Fundamentals & Application of Medium Voltage …

1 Slide #1 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 1 Page 1 Lunch & Learn MeetingFundamentals & Application of Medium Voltage adjustable Speed Drives (ASD)Manish VermaSenior Member IEEETMEIC IEEE IAS Atlanta ChapterNovember 21st2016, Noon 1:15 PMSlide #2 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 2 Page 2 Safety Moment-PetextriansAfter decades of decline, pedestrian fatalities are once again on the rise. Petextrians people who text while walking may be partly to blame, according to the report. (ABC News Report) Slide #3 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 3 Page 3 Quality MomentQuality means doing it right when no one is FordSlide #4 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 4 ParameterDescriptionService typesRotating machinery such as pumps, compressors, extruders, fans, blowers, Level (HP)500HP 130,000 HPVoltage range(kV) Medium Voltage , > kVApplicable dimension Slide #5 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage SPEED PER UNITMOTOR CURRENT -PUMOTOR CURRENTMOTOR TORQUETORQUE Motor Starting CharacteristicsSlide #6 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 6 Why is starting large motors stressful?

2 Highest current is seen when shaft is still Starting currents create stresses and torques that can damage motor and attached load The motor and the load must breakaway and accelerate Remember current equals heat! Balance allowed inrush amps with Voltage drop Balance power system effects with torque demand of loadPower System ChallengeSlide #7 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 7 Motor Speed Control StrategiesLarge MotorLarge MotorASDA vailable Motor Speed Control MethodsDirect-On-Line(DOL) adjustable Speed Drives (ASD)Other Mech. MethodsConstant Utility Frequency(50 or 60Hz)Adjust FrequencyLarge MotorPony MotorGood reference : Larabee, J.; Pellegrino, B.; Flick, B., "Induction motor starting methods and issues," Petroleum and Chemical Industry Conference, 2005. Industry applications Society 52nd Annual, vol., no., ,222, 12-14 Sept. 2005 Nevelsteen, J.; Aragon, H., "Starting of large motors-methods and economics," Petroleum and Chemical Industry Conference, 1988, Record of Conference Papers.

3 , Industrial applications Society 35th Annual, vol., no., ,96, 12-14 Sep 1988 Slide #8 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 8 TransformationUtilitySupplyConversionLoa dUtilizationAC MOTORCONVERTERRECTIFICATIONAC TO DCORORENERGYSTORAGEORINVERTERSWITCHINGDC TO ACORWhat is an ASD?Utility MainsMotorDriven EquipmentVFDI nput BreakerStep-Down Drive Isolation TransformerCooling SystemIndustrial Control BuildingFixed VoltageFixed FrequencyVar. VoltageVar. FrequencySlide #9 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 9 TransformationUtilitySupplyConversionLoa dUtilizationAC MOTORCONVERTERRECTIFICATIONAC TO DCORORENERGYSTORAGEORINVERTERSWITCHINGDC TO ACORWhat is an ASD? Other common terminologyPulses (DFE)Harmonic performance equivalent (AFE)Output Voltage Levels / Steps(higher the better, min 5-level from 0-Peak)Slide #10 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 10 What is an ASD?

4 Slide #11 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 11 What is an ASD?Slide #12 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 12 What is an ASD?Slide #13 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 13 What does an ASD mean for the motor?0 Motor In rush Current (650% FLA)Full LoadTorque, AmpsFrequency, RPMM otor Full Load CurrentAC Utility Line AmpsStarting TorqueDirect-on-line / Fixed FrequencyVariable Frequency Slide #14 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 14 What does an ASD mean for the motor?Motor StartingReduced inrush currentHigh Torque LoadsClose to unity power factorProcess ControlEnergy SavingsSpeed ControlTorque ControlMotor size optimization (eg: large inertia loads)Motor RunningPower factor improvementUnstable Voltage supplyQuick stopping (Regeneration)Reduced Mech. Wear / TearSlide #15 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 15 Medium Voltage drives range from 2300V 13800V.

5 Voltage defined at output. Input Voltage to the VFD between 138kV ASD = VFD = EVFD = VVVF (can be used interchangeably)What do we mean by Medium Voltage ASD Small Air-Cooled ASDL arge Water-Cooled ASDS lide #16 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 162,0004,0006,0008,00010,00012,000010010 ,00050,000100,000 ASD Output Voltage (V)Water CooledAir CooledMotor Horsepower (HP)Typical Range of ASDs14,000 Slide #17 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 17 Single VFD / single motorMotorCompressorBypassVFDU tilityMotorCompressorBypassVFDU tilityMotorBypassVFDC ompressorXFMRU tilityUtility = VFDVFD = MotorUtility = VFD VFD MotorUtility > VFD VFD = MotorVoltage Level ScenarioSimple Electrical One-line$$$Slide #18 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 18 Multi drive Multi MotorUtility Voltage bus Bus6000 HPVFD BusDB-5iPLC Coordination & InterfaceIncoming SwitchMPRA uxctMPRA uxctMPRA uxctMPRA uxctSynchronized BypassSynchronized BypassSynchronized BypassSynchronized BypassDB-5iIncoming Switch7500HP7500HP7500HP7500HP7500 HPSlide #19 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 19 Historical Overview195519651975198519952005 Gate TurnoffThyristorGTOB ipolar Power Transistor(BPT)Silicon Controlled Rectifier (SCR)

6 ThyristorFamilyDiode(D)Low Voltage InsulatedGate Bipolar Transistor (LV IGBT)Integrated Gate Commutated Thyristor(IGCT)Symmetric Gate Commutated. Thyristor(SGCT) Medium Voltage InsulatedGate Bipolar Transistor (MV IGBT)Injection EnhancedGate Transistor (IEGT)TransistorFamilyDC Motor DrivesSynchronous Motor drivesInduction Motor DrivesTime Line of adjustable Speed Drives195519651975198519952005 Ind/Synch Motor DrivesSlide #20 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 20A map-like diagram showing the elements of an AC drive and the relationships between them. AC Drive Topology:ASD Topologies The Common Threads: All AC Drives rectify AC to DC. All AC Drives use switches to create AC from DC. Drive topologieswere created as power rectifiers and switches grew in ratings and capabilities. Each new or uprated device opens up new applicationsSlide #21 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 21 Major ASD TopologiesCurrent Source Inverters(CSI) Voltage Source Inverters(VSI)Load Commutated Inverters (LCI)Pulse Width Modulated (PWM) Energy storage/DC Link is Capacitor Energy storage/DC Link is Inductor Maintains constant Voltage at DC Link Maintains constant current at DC Link Converter (AC/DC) is either Passive (using diodes) or Active (using PWM) Converter (AC/DC) is Active (using phase control or PWM)

7 Slide #22 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 22 Comparing Drives of All Topologies Current Source Drives LCI Load Commutated Inverter GTO/SGCT Current Source Induction Motor Drive Voltage Source Drives LV IGBT Paice Multilevel PWM MV IGCT PWM Diode or Active Source/Converter MV IGBT PWM Integrated package MV IEGT PWM Active or Diode Source/ConverterGood reference for more details: Lockley B, Paes, R. What s new with MV Drives , Pages: 43 58. Slide #23 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 23 ASD System ConsiderationsMust consider the whole system in which the ASD will work From Utility to finished product or process Consider environment Consider effects on utility Consider the needs of the load Consider the effect of ASD on the motor and drive train Utility MainsMotorDriven EquipmentVFDI nput BreakerStep-Down Drive Isolation TransformerCooling SystemIndustrial Control BuildingSlide #24 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 24 ASD Overall Success Factors Minimum first cost, including installation Maximum long-term payback.

8 Good match to process & loads. Long equipment life. Ease of use for operators & technicians. Minimum impact on nearby equipment. Easy to maintain & repair. Smallest foot printApplication considerations can divided into the following: Electrical/Load Application Factors Installation Factors (E-house integration/Cabling) ASD Protection & Cooling methodology ASD standards and Factory TestingSlide #25 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 25 Electrical/Power Application Factors Continuous kW or HP & duty cycle Torque & Power Overload requirements Load factors: CT, VT, CHP, regenerative, non-regenerative. Drive and Motor Voltage Power system compatibilityUtility MainsMotorDriven EquipmentVFDI nput BreakerStep-Down Drive Isolation TransformerCooling SystemIndustrial Control Building#1 -Define the process loads and duty cycle#2 -Define the power system requirements#3 Determine best drive solution!

9 Slide #26 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 26 Load Type Examples Constant Torque Conveyors Grinding Mills Kilns Reciprocating Compressors Positive Displacement [Screw Type] pumps, compressors Variable Torque ID / FD Fans Centrifugal Pumps Centrifugal Compressors Pipeline booster pumps Axial CompressorsTorque (%)Speed (%)Speed (%)Torque (%)Slide #27 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 27 Keep In MindDrives are sized & priced based on Motor Full Load Current AND Operating HP, 1800 rpm, 4000V, FLA 910A= 6300 HP, 450 rpm, 4000V, FLA 1240A= 8600 kVASlide #28 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 28 Lets take an [RPM] IN SECONDS >One duty cycle >Power = Speed x TorqueSlide #29 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 29 Drive Ratings and Torques Variable Torque(VT) ratings usually include 110 -115% OL rating for 60 seconds when starting from rated Temp Constant Torque(CT) rating usually includes 150% OL rating for 60 seconds when starting from rated Constant Torque applications , take a close look at the Speed Torque Curve for selecting the correct ASD sizeSlide #30 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 30 Power System Compatibility Power distribution (available utilization voltages) Protection.

10 Harmonics limits. Power factor control. Efficiency. Breakers, transformers, and cable must be rated to carry full kVA & harmonics. Transformers need to be drive isolation rated with proper considerations for the drive MainsMotorDriven EquipmentVFDI nput BreakerStep-Down Drive Isolation TransformerCooling SystemIndustrial Control BuildingSlide #31 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 31 Power system compatibility -Keep In Mind Always provide and electrical one-line diagram Some tips for ASD Voltage level selection 250HP 5000HP 5000HP 10,000HP >10,000 HPMotor PowerASD Input VoltageMotor , , , , 10, 11, kV , , 10, 11, , 25, 34, 66 kV10, 11, , 25, 34, 66, 110, 138 , , , , 10, 11 kV Matched to ASD output voltageMatched to ASD output voltageNote: if ASD is used for starting ONLY, then Motor Voltage = Utility Voltage (Max ) Slide #32 IEEE IAS Atlanta Chapter Lunch & LearnFor reference ONLYPage 32 MV drive $ / HP decreases with HP Installed costmust be considered including.