Drives For specific application

FACTORS AFFECTING THE SELECTION

OF DRIVE
• LIMIT OF SPEED RANGE
• EFFICIENCY
• BRAKING
• STARTING REQUIREMENTS
• POWER FACTOR
• LOAD FACTOR
• AVAILABILITY OF SUPPLY
• ECONOMICAL ASPECTS
 SELECTION OF MOTOR BASED ON
LOAD VARIATION
• CONTINOUS LOAD
• CONTINOUS VARIABLE LOAD
• PULSATING LOAD
• IMPACT LOADS
• SHORT TIME INTERMITTENT LOAD
• SHORT TIME LOAD
 CLASSES OF DUTY AND SELECTION OF
RATING OF MOTOR
• ONCE CYCLE OF VARIATION OF LOAD IS DUTY
• CONTINOUS DUTY
• CONTINOUS DUTY,VARIABLE LOAD
• SHORT TIME DUTY
• INTERMITTENT PERIODIC DUTY
• INTERMITTENT PERIODIC DUTY WITH STARTING
• INTERMITTENT PERIODIC DUTY WITH STARTING
AND BRAKING
 POWER LOSSES AND HEATING OF
MOTOR
• COPPER LOSS
• CORE LOSS
• POWER LOSSES CAUSE LOCALISED HEATING
AND RESPONSIBLE FOR TEMPERATURE RISE
OF THE MOTOR
 STEADY STATE CONDITION
• FINAL TEMPERATURE RISE IS REACHED WHEN
THE RATE OF PRODUCTION OF HEAT AND
RATE OF HEAT DISSIPATION ARE EQUAL
 CONTINOUS RATING
• CONTINOUS RATING OF A MACHINE IS THAT
RATING FOR WHICH THE TEMPERATURE RISE
IS JUST BELOW THE PERMISSIBLE VALUE OF
TEMPERATURE RISE
 HEATING AND COOLING CURVES
• A SMALLER TIME CONSTANT IS OBTAINED FOR
GOOD VENTILATION
• THE TIME CONSTANT IS INVERSELY
PROPORTIONAL TO SPECIFIC HEAT
DISSIPATION
• COOLING TIME CONSTANT IS THE TIME
REQUIRED TO COOL THE MACHINE
 SELECTION OF POWER RATING FOR
DRIVE MOTORS
• CONTINUOUS LOAD
• CONTINUOUS RATING SPECIFIES THE
MAXIMUM LOAD THAT THE MOTOR CAN
TAKE OVER A PERIOD FOR TIME
• CONTINUOUS VARIABLE LOAD
• CLASS OF DUTY IS SELECTED, BASED ON
AVERAGE POWER OR CURRENT
 To select proper motor of suitable size,
knowledge of following point is necessary

• The torque speed curve of the industrial load

is required -----this will fix the type of motor to
drive the load
• The environmental conditions in the industry
where the motor is located------- this will
decides the ambient temperature at which
the motor will operate
• Duty cycle of the load and frequency of
starting and braking---- the Kw rating of the
motor will decided by the load cycle, taking
into consideration both thermal as well as
mechanical overload capacity of the motor.
• If starting and braking of the motor is
employed very frequently -----then that
change the Kw rating of the motor
• The motor rating must be so chosen that it is
capable of driving highest loading in the duty
cycle without getting thermally overloaded,
providing the necessary torque at all
conditions.
• The speed control methods also decides the
type of motor----economic involved is also
due consideration.
• To meet certain duties in a particular
application special design of the motor may
be required
• Special controlling and protection circuit may
be needed for individual motor.
• Some industrial applications may have several
applications, may have several stages by the
time the end product is ready from the basic
raw material.
• While selecting motors for operating in these
stages , variety of motors may be needed
 Textile Mill
• Various stages in textile mill
– Ginning
– Blowing
– Cording
– Spinning
– Looms
Ginning

• The process of separating seeds from the raw

cotton picked from the field is called ginning
– Load speed is constant
– No speed control is required
– Squirrel cage induction motor can be used
Blowing
• The ginned cotton in the form of bales is
opened up and is cleaned up very well in a
blowing room.
• Normal three phase induction motor can be
used
• Motor having synchronous speed of 1000 or
1500 rpm may be used
Cording
• The process of converting clean cotton into
laps is done by Lap machines
• That is done by squirrel cage induction motor.
• These laps are then converted to slivers by a
process called cording
• A motor used for cording is required to
accelerate the drum having alarge moment of
inertia.
Cont…
• The motor should have high starting torque
and low starting current to keep starting
current minimum.
• Normally three phase totally enclosed fan
cooled squirrel cage motor can be used
• The rating of the motor depends upon the
type of fabric.
• For light fabric small rating motor of 1.5 kw
can be used
• Slip ring motor may be advantageously used
with rotor resistance starter provide high
starting torque
• Slivers are converted into uniform straight
fibre in a drawing machines
• However the motor selected must have a
capability to stop suddenly ,in case of sliver
breaking
Spinning
• Before the thread is ready for final spinning it
is thinned down in two or three stages by
processing it on a fly or speed frame
• A motor with smooth acceleration is
necessary to drive this frame.
• During spinning process the yarn is twisted
and made to have sufficient strength.
• The strengthened yarn is wound on Bobbins
• The spinning motors must be capable of
drawing ,twisting and winding operations
• The breakage must be minimum and yarn
produced must have uniform tension
• These motors must have uniform acceleration
to avoid yarn breakage
• Its speed torque curve must be as---

• Its starting torque is—150 to 200%

• Its peak torque is--- ---200 to 250%
• The difference between these torque must be
constant as motor speeds up
• A normal motor is therefore is not suitable for
this process
• A two speed pole change motor may be used
• It must have constant torque at both the
speeds, so that uniform tension is assured
both at the starting and at the running
• One can employ two different motor
• One for starting and low speeds another for
high speed
• In that case motors are costly
• But has several advantages
– It allows setting of any speed difference by
adjusting the pulley diameter and speed ratios
– The yarn tension can be adjusted independently
– There is no interruption in the production even
when one motor fails
Muley spinning
• For muley spinning , a group drive may be
employed
• The motor employed should have high
starting torque as well high operating torque
• A slip ring motor with rotor resistance control
can be used
• For operation like winding, warping, sizing,
normal motors may employed
• Low speed motor is required for that purpose
• Reduction in speed can be got by using gear.
• When the yarn is transferred from the bobbin,
a speed drop of 100 rpm is required
• So for these operations high slip motor are
preferred.
Looms
• The weaving of yarn into cloth is done in
looms.
• Requirement of loom motor are:
– Starting torque must be high to complete the pick
up job in a very short time
– The duty cycle consists of frequent starting and
stopping. The load on the loom motor is variable
and intermittent. To avoid frequent starting and
stopping the motor may be coupled or decoupled
from the load by means of clutch
• To suit the above requirement the Loom
motors are normally totally enclosed 3 phase
induction motor with high starting torque.
• Fan cooling of the motor is also employed to
avoid the collection of cotton fluff on the
motor surface
• The size of the motor will depends on the
fabric.
 Cranes and Hoist Drives
• Requirement
– Motion of crane hook in all the three direction
– Acceleration and retardation must be uniform, this is
more important than the speed control
– For exact positioning of the load creep speed must be
possible
– When the motion is in the horizontal direction braking
is not the problem
– In the case of vertical motion the movement of empty
cage has to be considered carefully
• The speed must be constant while lowering
down the load
• Mechanical braking must be available under
emergency condition
• Power lowering may be used when an empty
cage or light hooks are lowered
• Cranes motor can be either dc or ac
– Even though the electrical characteristics make DC
motors suitable as cranes motors suitable as
cranes motors
– The lower inertia , economical construction of
cage motor favors them as crane motors
– With the advent of thyristors and associated
power converters it is possible to have torque
control during starting , running and braking
DC systems for cranes
• speed control is achieved by means of ward
leonard system with all facilities of speed
control in forward and backward directions
with regeneration
– Among the dc motors series motors are extremly
suitable for crane operation
– They have the following features
• Good starting torque, high torque capability at
low speeds and light torque at high load
• Simple arrangements for braking of the
motors
• Power demand under highly load conditions
decreases due to fall in speed
• Electrical braking is possible even at low
speeds due to low critical speed
• The lowering speeds increase with the load.
Regenerative braking is not possible to limit
this speed
• However the speed torque characteristic of dc
series motors may be modified to suit all
phases of crane control
AC systems for cranes
• Among AC motors squirrel cage motors are
normally used . They have the following
features
– With the development of variable frequency
converter
– Widerange of speed control can be obtained
– They have fast acceleration and a fixed sequence
of operation
• Regenearative braking is not a problem this
occurs automatically when the load overhauls
or the empty cage is being raised
• The motor is simple and robust
• Limitations
– Non uniform sequence of operation can not be
handled
– Conventional methods of speed control are not
suitable if precise speed control is necessary
 Slip ring induction motor
– Speed torque curve can be modified by suitably
altering the rotor resistance
– The staring torque can also be varied to the
required value.
– Regeneration is possible .dynamic braking is
possible.
While selecting a motor for crane duty the
following points require consideration
– Breakdown torque must be greater than 250%
– The inertia must be small
– Must be withstand large frequency of starts
– Must have sufficient running torque and starting
torque
– The duty cycle must be specified
 Cement Mill
• Collection of raw material such as lime stone
• This is transported to the mill site and crushed
there
• Grinding of this crushed lime stone after the
addition with bauxite iron etc.
• By passing air through bottom the lime
powder is homogenised
• This is fed to cement kilns where the cement
clinker is made at high temprature
• The process where dry powder is used is
called dry process
• Wet process of cement making is also popular
• Hot clinker is then air cooled in special types
of coolers and made ready for storage
• After storing a few days gypsum is added in
required quantities and ground to the
required fineness
 Requirement of mill motors

• They should have high starting torque

• The starting current must be limited to a
maximum of two times of the full load value
to minimize voltage dips
• An overload capacity of 50 % for one minute
may be necessary ,occurring four times in an
hour
• The above requirements are very well met by
3 phase slip ring induction motor.
• Suitable starting torque may be accomplished
by means of rotor resistance control
Kiln Drives
• The rotary kiln drives depend upon the type of
cement making process
• The requirement for Kiln motor:
– Power requirement is very high
– Speed control ratio is 1:10
– Starting torque should be in the range 200 to 250%
– For small periods an overload capacity of 200 to
250% may be required
• The motor that meet the above requirement are
ac commutator motors and ward leonard control
dc motors.
• Speed range 1:2 in ac commutator motors
• Whereas speed range of 1:10 possible with DC
motors
• Lower efficiency , limitations due to commutator,
may be overcome by thyristorised drives
• When two motors are used to deliver the
power they must be designed to have equal
load sharing without overloading
• They must maintain the same speed
• For higher power rating these drives are not
suitable due to commutator ,then ac drives
are suitable
• A cyclo converter fed synchronous motor
meets the requirement
– The drive can be controlled to have an excellent
dynamic behaviour.
– The motor with self control has the characteristics
of a dc motor
Crusher Drives
• Requirement
– The starting torque of the order of 160%
– The breakdown torque is of the order of 200 to
250%
– Overload capacity of 15% may be required
– Slip ring Induction motor with rotor resistance
starters and speed control may be used
– A dc chopper can be used to control the
resistance
Fan or Blower drives
• The drives motor are located in outdoor
• Totally enclosed fan cooled motors are suitable
• The torque requirements are
– Starting torque: 120%
– Breakdown torque: 200 to 250%
– The speed in the range of 1000-1500 rpm
Slip ring Induction motor with rotor resistance
starters and speed control may be used
Compressor Drives

• The drives motor rating in the range of 300 to

450 kw
• Compressor have to started some times on
load and some time there may be means of
unloading for starting
• Totally enclosed fan cooled motors are
suitable
 Sugar Mill : Requirements for
various drive motors, selection of
motors for various processes
• Processing
• There are a number of steps in producing raw sugar from cane:
• Cane receiving and unloading (receive the cane at the factory and unload it from
the transport vehicles)
• Cane preparation (cutting and shredding cane to prepare it for juice extraction)
• Juice extraction (two technologies are in common use; milling or diffusion)
• Juice clarification (remove suspended solids from the juice, typically mud, waxes,
fibres)
• Juice evaporation (to concentrate the juice to a thick syrup of about 65°brix)
• Syrup clarification (remove suspended solids from the syrup, typically colloid size
of mud, waxes, fibres, etc.)
• Crystallisation
• Centrifugation (Separation of the sugar crystals from the mother liquor, done by
centrifugal machines)
• Sugar drying
• Packaging and delivery
Juice extraction
• There are two processes for extracting juice
from cane Milling, and Diffusion.
Milling
• Juice extraction by milling is the process of squeezing the
juice from the cane under a set mills using high pressure
between heavy iron rollers.
• Those mills can have from 3 up to 6 rolls; every set of mills is
called a tandem mill or mill train.
• To improve the milling extraction efficiency, imbibition water
is added at each mill.
• Hot water is poured over the cane just before it enters the
last mill in the milling train and is recirculated up to reach the
first mill.
• The juice squeezed from this cane is low in sugar
concentration and is pumped to the preceding mill and
poured onto the cane just before it enters the rollers, the
juice from this mill is the same way pumped back up the
milling train.
• Mixed juice (that is to say cane juice mixed with
the water introduced at the last mill) is
withdrawn from the first and second mills and is
sent for further processing. Milling trains
typically have four, five or six mills in the tandem.
• To improve the milling extraction performance
before the cane reaches the first mill, knife and
shredder preparation equipment is normally
used.
• Diffusion
• Sugarcane diffusion is the process of extracting the sucrose
from the cane with the use of imbibition but without the
squeezing by mills.
• Shredded cane is introduced into the diffuser at the feed end,
Hot water is poured over the shredded cane just before the
discharge end of the diffuser.
• The hot water percolates through the bed of cane and
removes sucrose from the cane.
• This dilute juice is then collected in a compartment under the
bed of cane and is pumped to a point a little closer to the feed
end of the diffuser and this dilute juice is allowed to percolate
through the bed of cane.
• Juice clarification
• Sugar cane juice has a pH of about 4.0 to 4.5 which is quite
acidic. Calcium hydroxide, also known as milk of lime or
limewater, is added to the cane juice to adjust its pH to 7.
• The lime helps to prevent sucrose's decay into glucose and
fructose.
• The limed juice is then heated to a temperature above its
boiling point.
• The superheated limed juice is then allowed to flash to its
saturation temperature: this process precipitates impurities
which get held up in the calcium carbonate crystals.
• The flashed juice is then transferred to a clarification tank
which allows the suspended solids to settle.
• The supernatant, known as clear juice is drawn off of the
clarifier and sent to the evaporators.
Juice evaporating

• The clarified juice is concentrated in a multiple effect

evaporator to make a syrup of about 50 percent
sucrose by weight.
 Crystallisation and centrifuging
• This syrup is further concentrated under vacuum in a vacuum boiling pan until it
becomes supersaturated, finely ground sugar crystals suspended in alcohol are
introduced into the vacuum pan as seed crystals around which sucrose is
deposited and these crystals then grow in size until they are ready to be
discharged.
• A number of boiling schemes are possible, the most commonly used boiling
scheme is the three-boiling scheme. This method boils the sugar liquors in three
stages, called A-, B- and C-.
• A batch type sugar centrifuge separates the sugar crystals from the mother
liquor. These centrifuges have a capacity of up to 2,200 kilograms (4,900 lb) per
cycle. The sugar from the centrifuges is dried and cooled and then stored in a silo
or directly packed into bags for shipment.
• The mother liquor from the first crystallization step (A-product) is again
crystallized in vacuum pans and then passed through continuous sugar
centrifuges.
• The mother-liquor is again crystallized in vacuum pans. Due to
the low purity the evapo-crystallization alone is not sufficient
to exhaust molasses, and so the so-called massecuite (French
for “boiled mass”) is passed through cooling crystallizers until
a temperature of approx. 45 °C (113 °F) is reached.
• Then the massecuite is re-heated in order to reduce its
viscosity and then purged in the C-produced centrifugals. The
run-off from the C-centrifugals is called molasses.
• The spun-off sugar from the B-product and C-product
centrifuges is re-melted, filtered, and added to the syrup
coming from the evaporator station.