Download - 4 metals workshop igor quintao
GE EnergyPower Conversion
We’re at work making change happen
METALS WORKSHOPBelo Horizonte18 April 2012Igor Quintão
2Team Account Planning Session
6/11/2012
Mechanical equipment
Electrical grid
Electrical machines
Variable speed drives
Automation and control
• Continuously advancing technology in critical components
• Helping to optimize the whole system architecture / system approach
• Mastering interfaces
++
Complete solution offering
3Team Account Planning Session
6/11/2012
Power Conversion – Products – Automation
| 3 | 3
Level 2
AC and DC Drives
Intelligent actuators/ instrumentation
Remote I/O Remote I/O
FieldbusFieldbus
Remote access
Ethernet TCP/IP
Set-up & ModelsEngineering & Diagnostics WorkstationHMI
Level 1
Level 0
VME based High Performance Controller HPC
Standard plc
HPCip
MV drives
4Team Account Planning Session
6/11/2012
Post-sale assistance / Service
5Team Account Planning Session
6/11/2012
Automation: Level 1
Basic functions• Real time operating system
• Functional multitasking
• Global / Local data transfer
• Remote and local I/O
HPCi controller, MV and DC drives
Key advantages for the user:• High reliability / availability
• Optimal maintainability
• Few and simple interfaces
• Unified open platform
• Easy connection to legacy hardware systems
• Minimum installation and start-up time
• Simple training
• Reduced spares
6Team Account Planning Session
6/11/2012
Automation: Level 1Engineering environment P80i – Programming Toolkit for C80-HPCi
Integrated environment for support tool• Program editors (FBD, SFC, LD), IEC-1131
compatible
• Programs and networks configuring tools
• Hardware configuration tools
• Debugging and commissioning tools
Multi-user networked access• Several P80i users can edit applications on
the same C80-HPCi
7Team Account Planning Session
6/11/2012
Automation: HMIHuman Machine Interface
Typical views
(Instrumentation)
8Team Account Planning Session
6/11/2012
Automation: Level 2
PDI
Supervision functions• Primary Data Input Management
o Using the main entry coil characteristics (PDI) sent by Level 3 computer (Customer)
• Product tracking & coil data sheet management
• Preset determination
• Speed optimization
• Mathematical Models
• Data collection & quality tracking
• Elaboration of reports (coil, shift, day, …)
9Team Account Planning Session
6/11/2012
Process: technological controls
Hydraulic Gap Control
FeedForward
AGCGap Correction
Feed Back AGCGap Correction
MassFlow Measure
Strip Speed estimation
Entry speed Exit speed
Torque Control
Inertia Compensation
Entry GaugeExit Gauge
MassFlow Gauge
Mathematical Model Level 2 PDI
Roll Force
Tension Corrections
ForceSet-up
AGC Dynamic ModelLevel 1
Set-up and product data
Rolling Mill Measures
AGC PRINCIPLES
Speed measures Speed measures
AGC Gains Calculation
FF : to anticipate entry deviation
MF : to measure standin gap thickness and to cancel measurement delay
Dynamic adjustment of the AGC gains to compensate for changes in hardness and all rolling mill conditions
AGC - Thickness Control - Principles for single stand Mill
FB : to center exit thickness
10Team Account Planning Session
6/11/2012
Process: simulationFull simulation:• Digital sensors, Absolute encoders, Thickness, Tension, Speed,
Flatness, Pulse Generators, Motor Currents…
Major advantages:• Reliability
• Shortening commissioningperiods
• Eliminating costly paralleloperation
• Training operators on the new system before the switchover
11Team Account Planning Session
6/11/2012
Automation: Aid in maintenance
Display of Missing Permissives• Automatic sequences
• Line run modes
Display of faults• Grouped faults
• History events
History• Storage of variables and events
• Display of recorded data
Operator aid on HMI
12Team Account Planning Session
6/11/2012
Automation: Aid in maintenance
Key features• Independent sample rates for each channel
• Recording of up to 1024 analog + 1024 digital channels
• Fastest data acquisition cycle is 1 ms for all signals
• Drivers are available for the most known PLCs in the market, including GE Energy C80-HPCi
• Acquisition from direct input or networks
• Step-wise X-Y zoom in and zoom out
• Calculations via a built-in formula editor: mathematical and logic functions
• Y/T, Y/X and FFT displays window options
• Data export to ASCII format and to databasesusing ODBC (including Excel format).
Operator aid - Process Data Acquisition
13Team Account Planning Session
6/11/2012
Automation: architectureExample for Tandem Cold Mill
14Team Account Planning Session
6/11/2012
Electrical and PowerLV drives – LV7000
MV drives – MV7000
Electrical rooms & pulpits
Motors100 MW
200 kW
15Team Account Planning Session
6/11/2012
Electrical and Power: DrivesLow Voltage Drives: LV7000• High performance drives from 0.75 kW
to 3600 kW
• 3 AC or Common DC bus power supply
• Frequency, speed and torque control
• 4-quadrant and active front-end inverter applications available
• Air or liquid-cooled possible
16Team Account Planning Session
6/11/2012
Power Conversion – Products – LV Drive
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DELTAModules
ReactorDC Link
AC Reactor
Rectifier
Fan
Inverter• Air cooled• 600kW• 440V - 690V
a.c.• 180kW ~
2.4MW
17Team Account Planning Session
6/11/2012
Power Conversion – Products – LV Drive
| 17
Inverter• Water cooled• 440V - 690V
a.c.• 600 kW ~ 3.6
MW
18Team Account Planning Session
6/11/2012
Electrical and Power: DrivesLV Drives on common DC bus• Only one common DC bus
is used to feed all AC Drives for strip transport
• Any regenerating drives send their power to other motoring drives via the DC link
• Battery support allows ride through of mains power loss
• Energy saving because AC current much less than sum of individual drives
• Full regeneration readily provided
• Ride through AC supply dips while maintaining strip tension
• AC input power factor : ~1, AC harmonics reduced
M1 M2
AC supply AC
ACCB Transformer
Inductionmotors
DC COMMON BUS
PWM inverters
Input bridge
converter
220 V AC
BatteryBatteryrectifier
19Team Account Planning Session
6/11/2012
Electrical and Power: Drives
Inverter-phase leg: the heart of the converter
Medium Voltage Drives: MV7000• Power range 4 up to 48 MW
• Voltage: 3.3 kV – 6.6 kV – 9.9 kV
• Powerful IGBT, based on Press-Pack technology
• Flexible design thanks to standar-dized modules, Active Front End design, DC-link configuration or stand-alone drive solutions
• Parallel connection for high ratings
• Compact design with excellent kW/m³ ratio
20Team Account Planning Session
6/11/2012
Power Conversion – Products – MV Drive
| 20
RANGE Topology Voltage (V)
Power (MW)
MV74005AC FP- AC 4160 0.5MV7401AC FP- AC 4160 0.9MV7402AC FP- AC 4160 1.8MV7403AC FP- AC 4160 3
MV7403 FP -WC 4160 2,5MV7405 FP -WC 4160 5MV7407 PP- WC 4160 7
Designed, manufactured and tested in Brazil
21Team Account Planning Session
6/11/2012
MV7400-Air Cooled and Water Cooled
• IGBT based 3 Level PWM drive– Active Front End (AFE) or
Diode Front End (DFE)– IEGT devices (Transistor
type)– Quick and easy change– High efficiency
22Team Account Planning Session
6/11/2012
COOLING WATER
Power Transformer
+
_
CONTROL & AUXILIARIES
NP
DC Capacitors 3-level NPP inverter (MEGAMODULE) Active Front EndControl AC out
MV73xx Drive Active Front End M 3~
Cooling unit
Pre-charge transformer
AC in
Electrical and Power: Drives
Single Line Diagram with 3-Level NPP Inverter
MV7000 up to date technology
23Team Account Planning Session
6/11/2012
Electrical and Power: Energy Quality
Energy quality systems: SVC and D-SVC• Used to compensate electrical
disturbances generated by large-scale consumers with fluctuating loads, like electrical arc furnaces and large drives
• Solution based on thyristor TCR or IGBT D-SVCs linked to fixed filters
• D-SVC solution is compact with enhanced performances
• Control system based on our PECe/HPCisystem (as drives and level 1)
• Application software developed with P80i programming tools
24Team Account Planning Session
6/11/2012
Electrical and Power: Energy Quality
More active power equals less tap-to-taptime equals increased production
Steel plant performances with SVCs
Power Increase = more Production • Shorter tap to tap melting time,
higher steel production
• Longer electrode life & lessrefractory material consumption
Neighbourhood disturbance & Utility• Minimum flicker perturbations
around
• No power factor penalties
• Voltage stability, less harmonics & transients