6 HI Cold Rolling Mill Power

Stack Revamping.
CMI Automation India
Innovation Project.
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Project Summery

There are Several 6 Hi Rolling Mill with DC motors and DC drives running worldwide.
Now DC motors and DC drives are getting obsolete from the market, and all new mills
are with AC supply system with AC Motors and AC Drives.
The DC motors are expensive and still are in use. But the DC drive manufacturing
support is not available with old techniques.
These DC drives were in two parts, Control electronics and Power sections.
The original Drive suppliers have migrated to new technology. And not able to support
with spare parts of old supplied systems (mainly Electronic Cards).
Many customer do not have adequate stock of spares. Those who are having will get
vanish soon.
Due to many tailor made components customer were dependent on Drive supplier.
The alternative with customer is either go with new DC drive technology or Replace
the complete drive and MOTOR
CMIA has develop a solution in which no drive replacement is required and can be
installed in very short downtime.
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Project Team and the Roles

Project Head:- Mr. Sanjay Purnapatre

Team Leader and Project manager:- Mr. Vikram Tambe
Engineering and Commissioning :-
Mr. Kunal Patil
Mr. Mehul Waghela.

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Innovation

CMIA was observing the scenario and did brainstorming on producing these obsolete
cards.
This was not feasible due to volume and availability of electronics components.
Then a detail study is made on the gate trigger current of thyristors and few efforts
were made to developed driver cards locally.
There were no opportunity to test this developments and it was very risky job.
During this study we came across that the driver current of one of driver card is able
to drive multiple thyristors without additional hardware.
With this hint we develop the solution and installed at one of customers location.
In this solution we replaced all proprietary items of supplier with generally available
items in market.
All the tailored made items were replaced with standard products available in market.

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Breakthroughs

We proposed this solution to M/s Bhushan steel sahibabad. M/s Bhushan Steel
convinced with our solution and issued the purchase order in 2013.
The mill is revamped in nov2013 and since then working as per the expectation
without a single problem till date.
Our another customer m/s YKGI Malyesia had severe problems in their mill for whom
we support extensively. M/S YKGI placed order on us in DEC 2014. the project was
commissioned in march 2015 and since then the mill is working very well since last
one year not a single problem has been reported.
M/S Bhushan Khopoli and M/S TAT Metal Turkey is discussing the proposal with
CMIA for same revamp.
For both the project we could optimised and execute the schedule in 15 days..
The project plan was executed so precisely that we could put the mill in operation on
14th day and with fully functional for production.

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What has been Achieved (Facts and
Figures)

CMIA Solution Competitors Solution Remark

Price 1,60,000.00 8,26,666.67 81% Saving
Shutdown Time 14 Days 30 days 53 % Saving
Time to complete Supply 8- 12 Weeks 24 Weeks 50 % Time Saving
Transport cost Toatal Weight less than 100 Kg Total Weight approx. 1000 Kg 90% Saving

Installation manpower and Equipment No cost to customer Cost to customer

Rework In ECR No Changes Required May required significant changes.

Scrap generation
Drawing Preparations Time
In case of obseletion of supplied solution
small amount of Electronic Scrap is
Generated Huge Electronic Scrap generated
Due to lot of re-engineering
3 week 2 Weeks additional time required
Re- Revamping is possible as standard
items are used. again huge cost involved as above

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 Technical Details ykgi mill

6 HI Cold Rolling Mill.

OEM CMIFPE
Motor and Drive Details
Motor
Motor KW voltage Motor current Field Current RPM Drive current Thyristors New Thyristors
Module
1 POR 400 Kw 400 V 1095 Amp 21/5 400/1200 1200 Amp SKKT520 Same
2 ETR 2240 Kw 800 V 3020 Amp 46/11.5 225/800 3770 Amp T1929N32TOF T1930N36TOF
3 DTR 2240 Kw 800 V 3020 Amp 46/11.5 225/800 3770 Amp T1929N32TOF T1930N36TOF
4 Mill 2 X 2500 Kw 980 V 2650 Amp 36/96 400/800 3770 Amp T1929N32TOF T1930N36TOF

Make of Motors :- Kirloskar India

Make Of Drive :- Siemens India
Make of Thyristors :- Infineon

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Technical Details

Following Parts Re-Engineered

Original Part Make current state Replaced part Make Advantage
DC Drive Control Module Siemens 6RA70 Obsolete New Control module Siemens 6 RA 80 Latest Product used
Thyristor trigger set siemens Propriotory Obsolete Removed N.A. No Dependency
DC CT PT siemens Propriotory Obsolete Universal tuned amplifier Knick No Dependency
Fuse Monitor Card Local Make Obsolete Standard Product Siemens Extended life cycle
Pulse distribution assly Local Make Obsolete Standard Product Siemens Extended life cycle
Power Supply Card Local make Obsolete Standard Product Phoenix No Dependency

All customised cables replaced with standard available

Drives are retuned as per new requirements.
This innovating solution proved that obsolete products can be replaced with ingenious
solutions and huge saving can be done for customer.
The effectiveness of the solution reduces the project execution time.
The effective project management reduces the down time and created a successful
story.

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Photos

Photos before revamp.

Photos after Revamp

MOM

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Benefits to Customer

Customer will not be dependent on CMIA or any other party for spares in future as all
parts can be purchased from open market.
The life of revamp solution is more than the life of replacing all drives with new
product.
No effect on mill performance.
No software changes required.
Easy for maintenance

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Vikram Tambe
Vikram.tambe@cmigroupe.com
+91-9833550638

www.cmigroupe.com

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