4100C BOSS AC Shovel Drive System Overview. WMEA Edmonton - June 2008

Transcription

1 4100C BOSS AC Shovel Drive System Overview WMEA Edmonton - June 2008

2 Overview Drives Partnership with ABB Deck Plan / One-Line Schematic ISU (IGBT Supply Unit) Shovel Motion Inverters Cabling / Grounding Centurion System Control / Hardware AC Motor Development 4100C BOSS Performance Current 4100C BOSS AC Shovel Orders Final Thoughts

3 P&H and ABB Drive Technology ABB is a world leader in AC & DC drives systems ABB continues to invest in R&D for AC and DC drive technology Upcoming DCS800 development ABB has thousands of ACS800 drive installations world-wide Partnership with P&H to increase performance of our mining equipment History with P&H

4 4100C BOSS Deck Plan

5 Inverter Lineup on Shovel

6 Base Frame for Inverter Lineup

7 One-Line / Main Xfmr. To ISU

8 DC Bus and Motion Inverters

9 IGBT Supply Unit Functionality Individual block consists of Inverter Modules (2), a line filter (LCL Filter Module), and AC & DC Fuses The IGBT Supply Unit rectifies three-phase AC current to Direct Current for the intermediate DC link, which further supplies the inverters that run the motors. The line filter suppresses the AC voltage distortion and current harmonics.

10 ISU Control Functionality The ISU controls the Charging Circuit and Main Circuit Breaker of the drive system. The charging contactor closes, connecting the intermediate DC link capacitors to the AC supply via the charging resistors. DC link voltage rises When the DC voltage is high enough, the Main Circuit Breaker is closed and the Charging Contactor is opened. Line-side converter synchronizes itself to the supply network and begins modulation. Motion Inverters are then ready for operation.

11 ISU Control - Continued DC Voltage Control DC Voltage Reference = 930VDC Controller Parameters are tuned by default, no need to reset them Reactive Power Control Q Power Reference of 1.0 (unity) for normal operation Power Factor control adjustments for Motivator Mode Operation Only two setpoints required Full regenerative operation

12 Main Circuit Breaker Cubicle

13 ISU Inverter Section View

14 Shovel Motion Inverter Units ABB Multidrive system with parallel operation for all motions. Each module is a complete three-phase inverter. Hoist1 and Hoist2 = 4 parallel inverters (each) Crowd, Swing1, Swing2, Propel1, Propel2 each have 2 parallel inverters All inverter modules have a rating of 580kVA This coupled with reduced-run operation allows for higher availability and machine run time. 4100C BOSS AC Drive system designed with 4100XPC AC Drive system in mind. Propel 1&2 = +1 module, add Swing3 cubicle

15 Motion Inverter Section

16 Motion Enhancements Higher speeds for Hoist and Crowd Higher peak horsepower Dedicated Propel drive system / No Transfer Switch Optimal performance with ABB DTC (Direct Torque Control)

17 DTC Direct Torque Control Field orientation achieved using ABB adaptive motor model to calculate motor torque directly and without using a PWM modulator Self-Identification / Auto-tuning completed using the Drive ID Run which identifies specific motor parameters (stator resistance, mutual inductance, saturation coefficients, etc.) Motor Torque and Stator Flux used as primary control variables Quick Torque response Accurate Torque control at low frequencies Torque repeatability No predetermined switching frequency of power devices reduces mechanical resonances and stress in gearboxes

18 DTC - Control Diagram

19 System Cabling / Grounding Symmetrical multicore cables are used Symmetrical arrangement of three phase leads and three earth conductors Continuous outer shield provides low impedance path for common mode current to return to the inverter 360 degree termination at both ends using Roxtec modules A conductive, low impedance foil is wrapped around the cable shield and entire Roxtec module High frequency bonding connections using braided straps and EMI shielding gaskets at motor frames Flat conductors provide a lower inductance path than round wires

20 System Cabling - Continued

21 Roxtec Connections

22 High Frequency Bonding

23 Inverter Connections

24 Centurion Control System Consistency with proven DC Centurion System Drive communication between AC800 and drives are identical Re-use of existing code between both systems with use of shared libraries New Control Cabinet with AC Drive Controller panels New I/O Assemblies Converter, RPC, and Transfer Cabinet I/O removed ISU I/O Station, Rear Machinery House I/O Station added

25 Control Cabinet / Drives

26 Drive Controllers

27 Parallel Drive Branching Unit

28 AC Shovel GUI Same look and feel as current DC System Consistency of symbols and images so operator s experience between shovels is similar DriveWindow tool for loading / saving drive parameters and making recordings of drive signals Drive Datalogger update / save function Each drive has two dataloggers enabled Once triggered by a fault, the GUI will upload & save the data, then re-start the datalogger for next event ShoveLink II as an available option Built-in expanded help files and information Schematic viewer with inventory links to Parts Book Flowcharts that simplify logic and troubleshooting

29 AC Motor Development Two motor frame sizes P&H HAF HP/1194 kw, used for both hoist motors P&H HAF HP/545 kw, used for Crowd, Swing, and Propel Heavy duty mechanical design Proven bearing designs Replaceable non destructive INPRO type brass bearing seals for improved contaminate protection Lower inertia for improved system performance Premium insulation system ( class H or better ) Insulated bearing and a shaft grounding feature Improved reliability No brushes, commutator, or exposed uninsulated conductors Single set of coils ( Stator coils as compared to armature coils, interpole coils, compensating coils, field coils)

30 Stator Winding Assembly

31 HAF8412 Hoist Core Assembly Cooling Scheme

32 AC Shovel Motor Rotor Assembly Cooling Scheme

33 4100C BOSS AC Shovel Performance Availability of the three operating 4100C BOSS AC shovels exceeding initial design criteria Preliminary production numbers show significant increase Faster motion operation, increased horsepower Instant propel feature allows operator to position shovel closer to the bank more often, which results in ideal shovel positioning for increased fill factors.

34 AC Shovel Systems Order Status Three (3) 4100C BOSS AC machines are currently operating at Suncor Energy in Fort McMurray Two more machines currently on order Two (2) 4100C BOSS AC machines ordered for U.S. market Lignite & Phosphate operations

35 Final Thoughts P&H is committed to strengthening our DC shovel offering with R&D and continuous improvements focusing on the entire shovel system. DC Motor Design (brush / commutator life) Performance / Productivity Power Quality Reliability DC Centurion Control will continue to be offered in all shovel models. Common Centurion platform allows for ease of implementation of product enhancements for AC and DC shovels.

36 THANK YOU!