Machines for VSD Applications

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ABB Machine with

Variable Speed Drive

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-Content

What is VSD

Machines with VSD

EX- motors with VSD

Electrical protection

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

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 VSI-MF topology

Converter

Converter with integrated input transformer ACS 5000 VSI-MF topology

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-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

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of energy per year, the equivalent of 15 nuclear power plants.

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Typical applications

Pumps

Compressor

Extruders

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-VSD system

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Content

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-What is a VSD system?

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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

Improved product quality

through better process control

Reduced process equipment

wear and longer lifetime of

equipment

Soft start and stop reduce

waste and save raw material

Noise reduction

Improved process efficiency

time speed Soft Start Production rise Energy saving Best quality

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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

20 % safety marginal needed

Stiff shaft design move critical speed above normal speed range

Benefit; hole speed range can be used 0 V ib ra tio n ve lo ci ty [m m /s ] Critical speed Speed range in VFD operation 6000 4000 2000 Rotation speed [rpm] 5,0 4,0 3,0 2,0 1,0 0,0

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-Stator design for VSD system

Factors affecting the design of insulation systems:

Electrical stress

Voltage peaks

Thermal stress

Higher temperature rice

Solid Insulation system

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)

Dedicated design tools

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-Bearings design in vsd system

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

ABB prevent that phenomena

Bearing insulation

N-end insulation

Both side insulation + grounding cable in D-end

Worst conditions for the test Hybrid bearings Spark test apparatus No ignition acc. to EN 50020 Shaft

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Cooling

Force ventilated cooling

Constant torque for hole speed

range

Available for all machines

types

IC 416

IC616/IC666 IC86W

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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

Dimensioning

Thermal sensor for surface temperature

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-Ex Motors with Converter supply

(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 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

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

Installation Requirements / ATEX 137 Product Requirements / ATEX 95

Protection

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.

EN 50019 / IEC 60079 -7

The combination shall be tested as a unit with the associated protective device.

“e”

Increased Safety

EN / IEC 60079 -14

To prevent any over-voltage spikes and higher temperatures in the motor.

EN 50021 / IEC 60079 -15

The motors shall be tested for this duty with the converter specified. In exceptional cases the

temperature class may be determined by calculation.

“n”

Non Sparking

§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.

EN/ IEC 60079-0/EN 50014

Precaution shall be taken to guard against any effect due to the

presence of circulating currents Minimum

requirements

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-Ex motors with converter supply / requirements

Installation Requirements / ATEX 137 Product Requirements / ATEX 95

Protection

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 EN 50281-1-1

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

“DIP” Dust Ignition

Proof

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 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.

“d” Flame Proof

EN / IEC 60079-14 No specific requirements. EN 50016 / IEC 60079 -2

The safety of the combination shall be shown by 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.

“p”

Pressurized

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-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

Proceed to the compliance with the “Minimum requirements” of the ATEX 137

The whole unit is the certified as a “work place”

Solutions for Motors with Converter supply

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-References

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-MEGADRIVE-LCI

Ormen Lange, Norway

Compressor drives

World’s longest export pipeline

Motor power 3 x 48 MW

Project Example

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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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-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.

Scope to ABB Transformers, Drives, Motors and Pump Control

Panels

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-References Oil, Gas and Petrochemicals

Pump Soft-starter Gas compression Agitator Pump Extruder Pump Pump Extruder Compressor Compressor Extruder Compressor Soft-starter Extruder Segment 2 2 6 2 2 2 5 4 4 1 2 1 4 3 2 Motor 10,60 15,00 95,82 4,30 1,90 10,00 3,00 3,80 6,20 4,25 9,50 5,35 23,80 29,63 2,40 Total (MW) 5 300 7 500 15 970 2 150 950 5 000 600 950 1550 4250 4750 5 350 5 950 9 875 1200 Power (kW) F-Conventer Application Project name Country ACS 1000 Oil & Gas

Ras Tanura SA

LCI.SO Oil & Gas

Yanbu SA

LCI.DR Oil & Gas

Ras Laffan QA ACS 1000 Petrochemicals LG Oman PP OM ACS 1000 Oil & Gas

Huwaila AE ACS 1000 Petrochemicals Sidpec Petrochemical EG ACS 1000 Oil & Gas

Bangestan NISOC IR

ACS 1000 Oil & Gas

MHI ADCO AE ACS 1000 Petrochemicals Petrokemiya SA ACS 1000 Oil & Gas

AMOC Lube Oil EG

ACS 1000 Oil & Gas

GSI ST ACS 1000 Petrochemicals JSW Arak HDP IR ACS 1000 Oil & Gas

South Pars IR

LCI.SO Oil & Gas

Darquiain Oil Filed IR

ACS 1000i Oil & Gas

Sabic Sharg SA

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-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)

Smooth start up of motors/generators

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-Sparks / Bearing Current

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 Cabling, grounding Filtering

ABB test results

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-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

0,80 1,00 1,20 1,40 1,60 1,80 2,00 2,20 0,00 0,20 0,40 0,60 0,80 1,00 1,20 IEC TS 60034-17 IEC TS 60034-25 A IEC TS 60034-25 B ABB Special Insul.

Limiting curves for impulse peak voltage in frequency converter operation, phase-to-phase at motor

0,80 1,00 1,20 1,40 1,60 1,80 2,00 2,20 0,00 0,20 0,40 0,60 0,80 1,00 1,20 IEC TS 60034-17 IEC TS 60034-25 A IEC TS 60034-25 B ABB Special Insul.

ABB Form wound ABB Form wound