Drive Solutions for Electric Utilities

Transcription

1 Drive Solutions for Electric Utilities metals cranes mining testing oil & gas solar inverters utilities cement

2 About TMEIC A Global network TMEIC is built on the combined and proud heritage of Toshiba and Mitsubishi-Electric in the industrial automation, control and drive systems business TMEIC s global business employs more than 2,200 employees, with sales exceeding US $24 billion, and specializes in Metals, Oil & Gas, Material Handling, Utilities, Cement, Mining, Paper and other industrial markets TMEIC Corporation, headquartered in Roanoke, Virginia, designs, develops and engineers advanced automation and variable frequency drive systems The factory for the World s factories TMEIC delivers high quality advanced systems and products to factories worldwide, while serving as a global solutions partner to contribute to the growth of our customers Customer Service At TMEIC, our focus is on the customer, working to provide superior products and excellent service, delivering customer success every project, every time Variable Frequency Drives in Electric Power Plants Every step of the way from the fossil fuel to the electric power, variable frequency drives (VFDs) are used to smoothly start large motors and continuously adjust the speed as required by the process Induction and synchronous motors driving boiler feed pumps, forced draft fans, induced draft fans, service water pumps, and conveyors use VFDs to provide high power, accurate speed control, and efficient flow control with significant energy savings Controlling fan flow by adjusting speed avoids wasting energy in flow control vanes, dampers, and louvers When large flows must be controlled and motor energy consumption is significant, varying the motor speed is the answer With large machines, the electrical power savings can amount to hundreds of thousands of dollars per year In addition, the drives smoothly start the motors, protecting them against starting inrush currents, thus avoiding thermal stress and extending motor life Page 2 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

3 Why Use Electrical Variable Frequency Drives? Here are some of the reasons to use electrical medium voltage drives: Increased Reliability Pages 4, 6, 7 To control speed and flow, adjustable speed motor-drive systems are more reliable than traditional mechanical approaches such as using louvers, valves, gears, or turbines Because electric drives have no moving parts, they provide very high reliability, typically exceeding a 15 year MTBF Dramatic Energy Savings Pages 4, 5, 9 On an induced draft fan with a variable speed motor-drive system, the flow control louver or vane is not required, avoiding large flow energy losses In fact, the variable speed motor-drive system is more efficient than all other flow control methods including turbines and hydraulic transmissions Significantly Less Maintenance Pages 8, 19 Power plants demand high system availability Because electric variable speed drive systems have no moving parts, they require virtually no maintenance This is in sharp contrast to speed and flow control devices such as louvers, guide vanes, valves, and turbines that do require maintenance Motors Soft Starting and Improved Power Factor Pages 6, 8 When electric drives soft start large motors, starting inrush current and its associated mechanical and thermal stress are eliminated This removes limitations on motor starts per hour, reduces insulation damage, and provides extended motor life To Start Gas Turbine Generators Large utility gas turbines are often started using an LCI (Load Commutated Inverter) VFD connected to the generator used as a motor Hundreds of LCI drives are in service in starter applications Why TMEIC Drives Make Sense Choose TMEIC, a Global Supplier Page 18 TMEIC sells and services drive systems worldwide, supported by engineering and service offices and spare parts depots in North & South America, Europe, Asia, Japan and Australia We ve got you covered! A Complete Family of Drives Page 19 Our family of low and medium voltage (LV and MV) drives covers all your needs - from 450 hp to over 40,000 hp and beyond, with a wide range of output voltages up to 11 kv Engineering Expertise Page 11 TMEIC drive and motor application engineers bring an average of 25 years of practical industry experience to your application After analyzing your system requirements, they can recommend the most cost effective solution and design the complete drive system for you Configuration Software Page 27 The TMDrive Navigator world-class configuration software is used on all TMEIC drives Live block diagrams and tune-up wizards streamline commissioning and maintenance activities 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 3 of 28

4 Drive Applications in the Power Plant Variable frequency drives are used to control the speed of fans, pumps, and mills in power plants VFDs are also used to smoothly start large motors, synchronize, and connect them across the line The following seven pages describe four typical applications and present the reasons why electric drives were chosen These selected drive applications are: 1 Induced draft fans 3 Boiler feed pumps 2 Multiple ID fans 4 Service water pumps Application 1 Induced Draft Fan on Boiler The ID fan creates furnace air flow, which must be continuously varied to match the fuel flow The process control system continuously monitors process conditions such as fuel feed, inlet air temperature, flue oxygen content, and required fuel-air ratio The control system then directs the fan to provide the air flow for optimum combustion Traditional flow control methods use constant speed motors with mechanical flow reducing devices such as: Inlet louvers (dampers) in the ducting Outlet louvers (dampers) in the ducting Flow guide vanes in the fan casing Variable slip clutches in the fan drive shaft Hydraulic variable speed transmissions These mechanical solutions have significant disadvantages: High energy consumption at reduced flow rates Mechanical wear and required maintenance Generation interruptions due to mechanical problems Limitations on motor starting duty The electrical solution replaces the mechanical equipment with a Dura-Bilt5i MV VFD This brings a number of advantages Advantages of the TMEIC Dura-Bilt5i MV VFD System Very High Reliability The Dura-Bilt5i MV uses 3,300 Volt Insulated Gate Bipolar Transistors (IGBT) allowing a simpler, more reliable inverter design Since mechanical flow devices are not used, process interruptions caused by mechanical failures are minimized Energy Savings Elimination of the air flow losses through the dampers is usually the most compelling reason for applying a Dura-Bilt5i MV drive The ID fan power can be several thousand hp and using a drive to vary air flow can result in energy savings of over $100,000 per year, as described on the next page Power System Friendly The converter is a 24-pulse diode rectifier with a performance exceeding the requirements of the IEEE standard for Total Harmonic Distortion (THD) This means that other equipment connected to the power system is not adversely affected by harmonic frequency disturbances Heat Pipe Cooling For most frames the IGBTs in the three inverter legs are cooled with heat pipe technology, which maintains uniform working temperature, prolongs the semiconductor life, reduces cooling fan power and noise, and saves valuable floor space in the plant Page 4 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

5 Energy Savings using a TMEIC Variable Frequency Drive Fan System Variable flow can be provided by varying fan RPM to precisely match process operating conditions The variable frequency drive provides variable fan speed which varies the air flow according to the system resistance Output Flow Main Power 144 kv or below Variable Frequency Three-phase Induction Motor Induced Air Flow from furnace Dura-Bilt5i MV VFD Induced Draft Fan The first chart shows how different fan speeds are used to select the proper operating points A through E on the system resistance curve Depending upon the size of the boiler, the required ID fan output power can vary from a few hundred hp to several thousand hp The second chart shows a system using mechanical dampers to achieve flow control Pairs of flow and pressure operating points correspond to points A through E Power level percentages shown are total input power including all motor, transformer, fan, and system losses as percentages of required fan output power The energy deltas (vertical lines) allow calculation of energy savings and drive cost justification A table of expected annual operating times and power level differences is shown below Energy cost factors for the site are applied and the annual savings calculated Static Pressure Rise Operating Point A 140 Pressure Drop and Power System Resistance Speed A Speed B Speed C Speed D Speed E Operating Point B Operating Point C Operating Point D Operating Point E Percent Power Outlet Damper Inlet Vanes Drive Power Fan Output Flow Power Flow % Flow Ref Point Required Flow % % Power Using Outlet Damper Control % Power Using Adjustable Speed Drive Delta % Power Saved % Time on Annual Basis % Saved on Annual Basis A B C D E Total Annual % Energy Consumption Savings 581 Savings Based on the annualized percent savings in the table, an ID fan system with 1,000 hp output, operating for 8,000 of 8,760 hours per year, at an energy cost of $0035 per kwh, saves: 1000 x 0746 x 581% x $035 x 8000 = $121,359 If installed added costs of drive equipment are $150,000, the payback period will be only 15 months A good return on investment! 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 5 of 28

6 Application 2 Drives for Multiple Induced Draft Fans This 1987 power plant had four large 3800 hp boiler ID fans driven by four Load Commutated Inverters (LCI) drives and synchronous motors in each of two units A fan power upgrade to 6600 hp was recently made to accommodate new pollution control equipment known as SCR (Selective Catalytic Reduction), which reduces nitrogen oxides in the flue gas from burning coal A fifth LCI drive was configured as a spare to be connected to any of the four motors as required Typical Fan Power Upgrade in progress The customer had several requirements when making this major upgrade to the 600 MW power station: Replace the original motors with higher power 6600 hp synchronous motors for 4160 V ac operation and 1200 rpm Ensure the replacement drives have at least the same high reliability as the original LCIs, and the latest control equipment Provide ability for the drive to soft start the motor and thereby reduce the current inrush and resulting overheating Ability for the standby drive to be switched to any of the four motors if required After reviewing their alternatives, the company decided to place the order for the drives, motors, and electrical system with the original vendor - TMEIC The system diagram is shown on the next page Advantages of the Variable Frequency Drive and Synchronous Motors High Reliability Based on the customer s 20 years of trouble-free operating experience with the LCI, the high reliability is proven In addition, the ability to back up any of the drives with the standby drive yields very high system availability Smooth Motor Starting The LCI controls the rotor field (through the exciter) and the stator current to provide a smooth starting profile without exceeding rated volts and amps, thereby protecting the motor against overheating Cost Savings The synchronous motor and LCI combination is one of the highest efficiency drive systems available, resulting in energy cost savings over the life of the system Water Cooling Technology in the Drive The water cooling system reduces maintenance, drive room cooling costs, and ambient noise The system is redundant and water hoses don t need to be disconnected for bridge service, see photo on next page Page 6 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

7 A Backup Drive to Start and Control Four Large Motors TMdrive-XL55 Sync Motor 66 kv 7000 HP 6000 Vac 1200 RPM TMdrive-XL55 Sync Motor 66 kv 7000 HP 6000 Vac 1200 RPM TMdrive-XL55 Sync Motor 66 kv 7000 HP 6000 Vac 1200 RPM TMdrive-XL55 Sync Motor 66 kv 7000 HP 6000 Vac 1200 RPM TMdrive-XL55 66 kv 6000 Vac Standby Drive Redundant SCRs in Drive Ensure High Availability The unique LCI bridge design uses full voltage rated SCRs (thyristors) in an N+1 configuration Each series SCR stack (see photo) has one extra SCR such that any SCR can fail and the stack will continue to operate at full power Since SCRs typically fail as a short circuit, no added parts or control circuits are required redundancy is inherent Diagnostics indicates the fault down to the cell level and, when a convenient time for service occurs, the SCR can be quickly replaced Replacement does not disturb the water cooling system 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 7 of 28

8 Application 3 Boiler Feed Pumps Boiler feed flow has to be controlled to match the boiler load and maintain steam drum level In the past, boiler feed pumps have been driven either by a variable speed steam turbine, or a fixed speed electric motor using a throttling valve to control feed flow Occasionally hydraulic variable transmissions were used These approaches have disadvantages as described below Using a VFD and electric motor has a number of benefits, also listed below Steam Turbine Drive Disadvantages Special mechanical maintenance is required on a regular basis Turbine can be expensive, especially if it is custom designed Fixed Speed Electric Motor Disadvantages High energy losses in the throttling valve at lower flows is expensive Motor is subjected to hard starts with resulting thermal stresses on the windings with reduced motor life Hydraulic Transmission Disadvantages The energy losses are significant at lower speeds of less than 80% After reviewing their alternatives, the company decided to place the order for the drives, motors, and electrical system with the original vendor - TMEIC The system diagram is shown on the next page Advantages of the Variable Frequency Drive and Synchronous Motors Energy Savings and Reduced Maintenance Elimination of the flow losses through the throttling valve and its associated maintenance are usually the most compelling reasons for applying a variable frequency drive The feed pump power can be several hundred hp or more, depending on the plant rating, and using a drive to vary feed flow can result in considerable energy savings, as described on the next page High Reliability Based on years of customer experience, the high reliability of AC drives is proven TMEIC MV drives for utility applications have an MTBF from 12 to 16 years Smooth Motor Starting The VFD controls the motor input frequency and current to provide a smooth starting profile without exceeding rated volts and amps, thereby protecting the motor against overheating, extending motor life, and eliminating voltage dips A VFD eliminates restrictions on the number of starts per hour that apply to across the line starts Heat Pipe or Water Cooling Technology in the Drive The advanced technology cooling system maintains uniform working temperature, prolongs semiconductor life, reduces cooling fan power and noise, and saves valuable floor space in the plant Page 8 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

9 Energy Savings using a TMEIC Variable Frequency Drive Pump System Flow can be controlled to match process operating conditions by varying pump RPM The variable frequency drive system does not require a flow control (throttling) valve Costs for the fixed and variable speed cases are compared below Variable Frequency Three-phase Boiler Feed Pump Main Power 144 kv or below Induction Motor Option Gearbox Output Flow MV Drive Boiler Feed Flow Throttling Valve Flow Control The example curves below are for a 600 hp pump for low head requirements In the pump curves, operating at 2400 GPM and 3560 RPM requires 550 hp (refer to point A) Reducing the flow to 1200 GPM with a throttling valve, at constant 3560 RPM speed, causes the pump to move back to point B; this point requires 400 hp Alternative Variable Pump Speed Flow Control (No Valve) Using a VFD, reducing the pump speed from A to C reduces the flow to 1200 GPM, but the head is much reduced, from 800 ft to 200 ft and the power required is only 70 hp This is 330 hp less than the first case, and represents the power which was lost in the throttling valve If much time is spent at low flows the energy savings using a VFD are considerable Typical pump head, flow, speed & power characteristics Energy Cost Savings with VFD In this example, the pump was consuming 400 hp at B but at C is only consuming 70 hp, so the energy saved by not throttling is 330 hp As a quick estimate, assume operation at point C for 60% of the time and at point A for 40% of the time With 90% combined motor efficiency and power costs of $005 per kwh, annual savings will be just under $60,000 Significant! Of course the larger the motor the larger the savings will be, and since energy costs will probably continue to rise, the life time savings will be large Typical VFD and Motor data: Drive efficiency Dura-Bilt5i MV - 965% Motor efficiency Induction - 957% Synchronous - 981% Drive power Dura-Bilt5i MV - Up to 7,000 hp Output Voltage Dura-Bilt5i MV - 2,000 to 4,200 Vac 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 9 of 28

10 Application 4 River Water Pumps for Cooling Flow of cooling water through the main turbine condenser varies with the volume of steam entering, which is proportional to the generating load This cooling flow usually comes from the cooling tower and has to be controlled based on the load Make up water compensates for evaporation in the cooling tower, and is pumped from a nearby river or lake The make up water flow also varies with the load and must be controlled Typical vertical water pumps This utility customer had three river water pumps for make-up water and planned to install new drives on two of them The requirements were: 160 Vac drives, each of 900 hp Each drive to have a bypass allowing the motor to run directly off the line at full speed if required Nominal pump speed 885 rpm with a % speed range Drives to be housed in a power house located close to the intake structure and pumps Power house to be air conditioned to allow operation of the drives with an external ambient temperature of 40ºC (104ºF) Dura-Bilt5i MV drives were chosen for this upgrade because they operate at 4,160 Vac, have a small footprint, and have built in control for synchronous bypass Cooling water requirements will also decrease as the cooling water temperature decreases Pumps driven by VFD s can efficiently accommodate these changes in flow requirements The cooling water pumping system has several levels of built-in redundancy Both drives have a bypass allowing the motor to run directly off the line at full speed if required Either drive can vary its pump speed to produce the desired combined flow to the cooling tower Advantages of the Dura-Bilt5i MV Pumping System Very High Reliability The Dura-Bilt5i MV uses 3,300 Volt Insulated Gate Bipolar Transistors (IGBT) allowing a simpler, more reliable inverter design Smooth Motor Starting The VFD controls the motor input frequency and current to provide a smooth starting profile without exceeding rated volts and amps, thereby protecting the motor against overheating, extending motor life, and eliminating voltage dips Synchronous Bypass The drive has built-in control to automatically synchronize the motor frequency and phase with the main power and close the contactors to allow the motor to run at full speed when required Heat Pipe or Water Cooling Technology in the Drive The advanced technology cooling system maintains uniform working temperature, prolongs semiconductor life, reduces cooling fan power and noise, and saves valuable floor space in the power house Page 10 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

11 Global Customer Support Network Comprehensive technical service is provided by our Customer Support Organization, staffed by TMEIC service engineers with offices and spare parts depots across the globe In North and South America Customers are supported by the TMEIC Corporation service personnel, design engineers and Spare Parts Depot in Virginia, and the TMEIC Factory in Japan In Europe TMEIC service engineers service all drive systems in Europe, supported by the European TMEIC Spare Parts Depot In Asia and the Pacific Rim TMEIC services drive systems throughout China, India and the Pacific Rim, supported by multiple Field Engineers, Spare Parts Depots, and the TMEIC factory in Japan Remote Drive Diagnostics TMEIC supports drive customers through the Remote Connectivity Module (RCM), a remote diagnostic service link with the TMEIC design and service engineers in Roanoke, Virginia The RCM enables seamless integration between your drives and our engineers Remote System Diagnostics TMEIC s remote system diagnostics tool, included in level 1 software, offers a quick path to problem resolution System faults are automatically identified, and provide an integrated view of product, process and system information TMEIC design and service engineers in Roanoke, Virginia, can analyze the data and provide steps for resolution For Service or Parts, call INTERNATIONAL: Hours / 7 days Remote Diagnostic Service reduces Mean Time To Repair (MTTR) Remote diagnostic service offers protection for your investment, by reducing downtime, lowering repair costs and providing peace of mind Remote diagnostics requires an internet connection between your plant and TMEIC for retrieval of fault logs and files to diagnose drive or system issues Features Reduced downtime and Mean-Time-to-Repair Secured connection Fault Upload Utility Benefits Quick support saves thousands of $ in lost production TMEIC engineers can quickly connect to the drive and diagnose many issues in a matter of minutes Customer-controlled access All remote activity is conducted with permission of the customer Drive start/ stop is not permitted remotely Proprietary Fault Upload Software Historical drive faults are identified; TMEIC design and service engineers can analyze the issue resulting in the fault and provide a solution 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 11 of 28

12 We Engineer the Medium Voltage Power System TMEIC application engineers design the power system from the medium voltage switchgear to the adjustable speed drive and motor A typical MV power system is shown below TMEIC Application Engineers size and select all the equipment for the optimal drive solution The critical engineering process for a successful installation is illustrated in the following Project Engineering section Icons indicate where the various teams of engineers in the factory and field service are involved in the project Medium Voltage Power System Transmission Voltages Distribution Voltages << >> Substation Transformer Breaker Instrumentation Drive Isolation Transformer MV switchgear is selected for the application considering: Instrumentation for equipment metering, monitoring, protection and control is selected, including: Drive isolation, input, and output, transformers are selected for the application considering: - The type, such as vacuum or SF6 - The size for the current and voltage - The CTs, PTs, and protective relays to operate the breaker - The enclosure for outdoor or indoor - The environment such as temperature and humidity - Amp transducer and ammeter - Watt and Watt-hour transducers - Phase CTs and phase overcurrent relay - Ground sensor CT and relay - Power quality monitor - The type, such as dry or liquid filled - Size for the kva and voltage - Cooling if required - The enclosure for outdoor or indoor - The environment such as temperature and humidity - Special drive requirements Page 12 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

13 Drive Utilization Voltage Motor Motor Load Load Adjustable Speed Drive Control PLC Motor Selection of the best adjustable speed drive for the application based on: - Continuous and overload torque and power requirements - Type of load, including constant or variable torque or regenerative - Drive and motor voltage - Power system compatibility - Overall efficiency of the ASD and motor combination - Harmonic analysis Selection of optional drive associated Equipment such as: - PLC for logic control, for example synchronizing multiple motors with the supply for soft start capability - Air conditioned equipment house if required - Switchgear if motor is to be synchronized with the line - Reactor for use with an LCI Selection of the motor and associated equipment including: - Induction, synchronous, or wound rotor motor - Motor size including the power, torque, voltage, current, and speed - Selection of the exciter if a synchronous motor is used - Required motor protection devices - Optional tachometer-special applications - Torsional analysis 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 13 of 28

14 Project Life Cycle Process The Project Teams Technical Proposal Specification Detailed Hardware & Software Design and Component Procurement Factory Acceptance Test System Commissioning System Maintenance and Service Customer Team Field Team Factory Team Training Team Technical Proposal Specification TMEIC Assists in the Project Planning Utility Voltage bus PLC Coordination & Interface DB5i MV Unit A Sync Ready DB5i MV Unit B Sync Ready 3-phase 3-phase Tie Contactor VFD Bus 1 CPT 2 PTs Mtr 1 Mtr 2 Mtr 3 Bypass Bus CT-1 CT-4 CT-5 During all phases of your project planning, TMEIC assists by supplying information, training, guide-form specifications, and general advice Experienced drive application engineers prepare a technical proposal that includes: Customized system architecture for your project Detailed equipment specifications for the drives, exciters, transformers, switchgear, and housings Thorough description of the PLC control functions, including logic for synchronizing and desynchronizing the motors Formal bid documentation Detailed description of equipment in proposal System architecture illustration Page 14 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

15 Detailed Hardware/Software Design & Procurement Electrical and mechanical prints Control logic and drive configuration Keypad configuration Based on the proposal specification, the project engineering team proceeds with four main tasks: Control Software Design Control engineers configure the drives and PLC controller logic, if a PLC is required for the application The illustration above shows a typical toolbox logic function diagram in Relay Ladder Diagram format The toolbox is used for drive configuration, tuning, sequencing, and drive diagnostics Operator Interface All TMEIC drives include a configurable keypad shown above Optionally, a touch panel operator station can be connected to the system Interface screens for maintenance and drive control are then configured The keypad provides real-time drive data and operator interaction Hardware Design All equipment is specified per the project requirements, and a complete set of elementary diagrams, layout, and outline drawings is created Component Procurement We work with our parent companies to source the most cost effective system components for your application 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 15 of 28

16 System Test TMEIC understands the importance of a thorough system test Our engineering team conducts a comprehensive factory test before shipment For example, the Dura-Bilt5i MV drive tests in the factory include: Full voltage check of power cells, insulation, and control circuits Acceleration and run test with unloaded MV motor Full current test into a reactor Validation of all I/O interfaces Validation of the drive test modes and any special logic, or optional PLC Dura-Bilt 5i MV Drive Factory Test Dura-Bilt 5i MV Control System Validation in the Factory Software tool for Drive and Logic Configuration Operator's Keypad Digital Motor Simulator Digital Load Simulator M Load Drive Simulator software Drive Control Logic Control Firing Control LAN Interface DB5i Microprocessor Controller Optional PLC with Logic, for example to soft start multiple motors PLC Diagram of Dura-Bilt5i MV Control System Test Setup U P C I/O modules Local Area Network to DCS Factory validation of the drive control system is available as an option, either in Roanoke, Virginia, or in Houston, Texas Validation of the optional LAN interface, DCS link, and PLC sequencing and logic can be done as shown opposite Drive, motor, and load simulators are available if required Using the simulated equipment, the PLC can be run through its sequencing and the resulting outputs validated Note: Logic for synchronizing a single motor to the line can be included in the Dura-Bilt5i controller, so a PLC is not required for this Page 16 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

17 System Commissioning In the commissioning phase, the TMEIC team includes the field engineers you know and trust, alongside the engineer who designed and tested the system This overlap of teams between engineering design and the site ensures a smooth and on-schedule startup The TMEIC service engineer, who is responsible for startup and commissioning, and for any future service required at the site, is part of the project team and participates in the factory system test to become familiar with the system Commissioning is supported by TMEIC design and service engineers Drive Training at the Factory or in Your Plant Customer engineers, maintenance and operations personnel are trained on the drives and control system at the TMEIC Training Center in Virginia This worldclass facility features large classrooms and fullyequipped training labs Classroom and hands-on training consists of 50% class time and 50% hands-on lab time Topics include: Overview of the drive system Function of the main assemblies Technical details of the components Drive and control system tools System diagnostics and service As an alternative to the standard factory training in Virginia, TMEIC can offer a course tailored to your project and held at your location In this case, a project engineer trains your operators, maintenance technicians and engineers in your facility Complete and Detailed Drive System Documentation Along with the hardware and software, TMEIC delivers complete system documentation: An electronic instruction book with all the prints on CD with a hyperlink index Recommended wiring and grounding procedures Renewal parts list Standard third-party vendor documentation At the end of the project, the drawings are updated to reflect the final changes 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 17 of 28

18 TMdrive -10e2 Low Voltage System Drive 575/690 AC 440/460 AC Volts The family of low voltage AC system drives has an integral DC bus structure with a wide variety of inverters (DC to AC) and converters (AC to DC) to match virtually any application in the paper industry , kw Hp 400, 460, 575, or 690 volt operation Motor power up to 1,949 kw Regenerative converter option Draw-Out Style Inverters For applications up to 193 kw (249 hp), draw-out style inverters are available in a very compact package Draw-out inverters are mounted on heavy-duty slides with staggered dc bus connectors on the back that connect with the bus when slid into the cabinet Motor cables are terminated at a common terminal block in the bottom of the cabinet Heat Pipe Cooling Technology The use of heat pipe technology provides a dramatic advance in power bridge cooling, including a significant reduction in the footprint of the power bridge, and fewer fans lower the audible noise Condenser Chill Plate The Thermal Cycle 1 Condensate to Vapor IGBT s are mounted to the multi-channeled chill plate which cools them Heat generated by the IGBTs vaporizes the refrigerant, moving it upwards through the chill plate to the finned condensing unit IGBT power switches 2 3 Vapor To Condensate Cooling air is pulled up through the IGBTs and the condensing unit, and cools the refrigerant, which condenses back to liquid Return of Condensate The condensed refrigerant returns to the bottom of the chill plate to start the thermal cycle over again Page 18 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

19 TMdrive-10e2 Operator Interfaces Cabinet Enclosure Displays Three-digit display alternates between speed and current while running, or a fault code when there is an error Standard Display LEDs give a quick indication of the status of the unit LED indication Ready On when the unit is ready to run Running On when the unit is running Alarm/Fault Blinking LED indicates alarm condition, while solid LED indicates a fault RJ-45 Ethernet port is used for local tool connection Interlock button disables the drive DC Bus Discharged On when DC Bus is Discharged Optional Enhanced Keypad Navigation Allows adjustment of drive parameters from the front of the equipment Controls Allow the equipment to be controlled in local mode from the front of the equipment Reset faults, reverse direction, inc/dec speed, jog, run and stop are available Switch to local mode to allow operation at this control panel Optional analog meters can be supplied in addition to either the standard or enhanced display Standard inverter I/O includes meter driver outputs that are +/- 10 V with 10-bit resolution For cabinet style equipment, four meters are provided For draw-out style, two meters are provided for each inverter Draw-out Enclosure Displays LEDs give a quick indication of the status of the unit LED indication Ready On when the unit is ready to run Running On when the unit is running Alarm/Fault Blinking LED indicates alarm condition, while solid LED indicates a fault DC Bus On when DC Bus is discharged Discharged 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 19 of 28

20 TMdrive -MVG 11,000 AC 10,000 AC 6,000 AC 3,000 AC Volts kw The TMdrive-MVG is a general-purpose, medium-voltage, variable-frequency AC drive for industrial power ratings up to 10 MW, in the voltage range of 3/33 kv, 6/66 kv and 10/11 kv Featuring high-quality Japanese design and manufacture, the TMdrive-MVG works with existing or new induction motors and meets users basic system requirements as described below High reliability, low harmonic distortion, and high power factor operation are designed into the MVG drive The TMdrive-MVG is available in 3 voltage classes: 3 33 kv Voltage Class: 3,000 3,300 V ac 6 66 kv Voltage Class: 6,000 6,600 V ac 11 kv Voltage Class: 10,000 11,000 V ac Features Conservative design using 1700-volt IGBTs (Insulated Gate Bipolar Transistor) High energy efficiency over 97% (design value) Benefits Highly reliable operation and expected 12-year drive MTBF, based on field experience with the large global installed base of TMdrive-MVG technology Considerable energy savings, in particular on flow control applications Diode rectifier ensures power factor greater than 95% in the typical speed control range Multiple level drive output waveform to the motor (13 levels for the 66 kv inverter) Direct drive voltage level Multi-pulse converter rectifier and phase shifted transformer Capacitors not required for power factor correction No derating of motor for voltage insulation or heating is required due to motor-friendly waveform No output transformer required No harmonic filter required to provide lower harmonic distortion levels than IEEE guidelines Designed to keep running after utility supply transient voltage dropouts up to 300 msec Uninterrupted service for critical loads Input isolation transformer included in drive package Better protection of motor Simplified installation Lower cost installation Page 20 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

21 Modular Architecture Creates Performance Advantages TMdrive-MVG (3 kv class) TMdrive-MVG (6 kv class) Power supply 30/33 kv three-phase 50/60 Hz Series connected inverter cells Power supply 60/66 kv three-phase 50/60 Hz Input transformer, phase shifted secondary windings (18-pulse equivalent) M DC-bus capacitor Inverter Cell Module removed from rack Diode rectifier Inverter Cell Module Single phase inverter Input transformer, phase shifted secondary windings M Inside the TMdrive-MVG Cabinet an example of the 6 kv class drive with inverter cell detail Input Transformer The special input transformer has phase-shifted secondary windings to produce multipulse converter operation This design exceeds the IEEE-1992 guidelines for current distortion Air Cooling Forced air cooling system with: Intake through cabinet doors Upwards flow through inverter cells and transformer Exhaust at top of cabinet Optional redundant cooling fan system is available Cell inverters Example: six banks of three, series connected inverter cells: Diode bridge rectifier IGBT PWM inverter DC link capacitor I/O Board The I/O board supports encoder, 24 V dc I/O, 115 V ac inputs and analog I/O, standard All I/O are terminated to a two-piece modular terminal block for ease of maintenance Control Functions A single set of control boards feeds all inverter cells The primary control board performs several functions: Speed & torque regulation Sequencing I/O mapping Diagnostic data gathering Provision for optional LAN interface 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 21 of 28

22 TMdrive -XL55 66 kv Drive Volts 6, ,000 1,340 4,000 5,364 10,000 13,400 20,000 kw 26,820 Hp The TMdrive-XL55 is a medium voltage, ac fed drive designed for high-efficiency and power-friendly operation in a broad range of industrial applications High reliability, low harmonic distortion, and high power factor operation are designed into the drive The TMdrive-XL55 is available for kv voltage class output Features Conservative design using 4500 V IGBTs Benefits Highly reliable operation, expected 10-year drive MTBF High energy efficiency approximately 986% Considerable energy savings Diode rectifier ensures power factor greater than 95% in the speed control range 36-pulse converter rectifier by using separated phase shifted transformer Multiple level drive output waveform to the motor (five levels for the 66 kv inverter) Synchronous transfer to line option with no interruption to motor current Remote input isolation transformer 66 kv direct drive voltage output level Capacitors not required for power factor correction No harmonic filter is required to provide lower harmonic distortion levels than the IEEE-519 guidelines Suitable for standard motors due to motor friendly wave form Allows control of multiple motors with one drive No motor current or torque transients when the motor transitions to the AC line Less power loss in drive room Less total space required Simplifies design and installation No output transformer required, saving cost, mounting space, and energy Page 22 of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved

23 TMdrive-Navigator - Simple Configuration and Maintenance The TMdrive-Navigator tool helps you maintain TMEIC drives yourself Engineers and technicians are empowered to understand how the drive works and what the drive is doing Any user can easily access current drive expertise and knowhow Desk-top like search technology links topical signal lists, block diagrams, help files, productdocumentation, change history, and user notes Windows techniques facilitate navigation within a drive and across the system The status of all drives is always in view High-speed data is automatically captured and saved in the event of a drive fault Users may also capture high speed data based on their own trigger conditions or perform high resolution real-time trending Fault data can be automatically pushed to key users The client-server architecture allows access to high performance data from remote locations with the same resolution as if you were in the plant Wizards support tuning of drive functions Live block diagrams provide a real-time graphical view of drive functions Functions can be configured directly from the graphical view Product documentation is integrated right into the tool Users may even capture their own notes to benefit future troubleshooting Compatible with: Windows XP, Vista 7 Windows Server 2003, TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved Page 23 of 28

24 A Family of Drives up to 11 kv TMdrive-10e2 TMdrive-50 TMdrive-XL55 TMdrive-MVG Global Office Locations: TMEIC Corporation Roanoke, Virginia, USA Web: wwwtmeiccom TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION (TMEIC) Tokyo, Japan Tel: Web: wwwtmeiccom TMEIC Europe Limited UK (London) Tel: Italy (Bari) Tel: Germany (Frankfurt) Tel: Poland (Krakow) Tel: Web: wwwtmeiceu TMEIC Industrial Systems India Private Limited Andhra Pradesh, India Web: wwwtmeicin TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION (TMEIC) Beijing, China Web: wwwtmeic-cncom TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION (TMEIC) Shanghai, China Web: wwwtmeic-cncom TMEIC Asia Company Ltd Kowloon Bay, Hong Kong Kaohsiung, Taiwan Web: wwwtmeiccom All specifications in this document are subject to change without notice This brochure is provided free of charge and without obligation to the reader or to TMEIC TMEIC does not accept, nor imply, the acceptance of any liability with regard to the use of the information provided TMEIC provides the information included herein as is and without warranty of any kind, express or implied, including, but not limited to, any implied statutory warranty of merchantability or fitness for particular purposes The information is provided solely as a general reference to the potential benefits that may be attributable to the technology discussed Individual results may vary Independent analysis and testing of each application is required to determine the results and benefits to be achieved from the technology discussed TMdrive is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION TMEIC is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION TM is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION 2011 TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION All Rights Reserved I-1108-A4