Nidec Industrial Solutions Digital Drive Upgrades - WMEA...

Nidec Industrial Solutions – Digital Drive Upgrades

2 Date Title, Author(s) Nidec Avtron Automation Company Confidential

What do we provide for Mining?

Drives, Motors, DC Power Supply, Encoders, and Systems

AC Drives DC Drives Encoders SR Drives

Drive Systems

Motors

MV Drives

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Introduction to Nidec Avtron Automation

March 19, 2014; Company Confidential

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Electric Shovels Electric Blasthole drills

Mining Industry Experience

Mine Hoists Draglines

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Overland Conveyors

Mining Industry Experience

Rectifiers

Overhead Cranes Crushers/Sizers

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Mining Shovel Experience

P&H 4100A

P&H 4100BOSS

P&H 4100TS

P&H 4100XPB

P&H 2800XPB

P&H 2800XP

P&H 2300XPB

P&H 2100BLC

BE 295B

BE 195B

Marion 301

Marion 191M


Drive Systems and Service

Capabilities and Expertise

• Drive and Drive System Manufacturing

• Project Management

• Design Engineering

• Installation, Startup, and Commissioning Services

• Custom enclosures and packaging

• Drive retrofit solutions

• PLC application and programming

• HMI application and programming

• Dedicated diagnostic systems

• Power quality studies

• Remote Machine Monitoring

• Training

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Scary times in the Mining Industry

Mining company stock capitalization is down from $2.5 Trillion in 2011 to less than $1 Trillion in 2015

4500 machines have been removed from service since January 2014 (Trucks, shovels, draglines, drills, large dozers, and wheel loaders)

Coal has gone from 50% of our power generation to 30-35% due to cheap natural gas and certain political opposition

Copper prices are at a six year low

Iron Ore is plagued by low prices and over capacity

Major layoffs from many OEMs in the Mining Industry

Plenty to Worry About…


New OEM Truck/Shovel Shipments

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But even scary times eventually end..

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Until the markets stabilize, how do you keep production up on a limited budget?

Mines must keep equipment running to stay in business

Have to manage available cash in a down market

Need to keep machine availability high to maintain cash flow until market stabilizes

Mines will need to upgrade existing equipment versus buying new machines

Smaller maintenance staffs, less capital, dealing with aging, obsolete equipment


Hardware Obsolescence is Rampant

Most OEMs operate with a 7 year product life cycle – and most excavators dig for 30-40 years


Shovel Electrical Drive Upgrade Options

Complete AC Drive and Motor Upgrade – Great technology for a new machine, but hard to justify in today’s market for an upgrade

DC Drive upgrade – Replace obsolete controls at reasonable cost, short downtime

PLC Upgrades – Add Ethernet and better Diagnostic capability

Remote Diagnostics – Save time on fixing problems

RPC Upgrade - Reduce capacitor cost by implementing rolling bank

Operator Chair and Controls – Happy operator, happy life.


What is important in choosing a drive system partner?

Reliability and ruggedness of hardware

Experience and focus on mining applications and equipment

Proven long-term support of hardware

Training

Spare parts availability

Overall system cost

Diagnostic capability

Good documentation

Referrals


9 Steps for a good drive upgrade project

Initial Meeting to discuss Scope of Supply

Machine survey

Design Review

Pre-startup planning meeting

Installation

Startup and Commissioning

Training

Spare parts on site for startup

Follow up meeting


Machine Survey

Provide the most up to date drawings

Provide machine setup sheet (C sheets)

Take recordings of typical operation for

a baseline

Take X-Y recordings (Dataq)

Define work scope required

Define work to be performed by the mine

and by the supplier


Design Review and Pre-Startup Planning

Review of System Design by Project Engineer,

Site Service Lead, and Mine Lead Electrical Contact

Define work to be done and when by Mine,

Drive Supplier, and outside Contractor (if used)


Installation and Commissioning

Success relies on how much planning and communication is done ahead of time


Training

Training on the system should be done right before or after startup

Students tend to be more attentive right around startup, stress is a great motivator to pay attention!

Most drive and logic issues come up within a week or two of startup. Having a service engineer/trainer remain after startup provides security and a real hands-on training experience.


Spare Parts and Remote Access

Kind of like going to the dentist…Spares are a bit of a pain but well worth it

Most hardware failures occur during startup. Mis-wiring is the most common cause. Having spare parts on hand is critical. Parts are still under warranty and it provides an insurance policy to keep the machine running.

Asking for a remote interface from some IT departments can also be a struggle….but can save so much time and production with faster response.


Recent Drive Upgrades

Large P&H 4100TS machine in Oil Sands – Oil prices crashed, went from boom times to watching every penny, obsolete controls, needed to improve support

P&H 4100A machine in Wyoming - Limited staff with only two shovels cannot afford downtime, had obsolete drive controls, wanted to improve remote diagnostic capability and supportability

Marion 191M in North Dakota – Unsupportable drive hardware with rare topology, needed to keep machine running

Different needs, same end goal


Oil Sands 4100TS Upgrade

Upgraded to Avtron ADD-32 Plus Drive Controllers with Ethernet

Added ControlLogix PLC with Ethernet

Added MineView2 Diagnostic Package for long term diagnostics

Replaced Pulse Transformers

Customer wanted to upgrade controls for better supportability

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Mine went from 5 AFMs to 4, and updated to ControlLogix PLC

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Improved Diagnostics for Mine-wide System


Wyoming 4100A Upgrades

Upgraded to Avtron Drive Controllers, Field Supplies, and Pulse Transformers

Added ControlLogix PLC with Ethernet

Added MineView Diagnostic Package

New Chair

Improved Remote Diagnostic capability

Can now troubleshoot from office or

Truck over app, providing instant help

Improved Local Supportability –

Use of familiar PLC improves # of techs who

can be used to troubleshoot


Wyoming 4100A Control Cabinet and PLC

Designed as a drop-in replacement to reduce shutdown required


Wyoming 4100A Controllers and Fields


Wyoming 4100A Improved Diagnostics


Wyoming 4100A Upgrades

Toughest part of a system upgrade…..making the operators happy with new controls

Nice seat went a long way….


And finally, the unique one….

North Dakota lignite mines have some of the latest shovels and draglines in North America

They also do a great job of maintaining their existing machines

But like a family that appears perfect from the outside and has a crazy uncle in the attic, they keep a few machines around that are just a tad different….


The only Marion 191M still digging coal in the US is located in….North Dakota


Machine Problem

Obsolete Drive – designed when Pong was

released and Gerald Ford was president

No parts

No service

Mine had updated the PLC and operator interface to modern

hardware and wanted to retain and interface

Machine was still in good shape mechanically, with good

maintenance history

And like an old paid-for F150, it can still move hay!


A bit like a Cuban classic….

Beautifully maintained, but what the heck is that under the hood?


The 191M Employs a 4-Leg, or H Bridge

Developed in the 70s to provide decent power factor without switching capacitors

Conventional SCRs switch line to line, 4-legged bridges switched line to Neutral at low motor volts and “gear-shifted” line to line at higher motor volts which yielded a better average power factor than just switching line to line.

No longer supported – Hardware support issues helped GE migrate to a continuous RPC on the 301M, and P&H had a 7-step RPC in the 1980/90s which provided better power factor

This different topology required custom firing software


Existing “4-Leg” Bridge and Obsolete Controller


Let the fun begin – rip out and tear out


New Hoist Controllers with new firing modules on existing SCRs


New Swing Bridges in existing cabinet


New Crowd Bridge in existing cabinet


New Auxiliary Panels


Operator Cab PLC

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Results?

All three mines now have a supportable drive system with improved diagnostics at a small fraction of the cost of new.

Each mine can now get more hardware locally, reducing downtime and expenses.

Mine maintenance staffs can be cross-trained on fewer platforms.

Remote access capability provides each mine with faster support and improves machine availability and production.

Nidec Industrial Solutions – Digital Drive Upgrades

Nidec Industrial Solutions Digital Drive Upgrades - WMEA...

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