02 Motor de Anillos

Curso de capacitacin GMD
Ringmotor
ABB University Chile, Noviembre 2012
Contents
Brief history/overview of GMDs
Installed base
Synchronous motors
Insulation systems
Ringmotor design
ABB Group
November 16, 2012 | Slide 2
Ringmotor design
Ringmotor components
Ringmotor manufacturing
Fame, laminations, winding, poles, sealing, cooling
Instrumentation: Air gap (stationary and rotating), PD
Summary
GMD System overview
T1 T1 T1
S
T2
Converter
transformer
Cycloconverter &
excitation
E-house &
Harmonic filter &
power factor
compensation
ABB Group
SM
ie
iT
n2
B
A
u+
u-
n1
iR
uR uS
uT
iS
i+
i-
3
Ringmotor
excitation
Auxiliaries
Controller (drive control,
system control)
History, overview of GMDs
In the sixties the cement process started to be controllable,
requirements of large cement and raw mills came up
The cement plant Le Havre in France, was the biggest and
most advanced cement plant at that time in1969
It was the first straight single line cement plant at that time
Single cement mill of 160 metric tons / hour was required
ABB Group
Single cement mill of 160 metric tons / hour was required
No gearbox manufacturer could supply a gearbox for this
size of power
BBC (later ABB) came up with the idea of a Gearless Mill Drive
(GMD) of 6400 kW
BBC was awarded to supply the first GMD in 1969 Le
Havre/France
History, overview of GMDs (cont.)
The first GMD was running with its original design from
1969 until 2000 and continuous with a new power part
(cycloconverter) its operation under full production
Le Havre GMD was controlled by the last generation of
mercury rectifiers
Since successfully beginning operation at the end of 1969,
ABB Group
Since successfully beginning operation at the end of 1969,
this first GMD in the world, operating with a cycloconverter
fed synchronous motor, has been followed by much more
such drives, firm confirmation that BBC were on the right
path
Competition came later into the game when performance
data from BBC was visibly very positive
BBC delivered first GMD for the mining industry in 1970 to
the Bougainville plant in Papua New Guinea
Recently ordered and installed base
ABB Group
Installed Base - Collahuasi, Chile
ABB Group
General
No upper design limit to the rated output
High power, huge capacity & throughput
Drive is constructed with a single motor
The air gap can be made sufficiently large
This allows the rotor to be mounted directly on the rotating
ABB Group
This allows the rotor to be mounted directly on the rotating
part of the mill body
Large air gap permits large air gap variations
Motor to operate at unit power factor
Basic GMD data
Motor type: Synchronous motor
Power range: 528 MW
Altitude: 4600 m.a.s.l.
Speed range: 015.5 rpm
Motor poles: up to 76 poles
ABB Group
Motor poles: up to 76 poles
Motor torque: up to 28000 kNm
Motor frequency: 0 5.8 Hz
Motor voltage: 0 5730 V ac
Motor current: 0 2500 A
Excitation current: 0 700 A dc
Basic GMD data (cont.)
Motor weight: up to 650 tons
Pole weight: up to 3 tons
Motor height: up to 20 m
Motor cooling: air or water cooled
Motor air gap: 12.5 22 mm
ABB Group
Motor air gap: 12.5 22 mm
Motor lifetime: up to 40 years or even more
System advantages
No gear box
Minimum number of mechanical components
Minimum number of electrical components
Only two wearing parts - brushes and dry sealing
No inching drive required
ABB Group
No inching drive required
Variable speed, the base for process optimization
Low maintenance
High availability & reliability
Bi-directional operation possible
Synchronous motors
Can be used in a very wide range (due to its possibilities of
adjustment)
Higher efficiency than induction motors
Less voltage drop during start-up
Number 2 with respect to number of drives
ABB Group
Number 1 with respect to output
Its a working horse !
Synchronous motors - fields of application
Compressors (turbo or reciprocating)
Pumps
Wind tunnels
Mills !
Wood grinders
ABB Group
Hot rolling mills
Hoist drives
Excavators
Tunnel bore machines
T-Bar drive (winter sport)
Vertical roller mills
And more
Synchronous motors (cont.)
ABB Group
Synchronous motors - Turbo-compressor rotor
ABB Group
Synchronous motors - Reciprocating compressor rotor
ABB Group
Synchronous motors - Mill drive rotor
ABB Group
Synchronous motors - components
ABB Group
Synchronous motor - basics
Rotational speed n = n
0
= f
1
/p (synchronous speed)
Slip s = 0
Stator with 3-phase AC winding
DC excitation for rotor winding (excitation current I
F
)
Either by an external DC generator or by a rectifier
ABB Group
Either by an external DC generator or by a rectifier
Current to the rotating field windings carried by brushes
and slip rings
Alternative: brushless excitation with diode bridge
Synchronous motor basics (cont.)
Cylindrical Motor
ABB Group
Salient Pole Motor
ABB Group
Cylindrical
Typically used for higher speeds (windage losses,
noise)
Often 2 pole design, e.g. turbo-generators (50 or 60 Hz)
with 3000 rpm or 3600 rpm
Long rotors
ABB Group
Long rotors
Cylindrical rotor design
Solid rotor (2p = 2 or 4)
Laminated rotor (2p 6)
Salient pole
Typically used for lower speeds
Larger number of poles
Single poles feasible due to lower centrifugal forces
Large diameter, short axial length
ABB Group
Air gap not constant over circumference
Salient pole rotor design
Solid poles (with or without damper rings)
Laminated poles
With complete damper winding
With damper cage
Nothing
Synchronous motor Stator core and frame
ABB Group
Synchronous motor Salient pole rotor (14P)
ABB Group
Synchronous motor Salient pole rotor (4P)
ABB Group
Synchronous motor Damper winding
Mechanical or electrical load variations can lead to torque
oscillations
This results in torsional vibrations and oscillations in the
current
The motor may fall out of synchronization
Damper winding
ABB Group
Damper winding
Damper winding is similar to cage of induction motor
Dampens these oscillations
Higher harmonics and resulting losses
Used to start synchronous motors similar to induction
motors
Synchronous motor Damper Winding (cont.)
ABB Group
Synchronous motor Slip rings on ringmotor
ABB Group
Synchronous motor Slip rings on ringmotor (cont.)
ABB Group
Synchronous motor Reactive power
Over-excitation
Generates reactive power
Motor acts as capacitor
Under-excitation
Uses reactive power
ABB Group
Uses reactive power
Motor acts as inductor
Sometimes used as phase shifting element to generate
reactive power needed for transformers and induction
motors
Synchronous condensor
Synchronous motor Power factor diagram
U
1
U
U
h
jX
h
I
1
jX
I
1
U
1
U
.
U
h
jX
h
I
1
jX
I
1
ABB Group
U
p
.
I
1
I
jX
I
1
U
p
I
1
I
Inductive (Lagging PF) Capacitive (Leading PF)

Synchronous motor Frame of reference
+ q axis
- q axis
+ d axis
ABB Group
- d axis
d: direct axis (in excitation direction) q: quadrature axis (in torque direction)
Synchronous motor Equivalent circuit
ABB Group
Quadrature axis (q)
Direct axis (d)
Synchronous motor Unbalanced magnetic pull
Depends on magnetic flux (distribution)
Occurs when the rotor is eccentric (out of center)
Can also occur from magnetic flux asymmetry
Force is destabilizing
Use of parallel paths in motor stator windings can reduce
ABB Group
Use of parallel paths in motor stator windings can reduce
UMP effects
Insulation systems
Temperature often the dominating ageing factor
Thermal classes (IEC 60085)
Maximum appropriate temperature
Class B 130C
Class F 155C
ABB Group
Class F 155C
Other factors of influence
Mechanical stress, vibration, different thermal
expansion
Moisture, dirt, chemicals, contaminants
Insulation systems (cont.)
Temperature rise (IEC 60034)
Difference of temperature of part and temperature
of coolant
Maximum ambient air temperature: 40C
Temperature rise is reduced if coolant temperature
exceeds 40C
ABB Group
exceeds 40C
Class B 85K
Motor winding is only a single turn winding; no interturn
failure possible
Temperature rise typically only approximately 50C
GMD Operating parameters
ABB Group
GMD - Mill diameters and power (typical)
> 25 feet:
typically SAG Mills
Pedestal Mounted Ringmotor
15 MW SAG Mills 28 MW
Mill Cylinder
ABB Group
25 feet:
typically Ball Mills
Foot Mounted Ringmotor
8 MW Ball Mills 22 MW
GMD Mill speed
Critical Speed
speed at which the centrifugal
force is big enough that the
material sticks to the mill shell
and therefore no grinding
effect occurs.
ABB Group
Mill internal diameter definition
depends on the mill supplier:
Shell to Shell
Liner to liner
GMD Mill speed on grinding process
ABB Group
GMD Mill speed on grinding process (cont.)
SAG Mills:
Rated Speed is btw. 74 % and 80 % of Mills Critical Speed
Max. Speed is btw. 80 % and 85 % of Mills Critical Speed
8 RPM Rated Speed (RS) 11 RPM (Typical)
Ball Mills
ABB Group
Max. Speed is btw. 80 % and 85 % of Mills Critical Speed
11 RPM Rated Speed (RS) 14 RPM (Typical)
Mill Speeds related parameters
0.3 Hz GMD Operating Frequency 6 Hz
Number of Rotor poles
48 to 76 poles (or more)
The bigger the Mill diameter the lower the Critical Speed
the higher the number of Rotor Poles
GMD Efficiency, operation
Motors have a high efficiency
Less number of poles than other designs
Low cooling air flow
Motor is running very soft; no unbalanced torque can be
noted (measured with the mill bearing pressure device)
ABB Group
Isolation switches for rotor and stator are directly built onto
the main terminal box
Only a 3 phase winding in the stator used (no parallel
circuits); no uncontrolled torque possible
GMD Mechanical design
Motor is rigid
Less deformation of the stator
More flexibility for the mill manufacturer
Motor poles can be individually adjusted
All torques and forces from rotor to mill flange only by
ABB Group
All torques and forces from rotor to mill flange only by
friction (no shear forces)
Good access to the liner bolts directly below the motor
Advanced sealing system (axial spring loaded dry system)
Motor heat exchanger not fixed to the motor housing. No
vibration will be transferred
GMD Ringmotor
Typical SAG Mill design
Typical Ball Mill design
Manufacturing
Frame
Stator core pack
ABB Group
Windings
Poles and pole fixing
Sealing
Cooling
Instrumentation
Air gap measurement
Partial discharge
Pedestal mounted motor
ABB Group
Typical SAG mill arrangement
ABB Group
Typical SAG mill arrangement (cont.)
ABB Group
Antamina SAG mill
ABB Group
Century Zinc SAG mill
ABB Group
Foot mounted motor
ABB Group
Typical Ball mill arrangement
ABB Group
Typical Ball mill arrangement (cont.)
ABB Group
Antamina Ball Mills
ABB Group
Cerro Verde ball mills
ABB Group
Cerro Verde ball mills
ABB Group
Manufacturing
Stator frame
Stator laminations
Stator winding
Rotor poles
Sealing system
ABB Group
Sealing system
Overpressure fans
Cooling circuit
Instrumentation
Air gap sensors
Partial discharge monitoring
Stator frame
ABB Group
Stator frame (cont.)
ABB Group
ABB Group
ABB Group
ABB Group
ABB Group
ABB Group
ABB Group
ABB Group
Stator laminations
ABB Group
Stator lamination stacking
ABB Group
Stator lamination stacking (cont.)
First lamination 2 mm
carbon steel plate
Remaining laminations 0.5
mm non grain orientated
silicon steel
ABB Group
First package of
laminations glued together
with resin
Same resin as the
windings, slightly diluted to
reduce viscosity
ABB Group
Keybars, hanging plates
and first set of laminations.
ABB Group
Lamination being stacked.
ABB Group
Lamination at stator
partition.
ABB Group
Stator lamination pressing
ABB Group
Stator lamination pressing (cont.)
ABB Group
Stator winding - Slot fill
Upper Wedge
Ripple Spring
Lower wedge, packer
Main insulation with
ABB Group
Main insulation with
Outer corona protection
Separator or RTD
Round Packing
Inner corona protection
(if necessary)
Stator winding Automatic taping
ABB Group
Stator winding - Bars
ABB Group
Stator winding Bars ready for insertion
ABB Group
Stator winding - Stator bar insertion
ABB Group
Stator winding - Wedging
ABB Group
Stator winding End connections
ABB Group
Stator winding End connections (cont.)
ABB Group
Stator winding End connections (cont.)
ABB Group
Stator winding - Stator terminals
ABB Group
Rotor Pole
ABB Group
Rotor Pole (cont.)
ABB Group
Pole mounting
ABB Group
Pole mounting (cont.)
ABB Group
Rotor pole
ABB Group
Rotor pole arrangement
ABB Group
Rotor pole arrangement (cont.)
Slip rings
ABB Group
Face for
teflon seal
Rotor cover
Central
fixation bolt
Mill flange Eccentric bushings
Lateral
fixation bolt
Pole central plate
Rotor cover
Rotor pole arrangement (cont.)
Slip rings
ABB Group
Face for
teflon seal
Rotor cover
Pole bolt with eccentric bushing
Mill flange
Central fixation bolt
Rotor pole - Manufacturing
ABB Group
Rotor pole - Pole units prior to impregnation
ABB Group
Sealing system
ABB Group
Sealing system (cont.)
Stator cover
Inside motor
ABB Group
Rotor cover
Spring
Mechanical
protection
Rubber seal
Sealing lip
Sealing lip
Teflon spacers
Inside mill
Inside motor
Sealing system (cont.)
ABB Group
Sealing system: Over-pressure fans
ABB Group
Sealing system: Over-pressure fans
2 fans with ~2 kW each
To generate over-pressure
inside the motor
Typical values:
400 Pa static pressure
1 m3/s air flow
ABB Group
1 m3/s air flow
At site altitude
Keep dust out of the motor
Symmetric design
Filter cartridge
1 10 m
Water resistant
Sealing system: Type 3 filter cartridge
ABB Group
Sealing system: Type 3 filter cartridge
ABB Group
Motor cooling
ABB Group
Motor general cooling arrangement
Air to water
Fan
Air
ABB Group
AC
Motor
Air
Heat Exchanger
Water
Motor general cooling arrangement (cont.)
Air to Water Air
Fan
Air
Fan
ABB Group
Air
Heat Exchanger
AC
Motor
Motor general cooling arrangement (cont.)
Air to Water to Air
Fan
Fan
Air
Air
ABB Group
Heat Exchanger Heat Exchanger
Air
Water
AC
Motor
Motor cooling systems: Chillers
ABB Group
Ringmotor instrumentation Stationary air gap sensors
Terminal Box
ABB Group
Terminal Box
Stationary air gap sensors (cont.)
3 static sensors
Redundancy
Alarm- and trip levels of the
air gap
Normal operation
ABB Group
16 mm, rotor centered
Alarm
Out of center by 4 mm
Trip
Out of center by 5 mm
Stationary air gap sensors - conditioner box
ABB Group
Stationary air gap sensors - Air gap measurement
Measuring method:
Contactless, capacitive
Scale range:
0,5 - 100 mm (depending on
probe dimensions)
Accuracy:
ABB Group
Accuracy:
2% approx.
Temperature range:
0C ....... +125C
Probe:
120 x 90 x 2 mm
Meter amplifier:
190 x 120 x 60 mm
Ringmotor instrumentation - Rotating air gap
measurement
ABB Group
Rotating air gap measurement (cont.)
Rotating sensor installed on a rotor pole, e.g. Pole # 1.
Same sensor type as static system
Transmitter and antenna installed on rotor cover
Power for transmitter supplied from rotor poles suitably
transformed and protected.
ABB Group
Digital signal transfer between transmitter and receiver
Frequency 2.4 GHz
Receiver installed outside stator frame . As close to line of
sight installation for optimum signal.
Key phasor (proximity sensor) installed on motor to
develop actual rotor pole position.
Rotating air gap measurement - Transmitter
ABB Group
Rotating air gap measurement Probe and
Conditioner
ABB Group
Rotating air gap measurement Antenna
ABB Group
Rotating air gap measurement - Visualisation
ABB Group
Rotating air gap measurement Visualisation (cont.)
ABB Group
Instrumentation - Partial Discharge (PD) Monitoring
During operation the insulation system of any electric motor is
subjected to a number of stresses.
On-line partial discharge allows PD activity to be recorded whilst
the GMD is subjected to normal operating stresses:
Thermal winding temperature, thermal cycling, etc
Electrical grid over-voltage, discharges in voids, etc.
ABB Group
Ambient humidity, oil, carbon dust, etc.
Mechanical vibrations, electromagnetic forces, etc.
On-line partial discharge is an additional measurement tool to
assess the integrity of the insulation of the GMD without having to
shut the GMD down.
Important terms:
On-line versus off-line
Continuous versus time interval measurements
PD possible areas of discharge
ABB Group
PD - Mechanisms
PD is a local breakdown phenomenon of microscopic voids
causing small sparks.
PD produce high frequency signals as a superposition to
the line voltage.
The high frequency signals can be measured by installing
couplers.
ABB Group
couplers.
Patterns gained from measurements allow identification
and localization of insulation defects and upcoming
failures.
Over time PD has an ageing effect on the insulation.
PD - Typical schematic
ABB Group
PD - Components
One per phase, one in neutral for noise filtering
Type CC7, 1000 pF
IEC 60034-27 gives guidelines for value of coupling
capacitor capacitance to be at least 1000 pF.
Allows safe and consistent hook-up point for
measurement.
ABB Group
measurement.
Surge protected to 90 V
IP65 enclosure
Closed during normal mill operation
MICAMAXX pdplus portable measurement device
Use for all installations
On-line PD measurements
Takes 30 seconds per phase measurement
Accomplished in approximately two minutes
Ringmotor is RUNNING (on-line measurement)
Thermal equilibrium (constant full load)
Rated Voltage
ABB Group
Rated Voltage
Rated Speed
Measured humidity
Measured winding temperature
Measured current/load and voltage
Allows for subsequent measurement comparisons
PD - Typical report information
ABB Group
PD - Typical report (cont.)
Specific report per measurement instance.
PD measurement is a trending tool.
Can compare subsequent measurements and be able to
advise future of the insulation.
Can advise suitable preventative maintenance measures,
e.g. clean the end winding from contamination.
ABB Group
e.g. clean the end winding from contamination.
Made more valuable when coupled with additional
measurement methods.
Summary, recap
Brief history/overview of GMDs
Installed base
Synchronous motors
Insulation systems
Ringmotor design
ABB Group
Ringmotor design
Ringmotor components
Ringmotor manufacturing
Fame, laminations, winding, poles, sealing, cooling
Instrumentation: Air gap (stationary and rotating), PD
ABB Group

02 Motor de Anillos

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

02 Motor de Anillos

Uploaded by

Copyright:

Available Formats

Curso de capacitacin GMD

Inductive (Lagging PF) Capacitive (Leading PF)

You might also like