Cog Brochure Revc_lowres

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ABB drives in chemical, oil and gasMedium voltage drives for greaterprofitability and performance


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ABB one of the worlds leading suppliers of variable speeddrives in the chemical, oil and gas industries

Most of the processes in the chemical, oil and gas industriesare complex and are exposed to the harshest environmentalconditions. These conditions put a high demand on the processequipment. Achieving high levels of efficiency and availabilitywill translate directly in an increased production output and animproved product quality .

A pioneer in AC drive technology, ABB s ta rted research inthe 1960s and industrial production in the 1970s. Today, ABBis one of the worlds leading suppliers of variable speed drivesystems. To date ABB has installed medium voltage driveswith a total rated power of more than 40,000 MVA.

Leading-edge drive technology in chemical, oil andgas industries

Al l p rocesses in the chemical, oi l a nd gas industries canbenefit from variable speed drives (VSDs).

Upstream ApplicationsOil and gas production and gathering PumpsGas treatment CompressorsGas exportSubseaMidstreamOil and gas transportation and distribution PumpsOil and gas storage Compressors

Gas liquefaction (LNG/CNG)Gas to liquid (GTL)Liquefied petroleum gas (LPG)DownstreamPetroleum refining PumpsPetrochemical plants Compressors

Air separation plants ExtrudersChemical industry Mixers

Blowers



Variable speed drives in chemical, oil and gas

The investment in high efficiency, largely maintenance-free,variable speed drives helps to keep costs under control.

Higher efficiency and less emissionsEnergy saving has never been higher on the agenda thantoday. People have become increasingly aware of the correla-tion between wasting energy and environmental damage andacknowledge the benefits of conserving energy by technicalmeans. By employing variable speed drives instead of throttlingor using by-pass vanes, the energy bill can be reduced byas much as 60 percent. ABB electric drives reduce NO xand CO 2 emissions on site that could delay granting of a

permit and cause penalties.

The power required to run a pump or a compressor is roughlyproportional to the cube of the speed. In other words, a pumpor compressor running at half speed can consume as littleas one eighth of the energy compared to one running at fullspeed. A small reduction in speed can make a big differencein the energy consumption. As many pump and compressorsystems often run at partial load, the use of a variable speeddrive can produce huge savings.

Power consumption for various pump control methods

Minimized environmental impact Variable speed control is the most eco-ef cient way to optimizeprocess performance. Variable speed drives reduce energyconsumption and NO x and CO 2 emissions. Furthermore, ABBselectric drives are designed using state-of-the-art DFE (Designfor Environment) guidelines covering the complete product lifecycle. This entails a long-term commitment to waste reductionand to reuse and recycle components.

Improved control and flexibility of processesOutputs of oil and gas fields can vary greatly in their com-pounds, density, volume flow rates and pressure levels. Thisimposes varying operating conditions on process equipment,which means that compressors and pumps, which mustexhibit a high degree of flexibility, cannot always be operatedat their optimum design point. The employment of variablespeed drives offers the possibility to control the processsimply and effectively by speed control and to run equip-

ment at its optimum operating points.



Improved product quality The p roduct qualit y opt imization of some plastic mate rialsrequires operating flexibility over a distinct speed range.

Variable speed drives adjust the speed prec ise ly to optimizethe operation of process machinery.

Power conversionSome processes have an energy excess, which can beconverted into rotating power. With variable speed drives

this rotating power can easily be converted into electricalenergy, synchronized to grid frequency and fed back intothe supply network.

Reduced starting impact on network and machineryStarting machinery with heavy load torque and/or highmass moment of inertia imposes large stresses on the supplynetwork and the mechanical parts of the shaft string of theinstalled equipment. A direct-on-line started electric motorcan cause starting currents of up to six times of nominalcurrent. This will, i n weak supply n etworks, cause massivevoltage drops on the supply bus as is often seen in remote

areas or offshore facilities.

Soft-starting machinery with variable speed drives resultsin the following benefits:

No voltage drops upsetting the process; no trips on otherelectrical devices on the same bus

No excessive thermal and mechanical stress on themotor leading to a longer lifetime

No mechanical stress on the shaft system leading to alonger lifetime

Immediate start-up without warming up delay (eg turbines) Gentle process start-up, controlled in all respects from

zero speed

All these factors contribute to high reliability and maximumavailability of a plant.

Benefits of variable speed drivesHigh performance and reliability increases plant availabilityand decreases maintenance costsSmooth torque over the entire speed range reduces noiseand vibration levels, which minimizes mechanical stressBetter efficiency, particularly at partial load results in lowerenergy costsNo inrush currents and voltage drops during startingRegeneration of rotating power and braking capability

Improved speed control and process optimizationEnhanced operating flexibility to suit the process needsLower impact on piping/valve system results in longer equipmentlife and less maintenanceBetter dynamic performance during starting and during supplygrid turbulencesNo on-site emissions

Motor current for various starting methods



Full drive package responsibility A single source of fering consolidated a nd coordinated work from design to production, testing, delivery and commissioninggives the following advantages to ABBs customers:

Minimized risk and reduced commissioning time

Optimization of the complete drive system with all associ-ated auxiliaries

System design supported by a professional engineeringteam and sophisticated IT tools

Integrated manufacturing and delivery schedules of thecomplete drive system

Verification of the functionalit y, as well as the load perfor-mance of the drive system

Fully integrated documentation

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Commissioning

Transport and erection

Main components of a variable speed drive system

ABB has the ability to offer the entire drive system, consistingof transformer, frequency converter, motor and auxiliaries.

The variable speed drive system components are s electedand engineered to ensure optimum operation, meeting therequirements of the application and complying with interna-tional standards for electrical equipment.

Power supply, mechanical interface, control interface,cooling, enclosure protection class, building constraints,cable terminations, transport lots and ambient conditionsare site dependent and are taken into consideration byproject engineering.

Al l system components are routine tested according tointernational standards. When required, acceptance testscan be performed in ABBs well equipped testing facilities.

Reliability and availability is a must ABB ensures the highest reliability by implementing standards

and procedures of quality in design and production conformingto ISO 9001. Tests are perfo rmed at various stage s duringthe manufacturing process in addition to the final tests beforedelivery. Redundancy of wearing components (eg coolingpumps) can be provided to increase availability while ena blingmaintenance intervals to be extended.



Medium voltage drives

The heart of the variable speed drive system is the frequencyconverter. ABB offers the entire range of frequency convertersfor medium voltage applications in the power range from 250 kWto more than 100 MW.

ABB medium voltage drives have been designed to ensure a longlifetime in harshest environments as can be found in chemical, oiland gas applications. ABB offers air-cooled and water-cooledconverters for different power and voltage requirements.

ACS 1000 (315 kW 5 MW, up to 4 .16 kV) The ACS 1000 is suitable for both ret rof it applications andnew standard induction motors. Due to its unique outputsine filter bearing currents and voltage reflections areeliminated. It is available with air and water cooling. The

ACS 1000i is a fully integrated drive including input transformerand input contactor.

ACS 2000 (250 1,600 kW, 4.0 6.9 kV) The ACS 2000 is sui tab le for retrofit applications and newstandard induction motors. It can be used without an inputisolation transformer, thereby allowing a direct connection to

the line supply (direct-to-line), with an integrated transformer,or for connection to an external input isolation transformer.

The ACS 2000 is available with an Act ive Front End (AFE) tominimize harmonics. It is also available for four-quadrantoperation for energy regeneration and reactive powercompensation.

ACS 5000 (2 32 MW, 6.0 6.9 kV) The ACS 5000 can be applied to standard industrial motors(induction, synchronous and permanent magnet) up to 6.9 kV.It is available with air and water cooling. The air-cooled

ACS 5000 can be delivered with integrated or separate input

transformer. The ACS 5000 is ideal for applications such aspumps and compressors (including high speed compressors).

ACS 60 00 (3 27 MW, up to 3.3 kV) ABBs water-cooled ACS 6000 is a modular drive designedfor the most dynamic and powerful single or multi-motorapplications for synchronous, induction and permanentmagnet motors. Inter-related motors can be connected to

the same ACS 6000 via common DC bus, enabling multi-machine operation with only one supply unit. It is the idealsolution for petrochemical applications such as extruders.

MEGADRIVE-LCI (2 72 MW or higher on request) ABBs MEGADRIVE-LCI is an optimal solution for highvoltage and high power converter applications. It is alsoavailable as soft starter for applications with synchronousmotors. Standard air-cooled and water-cooled designs areavailable for ratings up to 72 MW, engineered designs formore than 100 MW.

PCS 8000 (25 100 MW, up to 6.6 kV) The P CS 8000 is the r ight selection for high power com-pressor drives. It is a modular voltage source inverter withoptional semiconductor redundancy.



Medium voltage drives technology highlights

Reliability is the main guiding principle of the research anddevelopment activities for medium voltage drives.

EncoderlessEncoders are known to cause failures. They have an exposedposition on the motor. ABBs medium voltage drives can operatewithout encoder, thereby reducing maintenance costs andensuring high levels of availability.

Remote monitoring and diagnostics

DriveMonitor TM

allows secure real-time access to th e drive.It supports monitoring and diagnostics of ABB drives indepen-dent of the implemented control method, thus also enablingthe connection of existent installations.

The o ptional tool consists of a hardwa re module, as well asa software layer that automatically collects and analyzesselected drive signals and parameters.

Long-term monitoring functions deliver important informationon equipment status, tasks needed and possible performanceimprovements. Diagnostic procedures and trending can cover

not only the converter itself but other parts of the shaft trainas well.

High speed direct drive for gas compressors ABB supplies high-speed variable speed drives for compressorapplications. Combined with a high-speed motor (above 200 Hz),the motor can be coupled to the compressor without using agearbox. This compact solution requires less space and mainte-nance, has a lower noise level and a considerably higheravailability compared to a solution utilizing a step-up gearbox.

Direct Torque Control (DTC) The ACS drive control platfo rm is based on ABBs awardwinning Direct Torque Control (DTC), resulting in the highesttorque and speed performance ever achieved in mediumvoltage drives. Control of the drive is immediate and smoothunder all conditions.

Power loss ride throughDue to its power loss ride through function, the drive systemis able to withstand disturbances of the power supply. The drivewill continue to operate in an active but non-torque producingmode if the incoming supply voltage is cut off. The drive willbe active as long as the motor rotates and generates energyto the drive. It will resume normal operation immediately uponreturn of power supply.

Low parts count The fewer the par ts the higher the rel iabili ty. ABB uses highpower semiconductor switching devices and a topology that

brings down the part count to a minimum.

Fuseless design ABB medium voltage dr ives are designed to operate safelywithout fuses which are known to be unreliable, costly andsubject to aging. The fuseless design results in less spareparts and fast re-starting after an overcurrent trip.



Motors

ABBs medium voltage motors have earned an excellent repu-tation for performance and reliability. ABBs product rangeincludes induction as well as synchronous motors.

Induction motorsSquirrel cage induction motors are the workhorses of theindustry due to their versatility, reliability and simplicity. Inthe power range up to 12 MW a squirrel cage induction motoris usually the first choice. ABBs broad range of mediumvoltage AC induction motors includes ribbed cast iron fancooled motors and modular type welded frame motors. The

power range runs up to 23 MW. All ty pes of motor coolingmethods and enclosures are available, eg air or water desi-gned for installations in harsh environmental conditions aswell as for installations in hazardous areas. Different moun-ting designs - horizontal or vertical - are available.

Synchronous motorsSynchronous motors are typically considered for higherpower ratings (above 8 MW). In addition to the ir high powercapabilities, synchronous motors offer the benefits of highefficiency and high performance through the utilization of different rotor designs. New developments in permanentmagnet rotor designs have in some cases even eliminated

the need for the excitation circuit. As with modular inductionmotors, synchronous motors are available air or water cooled,self or forced ventilated. Designs for harsh environmentalconditions or hazardous areas are available as standard options.

Induction motor Synchronous motor



Converter transformers Application-specif ic dimension ingConverter transformers are especially designed for operationwith variable speed drives. They are built to match the requiredpulse number and the windings are capable to withstandharmonic currents and any mechanical stress caused bysteep current peaks.

Wide range of options

Converter transformers are available for nearly all ratingsand primary volt ages of more than 100 kV. Secondar yvoltages are optimized to match the conver ter and motorvoltage. Oil or dry ty pes for indoor or outdoor mounting areavailable. Transformers with a fourth winding for connectingharmonic filters are available. Busbar connections can alsobe provided.

Flexibility of location A separate t ransformer allows flexible instal lation, whichcan be next to the drive or, when space is limited, in anotherlocation. Transformers are generally installed outdoors for

safety, space savings and lower heat losses into the electricalroom. Alternatively, ABB offers variable speed drives fordirect-to-line connection or with integ rated transformer.

FiltersWhen designing a variable speed drive system, ABB paysspecial attention to minimizing the influence variable speeddrive systems can have on the power factor and ha rmoniccontent of the supply system. In almost all cases ABBsstandard design meets IEEE 519 requirements. ABB canoffer network evaluation for harmonics.

For special customer needs and high power ratings in weak networks, filters and power factor correction equipmentcan be provided.

Recooling equipmentFor sites where cooling water is not available ABB can offerfin-fan coolers or chillers for the cooling circuit of water-cooled frequency converters.

Switchgear ABB offers medium voltage distribution switchgear for a lldrive sizes and other distribution tasks in the plant. Theproduct range covers air and gas insulated panels with gas

or vacuum circuit breakers.

Outdoor control houses To reduce the time and cost of construction, instal lat ionand commissioning at site, outdoor control houses can beprovided. The control houses for the converter and its auxilia-ries are tailored to the specific needs and site conditions.Mezzanine floor for cabling and piping, air conditioning andfire detection are standard options.

Preinstalled and tested control house

Transformers and auxiliaries

ABB also offers transformers, filters, recooling equipment,switchgear and outdoor control houses.



Testing of variable speed drive systems

Thorough testing ensures proven functionality and performanceand reduces commissioning time.

To verify that qualit y s tandards and customer requirementsare fully met every component of a drive is subjected tothorough testing in ABBs modern test facilities.

Routine testsRoutine tests and functional tests form an integral part of thescope of supply of ABB medium voltage drives. They areperformed in accordance with international standards (eg IEC)and ABB quality assurance procedures (ISO 9001).

Combined tests ABB offers the possibil ity to perform a combined test w iththe complete drive system, including trans former, converterand motor.

Depending on the project requirements, the drive systemcan be tested with or without load.

With such a test the functionality as well as the loadperformance of the drive system can be verified. This willconfirm the design data and verify performance values as

well as reduce installation and commissioning time on site.

A full load test can, for example, be done with a back-to-back test setup. Back-to-back tests can be performed if twoidentical MEGADRIVE-LCI drives are ordered at the same time.

One drive system works in motor mode and i s loaded witha second drive system working in generator mode.

Back-to-back testCombined testwith load

Combined testwithout load

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Illustration of extended test layouts

Back-to-back test 48 MW / 3,500 rpmBack-to-back test 8 MW / 3,6 00 rpm



Electric versus gas turbine drives

The question of the relative merits of e lectr ic and gas turbinedrives is playing an increasingly important role in the decision-making process, especially at higher ratings. Frequently thediscussion is initiated by environmental aspects.

When electric power is available, an electric drive offerssignificant advantages. This is the driving force behind theenormous increase in the number of electric drives beinginstalled. The table below compares the most importantfeatures of the two solutions.

Comparison of Gas turbine Variable speed driveEfficiency low very highInvestment cost high mediumOperating cost to be evaluated to be evaluatedMaintenance high (important) very lowReliability medium high

Availabilit y medium highMean time to repair a factor to be considered very lowPollution, emissions high noneSpeed control range limited wideSpeed control accuracy medium highDesign flexibility low highStarting time medium to high shortNoise level very high medium

Influence on power supply none investigation requiredEnvironmental permit required not required

Refrigeration compressors in LNG plants were traditionallydriven by gas turbines. Gas turbines, however, must havestarting aid and require constant maintenance. Moreover,their efficiency deteriorates during their lifetime for several

reasons and at high ambient temperatures the rated outputpower of gas turbines decreases. By adding a variable speeddrive to the compressor shaft string, the electric drive startsthe gas turbine and can also compensate the declining drivingpower of the gas turbine at high ambient temperatures. Theseso-called starter/helper drives can also be operated as powergenerators when one of the gas turbines is running on excessof power to balance the power consumption between tworefrigeration trains.

If reliable electric power supply is available, the starter/helperdrives can be upsized to fully rated variable speed drivesystems to substitute the gas turbine. The entire liquefactionprocess can be optimized since variable speed drive systems

are more efficient at part load and require less shut downperiods for maintenance.

The fo llowing benefits, result ing from th is change, will lead toincreased profitability:

Lower investment cost Higher up-time (more production hours per year) Less maintenance Reduced operation/production cost

Optimizing costs and processes in LNG plants wi thvariable speed drives



Variable speed motor versus fixed speed motor withhydraulic coupling

For decades hydraulic couplings have been used in manyprocesses to control the speed of compressors and pumps.

Al though the p rinciple is wel l e stablished, development hasreached a stage where, in view of the advantages of a vari-able speed drive, the situation warrants reappraisal.

The t able below c ompares the most import ant characteri-stics of the two solutions.

A variable speed drive has a much higher ef ficiency, whichconsiderably reduces the overall life-cycle cost. The high inrushcurrent of xed speed motors can cause serious problems onweak power systems. The limited speed control range, thelack of supersynchronous speeds, the poor dynamic responseand higher maintenance cost are other points which limitthe application of the hydraulic coupling. The investmentcost for both solutions are roughly comparable.

The o ptimum drive sys tem has to be selected on the basisof the specific plant data, ie speed control range, powerrating, load characteristic, duty cycle, energy cost andreturn on investment.

Taking all these factors and the total life-cycle cost into consi-deration, an electric variable speed drive is the best solution.

Comparison of Hydraulic coupling Variable speed driveEfficiency low (varies with load) high (over entire load range)Cooling requirements high lowInitial investment cost low mediumMaintenance high low

Availabil it y medium to high high Total li fe-cycle cost high very l owInfluence on power supply none minimal with suitable topologyInrush current from supply up to 600% of rated current less than rated currentDynamic response low highEnvironmental influence high oil volume hazard noneSpace requirement at motor extended shaft length noneWeight very high mediumSpeed control range limited wide and easy to adjust

Mean time to repair several days few hours

The calculation is based on the following data:Power: 9 MW; service life: 15 years; cost per kWh: $0.07;operating time per year: 8,000 hours

VSD vs. hydraulic coupling

Break-even point 1.5 years

Net return on investment 900%

Net present va lue of savings $7,000,00 0Life-cycle cost savings 20%


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Service and support

ABB drives are backed by comprehensive service and support,from the customers initial inquiry throughout the entire life cycleof the drive system.

Technical advice As originato rs of AC drives technology in the late 1960s, ABB has over 40 years of applicat ion know-how in all indus-trial sectors, in virtually every country. ABBs specialistsare located around the world to offer advice that ensurestrouble-free operation of ABB drives.

Installation and commissioningProper installation and commissioning of the equipment,done by qualified and certified commissioning engineers,reduces start-up time, increases safety and reliability anddecreases life-cycle costs. In addition, operators can begiven practical training by experienced specialists on site.

Life-cycle management ABBs drive life-cycle management model maximizes the valueof the equipment and maintenance investment by maintaininghigh availability, eliminating unplanned repair costs and exten-ding the lifetime of the drive.

Life-cycle management includes: providing spare parts and expertise throughout the life cycle providing efficient product support and maintenance forimproved reliability

adding functionality to the initial product providing a smooth transition to a new technology at theend of the life cycle

Training ABB provides extensive training for its medium voltage drives. A range of training programs is of fered f rom basic tutorials toprograms tailored to the customers specific needs.

Global network, local presence After sales service is an integral part of providing the customer

with a reliable and efficient drive system. The ABB Group of companies operates in more than 100 countries and has aworldwide network of service operations.

Services for ABBs medium voltage drives Supervision of installation and commissioning Training Remote services Customized service agreements Preventive maintenance Local support 24 x 365 technical support

Spare parts and logistics network Worldwide service network


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