Machines for VSD Applications

Business Unit - Machines

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ABB Machine with Variable Speed Drive

Content What is VSD Machines with VSD Design Feature Benefits

EX- motors with VSD Electrical protection

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References

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What is a Variable Speed Drive (VSD)? The most efficient way to control the process is to control the speed, and the most efficient way to control the speed is to use an electric variable speed drive – a frequency converter

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A VSD controls the speed, torque or power on the shaft of an electric motor by converting the fixed voltage, fixed frequency at the network, into a variable voltage, variable frequency on the output to the motor In this way the drive can control the variables of a process, such as flow, by controlling the speed of a pump

ACS 5000 topology ACS 5000VSI-MF VSI-MF topology

Converter Converter with integrated input transformer

Why variable speed drives? 60 - 65% of industrial electrical energy is consumed by electric motors For each 1 USD spent to purchase a motor, 100 USD are spent for energy cost during its lifetime Today, only 5% of these motors are controlled by variable speed drives 30% of existing motors can be retrofitted with variable speed drives

The installed base of ABB drives saves more than 120 TWh of energy per year, the equivalent of 15 nuclear power plants.

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ABB drives reduce CO2 emissions by approx. 60 million tons per year.

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Typical applications P

Pumps

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Quadratic load n

Compressor

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Quadratic or constant torque n

Extruders

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Constant torque

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Content

VSD system

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What is a VSD system? The application (1), driven by a drive system, can be a pump, a compressor, an extruder … A motor (2) is needed to drive it. The most efficient way to control the process is to control the speed, and the most efficient way to control the speed is to use an electric variable speed drive – a frequency converter (3). A transformer (4) is usually necessary to adapt to the network and to isolate the network and drive or to relieve the motor from common mode voltages.

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Benefits of VSD system control Energy savings

speed Production rise Best quality

Improved product quality through better process control Reduced process equipment wear and longer lifetime of equipment

Energy saving

Soft Start

time

Soft start and stop reduce waste and save raw material Noise reduction

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Improved process efficiency

Content

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Critical parts of Motor designs for VSD application

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Rotor design for VSD system Strong construction Rotor bars mechanical locking Welded or brazed joint for end rings

Balancing Two-plane dynamic method Nominal speed

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Rotor design for VSD system - Critical speed Stiff shaft design move critical speed above normal speed range Benefit; hole speed range can be used

5,0 Vibration velocity [mm/s]

20 % safety marginal needed

4,0 3,0 2,0

Speed range in VFD operation

1,0 0,0

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Critical speed

0

2000 4000 Rotation speed [rpm]

6000

Stator design for VSD system Factors affecting the design of insulation systems: Electrical stress Voltage peaks

Thermal stress Higher temperature rice

Solid Insulation system

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A proven system with the origin more than 30 years back and tens of thousands of machines successfully in use by customers all over the world (Midacur)

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Dedicated design tools

Bearings design in vsd system Worst conditions for the test Hybrid bearings

No ignition acc. to EN 50020

Bearing currents The VSD might generate high frequency current in the bearings Bearing current might create sparks in the bearings and outside the frame Sparks may damage the bearings, lubrication or they can ignite explosive gas around the motor

Shaft

Insulated “bearing”

Motor frame

Spark test apparatus

ABB prevent that phenomena Bearing insulation

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N-end insulation Both side insulation + grounding cable in D-end

Cooling Force ventilated cooling Constant torque for hole speed range Available for all machines types IC 416

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IC616/IC666

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IC86W

Content

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Ex Motors with Converter supply

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Ex Safety with motors fed by VSD´s Electrical protection Sparks Bearing current Stator insulation Terminal box

Thermal sensor for electrical overload protection

Surface temperature protection

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Dimensioning

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Thermal sensor for surface temperature

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VSD current limit

Ex Motors with Converter supply Generic requirements (IEC 60079-0/EN 50014

ATEX 95)

No requirements

Installation rules (IEC/EN 60079-14

ATEX 137)

TT supply: A residual current device shall be used IT supply: An insulation monitoring device shall be provided to indicate the first earth fault

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Protection devices: Short-circuit and earth-fault protection devices shall prevent auto-reclosing under fault conditions Isolation: To allow work to be carried out safely, isolation (for example isolators, fuses and links) shall be provided

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Ex Motors with Converter supply Maintenance (IEC/EN 60079-17 ATEX 137) An initial inspection. During operation either a) regular periodic inspections (the interval of three years), or b) continuous supervision by skilled personnel

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A history of maintenance activities Isolating all incoming connections. (Isolation can be implemented by withdrawal of fuses and links or the locking off of an isolator or switch)

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Ex motors with converter supply / requirements Protection

Installation Requirements / ATEX 137

Minimum EN/ IEC 60079-0/EN 50014 requirements Precaution shall be taken to guard against any effect due to the presence of circulating currents

§2.4 Explosion protection measures …equipment,…and any associated connecting devices must only be brought into service if the explosion protection document indicates that they can be safely used in an explosive atmosphere.

“n” EN 50021 / IEC 60079 -15 Non Sparking The motors shall be tested for this duty with the converter specified. In exceptional cases the temperature class may be determined by calculation.

EN / IEC 60079 -14 To prevent any over-voltage spikes and higher temperatures in the motor.

“e” Increased Safety

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Product Requirements / ATEX 95

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EN 50019 / IEC 60079 -7 The combination shall be tested as a unit with the associated protective device.

EN / IEC 60079 -14 The combination shall be tested as a unit with the associated protective device. To prevent any over-voltage spikes and higher temperatures in the motor and bearing currents.

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Ex motors with converter supply / requirements Protection

Product Requirements / ATEX 95

“p” Pressurized

EN 50016 / IEC 60079 -2 EN / IEC 60079-14 The safety of the combination shall be shown by No specific requirements. calculations or other measures. The operational speed range must determine the position and pressurisation of the minimum pressure point within the enclosure. Electronic safety control equipment must be certified or duplicated two independent faults.

“d” Flame Proof

EN 50018 / IEC 60079 –1 No specific requirements NB Clarification sheet 00/02/059/CS The combination shall be design and tested always as a unit with converter parameters listed, or direct thermal protection with sufficient margin to protect bearings or rotor. Analysis of converter control electronic according to IEC 61508 or duplication of protection.

“DIP” Dust Ignition Proof

EN 50281-1-1 Temperature rise shall be measured using Unom +/- 5%.

Installation Requirements / ATEX 137

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EN / IEC 60079-14 §10.5 a) Either a direct temperature control by embedded temperature sensors or other effective measures. The action of the protective device shall be to cause the motor to be disconnected. The motor and converter combination does not need to be tested together; or b) the motor shall have been type-tested for this duty as a unit in association with the converter and with the protective device provided. EN 50281-1-2 The IP65 protection seals shall be inspected on a regular scheduled basis, the period of which will depend on the general environment, the amount of use and the manufacturer’s recommendations.

Solutions for Motors with Converter supply End user has several possibilities such as, and not limited to, examples below: Select ATEX certified packages of motor and associated converter The Motor vendor shall issue the Declaration of Conformity according to ATEX 95

Buy a complete machine which is itself certified as an “ATEX equipment” The Machine vendor shall issue the Declaration of Conformity by according to its own ATEX 95 requirements

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Proceed to the compliance with the “Minimum requirements” of the ATEX 137 The whole unit is the certified as a “work place”

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References

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MEGADRIVE-LCI Ormen Lange, Norway Compressor drives

Project Example

World’s longest export pipeline

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Motor power 3 x 48 MW

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Reference Case 1 Variable Speed Control of Oil Pump Project : Ras Tanura, KSA End customer :

Aramco

Driven equipment :

Oil pump

Drive System :

2 x 4500kW, 4 kV

Speed :

3600 RPM (30-105%)

Application :

Shipping pumps

Order received: December 1999

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First adjustable speed drive for Aramco, KSA

Reference case 2 KOC Crude Oil Export Pumps 3 * ACS5000 13,000 kW each Scope to ABB, Transformer’s VSD’s Chiller’s, project management Sold to Sulzer UK (EPC Hyundai)

Ras Laffan, Qatar 18 * ACS6000 7,500 kW each.

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Scope to ABB Transformers, Drives, Motors and Pump Control Panels

!!"

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References Oil, Gas and Petrochemicals Country Project name

Application

Segment

SA IR IR IR ST EG SA AE IR EG AE OM QA SA SA

Oil & Gas Oil & Gas Oil & Gas Petrochemicals Oil & Gas Oil & Gas Petrochemicals Oil & Gas Oil & Gas Petrochemicals Oil & Gas Petrochemicals Oil & Gas Oil & Gas Oil & Gas

Extruder Soft-starter Compressor Extruder Compressor Compressor Extruder Pump Pump Extruder Pump Agitator Gas compression Soft-starter Pump

Sabic Sharg Darquiain Oil Filed South Pars JSW Arak HDP GSI AMOC Lube Oil Petrokemiya MHI ADCO Bangestan NISOC Sidpec Petrochemical Huwaila LG Oman PP Ras Laffan Yanbu Ras Tanura

Motor

Power (kW)

Total (MW)

F-Conventer

2 3 4 1 2 1 4 4 5 2 2 2 6 2 2

1200 9 875 5 950 5 350 4750 4250 1550 950 600 5 000 950 2 150 15 970 7 500 5 300

2,40 29,63 23,80 5,35 9,50 4,25 6,20 3,80 3,00 10,00 1,90 4,30 95,82 15,00 10,60

ACS 1000i LCI.SO ACS 1000 ACS 1000 ACS 1000 ACS 1000 ACS 1000 ACS 1000 ACS 1000 ACS 1000 ACS 1000 ACS 1000 LCI.DR LCI.SO ACS 1000

ABB benefits Operating applications at variable speed has advantages which can have a direct impact on a company’s profits Energy savings Improved process control One supplier Better product quality Less stress on equipment reduced maintenance cost Elimination of mechanical equipment (e.g. valves, gearboxes) © ABB, BU Machines - 27 30-Oct-08

Smooth start up of motors/generators

Sparks / Bearing Current Experience

Phenomena Description The VSD might generate high frequency current in the bearings Bearing current might create sparks in the bearings and outside the frame Sparks may damage the bearings, lubrication or they can ignite explosive gas around the motor ABB documents indicates how to prevent that phenomena Bearing insulation

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Cabling, grounding Filtering

ABB test results

Stator insulation Safe voltage peaks Orange curve is valid for ABB Form wound low voltage machines MV Drives and sparks tests & studies to check that they are not causing sparks or aging due to high risk of PDs. Limiting curves for impulse peak voltage in frequency converter operation, phase-to-phase at motor

ABB Form wound

2,20 2,00 1,80 1,60 1,40 1,20

IEC IEC TS TS 60034-17 60034-17 IEC IEC TS TS 60034-25 60034-25 A A IEC TS 60034-25 IEC TS 60034-25 B B

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1,00 0,80 0,00

ABB ABB Special Special Insul. Insul.

0,20

0,40

0,60 Rise time 10-90 %, µs

0,80

1,00

1,20