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GEARLESS MILL DRIVE OVERVIEW
Coenie Mynhardt Engineering Manager - Winders
and
AGENDA
„
„
„
System overview
„ Introduction
„ Basic GMD data
„ Drive System efficiency
General description of individual components
„ Switch gear and Main Circuit Breaker
„ Ringmotor
„ Mechanical mill shell specification
„ Mechanical and electrical installation of the
PPRust GMD
„ Cycloconverter and excitation
„ Auxiliaries and E-house
Conclusion
and
INTRODUCTION
What is a Gearless Mill
Drive?
•
Gearless
•
The Mill shell forms
the spinning core of
the motor.
•
The ring shell forms
the stator.
Why GMDs?
• 1960’s building boom.
• Pressure to increase
throughput.
•
1st delivery in 1969 to
Ciment Lambert
(Lafarge)
• 7MW mill replacing
2 x 3.5MW mills
• Still operational 38
years later.
BASIC PPRUST GMD DATA
„
„
„
„
„
„
„
„
„
„
Motor type:
Power range:
Speed range:
Motor poles:
Motor torque:
Max Motor torque:
Motor frequency:
Motor voltage:
Motor current:
Excitation current:
Synchronous
17.5 MW
11.73 rpm
60 poles
14256 kNm
21384 kNm
5.86 Hz
4220 V/3ph
2531 A
745 Adc
and
DRIVE SYSTEM EFFICIENCY
„
„
„
System efficiency about 95%
System efficiency including
transformer, power electronics, GMD
and cooling
1% of system efficiency improvement
will add to a yearly energy cost saving
and
GENERAL DESCRIPTION OF INDIVIDUAL COMPONENTS
Converter transformer E-house & Auxiliaries
MV switches
f1
S
T2
T1
T1
Cycloconverter & excitation
n1
B
Controller
(drive control,
system control)
iA
u+
uiS
iT
Superior Control System Bus
1
uS
uR
uT
ie
SM
3
f2
Ringmotor
Communication
Processor
B448 Bus
Analog
and Digital
Input/Output
PSR2
Gate Control
Unit
iSBX
ARCnet
ARCnet® Bus
Overvolt. Protection
CROWBAR
Digital I/O
Excitat. int.
.....
Digital I/O
Customer
Converter
Electronics
Converter
Electronics
........
iR
Operation
Alarms
.....
1
........
i+
Analog
Interface
n2
T1
1
Superior
Control System
T93_0070.DRW
GENERAL DESCRIPTION OF INDIVIDUAL COMPONENTS
Converter transformer E-house & Auxiliaries
MV switches
S
T2
T1
T1
Cycloconverter & excitation
n1
B
Controller
(drive control,
system control)
iA
u+
uiS
iR
iT
ie
SM
3
Superior Control System Bus
uT
Ringmotor
1
Communication
Processor
B448 Bus
Analog
and Digital
Input/Output
PSR2
Gate Control
Unit
iSBX
ARCnet
ARCnet® Bus
Overvolt. Protection
CROWBAR
Digital I/O
Excitat. int.
Converter
Electronics
Converter
Electronics
.....
Digital I/O
Customer
Operation
Alarms
.....
1
........
u
S
u
R
........
i+
Analog
Interface
n2
T1
1
Superior
Control System
T93_0070.DRW
MAIN CIRCUIT BREAKER
„
GMD main circuit
breaker installation
SWITCHGEAR: SWITCH DISCONNECTOR
„
Switch-disconnector type SFG
„ 3 positions
CLOSE
OPEN
EARTH
SYSTEM OVERVIEW – THE RING MOTOR
Harmonic filter &
power factor
compensation
MV switches
f1
Converter transformer
S
T2
T1
T1
Auxiliaries
& E-house
n1
B
iA
Cycloconverter
& excitation
u+
i+
uiS
iR
iT
Superior Control System Bus
1
uS
uR
Communication
Processor
B448 Bus
uT
ie
SM
f2
Analog
and Digital
Input/Output
PSR2
Gate Control
Unit
iSBX
ARCnet
ARCnet® Bus
Digital I/O
Excitat. int.
Converter
Electronics
Converter
Electronics
.....
Digital I/O
Customer
Operation
Alarms
.....
1
........
Overvolt. Protection
CROWBAR
........
3
Analog
Interface
n2
T1
1
Superior
Control System
T93_0070.DRW
Ring Motor
Controller
(drive control,
system control)
THE RING MOTOR - COMPONENTS
PPRUST GMD STATOR
FRAME
and
PPRUST STACKED STATOR
CORE
and
WINDING PPRUST STATOR
QUARTER
and
VIEW OF GMD STATORS IN
ASSEMBLY
and
MOTOR POLE SHOP
and
POLE MOUNTING
MECHANICAL MILL SHELL
SPECIFICATIONS
„
„
„
„
„
„
Mill size: 7.925 M [26 feet] diameter
by 11.734 M [38.6 feet] long
Shell Inside diameter: 7,925 mm
Shell Length: 11,734 mm
Shell Plate thickness: 83/120 mm
Trunnion inside diameter: 3,060 mm
Rotating suspended mass
„
„
„
Mill structure: 980 tonnes
Charge: 1125 tonnes
Total: 2105
and
MECHANICAL AND
ELECTRICAL INSTALLATION
OF PPRUST GMD - 10/09/2007
and
POSITIONING OF FIRST SHELL
SECTION ONTO THE CRADLES
and
TOP & TAIL HEAD WITH 330 & 440
TON CRANES SIMULTANEOUSLY
and
TOP AND TAIL FIRST
SECTION USING 3 CRANES
and
LIFT FIRST SECTION
INTO POSITION
and
POSITION SECOND
STATOR SECTION
and
POSITION SECOND
STATOR SECTION
and
POSITION THIRD STATOR
SECTION
and
POSITION THIRD STATOR
SECTION
and
LIFT LAST STATOR
QUARTER INTO POSITION
and
MOTOR STATOR
ELECTRICAL CONNECTIONS
and
MOTOR STATOR
ELECTRICAL CONNECTIONS
and
ROTOR POLE
INSTALLATION
and
SLIPRINGS FITTED
and
Slip rings
MOTOR COMPLETE IN
MAINTENANCE POSITION
and
BRAKE SYSTEM
AIR GAP SENSORS PLACEMENT
„
Signal Conditioner
Supply and Output Cable
„
Terminal Box
„
„
Alarm- and trip
levels of the air
gap
Normal operation
„ 16 mm , rotor
centered
Alarm
„ Out of center
by 4 mm
Trip
„ Out of center
by 5 mm
SYSTEM OVERVIEW - CYCLO CONVERTER
Converter transformer
MV switches
Auxiliaries
& E-house
f1
S
T2
T1
T1
n1
B
Cycloconverter
& excitation
iA
u+
i+
uiS
iR
iT
Superior Control System Bus
1
uS
uR
Communication
Processor
B448 Bus
uT
f2
PSR2
Gate Control
Unit
iSBX
ARCnet
ARCnet® Bus
Overvolt. Protection
CROWBAR
Digital I/O
Excitat. int.
Converter
Electronics
Converter
Electronics
.....
Digital I/O
Customer
Operation
Alarms
.....
1
........
SM
3
Analog
and Digital
Input/Output
........
ie
Analog
Interface
n2
T1
1
Superior
Control System
T93_0070.DRW
GMD BLOCK DIAGRAM
23kV / 50Hz / 3ph -15/+5%
3.3 kV / 3ph / 50Hz
380 V / 3ph / 50Hz
4
1
24
22
380 V / 3ph+N / 50Hz
Circuit
Breaker
Rotor
Lighting
Legend
Power
2
Main Circuit
Breaker Stator
VAR
VMS
Tower
DCS
Volt
Synchronisation
Transformer
Distributed
Control System (not ABB Scope)
Amp
4
1pc for 3 mills
5
6
7
Others
8
38
Stator
Transformer 2
Stator
Transformer 1
Excitation
Transformer
Telephone
39a
Stator
Transformer 3
ABB
Switzerland
44
43
9
23
Circuit
Breaker
25
26
27
23a
10
13
12
11
Differential
Protect. Relay
+F16
Air condition
redundant
120VAC / 50Hz/ 1ph
UPS
Fire Fighting
System
+F14
MCC-supplied
40
39
MCC
+F05...+F20
+CA
+CB
40
+CC
+F03
Video Monitoring
System +F04
Cyclo-Converter 12-Pulse
Excitation
16
PLC
PSR +F02
Control & Regulation
30
Cycloconv.Recooling Unit
+F01
31
Cooling pumps redundant
19
28
+F15
VMS Tower
Data Logger
33
14
21
15
E-House
42
41. Mill Brake Control & Supervision
42. Knife switch (rotor/stator) Control & Supervision
PT100
9x Probe
37
air gap
PT100
air temp.
M
2x heat
exchanger
dust sealing
Y
water leakage
W
water flow
U
Excitation
2 x Make up Fan
Heater
Ringmotor
* x Motor Fans
34
V
MLCB
Motor Local Control
Box
36
29
35
20
36. Interconnection MLCB to PLC
37 Arcnet Interface MLCB to PSR
38. Interface PLC to DCS
39. Serial Interace VMS to PLC
39a.Serial Interace VMS to Monitor in DCS
40. UPS Power Supply (PSR,PLC, VMS)
Knife switches
17
1. MCC LV Power Supply
2. Synchronisation Transformer HV Supply
4. HV Power Supply stator
5. Excitation Transformer Power Supply
6. Stator Transformer 1 Power Supply
7. Stator Transformer 2 Power Supply
8. Stator Transformer 3 Power Supply
9. Synchronisation Voltage
10. Excitation Converter Power Supply
11. Stator Phase (R) Power Supply
12. Stator Phase (S) Power Supply
13. Stator Phase (T) Power Supply
14. Motor Excitation Power Supply
15. Motor Phase U,V,W Power Supply &
Motor Starpoint
16. Converter Auxiliary LV Power Supply
17. Space Heater, Motor Fans Power Supply
18. Mill Brake Power Supply
19. Cycloconverter Recooling System
Auxiliary Power Supply
20. Mill Lubrication System
Auxiliary Power Supply
21. MCC Control and Supervision
22. Excitation Breaker Control and Supervision
23. Excitation Transformer Supervision
23a. Excitation Circuit Breaker Supervision
24. Main Breaker Control and Supervision
25. Stator Transformer 1 Supervision
26. Stator Transformer 2 Supervision
27. Stator Transformer 3 Supervision
28. Serial Interface PSR to PLC (RS 232 / DH+)
29. Motor Winding temperature Supervision
Water inlet / outlet temp. supervision by PT100
30. Cycloconverter control & supervision
31. Cycloconverter Recooling System
Supervision
32. Mill Lubrication system Supervision
33. Excitation converter control
34. Air Gap Supervision
32
Mill Lubrication System
Mill Brake
System
(scope of mill supplier)
(scope of mill supplier)
18
41
43. Line current, line power, line VAR signals to PLC
44. Transformer Differential Protection
POWER DEVICES
Water cooling
Thyristor pressing device
POWER CONNECTIONS
Power Part input bus bar connections
Cycloconverter basics
„
„
„
The cyclo consists of three star-connected antiparallel 6-pulse rectifier thyristor bridges, each
supplies one motor phase.
Thyristors bridges are line commutated
6-pulse
f1
f2
f1
„
12-pulse
f2
30°
0°
bridge A bridge B
Cycloconverter – technical data
„
The benefits of 12 pulse configuration are:
„ Fastest response times in current and torque
control
„ Lowest network harmonic distortion
„ Lowest losses
„ Lowest shaft torque ripple
„ The torque rise time , which can be reached
with a motor supplied by 12-pulse converter
is better than obtained with 6-pulse
converter. In this configuration the 5th, 7th
17th and 19th etc. harmonic network
currents are totally cancelled,remaining 11,
13, 23, 25th, etc.
CYCLOCONVERTER – POWER PLANT
CYCLOCONVERTER – POWER PLANT
EXCITATION
CYCLOCONVERTER – COOLING UNIT
Introduction / PSR terms
„
The name PSR
„ The abbreviation PSR is derived from
"Programmierbarer Schneller Regler"
(Programmable High Speed Controller).
It is used in this form in all languages.
In older English documents, the
abbreviation PHSC may be found
instead of PSR.
and
Block diagram - PSR structure
Superior Control System Bus
1
Communication
Processor
Analog
and Digital
Input/Output
PSR2
Gate Control
Unit
iSBX
ARCnet
ARCnet® Bus
Digital I/O
Excitat. int.
.....
Digital I/O
Customer
Converter
Electronics
Converter
Electronics
Operation
Alarms
.....
1
........
Overvolt. Protection
CROWBAR
........
Analog
Interface
B448 Bus
1
Superior
Control System
T93_0070.DRW
Cycloconverter – drive controller
Control Panel
PSR2 drive controller
Gate control units
Pulse amplifier
Thyristor
supervision
Cycloconverter – general control
PSR2- drive controler
Filter
=
3
ixR,S,T
/ ψx / = ψα 2 + ψβ 2
ψ flux
& speed
calculation
Voltage
integration
id, iq
Int.
dq
nw
Speed Controller
Current controller
kp
kp
3
- nx
Pulse amplifier
Gate control unit
=
Ust
6
6
bridge A
R,S,T
3
iw
d,q
3
bridge B
bridge A
U
iw R,S,T
Pulse amplifier
Bridge commutating
RUB
SUB
TUB
SWI
6
bridge B
Filter
3
UxM R,S,T
Excitation converter
iwe calculation
ψw
ψ
ψx
flux
controler
Pulse amplifier
iwe
6
SM
TYPICAL CURRENT AND VOLTAGE WAVEFORMS
„
The cycloconverter produces the machine stator voltages
direct from the mains voltages by means of phase angle
control. The converter control angle is controlled such that
converter output voltages with a mean sinusoidal
characteristic result. Both the frequency and the amplitude
are adjustable.
e = current change over interval (about 5ms)
f2 = frequency at converter output
1 = three-phase input voltage with mains
frequency
2 = mean value of output voltage
bridge A
bridge B
TYPICAL CURRENT AND VOLTAGE WAVEFORMS
bridge A
bridge B
A
A
B
B
CONTROLLING THE MOTOR TORQUE
„
Rapid torque control is an important aspect
of a regulating drive. The drive torque at the
motor shaft should follow the torque value
specified by a higher-order control system,
for example a speed controller.
„
Motor torque is proportional to
„
Motor current
Motor flux
„
M=⍦•I
„
Controlling the motor torque
„
„
In the synchronous machine, the torque is the vectorial product of the stator
current Ι and the resultant stator flux linkage ⍦. The torque is a maximum when
these two vectors are perpendicular to each other.
To obtain a torque which is proportional to the amplitude of the three-phase
system, the phase position and frequency of the reference values must be
calculated, that at that moment in the machine, the vector of the linear current
density of the stator current Ι with the reference length iw is perpendicular to the
rotating vector of the resultant stator flux linkage ⍦1, resp. ⍦2 (or standing for
“machine air gap flux”).
„
Subscripts 1 and 2 indicate two different load points.
„
The currents Ι1 and Ι2 of different magnitude are always in phase with the motor
voltages U1 and U2, i.e. cos φ 1
Mδ = Ψ2 ⋅ I 2
U2
U1
I2
Ψs 2
Ψ2
I1
ϑ
90°
Ψ1
Ψs1
Ψe1
Ψe2
OPERATING CURVE
Line Voltage, Line Frequency
Machine Current
Machine Torque
Motor Power
Motor Voltage
Excitation Current
max. 0.95
cos ϕ N
base
speed
constant torque
up to base speed
max.
speed
Field-weakening
constant power
n
STARTING CURVE
CREEPING SPEED CONTROL
Cycloconverter protection overview
Medium supply voltage
Synchronisation
voltage
f1
SG
Cycloconverter
Transformer
T1
Excitation
Transformer
Excitation
Converter
Line under-/ overvoltage
Line under-/ overfrequency
T3
T2
Cycloconverter
U>
- oil & winding temp.
- buchholz
- overpressure, - oil level
- diff. protection
Overvoltage arrester netside
Overcurrent protection CSA 463
Overcurrent protection
B
Rotor thermal protect.
i-
=
A
~
Rotor Ground fault supervision
U>
U>
R
R
u+
i+
u-
Overvoltage arrester rotorside
Overvoltage arrester motorside
iS
iR
iT
uS
uR
uT
ie
f2
Ringmotor
Y
~
3
~
SM
Stator Ground fault supervision
THE E-HOUSE - SYSTEMS
Containerized E-house
Video Monitoring System
PLC
MCC’s
Rear: cyclo-converter
power connections
& cooling
Cycloconverter:
thyristor stack
Excitation
converter
PSR2 drive
controller
TRANSIENT RECORDER SET-UP
1
2
3
4
5
6
7
8
Transient Recorder
A
A
so
rd
PC + PCI Card
For Commissioning
and Troubleshooting
PX
I I/
O
Ca
es
roc
IP
PX
Ethernet
Connection
Option 2
B
PXI Chassis
* Mail
* SMS
VMS Port & AB - PLC
File
Programming Port
PLC
Portable PC
Converter
RS232 / RS485
ABB Remote PC
COM1
VMS System PC
PSR Programming Port
C
Trigger
PSR
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sind ohne unsere ausdrückliche Zustimmung verboten.
© Asea Brown Boveri
DF1
Optional Connection
Converter RS232 / RS485
Ethernet
Switch box
D
DF1
PC 2-3
Shielded Cable
Public Telephone
Network
COM2
E
Po
we
rS
We reserve all rights in this document and in the information contained therein.
Reproduction, use or diclosure to third parties without express autority
is strictly forbidden.
© Asea Brown Boveri
B
up
p ly
A BB Office
r
Plant Side
D
from
Kombi I/O
Connector
(SCB 100)
Public Telephone
Network
Calculated
Value in PSR
Electrical Signal
Actual value
Telefon
E
Telefon
GMD System
F
F
Revision
Date
Name
Issued
13.11.00 C.Riquelme
xx
Released
Office resp. IBDE
1
ABB
Industrie AG
Switzerland
xxPROJECT
Checked
2
original
replaced
3
+
ABB- Proj.-no: xx
replaced by
4
=
3BHS x
Data Logger Gearless Mill Drive
5
6
Cust.- Proj.-no: x
7
page
1
of
1
Path: S:\ibde\produkt&systems\Fachgebietsarbeiten\Data Logger GMD\Logger_0.vsd
E-house and auxiliaries
„
E-House is housing the following equipments:
„
„
„
„
„
„
„
„
„
Cycloconverter power part incl. cooling & control
MCC for the complete drive system (Motor & Mill
auxiliaries)
PLC panel
VMS system
Transformer differential protection panel (optional)
UPS incl. bypass switch
Fire fighting system
Lighting panel
Air condition
Containerized E-room backside
Containerized E-room backside
Containerized E-room MCC
Controller (drive control and
system control)
DCS
see DCS Signal List
Ethernet
Profibus
ControlNet
Modbus
VMS
OperatelT
RSView
Ethernet
OPC
PLC
PLC specific
Serialbus
I/O
see I/O Signal List
serial communication
DF1(Allen Bradley) or
Modbus
PSR
Controller (drive control and system
control)
„
The cycloconverter drive controller named PSR2 is an
ABB developed high speed controller for:
„ Current control
„ Flux control
„ Speed control
„ Sequence control
„ Pulse firing control
„ Control & supervision of the cycloconverter &
cooling unit
„ Drive specific control & supervisions:
„ - main circuit breaker control
„ - mill brake control logic
„ - frozen charge protection
„ - air gap monitoring & supervision
„ - mill creeping (low speed operation)
„ - positioning of the mill etc. …)
Controller (drive control and
system control)
„
PLC is responsible for the overall system control
and supervision of the following tasks:
„ Communication with client’s DCS system
„ Communication to the VMS system
„ Communication with the PSR2 drive controller
„ Cycloconverter transformers supervision
„ Excitation transformer supervision
„ Ringmotor auxiliary system (control &
supervision)
„ Mill lube & brake system (control & supervision)
„ MCCs
„ Air condition
„ Fire fighting system
„ Alarm/ Fault handling of auxiliary drives/ devices
Controller (drive control and
system control)
„
„
„
VMS system = Video Monitoring System
The VMS will interface with the GMD through the
overall PLC system.
The VMS is configured and implemented to allow the
operator to monitor the GMD system based on
graphics page displays. It also provides assistance in
maintenance and trouble shooting the system.
„ Function Level 1:
„ Monitoring of system status
„ Monitoring of all alarms and faults
„ Monitoring of all process interlocks
„ Data logger
„ Trending of process variables
Controller (drive control and
system control)
„
„
VMS system = Video Monitoring System
Optional:
„ Function Level 2:
„ Provide information about the location of sensors
and devices that can raise an alarm. This will be
divided into 4 location levels, each giving more detail
as to where the sensor or faulty piece of equipment
can be found by drawings or photos for physical
location
„ Function Level 3:
„ Provide direct links to
„ Operation manuals
„ Maintenance & service manuals
„ Test reports
„ P&I diagrams (general)
„ Part lists
„ Circuit diagrams & drawings
Controller (drive control and system control)
Main page logger
VMS –Brake system
VMS –Cyclo system
VMS – Various systems
VMS –Ring motor supervision
VMS –Lube system
VMS –Lube system
VMS – E-house supervision
Transient recorder
„
„
„
„
For the drive controller purposes it is
used the PSR (programmable high speed
controller)
For the drive and the auxiliaries control
purposes is used the PLC
For the drive and the auxiliaries
visualisation purposes is used the VMS
The ABB transient recorder is a HighSpeed Recording and Analysis System
service tool, which can be used for
trouble shooting as well for process
optimization.
Transient recorder user interface
CONCLUSION
• GMDs are the future for SAG and Ball
Mills
• GMDs achieve availabilities of 98,5 to 99%
• More and more GMDs are being installed
• GMDs are being applied to
• Ever lower power (e.g. 8,3 MW San
Cristobel)
• Ever larger powers (e.g. 22 MW, Los
Bronces)
• GMDs are being considered for 33,5 MW
44 feet grinding mills.
and
ACKNOWLEDGEMENT
„
„
ABB
FLSmidth Minerals
THANK YOU!
and