Sprs
Sprs
Sprs
I Saving energy
by Paul Blaiklock and William Horvath, TMEIC GE, USA
Wound rotor induction motors (WRIM) have been popular for decades in the cement and mining industry for starting and driving large grinding mills. In fact, until about 1985, a wound rotor induction motor was the only large ac motor that controlled starting characteristics and adjustable speedcapability.
WRIM is a type of induction motor with unique construction. Its three-phase stator is typical of any induction machine and is usually connected directly to the power system, usually a medium voltage source such as 2.3kV, 4.16kV, or 6.6kV. The rotor also has a three-phase winding, usually connected in a wye (or star) circuit. The three terminals of the rotor winding are connected to separate slip rings. Brushes ride on these slip rings and the rotor winding is connected to an external liquid rheostat or resistor bank. This resistance, when inserted into the rotor circuit, adds to the rotor resistance and reduces startingcurrents. The motor speed can be adjusted by changing the resistance. The continuous power flowing into the resistor is lost as heat. Adding resistance to the rotor circuit also changes the speed at which maximum torque occurs for the motor, so high torques can be produced at low speed for starting loads with high breakaway torque requirements.
Stator
Utility Supply
SPR drive consists of two interconnected power converters as shown in Figure 2. The rotor converter is connected to the three-phase rotor winding. The feedback power converter is connected to the power system, usually through a transformer that matches the output voltage of the converter to the power system. The regenerative or feedback power converter is controlled to modulate the amount of power put back into the power system, allowing control of the motor speed. All the rotor energy previously lost as heat in the rheostat is now saved, and for large motors, this amounts to significant cost savings.
Rheostat
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Plants that have a weak power system because of a long supply line or minimally sized local generator. This makes it hard or impossible to start large motors, particularly those which must start underload.
contactor/resistor arrangement or liquid rheostat system, depending on customer preference and load torque starting requirements. This complete system integrates the starting and speed control functions into one drive system. On the other hand, it is also possible to retrofit the SPR drive system to an existing motor and retain the existing starting means. The level of coordination between the SPR and the starting means is determined on a project by project basis.
drives. As a bonus, any excess capacity built in to the source converter can be used to correct other lagging power factor loads on the system. Low harmonics at utility Previous thyristor based systems injected significant harmonic currents into the utility system. In contrast, the PWM SPR converter is switched at a higher frequency (usually 1500Hz or higher). The harmonic currents from this type of converter are centered around the switching frequency and multiples of it. These currents are greatly reduced by the impedance (15-20 per cent on the drive rating base) in the source reactor. If a harmonic study reveals that the additional filtering is needed, a simple high pass filter can reduce the remaining high frequency harmonics. This type of filter is not sensitive to changes in the power system because it is closely connected to the PWM converter, so future changes are not likely to disturb it. The PWM converter needs no reactive power support, so the filter is not sized to provide that. No motor torque pulsations Unlike other WRIM controls, a PWM SPR drive does not create torque pulsations in the motor. The PWM converter provides very smooth rotor current control, so the torque output from the motor has very low ripple. As a result, there are no requirements for special damped couplings or banned speeds due to mechanicalresonance. Controlled speed range The controlled speed range the low voltage PWM drive can provide is typically from 70-100 per cent of rated speed. The lower speed range is set by the point where the rotor volts fall below the typical 690 volt rating of the converter. Additionally, since the PWM converter connected to the rotor can create a voltage of desired frequency and magnitude, the speed can be varied smoothly. The motor can be run very close to synchronous speed, even above synchronous speed if the motor and mechanical load will allow this.
Figure 3: one of two wound rotor motors for a 10,000kW SAG mill
Modern technology
The PWM SPR drive is based on stateof-the-art, proven low voltage induction motor drive equipment. Since such drives
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are in volume production at this time, support should be available for years to come. Getting renewal parts for older thyristor based SPR drive products can be very difficult, especially if the need is for electronic parts.
Power savings
The example below compares three possible arrangements for variable speed operation of a 5000kW motor. The first case is a WRIM using a rheostat for starting and speed control, the second is an induction motor (or WRIM with shorted rings) driven by a medium voltage variable speed drive, and the third is a WRIM with speed controlled by a relatively small low voltage SPR drive. In the induction
Source Reactor
motor system, all the motor power passes through the MV drive. With the SPR drive system, only a fraction of the motor power passes through the SPR, so it is a smaller and less expensive LV drive. With the induction motor and variable speed drive, the motor can be smoothly started but the drive is a significant cost adder. Also there is no backup starter if the drive fails; but with the WRIM the rheostat is available to start the motor.
Energy consumption
Wound Rotor Induction Motor Starting Circuit PWM Source Converter
P4
P5
P4 Power flow
to SPR
Rheostat
P3
P3
Mill load
P2
In Case 1 of Table 1, for the given load at reduced speed, the WRIM with rheostat uses the most power (P1) because of heat wasted in the variable resistance. For Cases 2 and 3, the energy savings relative to the WRIM case are calculated in thetable. For a mill motor rated at 5000kW, running at 80 per cent speed, the power saving using the SPR drive, Case 3, is 970kW. Assuming two motors as in the 10,000kW mill example, and an electricity cost of 7/kWh, the annual savings are US$1,189,600. The savings with the MVPWM stator drive are a little less than the SPR case. Note that the lost, or recovered, slip power is Slip X Rated Power, so at lower speeds the savings are even higher.
P3
Figure 7: comparison of three possible arrangements for variable speed mill operation
MOTOR TECHNOLOGY
923
970kW
US$566,000
US$594,800
Various advantages
In addition to energy savings, lower cost, and simple starting device, the SPR drive system has other advantages over a high power medium voltage variable speed drive (VSD): There is inherent fault tolerance since it is possible to operate the motor even if the drive is faulted Smaller footprint than a MV PWM variable speed drive Can work with any stator rated voltage. For constant torque loads it is possible
to get more horsepower out of the same motor by running at speeds over 100 per cent. This requires the SPR drive to put power into the rotor, and assumes the motor is rated for higher speed The SPR drive can provide additional reactive power (VAR) compensation.
Conclusion
In addition to numerous large WRIM motors on grinding mills, slip power recovery drives have been applied in other industries, such as in municipal
water plants (pumping), and in paper plants (induced draft fans). Many of the SPR installations have been retrofits to existing controls for large WRIMs, that use rheostats for speed control. In these upgrades the rheostats are often kept for motor starting. Experience in all these industries shows the new SPR system, as well as providing the required high starting torque, has many advantages including energy savings, effective adjustable speed operation and high reliability. ________I
SPR Drive Moderate High (new) or existing Lowest Low High Rheostat
Energy losses/waste heat Maintenance required Starting torque Starting device/backup High Moderate High Rheostat Low Low High No backup Low Low High Rheostat