Randy Huebner MV Drives North America
World Market size & growth ABB specific data Applications in Utilities ABB MV Drive Products North America – Competitors Outline
World Market size and growth 00-04 USD CAGR: 15% CHF CAGR: 6% Unit CAGR 14%
Turgi ABB Drives USA • ABB US Drive Headquarters New Berlin, WI • 180M Sales 2004 • 330 Employees • ISO 9001 Facility • LV & MV Drives & Motors • Power Electronics • Ratings: 3 - 135,000HP ABB MV Drive Headquarters Turgi Switzerland MFG Location for MV Drives Products World leader in MV Drives
ATAP Projects Business – North America Chuck Clark Rick Hepperla Pat Hogan Bernard Lafrance Joe Maloni Bernard Lafrance Dane Maisel Mike Wallin
Large Motors Applied in Power Generation • Circulating and Cooling Water Pumps • Boiler Feed Water Pumps • Fans • Compressors • Coal Mills • LCI Starters for Generators • Any of these Motors can use a Drive!!
Fans Chimney Boiler Cooling tower fan Desulfurization Electric precipitator Air preheater ID Fan Primary fan Secondary fan
Visualization of power flow Source: Hugo Stadler, Lohr GmbH
Common Applications • ID Fans and Scrubber Upgrades • Scrubber upgrade requires larger ID Fan • Power supply is not large enough to start motor • Matched ID fans to to balance the load • ID fans and FD Fans on swing plants help turn down ratio of the plant
ACS 6000c ACS 1000 MV Drives Portfolio (standard converters) P (kW) 50’000 27’000 ACS 6000 ACS 5000 16’000 LCI 10’000 Motor Power 9’000 7’000 5’000 ACS 1000 Step-Up 2’000 315 U (kV) 1.0 1.5 1.8 2.4 3.3 4.16 6.0 6.9 8.0 13.8 Motor Voltage
ACS 1000, ACS 5000 , ACS 6000 • Reliability and Availability • Robustness and Performance • Efficiency • Compatibility
Reliability - Semiconductors • IGCT semiconductors and 3-level VSI design • Low part count • Least complex and most robust design • No series or parallel connection of power semiconductors
Reliable Components • Fuseless design • Faster and better protection than medium voltage power fuses • Long-life capacitors • Advanced, self-healing, environmental friendly, foil capacitors have a substantially longer lifetime than electrolytic capacitors • Lower lifetime costs • Built-in input surge protection • Surge arresters at the isolation transformer primary side • Tolerant to network disturbances • Increased reliability
Worldwide Service and Support • Installation and commissioning • Training • On-board diagnostics • Remote diagnostics • Customized service programs • Local technical support • Local service support • Spare parts and logistics network • 24 x 365 support line
Robustness and Performance - DTC • Direct Torque Control (DTC) • Most powerful control platform • Power loss ride-through of one second • Flying start and automatic restart • Flux optimization • Critical speed avoidance bands Typical torque response (t) of a DTC drive, compared with flux vector control and open loop pulse width modulation (PWM)
Robustness and Performance – Power Ride Through At least 1sec for main power and auxiliary power
Compatibility – Input / Network • 24-pulse or 12-pulse diode rectifiers, fulfilling IEEE 519 • No active switching elements on line side interface (only for 4 Q operation) • No filter at the line side • No oscillation problems • No power factor compensation
Compatibility – Fieldbus adapters • Control System • Connection to higher-level process controllers • Flexible hardware I/Os for remote control, allowing easy customization • Large variety of available fieldbus interfaces • Profibus • Modbus • DeviceNet • LonWorks • CANopen • InterBus-S • Ethernet
ACS 1000 Main Features • Inverter design
ACS 1000 Sine Filter • Output sine filter • Actively controlled LC low pass filter • Eliminates virtually all inverter switching harmonics to the motor • Keeps motor and bearings common mode voltage free Drive output voltage to the motor Inverter output voltage
Stray capacitance to ground of: • Transformer • Cables • Converter Compatibility – Common Mode • The produced common mode voltage is only seen by the transformer secondary windings against ground • The Common Mode is keept inside the Drive System
ACS 1000 Air cooled or Water cooled
6.5ft excl. air outlet cover 10ft 3ft ACS1000 Air Cooled Front View Air Cooled Range: 0.4 - 2 MVA; 2.3, 3.3 and 4kV;
ACS1000 Water Cooled Front View 15ft 6.5ft Water Cooled Range: 2 - 6 MVA; 3.3 and 4kV; 3ft
ACS 1000i • Special features: • Full integrated solution, including transformer, input switch and disconnector • Easy to install • Standard 24-pulse rectifier bridge • Small footprint • No auxiliary power required Three cables in – three cables out!
ACS 5000 and ACS 6000 • High power drives (5000HP – 40’000HP) • Suitable for induction, synchronous and permanent magnet motors • ACS 5000 • General drive for pump, fan and compressor applications • 6.0 – 6.9kV output voltage • ACS 6000 • High performance drive • Active front end or diode bridge input • Reactive power compensation • Single drive and Multi drive topology
INU Power Stack(s) ACS 5000 and ACS 6000 Common Platform Power Motor Voltage ACS 6/5000 Inverter Unit 3MVA 5MVA 3kV 7MVA 9MVA 12MVA 6kV
Technology Basis 3 level IGCT phase To motor To motor To “converter starpoint” • ACS 6000: • One 3 level phase module per motor phase -> 3.3kV output voltage • ACS 5000: • two 3 level phase modules per motor phase (in series) -> 6.9kV output voltage
Power flow Motoring mode ACS 6000 VSI ”System topology” 2Q drive
ACS 5000 VSI - MF ”System topology” Converter Starpoint
North American Market • Market Size • Competitors
North America – Sales Channel values DOMESTIC • GE • GE-Toshiba • Rockwell • Robicon IMPORTED DRIVES • ABB • Siemens • Alstom • Other marginal players (WEG..) This is our perception of the North American Market.
North America – the main players DOMESTIC • GE • GE-Toshiba • Rockwell • Robicon IMPORTED DRIVES • ABB • Siemens • Alstom • Other marginal players (WEG..) This is our perception of the North American Market.
Main Competitors • ASI Robicon • AB Rockwell • GE Toshiba
Robicon • Fighting for time and money • Expressed strategic focus: COG – (Exxon projects) • New HV IGBT module with less parts • New capacitors of “self-healing” film type (developed and used by ABB for 10 years) • We are eagerly waiting for news on who will buy them. Until then – customers are taking a certain risk dealing with them. (Many want to bail out)
ASI Robicon • Main Products: • Baby Harmony and Perfect Harmony • Messages: • Company Under chapter 11 • Availability • ACS 1000 reduces the maintenance required on the drive. There are no components in the power circuit to be changed and maintained. • Robicons Harmony drives requires extensive maintenance work. According to the user manual: • This results in 8 inspections in the first year, taken 8 to 12 hours per shut-down (increased maintenance and lost production output).
ASI Robicon • Reliability and Lifetime cost: Capacitors • ACS 1000 is designed to minimize lifetime cost. There are for example no electrolyte capacitors used in the power circuit of the drive. • Robicon use electrolyte capacitors, which have to be changed all 5 years according to their manual. • By changing the capacitors the core of the drive (inverter) has to be disassembled. This brings a high risk of failure (No burne in after reassembly).
Fuses ASI Robicon • Reliability and Lifetime cost: Fuses / Fuseless • In ABB medium voltage drives are no power fuses to protect the converter. The converters are based on a fuseless design. • In Robicon’s Harmony drives all the power cells are protected with fuses.
ASI Robicon • Ride Through • ACS 1000 offers a ride through of at least 1s due to DTC. In many practical situations a ride through of at least 500ms is required (Example: main bus transfers). • Harmony offers a ride through capability of only 6 cycles. -> see flyer • Common tools • ABB offers a wide range of automation products. For the different product, the same tools are used to monitor and configure. ABB’s medium voltage drives use exactly the same tools as ABB’s low voltage drives. • Robicon is only offering a small range of products with automation technologies. This means that product specific tools and skills are required.