Medium Voltage Drives - WMEA

1 TM GE Automations SystemsWestern Mining Electrical AssociationMedium Voltage DrivesOverview, Evolution & ApplicationBill Horvath, PETMGE Automation Systems Western Mining Electrical AssociationNovember 2004 November 2004 TMGE Automation Systems - All rights Reserved2TM GE Automations SystemsWestern Mining Electrical AssociationMV drive Session overview Provide links to more reference materials. Review the benefits of ASDs in motor starting and control Cover basic drive application Cover basic tradeoffs between MV & LV Drives Review one recent mining conveyor MV drive application Trace the Evolution of MV Drives & circuit configuration Compare each historical and current major MV drive topology Compare each drive topology's major strengths and weaknesses. Review the TMGE Dura-Bilt5i MV IGBT drive as an example of current technology November 2004 TMGE Automation Systems - All rights Reserved3TM GE Automations SystemsWestern Mining Electrical AssociationMV drive Materials -1 MV drive Evolution White Paper GEZ-S1006 Engineering Reference Manual & CDROM.

2 GET-S1009 Obtain from TMGE General 2004 TMGE Automation Systems - All rights Reserved4TM GE Automations SystemsWestern Mining Electrical AssociationMore MV drive Materials -2 Electronic MV TM GE Automation Web 2004 TMGE Automation Systems - All rights Reserved5TM GE Automations SystemsWestern Mining Electrical AssociationAC Motors & Control overview Induction Motor Basic Characteristics Load Types Starting and Running Torque-Speed Profiles Typical applications Starting and Running Control Methods Variable Frequency Drives Low Voltage vs Medium Voltage MV drive Evolution TMGE Automation Systems Dura-Bilt5i MV OverviewNovember 2004 TMGE Automation Systems - All rights Reserved6TM GE Automations SystemsWestern Mining Electrical AssociationInduction Motor Speed-Torque ProfileLockedRotor TqPull UpTorquePeak[Breakdown]Torque, BDTR ated TorqueSyncRPMRPMR ated SlipRPM =Sync - Rated RPMR atedRPMT orqueSync Rpm = 120 x Freq.#Poles Sync Rpm = 120 x Freq.#Poles November 2004 TMGE Automation Systems - All rights Reserved7TM GE Automations SystemsWestern Mining Electrical AssociationMotor StartingNovember 2004 TMGE Automation Systems - All rights Reserved8TM GE Automations SystemsWestern Mining Electrical AssociationMotor StartingFactors That Apply Inrush Amps and Duration Motor Limit on Number of Starts Per Hour Motor Connected Inertia Limits Load Mechanical Issues Pumps, Piping & Hydraulic issues Coupling Stress Starting Torque vs Load RequirementsNovember 2004 TMGE Automation Systems - All rights Reserved9TM GE Automations SystemsWestern Mining Electrical AssociationFull- Voltage Motor StartingSingle Motor, Single StarterMultiple Motors, SingleStarterTorqueAmpsFull LoadTorque.

3 AmpsRPM >Full Voltage Amps & Torquevs SpeedNovember 2004 TMGE Automation Systems - All rights Reserved10TM GE Automations SystemsWestern Mining Electrical AssociationReduced - Voltage Motor StartingReducedVoltageStarterBypassStart Inrush amps ~ VoltsTorque ~ Volts2 TorqueAmpsFull LoadTorque, AmpsRPM >Reduced VoltageMotor Amps & Torque vs is = line current and torque are limited for a soft start, but no true speed or torque control is 2004 TMGE Automation Systems - All rights Reserved11TM GE Automations SystemsWestern Mining Electrical AssociationMotor on AC Adjustable Speed DriveMotor AvailableTorqueFull LoadTorque LevelTorque, AmpsAmpsAC Adjustable Speed DriveMotor Amps & Torque vs SpeedMAdjustableSpeedDriveNo Starting Inrush amps,Torque & Volts Controlled toMatch and Voltage are current, motor Voltage torque regulation provide true speedand torque : Process and energy use can be APPLICATION12TM GE Automations SystemsWestern Mining Electrical AssociationDrive Ratings and Torques Variable Torque-ratings usually include 110 -115% OL rating for 60 seconds at rated TempNovember 2004 TMGE Automation Systems - All rights Reserved13TM GE Automations SystemsWestern Mining Electrical AssociationLoads & Motor Capability CurvesTEFCV ariable Load [Pump, Fan]Constant TorqueLoad, Example 2 Constant TorqueLoad, Example 1 RPM -- >Load TorqueTheoretical Motor CapabilityActual Motor Capability100% Load Point,NP RPM, Sine wave powerInduction Motor CapabilitiesUnder Variable Speed June 4, 98 November 2004 TMGE Automation Systems - All rights Reserved14TM GE Automations SystemsWestern Mining Electrical AssociationPump & Fan Affinity Laws.

4 1-2-3010%20%30%40%50%60%70%80%90%100%HP - %flow - % Speed% of Total-1 Flow Rate Varies 1stpower of Speed [Proportional]-2 Pressure & Load Torque Varies as the 2ndpower [square] of Speed-3 Horsepower at Motor Shaft varies as the 3rdpower [cube] of SpeedNovember 2004 TMGE Automation Systems - All rights Reserved15TM GE Automations SystemsWestern Mining Electrical AssociationFans Fans --Things to RememberThings to Remember Fans have variable torque loads. Blowers mayhave constant torque or variable torque loads. Load torque goes up as the square of the speed. Horsepower load goes up as the cube of the speed. Torque needed to run an Induced Draft fan increases significantly as gas temperature decreases. Fan Motor sizing greatly effected by across the lineNovember 2004 TMGE Automation Systems - All rights Reserved16TM GE Automations SystemsWestern Mining Electrical AssociationNovember 2004 TMGE Automation Systems - All rights Reserved17TM GE Automations SystemsWestern Mining Electrical AssociationVariable Torque drive ApplicationsNovember 2004 TMGE Automation Systems - All rights Reserved18TM GE Automations SystemsWestern Mining Electrical AssociationMultiple Motor Pumping ApplicationST1ST2ST3M1M2M3 MTR1 MTR2 MTR3 Starting/Running Drive4160 VDriveStarting/RunningContactorsPumpMoto rsAcross the LineContactors4160 VNovember 2004 TMGE Automation Systems - All rights Reserved19TM GE Automations SystemsWestern Mining Electrical AssociationDrive Ratings and TorquesConstant Torque[CT]

5 Rating usually includes 150% -250% OL rating for 60 seconds when at rated 2004 TMGE Automation Systems - All rights Reserved20TM GE Automations SystemsWestern Mining Electrical AssociationConstant Torque Characterized as a load curve that looks likeVariableLoad[Pump,Fan]ConstantTorque Load,Example2 ConstantTorqueLoad,Example1 RPM-->LoadTorqueTheoreticalMotorCapabili tyActualMotorCapability100%LoadPoint,NPR PM,SinewavepowerNovember 2004 TMGE Automation Systems - All rights Reserved21TM GE Automations SystemsWestern Mining Electrical AssociationConveyor or Mill Loadingconveyor typical demandTypical InductionMotor Char on 60 Hz powerTORQUEFREQ, SPEEDBREAKAWAYTORQUEN ovember 2004 TMGE Automation Systems - All rights Reserved22TM GE Automations SystemsWestern Mining Electrical AssociationConveyor or Mill Loadingconveyor typical demandTypical Induction Motor Char on 60 Hz powerTORQUEFREQ, SPEEDBREAKAWAYTORQUEVFD CONTROLLED MOTOR -ENOUGH TORQUE ACROSS THE RANGEN ovember 2004 TMGE Automation Systems - All rights Reserved23TM GE Automations SystemsWestern Mining Electrical AssociationNovember 2004 TMGE Automation Systems - All rights Reserved24TM GE Automations SystemsWestern Mining Electrical AssociationCrushing and Crushing and Conveying SystemsConveying SystemsTM GE Automations SystemsWestern Mining Electrical AssociationExample MV drive Mining ApplicationMINE-MOUTH TO PROCESSING PLANT CONVEYORN ovember 2004 TMGE Automation Systems - All rights Reserved26TM GE Automations SystemsWestern Mining Electrical AssociationApplication Story Long Molybdenum Mine in Colorado had 15 mile long train to take ore from mine tunnel to processing plant equipment became obsolete, segment conveyor at variable speed was winning concept to replace length of conveyors over 15 miles!

6 One section over 10 miles!November 2004 TMGE Automation Systems - All rights Reserved27TM GE Automations SystemsWestern Mining Electrical AssociationPWM-3 1000 kVA13,800/2300 kVC 1000 HP PWM-3 w/1 1000 HP Motor Basic configuration for Pulleys 4, 5, 6, 7 PWM-3. 2250 kVA13,800/2400 kVA 2250 HP PWM-3 w/1 2250 HP Motor Basic Configuration for Pulleys 1, 2, 3 ELECTRICAL ONE LINES2000 HP drive CanAccommodate [2]1000 HP MotorsB 2000 HP PWM-3 w/ two 1000 HP Motors Alternate for pulley 4 PWM-3 2000 kVA13,800/2300 kV1000 kVELECTRICAL ONE LINESPC-2 ConveyorPlan miles, kMCONVEYOR ,500 ft2,400 ,100 ft213 Head end equip house@ 9500 feet AMSLGRADE = Variable 5% to 1%5%3%1%GRADE = Variable 0% to 8%CONVEYOR PC-1 CONVEYOR PC-3PC-1 ConveyorPlan View4 Head end equip house@ 7,100 feet AMSLPC-3 ConveyorPlan ViewHead end equip house@ 9,500 feet miles, miles, kM65 Tail end equip house@ 9,500 feet AMSL2 x 1000 HP2 x1000 HP1 x1000 HP1 x2250 HP2 x2250 HP1 x2250 HP1 x1000 HPApplication Story Long Conveyor8/18 Slide S-21 November 2004 TMGE Automation Systems - All rights Reserved28TM GE Automations SystemsWestern Mining Electrical AssociationApplication Story Long ConveyorConveyor Mechanical ApplicationConsiderationsStretch, Length, Belt weight,load weight,speedFrictionT1T2T3T4D1D2D3 Tension Ratios,Dynamic Response,Programmed Torque.

7 Load SharingNovember 2004 TMGE Automation Systems - All rights Reserved29TM GE Automations SystemsWestern Mining Electrical AssociationPC-2 UPHILL CONVEYOR with PWM DrivesPC-2 ConveyorPlan View213 Head end equip house@ 9500 feet AMSL1 x2250 HP2 x2250 HP1 x2250 HPPWM-3. 2250 kVA13,800/2400 kVA 2250 HP PWM-3 w/1 2250 HP Motor Basic Configuration for Pulleys 1, 2, 3 ELECTRICAL ONE LINES8/18 Slide S-23 November 2004 TMGE Automation Systems - All rights Reserved30TM GE Automations SystemsWestern Mining Electrical AssociationPC-3 OVERLAND CONVEYOR with PWM-3 DrivesPC-3 ConveyorPlan ViewHead end equip house@ 9,500 feet AMSL765 Tail end equip house@ 9,500 feet AMSL2 x1000 HP1 x1000 HP1 x1000 HPPWM-3 1000 kVA13,800/2300 kVC 1000 HP PWM-3 w/1 1000 HP Motor Basic configuration for Pulleys 4, 5, 6, 7 8/18 Slide S-24 November 2004 TMGE Automation Systems - All rights Reserved31TM GE Automations SystemsWestern Mining Electrical AssociationPC-1 FEED CONVEYOR with PWM-3 DrivesPC-1 ConveyorPlan View4 Head end equip house@ 7,100 feet AMSL2 x 1000 HPPWM-3 1000 kVA13,800/2300 kVC 1000 HP PWM-3 w/1 1000 HP Motor Basic configuration for Pulleys 4, 5, 6.

8 7 8/18 Slide S-22 November 2004 TMGE Automation Systems - All rights Reserved32TM GE Automations SystemsWestern Mining Electrical AssociationApplication Story Long ConveyorMotor Challenges High Starting Torque for PC3 Two sizes: 1000 HP & 2250 HP each wide speed rangeDrive Challenges 24/7 Reliable Energy Efficient Low Maintenance High overload torques in winter on PC3 Power Challenges Long power feeds Cable capacitance created resonance high order harmonicsControl Challenges Precise, programmable torque for belt tension control Head-to-tail tension coordination for PC3. Allow variable speed operation of any motorMotor SolutionGE kv induction motor separate cooling air by userDrive And Control SolutionGE Innovation PWM 2300 volt 3-level, 18 pulse rectifiers. Utilized Innovation Series Controller for torque programming & PLC Ethernet Solution3-level Inverter with IEEE 519 compliant 18 pulse converters and high frequency filters to eliminate cable resonance at 19thharmonicChallenges & SolutionsNovember 2004 TMGE Automation Systems - All rights Reserved33TM GE Automations SystemsWestern Mining Electrical AssociationCustomer Benefits Train system replacement with conveyor has proven to be very reliable.

9 Variable speed operation on the conveyor resulted in added energy savings, reduced friction and belt wear. Biggest risks and failure potentials were avoided by careful design:9 Slippage and stretch of long strand 20 mile total length PC2 with 4 x 2250 HP at head end9 Tension control of up-and-down PC3 overland with many curvesApplication Story Long ConveyorNovember 2004 TMGE Automation Systems - All rights Reserved34TM GE Automations SystemsWestern Mining Electrical AssociationAll AC drive Selection Factors Load type: CT, VT, CH, Regen or non-regen Physical Environment at drive location Power system compatibility Precision of control needed Overload ratings needed Operator control & digital communication needed drive Output Voltage & Motor Application November 2004 TMGE Automation Systems - All rights Reserved35TM GE Automations SystemsWestern Mining Electrical AssociationDrive Output Voltage & Motor ApplicationLV Drives : defined as having output volts <690 volts Why Pick LV [<690v] drive & Motor?

10 Why pick MV over LV?Trends:Some users select MV at >250 HPMany users select MV over 500 2004 TMGE Automation Systems - All rights Reserved36TM GE Automations SystemsWestern Mining Electrical AssociationDrive Output Voltage & Motor Application Why Pick LV [<690v] drive & Motor? LV Drives are lower cost / HP than MV Reduces some safety & MV training concerns HP range is small enough Individual preference Why pick MV [>690v] drive & Motor over LV? Lower cost wiring, smaller cables Lower power system harmonic impact High HP LV require dual winding motors Individual preference Trend:Some users select MV at >250 HPMany users select MV over 500 HP. Why Pick LV [<690v] drive & Motor?Why Pick LV [<690v] drive & Motor? LV Drives are lower cost / HP than MVLV Drives are lower cost / HP than MV Reduces some safety & MV training concernsReduces some safety & MV training concerns HP range is small enoughHP range is small enough Individual preferenceIndividual preference Why pick MV [>690v] drive & Motor over LV?