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CBIP Substation Manual_2006
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A y A year ear o o inninnovovatiations ons 66 Instruments Instruments that that harvest harvest energy energy 4747 Motors Motors without without sparks sparks 5252 Data Data sharing sharing in in substations substations 7373
InnovationInnovation
11
Abb Review Full description
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The cover o this issue oThe cover o this issue o ABB ABB
Review Review depicts aspects o thedepicts aspects o the striking architecture o the striking architecture o the YYas Hotelas Hotel in Abu Dhabi. While visitors canin Abu Dhabi. While visitors can hardly ail to notice the buildinhardly ail to notice the building’g’ss ascinating design, most will probablyascinating design, most will probably not be aware that another greatnot be aware that another great innovation is also contributing toinnovation is also contributing to their comort: ABB’s i-bustheir comort: ABB’s i-bus®® KNXKNX building control system.building control system.
The products and services The products and services o tomor-o tomorrow’row’s world will rely on s world will rely on the interplaythe interplay o numerous innovations in dierento numerous innovations in dierent areas o research and development.areas o research and development. This issue oThis issue o ABB ABB RevReview iew looks at alooks at a selection o recent breakthroughsselection o recent breakthroughs achieved by the achieved by the companycompany..
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development work development work
The smart eVolutionThe smart eVolution eVD4 brings simplicity and reliability to medium-voltageeVD4 brings simplicity and reliability to medium-voltage
distribution networksdistribution networks
A s A seiseismic mic swiswitchtch Certiied switchgear or nuclear power plants isCertiied switchgear or nuclear power plants is
providing a critical link in the chainproviding a critical link in the chain
Driving valueDriving value Sophisticated ring-geared mill drives rom ABB (Part 1)Sophisticated ring-geared mill drives rom ABB (Part 1)
Onshore and onboardOnshore and onboard Looking at the shoreside and shipside technologies andLooking at the shoreside and shipside technologies and
the case or standardization in shore-to-ship powerthe case or standardization in shore-to-ship power
The ive-level converter The ive-level converter ANPC- ANPC-5L te5L technolochnology and gy and the Athe ACS 20CS 2000 dr00 dr iveive
Harvest timeHarvest time Harvesting energy to create truly autonomous Harvesting energy to create truly autonomous devicesdevices
or industrial processesor industrial processes
Spark-ree saetySpark-ree saety Synchronous and induction motors and Synchronous and induction motors and generatorsgenerators
with guaranteed spark-ree operationwith guaranteed spark-ree operation
Motoring aheadMotoring ahead Synchronous motors controlled by Synchronous motors controlled by variable-speedvariable-speed
drives are bringing higher eiciencies to many industrialdrives are bringing higher eiciencies to many industrial
applicationsapplications
The other alternative uelThe other alternative uel Energy eiciency is a critical part o a sustainableEnergy eiciency is a critical part o a sustainable
energy policy or many power plantsenergy policy or many power plants
Surviving a strikeSurviving a strike ABB ABB helphelps ds dististribuributiotion trn transansormeormers rs survsurvive ive rapirapidd
voltage transientsvoltage transients
Sharing valuesSharing values ABB ABB is is implimplemenementinting tg the he irst irst commcommerciaercia l il instansta llatllat
IEC 61850-9-2 process-bus technologyIEC 61850-9-2 process-bus technology
The results are inThe results are in ABB ABB ReviReview ew readership surveyreadership survey
ProductivityProductivity
EnergyEnergy
QuestionnaireQuestionnaire
Peter TerwieschPeter Terwiesch Chie Technology OicerChie Technology Oicer
ABB ABB Ltd.Ltd.
Process plants use myriad sensors andProcess plants use myriad sensors and
actuators. Many o these actuators. Many o these require only smallrequire only small
amounts o energy to unction, but amounts o energy to unction, but
the continuity o this supply the continuity o this supply can present acan present a
signiicant challenge. An alternative to signiicant challenge. An alternative to
or batteries is extracting energy rom theiror batteries is extracting energy rom their
environment (eg, rom thermoelectric eectsenvironment (eg, rom thermoelectric eects
or vibrations).or vibrations). ABB ABB ReviReview ew looks at this in anlooks at this in an
article on energy harvesting.article on energy harvesting.
In the domain o In the domain o transmission and distri-transmission and distri-
bution, ABB has played and is bution, ABB has played and is
a major role in the development o ta major role in the development o t
IEC 61850 standard or substation com-IEC 61850 standard or substation com-
munication.munication. ABB ABB RevReview iew dedicates an articlededicates an article
to a signiicant milestone: the ongoingto a signiicant milestone: the ongoing
upgrade o a series o substations upgrade o a series o substations
lia, representing the irst commercial imple-lia, representing the irst commercial imple-
mentation o IEC 81850-9-2 LE. This subsec-mentation o IEC 81850-9-2 LE. This subsec-
tion o the standard represents an importanttion o the standard represents an important
step orwards in digital communication instep orwards in digital communication in
substations. Further articles look at substations. Further articles look at
types o switchgear and at protectingtypes o switchgear and at protecting
transormers against lightning.transormers against lightning.
I trust that tI trust that t he innovations presented in thishe innovations presented in this
edition o edition o ABB ABB ReviReview ew will raise your aware-will raise your aware-
ness o their potential and inspire you to ness o their potential and inspire you to
ways o putting them to good use.ways o putting them to good use.
Enjoy your reading!Enjoy your reading!
Peter TerwieschPeter Terwiesch
ABB ABB LtdLtd..
Dear Reader,Dear Reader, T Technechnoloology igy is a s a dede ininining ag aspecspect ot o mo moderdernn
society. To athom how much we depend onsociety. To athom how much we depend on
individual technologies, we need look noindividual technologies, we need look no
urther than the manuacturing processes onurther than the manuacturing processes on
which we depend or the power-supply thatwhich we depend or the power-supply that
keeps our lights burning. The extent to whichkeeps our lights burning. The extent to which
tomorrow’s world will be dierent rom today’stomorrow’s world will be dierent rom today’s
will depend to a signiicant degree on thewill depend to a signiicant degree on the
technological progress and technological progress and breakthroughsbreakthroughs
that will emerge between now and then.that will emerge between now and then.
Throu Through gh its its researesearch arch and nd devedeveloplopment ment lablabs,s,
ABB ABB is pis proud roud to to play play a cea centrantra l i l i not not deideiningning
part in advancing some o the contributingpart in advancing some o the contributing
technologies.technologies.
In this issue o In this issue o ABB ABB ReviReview ew , 11 innovations, 11 innovations
selected rom ABB labs across the globe areselected rom ABB labs across the globe are
presented in short articles. Many o these arepresented in short articles. Many o these are
additionally discussed in greater depth in this,additionally discussed in greater depth in this,
recent and upcoming issues o the journal.recent and upcoming issues o the journal.
One area that has led to huge One area that has led to huge changes inchanges in
recent decades is power electronics. Com-recent decades is power electronics. Com-
pact and reliable semiconductor devices arepact and reliable semiconductor devices are
permitting electrical power to be convertedpermitting electrical power to be converted
with an with an unprecedented degree o lexibility,unprecedented degree o lexibility,
eiciency and controllability.eiciency and controllability. ABB ABB RevReview iew
dedicates three articles to drives and dedicates three articles to drives and convert-convert-
ers. One o these looks at ers. One o these looks at the award-winningthe award-winning
ACS ACS 2002000 d0 driverive, A, ABB’s irBB’s irst st trantransosormerrmerlessless
medium-voltage drive.medium-voltage drive.
Motors are important to virtually all manuac-Motors are important to virtually all manuac-
turing processes, and are customized orturing processes, and are customized or
numerous dierent applications. One articlenumerous dierent applications. One article
looks at ABB’s spark-ree motors and theirlooks at ABB’s spark-ree motors and their
signiicance in explosion protection. Insigniicance in explosion protection. In
another article, we present ABB’s low-lossanother article, we present ABB’s low-loss
synchronous motors. Zooming out to thesynchronous motors. Zooming out to the
broader picture o energy eiciency, abroader picture o energy eiciency, a
thought-provoking paper proposes that thethought-provoking paper proposes that the
COCO 22
reduction rom raising the eiciency o reduction rom raising the eiciency o
EditorialEditorial
InnovationsInnovations
Innovation highlights
ABB is cont inuously seeking to urther strengthen and expand its product portolio. Across the world, the company’s research and development labs are hard at work creating the technologies, products and solutions that will urther raise the productivity, eiciency and lexibility o its customers’ operations. The successes
scored every year are numerous, and selecting most notable o these is no easy task. The current selection is a cross section o recent successes. Many o these, as well as other technological achievements, are discussed at greater length in this and orthcoming issues o ABB Review .
ABB has added a new model to its mid-range IRB 2600 robot amily: the IRB 2600ID. The ID in the name stands or integrated dressing, meaning the arc-welding hose package is routed inside the robot’s upper arm and wrist.
Integrated dressing is about more
than smart looks. Because swinging
cables must no longer be taken into
account, the robot’s movement is
totally predictable. This makes the
robot easier to program and permits
aster movements. With its slim arm
and wrist, the robot can enter restrict-
ed spaces, taking on challenges such
as circular welds without compromis-
by up to 75 percent and up to three
production stops per year can be
eliminated. Complete weld packages,
able rom several major arc-welding
process equipment suppliers including
density installations with 50
For more inormation on robots rom ABB, please
visit www.abb.com/robotics
secondary equipment, where it is
used or eicient protection and
control o the entire substation. Prior
to the emergence o the new stan-
dard, this communication would
typically have required extensive
advantages. As the bus is opt ical,
risks caused by high voltage are
reduced. Maintenance is also simpli-
ied as electronic components can be
exchanged without having to shut
down the entire system. The intro-
duction o IEC 61850-9-2 LE is being
accompanied by the introduction o
a powerul testing and diagnosis
toolbox.
IEC 61850 is a standard that sup- ports both communication between devices and data sharing in substation automation. The IEC 61850-9-2 section o the standard describes the sharing o analog values on the process bus. ABB is currently installing the world’s rst implemen- tation o a process bus according to this section.
A process bus is the communication
network between primary equipment
For more inormation, see “Sharing values” on
pages 73 o this issue o ABB Review
The technologies rom ABB’s well- known and ast-acting vacuum interrupter and the world’s astest limiting and switching device, the Is-limiter, have been cleverly combined to orm an arc-ault protection system or new (internal arc classi- ed) and older generation medium- voltage switchgear that operates in the ultraast range.
The system operates on the principle
that the uncontrolled release o energy
rom an internal arc ault is prevented
by rapid metallic 3-phase earthing.
Characterized by a signiicantly low
impedance, this type o connection
primary switching elements (each con-
sisting o a two-part vacuum chamber
embedded in epoxy resin), and a
quick release electronic unit or the
rapid and reliable detection o ault
currents and arc light intensity in the
compartment. With an extremely short
switching time o less than 1.5 ms,
Speed and saety in switchgear
First commercial IEC 61850-9-2 LE installation
Vacuum
device
Drive
and repair costs resulting rom aults
will be drastically reduced while
system availability will increase.
For more detailed inormation about ABB’s ultraast
earthing switch, please see “S3 – Speed, saety and
savings” in ABB Review 2/2010, pages 84–87.
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In the process industry, sensors relay inormation that is used to help maximie reliability and availability. Sensors reuire wiring or power and communication, a actor that adds to the cost and complexity o installation. While batteries are used to power many wireless devices, exchanging them at regular intervals may oset the savings o having wireless sensors in the rst place. Here energy harvesting (EH) can provide a solution.
radiation, and vibration and kinetic
energy rom lowing media or moving
parts.
or there may be times when the EH
system supplies more energy than is
actually needed. In any case buers
(eg, special capacitors, primary or
secondary cells) are needed to over-
come times when the harvesting device
is unable to supply enough energy or
the sensor node. An appropriate power
management system is also required
or a truly autonomous power supply.
Research at ABB has realized a
complete autonomous temperature
Wireless and autonomous
ABB has launched i ts 72.5 kV ENK series o gas-insulated switchgear (GIS). Notable attributes include a 25 percent smaller ootprint compared with existing products with similar perormance, and a 50 percent reduction in the amount o SF
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plug-and-switch technology and an
uture smart grid requirements.
its greater ease o operation, such as
ready access to the operating mecha-
nism rom the ront panel, and the
current transormers located outside
the gas compartment.
global leader in high-voltage GIS
technology, with more than 20,000
bays installed and in operation around
the world.
nominal voltage
GIS makes it ideal or installation in
locations where space is constrained,
such as in cities. Even indoor installa-
tions are possible. ABB also oers GIS
or oshore and mobile applications.
The company pioneered the irs t
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Since being rst released in 2004, ABB’s Extended Automation System 800xA has been adopted by more than 6,000 customers. The system has improved operator eectiveness, achieved seamless control solutions and integrated diverse and usually separate systems. Version 5.1, released in 2010, introduces urther enhancements, improving perormance, usability and operator eectiveness.
One area where Version 5.1 presents
notable advantages is in engineering
and change management. The Task
Analysis Tool permits the evaluation o
an application prior to its download-
ing, showing, among others, latency
and conlicts. The Detailed Dierence
Report highlights modiications made
in control applications and graphics.
The new version also includes a new
member o the AC800M controller
amily, the PM891, with approximately
three times the clock speed (450 Mhz)
and our times the memory o its
predecessor, making it the most
powerul controller in its class. Virtual-
ization reduces the physical number
o PCs by as much as 75 percent.
This signicantly lower ootprint also
reduces energy consumption and
These changes re lect
Version 5.1.
in greater depth in an upcoming edition o
ABB Review .
System 800xA version 5.1
New and advanced technologies are enabling the development o highly integrated and versatile products. One such device, the eVD4 automatic circuit breaker, enables easy, fexible and reliable medium-voltage switchgear projects. This breaker is a major step orward in terms o perormance, simplicity (it is charac- teried by a small number o highly reliable components and can be customied with a wide range o
network. The technology used to
develop the sensors has helped to
reduce equipment size, improve
and IED enables the accurate and
reliable monitoring and registering
ing better protection or both operat-
ing personnel and the substation
equipment.
dard and GOOSE unctionality, which
eVolving breakers
specially designed Relion®-based
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ABB has already established a market presence or inverters that connect large photovoltaic arrays to the grid. But what about smaller acilities, such as panels tted on the roos o residential and commercial buildings? ABB’s new string inverter combines an easy-to-use interace and simple installation with high perormance and advanced
household can understand it. ABB’s
string inverter comes with an intuitive
remote display unit. This starts with
A third level o complexity
engineers and reports on numerous
technical details. The string inverter
The power plant or at home
DC (direct current) ast chargers are becoming widely acknowledged as a key enabler or e-mobility. Unlike AC charging, which relies on a smaller charging converter inside the car and is suitable or charging overnight, DC ast chargers move the charging converter out o the car and into the inrastructure where it can be shared between many vehicles. This allows high-power charging without burdening individual vehicles with signicant additional weight and cost, and has the added benet o several means to manage the utility grid impact.
ABB’s activi ties in e-mobili ty inra-
structure took a signiicant step
orward with the successul certiica-
tion o ABB’s CHAdeMO-compliant
DC ast charger in early November
2010 and the subsequent installation
at the irst pilot site, the Hong Kong
Science and Technology Park, with
utility partner China Light and Power.
The CHAdeMO standard is the most
widely accepted or DC ast charging.
It has been endorsed by numerous
large vehicle manuacturers, and the
irst mass-market DC ast-charge-
dard were released in 2010, with more
to come in 2011 and 2012.
ABB worked together with CHAdeMO
certiication engineers rom the Tokyo
Electric Power Corporation to achieve
this milestone. Through this group
eort, certiication was achieved in
record time, and the pilot installation
completed only two days later.
ABB’s DC ast charger
The new ABB DC ast char
its perormance immediately as the
primary ast-charging point or the
vehicles o the Hong Kong EV
ollowing EVS-25 (the World Electric
Vehicle Symposium and Expo
o China Light and Power utility’s
Mitsubishi “i MiEV” vehicles in a row.
For more inormation on electric vehicle
charging, see “Dawn o a new age” on page 77
o ABB Review 2/2010.
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In the same way that lighting aects a photograph, so too can lighting aect the mood o a room. Euipped with innovative LED technology and a host o options or light direction and intensity as well as color temperature and appearance, Busch- Jaeger has, in collaboration with the renowned architect and designer Hadi Teherani, developed a new lighting system or both residential and oce buildings.
Busch-iceLight is a modular, versatile
lighting system that can be used as an
inormation or orientation light or to
The lighting element can be adjusted
in ive dierent directions to precisely
deine the light direction and beam.
Two settings are available or the color
temperature o the light, ie, warm
Busch-iceLight
The streamlined rotor structure o ABB’s synchronous reluctance motors eliminates rotor cage losses, thereore increasing eciency and compactness. The possibility o achieving standard power and torue levels at merely a low class-A temperature rise (60 K) improves the lietime o the motor insulation, and lengthens the bearing lietime or greasing intervals.
Synchronous motors controlled by
the energy eiciency o many indus-
trial applications. What most applica-
tions have in common is the need
or their motor to be as eicient as
possible and to have the longest
possible lietime while simultaneously
not increasing maintenance demands
reluctance motors (oten called a
SynRM) employ the magnetic principle
o reluctance. They are physically
smaller in size, helping machine
builders to design smaller, lighter, and
more eicient equipment. The motor
is inherently sae in operation since,
without magnets, no back-EMF
ity o high speed operation helps to
eliminate mechanical power transmis-
This eventual ly enables the integration
o the motor and the load equipment.
For more inormation, see “Motoring ahead” on
page 56 o this edition o ABB Review .
The low-loss motor
system, Busch-iceLight ensures
high-quality design sheets and special
pictograms are available, making the
system adaptable to users’ needs.
0
JUKKA TOLVANEN, TERO AHONEN, JUHA VIHOLAINEN – In the past, innovations like the light bulb and the telephone oten originated rom individ-How collaboration
is supporting ABB’s
works as a network through which the
participating international companies
knowledge on a aster and
than would be possible by
Jacobson explains that cooperation is
more strategic or the companies involved
when they allocate their own R&D human
resources or several years and are willing
to share their results, rather than just
allocating unding or outsourced propri-
etary R&D. Such industry involvement
also ensures wide interaces or knowl-
edge transer, innovations and guidance.
An eective way to
grams has been ound: First the compa-
nies deine the theme that they
important or their uture businesses and
or which they would be willing to allo-
cate their own resources and share the
deliverables. Then the universities and
research institutes respond to this mar-
ket pull with their research initiatives,
creating a reciprocal science push. Ja-
cobson points out that this also saves
resources at the universities as they do
not have to waste time on completing
research applications that typically have
a low success rate, but instead receive
eedback that is immediate, interactive
and iterative.
energy markets and smart grids. Here
the main contributors are Nokia Siemens
Networks and ABB. Other areas on the
agenda are, or instance, eicient energy
use and distributed energy systems.
One solution to deal with these issues is
to have a common research center or
community to manage R&D activities. In
Finland, the strategic center or science,
technology and innovation in the energy
and environmental sector (CLEEN Ltd.)
has been ounded to catalyze interna-
tional and cross-industrial cooperation in
the energy and environmental technolo-
gy ields. As a limited company owned
by global companies and the most rele-
vant national research institutes and uni-
versities, CLEEN acilitates cooperative
innovative solutions, technology and ser-
vices that are beyond the R&D capabili-
ties o a single company or area o indus-
try [1]. Two-thirds o CLEEN’s 44 owners
are private companies including several
global technology and market leaders,
like ABB, Metso and Wärtsilä. ABB is
one o the ounders and an active mem-
ber in CLEEN’s operations that has pro-
vided new possibilities or cooperative
research with other companies, organi-
zations and research institutions.
possibility o receiving external unding,
which is oten essential or wide research
consortiums exe-
cuting long-term
with its new innovation program. This kind
o support enables a change in the inno-
vation culture rom a one-company show
to network-based open innovation.
Modern cooperation between companies and universities CLEEN is part o a major overhaul o the
Finnish innovation system. To advance
this goal the Finnish government has ini-
tiated six centers or strategic science,
A ccording to the well-known
saying, “two heads are better
than one.” In the ields o
engineering and technology,
cooperation between dierent compa-
nies and organizations. For instance, in-
novations on how to improve the energy
eiciency o electrical systems clearly
require technical expertise, but also eco-
nomical and social expertise in order to
obtain totally new and easible products
and services.
required rom several areas o engineer-
ing, requiring the participation o several
companies. As a single company may
hold world-class competence only in
certain areas, cooperation between di-
erent companies and organizations can
be the most easible approach or new
ideas and innovations, which may cover
several dierent business segments.
CLEEN Ltd. has been ounded to catalyze international and cross-industrial cooperation in the energy and environmental technology ields.
Eicient energy use The eic ient energy use
ocuses on the development o methods
that can improve the energy eiciency o
devices and systems. The target sectors
are industry and service where approxi-
mately 60 percent o the total produced
energy is consumed. The primary goals
o the research program are to:
– Develop new methods, business
achieve radical improvements in
signiicant energy eiciency improve-
ments with minor investments
energy eiciency development
topic, the expertise and active participa-
tion o dierent parties – such as the
manuacturing industry,
o the research work is three to
beore the product phase or service
phase. The main results o the research
distance scale. Compared with tradition-
al electric grids, smart grids enable more
eicient use and control o distributed
electricity generation, and the intelligent
use o electric car batteries as a part
o the electrical distribution system.
Research topics in the smart grids and
energy markets (SGEM) program are:
– Future inrastructure o energy
systems
services allowed by the smart grid
technology
real environment utilizing Finnish R&D
and innovation inrastructure. At the
same time, the beneits o an interactive
international research environment will
gy (ICT) and smart grid providers. This
consortium program has several partici-
pants rom industry, research institutes
ABB is one o the ounders and an active member in CLEEN’s operations.
1 Smart grids and energy markets (SGEM)
ABB Oy 6.3%
Aidon Oy 0.1%
Empower Oy 4.5%
Emtele Oy 1.5%
Fingrid Oy 2%
University o Kuopio 1.0%
MIKES 0.4%
Univerity o Vaasa 2.8%
Tekla Oyj 3.7%
Vantaan Ene rgia Sähköverk ot
Oy 0.9%
Industrial Partners 60.8%
an excellent source o new research top-
ics and the possibility o extending its ex-
pertise in the area o energy eciency o
electric motors, VSDs and rotating ma-
chinery. The cooperation has allowed
CDMC research sta to be innovative
ticipants in the research and development
process o new products and services.
Depending on the project, the results o
the research can also be published as
PhD theses and journal articles, or in the
orm o patent applications. The research
projects have been related to the control
methods o VSDs, eciency improve-
ments o electric motors, and the control
and diagnostics o rotating machinery
such as centriugal pumps.
Cooperation with other companies and
universities oten brings new and innova-
tive ideas. One example o this can be
seen in the ollowing article “Audit
its.” R&D collaboration thereore should
not be overlooked, as more extensive
research projects can be ormed and
expertise rom dierent areas can be
utilized in the research. Whether this is
reached through consortium research
with other companies and
universities or research institutes, there
are beneits or all concerned.
Jukka Tolvanen
Reerences [1] CLEEN Ltd. The Finnish Cluster or Energy
Environment. Retrieved August 24, 2010, rom
http://www.cleen.i.
Technology. Ret rieved Aug
Russian business and industry related to
the above areas [2].
pumping systems and electric motors,
and strong expertise in the energy ei-
ciency o these appliances, LUT has
been able to carry out academic re-
search, which has also helped with the
R&D o new ABB products. Both direct
torque control (DTC) o permanent mag-
net synchronous machines (PMSMs) and
sensorless low rate estimation or cen-
triugal pumps have been studied at
LUT 2 [3,4]. These research topics have
resulted in several patent applications,
scientiic publications and also direct
eedback to ABB’s R&D team or drives.
Consequently, the research expertise
cooperation with ABB on electric motors
and variable-speed
laboration between industry and universi-
ties can be a ruitul source o innovation
and new technology. Oten cooperation
between universities and industry pro-
vides synergy or both parties, as univer-
sities may have and suggest interesting
research topics, and product manuactur-
ers may benet in the orm o innovative
R&D and testing o new ideas with univer-
sities’ test acilities. This kind o coopera-
tion has been successully carried out
between ABB and Lappeenranta Univer-
sity o Technology, Finland (LUT) in the
eld o electric motors and variable-speed
drives (VSDs), which are an essential so-
lution to improve the energy eciency o
rotating machinery.
tion and research in the areas o engi-
neering and economics. The university's
2 Research acilities at LUT or pumping systems
Direct collaboration between industry and universities can be a ruitul source o innova-
Audit beneits
ABB and Lappeenranta University o Technology are collaborating on an energy audit project or more ecient and durable pumping systems.
The energy audit project (EAP) at
Lappeenranta University o Technol-
2008. An energy audit is an analysis
o the energy consumption o a given
process or a system 1. The clients
are energy consumers mainly in
industrial ields. The auditing process
concentrates on inding ineiciently
operating applications with rotating
usually involve pumps.
project is the result o a long-lasting
cooperation between ABB and LUT,
especially in the ield o researching
the eiciency o pumping systems.
The project has provided special
knowledge about the energy eiciency
o pumping applications. In addition,
speciic simulation tools to determine
the energy eiciency o pumping
systems were developed during this
project.
Auditing industrial energy usage The main goal o this project was to
create an easy-to-use method or
auditing rom which all participants
could beneit. The aim o the audit is
to obtain inormation about the energy
consumption o the system in its
present state and to identiy the
actors aecting it. The second step is
to identiy the economic opportunities
or improving the eiciency o the
system and achieving cost savings.
The end product o the audit is an
action plan on how to achieve
improved energy eiciency.
sensorless low calculation unction
tested in laboratory acilities. Test
results were then published in World
Pumps journals in 2005 and 2006.
As VSD are capab le o estimating
motor operation without sensors on
the motor shat, they can also be
used to estimate the operation o a
pump or other load o the motor.
For instance, the sensorless low
calculation unction available in ABB’s
industrial drives utilizes the internal
rotational speed and shat power
estimates o the drive to inorm the
user about the pump low rate without
additional sensors on the pump. This
unction can be used in an application
where the pump low rate is required
inormation, but it is not applied or
revenue metering.
carried out to ind new ways o
detecting cavitation 1 and or energy-
eicient control o parallel-driven
pumps. These studies permit the main
causes o pump ailures to be elimi-
nated, and the total energy consump-
tion o pumping systems to be
substantially decreased.
Signicant energy savings could be achieved using advanced variable speed control with parallel-connected pumps.
Meeting with the client
Gathering the initial data
the abnormal operation o the pump.
In the case o centriugal pumps,
cavitation is one o the widely known
reasons or decreased pumping
cavitation have been developed.
on additional measurements that
cases. The installation o sensors may
be costly and the amount o pumps
that should be monitored may be so
provide real beneits to the user, as
there is no need or additional sensors
and installations [2].
savings due to the lowered energy
consumption. As parallel-connected
the o/on control method, there is a
huge savings potential by operating the
required amount o centriugal pumps
at a lower rotational speed compared
with the traditional o/on control
method. This has been veried by test
measurements carried out at LUT.
Several real-lie research cases have
also been conducted in industrial raw
water pumping applications, power
The results have shown that signi icant
energy savings could be achieved
using advanced variable speed control
with parallel-connected pumps. One
speciic energy consumption o two
parallel operating centriugal pumps is
shown in 2. With the variable-speed
control or both pumps, speciic
energy consumption can be minimized
at lower low rates [3].
savings can be more easily developed
than by acting alone.
Reerences [1] Aranto, N., Ahonen, T., Viholainen, J. (2009,
September 1417). Energy audits: University
approach with ABB. Proceedings o the 6th
International Conerence on Energy Eiciency
in Motor Driven Systems (EEMODS ’09).
European Commission Joint Research
Centre, Institute or Energy.
J. (2010, June 2224). Novel method or
detecting cavitation in centriugal pump with
requency converter. Proceedings o the 7th
International Conerence on Condition
Monitoring and Machinery Failure Prevention
Technologies (CM and MFPT
and Coxmoor Publishing
Aranto, N. , Kestilä, J. (2009,
2 Speciic energy consumption o dierent low control methods or two connected centriugal pumps
0 200 400 600 800 1,000 1,200 1,400
S p e c i f i c e n e r g y ( k W h / m 3 )
Flowrate (l/s)
0.50
0.40
0.30
0.20
0.10
0.00
As VSD are capable o estimating motor operation without sensors on the motor shat, they can also be used to estimate the operation o a pump or other load o the motor.
CALOGERO SAELI, CALLISTO GATTI, CARLO GEMME, EMILIA DANERI, CARLO
CEREDA – Over the last decade, medium-voltage distribution networks have experienced signicant changes thanks to the continuing evolution in technology. ABB is leading this evolution by providing customers with new products, such as Relion® protection and control devices, current
eVD4 brings simplicity and reliability to medium-voltage
The smart eVolution
intelligent electronic device (IED) dedi-
cated to the protection, control, mea-
surement and supervision o utility sub-
stations and industrial electrical systems.
It is installed into the chassis o the
as a plug-in device via a
The RBX615 unit guar
and distribution substation busbar sys-
tems, and it is suitable or any radial dis-
The eVD4 series combines innovative
ABB technologies in the ield o mechan-
ics, electronics and sensors. The result
is a highly integrated device that com-
bines measurement, protection and con-
trol capability with primary power dis-
connection, switching and interruption
technology.
Innovation and a sound oundation o proven technology The eVD4 is based on ABB’s VD4 me-
chanically actuated vacuum MV circuit
breaker and the
new Relion® prod-
uct and sensor
trend toward the evolution o
new technologies that are en-
abling the development o new solutions
to meet the present and uture needs o
distribution networks. The IEC 61850
standard, or example, is driving inno-
vation in energy distribution devices,
enabling new unctionalities and new
architectures or MV switchgear while
increasing standardization. Products
component standardization and greater
the market. Not only do they improve
reliability, but they also reduce the time
and eort needed or installation and
maintenance.
primary distribution environment.
One such product series, the innovative
The innovative eVD4 aut matic circuit breaker amily has been developed specically to
1 PCM600 is IEC 61850 compliant, which simpliies IED engineering and exchange with other IEC 61850-compliant tools.
a
b
c
d
e
circuit-breaker only)
b Relay signals
d Truck or the withdrawable circuit breaker
e RBX615 control and protection relay
Opening push button
geared motor
(withdrawable circuit-breaker only)
signaling device
40 kA. The RBX615 relay can be
with ive dierent protection proiles,
each o which correspond to a particular
set o protection unctions that require
both current and voltage measurements.
Because it is integrated into the eVD4,
the design o the relay has been opti-
mized speciically so that it can perorm
the monitoring, control and diagnostic
unctions o the eVD4.
circuit breaker more than satisies the
requirements o simplicity (it
components and can be customized
with a wide range o easily and rapidly
installed accessories) and saety (a
dy metal rame ixes the poles and the
operating mechanism are ixed).
mechanical opening and closing releases
and dedicated interlocks. Correct opera-
tion requires the immediate availability o
stored energy, which can (in the case o
the eVD4) be low because o lightweight
interrupter contacts and reduced contact
travel or switching. This limits the wear
on the system and makes the circuit
breaker practically maintenance-ree. Up
to 30,000 open/close operations are
possible over the lietime o the
Proximity sensors
with high reliability. For example, these
sensors detect the breaker’s open/close
status, the spring’s charge/discharge
state and the position o the truck. This
inormation is then sent to the RBX615
relay via a dedicated wire link.
An enhanced auxiliary circu
connection not only or t
er’s auxiliary circuits but also or the
relay connections, ie, the communication
2 Comparing a ully automatic eVD4 breaker with a standard MV circuit breaker in all stages o the product lie cycle
Speciication The h igh level o l exibi lity o the eVD4
simpliies speciication requirements.
In other words:
parameters; the rating o the sensors is
derived rom the rating o the circuit breaker,
whereas the type o sensors (only current or
combined current and voltage version) is
derived rom the protection proile.
– All RBX615 preconigurations can be
customized to provide the best match to
the network requirements.
Supply management Rather than a number o separate orders, just
one single order and one unique reerence is
required to ensure the delivery o a complete
MV switchgear solution.
Fast delivery The h ighly techn ical production line combined
with component standardization enables ABB to
guarantee the same delivery time or the eVD4
as or a st andard circuit breaker.
Installation The eVD4 is a ready-to-ins tall solut ion. As the
sensors are an integrated part o the complete
unit, no wiring or additional work is needed; all
the relay wiring is instantaneously connected
by the circuit-breaker plug.
As an integrated solut ion, a large proporti on o
the switchgear wiring is built into the circuit
breaker, which results in a more standardized
product. The amount o wiring destined or the
low-voltage compartment is limited and the risk
o wiring errors is signiicantly reduced. This in
turn makes a complete switchgear solution aster
and easier to engineer.
Reduced eort or actory acceptance test (FAT) with increased saety and reliability
A ul ly tested and integrated solut ion w ith
ewer switchgear wires reduces the eort
needed to complete compulsory FAT tests.
Easy maintenance, the optimiation o spare part stocks and reduced mean time to repair (MTTR)
The eVD4 is built rom s tandard components that
can be used across a wide range o applications.
In addition, with just a ew variations, all circuit
breaker models within the eVD4 amily are
covered and so only a small number o spare
parts need to be kept in stock. All accessories
are readily available and can be easily main-
tained. This integrated solution allows ast
system recovery in case o ailure, and all the
core components o the switchgear will be
replaced by simply replacing the eVD4.
The RBX615 protection and control unit is integrated into the eVD4 and perorms the monitoring, control and diagnostic unctions.
tion channels, which are available within
switchgear’s low-voltage (LV) compart-
ment, can be accessed through the cir-
cuit-breaker plug that is connected to
the LV compartment socket.
trol in MV power systems. The technolo-
gy used to develop the sensors has re-
sulted in a reduction in equipment size,
improved equipment perormance and
an increased level o standardization.
This combination o sensors and IED (the
RBX615) enables the accurate and reli-
able monitoring and registering o net-
work parameters while providing better
protection or both operating personnel
and the substation equipment.
gurations can also be carried out via a
human machine interace (HMI) located
on the relay ront panel 6.
This interace shows the sing le-l ine dia-
gram (SLD) on the let with the relay
menu on the right. The SLD can be edit-
ed using the graphical display editor tool
inside the PCM600. The symbols indi-
cated are dynamically linked to the relat-
ed object (eg, circuit breaker, circuit-
breaker racking gear, earthing switch,
line disconnector) and their status is
shown in the display. Moreover, the sta-
tus o these objects can be easily con-
trolled rom the HMI.
a point-to-point connection between
tion, the HMI is automatically displayed
in the Web browser, allowing the user to
modiy the parameters o the protection
unctions as well as download distur-
bance records and several other ea-
tures. No additional sotware needs to
be installed on the client PC to commu-
The eVD4 has been designed to ully
exploit the potential o the IEC 61850
standard and generic object-oriented
substation events (GOOSE) technol-
relay-to-relay communication, by means
required, a traditional point-to-point
relay is possible through 12 digital inputs
and eight digital outputs in the plug.
To enable easy insta llat ion o the eVD4, a
dedicated panel socket accessory has
been designed.
the eVD4 4. The shape and pin layout o
the relay have been optimized to enable
a straightorward plug-in interace to the
breaker using a dedicated docking unit.
It is available with ve dierent precong-
ured protection proles, three o which
ocus on eeder protection and the re-
maining two are mainly intended or mo-
tor protection 5. The precongurations
can be ully customized by the protection
and control IED manager tool, PCM600 1,
The eVD4 ploits the potential o the IEC 61850 standard and GOOSE technology, including the horizontal high- speed relay-to-r lay communication.
3 The enhanced auxiliary circuit plug o the eVD4 circuit breaker 4 The RBX615 relay is based on ABB’s Relion ® technology
this guarantees excellent linearity. The
current sensors or the eVD4 breaker
output measurements are linear up to
the maximum value set or the protection
thresholds.
molded into the sensor and aces the
circuit-breaker bushing. The output sig-
nal is a voltage directly proportional to
the primary voltage. As with the current
sensors, the voltage sensors are char-
acterized by the absence o erroreso-
nance phenomena and insensitivity to
the eects o DC components.
The advantages o usin
linear measurements and versatile pro-
tection; saety; small power comsump-
tion; and that they are an environmen-
tally riendly solution.
With no resonance and hysteresis phe-
nomena the sensors exhibit good dy-
namic perormance and are linear right
up to the highest currents and voltages.
As a resul t, they ensure
perormance and enable multisided dis-
turbance analysis.
sensors (based on the Rogowski coil
principle) and a combined current and
voltage sensor known as a combi-sen-
sor 7. The choice o sensor depends
on the protection proile o the RBX615.
The sensors are used to:
− Convert large currents and voltages in
the primary circuit o the network to
an appropriate signal or secondary
circuit equipment (ie, the protection
relay RBX615)
currents and voltages that might
occur on the primary side during a
short circuit in the network
The entire range o currents and voltages
is covered with just three sensor sizes,
which extend up to the maximum rated
current and voltage o the circuit breaker.
A broken circu it or a short circu it in the
signal cable is not dangerous and will
cause no damage.
Rogowski coil, a uniorm winding on a
Two types o sensors are used in the eVD4: current sensors (based on the Rogowski coil principle) and a combined current and voltage sensor known as a combi- sensor.
5 The RBX615 relay can accommodate ive dierent preconigured protection proiles
Description Coniguration
Nondirectional overcurrent protection and
measurement o the phase voltages
Feeder 2 (F2)
o the phase voltages, and undervoltage and
overvoltage protection
measurement Motor 1 (M1)
Motor protection based on the current
and voltage measurements Motor 2 (M2)
6 The parameters o the protection and control logic provided preconigurations are modiied using the relay HMI
a Application
b Closing
c Opening
d Escape
a
l
m
communication systems. The entire
drastically reduced complexity o the
switchgear in terms o engineering, wir-
ing and testing, to the commissioning
and maintenance o the panel, the eVD4
is a major step orward in terms o per-
ormance, simplicity, reliability, saety
and cost eectiveness.
pared with that o instrument transorm-
ers. In addition, there are no losses in the
secondary cabling. These savings con-
tribute to increasing the lie span o the
equipment, and in a utility such savings
are signiicant.
sumption is negligible.
7 The choice o current or voltage sensors depends on the relay protection proile
The eVD4 is a major step orward in terms o perormance, simplicity, reliability, saety and cost eectiveness.
8 The current sensors are based on the Rogowski coil principle
Rogowski coil
I p
V out
For a sinusoidal current
In all cases, even i the primary current is non-
sinusoidal, a signal reproducing the actual
primary current waveorm is obtained by
integrating the transmitted signal.
to the current, with 90° phase shit (lead).
V out
= M di
dt
9 The voltage sensors use a capacitive divider or voltage indication
Capacitive divider
C 1
C 2
V p
V out
The transmitted signal is:
the actual primary voltage waveorm.
(capacitive divider)V out
A seismic switch
cause ailures o qualiied equipment. For
this reason it is necessary to establish a
“qualiied lie” or equipment with signii-
cant aging mechanisms. Qualiied lie is
the period o time beore the start o a
design basis event or which equipment
has demonstrated that it meets the de-
sign requirements or the speciied ser-
vice conditions [1].
The purpose o climat
perorm its saety unction beore, during
and ater variation o the humidity and
temperature levels in the environment
where the equipment will be installed. The
test determines the suitability o equip-
ment under conditions o high humidity
combined with cyclic temperature chang-
es and production o con
operating basic earthquake (OBE) or, in
case o a very strong earthquake, it must
be able to shut down the reactor, known
as a sae shutdown earthquake (SSE). An
additional requirement is veriying the
unctionality o each component under
very intense environmental conditions in
terms o temperature/humidity and ater
a thermal/radiation aging process.
dards the ollowing methods can be
used to qualiy system components
(alone or in combination):
representative sample o equipment,
tests, simulating the eects o
signiicant aging mechanisms during
normal operation.
or rom equip-
ment o similar
design that has
tail and only using equipment
that has been certiied is cru-
cial: It is never acceptable to turn the key
o a nuclear plant until it is certain that
every component playing a saety unc-
tion has been ully tested and certiied.
Detailed parameters or certiication are
speciied in American IEEE 1 and Euro-
pean IEC 2 standards.
The ualiication process Every supplier o products or the saety
chain o a nuclear power plant (NPP)
must go through a speciic qualiication
process, the purpose o which is to veriy
and certiy complete reliability o system
components.
also be required to operate under very
intense conditions. This is why the main
purpose o a qualiication process is to
veriy the ability to operate during various
and well-deined environmental settings.
The system must be continue unctioning during a so-called operating basic earthquake (OBE) or, in case o a very strong earthquake it must be able to shut down the reactor
1 Example o reuired response spectrum (RRS)
Frequency (Hz)
3
2
1
0
A c c e l e r a t i o n ( g )
are designed to remain unctional.
EMC ualiication
tion in case o high electromagnetic
stress, which may occur during accident
conditions. Two types o testing, which
reproduce the actual coniguration o the
instrumentation and control (I&C) devic-
es installed in the primary equipment,
including wiring, are perormed on all o
the equipment.
perormed in order to veriy the level o
immunity o the equipment
quency range.
measured over a broad spectrum.
Detailed unctional tests are perormed on
all o the I&C unctions, such as protec-
tion or control unctions integrated into a
single piece o equipment. The sotware
qualication process ollows IEC stan-
dards specically developed or NPPs;
these are described in IEC 60780
The ABB answer ABB has the products, th
the technical means to ensure that all
NPP requirements are met. The ABB
Competence Center located in Dalmine,
Italy, has several recent reerences or
MV NPP switchgear in Europe: Tihange
and Doel in Belgium, Cernavoda in Ro-
mania, Oskarsham in Sweden and Leib-
stadt in Switzerland. For each o these
projects, ABB’s products underwent a
rigorous qualiication procedure. This
process veriied equipment unctionality
in the case o seismic events and severe
environmental conditions.
ratories and know-how, the company also
Seismic and airplane impact test ualiication
IEC 60980 [2] and IEEE 344 [3] standards
represent the two main reerence stan-
dards or the seismic qualiication o
saety electrical equipment or nuclear
power stations. The response spectra
are not deined in either standard, since
they can vary depending on the geo-
graphic area and building structure. They
are thereore normally deined in techni-
cal project speciications.
sists o a tri-axial independent multire-
quency test perormed on the basis o
time histories (plots o the acceleration
as a unction o time) artiicially synthe-
sized rom a given required response
spectrum (RRS). The RRS takes into ac-
count the characteristics o the geo-
graphic location and o the supporting
structure or building 1. The time-his-
tory method is considered the best way
to simulate seismic loads during the
qualiication o equipment.
earthuakes are simulated:
OBE/S1: an earthquake that produces
accelerations where eatures or contin-
The ABB Compe- tence Center located in Dalmine, Italy, has several recent reerences or medium voltage switchgear or nuclear plants in Europe: Tihange and Doel in Bel- gium, Cernavoda in Romania, Oskar- sham in Sweden and Leibstadt in Switzerland.
2 The climatic testing cycle o the Doel NPP ualiication
cycle 6
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
0 A M
0 A M
0 A M
0 A M
0 P M
0 P M
0 P M
0 P M
0 P M
0 P M
0 P M
0 P M
0 P M
0 P M
0 P M
0 A M
0 A M
0 A M
0 A M
0 A M
0 A M
0 A M
0 A M
0 A M
0 A M
transormers itted onto removable
trucks. As required in the contract, the
replacement o all circuit breakers and
VT trucks took place
years, during the annual routine mainte-
nance shut-downs.
and IEEE standards or MV apparatus
ment is used or distribution o energy
supplied by diesel emergency generators.
The equipment supplied was qual iied
according to IEEE 323 and 344 stan-
dards and customer speciications,
which included a request or climatic and
seismic tests 2. A specimen switch-
gear was identiied so that all o the char-
acteristics that were part o the supply
were included. A qualiication program
was implemented on these proto-
types 3, achiev-
pressurized water
reactors (PWRs),
needed, thereore achieving shorter
scheduling times and a reduction in costs.
In 2009, Areva NP, an engineering, pro-
curement and construction (EPC) leader
in NPPs, certied that the ABB Compe-
tence Center satises the conditions or
“planning and production o medium volt-
age switchgear or nuclear power plants.”
MV Switchgear – UniGear zS1 Medium-voltage switchgear is one o the
most important links in the power distri-
bution chain. ABB has developed the
UniGear ZS1 switchgear with the aim o
satisying all users’ requirements. Uni-
Gear ZS1 is a combination o consoli-
dated solutions and innovative compo-
nents rom ABB. The MV switchgear is
suitable or indoor installations. Metal
partitions segregate the compartments
air-insulated. The range o apparatus or
UniGear ZS1 switchgear is the most
complete available on the market, and
includes vacuum and gas circuit break-
ers and vacuum contactors with uses.
Industry applications
4 Example o numerical evaluation o the struc - ture used or analytical seismic ualication
5 Example o ampliied deormati UniGear zS1 structure
3 Seismic test arrangement on UniGear zS1 during Doel NPP ualiication
Medium-voltage switchgear is one o the most important links in the power distribution chain. ABB’s UniGear ZS1 switchgear is a combination o consolidated solutions and innovative components rom ABB.
ing and closing currents, as opposed to
other switchgear components that are
static, in most cases breakers are the
equipment most prone to aging. There-
ore breakers are the components that
are generally in the worst condition and
replacing them with new ones is the
solution.
its own as well as competitors’ breakers.
The most extensive job
ted 344 CEM Gardy breakers with HD4
SF 6
Dalmine, Italy
Reerences [1] IEEE 323 IEEE standard or qualiying
equipment or nuclear power generating
stations.
qualiication o class 1E equipment or nuclear
power generating stations.
equipment o the saety system – Qualiication.
[4] IEC 60980 Recommended practices
qualiication o electrical equipment o the saety
system or nuclear generating stations.
plant produces about 10 percent o the
electricity needs o Sweden and its reac-
tors use boiling water reactor (BWR)
technology.
gear installations, each o them com-
prising seven UniGear ZS1 panels with
a 12 kV / 1,600 A / 50 kA rating and
equipped with ABB HD4 SF 6
breakers.
power distribution supplied by diesel
generators or emergencies and the
equipment supplied was qualiied ac-
cording to IEEE 323 and IEEE 344 stan-
dards, as well as the customer’s speci-
ications, which required seismic
and testing methods. Both o these
were carried out in collaboration with the
CESI-ISMES laboratories located a ew
kilometers rom the ABB MV switchgear
actory 4, 5.
Moderniation o existing NPPs
In addition to ABB’s own products, laboratories and know-how, the company also can rely on a dedicated partnership with state-o-the- art laboratories.
zS1 switchgear
Driving value
tion conditions (ie, starting, normal grind-
ing operation, stopping) a mechanically
riendly system is required.
The electric drive system
converter transormer, an
asynchronous motors. The ollowing
mance during start, operation and stop
sequences and how the sytem helps to
variables (torque and lux) are directly
controlled by inverter switching. Opera-
tional- and maintenance-related unc-
variable-speed drives and the accurate
control that is part o the drive design.
In addition, all inherent eatures o a
requency-converter drive beneit the
system and provide greater lexibility in
the control o the complete grinding pro-
cess. These beneits include very accu-
rate current and torque measurements,
power-drop ride through and earth-ault
and short-circuit protection.
can be split into operational,
maintenance and protection:
tion, it is important that critical situations
are avoided as much as possible; main-
tenance unctionality must be quick and
easy to execute; and protection o the
system is important under all operating
conditions.
especially dual-pinion systems 1, the
mechanical stress added by the motors
can be signiicant. Thereore the control
concept between the two motors must
be ast and accurate to avoid any addi-
tional stress to the pinions and ring gear.
These demands can not only be reached
but exceeded with ABB’s latest genera-
tion o medium-voltage (MV) requency-
converter drives, which contain new and
dedicated mill unctions. The addition o
an extra controller (ie, a mill controller)
not only permits the inclusion o a lot o
1 Dual-pinion high-speed mill drive and dual-pinion low-speed mill drive
With gearbox Without gearbox
2 A simplied overview o a dual-pinion high-speed mill drive and dual-pinion low-speed mill dri
With gearbox Without gearbox
Up to 36 kV, 50 or 60 Hz Up to 36 kV, 50 or
Included in
ABB scope
Included in
ABB scope
Inverter 1 Inverter 1
ACS 6000
speed reerence. To perorm a smooth
and sae start, the drive system irst
ramps up to the predeined starting
speed (typically about 10 percent o
nominal speed) where it is maintained
and the torque and mill angle monitored.
Normally the material in the mill cas-
cades beore the mill has turned 90 de-
grees. However, i the charge is locked
or “rozen,” it will drop rom the top o the
mill ater it has turned 180 degrees. This
could severely damage the mill and its
bearings, resulting in an extensive and
unscheduled shutdown. This situation
drive control technology which only re-
leases the drive to ollow the customer’s
DCS speed reerence i the mill controller
measures cascading o the material by a
decreasing torque beore the critical an-
gle is reached 3. From then on the
drive is under the customer’s control,
which means it will accurately ollow any
speed change requested by the DCS.
During startup there is a potential risk
o a dropping rozen charge, which can
seriously damage the mill shell, bearings
and other equipment. ABB’s mill control-
ler completely eliminates this risk, and no
urther actions like creeping are required
beore giving a start command, even
ater a long downtime. I a rozen charge
really does exist in the mill, the drive will
trip and perorm a coast stop beore the
critical angle is reached. In short, starting
is extremely smooth or the mechanical
components, such as the gearbox, pin-
ion and ring gear as no huge torque
spikes occur.
in 3 is magniied in 4. The very irst
small torque peak (in maroon) demon-
strates the breakaway torque ater which
the motor speed is ramped up slowly
and gently while the torque increases
with the mill rotating angle. At an angle o
approximately 30 degrees (the irst main
torque peak is roughly 94 percent o
rated torque, and the second and maxi-
mum torque peak is approximately
ble, inally enabling the mill controller to
release the drive so that it can ollow the
DCS speed reerence.
starting levels (higher torque limitation,
such as 130 percent o rated torque) and
or normal operation ater starting (lower
torque limitation, such as 110 percent o
rated torque).
the starting process barely aects the
electrical supply network because, as
the motor is decoupled rom the network
via the ACS 6000 converter, there are no
high starting currents as is typical with
direct-online motors. Thereore, the cur-
rent drawn rom the network during
In ring-geared mill drives (RMDs), the mechanical stress added by the motors can be signiicant, and the control concept between them must be ast and accurate.
3 A complete start/stop seuence
Starting: Between 80 and 118 seconds
Operation: Between 118 and 550 seconds
Stopping: Between 550 and 690 seconds
Time ( s)
Motor speed (rpm)
85 90 95 100 105 110 115 120
0
1 0 0
2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 7 0 0 8 0 0 9 0 0 1 0 0 0
0
can deliver constant torque over the
tire speed range. It is also possible to
above nominal speed but with reduced
torque (constant power operation area).
In 5, the operator slowly ramps up to
the reerence speed. Ater remaining at
two-thirds o the nominal speed
than a minute, the mill is ramped up to a
top speed o almost 1,500
rated speed). Though it jumps slightly
during the ramp-up (the acceleration
torque is about 7 percent o nominal
torque), the torque remains airly con-
stant over the entire speed range.
Stop seuence with controlled rollback
When a stop command has been issued
by the DCS, the mill controller will as-
sume ull control o the stop sequence.
To avoid the unnecessary an
ward and orward rocking o the mill
caused by a coast stop, ABB has
mented a unction called “controlled roll-
back,” which quickly brings the mill into a
torque-ree position in a controlled way.
It works by ramping the speed down to
zero. When it reaches zero, the drive
system then proceeds slowly in the re-
verse direction in order to roll back the
mill until no torque remains in the sys-
tem 6. During this time the motor acts
as a generator by reclaiming the poten-
tial energy let in the system due to the
presence o material in the mill with a
certain angle.
For ast, easy and sae maintenance o the mill, ABB has implemented dedicated maintenance unctions in the mill controller.
6 A complete stop seuence
575 600 625 650 675
0
0
630 640 650 660 670 680
1 4 0
1 5 0
1 6 0
1 7 0
1 8 0
1 9 0
2 0 0
- 1 0
0
er). ABB also oers the option o a truly
our-quadrant drive system with an ac-
tive rectiier unit, which enables braking
energy to be ed back into the network.
This opt ion sign iicantly reduces the time
required to roll back the mill.
A close-up o the control led rollback area
(rom 6 ) is shown in 7. When the mill
speed has been ramped down and the
mill is in an unbalanced position, the
motor rst creates a positive torque that
just about holds the mill with the charge
unbalanced. Slightly reducing the torque
changes the direction o rotation, which
then causes the mill to gently roll back
until the charge is balanced. The data
in 7 clearly show that the torque (ap-
plied to the pinion teeth) is always positive
during the complete procedure, meaning
there can be no backlash between the
pinion and ring gear, and contact between
the two is always maintained. I backlash
were to happen, it would be shown by a
drop in torque to zero or below.
In this particular coniguration, the motor
speed during controlled rollback is only
12.8 rpm, which is about 0.85 percent o
nominal speed! In other words, the mill is
smoothly rolled back in a controlled
manner at a speed o about 0.1 rpm.
Even at this very low speed, the system
still runs stable thanks to ABB’s ad-
vanced DTC technology. In addition, the
time between reaching zero speed and
zero torque (ie, mill stopped and no over-
shooting) takes about 55 seconds. While
The latest generation o ABB MV requency convert- ers provides excellent opportunities to improve the grinding process used in the miner-
By looking at the angle curve (in 7 ), it
can be observed that the mill was rolled
back by 30 degrees, rom about 178
degrees to approximately 148 degrees
(ie, the angle curve decreases once the
mill speed becomes negative at approxi-
mately 630 seconds). This matches per-
ectly with the measured cascading
angle during the startup in 4.
Coast stop (rocking mill) To ul ly appreciate the dist inct beneits o
variable-speed operation and thereore
controlled rollback, a coast stop rom
nominal speed was tested on the same
mill. The test showed that the time taken
or the mill to reach a complete stand-
still, (ie, when the backward and orward
rocking o the mill had ceased) ater the
“stop” command was received was
about 180 seconds 8.
Time ( s)
- 5 0
- 2 5 0
1 5 0 0
Time ( s)
Motor speed (rpm)
- 2 0 0
- 1 5 0
- 1 0 0
During the deceleration process, the
tooth o the ring gear hits the tooth o the
pinion several times to break the motor
speed. Not only does this cause back-
lash, but it also severely stresses the
gear teeth.
o the mill, ABB has implemented dedi-
cated maintenance unctions in the mill
controller.
Creeping
tion or mills, is nothing more than turn-
ing the mill at very low speeds or main-
tenance purposes, such as the visual
inspection o bearings or manual posi-
tioning or a liner change. In
by any desired angle or number o liner
rows. In act it is a very helpul unction
during liner replacement because it helps
to reduce downtime and increase avail-
ability. Initiated by a local control panel or
the DCS, the operator preselects the
positioning mode, direction o rotation
and desired angle or number o liners.
An automatic positionin
in 11: The material cascades at 27 de-
grees; the drive keeps running at low
speed or a certain time beore ramping
down; at zero speed the mill has turned
209 degrees at which point the torque
value is 94 percent o nominal torque
(meaning the mill is ully loaded); and the
drive then runs in reverse, slowly reduc-
ing the torque. By the time the drive
stops (101.6 seconds later), the mill has
turned 179.2 degrees, which translates
into an inaccuracy o only 0.5 percent!
The opt imum positioning
responds to 10.5 percent (10 percent is
typical) o nominal speed. At this speed,
the angle inaccuracies were below 1
cent or all tests.
reerence o 180 degrees. Even i deor-
mation is not a real problem or grinding
mills in the minerals industry
can still be used during longer mill stops
(eg, maintenance) to prevent a rozen
charge rom occurring. Operators need
only preselect a deormation protection
mode and the preerred direction o
tion beore issuing a start command.
mill controller then takes care o the
180 degree turn in exactly the same way
as that illustrated in 11.
Froen charge remover
mostly on ball mills. Ater one has been
detected, the rozen material needs to be
The automatic positioning unction allows operators to accurately turn the mill by any desired angle or number o liner rows.
11 Automatic positioning routine with 180 degree angle reerence
470 480 490 500 510 520 530 540 550 560
0
0
100 150 200 250 300
Time ( s)
- 2 5
be initiated rom a local control panel
close to the mill, but it can also be acti-
vated remotely rom the DCS. The start
procedure is completely controlled by
the mill controller and rozen charge pro-
tection is activated when creeping mode
is selected. Creeping speed is typically
5 percent o nominal speed but can be
adjusted to between 1 and 10 percent
ater a successul start.
A complete creeping sequence is shown
in 10. The creeping speed is set at
48 rpm or 3.2 percent o nominal speed;
cascading is detected at a mill angle o
23.5 degrees and a torque o 73 per-
cent o nominal torque. The operator
keeps the mill running at this speed or
420 degrees beore initiating a stop
(ie, irst) quadrant, no backlash phenom-
enon can occur between the pinions
ring gear.
pable o adding signiicant value to grind-
ing mills in terms o eicient operation
and maintenance. But this drive system
is also available or dual pinion mill drives,
ie, when two motors are mechanically
connected via the mill ring gear and
operating together to turn the mill. This
obviously requires accurate load sharing.
Part two o this article will show, using
ield measurements, the amazing accu-
racy o a 2 × 5 MW dual pinion mill drive
system.
ABB Switzer land Ltd.
Further reading [1] Ravani von Ow, T., Bomvisinho, L. (2010).
Use of the latest technology to overcome the
demands of mill operation.
Operators Conerence, Ottawa, Canada.
[2] Ravani von Ow, T., Gerhard, B. (2010).
12 Froen charge remover with controlled rollback
0
Motor speed (rpm) Motor torque (%) Mill angle (deg)
4290 4295 4300 4305 4310 4315 4320 4325 4330 4335 4340 4345
Time ( s)
- 2 5
4290.0 4292.5 4295.0 4297.5 4300.0 4302.5
0
rozen charge remover unction tries to
loosen the material by applying torque
steps to the system. The optimal ampli-
tude and duration o these steps are
ound and set during commissioning. The
amplitude o the torque steps are deined
in a way that adds a certain percentage
unction can be applied in both positive
and negative directions.
quence with a positive direction o rota-
tion and controlled rollback is shown
in 12 and a close-up o the initial part
o the sequence is given in 13.
Torque steps, also relected by speed
changes, are ap-
breakaway and are
implemented by a
sequence o ac-
celerating and de-
the rozen charge.
The amplitude o
ABB’s dedicated mill unctions are capable o adding signiicant value to grinding mills in terms o eicient operation and maintenance.
Looking at the shoreside and shipside tech-
LUTz THURM, ISMIR FAzLAGIC, THORSTEN HARDER, KNUT MARqUART –
The environmental ootprint o port areas is under scrutiny port authorities and shipowners have explored dierent solutions to
Onshore and onboard
ously and enable the supply o 50 and
60 Hertz power regardless o the local
grid requency. They also comprise the
connecting cables and berth terminals.
For each shore-based power
dedicated transormer
galvanic separation (a nonmetallic
supply grid and the ship’s internal sys-
tem), so that an earth ault in the ship’s
electrical system will not endanger the
port grid or vice versa. Second, the
transormer steps down the power sup-
ply rom a voltage level optimized or dis-
o the port and the power it will provide.
Additional investments stem rom con-
struction and installation at the quay and
potential needs related to strengthening
the port’s electricity grid.
Power supply in ports is typically equiva-
lent to that o a small actory, with elec-
tricity needed to power shoreside load-
ing and unloading inrastructure such as
cranes, belts and gantries, cooling, heat-
ing as well as incidentals. Most ports
have access to
enough power to
run these consum-
secondary needs.
sel, the electrical
icient to handle signiicant shore-to-ship
power connections without a major im-
provement to their grid. This may involve
investing in a new substation or installing
a new incoming power line with more
power; both o these actions would in-
A case has been made or
shore-to-ship power sup-
ed by power plants on land versus ships’
diesel engines running on bunker uels
is one o the main advantages o this
technology. Through shore-based pow-
local problem (pollution) with a speciic,
local solution (power connection rom
shore). For ports, the ability to supply
power to ships at berth enables them to
establish a more eicient and powerul
overall electrical supply as a utility. In ad-
dition, the investment in inrastructure is
sustainable over decades with long-term
revenues. For the port area community,
there is an additional beneit o reduced
noise and vibration in harbor areas. And
with standardization o shore-to-ship
ogy becomes more worthwhile.
Shoreside technology The technology requi red to provide on-
Power supply in ports is typically equivalent to that o a small actory, with electricity needed to power shoreside loading and unloading inrastructur
1 General overview o shore-to-ship power supply
a
b
c
sized container that houses the power
transormer, the MV switchgear with an
automated earthing switch, protection
terace. The major beneit o a compact
shoreside inrastructure is that it
smooth dockside operations and can
also be made mobile.
retr

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