like to thank all the officers, staffs and workers of New Bar

Mill, TATA STEEL for their consistent efforts to assist me in my project.

I would like to express my gratitude to Ms.C KHULLAR In-Charge, Vacation

Training, SHAVAK NANAVATI TECHNICAL INSTITUTE (SNTI), for giving me

the opportunity for in plant training in Tata steel

CONTENTS

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Sl No.

Topics Page No.

1 INTRODUCTION ON TATA TISCON AND NEW BAR MILL 5-10

2 NBM AUTOMATION CONFIGURATION DIAGRAM 11

3 INTRODUCTION ABOUT PLC 12-15

4 DESCRIPTION ABOUT DRIVE SECTION 15-17

5 DRIVE PLC COMMUNICATION SET UP AT NBM 18

6 NETWORK LAYOUT 19

7 COMPONENTS OF NETWORK LAYOUT 19-20

8 PROBLEMS 20-25

9 PROBLEM DATA HISTORY 26

10 ABB RECOMMENDATION 27

11 NBM ACS 600 LINE BUS FAULT 27-28

12 PROBLEM AND NETWORK MODIFICATION IN RECENT YEARS

28-35

13 PROFIBUS 36-38

14 ETHERNET AND CABLE 38-40

15 CONCLUSION 41

INTRODUCTION

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(TATA TISCON and NEW BAR MILL)

Tata Steel, the 12th largest steel producer in the world, is one of the first few companies

in India to introduce Thermo Mechanically Treated reinforcement bars, using the latest

technology - the ‘Tempcore Process’ (introduced in India for the first time which imparts

high strength to the bar as against cold twisting, a traditional manufacturing process.

TATA TISCON 500D is superior to traditional rebars in the market owing to low levels of

Sulphur & Phosphorus (S&P) which are harmful impurities in steel. TATA TISCON is

produced through a combination of superior processes. The steel for TATA TISCON

500D is produced through primary steel making route, using iron ore from captive

mines. It is subsequently processed through the blast furnace, LD & LF (ladle refining)

to refine the steel to the fullest extent and continuously cast into billets. The resultant

steel is of superior quality, containing no harmful ingredients (like Sulphur and

Phosphorus) and ensures the desired and consistent properties in the rebar.

Tata Steel has set up a new bar mill with the latest technology supplied by Morgan,

USA. This mill has both horizontal and vertical stands, a series of zero-tension loopers

and a fully automated bar bundling and master bundling system. Spacious billet yard for

cast-wise stacking of billets, reheating furnace, pre-finishing and finishing mill, cold

shear to cut bars, roughing mill, intermediate mill and the latest TMT facilities are the

other features of the bar mill. TATA TISCON 500D rebars are ‘hot rolled’ from steel

billets and subjected to PLC controlled on-line thermo-mechanical treatment in three

successive stages:

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(a)Quenching - The hot rolled bar leaving the final mill stand is rapidly quenched

by a special water spray system. This hardens the surface of the bar to a depth

optimized for each section through formation of martensitic rim while the core

remains hot and austenitic.

(b) Self Tempering - When the bar leaves the quenching box, the core remains

hot compared to the surface, allowing heat to flow from the core to the surface,

causing tempering of the outer martensitic layer into a structure called 'Tempered

Martensite.' The core still remains austenitic at this stage.

(c) Atmospheric Cooling - This takes place on the cooling bed

where the austenitic core is transformed into a ductile ferrite-pearlite structure. Thus the

final structure consists of an optimum combination of a strong outer layer (tempered

martensite) with a ductile core (ferrite-pearlite). This gives TATA TISCON 500D its

unique combination of higher strength and ductility.

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Key Highlights of NBM:

• Best ever Production in FY13, Fy’14 H1 and Q3

• Best ever monthly production(75710 MT, May’13)

• Increased 10 mm mill speed from 27m/s to 31m/s.

• Consistent mill operation of 12mm @ 27 m/s.

• Reduction of set up time to 3 hrs and Reduction in planned shutdown hours.

• Zero customer complaint since 2011

• Reduction in inspection & in process rejections

• Zero LTI.

• 100% employee involvement in improvement initiatives.

• One kaizen team, Aquarius won par excellence NCQC award.

• NBM Won JWQC apex winner award for DM.

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Technical Specification of Billets:

Area (mm2) Length (m) Weight (kgs) Bendness DD

150*150 11.75 - 11.98 2110 kgs<70 mm/12

mm<17 mm

Chemical Composition of Re-bars produced:

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MILL OVERVIEW

• Mill configuration is with 16 No-Housing stands. The first 8 stands are in a

vertical/horizontal configuration to avoid twist rolling of the 150mm billet.

• Stands 9 to 12 are all horizontal stands with Stands 13 to 16 in single line of 4

stands for Phase 1 and stands 17 to 22 are part of the 6-stand No Twist Mills and

are in two separate lines.

• Shears are provided after Stand No. 8, before the No Twist Mills and after the

water boxes for dividing products to the cooling beds.

• Water boxes are provided for quenching of re-bars 8 mm to 16 mm to produce

HYQST products.

• Powered slitter is provided after stand 16H and a provision has been kept to add

another powered slitter after stand 12H. The process section is then finish rolled

through the No Twist Mills.

• Bars 8, 10, 12 and 16 mm rolled in single strand through stands 1V to 16H are

slit 2-way and rolled through two groups of No Twist Mill stands 17 through 22.

• The downstream facilities for cooling, bundling and tying equipment are designed

with flexibility in terms of rolling small sizes at higher speeds, ease of adjusting

equipment during the learning curve and providing time for maintenance and

changes in the mill without affecting productivity.

• Bars emerging from two lines after the dividing shears are distributed bed outlet.

• Bar in each line is fed alternately to two delivery trough lines with the help of a

diverter switch located in front of each dividing shear.

• The bars are braked by a set of pinch rolls before entering the high-speed entry

equipment to the cooling bed. The bars thus collected are released through a set

of guides to the notch of the cooling bed. (TWIN ROTARY DRUM DELIVERY

SYSTEM for high speed entry to cooling bed )

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• Two such lines discharge bars to one side of the cooling bed, and the rakes

make a stroke after two sets of bars are dropped on the notches.

• After the bars are sufficiently cooled, the front end of the bars will get aligned by

the aligning rollers to improve yield while cutting order lengths 6 to 12m from the

cooling bed lengths of 72 m.

• At the discharge of the rake section of the cooling bed, bars drop on the adjacent

chain transfer provided with compartments and indexing features. This will assist

in collecting a number of pre-selected bars that will form a pre-defined bundle.

• Once the chain is full with layer of sub-bundles a tray transfer mechanism will

pick up the layer and deliver the same to the cooling bed run-out roller table,

having the same width and also with compartments to accommodate pre

selected sub-bundle layer in each segment.

• The layer will be run towards the cold shear for cutting order lengths with the help

of a gauge head. The cold shear is equipped with rapid blade change facilities.

• Downstream the cold shear four outlets for bundling of re bars are designed to

handle 6 to 12 m in single row and Station 4 is basically designed with short

separation facility.

• At the sub-bundling station the system is capable of forming 3 to 5 ton bundles

with wire ties.

• The loose bundle is held firmly by bundle forming units, before and after the

strapping machine, to have a compact round bundle formed before the strapping

operation is initiated. There is also the facility of loose bundles handling facility,

which ensures 100% compact bundle tying before weighing.

• The strapped bundle is transported on another roller table to the weigh scale

located along the roller table. Once the weighing is complete the chain transfer

removes the weighed and tagged bundle away from the roller table and

advances the same to the unloading point of the chain conveyor.

• The bundles are ready for removal by the shipping overhead cranes from two

unloading stations, located apart on either side and stacked for dispatch.

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NBM AUTOMATION CONFIGURATION DIAGRAM

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INTRODUCTION ABOUT PLC

A programmable logic controller, PLC, or programmable controller is a digital

computer used for automation of typically industrial electromechanical processes, such

as control of machinery on factory assembly lines, amusement rides, or light fixtures.

PLCs are used in many machines, in many industries. PLCs are designed for multiple

arrangements of digital and analog inputs and outputs, extended temperature ranges,

immunity to electrical noise, and resistance to vibration and impact. Programs to control

machine operation are typically stored in battery-backed-up or non-volatile memory. A

PLC is an example of a "hard" real-time system since output results must be produced

in response to input conditions within a limited time, otherwise unintended operation will

result.

Programmable logic relay (PLR)

In more recent years, small products called PLRs (programmable logic relays), and also

by similar names, have become more common and accepted. These are much like

PLCs, and are used in light industry where only a few points of I/O (i.e. a few signals

coming in from the real world and a few going out) are needed, and low cost is desired.

These small devices are typically made in a common physical size and shape by

several manufacturers, and branded by the makers of larger PLCs to fill out their low

end product range. Popular names include PICO Controller, NANO PLC, and other

names implying very small controllers. Most of these have 8 to 12 discrete inputs, 4 to 8

discrete outputs, and up to 2 analog inputs. Size is usually about 4" wide, 3" high, and

3" deep. Most such devices include a tiny postage-stamp-sized LCD screen for viewing

simplified ladder logic (only a very small portion of the program being visible at a given

time) and status of I/O points, and typically these screens are accompanied by a 4-way

rocker push-button plus four more separate push-buttons, similar to the key buttons on

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a VCR remote control, and used to navigate and edit the logic. Most have a small plug

for connecting via RS-232 or RS-485 to a personal computer so that programmers can

use simple Windows applications for programming instead of being forced to use the

tiny LCD and push-button set for this purpose. Unlike regular PLCs that are usually

modular and greatly expandable, the PLRs are usually not modular or expandable, but

their price can be two orders of magnitude less than a PLC, and they still offer robust

design and deterministic execution of the logics.

LADDER DIGRAM

Machine control design is a unique area of engineering that requires the knowledge of

certain specific and unique diagramming techniques called ladder diagramming.

Although there are similarities between control diagrams and electronic diagrams, many

of the component symbols and layout formats are different. This chapter provides a

study of the fundamentals of developing, drawing and understanding ladder diagrams.

We will

Begin with a description of some of the fundamental components used in ladder

diagrams.

Programmable controllers can implement the entire “old” ladder diagram Conditions and

much more. Their purpose is to perform this control Operations in a more reliable

manner at lower cost. A PLC implements, in Its CPU, all of the old hardwired

interconnections using its software instructions. This is accomplished using familiar

ladder diagrams in a manner that is transparent to the engineer or programmer. As you

will see throughout this Book, knowledge of PLC operation, scanning, and instruction

programming is vital to the proper implementation of a control system.

SCAN TIME

A PLC program is generally executed repeatedly as long as the controlled system is

running. The status of physical input points is copied to an area of memory accessible

to the processor, sometimes called the "I/O Image Table". The program is then run from

its first instruction rung down to the last rung. It takes some time for the processor of the

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PLC to evaluate all the rungs and update the I/O image table with the status of outputs.

This scan time may be a few milliseconds for a small program or on a fast processor,

but older PLCs running very large programs could take much longer (say, up to 100 ms)

to execute the program. If the scan time were too long, the response of the PLC to

process conditions would be too slow to be useful.

COMMUNICATION

PLCs have built-in communications ports, usually 9-pin RS-232, but optionally EIA-

485 or Ethernet. Modbus, BAC net, or DF1 is usually included as one of

the communications protocols. Other options include various fieldbuses such as Device

Net, Profibus or Profinet. Other communications protocols that may be used are listed in

the List of automation protocols.

REDUNDANCY

Some special processes need to work permanently with minimum unwanted down time.

Therefore, it is necessary to design a system which is fault-tolerant and capable of

handling the process with faulty modules. In such cases to increase the system

availability in the event of hardware component failure, redundant CPU or I/O modules

with the same functionality can be added to hardware configuration for preventing total

or partial process shutdown due to hardware failure.

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Allen-Bradley PLC

DESCRIPTION

(About Drive Sections)

A drive section includes one to three inverters depending on the Inverter power rating.

As a standard the inverters are protected with fuses. An optional

Disconnecting switch can be selected to disconnect the inverter from

The DC supply.

The inverter main circuit includes DC capacitors, discharging resistors,

Clamping capacitors and six Insulated Gate Bipolar Transistors. (IGBTs).

Inverter Module FrameSizesInverter modules are installed into cubicles depending upon the

Physical size of the module. The frame sizes are: R2i, R3i, R4i, R5i, R6i,

R7i, R8i, R9i, R10i, R11i or R12i.

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ACS 600 AC450

ADVANT CONTROLLER450

The Advant Controller 450 consists of a CPU sub-rack with two positions for redundant

CPU modules, sub-module carriers for communication sub-modules as well as a part

with regulatory and backup power. The S100 I/O is located in subsequent I/O sub-racks,

which can be placed in cabinets adjacent to the CPU cabinet or in a remote location

separated by optical fiber.

The Advant Controller 450 covers a wide range of functions such as:

Regulatory control including advanced PID and self-tuning adaptive control.

Logic and sequence control.

Data and text handling, arithmetic, and positioning.

Self-configuration capabilities which make it possible to add hardware while the

controller is in full operation

Full on-line configuration capabilities while the application is running.

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Support for a wide range of central and distributed I/O modules for maximum

configuration possibilities, with a maximum I/O capacity of 5700 I/O points.

Support for local and central operator interface for manual control operations, event and

alarm handling, trend curve presentation etc.

Interoperability concerning all communication levels from plant floor fieldbuses to high-

speed plant network.

Support for Profibus ABB’s redundant Advant Fieldbus 100, and other protocols.

Time synchronization with other nodes in an automation system at an accuracy better

than 3 ms. The controller and its I/O can time tag events with a resolution of 1ms

Backup of system and application RAM with separate power supply, local battery or

station battery as well as back-up of application on flash PROM cards.

ACS 600

The ACS 600 product family includes: a fully customized product for demanding system

applications (ACS 600 MultiDrive) drives for general purpose standard applications

(ACS 600 SingleDrive) drives for special applications such as positioning and cranes

(ACS 600 CraneDrive, ACS 600 MotionControl) drives for special branches (ACS 600

MarineDrive) ACS 600 MultiDrive is designed for the optimum configuration in multiple

drive applications. Whether an application involves a drive or two hundred drives, there

is an optimum configuration to meet the application need. ACS 600 MultiDrive consists

of four different section types: a supply section; a braking section, several drive sections

and control sections. The section type determines which type of equipment are in each

section cubicle. The modularity is a key-feature of the construction.

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DRIVE PLC COMMUNICATION SET UP AT NBM:PROTOCOL: ADVANT FIELD BUS 100Advant Fieldbus 100 (AF 100) is a high performance fieldbus, which is used for:

• Communication between Advant Controllers

• Communication between Advant Controllers and S800 I/O Stations, AC 800M

controllers, AC 100 OPC Server, and the equipments developed and sold by other ABB

companies.

In an AF 100 bus, it is possible to reach up to 80 stations within a total physical distance

of up to 13300 meters (43300 feet).

Advant Fieldbus supports three transmission media:

• Twisted pair (Twp)

• Coaxial (RG59 and RG11)

• Optical media.

An AF 100 bus can be built up with all the three media, where a part of one kind of

media is a specific segment.

The following rules apply to the segments:

• To each twisted pair segment, 32 stations can be connected, and the maximum

segment length is 750 meters (2500 feet)

• The coaxial segment can be:

– 300 meters (1000 feet) with cable RG59 or

– 700 meters (2300 feet) with cable RG11.

• The optical media is only used in point-to-point communication, and it allows the total

length of a bus segment to be up to 1700 meters (5500 feet).

• If back-to-back coupled optical segments are used, it is possible to reach up to a

physical length of 13300 meters (43300 feet).

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Network layout

COMPONENTS OF NETWORK LAYOUT

RDCO Communication modules

The RDCO-0x DDCS Communication options are add-on modules for the • RMIO Motor

Control and I/O board (also part of RDCU control units) • BCU control units. RDCO

modules are available factory-installed as well as retrofit kits. The RDCO module

includes the connectors for fiber optic DDCS channels CH0, CH1, CH2 and CH3. The

usage of these channels is determined by the application program; see the Firmware

Manual of the drive. However, the channels are normally assigned as follows: CH0 –

overriding system (eg. fieldbus adapter) CH1 – I/O options and supply unit CH2 –

Master/Follower link CH3 – PC tool (ACS800 only). There are several types of the

RDCO. The difference between the types is the optical components. In addition, each

type is available with a coated circuit board, this being indicated by a “C” suffix, eg.

RDCO-03C.

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MODULE TYPE

OPTICAL COMPONENT TYPECH0 CH1 CH2 CH3

RDCO-01(C) 10 MBd 5 MBd 10 MBd 10 MBd

RDCO-02(C) 5 MBd 5 MBd 10 MBd 10 MBd

RDCO-0(C) 5 MBd 5 MBd 5 MBd 5 MBd

RDCO-04(C) 10 MBd 10 MBd 10 MBd 10 MBd

The optical components at both ends of a fiber optic link must be of the same type for

the light intensity and receiver sensitivity levels to match. Plastic optical fiber (POF)

cables can be used with both 5 MBd and 10 MBd optical components. 10 MBd

components also enable the use of Hard Clad Silica (HCS) cables, which allow longer

connection distances thanks to their lower attenuation.

PROBLEMS:

The Incidence –BPRA2 Bus Fault :

Department : New Bar MillSection : IEM

Date : 16.11.2010

Time : 11:30 PM

Location : BPR -A2Delay : 60 Min.

Observations:1. Bar Overshoot in line A.

2. BPR A2 tripped in bus fault

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Action Taken:1. Drive reset

2. Tightened the FO cable between NDBU & RDCU

Analysis:

1. FO cable connector may become loose.

2. Due to Dust/vibration there may be a loss in communication at connections

Probable reasons of failure:

1. Aging of FO cable

2. Aging of FO connectors

3. Dusty environment

Recommendations:

1. Schedule maintenance and testing of FO cables and connections.

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The Incidence –BPRA2 Bus Fault

Department : New Bar MillSection : IEM

Date : 18.12.2010

Time : 07:30 PM

Location : BPRDelay : 184Min.

Observations:3. DSA cobble detect alarm.

4. BPR A2 tripped in bus fault

Action Taken:

1. Replaced the FO cable between NDBU & RDCU

Analysis: -

Defective FO cable were checked and found communication loss (dB is

Higher than normal value. (Greater than 15 dB)

Due to Dust/vibration there may be a loss in communication at

Probable reasons of failure:

1. Dusty environment

Recommendations:

1. Schedule maintenance and testing of FO cables and connections.

All dust entry points should be sealed through filters at the door

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The Incidence – AF#100 Bus Fault in AM1CPU3 during shutdown job.

Department : New Bar Mill

Section : IEM

Date : 24.01.2014

Time : 10:00 AM

Location : Lineup#1

Delay--- : Nil

Observations: AF100_Bus4 of AM1_CPU3 made down to change the end terminator

and CI810 to NDBU FO cable by making pin ‘IMPL’ to 0

After changing the end terminator & FO cable, bus tried to restart by

making pin ‘IMPL’ to 1.

During restarting, ‘AF#100S’ of Lineup#1 (station#42), ‘PHE’ (Peripheral

H/W error) warning came in the database element.

Probable reasons of failure: During the BUS down time, the individual stations as well as drive units

should be made down.

During restarting of BUS, the individual stations as well as drive units should

be restarted.

Action Taken: Tried to reset the error by making ‘IMPL’ & ‘SERVICE’ pins to 0 and to 1

but error was persisting

Then restored the CI810 to NDBU FO cable, but no improvement found

Then all the related drives RMIO and TSU’s CON2 power supply of

LU#1&2 recycled and then found working ok.

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Recommendations:

Sl. NoRecommendations Remarks

1 All AF#100 BUS TBM maintenance to be done immediately

COMMUNICATION MODULE Fault code: 7510

CAUSE: Fieldbus communication break detected on fieldbus module or on

communication channel CH0 receive.

WHAT TO DO: Check the connections of fieldbus adapter module. With an ABB Advant

overriding system check channel CH0 optical fibres between the RMIO board and

overriding system (or Nxxx type of fieldbus adapter). Test with new optical fibres. Check

the earthings of fieldbus cables.

Check that the node address is correct in the drive. Check the status of the fieldbus

adapter. See appropriate fieldbus adapter manual.

Check parameter settings of Group 51, if a fieldbus adapter is present. Check the

connections between the fieldbus and the adapter. Check that the bus master is

communicating and correctly configured.

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PROBLEM HISTORYdata taken from JUNE 2015 TO FEB 24 2015

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ABB RECOMENDATION

NBM ACS 600 lineup bus fault

Problem:

• At NBM we have frequent tripping of stand drives of line up #1 in bus fault from

last 2years.

• Recently the tripping has become very frequent.

Background:

• Lineup 1 is ACS 600 MultiDrive with 1 TSU and 5 inverter, bus fault is common in

inverter 1 and inverter 3.

• Drive communicates with PLC (AC450) via AF100 and CI-810 module. From C1

810 we have FO going to NDBU95 and from there it goes to RMIO via RDCO.

• From controller (PLC) AF 100 bus goes to lineup 2, from lineup 2 AF100 goes to

lineup 1 and terminates.

Action taken in past:

• FO cable changed from NDBU to RMIO, RDCO changed, and NDBU changed.

• light intensity checked found OK,

• terminating resistance of AF100 at CI 810 changed

Recent action:

Recommendation Status

Checking 24 volts of RDCU card Done

Grounding of RDCU card Done

Shorting unused FO channel of RDCO Done

Moving CI810 card of lineup 1and lineup 2

to PLC panel

Done

Monitoring FC duty Done

6 page checklist

To remove tube light choke from PLC panel

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• Power at RDCO card was checked and found OK.

• In shutdown from 4-6 December 2014, we modified network between lineup 2

and lineup 1. AF100 cable loop was shortened by shifting C1810 of lineup 1, in

same panel as lineup 2.

• On 30.12.2014 during section change we changed Af100 cable between lineup

2 and lineup 1 to make the length greater than 3 meters to avoid reflection as per

ABB

• In January 2015 we have shorted unused FO channel ( channel 1&2) of RDCO

with FO cable.(stand 1 and 6)

• In January 2015 we have provided extra grounding of the RDCU card (stand 1

and 6)

• In Feb 2015 we again modified the drive network. We moved both CI810 card of

lineup 2 and lineup 1 to PLC panel, HCS cable was laid from CI810 card in PLC

panel to BDBU in lineup 2 and 1.

• Also we have done trending of drive parameter FC duty in IBA.

Network modified recently (4-6 dec 2014)

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Modification and problem on 30 dec 2014

Based on ABB recommendation to avoid reflection in AF100 cable it was decided to

increase AF100 cable length from 1 mtrs to 3.5 mtrs, so cable between CI810 card of

lineup 2 and lineup was changed

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Modification and problem on 11 Feb 2015Lineup 1FO cable replaced by AF100 cable and modem removedBoth CI 810 card of lineup 2 and lineup 1 moved to AM1 PLC panel

Stand 6 bus fault, 14 feb 2015 , FC duty trend

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• Stand 6 had bus fault, bus fault only happens in stand 1 and stand 6.

• Stand 1,5,7,8 ,6 are in lineup 1.

• Stand 2,3,4 are in lineup 2 .

• Lineup 1 and lineup 2 are in same AF100 bus( stand 1,2,3,4,5,6,7,8) , coming

from AM1 CPU3.

• Stand 9,10 are in lineup 2, stand 11,12 are in lineup 3

• Part lineup 2( stand 9, 10 ) and lineup 3 are in one AF100 bus coming from AM2

CPU1.

• FC duty is high(80 %) in some drives and it falls to 60 % when mill is not running

Modification in RDCU /RDCO card

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• Additional grounding done through cable

• Although card was grounded through mounting channel ,

Unused channel 1 and 2 RX TX shorted using FO cable

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ERROR LOG IN PLC FOR BUS FAULT

Action done on 4 march 2014 Regarding stand #6 bus fault.

• Stand #6 RDCU AND RDCO card changed.

• RTAC card changed for stand 6

• NDBU TO RDCU FO cable changed.

• CH# 3 and CH0 both FO cables changed.

• DB loss test for following FO cables was done.

• CH 0 NDBU to RDCO

• Line up 1NDBU to CI810

• Both results found o.k.

• Line up #1 NDBU channel changed for TSU and all its inverter e.g. stand#5, 6, 7,

8 and 1.

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Action taken on by NBM IEM in March 2014

Action before 4 march 2014

Lineup 1 all drive channel 3 communication to IBA server stopped.

After: termination of CI810 done using TC505 and prefabricated trunk cable

Before: CI810 terminating done using AF100 cable

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AF100 bus modification after ABB suggestion based on checklist

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PROFIBUS

PROFIBUS (Process Field Bus) is a standard for fieldbus communication in automation

technology and was first promoted in 1989 by BMBF (German department of education

and research) and then used by Siemens.

The goal was to implement and spread the use of a bit-seria l  field bus based on the

basic requirements of the field device interfaces. For this purpose, member companies

agreed to support a common technical concept for production (i.e. discrete or

factory automation) and process automation . First, the complex communication protocol

Profibus FMS (Field bus Message Specification), which was tailored for demanding

communication tasks, was specified.

There are two variations of PROFIBUS in use today; the most commonly used

PROFIBUS DP, and the lesser used, application specific, PROFIBUS PA:

• PROFIBUS DP (Decentralised Peripherals) is used to operate sensors and

actuators via a centralised controller in production (factory) automation applications.

The many standard diagnostic options, in particular, are focused on here.

• PROFIBUS PA (Process Automation) is used to monitor measuring equipment via a

process control system in process automation applications. This variant is designed

for use in explosion/hazardous areas (Ex-zone 0 and 1). The Physical Layer (i.e. the

cable) conforms to IEC 61158-2, which allows power to be delivered over the bus to

field instruments, while limiting current flows so that explosive conditions are not

created, even if a malfunction occurs. The number of devices attached to a PA

segment is limited by this feature. PA has a data transmission rate of 31.25 kbit/s.

However, PA uses the same protocol as DP, and can be linked to a DP network

using a coupler device. The much faster DP acts as a backbone network for

transmitting process signals to the controller. This means that DP and PA can work

tightly together, especially in hybrid applications where process and factory

automation networks operate side by side.

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Bit-transmission layer

Three different methods are specified for the bit-transmission layer:

• With electrical transmission pursuant to EIA-485, twisted pair cables with

impedances of 150 ohms are used in a bus topology. Bit rates from 9.6 kbit/s to 12

Mbit/s can be used. The cable length between two repeaters is limited from 100 to

1200 m, depending on the bit rate used. This transmission method is primarily used

with PROFIBUS DP.

• With optical transmission via fiber optics, star-, bus- and ring-topologies are used.

The distance between the repeaters can be up to 15 km. The ring topology can also

be executed redundantly.

With MBP (Manchester Bus Powered) transmission technology, data and field bus

power are fed through the same cable. The power can be reduced in such a way that

use in explosion-hazardous environments is possible. The bus topology can be up to

1900 m long and permits branching to field devices (max. 60 m branches). The bit rate

here is a fixed 31.25 kbit/s. This technology was specially established for use in process

automation for PROFIBUS PA.

DIFFERENCES(Profibus DP and profibus AP)

PROFIBUS DP uses two core screened cable with a violet sheath, and runs at speeds

between 9.6kbit/s and 12Mbit/s. A particular speed can be chosen for a network to give

enough time for communication with all the devices present in the network. If systems

change slowly then lower communication speed is suitable, and if the systems change

quickly then effective communication will happen through faster speed. The RS485

balanced transmission used in PROFIBUS DP only allows 126 devices to be connected

at once; however, more devices can be connected or the network expanded with the

use of hubs or repeaters.

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PROFIBUS AP is slower than PROFIBUS DP and runs at fixed speed of 31.2kbit/s via

blue sheathed two core screened cable. The communication may be initiated to

minimize the risk of explosion or for the systems that intrinsically need safe equipment.

The message formats in PROFIBUS AP are identical to PROFIBUS DP.

(Profinet and Profibus)Profinet: an open standard for industrial Ethernet with adaptations for improved real-

time applications. It can directly connect PLCs and IO devices.

Profibus: a fieldbus system for real-time distributed control. It is used for process and

field communication in cell networks with few stations and for data communication. It

connects PLCs, sensors, actuators and other automation devices.

ETHERNET

Ethernet is a family of computer networking technologies for local area

networks (LANs) and metropolitan area networks (MANs).

It’s refined to support higher bit rates and longer link distances. Over time, Ethernet has

largely replaced competing wired LAN technologies such as token ring ,FDDI,

and ARCNET.

The ethernet standard comprise several wiring and signaling variants of the OSI physics

layer in use with Ethernet. The original10BASE5 Ethernet used coaxial cable as

a shared medium. Later the coaxial cables were replaced with twisted pair and fiber

optics links in conjunction with hubs or switches.

Ethernet data transfer rates have been increased from the original 3 megabits per

second (Mbit/s) to the latest 100 gigabits per second (Gbit/s), with 400 Gbit/s expected

by early 2017.

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CABLE

An electrical cable comprises two or more wires running side by side and bonded,

twisted, or braided together to form a single assembly, the ends of which can be

connected to two devices, enabling the transfer of electrical signals from one device to

the other. Cables are used for a wide range of purposes, and each must be tailored for

that purpose. Cables are used extensively in electronic devices for power and signal

circuits. Long-distance communication takes place over undersea cables. power

cables are used for bulk transmission of alternating and direct current power, especially

using high-voltage cable. Electrical cables are extensively used in building wiring for

lighting, power and control circuits permanently installed in buildings

Electrical cable types

A 250 V, 16 A electrical cable on a reel.

• Coaxial cable: used for radio frequency signals, for example in cable

television distribution systems.

• Communications cable

• Direct-burried cable

• Flexible cable

• Heliax cable

• Non- Metallic sheathed cable (or nonmetallic building wire, NM, NM-B)

• Metallic sheathed cable (or armored cable, AC, or BX)

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• Multicore cable (consist of more than one wire and is covered by cable jacket)

• Paired cable: Composed of two individually insulated conductors that are usually

used in DC or low-frequency AC applications

• Ribbion Cable: Useful when many wires are required. This type of cable can easily

flex, and it is designed to handle low-level voltages.

• Shielded cable: used for sensitive electronic circuits or to provide protection in high-

voltage applications.

• Single cable (from time to time this name is used for wire)

• Submersible cable

• Twinax cable

• Twin Lead: This type of cable is a flat two-wire line. It is commonly called a 300 Ω

line because the line has an impedance of 300 Ω. It is often used as a transmission

line between an antenna and a receiver (e.g., TV and radio). These cables are

stranded to lower skin effects.

• Twisted Pair: Consists of two interwound insulated wires. It resembles a paired

cable, except that the paired wires are twisted

Twisted pair cabling is a type of wiring in which two conductors of a single circuit are

twisted together for the purposes of canceling out electromagnetic interferences (EMI)

from external sources; for instance, electromagnetic radiation from unshielded twisted

pair (UTP) cables, and crosstalk between neighboring pairs.

P a g e | 41

CONCLUSION

During the project work, the NBM Process Layout was studied. The automation diagram

indicating the connection between Drives and PLCs was also studied. PLC and

DRIVES of ABB were used there and studies was also done on the communication

protocol between the PLC and Drive i.e. Advant FieldBus100 (AF100) and the

communication of the PLC and the HMI (Human Machine Interface) i.e. MB300 was

used. Studies were also made about the Multidrives used for the motors of all the

stands of the mill and how they work.

The recurring problem of bus fault occurred in the past were studied for example

AF#100 Bus Fault in AM1CPU3. To sort out the problem various actions were taken

sequentially finally all the related drives RMIO and TSU’s CON2 power supply of

LU#1&2 were recycled and the problem was solved

Besides the above, various other departments were visited such as Steel melting in LD

shop, Electric arc furnace, Pig iron making through Blast Furnace, Continuous Casting,

Hot Strip Mill, etc where different processes in operation were observed.