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Drive Solutions for Electric Utilities

Variable Frequency Drives in Electric Power Plants

Controlling fan fl ow by adjusting speed avoids wasting energy in fl ow control vanes, dampers, and louvers. When large fl ows must be controlled and motor energy consumption is signifi cant, varying the motor speed is the answer. With large machines, the electrical power

Every step of the way from the fossil fuel to the electric power, variable frequency drives (VFDs) are used to smoothly start large motors and continuously adjust the speed as required by the process. Induction and synchronous motors driving boiler feed pumps, forced

savings can amount to hundreds of thousands of dollars per year. In addition, the drives smoothly start the motors, protecting them against starting inrush currents, thus avoiding thermal stress and extending motor life.

About TMEICA Global networkTMEIC is built on the combined and proud heritage of Toshiba and Mitsubishi-Electric in the industrial automation, control and drive systems business. TMEIC’s global business employs more than 2,200 employees, with sales exceeding U.S. $2.4 billion, and specializes in Metals, Oil & Gas, Material Handling, Utilities, Cement, Mining, Paper and other industrial markets.

TMEIC Corporation, headquartered in Roanoke, Virginia, designs, develops and engineers advanced automation and variable frequency drive systems.

The factory for the World’s factoriesTMEIC delivers high quality advanced systems and products to factories worldwide, while serving as a global solutions partner to contribute to the growth of our customers.

Customer ServiceAt TMEIC, our focus is on the customer, working to provide superior products and excellent service, delivering customer success every project, every time.

draft fans, induced draft fans, service water pumps, and conveyors use VFDs to provide high power, accurate speed control, and effi cient fl ow control with signifi cant energy savings.

of 28 © 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION. All Rights Reserved.

Why Use Electrical Variable Frequency Drives?Here are some of the reasons to use electrical medium voltage drives:

Increased Reliability Pages 4, 6, 7To control speed and fl ow, adjustable speed motor-drive systems are more reliable than traditional mechanical approaches such as using louvers, valves, gears, or turbines. Because electric drives have no moving parts, they provide very high reliability, typically exceeding a 15 year MTBF.

Dramatic Energy Savings Pages 4, 5, 9On an induced draft fan with a variable speed motor-drive system, the fl ow control louver or vane is not required, avoiding large fl ow energy losses. In fact, the variable speed motor-drive system is more effi cient than all other fl ow control methods including turbines and hydraulic transmissions.

Signifi cantly Less Maintenance Pages 8, 19Power plants demand high system availability. Because electric variable speed drive systems have no moving parts, they require virtually no maintenance. This is in sharp contrast to speed and fl ow control devices such as louvers, guide vanes, valves, and turbines that do require maintenance.

Motors Soft Starting and Improved Power Factor Pages 6, 8When electric drives soft start large motors, starting inrush current and its associated mechanical and thermal stress are eliminated. This removes limitations on motor starts per hour, reduces insulation damage, and provides extended motor life

To Start Gas Turbine Generators Large utility gas turbines are often started using an LCI (Load Commutated Inverter) VFD connected to the generator used as a motor. Hundreds of LCI drives are in service in starter applications.

Why TMEIC Drives Make Sense

Choose TMEIC, a Global Supplier Page 18TMEIC sells and services drive systems worldwide, supported by engineering and service offi ces and spare parts depots in North & South America, Europe, Asia, Japan and Australia.

We’ve got you covered! A Complete Family of Drives Page 19Our family of low and medium voltage (LV and MV) drives covers all your needs - from 450 hp to over 40,000 hp and beyond, with a wide range of output voltages up to 11 kV.

Engineering Expertise Page 11TMEIC drive and motor application engineers bring an average of 25 years of practical industry experience to your application. After analyzing your system requirements, they can recommend the most cost effective solution and design the complete drive system for you.

Confi guration Software Page 27 The TMDrive Navigator world-class confi guration software is used on all TMEIC drives. Live block diagrams and tune-up wizards streamline commissioning and maintenance activities.

© 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION. All Rights Reserved. of 28

Application 1. Induced Draft Fan on Boiler

Drive Applications in the Power PlantVariable frequency drives are used to control the speed of fans, pumps, and mills in power plants. VFDs are also used to smoothly start large motors, synchronize, and connect them across the line. The following seven pages describe four typical applications and present the reasons why electric drives were chosen. These selected drive applications are:

1. Induced draft fans

2. Multiple ID fans

3. Boiler feed pumps

4. Service water pumps

The ID fan creates furnace air fl ow, which must be continuously varied to match the fuel fl ow. The process control system continuously monitors process conditions such as fuel feed, inlet air temperature, fl ue oxygen content, and required fuel-air ratio. The control system then directs the fan to provide the air fl ow for optimum combustion.

Advantages of the TMEIC Dura-Bilt5i MV VFD System

Very High Reliability – The Dura-Bilt5i MV uses 3,300 Volt Insulated Gate Bipolar Transistors (IGBT) allowing a simpler, more reliable inverter design. Since mechanical fl ow devices are not used, process interruptions caused by mechanical failures are minimized.

Energy Savings – Elimination of the air fl ow losses through the dampers is usually the most compelling reason for applying a Dura-Bilt5i MV drive. The ID fan power can be several thousand hp and using a drive to vary air fl ow can result in energy savings of over $100,000 per year, as described on the next page.

Power System Friendly – The converter is a 24-pulse diode rectifi er with a performance exceeding the requirements of the IEEE 519-1992 standard for Total Harmonic Distortion (THD). This means that other equipment connected to the power system is not adversely affected by harmonic frequency disturbances.

Heat Pipe Cooling – For most frames the IGBTs in the three inverter legs are cooled with heat pipe technology, which maintains uniform working temperature, prolongs the semiconductor life, reduces cooling fan power and noise, and saves valuable fl oor space in the plant.

Traditional fl ow control methods use constant speed motors with mechanical fl ow reducing devices such as:• Inlet louvers (dampers) in the ducting• Outlet louvers (dampers) in the ducting• Flow guide vanes in the fan casing• Variable slip clutches in the fan drive shaft• Hydraulic variable speed transmissions

These mechanical solutions have signifi cant disadvantages:• High energy consumption at reduced fl ow rates• Mechanical wear and required maintenance• Generation interruptions due to mechanical problems• Limitations on motor starting duty

The electrical solution replaces the mechanical equipment with a Dura-Bilt5i MV VFD. This brings a number of advantages.


Output Flow

Induced Air Flowfrom furnace

Induced Draft Fan

Main Power14.4 kV orbelow

VariableFrequencyThree-phase

Dura-Bilt5i MV VFD

InductionMotor

Flow

Pre

ssur

e D

rop

and

Pow

er

Speed A

Speed B

Speed C

Speed E

SystemResistance

Speed D

Operating Point A

Operating Point B

Operating Point C

Operating Point D

Operating Point E

% Flow

Per

cent

Pow

er

140

120

100

80

60

40

20

020 40 60 80 100

DrivePowerInlet

Vanes

OutletDamper

Static Pressure Rise

FanOutputFlowPower

Ref Point

Required Flow %

% Power Using Outlet Damper

Control

% Power Using Adjustable Speed

Drive

Delta % Power Saved

% Time on Annual Basis

% Saved on Annual Basis

A 90 120 91 29 15 4.35

B 80 117 66 51 25 12.75

C 70 111 46 65 25 16.25

D 60 103 34 69 20 13.8

E 50 96 23 73 15 10.95

Total Annual % Energy Consumption Savings 58.1

Energy Savings using a TMEIC Variable Frequency Drive Fan System

Variable fl ow can be provided by varying fan RPM to precisely match process operating conditions. The variable frequency drive provides variable fan speed which varies the air fl ow according to the system resistance.

The fi rst chart shows how different fan speeds are used to select the proper operating points A through E on the system resistance curve. Depending upon the size of the boiler, the required ID fan output power can vary from a few hundred hp to several thousand hp. The second chart shows a system using mechanical dampers to achieve fl ow control. Pairs of fl ow and pressure operating points correspond to points A through E.

Power level percentages shown are total input power including all motor, transformer, fan, and system losses as percentages of required fan output power. The energy deltas (vertical lines) allow calculation of energy savings and drive cost justifi cation. A table of expected annual operating times and power level differences is shown below. Energy cost factors for the site are applied and the annual savings calculated.

Savings. Based on the annualized percent savings in the table, an ID fan system with 1,000 hp output, operating for 8,000 of 8,760 hours per year, at an energy cost of $0.035 per kWh, saves:

1000 x 0.746 x 58.1% x $.035 x 8000 = $121,359

If installed added costs of drive equipment are $150,000, the payback period will be only 15 months. A good return on investment!


Application 2. Drives for Multiple Induced Draft Fans

This 1987 power plant had four large 3800 hp boiler ID fans driven by four Load Commutated Inverters (LCI) drives and synchronous motors in each of two units. A fan power upgrade to 6600 hp was recently made to accommodate new pollution control equipment known as SCR (Selective Catalytic Reduction), which reduces nitrogen oxides in the fl ue gas from burning coal. A fi fth LCI drive was confi gured as a spare to be connected to any of the four motors as required.

Advantages of the Variable Frequency Drive and Synchronous Motors

High Reliability – Based on the customer’s 20 years of trouble-free operating experience with the LCI, the high reliability is proven. In addition, the ability to back up any of the drives with the standby drive yields very high system availability.

Smooth Motor Starting – The LCI controls the rotor fi eld (through the exciter) and the stator current to provide a smooth starting profi le without exceeding rated volts and amps, thereby protecting the motor against overheating.

Cost Savings – The synchronous motor and LCI combination is one of the highest effi ciency drive systems available, resulting in energy cost savings over the life of the system.

Water Cooling Technology in the Drive – The water cooling system reduces maintenance, drive room cooling costs, and ambient noise. The system is redundant and water hoses don’t need to be disconnected for bridge service, see photo on next page.

The customer had several requirements when making this major upgrade to the 600 MW power station: • Replace the original motors with higher

power 6600 hp synchronous motors for 4160 V ac operation and 1200 rpm.

• Ensure the replacement drives have at least the same high reliability as the original LCIs, and the latest control equipment.

• Provide ability for the drive to soft start the motor and thereby reduce the current inrush and resulting overheating.

• Ability for the standby drive to be switched to any of the four motors if required.

After reviewing their alternatives, the company decided to place the order for the drives, motors, and electrical system with the original vendor - TMEIC. The system diagram is shown on the next page

Typical Fan Power Upgrade in progress


A Backup Drive to Start and Control Four Large Motors

Redundant SCRs in Drive Ensure High Availability

The unique LCI bridge design uses full voltage rated SCRs (thyristors) in an N+1 confi guration. Each series SCR stack (see photo) has one extra SCR such that any SCR can fail and the stack will continue to operate at full power. Since SCRs typically fail as a short circuit, no added parts or control circuits are required – redundancy is inherent.

Diagnostics indicates the fault down to the cell level and, when a convenient time for service occurs, the SCR can be quickly replaced. Replacement does not disturb the water cooling system.

TMdrive-XL55Sync.Motor

6.6 kV 7000 HP1200 RPM6000 Vac

Sync.Motor

6.6 kV 7000 HP1200 RPM6000 Vac

Sync.Motor

6.6 kV 7000 HP1200 RPM6000 Vac

Sync.Motor

6.6 kV 7000 HP1200 RPM6000 Vac

6.6 kV6000 Vac

TMdrive-XL55

TMdrive-XL55

TMdrive-XL55

TMdrive-XL55

Standby Drive


Application 3. Boiler Feed Pumps

Boiler feed fl ow has to be controlled to match the boiler load and maintain steam drum level. In the past, boiler feed pumps have been driven either by a variable speed steam turbine, or a fi xed speed electric motor using a throttling valve to control feed fl ow. Occasionally hydraulic variable transmissions were used. These approaches have disadvantages as described below. Using a VFD and electric motor has a number of benefi ts, also listed below.

Advantages of the Variable Frequency Drive and Synchronous Motors

Energy Savings and Reduced Maintenance – Elimination of the fl ow losses through the throttling valve and its associated maintenance are usually the most compelling reasons for applying a variable frequency drive. The feed pump power can be several hundred hp or more, depending on the plant rating, and using a drive to vary feed fl ow can result in considerable energy savings, as described on the next page.

High Reliability – Based on years of customer experience, the high reliability of AC drives is proven. TMEIC MV drives for utility applications have an MTBF from 12 to 16 years.

Smooth Motor Starting – The VFD controls the motor input frequency and current to provide a smooth starting profi le without exceeding rated volts and amps, thereby protecting the motor against overheating, extending motor life, and eliminating voltage dips. A VFD eliminates restrictions on the number of starts per hour that apply to across the line starts.

Heat Pipe or Water Cooling Technology in the Drive – The advanced technology cooling system maintains uniform working temperature, prolongs semiconductor life, reduces cooling fan power and noise, and saves valuable fl oor space in the plant.

Steam Turbine Drive Disadvantages • Special mechanical maintenance is required

on a regular basis.

• Turbine can be expensive, especially if it is custom designed.

Fixed Speed Electric Motor Disadvantages• High energy losses in the throttling valve at

lower fl ows is expensive.• Motor is subjected to hard starts with

resulting thermal stresses on the windings with reduced motor life.

Hydraulic Transmission Disadvantages• The energy losses are signifi cant at lower

speeds of less than 80%.

After reviewing their alternatives, the company decided to place the order for the drives, motors, and electrical system with the original vendor - TMEIC. The system diagram is shown on the next page


Energy Savings using a TMEIC Variable Frequency Drive Pump System

Flow can be controlled to match process operating conditions by varying pump RPM. The variable frequency drive system does not require a fl ow control (throttling) valve. Costs for the fi xed and variable speed cases are compared below.

Throttling Valve Flow Control. The example curves below are for a 600 hp pump for low head requirements. In the pump curves, operating at 2400 GPM and 3560 RPM requires 550 hp (refer to point A). Reducing the fl ow to 1200 GPM with a throttling valve, at constant 3560 RPM speed, causes the pump to move back to point B; this point requires 400 hp.

Alternative Variable Pump Speed Flow Control (No Valve). Using a VFD, reducing the pump speed from A to C reduces the fl ow to 1200 GPM, but the head is much reduced, from 800 ft to 200 ft and the power required is only 70 hp. This is 330 hp less than the fi rst case, and represents the power which was lost in the throttling valve. If much time is spent at low fl ows the energy savings using a VFD are considerable.

Energy Cost Savings with VFD In this example, the pump was consuming 400 hp at B but at C is only consuming 70 hp, so the energy saved by not throttling is 330 hp. As a quick estimate, assume operation at point C for 60% of the time and at point A for 40% of the time. With 90% combined motor effi ciency and power costs of $0.05 per kWh, annual savings will be just under $60,000. Signifi cant! Of course the larger the motor the larger the savings will be, and since energy costs will probably continue to rise, the life time savings will be large.

Typical VFD and Motor data:• Drive effi ciency – Dura-Bilt5i MV - 96.5%

• Motor effi ciency – Induction - 95.7% – Synchronous - 98.1%

• Drive power – Dura-Bilt5i MV - Up to 7,000 hp

• Output Voltage – Dura-Bilt5i MV - 2,000 to 4,200 Vac

Typical pump head, flow, speed & power characteristics

Output Flow

Boiler Feed Flow

Boiler Feed Pump

Main Power14.4 kV orbelow

Induction Motor

MV Drive

Induction Motor

Variable FrequencyThree-phase

Gearbox

Option


Application 4. River Water Pumps for Cooling

Flow of cooling water through the main turbine condenser varies with the volume of steam entering, which is proportional to the generating load. This cooling fl ow usually comes from the cooling tower and has to be controlled based on the load. Make up water compensates for evaporation in the cooling tower, and is pumped from a nearby river or lake. The make up water fl ow also varies with the load and must be controlled.

The cooling water pumping system has several levels of built-in redundancy. Both drives have a bypass allowing the motor to run directly off the line at full speed if required. Either drive can vary its pump speed to produce the desired combined fl ow to the cooling tower.

Advantages of the Dura-Bilt5i MV Pumping System

Very High Reliability– The Dura-Bilt5i MV uses 3,300 Volt Insulated Gate Bipolar Transistors (IGBT) allowing a simpler, more reliable inverter design.

Smooth Motor Starting – The VFD controls the motor input frequency and current to provide a smooth starting profi le without exceeding rated volts and amps, thereby protecting the motor against overheating, extending motor life, and eliminating voltage dips.

Synchronous Bypass – The drive has built-in control to automatically synchronize the motor frequency and phase with the main power and close the contactors to allow the motor to run at full speed when required.

Heat Pipe or Water Cooling Technology in the Drive – The advanced technology cooling system maintains uniform working temperature, prolongs semiconductor life, reduces cooling fan power and noise, and saves valuable fl oor space in the power house.

This utility customer had three river water pumps for make-up water and planned to install new drives on two of them. The requirements were:

• 160 Vac drives, each of 900 hp.

• Each drive to have a bypass allowing the motor to run directly off the line at full speed if required.

• Nominal pump speed 885 rpm with a 30-100% speed range.

• Drives to be housed in a power house located close to the intake structure and pumps.

• Power house to be air conditioned to allow operation of the drives with an external ambient temperature of 40ºC (104ºF).

Dura-Bilt5i MV drives were chosen for this upgrade because they operate at 4,160 Vac, have a small footprint, and have built in control for synchronous bypass.

Cooling water requirements will also decrease as the cooling water temperature decreases. Pumps driven by VFD’s can effi ciently accommodate these changes in fl ow requirements.

Typical vertical water pumps


Global Customer Support NetworkComprehensive technical service is provided by our Customer Support Organization, staffed by TMEIC service engineers with offices and spare parts depots across the globe.

In North and South AmericaCustomers are supported by the TMEIC Corporation service personnel, design engineers and Spare Parts Depot in Virginia, and the TMEIC Factory in Japan.

In EuropeTMEIC service engineers service all drive systems in Europe, supported by the European TMEIC Spare Parts Depot.

In Asia and the Pacific RimTMEIC services drive systems throughout China, India and the Pacific Rim, supported by multiple Field Engineers, Spare Parts Depots, and the TMEIC factory in Japan.

Remote Diagnostic Service reduces Mean Time To Repair (MTTR)Remote diagnostic service offers protection for your investment, by reducing downtime, lowering repair costs and providing peace of mind. Remote diagnostics requires an internet connection between your plant and TMEIC for retrieval of fault logs and fi les to diagnose drive or system issues.

Features Benefi ts

• Reduced downtime and Mean-Time-to-Repair

Quick support saves thousands of $ in lost productionTMEIC engineers can quickly connect to the drive and diagnose many issues in a matter of minutes.

• Secured connectionCustomer-controlled accessAll remote activity is conducted with permission of the customer. Drive start/stop is not permitted remotely.

• Fault Upload UtilityProprietary Fault Upload SoftwareHistorical drive faults are identifi ed; TMEIC design and service engineers can analyze the issue resulting in the fault and provide a solution.

Remote Drive DiagnosticsTMEIC supports drive customers through the Remote Connectivity Module (RCM), a remote diagnostic service link with the TMEIC design and service engineers in Roanoke, Virginia. The RCM enables seamless integration between your drives and our engineers.

Remote System DiagnosticsTMEIC’s remote system diagnostics tool, included in level 1 software, offers a quick path to problem resolution. System faults are automatically identified, and provide an integrated view of product, process and system information. TMEIC design and service engineers in Roanoke, Virginia, can analyze the data and provide steps for resolution.

For Service or Parts, call

1-877-280-1835

INTERNATIONAL:

+1-540-283-201024 Hours / 7 days


Drive isolation, input, and output,transformers are selected for theapplication considering:

- The type, such as dry or liquid filled- Size for the kVA and voltage- Cooling if required- The enclosure for outdoor or indoor- The environment such as temperature and humidity- Special drive requirements

SubstationTransformer

MV switchgear is selected for the application considering:

- The type, such as vacuum or SF6 - The size for the current and voltage - The CTs, PTs, and protective relays to operate the breaker - The enclosure for outdoor or indoor - The environment such as temperature and humidity

Instrumentation for equipmentmetering, monitoring, protectionand control is selected, including:

- Amp transducer and ammeter- Watt and Watt-hour transducers- Phase CTs and phase overcurrent relay- Ground sensor CT and relay- Power quality monitor

Distribution Voltages

Breaker InstrumentationDrive IsolationTransformer

Transmission Voltages

<< >>

We Engineer the Medium Voltage Power System

TMEIC application engineers design the power system from the medium voltage switchgear to the adjustable speed drive and motor. A typical MV power system is shown below. TMEIC Application Engineers size and select all the equipment for the optimal drive solution.

The critical engineering process for a successful installation is illustrated in the following Project Engineering section. Icons indicate where the various teams of engineers in the factory and fi eld service are involved in the project.

Medium Voltage Power System


Selection of the best adjustable speed drive for the application based on:

- Continuous and overload torque and power requirements - Type of load, including constant or variable torque or regenerative - Drive and motor voltage - Power system compatibility- Overall efficiency of the ASD and motor combination - Harmonic analysis

Selection of optional driveassociated Equipment such as:

- PLC for logic control, for example synchronizing multiple motors with the supply for soft start capability- Air conditioned equipment house if required- Switchgear if motor is to be synchronized with the line- Reactor for use with an LCI

Selection of the motor and associatedequipment including:

- Induction, synchronous, or wound rotor motor

- Motor size including the power, torque, voltage, current, and speed- Selection of the exciter if a synchronous motor is used- Required motor protection devices- Optional tachometer-special applications- Torsional analysis

Drive Utilization Voltage

Motor Load

Control PLCAdjustable Speed Drive Motor

Motor Load


System architecture illustrationDetailed description ofequipment in proposal

Utility Voltage bus

Bypass Bus

DB5i MV Unit BSync Ready

Mtr 1 Mtr 2 Mtr 3 2 PTs 1 CPT

VFD Bus

3-phase

3-phase

DB5i MV Unit ASync Ready

CT-1 CT-4 CT-5

PLC Coordination& Interface

Tie Contactor

FactoryAcceptance

Test

System Maintenance and Service

Technical Proposal

Specification

DetailedHardware &

Software Design and Component

Procurement

Customer Team

Field TeamFactory TeamTraining Team

The Project Teams

Project Life Cycle Process

System Commissioning

Technical Proposal Specifi cation

TMEIC Assists in the Project Planning

During all phases of your project planning, TMEIC assists by supplying information, training, guide-form specifi cations, and general advice. Experienced drive application engineers prepare a technical proposal that includes:

• Customized system architecture for your project.

• Detailed equipment specifi cations for the drives, exciters, transformers, switchgear, and housings.

• Thorough description of the PLC control functions, including logic for synchronizing and de-synchronizing the motors.

• Formal bid documentation.


Based on the proposal specifi cation, the project engineering team proceeds with four main tasks:

• Control Software Design. Control engineers confi gure the drives and PLC controller logic, if a PLC is required for the application. The illustration above shows a typical toolbox logic function diagram in Relay Ladder Diagram format. The toolbox is used for drive confi guration, tuning, sequencing, and drive diagnostics.

• Operator Interface. All TMEIC drives include a confi gurable keypad shown above. Optionally, a touch panel operator station can be connected to the system. Interface screens for maintenance and drive control are then confi gured. The keypad provides real-time drive data and operator interaction.

• Hardware Design. All equipment is specifi ed per the project requirements, and a complete set of elementary diagrams, layout, and outline drawings is created.

• Component Procurement. We work with our parent companies to source the most cost effective system components for your application.

Detailed Hardware/Software Design & Procurement

Electrical andmechanical prints

Control logic anddrive configuration

Keypadconfiguration


System Test

TMEIC understands the importance of a thorough system test. Our engineering team conducts a comprehensive factory test before shipment.

For example, the Dura-Bilt5i MV drive tests in the factory include:

• Full voltage check of power cells, insulation, and control circuits

• Acceleration and run test with unloaded MV motor

• Full current test into a reactor

• Validation of all I/O interfaces

• Validation of the drive test modes and any special logic, or optional PLC

Factory validation of the drive control system is available as an option, either in Roanoke, Virginia, or in Houston, Texas.

Validation of the optional LAN interface, DCS link, and PLC sequencing and logic can be done as shown opposite. Drive, motor, and load simulators are available if required. Using the simulated equipment, the PLC can be run through its sequencing and the resulting outputs validated.

Note: Logic for synchronizing a single motor to the line can be included in the Dura-Bilt5i controller, so a PLC is not required for this.

Dura-Bilt 5i MV Drive Factory Test

Dura-Bilt 5i MV Control System Validation in the Factory

Diagram of Dura-Bilt5i MV Control System Test Setup

Operator's Keypad

Digital Motor Simulator

Digital LoadSimulator

DB5i Microprocessor Controller

Local Area Network to DCS

Optional PLC with Logic,for example to soft startmultiple motors

I/O modules

PLC

CPU

Software tool for Drive and Logic Configuration

M Load

Drive Simulator software

Drive Control

Logic Control

Firing Control

LAN Interface


System Commissioning

Along with the hardware and software, TMEIC delivers complete system documentation:

• An electronic instruction book with all the prints on CD with a hyperlink index

• Recommended wiring and grounding procedures

• Renewal parts list

• Standard third-party vendor documentation

At the end of the project, the drawings are updated to refl ect the fi nal changes.

Drive Training at the Factory or in Your Plant

Complete and Detailed Drive System Documentation

Customer engineers, maintenance and operations personnel are trained on the drives and control system at the TMEIC Training Center in Virginia. This world-class facility features large classrooms and fully-equipped training labs.

Classroom and hands-on training consists of 50% class time and 50% hands-on lab time. Topics include:• Overview of the drive system• Function of the main assemblies• Technical details of the components• Drive and control system tools• System diagnostics and service

As an alternative to the standard factory training in Virginia, TMEIC can offer a course tailored to your project and held at your location. In this case, a project engineer trains your operators, maintenance technicians and engineers in your facility.

In the commissioning phase, the TMEIC team includes the field engineers you know and trust, alongside the engineer who designed and tested the system. This overlap of teams between engineering design and the site ensures a smooth and on-schedule startup.

The TMEIC service engineer, who is responsible for startup and commissioning, and for any future service required at the site, is part of the project team and participates in the factory system test to become familiar with the system. Commissioning is supported by TMEIC design and service engineers.


TMdrive®-10e2 Low Voltage System Drive

kWHp

440/460 AC

575/690 AC

Volts

200268

10001,340

2000

2680100134

50

67

The family of low voltage AC system drives has an integral DC bus structure with a wide variety of inverters (DC to AC) and converters (AC to DC) to match virtually any application in the paper industry.

• 400, 460, 575, or 690 volt operation

• Motor power up to 1,949 kW

• Regenerative converter option

Draw-Out Style InvertersFor applications up to 193 kW (249 hp), draw-out style inverters are available in a very compact package.

Draw-out inverters are mounted on heavy-duty slides with staggered dc bus connectors on the back that connect with the bus when slid into the cabinet.

Motor cables are terminated at a common terminal block in the bottom of the cabinet.

Heat Pipe Cooling TechnologyThe use of heat pipe technology provides a dramatic advance in power bridge cooling, including a significant reduction in the footprint of the power bridge, and fewer fans lower the audible noise.

The Thermal Cycle

Condensate to VaporIGBT’s are mounted to the multi-channeled chill plate which cools them. Heat generated by the IGBTs vaporizes the refrigerant, moving it upwards through the chill plate to the finned condensing unit.

Vapor To CondensateCooling air is pulled up through the IGBTs and the condensing unit, and cools the refrigerant, which condenses back to liquid.

Return of CondensateThe condensed refrigerant returns to the bottom of the chill plate to start the thermal cycle over again.

1

2

3

Condenser

IGBT powerswitches

ChillPlate


Three-digit display alternates between speed and current while running, or a fault code when there is an error.

TMdrive-10e2 Operator Interfaces

LEDs give a quick indication of the status of the unit.

LED indicationReady On when the unit is ready to run

Running On when the unit is running

Alarm/Fault Blinking LED indicates alarm condition, while solid LED indicates a fault

DC Bus On when DC Bus is DischargedDischarged

NavigationAllows adjustment of drive parameters from the front of the equipment

ControlsAllow the equipment to be controlled in local mode from the front of the equipment.

• Reset faults, reverse direction, inc./dec. speed, jog, run and stop are available.

• Switch to local mode to allow operation at this control panel.

Optional analog meters can be supplied in addition to either the standard or enhanced display. Standard inverter I/O includes meter driver outputs that are +/- 10 V with 10-bit resolution. For cabinet style equipment, four meters are provided. For draw-out style, two meters are provided for each inverter.

LEDs give a quick indication of the status of the unit.

LED indicationReady On when the unit is ready to run

Running On when the unit is running

Alarm/Fault Blinking LED indicates alarm condition, while solid LED indicates a fault

DC Bus On when DC Bus is dischargedDischarged

RJ-45 Ethernet port is used for local tool connection

Interlock button disables the drive

Standard Display

Optional Enhanced Keypad

Draw-out Enclosure Displays

Cabinet Enclosure Displays


The TMdrive-MVG is a general-purpose, medium-voltage, variable-frequency AC drive for industrial power ratings up to 10 MW, in the voltage range of 3/3.3 kV, 6/6.6 kV and 10/11 kV.

Featuring high-quality Japanese design and manufacture, the TMdrive-MVG works with existing or new induction motors and meets users’ basic system requirements as described below.

High reliability, low harmonic distortion, and high power factor operation are designed into the MVG drive.

The TMdrive-MVG is available in 3 voltage classes:3 – 3.3 kV Voltage Class: 3,000 – 3,300 V ac6 – 6.6 kV Voltage Class: 6,000 – 6,600 V ac11 kV Voltage Class: 10,000 – 11,000 V ac

TMdrive®-MVG

Features Benefi ts

Conservative design using 1700-volt IGBTs (Insulated Gate Bipolar Transistor)

Highly reliable operation and expected 12-year drive MTBF, based on fi eld experience with the large global installed base of TMdrive-MVG technology

High energy effi ciency over 97% (design value) Considerable energy savings, in particular on fl ow control applications

Diode rectifi er ensures power factor greater than 95% in the typical speed control range

Capacitors not required for power factor correction

Multiple level drive output waveform to the motor (13 levels for the 6.6 kV inverter)

Direct drive voltage level

No derating of motor for voltage insulation or heating is required due to motor-friendly waveform No output transformer required

Multi-pulse converter rectifi er and phase shifted transformer

No harmonic fi lter required to provide lower harmonic distortion levels than IEEE-519-1992 guidelines

Designed to keep running after utility supply – transient voltage dropouts – up to 300 msec.

Uninterrupted service for critical loads

Input isolation transformer included in drive package

Better protection of motor

Simplifi ed installation

Lower cost installation

kW200100 40001000 10000

11,000 AC

10,000 AC

6,000 AC

3,000 AC

Volts


Modular Architecture Creates Performance Advantages

Air Cooling Forced air cooling system with:

Intake through cabinet doors Upwards flow through inverter cells and transformer Exhaust at top of cabinet Optional redundant cooling fan system is available.

Cell inverters Example: six banks of three, series connected inverter cells:

I/O Board The I/O board supports encoder, 24 V dc I/O, 115 V ac inputs and analog I/O, standard. All I/O are terminated to a two-piece modular terminal block for ease of maintenance.

Control Functions A single set of control boards feeds all inverter cells. The primary control board performs several functions: Speed & torque

regulation Sequencing I/O mapping Diagnostic data

gathering Provision for optional

LAN interface

Inside the TMdrive-MVG Cabinet – an example of the 6 kV class drive with inverter cell detail.

Seriesconnectedinverter cells

.

M Input transformer, phase shifted secondary windings (18-pulse equivalent)

TMdrive-MVG (3 kV class)

.

M

.

TMdrive-MVG (6 kV class)

. .

..

...

.

.

.

.

.

Dioderectifier

Single phaseinverter

Inverter Cell Module removed from rack

DC-buscapacitor

Power supply 3.0/3.3 kV three-phase 50/60 Hz

Power supply6.0/6.6 kVthree-phase50/60 Hz

Input transformer, phase shifted secondary windings

Inverter Cell Module

Diode bridge rectifier IGBT PWM inverter DC link capacitor

Input Transformer The special input transformer has phase-shifted secondary windings to produce multi-pulse converter operation. This design exceeds the IEEE-1992 guidelines for current distortion.


The TMdrive-XL55 is a medium voltage, ac fed drive designed for high-effi ciency and power-friendly operation in a broad range of industrial applications.

High reliability, low harmonic distortion, and high power factor operation are designed into the drive.

The TMdrive-XL55 is available for 6.0 – 6.6 kV voltage class output.

TMdrive®-XL55 6.6 kV Drive

Features Benefi ts

Conservative design using 4500 V IGBTsHighly reliable operation, expected 10-year drive MTBF

High energy effi ciency approximately 98.6% Considerable energy savings

Diode rectifi er ensures power factor greater than 95% in the speed control range.

Capacitors not required for power factor correction

36-pulse converter rectifi er by using separated phase shifted transformer.

No harmonic fi lter is required to provide lower harmonic distortion levels than the IEEE-519 guidelines.

Multiple level drive output waveform to the motor (fi ve levels for the 6.6 kV inverter)

Suitable for standard motors due to motor friendly wave form.

Synchronous transfer to line option with no interruption to motor current

Allows control of multiple motors with one drive

No motor current or torque transients when the motor transitions to the AC line

Remote input isolation transformer

Less power loss in drive room

Less total space required

Simplifi es design and installation

6.6 kV direct drive voltage output levelNo output transformer required, saving cost, mounting space, and energy

Volts

6,600

1,0001001,340134

20,00026,820

kWHp

10,00013,4005,364

4,000


The TMdrive-Navigator tool helps you maintain TMEIC drives yourself. Engineers and technicians are empowered to understand how the drive works and what the drive is doing. Any user can easily access current drive expertise and know-how

Desk-top like search technology links topical signal lists, block diagrams, help fi les, productdocumentation, change history, and user notes. Windows techniques facilitate navigation within a drive and across the system. The status of all drives is always in view.

High-speed data is automatically captured and saved in the event of a drive fault. Users may also capture high speed data based on their own trigger conditions or perform high resolution real-time trending.

Fault data can be automatically “pushed” to key users. The client-server architecture allows access to high performance data from remote locations – with the same resolution as if you were in the plant.

Wizards support tuning of drive functions.

Live block diagrams provide a real-time graphical view of drive functions. Functions can be confi gured directly from the graphical view. Product documentation is integrated right into the tool. Users may even capture their own notes to benefi t future troubleshooting.

Compatible with:• Windows XP, Vista 7• Windows Server 2003, 2008

TMdrive-Navigator - Simple Configuration and Maintenance


TMdrive-10e2 TMdrive-50 TMdrive-MVGTMdrive-XL55

Global Offi ce Locations:

TMEIC CorporationRoanoke, Virginia, USAEmail: [email protected]: www.tmeic.com

TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION (TMEIC)Tokyo, JapanTel: +81-3-5444-3828Web: www.tmeic.com

TMEIC Europe LimitedUK (London) Tel.: +44 870 950 7212Italy (Bari) Tel: +39-080-504-6190Germany (Frankfurt) Tel: +49-6968-194722Poland (Krakow) Tel: +48-12432-3400Email: [email protected]: www.tmeic.eu

TMEIC Industrial Systems India Private LimitedAndhra Pradesh, IndiaEmail: [email protected]: www.tmeic.in

© 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION. All Rights Reserved.

TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION (TMEIC)Beijing, ChinaEmail: [email protected]: www.tmeic-cn.com

TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION (TMEIC)Shanghai, ChinaEmail: [email protected]: www.tmeic-cn.com

TMEIC Asia Company Ltd.Kowloon Bay, Hong KongKaohsiung, TaiwanWeb: www.tmeic.com

All specifi cations in this document are subject to change without notice. This brochure is provided free of charge and without obligation to the reader or to TMEIC. TMEIC does not accept, nor imply, the acceptance of any liability with regard to the use of the information provided. TMEIC provides the information included herein as is and without warranty of any kind, express or implied, including, but not limited to, any implied statutory warranty of merchantability or fi tness for particular purposes. The information is provided solely as a general reference to the potential benefi ts that may be attributable to the technology discussed. Individual results may vary. Independent analysis and testing of each application is required to determine the results and benefi ts to be achieved from the technology discussed.

TMdrive is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION.TMEIC is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION.TM is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION.

I-1108-A4

A Family of Drives up to 11 kV

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