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<strong>Drive</strong> <strong>Solutions</strong> <strong>for</strong> <strong>the</strong><br />

<strong>Oil</strong> <strong>and</strong> <strong>Gas</strong> <strong>Industry</strong><br />

metals<br />

cranes<br />

paper<br />

cement<br />

oil & gas<br />

mining<br />

utilities<br />

rubber &<br />

plastics


About TMEIC <strong>GE</strong><br />

TMEIC <strong>GE</strong> is a joint venture between General<br />

Electric, Toshiba, <strong>and</strong> Mitsubishi Electric in <strong>the</strong><br />

industrial system drives business.<br />

The adjacent<br />

diagram shows how <strong>the</strong> companies came toge<strong>the</strong>r<br />

between 2000 <strong>and</strong> 2003 to create an organization of<br />

2,200 people with annual sales exceeding $2B.<br />

TMEIC <strong>GE</strong> is built upon <strong>the</strong> combined <strong>and</strong> proud<br />

heritage of <strong>the</strong>se great companies. We focus on <strong>the</strong><br />

customer, working to provide superior products <strong>and</strong><br />

excellent service, delivering customer success every<br />

project, every time.<br />

General<br />

Electric<br />

Toshiba<br />

Mitsubishi<br />

Electric<br />

TMEIC <strong>GE</strong> Automation Systems<br />

Adjustable Speed <strong>Drive</strong>s in <strong>the</strong> <strong>Oil</strong> & <strong>Gas</strong> <strong>Industry</strong><br />

Every step of <strong>the</strong> way, from <strong>the</strong> wellhead to <strong>the</strong> finished<br />

fuel products, large, adjustable-speed drives are use to<br />

start motors <strong>and</strong> control flow.<br />

In gas & oil pipelines, driving large pumps <strong>and</strong><br />

compressors, varying speed to control flow –<br />

see Application 3, page 10.<br />

In offshore plat<strong>for</strong>ms, driving gas<br />

compressors <strong>and</strong> oil pumps, moving<br />

fluids to onshore – see Application 2,<br />

page 8.<br />

In liquefied natural gas plants, driving<br />

large compressors <strong>and</strong> varying speed to<br />

control flow – see Application 4, page 12.<br />

In refineries, driving large compressors<br />

<strong>and</strong> varying speed to control flow – see<br />

Application 1, page 6.<br />

The compressors <strong>and</strong> pumps use drives to smoothly start<br />

<strong>the</strong> large motors <strong>and</strong> continuously adjust <strong>the</strong> speed to<br />

control flow. Controlling flow by adjusting speed avoids<br />

energy wasted in <strong>the</strong> throttling valves. When large flows<br />

are involved <strong>and</strong> <strong>the</strong> motor energy consumption is<br />

significant, varying <strong>the</strong> speed is <strong>the</strong> answer.<br />

With large machines, <strong>the</strong> electrical power savings amount<br />

to hundreds of thous<strong>and</strong>s of dollars per year. In addition,<br />

<strong>the</strong> motor is protected against starting inrush currents, <strong>and</strong><br />

control valve maintenance expenses <strong>and</strong> resulting<br />

downtime are minimized.<br />

Page 2 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Preliminary<br />

Revised: 5-22-09


Why Use Electrical Adjustable Speed <strong>Drive</strong>s?<br />

Here are some of <strong>the</strong> reasons to use electrical medium voltage drives:<br />

Increased Reliability – Pages 5, 6<br />

Variable speed motor-drive systems are more reliable than traditional approaches such as using<br />

turbines to control flow. They can also be configured in redundant channel configurations such as<br />

triple module redundancy (TMR) <strong>for</strong> very high reliability.<br />

Dramatic <strong>Energy</strong> Savings – Pages 5, 6, 10<br />

With a variable speed motor-drive system, <strong>the</strong> flow control valve is not required, avoiding large flow<br />

energy losses. In fact, <strong>the</strong> variable speed motor-drive system is more efficient than all o<strong>the</strong>r flow<br />

control methods including turbines <strong>and</strong> hydraulic transmissions. For more in<strong>for</strong>mation on this topic,<br />

refer to Selecting Variable Speed <strong>Drive</strong>s <strong>for</strong> Flow Control in <strong>the</strong> library at www.tmeicge.com.<br />

Significantly Less Maintenance – Pages 5, 6<br />

The oil & gas industry is all about system availability; variable speed motor-drive systems require<br />

virtually no maintenance. This is in sharp contrast to flow control valves, guide vanes, <strong>and</strong> turbines<br />

that do require extensive periodic maintenance <strong>and</strong> associated downtime.<br />

Air & Noise Pollution Virtually Eliminated – Pages 6, 12<br />

<strong>Gas</strong> turbines used to drive compressors can generate significant air <strong>and</strong> noise pollution. In populated<br />

areas, this can be a serious issue. Variable speed motor-drive systems generate no air pollution <strong>and</strong><br />

negligible noise.<br />

Soft Starting One or Multiple Motors, <strong>and</strong> Power Factor Correction – Pages 6, 9<br />

When electric drives start large motors, starting inrush current with associated mechanical <strong>and</strong><br />

<strong>the</strong>rmal wiring stress is eliminated. This removes limitations on motor frequency of starts, reduces<br />

insulation damage, <strong>and</strong> provides extended motor life. With synchronization logic, one drive can start<br />

multiple motors. Many large drive configurations also improve overall system power factor.<br />

Why TMEIC <strong>GE</strong> MV <strong>Drive</strong>s Make Sense<br />

Choose TMEIC <strong>GE</strong>, a <strong>Global</strong> Supplier – Page 20<br />

TMEIC <strong>GE</strong> sells <strong>and</strong> services drive systems round <strong>the</strong> world, supported by engineering <strong>and</strong> service<br />

offices <strong>and</strong> spare parts depots in North America, South America, Europe, Asia, <strong>and</strong> Australia.<br />

We’ve got you covered! A Complete Family of <strong>Drive</strong>s – Page 21<br />

Our family of medium voltage (MV) drives covers all your needs from 450 hp up to 120,000 hp (335<br />

kW to 90,000 kW); with a wide voltage range up to 7.2 kV to meet your requirements.<br />

Our Medium Voltage (MV) System Experts can Help You – Page 14<br />

TMEIC <strong>GE</strong> drive <strong>and</strong> motor application engineers bring an average of 20 years of practical industry<br />

experience to your application. After analyzing your MV system requirements, <strong>the</strong>y can recommend<br />

<strong>the</strong> most cost effective solution <strong>and</strong> design <strong>the</strong> system <strong>for</strong> you.<br />

Common Toolbox Software – Pages 17, 22, 24<br />

The <strong>GE</strong> Control System Toolbox is world-class configuration software. It is used on all <strong>the</strong> TMEIC<br />

<strong>GE</strong> drives <strong>and</strong> legacy <strong>GE</strong> drives, so once trained, your service engineers can work on any of our<br />

drives without going back to school.<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 3 of 32<br />

Preliminary


Comparison of Electrical & Mechanical Flow Control Methods<br />

Flow Control Methods<br />

Power Train Train<br />

Electrical <strong>Drive</strong>s <strong>Drive</strong>s<br />

Electric<br />

Frequency<br />

Control<br />

Electric<br />

Frequency<br />

Control<br />

2,216 kW<br />

Three-<br />

Phase<br />

Electric<br />

Supply<br />

* Annual Electric<br />

Cost $1,358,709<br />

TMdrive-70<br />

Electric<br />

Adjustable<br />

Speed<br />

<strong>Drive</strong> (ASD)<br />

96.4%<br />

Redundant<br />

Elect. ASD<br />

Channel 1<br />

Channel 2<br />

Channel 3<br />

97.3%<br />

2,136 kW<br />

Electric Motor<br />

98%<br />

Variable speed<br />

Synchronous<br />

Electric Motor<br />

Variable speed<br />

2,094 kW<br />

1:1<br />

1:1<br />

85%<br />

1,780 kW<br />

<strong>Gas</strong> flow<br />

Variable speed compressor<br />

2,196 kW LCI 2,136 kW<br />

2,094 kW<br />

1,780 kW<br />

Three-<br />

Phase<br />

Electric<br />

Supply<br />

*<br />

Annual Electric<br />

Cost $1,346,604<br />

2,698 kW<br />

98% 85%<br />

2,644 kW<br />

<strong>Gas</strong> flow<br />

Variable speed compressor<br />

1,780 kW<br />

Mechanical Control Control<br />

Valve Control<br />

Hydraulic<br />

Variable Speed<br />

Control<br />

Steam or Fuel<br />

Control<br />

*<br />

*<br />

*<br />

Three-<br />

Phase<br />

Electric<br />

Supply<br />

Annual Electric<br />

Cost $1,654,388<br />

Three-<br />

Phase<br />

Electric<br />

Supply<br />

Annual Electric<br />

Cost $1,416,492<br />

Steam,<br />

<strong>Gas</strong>, or<br />

Kerosene<br />

Motor<br />

Starter<br />

Motor<br />

Starter<br />

Fuel or<br />

Steam<br />

Control<br />

2,310 kW<br />

Electric Motor<br />

98%<br />

Fixed speed<br />

Electric Motor<br />

98%<br />

Fixed speed<br />

Turbine<br />

37%<br />

Variable speed<br />

2,264 kW<br />

1:1<br />

1: N<br />

Hydraulic<br />

Var. Speed<br />

Control<br />

92.5%<br />

5,659 kW 2,094 kW<br />

Annual <strong>Gas</strong><br />

Cost $1,963,084<br />

1:1<br />

2,094 kW<br />

85%<br />

Valve<br />

Control<br />

Fixed speed compressor<br />

85%<br />

1,780 kW<br />

<strong>Gas</strong> flow<br />

Variable speed compressor<br />

85%<br />

1,780 kW<br />

<strong>Gas</strong> flow<br />

Variable speed compressor<br />

* Common conditions <strong>for</strong> above cases :<br />

- LCI drive is <strong>the</strong> basis <strong>for</strong> cost comparison - LCI has 97.3% efficiency<br />

- Nominal 4,000 hp compressor<br />

- Synchronous motor is used, efficiency 98% - Power cost $0.07/kWh.<br />

- Continuous operation at 85%<br />

(induction motor efficiency is 95%)<br />

- Natural gas cost, industrial rate,<br />

rated speed or equivalent flow<br />

- <strong>Gas</strong> turbine has 37% <strong>the</strong>rmal efficiency<br />

Dec. 2005, is $12.00/1,000 cu ft<br />

Page 4 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Preliminary<br />

Revised: 5-22-09


Save <strong>Energy</strong>, Increase Reliability, Control Motor Current, Reduce Pollution, Reduce Noise<br />

Strengths/Limitations Availability <strong>Energy</strong> Cost<br />

+ Very high efficiency<br />

+ ASD has high reliability<br />

+ Protects <strong>the</strong> motor against<br />

starting inrush currents<br />

+ Can have alternate assignments<br />

- May require an air conditioned<br />

area or equipment house<br />

- May require an increaser gearbox<br />

+ Very high efficiency<br />

+ Redundant ASD has very high<br />

reliability<br />

+ Protects <strong>the</strong> motor against<br />

starting inrush currents<br />

+ Can have alternate assignments<br />

- May require an air conditioned<br />

area or equipment house<br />

- May require an increaser gearbox<br />

Availability<br />

1.0000<br />

0.999992<br />

0.9990<br />

Availability<br />

1.0000<br />

0.999994<br />

0.9990<br />

Advanced Pulse Width<br />

Modulated drive TMdrive-70<br />

Adjustable Speed <strong>Drive</strong><br />

The only online<br />

maintenance required is<br />

changing <strong>the</strong> filters<br />

MTBF is 127,000 hours<br />

Repair time (MTTR) is 1.0<br />

hour; spares are required<br />

Individual LCI channels can<br />

be isolated <strong>and</strong> repaired at<br />

any time while <strong>the</strong> o<strong>the</strong>r 2<br />

channels continue to drive<br />

<strong>the</strong> motor<br />

MTBF is 175,000 hours<br />

Repair time (MTTR) is 1.1<br />

hours; spares are required<br />

<br />

*<br />

TMdrive-70 ASD flow control<br />

system uses $1,358,709 of<br />

electrical energy per year.<br />

*<br />

LCI ASD flow control system<br />

uses $1,346,604 of electrical<br />

energy per year, <strong>the</strong> basis <strong>for</strong><br />

cost comparison.<br />

+ Valve is very reliable<br />

+ Valve is fast acting <strong>for</strong> good flow<br />

control<br />

+ Valve is compact<br />

- Large energy loss in <strong>the</strong> throttling<br />

valve<br />

- Valve requires frequent<br />

maintenance<br />

- May require an increaser gearbox<br />

+ Can adjust speed well above <strong>and</strong><br />

below <strong>the</strong> motor speed<br />

+ Hydraulic transmission is reliable<br />

- Very low efficiency at lower speeds<br />

- Dedicated to motor; no redundancy<br />

- Repair is a lengthy procedure<br />

+ Can run at high speeds so gearbox<br />

is not required<br />

- <strong>Gas</strong> turbine requires frequent<br />

maintenance<br />

- Dedicated to motor, no redundancy<br />

- <strong>Gas</strong> turbine can produce air<br />

pollution <strong>and</strong> noise<br />

Note : Efficiency of mechanical devices decreases at<br />

lower speeds, but electric drive efficiency is constant<br />

over <strong>the</strong> operating range, so savings using ASD<br />

increase as speeds are lowered; see page 31.<br />

Availability<br />

1.0000<br />

0.99963<br />

0.9990<br />

Availability<br />

1.0000<br />

0.99923<br />

0.9990<br />

Availability<br />

1.0000<br />

0.9990<br />

0.9990<br />

Routine maintenance such<br />

as tightening packing can be<br />

done on line<br />

Control valve is down <strong>for</strong><br />

between 1 to 7 days if it fails<br />

<strong>and</strong> <strong>the</strong>re is no spare<br />

estimate MTTR is 96 hours<br />

MTBF approx 260,000 hours<br />

Spare valve required<br />

Maintenance intervals up to<br />

80,000 hours<br />

Hydraulic transmission is<br />

down <strong>for</strong> as much as 84<br />

hours (3 1/2 days) if a failure<br />

occurs (published literature)<br />

MTBF is 110,000 hours<br />

<strong>Gas</strong> turbine requires a<br />

month downtime every 3<br />

years; MTBF is 8,000 hours.<br />

Liquid fuel turbine requires 8<br />

hours downtime every year<br />

Steam turbine is taken down<br />

every 4 years<br />

Assume MTTR is 8 hours<br />

Mean Time To Repair (MTTR) <strong>and</strong><br />

Mean Time Between Failures (MTBF) are<br />

based on plant operating experience.<br />

* Valve flow control system<br />

uses $1,654,388 of electrical<br />

energy per year.<br />

This is $308,000 more than<br />

<strong>the</strong> electric adjustable speed<br />

drive.<br />

* Hydraulic gearbox flow<br />

control uses $1,416,492 of<br />

electrical energy per year.<br />

This is $70,000 more than <strong>the</strong><br />

electric adjustable speed<br />

drive.<br />

* <strong>Gas</strong> turbine flow control uses<br />

$1,963,084 of gas energy per<br />

year.<br />

This is $616,000 more than<br />

<strong>the</strong> electric adjustable speed<br />

drive.<br />

Availability =<br />

MTBF<br />

MTBF+ MTTR<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 5 of 32<br />

Preliminary


<strong>Drive</strong> Applications <strong>for</strong> Compressors & Pumps<br />

Adjustable speed drives are often used to control <strong>the</strong> speed of compressors <strong>and</strong> pumps in <strong>the</strong> oil <strong>and</strong> gas industry. Most of<br />

<strong>the</strong> ASD applications control flow through pipelines <strong>and</strong> control <strong>the</strong> input flow to large process units. The following seven<br />

pages describe five typical applications <strong>and</strong> present <strong>the</strong> reasons why an electrical solution was chosen.<br />

1. Refinery compressors 4. Gearless high-speed compressor drive<br />

2. Offshore plat<strong>for</strong>m pumps 5. Liquid natural gas plant compressors<br />

3. <strong>Gas</strong> pipeline compressors<br />

Application 1. Refinery 1. Refinery Compressors<br />

Compressors<br />

A large refinery used gas turbines to drive two compressors. The turbines generated nitrogen oxides (NOX), noise pollution,<br />

<strong>and</strong> required more maintenance than electric motor drives. The refinery looked at using electric motors <strong>and</strong> hydraulic<br />

variable speed gearboxes, compared this with electric drives, <strong>and</strong> chose an electric drive as <strong>the</strong> best solution.<br />

The refinery’s new approach was to:<br />

• Replace <strong>the</strong> two gas turbines with two electric<br />

motors of 30,000 hp, <strong>and</strong> use one LCI adjustable<br />

speed drive <strong>for</strong> motor starting <strong>and</strong> speed control.<br />

• Use gear boxes to increase <strong>the</strong> speed input to <strong>the</strong><br />

compressors from <strong>the</strong> 1,800 rpm motor speed.<br />

• Use <strong>the</strong> adjustable speed drive to start one motor<br />

<strong>and</strong> synchronize it with <strong>the</strong> 13.8 kV bus.<br />

• Employ switchgear to put this motor across <strong>the</strong><br />

line <strong>and</strong> run <strong>the</strong> compressor at constant speed.<br />

• Use <strong>the</strong> adjustable speed drive to start <strong>the</strong> second<br />

motor <strong>and</strong> continuously vary <strong>the</strong> speed of <strong>the</strong><br />

second compressor to obtain <strong>the</strong> flow required by<br />

<strong>the</strong> process.<br />

Advantages of <strong>the</strong> <strong>Drive</strong> System<br />

Very high reliability – The LCI has built in channel <strong>and</strong> component redundancy allowing operation with<br />

a single failure without any reduction in power output. Consisting of three parallel active channels, <strong>the</strong><br />

LCI can operate on two channels while <strong>the</strong> third is being repaired. This is a TMR system with no voting.<br />

See next page.<br />

Eliminate air & noise pollution – <strong>Gas</strong> turbine exhaust NOX <strong>and</strong> noise are avoided completely,<br />

producing an environmentally friendly installation.<br />

The electrical drive system, <strong>the</strong>re<strong>for</strong>e, does not<br />

present problems meeting federal <strong>and</strong> state air <strong>and</strong> noise pollution limits.<br />

<strong>Energy</strong> savings – The LCI provides higher energy efficiency than ei<strong>the</strong>r gas turbines or hydraulic<br />

variable speed drives. In addition, <strong>the</strong> synchronous motors have 17% higher efficiency than <strong>the</strong> turbines<br />

<strong>the</strong>y replace.<br />

Increased run time compared to turbine – Electric drives <strong>and</strong> AC motors require much less<br />

maintenance <strong>and</strong> down time than gas turbines. <strong>Drive</strong> availability is <strong>the</strong> highest of all adjustable speed<br />

choices; <strong>for</strong> this application 0.999994.<br />

Page 6 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Preliminary Systems. All Rights Reserved.<br />

Revised: 5-22-09


Adjustable Speed <strong>Drive</strong> System One-Line Diagram<br />

The TMEIC <strong>GE</strong> LCI (Load Commutated Inverter) was selected <strong>for</strong> this drive application. It is a medium voltage drive <strong>and</strong><br />

operates at 4.16 kV. Trans<strong>for</strong>mers drop <strong>the</strong> voltage from 13.8 kV, <strong>and</strong> after <strong>the</strong> drive, trans<strong>for</strong>mers increase <strong>the</strong> voltage to<br />

13.8 kV to supply <strong>the</strong> motors. The drive has two levels of redundancy as shown in <strong>the</strong> diagram.<br />

138 kV bus<br />

138 kV bus<br />

Two Levels of Redundancy<br />

60/65 MVA<br />

138/13.8 kV<br />

OA/FA<br />

13.8 kV bus NO<br />

18-pulse<br />

LCI drive<br />

system<br />

60/65 MVA<br />

138/13.8 kV<br />

OA/FA<br />

Device Level Redundancy. Each set of six<br />

silicon controlled rectifiers (SCR) in <strong>the</strong> power<br />

bridge includes an extra SCR to create N+1<br />

redundancy. If one SCR fails, <strong>the</strong> o<strong>the</strong>r five can<br />

operate at full power. This raises <strong>the</strong> reliability<br />

of each channel <strong>and</strong> also reduces <strong>the</strong> stress<br />

on <strong>the</strong> individual SCRs, providing longer life.<br />

15 MVA<br />

13.8/4.16 kV<br />

One channel power bridge showing<br />

thyristor (SCR) stacks <strong>and</strong> water cooling.<br />

15 MVA<br />

4.16/13.8 kV<br />

Exciters<br />

Channel Level Redundancy. The LCI has<br />

three 15,000 hp channels, <strong>and</strong> has <strong>the</strong><br />

capability of driving ei<strong>the</strong>r of <strong>the</strong> motors. If<br />

maintenance is being per<strong>for</strong>med on one<br />

channel, <strong>the</strong> o<strong>the</strong>r two channels can continue<br />

to power <strong>the</strong> motor. The out-of-service channel<br />

can <strong>the</strong>n be isolated, repaired, <strong>and</strong> returned to<br />

service. As a result, <strong>the</strong> drive reliability is<br />

extremely high <strong>and</strong> <strong>the</strong> equipment up time<br />

much higher than any o<strong>the</strong>r systems.<br />

30,000 HP, 1,800 RPM<br />

Synchronous Motor<br />

M<br />

30,000 HP, 1,800 RPM<br />

Synchronous Motor<br />

Gear boxes &<br />

compressors<br />

M<br />

Power Circuits. The LCI is an 18-pulse drive<br />

system using thryristors (SCRs) in <strong>the</strong><br />

converters <strong>and</strong> inverters. The system<br />

generates only a small harmonic disturbance<br />

to <strong>the</strong> power system.<br />

The two levels of redundancy illustrated above provide a 20-year system Mean Time Between Failures (MTBF) <strong>and</strong> excellent<br />

up-time with availability of 0.999994.<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 7 of 32<br />

Preliminary


Application 2. Offshore Plat<strong>for</strong>m Pumps<br />

Application 2. Offshore 2. Offshore Plat<strong>for</strong>m Offshore<br />

Plat<strong>for</strong>m Pumps Plat<strong>for</strong>m<br />

Pumps<br />

Pumps<br />

Five production pumps on this offshore plat<strong>for</strong>m feed oil into a pipeline taking <strong>the</strong> product to onshore facilities. Three of <strong>the</strong><br />

2,250 hp pumps were under control of adjustable speed drives to adjust <strong>the</strong> total flow to dem<strong>and</strong>, <strong>and</strong> <strong>the</strong> o<strong>the</strong>r two were on<br />

fixed Five production speed. The pumps original on drives this offshore were obsolete plat<strong>for</strong>m <strong>and</strong> feed spare oil into parts a pipeline were difficult taking to <strong>the</strong> obtain. product In to addition, onshore <strong>the</strong> facilities. older drives Three required of <strong>the</strong><br />

power 2,250 hp factor pumps correction were under <strong>and</strong> power control line of filters adjustable to keep speed <strong>the</strong> power drives clean. to adjust These <strong>the</strong> total filters flow were to dem<strong>and</strong>, very noisy <strong>and</strong> <strong>for</strong> <strong>the</strong> employees o<strong>the</strong>r two working were on in<br />

<strong>the</strong> fixed equipment speed. The room original <strong>for</strong> long drives periods. were obsolete <strong>and</strong> spare parts were difficult to obtain. In addition, <strong>the</strong> older drives required<br />

power factor correction <strong>and</strong> power line filters to keep <strong>the</strong> power clean. These filters were very noisy <strong>for</strong> employees working in<br />

<strong>the</strong> equipment room <strong>for</strong> long periods.<br />

The oil production company wanted to:<br />

The • oil production Replace <strong>the</strong> company old drives wanted with new to: maintainable drives.<br />

Obtain high drive reliability backed by a five-year warranty.<br />

• Replace<br />

Obtain better<br />

<strong>the</strong> old<br />

system<br />

drives<br />

power<br />

with new<br />

factor<br />

maintainable<br />

without <strong>the</strong><br />

drives.<br />

use of correction.<br />

• Obtain<br />

Eliminate<br />

high<br />

<strong>the</strong><br />

drive<br />

noisy<br />

reliability<br />

power<br />

backed<br />

line filters<br />

by a five-year<br />

by using<br />

warranty.<br />

drives with<br />

• Obtain inherent better low harmonic system power distortion. factor without <strong>the</strong> use of correction.<br />

• Eliminate Have <strong>the</strong> ability <strong>the</strong> noisy to per<strong>for</strong>m power synchronous line filters bypass.<br />

using drives with<br />

inherent<br />

Reduce <strong>the</strong><br />

low<br />

component<br />

harmonic distortion.<br />

count to increase reliability <strong>and</strong> reduce<br />

• Have maintenance. <strong>the</strong> ability to per<strong>for</strong>m synchronous bypass.<br />

• Reduce <strong>the</strong> component count to increase reliability <strong>and</strong> reduce<br />

In making maintenance. its selection <strong>for</strong> <strong>the</strong> new drives, <strong>the</strong> company regarded<br />

experienced, local service support from <strong>the</strong> New Orleans office as<br />

In important. making its Throughout selection <strong>the</strong> <strong>for</strong> process, <strong>the</strong> new strong drives, application <strong>the</strong> company support regarded from<br />

experienced, <strong>the</strong> TMEIC <strong>GE</strong> local engineering service support office in from Virginia <strong>the</strong> proved New Orleans valuable. office as<br />

important. Throughout <strong>the</strong> process, strong application support from<br />

<strong>the</strong> TMEIC <strong>GE</strong> engineering office in Virginia proved valuable.<br />

The first of <strong>the</strong> three old drives was replaced with a Dura-Bilt5i MV. After evaluation, a second Dura-Bilt was installed on <strong>the</strong><br />

second pump. Each drive is equipped with <strong>the</strong> components <strong>for</strong> synchronous bypass in <strong>the</strong> future, although <strong>the</strong> actual bypass<br />

The contactors first of were <strong>the</strong> three not old initially drives included. was replaced A power with study a Dura-Bilt5i per<strong>for</strong>med MV. by After TMEIC evaluation, <strong>GE</strong> showed a second that <strong>the</strong> Dura-Bilt remaining was installed old drive on could <strong>the</strong><br />

second operate pump. without Each any filters drive since is equipped it represents with <strong>the</strong> a small components portion <strong>for</strong> of <strong>the</strong> synchronous load <strong>the</strong> bypass plat<strong>for</strong>m. in <strong>the</strong> future, although <strong>the</strong> actual bypass<br />

contactors were not initially included. A power study per<strong>for</strong>med by TMEIC <strong>GE</strong> showed that <strong>the</strong> remaining old drive could<br />

operate without any filters since it represents a small portion of <strong>the</strong> load on <strong>the</strong> plat<strong>for</strong>m.<br />

Benefits of <strong>the</strong> Dura-Bilt5i MV Pump System<br />

Benefits of <strong>the</strong> Dura-Bilt5i MV Pump System<br />

High Reliability. Advanced design including use of medium voltage Insulated Gate Bipolar Transistors<br />

(IGBTs), oil-filled capacitors, a built-in copper wound trans<strong>for</strong>mer, <strong>and</strong> surge <strong>and</strong> transient protection<br />

creates High Reliability. a drive with Advanced high reliability. design including use of medium voltage Insulated Gate Bipolar Transistors<br />

(IGBTs), oil-filled capacitors, a built-in copper wound trans<strong>for</strong>mer, <strong>and</strong> surge <strong>and</strong> transient protection<br />

creates a drive with high reliability.<br />

Low Harmonic Distortion. The 24-pulse rectifier’s low harmonic impact of less than 1.5% distortion<br />

gives clean operation without <strong>the</strong> use of filters, allowing <strong>the</strong> original filters to be disconnected.<br />

Low Harmonic Distortion. The 24-pulse rectifier’s low harmonic impact of less than 1.5% distortion<br />

gives clean operation without <strong>the</strong> use of filters, allowing <strong>the</strong> original filters to be disconnected.<br />

High Power Factor. The new system has a very good power factor of better than 0.95 <strong>and</strong> does not<br />

require any external power factor correction equipment.<br />

High Power Factor. The new system has a very good power factor of better than 0.95 <strong>and</strong> does not<br />

require any external power factor correction equipment.<br />

Compact <strong>Drive</strong>. The Dura-Bilt drive system fits in a smaller space than <strong>the</strong> original system because<br />

<strong>the</strong> trans<strong>for</strong>mer is integrated into <strong>the</strong> cabinet <strong>and</strong> <strong>the</strong> heat pipe cooling allows a very compact drive.<br />

Compact <strong>Drive</strong>. The Dura-Bilt drive system fits in a smaller space than <strong>the</strong> original system because<br />

<strong>the</strong> trans<strong>for</strong>mer is integrated into <strong>the</strong> cabinet <strong>and</strong> <strong>the</strong> heat pipe cooling allows a very compact drive.<br />

Page 8 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Preliminary Systems. All Rights Reserved.<br />

Preliminary<br />

Revised: 5-22-09


Pump System One-Line Diagram<br />

Plat<strong>for</strong>m MV Bus<br />

In this diagram, <strong>Drive</strong> 1 is shown<br />

with a synchronous bypass<br />

option, which can be added in <strong>the</strong><br />

future. This option will allow <strong>the</strong><br />

drive to:<br />

DB5i MV<br />

<strong>Drive</strong> 1<br />

Motor 1<br />

DB5i MV<br />

<strong>Drive</strong> 2<br />

Motor 2<br />

Older<br />

<strong>Drive</strong><br />

Motor 3<br />

Motor 4<br />

Motor 5<br />

• Start Motor 1 with low<br />

current inrush.<br />

• Bring <strong>the</strong> motor up to<br />

synchronous speed.<br />

• Synchronize <strong>the</strong> motor with<br />

<strong>the</strong> supply bus.<br />

• Put <strong>the</strong> motor across <strong>the</strong><br />

line <strong>and</strong> disconnect <strong>the</strong><br />

drive from <strong>the</strong> supply.<br />

• Allow <strong>Drive</strong> 2 to control<br />

Pump 2 flow as required<br />

by <strong>the</strong> flow dem<strong>and</strong>.<br />

This configuration allows Motor 1<br />

to run at full speed without <strong>the</strong><br />

heat losses in <strong>the</strong> drive. The<br />

synchronous option can be<br />

extended to <strong>the</strong> second drive if<br />

required.<br />

Pump 1<br />

Pump 2 Pump 3 Pump 4 Pump 5<br />

Future Improvements<br />

The customer has <strong>the</strong> option in <strong>the</strong> future to retire <strong>the</strong> last old drive <strong>and</strong><br />

install contactors on all motors <strong>and</strong> <strong>the</strong> two drives. With appropriate<br />

PLC control logic, <strong>the</strong> system will allow ei<strong>the</strong>r Dura-Bilt to start <strong>and</strong> run<br />

any of <strong>the</strong> five motors, <strong>and</strong> put <strong>the</strong>m across <strong>the</strong> line.<br />

This future system improvement will provide:<br />

• The maximum flexibility to operate <strong>the</strong> pumps under a wide<br />

range of situations.<br />

• Soft starting available <strong>for</strong> all motors to minimize system impact<br />

<strong>and</strong> deterioration of <strong>the</strong> windings caused by inrush current.<br />

• Reduction in <strong>the</strong> impact of drive downtime since no motor is<br />

dedicated to any drive.<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 9 of 32<br />

Preliminary


Application 3. <strong>Gas</strong> Pipeline Compressors<br />

Application 3. <strong>Gas</strong> 3. <strong>Gas</strong> Pipeline Pipeline Compressors<br />

Compressors<br />

The remote gas pipeline station used two compressors in series, driven by internal combustion engines. With this<br />

The arrangement, remote gas non-optimal pipeline flow station often used wasted two energy, compressors <strong>and</strong> fixed in pumping series, steps driven provided by internal poor combustion pipeline flow engines. control.<br />

With this<br />

arrangement, non-optimal flow often wasted energy, <strong>and</strong> fixed pumping steps provided poor pipeline flow control.<br />

The pipeline company sought a new motor <strong>and</strong><br />

flow The control pipeline system company which sought would:<br />

a new motor <strong>and</strong><br />

flow control system which would:<br />

• Be responsive to fast changes in load.<br />

•<br />

Reduce Be responsive<br />

energy to<br />

usage.<br />

fast changes in load.<br />

•<br />

Increase Reduce energy<br />

reliability.<br />

usage.<br />

•<br />

Reduce Increase<br />

maintenance reliability.<br />

costs.<br />

• Reduce<br />

<strong>the</strong> maintenance<br />

heat load costs.<br />

in <strong>the</strong> building.<br />

•<br />

Keep Reduce<br />

<strong>the</strong> <strong>the</strong><br />

existing heat load<br />

induction in <strong>the</strong><br />

motors building.<br />

<strong>and</strong> speed<br />

• increasing Keep <strong>the</strong> existing gearboxes.<br />

induction motors <strong>and</strong> speed<br />

• Produce increasing<br />

clean gearboxes.<br />

electrical power with low<br />

• harmonics.<br />

Produce clean electrical power with low<br />

harmonics.<br />

After reviewing alternatives, <strong>the</strong> company decided<br />

to After replace reviewing <strong>the</strong> alternatives, two existing <strong>the</strong> internal company combustion<br />

decided<br />

engines to replace with <strong>the</strong> two medium existing internal voltage combustion adjustable<br />

speed engines drives with <strong>and</strong> two motors medium to match voltage <strong>the</strong> adjustable pressure<br />

<strong>and</strong> speed flow drives needs <strong>and</strong> of <strong>the</strong> motors pipeline.<br />

to match <strong>the</strong> pressure<br />

<strong>and</strong> flow needs of <strong>the</strong> pipeline.<br />

Induction Motor <strong>and</strong> Gearbox<br />

(compressor Induction located Motor on <strong>the</strong> <strong>and</strong> o<strong>the</strong>r Gearbox side of wall).<br />

(compressor located on <strong>the</strong> o<strong>the</strong>r side of wall).<br />

The new system uses two Dura-Bilt5i MV drives connected to<br />

induction The new motors. system uses These two motors Dura-Bilt5i drive <strong>the</strong> MV compressors drives connected through<br />

to<br />

gear induction boxes. motors. To house These <strong>the</strong> motors drives, a drive completely <strong>the</strong> compressors preassembled, through airconditioned<br />

gear boxes. power To house <strong>the</strong> was drives, selected.<br />

a completely preassembled, airconditioned<br />

power house was selected.<br />

Benefits of <strong>the</strong> Dura-Bilt5i MV Compressor <strong>Drive</strong> System<br />

Benefits of <strong>the</strong> Dura-Bilt5i MV Compressor <strong>Drive</strong> System<br />

The system meets all of <strong>the</strong> customer’s requirements. In particular,<br />

The <strong>the</strong> system benefits meets all include:<br />

of <strong>the</strong> customer’s requirements. In particular,<br />

<strong>the</strong> system benefits include:<br />

Cost Savings. The savings, including reduced energy usage costs <strong>and</strong> reduced<br />

Cost maintenance, Savings.<br />

provides The a savings, short payback including on <strong>the</strong> reduced drive system energy investment. usage costs On <strong>and</strong> a system reduced<br />

like<br />

maintenance, this, <strong>the</strong> payback provides can be a three short years payback or less. on <strong>the</strong> drive system investment. On a system like<br />

this, <strong>the</strong> payback can be three years or less.<br />

Better Flow Control. The compressor operating point can be changed quickly in<br />

Better response Flow to changing Control.<br />

pipeline The compressor conditions resulting operating improved point can flow be control changed <strong>and</strong> quickly reduced in<br />

response energy waste. to changing pipeline conditions resulting in improved flow control <strong>and</strong> reduced<br />

energy waste.<br />

Fast Installation. System installation was fast using <strong>the</strong> pre-assembled power house,<br />

Fast <strong>and</strong> startup Installation. was fast System because installation <strong>the</strong> equipment was in fast <strong>the</strong> using power <strong>the</strong> house pre-assembled was pre-tested. power house,<br />

<strong>and</strong> startup was fast because <strong>the</strong> equipment in <strong>the</strong> power house was pre-tested.<br />

Page 10 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Preliminary<br />

Preliminary<br />

Revised: 5-22-09


<strong>Drive</strong> System Technical Details<br />

Input Flow<br />

Induction Motor<br />

Compressor 1<br />

4.16 kV Bus<br />

Gear<br />

box<br />

Induction Motor<br />

Compressor 2<br />

Gear<br />

box<br />

Dura-Bilt5i<br />

MV Adjustable Speed<br />

<strong>Drive</strong>s 5,000 hp each<br />

Output Flow<br />

<strong>Drive</strong>s:<br />

<strong>Drive</strong> Inverters:<br />

• Two Dura-Bilt5i MV drives • Five-level neutral point clamped PWM inverter<br />

• 4.16 kV rating • 3,300 Volt IGBTs<br />

• 5,000 hp each • Heat pipe cooling<br />

<strong>Drive</strong> Rectifiers:<br />

Actual Motor Operating Conditions:<br />

• 24-pulse diode converter • 4,500 hp<br />

• Less than half <strong>the</strong> lowest IEEE 519 st<strong>and</strong>ard<br />

• 49 Hz supply from drive<br />

harmonic current distortion limit<br />

• 1,443 rpm output<br />

Modular Design of <strong>the</strong> Dura-Bilt5i MV<br />

Dura-Bilt5i MV <strong>Drive</strong><br />

Diode Rectifier<br />

24-pulse source<br />

Built-in Trans<strong>for</strong>mer<br />

Three Roll Out Inverter Phase Leg<br />

Assemblies:<br />

• Medium voltage IGBTs<br />

• Heat pipe cooling<br />

• <strong>Oil</strong>-filled capacitors<br />

• Fiber optic link<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 11 of 32<br />

Preliminary


Application 4. High-Speed 4. High-Speed Motor <strong>Drive</strong>s Motor <strong>Gas</strong> <strong>Drive</strong>s Compressors <strong>Gas</strong> Compressors<br />

Conventional gas pipeline compressors are driven<br />

directly by gas turbines. However, <strong>the</strong> turbines have high<br />

operating <strong>and</strong> maintenance costs <strong>and</strong> generate nitrogen<br />

oxides (NOx) <strong>and</strong> CO 2 . This gas pipeline application<br />

uses <strong>the</strong> TMdrive-80 ASD coupled to a high-speed<br />

synchronous motor to drive <strong>the</strong> gas compressors. With<br />

motor speeds up to 8,200 rpm, no gearbox is required.<br />

The compressor stations on <strong>the</strong> gas pipeline use this<br />

TMEIC all-electric variable speed drive system as<br />

illustrated below.<br />

Pipeline Compressor Station<br />

VSD ASD M Compressor<br />

TMdrive-80 ASD<br />

Natural <strong>Gas</strong><br />

Compressor <strong>Drive</strong> & Motor<br />

Natural <strong>Gas</strong><br />

High-Speed, Two-pole,<br />

Synchronous Motor -<br />

5,200 rpm<br />

The TMdrive-80 high-speed GCT (Gate Commutated Turn-off Thyristor) inverter has <strong>the</strong> world’s largest capacity. The<br />

GCT can operate at elevated speeds <strong>and</strong> be applied to voltages of 3.3 kV. The TMdrive-80 configuration perfectly fits<br />

large gas compressor applications.<br />

Advantages of <strong>the</strong> High-Speed <strong>Drive</strong> System<br />

High reliability & Availability – The TMdrive-80 <strong>and</strong> synchronous motor have a much higher<br />

reliability than <strong>the</strong> gas turbine, based on field experience. In addition, repair time is shorter so<br />

system availability is excellent.<br />

Air & Noise Pollution Eliminated – <strong>Gas</strong> turbine exhaust NOx <strong>and</strong> CO 2 <strong>and</strong> noise are avoided<br />

completely, producing an environmentally friendly installation.<br />

Low Operating & Maintenance Costs– The TMdrive-80 <strong>and</strong> synchronous motor combination<br />

has a much higher energy efficiency than <strong>the</strong> gas turbine. In addition, maintenance <strong>and</strong> repair<br />

costs are significantly reduced.<br />

Application 5. LNG 5. LNG Plants Plants<br />

Electric drive systems power <strong>the</strong> compressors in<br />

liquid natural gas (LNG) plants. These<br />

compressors are very large in size <strong>and</strong> use<br />

synchronous motors running at 3,600 rpm.<br />

Liquefied Natural <strong>Gas</strong> Plant<br />

End flash<br />

Liquefaction<br />

-178 o C<br />

Natural<br />

LNG<br />

<strong>Gas</strong> -160 o C<br />

End flash<br />

The drive used is <strong>the</strong> TMdrive-XL85, which<br />

employs GCT inverters at 7.6 kV. This drive can<br />

be exp<strong>and</strong>ed by adding parallel channels to obtain<br />

power levels up to 90 MW. Refer to <strong>the</strong> section on<br />

<strong>Drive</strong>s <strong>for</strong> more in<strong>for</strong>mation on <strong>the</strong> TMdrive-XL85.<br />

D<br />

M<br />

Propane<br />

Compressor<br />

M D<br />

MR Compressors<br />

LNG Process<br />

Compressors<br />

50~100 MW<br />

Page 12 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


Project Engineering<br />

Project Engineering<br />

TMEIC <strong>GE</strong>’s Engineering <strong>Drive</strong> Team in Virginia<br />

TMEIC <strong>GE</strong>’s Engineering <strong>Drive</strong> Team in Virginia<br />

Experienced <strong>Drive</strong> Engineering Team<br />

Experienced The drive engineering <strong>Drive</strong> Engineering team is experienced Team in <strong>the</strong> oil <strong>and</strong><br />

gas industry <strong>and</strong> gained its experience working in <strong>the</strong><br />

The drive engineering team is experienced in <strong>the</strong> oil <strong>and</strong><br />

plants with technicians <strong>and</strong> mechanical suppliers. This<br />

gas<br />

engineering<br />

industry<br />

background,<br />

<strong>and</strong> gained its<br />

coupled<br />

experience<br />

with<br />

working<br />

state-of-<strong>the</strong>-art<br />

in <strong>the</strong><br />

plants<br />

technology,<br />

with technicians<br />

enables TMEIC<br />

<strong>and</strong><br />

<strong>GE</strong><br />

mechanical<br />

to consistently<br />

suppliers.<br />

meet<br />

This<br />

<strong>the</strong><br />

engineering background, coupled with state-of-<strong>the</strong>-art<br />

dem<strong>and</strong>ing requirements of <strong>the</strong> industry.<br />

technology, enables TMEIC <strong>GE</strong> to consistently meet <strong>the</strong><br />

dem<strong>and</strong>ing<br />

Experienced<br />

requirements<br />

drive engineers<br />

of <strong>the</strong> industry.<br />

jointly define <strong>the</strong> MV<br />

equipment <strong>and</strong> control strategy with your engineers <strong>and</strong><br />

Experienced<br />

<strong>the</strong> OEM. This<br />

drive<br />

is followed<br />

engineers<br />

by<br />

jointly<br />

detailed<br />

define<br />

design<br />

<strong>the</strong><br />

of<br />

MV<br />

<strong>the</strong><br />

equipment<br />

system, control<br />

<strong>and</strong><br />

logic,<br />

control<br />

<strong>and</strong><br />

strategy<br />

configuration<br />

with your<br />

of <strong>the</strong><br />

engineers<br />

drives.<br />

<strong>and</strong><br />

<strong>the</strong> OEM. This is followed by detailed design of <strong>the</strong><br />

system, Comprehensive control logic, Factory <strong>and</strong> configuration Test Minimizes of <strong>the</strong> Risk drives.<br />

Comprehensive We underst<strong>and</strong> Factory that delay Test in Minimizes commissioning Risk is very<br />

expensive, so we take steps to hold our startup schedule:<br />

We underst<strong>and</strong> that delay in commissioning is very<br />

expensive, so we take steps to hold our startup schedule:<br />

• Complete factory test including applying power to <strong>the</strong><br />

bridges, exercising <strong>the</strong> control with process<br />

• Complete<br />

simulation,<br />

factory<br />

<strong>and</strong> checking<br />

test including<br />

test modes.<br />

applying power to <strong>the</strong><br />

bridges, exercising <strong>the</strong> control with process<br />

• simulation, The local commissioning <strong>and</strong> checking test engineers modes. are part of <strong>the</strong><br />

project team, allowing a seamless transition from <strong>the</strong><br />

• The<br />

factory<br />

local<br />

to your<br />

commissioning<br />

plant.<br />

engineers are part of <strong>the</strong><br />

project team, allowing a seamless transition from <strong>the</strong><br />

• factory For complex to your applications, plant. factory control engineers<br />

organize <strong>the</strong> factory test <strong>and</strong> assist with <strong>the</strong><br />

• For complex applications, factory control engineers<br />

commissioning.<br />

organize <strong>the</strong> factory test <strong>and</strong> assist with <strong>the</strong><br />

Local commissioning.<br />

Commissioning Team Ensures Knowledgeable<br />

Ongoing Service<br />

Local Commissioning Team Ensures Knowledgeable<br />

Ongoing Our field Service service organization is broad <strong>and</strong> deep with<br />

extensive experience in <strong>the</strong> industry providing you with a<br />

Our<br />

strong<br />

field<br />

local<br />

service<br />

service<br />

organization<br />

presence<br />

is<br />

<strong>for</strong><br />

broad<br />

startup<br />

<strong>and</strong><br />

<strong>and</strong><br />

deep<br />

ongoing<br />

with<br />

extensive experience in <strong>the</strong> industry providing you with a<br />

service work, both in North America <strong>and</strong> overseas.<br />

strong local service presence <strong>for</strong> startup <strong>and</strong> ongoing<br />

service work, both in North America <strong>and</strong> overseas.<br />

Preliminary<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Preliminary<br />

Page 13 of 32


We Engineer <strong>the</strong> Medium Voltage Power System<br />

TMEIC <strong>GE</strong> application engineers design <strong>the</strong> power system from <strong>the</strong> medium voltage switchgear to <strong>the</strong> adjustable speed drive<br />

<strong>and</strong> motor. The critical engineering process <strong>for</strong> a successful installation is illustrated in <strong>the</strong> chart (top of next page) <strong>and</strong><br />

detailed in this Project Engineering section. Icons indicate where <strong>the</strong> various teams of engineers in <strong>the</strong> factory <strong>and</strong> field<br />

service are involved in <strong>the</strong> project.<br />

A typical MV power system is shown below. We size <strong>and</strong> select all <strong>the</strong> equipment <strong>for</strong> <strong>the</strong> optimal drive solution.<br />

Medium Voltage Power S<br />

ystem<br />

Transmission Voltages<br />

Distribution Voltages<br />

><br />

Substation<br />

Trans<strong>for</strong>mer<br />

Breaker<br />

Instrumentation<br />

<strong>Drive</strong> Isolation<br />

Trans<strong>for</strong>mer<br />

MV s<br />

witchgea<br />

r is selected <strong>for</strong> <strong>the</strong><br />

application c<br />

onsidering:<br />

- The type, such as vacuum or S<br />

F6<br />

- The size <strong>for</strong> <strong>the</strong> current <strong>and</strong> v<br />

oltage<br />

- The CTs, PTs, <strong>and</strong> protective r<br />

elays<br />

to operate <strong>the</strong> b<br />

reaker<br />

- The enclosure <strong>for</strong> outdoor or i<br />

ndoor<br />

- The environment such a<br />

s<br />

temperature <strong>and</strong> h<br />

umidity<br />

Instrumentation <strong>for</strong> e<br />

quipment<br />

metering, monitoring, p<br />

rotection<br />

<strong>and</strong> control is selected, i<br />

ncluding:<br />

- Amp transducer <strong>and</strong> a<br />

mmeter<br />

- Watt <strong>and</strong> Watt-hour t<br />

ransducers<br />

- Phase CTs <strong>and</strong> phase overcurrent r<br />

elay<br />

- Ground sensor CT <strong>and</strong> r<br />

elay<br />

- Power quality m<br />

onitor<br />

<strong>Drive</strong> isolation, input <strong>and</strong> output,<br />

trans<strong>for</strong>mers are selected <strong>for</strong> <strong>the</strong><br />

application c<br />

onsidering:<br />

- The type, such as dry or liquid fi<br />

lled<br />

- Size <strong>for</strong> <strong>the</strong> kVA <strong>and</strong> v<br />

oltage<br />

- Cooling if r<br />

equired<br />

- The enclosure <strong>for</strong> outdoor or i<br />

ndoor<br />

- The environment such a<br />

s<br />

temperature <strong>and</strong> h<br />

umidity<br />

- Special drive r<br />

equirements<br />

Page 14 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


TM<strong>GE</strong><br />

Technical TM<strong>GE</strong><br />

Technical Proposal<br />

Specification Proposal<br />

Specification<br />

TM<strong>GE</strong><br />

Detailed<br />

TM<strong>GE</strong><br />

Hardware Detailed &<br />

Software Hardware Design &<br />

Software <strong>and</strong> Component Design<br />

<strong>and</strong> Procurement Component<br />

Procurement<br />

TM<strong>GE</strong><br />

TM<strong>GE</strong><br />

Factory<br />

Acceptance<br />

Factory<br />

Acceptance<br />

Test<br />

Test<br />

TM<strong>GE</strong><br />

TM<strong>GE</strong><br />

System System<br />

Commissioning<br />

System System<br />

Commissioning<br />

System<br />

Maintenance<br />

System<br />

Maintenance<br />

<strong>and</strong> Service<br />

<strong>and</strong> Service<br />

The Project Teams<br />

The Project Teams<br />

Customer Team<br />

Customer Field Team Team<br />

TM<strong>GE</strong> Field Factory Team Team<br />

TM<strong>GE</strong> Training Factory Team<br />

Training Team<br />

<strong>Drive</strong> Utilization Voltage<br />

<strong>Drive</strong> Utilization Voltage<br />

M<br />

M<br />

Load<br />

Load<br />

Adjustable Speed <strong>Drive</strong><br />

Adjustable Speed <strong>Drive</strong><br />

Reactor<br />

Reactor<br />

Heat Exchanger<br />

Heat Exchanger<br />

Motor<br />

Motor<br />

Control PLC<br />

Control PLC<br />

Selection of <strong>the</strong> best adjustable speed<br />

drive Selection <strong>for</strong> <strong>the</strong> of application <strong>the</strong> best adjustable based on:<br />

speed<br />

drive <strong>for</strong> <strong>the</strong> application based on:<br />

- Continuous <strong>and</strong> overload torque<br />

Continuous <strong>and</strong> power r<strong>and</strong> equirements overload torque<br />

- Type <strong>and</strong> power of load, requirements<br />

including constant<br />

Type or variable of load, torque including or regenerative<br />

constant<br />

- <strong>Drive</strong> or variable <strong>and</strong> motor torque voltage<br />

or regenerative<br />

- <strong>Drive</strong> Power <strong>and</strong> system motor compatibility<br />

voltage<br />

- Power Overall system efficiency compatibility<br />

of <strong>the</strong> ASD <strong>and</strong><br />

motor Overall combination<br />

efficiency of <strong>the</strong> ASD <strong>and</strong><br />

- motor Harmonic combination<br />

analysis<br />

- Harmonic analysis<br />

Selection of optional drive<br />

Selection associated of equipment optional dsuch rive as:<br />

associated equipment such as:<br />

- Reactor <strong>for</strong> use with an LCI<br />

- Reactor Heat exchangers <strong>for</strong> use with if required an LCI<br />

- Air Heat conditioned exchangers equipment if required<br />

house Air conditioned if requiredequipment<br />

- house Switchgear if required if motor is to be<br />

synchronized Switchgear if motor with <strong>the</strong> is line to be<br />

- synchronized PLC <strong>for</strong> logic control, with <strong>the</strong> <strong>for</strong> lineexample<br />

- synchronizing PLC <strong>for</strong> logic control, multiple <strong>for</strong> motors example with<br />

synchronizing <strong>the</strong> supply <strong>for</strong> soft multiple start motors capability with<br />

<strong>the</strong> supply <strong>for</strong> soft start capability<br />

Selection of <strong>the</strong> motor <strong>and</strong> associated<br />

Selection equipment of including: <strong>the</strong> motor <strong>and</strong> associated<br />

equipment including:<br />

- Induction or synchronous motor<br />

- Induction Motor size or including synchronous power, motor torque,<br />

voltage, Motor size current, including <strong>and</strong> power, speed torque,<br />

- voltage, Selection current, of <strong>the</strong> exciter <strong>and</strong> speed if a<br />

synchronous Selection of <strong>the</strong> motor exciter is used if a<br />

- synchronous Required motor motor protection is useddevices<br />

- Required Optional tachometer motor protection <strong>for</strong> special devices<br />

applications<br />

Optional tachometer <strong>for</strong> special<br />

- applications<br />

Torsional analysis<br />

- Torsional analysis<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 15 of 32


TM<strong>GE</strong><br />

Technical Proposal Specification<br />

TMEIC <strong>GE</strong> Assists in <strong>the</strong> Project Planning<br />

TMEIC <strong>GE</strong><br />

Inputs<br />

Articles, Newsletters, Web Site,<br />

MV School, Brochures<br />

Guide<strong>for</strong>m Spec, ROI Analysis,<br />

Budgetary Alternatives<br />

Bid Package<br />

Preparation<br />

Customer<br />

Project Potential Value RFQ Bid Bid<br />

Definition <strong>Solutions</strong> Analysis Spec Package Evaluation<br />

13 KV<br />

4160 V<br />

Starting<br />

LCI<br />

LCI<br />

Isolation<br />

Contactor<br />

IC1<br />

M1<br />

Starting<br />

Contactors<br />

ST1<br />

Motors,<br />

Fixed or<br />

Variable<br />

Speed<br />

MTR1<br />

Motor<br />

Exciters<br />

Excitation<br />

M2<br />

ST2<br />

MTR2<br />

Excitation<br />

M3<br />

ST3<br />

MTR3<br />

Excitation<br />

Run Breakers<br />

System architecture illustration<br />

Detailed description of equipment in proposal<br />

During all phases of your project<br />

planning, TMEIC <strong>GE</strong> is willing to assist<br />

by supplying in<strong>for</strong>mation, training,<br />

guide-<strong>for</strong>m specifications, <strong>and</strong> general<br />

advice. Experienced MV drive<br />

application engineers prepare a<br />

technical proposal that includes:<br />

• Customized system architecture <strong>for</strong><br />

your project.<br />

• Detailed equipment specifications<br />

<strong>for</strong> <strong>the</strong> drives, exciters, trans<strong>for</strong>mers,<br />

switchgear, <strong>and</strong> housings.<br />

• Thorough description of <strong>the</strong> PLC<br />

control functions, including logic <strong>for</strong><br />

synchronizing <strong>and</strong> de-synchronizing<br />

<strong>the</strong> motors.<br />

• Formal bid documentation.<br />

Page 16 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


TM<strong>GE</strong><br />

Detailed Hardware/Software Design & Procurement<br />

Electrical <strong>and</strong><br />

mechanical prints<br />

Control logic <strong>and</strong><br />

drive configuration<br />

HMI screen design<br />

Based on <strong>the</strong> proposal specification, <strong>the</strong> project engineering team proceeds with four main tasks:<br />

• Control Software Design. Control engineers configure <strong>the</strong> drives <strong>and</strong> PLC controller logic, if a PLC is required <strong>for</strong><br />

<strong>the</strong> application. The illustration above shows a typical toolbox logic function diagram in Relay Ladder Diagram <strong>for</strong>mat.<br />

The toolbox is used <strong>for</strong> drive configuration, tuning, sequencing, <strong>and</strong> drive diagnostics.<br />

• Optional HMI Screen Design. Interface screens <strong>for</strong> maintenance <strong>and</strong> drive control are configured using <strong>the</strong> touch<br />

panel engineering tools. These screens provide real-time drive data <strong>and</strong> operator interaction.<br />

• Hardware Design. All equipment is specified per <strong>the</strong> project requirements, <strong>and</strong> a complete set of elementary<br />

diagrams, layout, <strong>and</strong> outline drawings is created.<br />

• Component Procurement. We work with our parent companies to source <strong>the</strong> most cost effective system<br />

components <strong>for</strong> your application.<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 17 of 32


TM<strong>GE</strong><br />

System Test<br />

Underst<strong>and</strong>ing <strong>the</strong> importance of a<br />

thorough system test, <strong>the</strong> TMEIC<br />

<strong>GE</strong> engineering team conducts a<br />

comprehensive factory test be<strong>for</strong>e<br />

shipment. These tests consist of:<br />

• Complete staging of <strong>the</strong><br />

system with <strong>the</strong> drive,<br />

controller, I/O, <strong>and</strong><br />

communication networks.<br />

• 460 V gate test of all power<br />

semiconductors.<br />

• Test of <strong>the</strong> bridges at high<br />

current connected to an<br />

external load.<br />

• Validation of current <strong>and</strong><br />

voltage feedbacks.<br />

• Validation of all I/O interfaces,<br />

<strong>and</strong> <strong>the</strong> touch panel.<br />

• Validation of <strong>the</strong> drive test<br />

modes.<br />

• Test of <strong>the</strong> cooling system.<br />

Typical LCI drive test setup in <strong>the</strong> factory<br />

LCI Control Validation in <strong>the</strong> Engineering Lab<br />

Toolbox software <strong>for</strong> <strong>Drive</strong><br />

<strong>and</strong> Logic Configuration<br />

LCI STATUS<br />

Touch Panel<br />

Display & Control<br />

<strong>Drive</strong> Control<br />

Logic Control<br />

Firing Boards<br />

Exciter Control<br />

LCI Controller<br />

Simulation Software<br />

<strong>Drive</strong> Simulator<br />

M<br />

Load<br />

Optional PLC with<br />

Logic <strong>and</strong> Simulation of<br />

multiple Bypass<br />

Contactors<br />

Logic <strong>for</strong> Soft Start <strong>and</strong><br />

Synchronization of Multiple<br />

Motors <strong>for</strong> example<br />

Diagram of LCI <strong>Drive</strong> Test Setup<br />

Digital Motor<br />

Simulator<br />

Digital Load<br />

Simulator<br />

Validation of <strong>the</strong> optional<br />

LAN-DCS link <strong>and</strong> PLC<br />

sequencing <strong>and</strong> logic is done<br />

in <strong>the</strong> engineering lab using a<br />

simulated drive, motor, <strong>and</strong><br />

load. Using <strong>the</strong> computer<br />

simulated equipment, <strong>the</strong><br />

PLC is run through its<br />

sequencing <strong>and</strong> <strong>the</strong> resulting<br />

outputs validated.<br />

Note that logic <strong>for</strong><br />

synchronizing a single motor<br />

can be included in <strong>the</strong> LCI<br />

controller so a PLC is not<br />

required.<br />

Page 18 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


TM<strong>GE</strong><br />

System Commissioning<br />

In <strong>the</strong> commissioning phase of <strong>the</strong> project, your TMEIC<br />

<strong>GE</strong> team may include <strong>the</strong> local field engineers <strong>and</strong> factory<br />

service engineers, all supported by <strong>the</strong> engineers who<br />

designed <strong>and</strong> tested <strong>the</strong> system. This overlap of teams<br />

between <strong>the</strong> factory <strong>and</strong> <strong>the</strong> plant ensures a smooth <strong>and</strong><br />

on-schedule startup.<br />

The local service engineer takes responsibility <strong>for</strong> <strong>the</strong><br />

machine startup <strong>and</strong> commissioning <strong>and</strong> is available later if<br />

any service is required at <strong>the</strong> plant.<br />

<strong>Drive</strong> Training at <strong>the</strong> Factory or in Your Plant<br />

We can offer a course tailored to your project <strong>and</strong><br />

held at your location.<br />

Complete <strong>and</strong> Detailed <strong>Drive</strong> System Documentation<br />

Along with <strong>the</strong> hardware <strong>and</strong> software, TMEIC <strong>GE</strong><br />

delivers complete system documentation:<br />

• An electronic instruction book with all <strong>the</strong> prints<br />

on CD with a hyperlink index<br />

• Recommended wiring <strong>and</strong> grounding<br />

procedures<br />

• Renewal parts list<br />

• St<strong>and</strong>ard third-party vendor documentation<br />

At <strong>the</strong> end of <strong>the</strong> project, <strong>the</strong> drawings are updated<br />

to reflect <strong>the</strong> final changes.<br />

Customer engineers, service, <strong>and</strong> operations personnel<br />

are trained on <strong>the</strong> drives <strong>and</strong> control system at <strong>the</strong> <strong>GE</strong><br />

Training Center in Salem, Virginia. This world-class facility<br />

has 8 large classrooms, 5 fully equipped training labs, <strong>and</strong><br />

offers 61 different product courses to customers.<br />

Classroom <strong>and</strong> h<strong>and</strong>s-on training consists of 50% class<br />

time <strong>and</strong> 50% h<strong>and</strong>s-on lab time. Topics include:<br />

• Overview of <strong>the</strong> drive system<br />

• Function of <strong>the</strong> main assemblies<br />

• Technical details of <strong>the</strong> components<br />

• <strong>Drive</strong> <strong>and</strong> control system programming using <strong>the</strong><br />

Control System Toolbox<br />

• System diagnostics <strong>and</strong> service<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 19 of 32


System Maintenance & Service<br />

The Fastest Service Response in <strong>the</strong> <strong>Industry</strong> *<br />

Comprehensive technical service is provided by our large service organization with offices geographically distributed to<br />

provide a service presence near your plant. Service in North America, Europe, <strong>and</strong> Asia is discussed at <strong>the</strong> bottom of <strong>the</strong><br />

page. (* fastest response based on a recent survey).<br />

NORTH<br />

AMERICA<br />

Amsterdam, Holl<strong>and</strong><br />

European Spare<br />

Parts Depot<br />

London<br />

Frankfurt<br />

E U R O P E<br />

Warsaw<br />

A S I A<br />

P A C I F I C<br />

O C E A N<br />

Houston, TX<br />

Pittsburgh, PA<br />

Roanoke, VA<br />

Head Office<br />

A T L A N T I C<br />

O C E A N<br />

Bari<br />

Kuwait<br />

Beijing<br />

Hong Kong<br />

P A C I F I C<br />

O C E A N<br />

TOKYO<br />

Shanghai, China<br />

TMEIC Asian Spare Parts Depot<br />

SOUTH<br />

AMERICA<br />

AFRICA<br />

Hyderabad<br />

Kuala Lumpur<br />

Singapore<br />

I N D I A N<br />

O C E A N<br />

Jakarta<br />

Rio de Janeiro<br />

Sao Paulo<br />

Buenos Aires<br />

Johannesburg<br />

AUSTRALIA<br />

Sydney<br />

Atlanta, GA<br />

North America<br />

Spare Parts Depot<br />

Amsterdam, Holl<strong>and</strong><br />

European Spare<br />

Parts Depot<br />

London<br />

Warsaw<br />

Frankfurt<br />

Tokyo, Japan<br />

TMEIC Head Office & Factory<br />

Bari<br />

Wherever You Are, We Are Close By<br />

In North America:<br />

In Europe:<br />

In Asia:<br />

The TMEIC <strong>GE</strong> Service <strong>and</strong> Parts organizations service all drive system customers out of <strong>the</strong>ir<br />

field offices in North America. They are supported by remote diagnostic service provided by <strong>the</strong><br />

<strong>GE</strong> OnSite Support organization, <strong>the</strong> TMEIC <strong>GE</strong> factory service personnel, <strong>and</strong> <strong>the</strong> TMEIC<br />

(Toshiba Mitsubishi-Electric Industrial Systems Corporation) North America Spare Parts Depot in<br />

Atlanta, Georgia.<br />

TMEIC <strong>GE</strong> services all systems in Europe supported by <strong>the</strong> TMEIC <strong>GE</strong> international offices in <strong>the</strong><br />

UK, Germany, <strong>and</strong> Pol<strong>and</strong>; <strong>the</strong> TMEIC Spare Parts Depot in Amsterdam, Holl<strong>and</strong>; <strong>the</strong> <strong>GE</strong> OnSite<br />

Support service in <strong>the</strong> USA; <strong>and</strong> <strong>the</strong> TMEIC <strong>GE</strong> factory service personnel in Salem, Virginia.<br />

TMEIC <strong>GE</strong> services drive systems throughout Asia <strong>and</strong> <strong>the</strong> Pacific supported by <strong>the</strong> TMEIC factory<br />

in Japan, <strong>and</strong> multiple Field Engineers distributed throughout Sou<strong>the</strong>ast Asia. The <strong>GE</strong> OnSite<br />

Support service is also available to customers as an option.<br />

Page 20 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


The World’s Largest Fleet of Installed MV <strong>Drive</strong>s<br />

Load Commutated Inverter LCI<br />

Dura-Bilt5i MV<br />

TMdrive-70<br />

Power Rating of<br />

MV <strong>Drive</strong> Family<br />

TMdrive-80<br />

TMdrive-XL85<br />

TMdrive-70<br />

LCI<br />

Dura-Bilt5i<br />

200 300 400 1,000 2,000<br />

268 402 536<br />

1,340 2,682<br />

4,000<br />

5,364<br />

10,000<br />

13,400<br />

20,000<br />

26,800<br />

50,000<br />

67,000<br />

90,000<br />

120,000<br />

kW<br />

Hp<br />

TMEIC <strong>GE</strong>’s Family of Medium Voltage AC System <strong>Drive</strong>s<br />

Largest Installed Base. Since <strong>the</strong> LCI was introduced in 1979, over 2 million hp of drives have been installed <strong>and</strong> are in<br />

service. More recently a large number of Innovation Type G, H, <strong>and</strong> SP drives have been installed, as well as <strong>the</strong> new<br />

technology Tosvert, Dura-Bilt, <strong>and</strong> TMdrives. This represents <strong>the</strong> largest installed base of MV drives of any manufacturer.<br />

Significant Investment in MV Technology. TMEIC <strong>GE</strong>’s Tosvert, Dura-Bilt, <strong>and</strong> TMdrive products represent a large<br />

investment in MV drive technology, including development of semiconductor devices such as <strong>the</strong> IEGT <strong>and</strong> GCT.<br />

The Highest Reliability. <strong>GE</strong> <strong>and</strong> TMEIC <strong>GE</strong> drives provide <strong>the</strong> highest reliability based on field experience <strong>and</strong> customer<br />

satisfaction survey results in North America.<br />

The Control System Toolbox. The Windows-based toolbox software is <strong>the</strong> universal tool across all drives providing<br />

configuration, tuning, sequencing, <strong>and</strong> drive diagnostics <strong>for</strong> <strong>the</strong> entire family.<br />

Large Spare Parts Stock. <strong>GE</strong>’s spare parts organization <strong>and</strong> TMEIC <strong>GE</strong>’s parts depots both stock <strong>the</strong> line of MV drive parts<br />

<strong>and</strong> provide rapid delivery to your plant anywhere in <strong>the</strong> world.<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 21 of 32


Load Commutated Inverter (LCI) System <strong>Drive</strong> Overview<br />

4,160 AC<br />

2,300 AC<br />

Volts<br />

2,000<br />

2,682<br />

10000<br />

13,400<br />

LCI<br />

LCI<br />

50,000<br />

67,000<br />

kW<br />

Hp<br />

The TMEIC <strong>GE</strong> LCI drive is ideal <strong>for</strong> any high power<br />

synchronous motor application requiring adjustable<br />

speed operation or soft starting. With an optional output<br />

trans<strong>for</strong>mer, <strong>the</strong> LCI can operate with any motor voltage.<br />

Motor field excitation is included as well as a<br />

synchronizing <strong>and</strong> de-synchronizing function to smoothly<br />

start large motors.<br />

Power Converter Blocks:<br />

2,300 Volt, 6-pulse source – 5,224 kW, 7,000 hp<br />

2,300 Volt, 12-pulse source – 10,448 kW, 14,000 hp<br />

4,160 Volt, 6-pulse source – 13,433 kW, 18,000 hp<br />

4,160 Volt, 12-pulse source – 13,433 kW, 18,000 hp<br />

LCI power converter blocks can be paralleled to deliver<br />

ratings in excess of 70,000 hp. Multi-channel (block)<br />

operation gives <strong>the</strong> opportunity <strong>for</strong> dual <strong>and</strong> triple<br />

channel redundancy <strong>for</strong> very high reliability applications.<br />

Features<br />

Unique Bridge Design<br />

Each bridge uses full voltage rated SCRs<br />

(thyristors) in an N+1 configuration.<br />

Highest System Efficiency<br />

The synchronous motor <strong>and</strong> LCI combination is one<br />

of <strong>the</strong> highest efficiency drive system available.<br />

Benefits<br />

Maximize Reliability <strong>and</strong> Up-Time<br />

N+1 redundancy insures full power output even in<br />

<strong>the</strong> event of an SCR device failure.<br />

Most Cost Effective High HP Systems<br />

High efficiency means reduced energy<br />

consumption <strong>and</strong> lower costs over <strong>the</strong> project life.<br />

Input Configuration<br />

The drive can be configured <strong>for</strong> 6-, 12-, or 24-pulse<br />

input.<br />

Water Cooled Technology<br />

Fully redundant cooling system; hoses don’t need<br />

to be disconnected <strong>for</strong> bridge service.<br />

Windows-Based Configuration <strong>and</strong><br />

Maintenance Tools<br />

For PC-based configuration, <strong>the</strong> toolbox features<br />

animated block diagrams <strong>and</strong> a trend window.<br />

Built-In Line Regeneration<br />

<strong>Energy</strong> in <strong>the</strong> load can feed back into <strong>the</strong> source<br />

converter <strong>and</strong> out to <strong>the</strong> MV supply.<br />

Power System Friendly<br />

Flexible input configuration choice allows cost<br />

effective installations <strong>for</strong> low harmonic distortion.<br />

Compact, Quiet Design<br />

Reduces <strong>and</strong> simplifies maintenance, reduces<br />

ambient noise, <strong>and</strong> saves valuable floor space.<br />

Faster Commissioning & Maintenance<br />

These world-class tools improve productivity in<br />

commissioning <strong>and</strong> maintenance, <strong>and</strong> can be used<br />

on all TMEIC <strong>GE</strong> drive products.<br />

Large <strong>Energy</strong> Savings<br />

Load energy, which would o<strong>the</strong>rwise be turned into<br />

heat, is recovered, resulting in reduced utility bills.<br />

Page 22 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


LCI Control Features:<br />

• Load commutation above 10% base speed<br />

• Sensorless speed control<br />

• Speed control range: 10-150% of base speed<br />

with logic to prevent reverse operation<br />

• Built-in regeneration <strong>for</strong> smooth control of<br />

loads<br />

Cabinet Lineup:<br />

Length - 158 in (4,000 mm) <strong>for</strong> 7,000 hp<br />

version.<br />

- 220 in (5,600 mm) <strong>for</strong> 18,000 hp<br />

version.<br />

Height - 100 in (2,500 mm) <strong>for</strong> all cabinets.<br />

Depth - 55 in (1,400 mm) <strong>for</strong> all cabinets.<br />

Cooling System<br />

In <strong>the</strong> closed loop cooling system, coolant<br />

circulates from <strong>the</strong> pump discharge, to <strong>the</strong> heat<br />

exchanger, to <strong>the</strong> power conversion bridges, <strong>and</strong><br />

back to <strong>the</strong> pump. Pumps can be switched over<br />

<strong>and</strong> changed without interrupting cooling.<br />

1<br />

N<br />

AC<br />

Voltage<br />

Input<br />

N +1 SCR<br />

redundancy<br />

Color Touch<br />

Screen<br />

Source Bridge<br />

DC Link<br />

Reactor<br />

Main<br />

Control<br />

Module<br />

VersaMax<br />

I/O Modules<br />

Load Bridge<br />

AC<br />

Voltage<br />

Output<br />

Optional<br />

Transf ormer<br />

Sy nchronous<br />

Motor<br />

Excitation<br />

Voltage<br />

Controller<br />

Optional Tach Signal<br />

LCI Source <strong>and</strong> Load Bridge Configuration<br />

SCR water<br />

cooling hoses<br />

Source bridge<br />

with series SCR<br />

cells <strong>and</strong> heat<br />

sinks<br />

Cell replacement without<br />

opening water cooling loop<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 23 of 32


Dura-Bilt5i Medium Voltage PWM <strong>Drive</strong><br />

4,160<br />

3,300<br />

2,300<br />

Volts<br />

200 400<br />

268 536<br />

1,000<br />

1,340<br />

4,000<br />

5,364<br />

kW<br />

Hp<br />

Dura-Bilt5i delivers simple operation in a robust <strong>and</strong><br />

compact design, providing a cost effective solution <strong>for</strong> a<br />

broad range of medium voltage applications.<br />

Backed by its five-year warranty, <strong>the</strong> Dura-Bilt5i MV delivers<br />

value through low cost of ownership <strong>and</strong> high reliability.<br />

Power levels available include:<br />

• 2000 Series – 2,300 Volts Out, 300 to 3,000 hp<br />

• 3000 Series – 3,300 Volts Out, 300 to 4,000 hp<br />

• 4000 Series – 4,160 Volts Out, 400 to 7,000 hp<br />

Rugged design features <strong>for</strong> high reliability include:<br />

• Inverter heat pipe cooling.<br />

• Diode rectifier converter with 24-pulse circuit <strong>for</strong> low<br />

input current distortion.<br />

• Neutral point clamped pulse width modulated inverter<br />

using medium voltage IGBTs.<br />

Cabinet Size: 1,000 hp drive is 74 inch (1,880 mm) long<br />

5,500 hp drive is 222 inch (5,639 mm) long<br />

Cabinet height is 104 inch (2,634 mm) long<br />

Features<br />

Medium Voltage IGBTs<br />

Each inverter uses 3,300 Volt Insulated Gate<br />

Bipolar Transistors (IGBTs).<br />

Benefits<br />

Rock Solid Reliability<br />

High power IGBTs allow a simpler, more reliable<br />

inverter design with fewer power switches.<br />

24-Pulse Converter<br />

Each phase leg of <strong>the</strong> converter includes a 24-<br />

pulse diode rectifier.<br />

Heat Pipe Cooling Technology<br />

Each of <strong>the</strong> three inverter legs use heat pipe<br />

cooling <strong>for</strong> <strong>the</strong> IGBTs.<br />

Power System Friendly<br />

This design exceeds <strong>the</strong> IEEE 519-1992<br />

specification <strong>for</strong> Total Harmonic Distortion (THD)<br />

without requiring filters.<br />

Compact Quiet Design<br />

The heat pipe cooling reduces fan noise <strong>and</strong> saves<br />

valuable floor space in your plant.<br />

Windows-Based Configuration <strong>and</strong><br />

Maintenance Tools<br />

For PC-based configuration, <strong>the</strong> Control System<br />

Toolbox features:<br />

• Animated block diagrams<br />

• <strong>Drive</strong> tune up wizards<br />

• Integrated trend window<br />

Faster Commissioning <strong>and</strong> Maintenance<br />

These world-class tools improve productivity in<br />

commissioning <strong>and</strong> maintenance <strong>and</strong> can be used<br />

on all TMEIC <strong>GE</strong> drive products.<br />

Page 24 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


Dura-Bilt5i MV Power Bridge Technology Driving <strong>the</strong> Five-Year Warranty<br />

Typical inverter voltage &<br />

currrent wave<strong>for</strong>ms <strong>for</strong> 5/9 level<br />

pulse width modulated output.<br />

Current<br />

1 of 3 phases shown in detail<br />

C (W)<br />

C (W)<br />

Copper-wound trans<strong>for</strong>mer<br />

with electrostatic shield<br />

B (V)<br />

A (U)<br />

Trans<strong>for</strong>mer/Source<br />

compartment<br />

24-pulse source<br />

B (V)<br />

A (U)<br />

Inverter compartment<br />

phase-leg assemblies<br />

Main power<br />

14.4 kV or below,<br />

50-60 Hz<br />

Integral<br />

pre-charge<br />

circuit<br />

Incoming power<br />

compartment<br />

Medium voltage IGBTs<br />

Induction<br />

motor<br />

3<br />

M<br />

E<br />

St<strong>and</strong>ard<br />

integral lightning<br />

arrestor<br />

Integral<br />

disconnect<br />

option<br />

Sensing &<br />

control power<br />

potential<br />

trans<strong>for</strong>mers,<br />

120 V output<br />

St<strong>and</strong>ard<br />

E.S. Shield<br />

Voltage<br />

detection<br />

module<br />

Optical<br />

link<br />

module<br />

Current<br />

feedback<br />

Output<br />

disconnect<br />

option<br />

<strong>Drive</strong><br />

bypass<br />

option<br />

Auxiliary & control power<br />

480 V ac st<strong>and</strong>ard,<br />

o<strong>the</strong>rs available<br />

3<br />

Power<br />

Supplies<br />

Phase detection<br />

module<br />

+5 V dc<br />

+/-15 V dc<br />

+24 V dc<br />

0 V dc<br />

Controller<br />

Redundant<br />

fans option<br />

Gate signal<br />

distributor<br />

LAN interface<br />

External I/O<br />

Heat pipe cooling<br />

assembly<br />

Additional Features<br />

• Operator keypad provides real time drive data • Fuse protection on source diodes with blown fuse<br />

• Integral copper wound trans<strong>for</strong>mer rated <strong>for</strong> 115°C<br />

indication<br />

rise with electrostatic shield • Operation at 0° to +40°C; up to +50°C with derating<br />

• Incoming power protected by lightning arrestors • Speed regulation ±0.01% with speed sensor; ±0.5%<br />

• Roll out inverter phase leg assemblies<br />

without<br />

• DC bus capacitors, oil filled <strong>for</strong> long life<br />

• Field oriented vector control torque accuracy ±3% with<br />

• Closed transfer synchronizing control<br />

temp sensor<br />

• Induction or synchronous motor<br />

• 3% or less motor current harmonic distortion<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 25 of 32


TMdrive-70 <strong>and</strong> TMdrive-80 Medium Voltage <strong>Drive</strong>s<br />

3.3 kV<br />

3.3 kV<br />

2,000<br />

2,682<br />

4,000<br />

5,364<br />

10,000<br />

13,400<br />

TM-80<br />

TM-70<br />

50,000 kW<br />

67,000 Hp<br />

The TMdrive-70 – Designed <strong>for</strong> high-power applications<br />

Frame 8000 – 3,300 Volts out, motor power 10,000 hp<br />

Frame 20000 – 3,300 Volts out, motor power 26,000 hp<br />

Frame 40000 – 3,300 Volts out, motor power 52,000 hp<br />

Rugged design features <strong>for</strong> high reliability:<br />

• Water cooled power bridge<br />

• Converter <strong>and</strong> inverter using medium voltage Injection<br />

Enhanced Gate Transistor (IEGT) power semiconductors with<br />

high-speed switching<br />

• Pulse Width Modulation using fixed pulse pattern control to<br />

reduce switching losses<br />

• Neutral point clamp diodes<br />

• Regenerative IEGT converter available<br />

TMdrive-70 cabinet sizes:<br />

Frame 8000 cabinet is 126 inch (3,200 mm) long, 94 inch high.<br />

Frame 20000 cabinet is 220 inch (5,600 mm) long, 94 inch high.<br />

Frame 40000 cabinet is 252 inch (6,400 mm) long, 94 inch high.<br />

plus a second cabinet, which is 189 inch (4,800mm) long.<br />

Features<br />

IEGT-based Converter <strong>and</strong> Inverter, TM-70<br />

Both <strong>the</strong> converter <strong>and</strong> inverter use state-of-<strong>the</strong>art<br />

technology <strong>and</strong> design based on <strong>the</strong> Injection<br />

Enhanced Gate Transistor (IEGT).<br />

GCT-based Converter <strong>and</strong> Inverter, TM-80<br />

Both <strong>the</strong> converter <strong>and</strong> inverter use state-of-<strong>the</strong>art<br />

technology <strong>and</strong> design based on <strong>the</strong> Gate<br />

Commutated Turn-off thyristor (GCT).<br />

Water Cooled Power Bridge<br />

Draw-out phase leg assemblies are water-cooled<br />

<strong>and</strong> have quick disconnect fittings.<br />

Modular Design<br />

Power bridge assemblies come in convenient<br />

draw-out modules.<br />

High-Speed Switching<br />

The IEGT is switched at a rate of 500 Hz in <strong>the</strong><br />

TM-70, <strong>and</strong> <strong>the</strong> power bridge is a three-level<br />

design.<br />

Benefits<br />

<strong>Drive</strong> Provides Near Unity Power Factor to <strong>the</strong> Load<br />

The IEGT phase leg assemblies provide power at near<br />

unity power factor with minimum harmonic distortion<br />

<strong>and</strong> lower switching losses.<br />

<strong>Drive</strong> Capable of Higher Capacity<br />

The GCT phase leg assemblies provide high power at<br />

near unity power factor with minimum harmonic<br />

distortion.<br />

Equipment Footprint Reduced<br />

Efficient water-cooling allows reduced drive footprint,<br />

saving valuable space in your facility.<br />

Maintenance Minimized<br />

Modular power bridge assemblies <strong>and</strong> quick<br />

disconnects minimize <strong>the</strong> time <strong>for</strong> any maintenance<br />

activities.<br />

Motor <strong>and</strong> Power System Friendly<br />

The high-speed switching coupled with <strong>the</strong> bridge<br />

design delivers a smooth sine wave to <strong>the</strong> motor <strong>and</strong><br />

power system.<br />

Page 26 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


Flexible Topologies to Meet Your Needs<br />

The TMdrive-70 8000/10000 Frame IEGT regenerative Converter <strong>and</strong> Inverter are shown below. A non-regenerative diode<br />

converter is also available. Converter <strong>and</strong> inverter banks can be paralleled to obtain high powers <strong>for</strong> driving large induction<br />

or synchronous motors.<br />

Three-Level Phase Leg Assembly <strong>for</strong> both Converter <strong>and</strong> Inverter – TM-70<br />

TM-70 Phase Leg Assembly<br />

TM-70 10 MVA Converter<br />

TM-80 14 MVA Converter<br />

10 MVA Inverter<br />

14 MVA Inverter<br />

Additional Features – TM-70:<br />

• Control cards common to <strong>the</strong> TMEIC <strong>GE</strong> drive family.<br />

• Common Microsoft Windows-based configuration<br />

toolbox software with local or remote connectivity.<br />

• High drive efficiency of 98.5% at rated load.<br />

• <strong>Oil</strong>-filled DC capacitors to provide long life.<br />

• Field exciter available <strong>for</strong> synchronous motors.<br />

• Operation at 0° to +40°C; up to +50°C with derating.<br />

• Vector control speed regulation ±0.01% with speed<br />

sensor; ±0.1% without.<br />

• Vector control torque linearity ±3% with temp sensor,<br />

<strong>for</strong> induction motor.<br />

• Very low motor current harmonic distortion.<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 27 of 32


TMdrive-XL85, <strong>the</strong> 7.2 kV <strong>Drive</strong> <strong>for</strong> High Power Applications<br />

TMdrive-XL85, <strong>the</strong> 7.2 kV <strong>Drive</strong> <strong>for</strong> High Power Applications<br />

Volts<br />

Volts<br />

7,600<br />

7,600<br />

2,000<br />

2,682 2,000<br />

2,682<br />

4,000 10,000<br />

50,000 90,000 kW<br />

4,000 5,364 13,400 10,000<br />

50,000 67,000 120,000 90,000 kW Hp<br />

5,364 13,400<br />

67,000 120,000 Hp<br />

The TMdrive-XL85 is a medium voltage, ac fed<br />

The drive TMdrive-XL85 designed <strong>for</strong> is high-efficiency medium voltage, <strong>and</strong> powerfriendly<br />

designed operation <strong>for</strong> in high-efficiency a broad range <strong>and</strong> of industrial power-<br />

ac fed<br />

drive<br />

friendly applications. operation in broad range of industrial<br />

applications.<br />

High reliability, low harmonic distortion,<br />

High <strong>and</strong> high reliability, power low factor harmonic operation distortion, are<br />

<strong>and</strong> designed high into power <strong>the</strong> drive. factor operation are<br />

designed into <strong>the</strong> drive.<br />

The TMdrive-XL85 is available with up to 7.2 kV<br />

The class TMdrive-XL85 voltage output. is available with up to 7.2 kV<br />

class voltage output.<br />

Features<br />

Benefits<br />

Features<br />

Benefits<br />

• Conservative design using 6000 V - 6 000 A • Highly reliable operation, expected 20 year drive<br />

Conservative GCTs design using 6000 000 Highly MTBF reliable operation, expected 20 year drive<br />

GCTs<br />

MTBF<br />

• High energy efficiency approximately 98.6% • Considerable energy savings<br />

High energy efficiency approximately 98.6% Considerable energy savings<br />

Please add<br />

icons Please add<br />

icons<br />

Please<br />

add Please icons<br />

add icons<br />

Please add<br />

icons Please add<br />

icons<br />

• Diode rectifier ensures power factor greater<br />

Diode than 95% rectifier in <strong>the</strong> ensures speed control power range factor greater<br />

than 95% in <strong>the</strong> speed control range<br />

• 36-pulse converter rectifier by using separated<br />

36-pulse phase shifted converter trans<strong>for</strong>mer rectifier by using separated<br />

phase shifted trans<strong>for</strong>mer<br />

• Multiple level drive output wave<strong>for</strong>m to <strong>the</strong><br />

Multiple motor (five level levels drive <strong>for</strong> <strong>the</strong> output 7.2 kV wave<strong>for</strong>m inverter) to <strong>the</strong><br />

motor (five levels <strong>for</strong> <strong>the</strong> 7.2 kV inverter)<br />

• Synchronous transfer to line option with no<br />

Synchronous interruption to motor transfer current to line option with no<br />

interruption to motor current<br />

• Separated input isolation trans<strong>for</strong>mer included in<br />

Separated drive package input isolation trans<strong>for</strong>mer included in<br />

drive package<br />

• Capacitors not required <strong>for</strong> power factor<br />

Capacitors correction not required <strong>for</strong> power factor<br />

correction<br />

• No harmonic filter required to provide lower<br />

No harmonic harmonic distortion filter levels required than to IEEE-519-1992<br />

provide lower<br />

harmonic guidelines distortion levels than IEEE-519-1992<br />

guidelines<br />

• Suitable <strong>for</strong> st<strong>and</strong>ard motors due to motor<br />

Suitable friendly wave<strong>for</strong>m<br />

st<strong>and</strong>ard motors due to motor<br />

friendly wave<strong>for</strong>m<br />

• Allows control of multiple motors with one drive<br />

Allows control of multiple motors with one drive<br />

• No motor current or torque transients when <strong>the</strong><br />

No motor motor transitions current to or <strong>the</strong> torque AC line transients when <strong>the</strong><br />

motor transitions to <strong>the</strong> AC line<br />

• Less power loss in <strong>Drive</strong> Room<br />

Less power loss in <strong>Drive</strong> Room<br />

• Less total space required<br />

Less total space required<br />

• Simplifies design <strong>and</strong> installation<br />

Simplifies design <strong>and</strong> installation<br />

Page 28 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


TMdrive-XL85 Adjustable Speed <strong>Drive</strong><br />

Converter:<br />

• Low harmonic distortion<br />

• Input from six windings<br />

• 36-pulse diode converter<br />

Converter<br />

(Source)<br />

Compartment<br />

1 of 3 phases shown in detail<br />

C (W)<br />

B (V)<br />

A (U)<br />

C (W)<br />

B (V)<br />

A (U)<br />

Inverter Compartment<br />

Phase-Leg<br />

Assemblies<br />

Inverter:<br />

• Low harmonic distortion<br />

• Five-level GCT circuit<br />

Synchronous motor <strong>for</strong><br />

high power levels.<br />

Voltage 7.6 kV<br />

M<br />

Trans<strong>for</strong>mer<br />

Redundant TMdrive-XL85 Configuration<br />

A redundant configuration of <strong>the</strong> TMdrive-XL85 can be<br />

built using four active channels (blocks) connected as<br />

shown in <strong>the</strong> diagram. The system has:<br />

• Four trans<strong>for</strong>mers <strong>and</strong> four TMdrive-XL85<br />

channels.<br />

• Four parallel connections.<br />

• A very clean wave<strong>for</strong>m.<br />

• Contacts to isolate any one channel.<br />

The redundant function is as follows:<br />

1. A problem is detected in one channel.<br />

2. The suspect channel is isolated <strong>and</strong> stopped.<br />

3. The three o<strong>the</strong>r channels continue operation <strong>and</strong><br />

deliver full power to <strong>the</strong> motor.<br />

4. The out-of-service channel is repaired <strong>and</strong><br />

brought back on line.<br />

Trans<strong>for</strong>mers<br />

T C I<br />

T C I<br />

T C I<br />

T C I<br />

TMdrive-85<br />

<strong>Drive</strong>s<br />

Simplified Block Diagram of Redundant ASD<br />

SM<br />

Synchronous<br />

Motor<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 29 of 32


Appendix. <strong>Energy</strong> Savings Payback Calculations<br />

Replacing a mechanical speed control device with an adjustable speed drive usually produces large energy savings plus a<br />

reduction in maintenance costs. This appendix outlines how <strong>the</strong> energy savings can be calculated as follows:<br />

1. Calculate <strong>the</strong> cost of energy used by <strong>the</strong> electric drive speed control system, outlined on this page.<br />

2. Calculate <strong>the</strong> cost of energy used by <strong>the</strong> mechanical speed control system, outlined on <strong>the</strong> next page.<br />

The difference is <strong>the</strong> energy cost savings. Typical power consumption curves <strong>for</strong> pumps <strong>and</strong> fans are shown below.<br />

Power (pu)<br />

1.0<br />

0.8<br />

0.6<br />

0.4<br />

0.2<br />

0<br />

o<br />

Pump with<br />

throttling valve<br />

<strong>Energy</strong><br />

savings<br />

o<br />

o<br />

o<br />

o<br />

20% 40% 60% 80% 100%<br />

RPM/Flow (pu)<br />

o<br />

Electrical<br />

ASD<br />

Example: Pump power savings using electric drive (ASD)<br />

Power (pu)<br />

1.0<br />

0.8<br />

0.6<br />

0.4<br />

0.2<br />

0<br />

Fan with<br />

damper<br />

<strong>Energy</strong><br />

savings<br />

Fan with inlet<br />

guide vanes<br />

0% 20% 40% 60% 80% 100%<br />

RPM / Flow (pu)<br />

Electrical<br />

ASD<br />

Example: Fan power savings using electric drive (ASD)<br />

Below is an example of <strong>the</strong> energy cost calculation <strong>for</strong> a pump driven by a motor <strong>and</strong> electric drive. The calculation <strong>for</strong> <strong>the</strong><br />

mechanical system is similar <strong>and</strong> is described on <strong>the</strong> next page. Since energy consumption varies with speed <strong>and</strong> flow, you<br />

need <strong>the</strong> load profile table which shows <strong>the</strong> number of hours running at <strong>the</strong> various flows. Refer to <strong>the</strong> example below.<br />

<strong>Energy</strong> Cost <strong>for</strong> Electric <strong>Drive</strong> Speed Control<br />

Step 9<br />

Step 8<br />

Step 6<br />

<strong>Energy</strong> Cost<br />

Input kW<br />

$0.07/kWh<br />

1,212<br />

<strong>Energy</strong><br />

<strong>Drive</strong><br />

Cost<br />

Efficiency<br />

$371,500/yr<br />

96.5%<br />

Calculation<br />

details<br />

Step 10<br />

Three-Phase<br />

Electric Supply<br />

Step 7<br />

Electric<br />

Adjustable<br />

Speed<br />

<strong>Drive</strong><br />

Motor<br />

Step 4<br />

Motor<br />

Input kW<br />

Shaft kW<br />

1,169<br />

Motor<br />

1,119<br />

Input<br />

Efficiency<br />

Shaft hp<br />

95.7%<br />

1,500<br />

Step 5<br />

Step 3<br />

Electric Motor<br />

Shaft<br />

Variable speed motor<br />

Pump<br />

Chart & Load<br />

Curve<br />

Step 2<br />

Variable speed pump<br />

Step1<br />

Desired<br />

Flow<br />

90%<br />

Start<br />

here<br />

Output Flow<br />

<strong>and</strong> Pressure<br />

Step 1<br />

Step 2<br />

Step 3<br />

Select <strong>the</strong> desired pump<br />

output flow, <strong>for</strong> example<br />

90%, <strong>and</strong> number of<br />

hours/day at this flow,<br />

<strong>for</strong> example 12.<br />

Obtain <strong>the</strong> variable<br />

speed pump<br />

per<strong>for</strong>mance chart <strong>and</strong><br />

<strong>the</strong> load pressure-flow<br />

curve, which is <strong>the</strong> flow<br />

resistance of <strong>the</strong><br />

process being fed.<br />

Find <strong>the</strong> pump input<br />

power.<br />

Percent Pressure (or Head)<br />

100<br />

Pump Per<strong>for</strong>mance Chart & Load Curve<br />

Load Curve<br />

(Process)<br />

Pump Chart<br />

Speed N2<br />

1,800 rpm<br />

80<br />

B<br />

1,500 hp<br />

A<br />

90 100<br />

Percent Output Flow<br />

Pump hp<br />

2,000<br />

Overlay <strong>the</strong> load pressure-flow curve on <strong>the</strong> pump<br />

chart <strong>and</strong> find <strong>the</strong> pump input shaft horsepower at<br />

<strong>the</strong> 90% flow (point B). You need <strong>the</strong> load profile.<br />

See example below.<br />

Pump input power at N2 rpm = 1,500 hp<br />

at point B, 90% flow.<br />

Daily Load Profile (example)<br />

Operation<br />

Hours/day<br />

Percent<br />

Flow<br />

5<br />

100%<br />

12<br />

90%<br />

5<br />

80%<br />

1<br />

70%<br />

1<br />

60%<br />

Step 4<br />

Convert <strong>the</strong> input shaft<br />

horsepower to shaft kW<br />

Conversion: Horsepower x 0.746 = kW<br />

Input shaft kW = 1,500 hp x 0.746 = 1,119 kW<br />

Step 5<br />

Step 6<br />

Obtain <strong>the</strong> electric<br />

motor efficiency<br />

Example: Induction motor efficiency 95.7% from<br />

manufacturer's data sheets (find at each RPM)<br />

Motor input power = 1,119 kW/0.957 Efficiency<br />

= 1,169 kW<br />

Step 7<br />

Step 8<br />

Obtain <strong>the</strong> adjustable<br />

speed drive efficiency<br />

Example: <strong>Drive</strong> efficiency 96.5% from manufacturer's<br />

data sheets (find at each RPM)<br />

<strong>Drive</strong> input power = 1,169 kW/0.965 Efficiency<br />

= 1,212 kW<br />

Step 9<br />

Step 10<br />

Obtain <strong>the</strong> electric<br />

power cost<br />

Example: <strong>Energy</strong> cost = $0.07/kWh. Calculate cost <strong>for</strong><br />

<strong>the</strong> hours at this flow from load profile; in this example it<br />

is 12 hours/day.<br />

<strong>Energy</strong> cost = 1,212 kW x 0.07$kWh x 12 hrs/day<br />

x 365 days per year = $371,500 per year. (Repeat<br />

calculation <strong>for</strong> o<strong>the</strong>r flows in load profile <strong>and</strong> total).<br />

Page 30 of 32<br />

© 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Revised: 5-22-09


Three-<br />

Phase Electric<br />

Electric Supply<br />

Supply<br />

Calculations <strong>for</strong> Mechanical Speed Control Systems<br />

Calculations <strong>for</strong> Mechanical Speed Control Systems<br />

If <strong>the</strong> energy cost is to be compared with a mechanical variable speed system, <strong>the</strong> previous calculation must be repeated.<br />

There If <strong>the</strong> energy are three cost main is to mechanical be compared flow with control mechanical systems as variable described speed in system, <strong>the</strong> large <strong>the</strong> table previous of pages calculation 4 <strong>and</strong> 5: must be repeated.<br />

There<br />

•<br />

are<br />

A fixed<br />

three<br />

speed<br />

main mechanical<br />

motor <strong>and</strong> pump,<br />

flow control<br />

compressor,<br />

systems<br />

or<br />

as<br />

fan<br />

described<br />

with a flow<br />

in <strong>the</strong><br />

throttling<br />

large table<br />

valve<br />

of<br />

or<br />

pages<br />

variable <strong>and</strong><br />

guide<br />

5:<br />

vanes.<br />

• A fixed<br />

fixed<br />

speed<br />

speed<br />

motor<br />

motor<br />

<strong>and</strong><br />

<strong>and</strong><br />

hydraulic<br />

pump, compressor,<br />

variable speed<br />

or fan<br />

transmission<br />

with flow throttling<br />

driving a<br />

valve<br />

variable<br />

or variable<br />

speed pump<br />

guide<br />

or<br />

vanes.<br />

compressor.<br />

• A variable<br />

fixed speed<br />

speed<br />

motor<br />

steam<br />

<strong>and</strong><br />

or<br />

hydraulic<br />

gas turbine<br />

variable<br />

driving<br />

speed<br />

a variable<br />

transmission<br />

speed pump<br />

driving<br />

or compressor.<br />

variable speed pump or compressor.<br />

The methods variable <strong>for</strong> calculating speed steam <strong>the</strong>se or costs gas turbine are outlined driving in <strong>the</strong> variable chart speed below. pump A load or profile compressor. similar to <strong>the</strong> previous page is<br />

used. The methods Spreadsheets <strong>for</strong> calculating <strong>for</strong> calculating <strong>the</strong>se costs <strong>the</strong> savings are outlined <strong>and</strong> payback in <strong>the</strong> chart <strong>for</strong> below. a fan are available load profile from similar <strong>the</strong> Web to <strong>the</strong> site previous www.tmge.com page is .<br />

used. Spreadsheets <strong>for</strong> calculating <strong>the</strong> savings <strong>and</strong> payback <strong>for</strong> fan are available from <strong>the</strong> Web site www.tmge.com Fig. 1 Pump Per<strong>for</strong>mance Chart & Load Curve To calculate <strong>the</strong> energy used by a flow<br />

Flow Throttling Valve Control<br />

Fig. 1 Pump Per<strong>for</strong>mance Chart & Load Curve To throttling calculate system, <strong>the</strong> energy start with used <strong>the</strong> by desired a flow<br />

Flow Throttling Valve Control<br />

throttling output flow, system, say 90%. start Obtain with <strong>the</strong> <strong>the</strong> desired pump<br />

Pump hp<br />

output per<strong>for</strong>mance flow, say chart 90%. (head Obtain vs flow, <strong>the</strong> pump with pump<br />

Pump 1,900 hp<br />

per<strong>for</strong>mance horsepower). chart Find <strong>the</strong> (head horsepower vs flow, with required pump<br />

1,900<br />

C A<br />

horsepower). when <strong>the</strong> pump Find is running <strong>the</strong> horsepower at <strong>the</strong> fixed required<br />

Electric Motor<br />

100<br />

C A<br />

when <strong>the</strong> pump is running at <strong>the</strong> fixed<br />

Electric Motor<br />

100<br />

motor speed of 1,800 rpm <strong>and</strong> delivering<br />

Threemotor<br />

speed of 1,800 rpm <strong>and</strong> delivering<br />

Three- Phase<br />

Valve or<br />

<strong>the</strong> reduced flow at C in Figure 1. Proceed<br />

Phase Electric<br />

Valve Damper or<br />

<strong>the</strong> as in reduced <strong>the</strong> electrical flow at example, C in Figure working 1. Proceed back<br />

Electric Supply<br />

Damper Control<br />

Valve as to <strong>the</strong> in <strong>the</strong> motor. electrical Calculate example, <strong>the</strong> shaft working kW used back<br />

Supply<br />

Control<br />

Valve<br />

Fixed speed Fixed speed<br />

Open to <strong>and</strong> <strong>the</strong> <strong>the</strong> motor. electrical Calculate power <strong>the</strong> cost. shaft kW used<br />

Fixed speed Fixed speed<br />

Open <strong>and</strong> References <strong>the</strong> electrical below power give examples. cost.<br />

References below give examples.<br />

80 90 100<br />

Repeat <strong>for</strong> <strong>the</strong> o<strong>the</strong>r flows in <strong>the</strong> load<br />

80 Percent Output 90 Flow 100<br />

Repeat profile, <strong>and</strong> <strong>for</strong> <strong>the</strong> total o<strong>the</strong>r energy flows in usage. <strong>the</strong> load<br />

Percent Output Flow<br />

profile, <strong>and</strong> total <strong>the</strong> energy usage.<br />

Hydraulic Variable Speed Control<br />

Hydraulic Variable Speed Control<br />

Speed<br />

Electric Motor<br />

Three-<br />

Speed<br />

Electric Motor<br />

N2<br />

Hydraulic<br />

Phase<br />

N2<br />

Efficiency % %<br />

100<br />

100<br />

90<br />

90<br />

80<br />

80<br />

Fixed speed<br />

Fixed speed<br />

Var. Hydraulic Speed<br />

Var. Control Speed<br />

Control<br />

70<br />

70 60 70 *<br />

*<br />

60 70<br />

Output 80 80 Speed 90 90<br />

%<br />

100<br />

100<br />

Output Speed %<br />

Variable Speed Turbine Control<br />

Variable Speed Turbine Control<br />

Steam,<br />

Steam, <strong>Gas</strong>, or<br />

<strong>Gas</strong>, Kerosene or Fuel or<br />

Kerosene Fuel Steamor<br />

Control Steam<br />

Control<br />

Electric <strong>Drive</strong><br />

Electric <strong>Drive</strong><br />

Hydraulic Transmission<br />

Hydraulic Transmission<br />

Hydraulic Coupling<br />

Hydraulic Coupling<br />

Variable speed<br />

Variable turbine speed<br />

turbine<br />

Speed<br />

Speed N2<br />

N2<br />

Variable speed<br />

Variable speed<br />

Figure 2.<br />

Figure Hydraulic 2.<br />

Hydraulic Transmission<br />

Transmission<br />

Efficiency<br />

Efficiency<br />

Variable speed<br />

Variable speed<br />

Percent Pressure (Head)<br />

Pump Curve<br />

Pump Curve<br />

1,800 rpm<br />

1,800 rpm<br />

Fig. 3 Pump Per<strong>for</strong>mance Chart & Load Curve<br />

Fig. 3 Pump Per<strong>for</strong>mance Chart & Load Load Curve<br />

Load Curve<br />

Curve (Process)<br />

A (Process)<br />

100<br />

A<br />

100<br />

Percent Pressure (Head)<br />

Fig. 4 Pump Per<strong>for</strong>mance Chart & Load Curve<br />

Fig. 4 Pump Per<strong>for</strong>mance Chart & Load Load Curve<br />

Load Curve<br />

Curve (Process)<br />

A (Process)<br />

100<br />

A<br />

100<br />

Percent Pressure (Head)<br />

Pump Curve<br />

Pump Curve<br />

1,800 rpm<br />

1,800 rpm<br />

Speed N2<br />

Speed N2<br />

80 90 100<br />

80Percent Output 90 Flow 100<br />

Percent Output Flow<br />

Pump Curve<br />

Pump Curve<br />

1,800 rpm<br />

1,800 rpm<br />

Speed N2<br />

Speed N2<br />

B<br />

B1,500 hp<br />

1,500 hp<br />

B<br />

B1,500 hp<br />

1,500 hp<br />

80 90 100<br />

80Percent Output 90 Flow 100<br />

Percent Output Flow<br />

To calculate <strong>the</strong> energy used by a variable<br />

To speed calculate hydraulic <strong>the</strong> transmission energy used by system, a variable start<br />

speed with <strong>the</strong> hydraulic desired pump transmission output flow. system, Using start<br />

with <strong>the</strong> pump <strong>the</strong> desired chart, find pump <strong>the</strong> output horsepower flow. Using<br />

<strong>the</strong> required pump when chart, <strong>the</strong> find pump <strong>the</strong> horsepower is running at <strong>the</strong><br />

required reduced speed when <strong>the</strong> N2 pump <strong>and</strong> delivering is running <strong>the</strong> at <strong>the</strong><br />

reduced speed flow at N2 B in <strong>and</strong> Figure delivering 3. Obtain <strong>the</strong> <strong>the</strong><br />

reduced transmissiom flow at efficiency B in Figure from 3. <strong>the</strong> Obtain <strong>the</strong><br />

transmissiom manufacturer (Figure efficiency 2). from Note <strong>the</strong> <strong>the</strong> low<br />

manufacturer efficiency at reduced (Figure speeds. 2). Note Proceed <strong>the</strong> low as<br />

efficiency in <strong>the</strong> electrical at reduced example, speeds. working Proceed back as to<br />

in <strong>the</strong> <strong>the</strong> motor electrical <strong>and</strong> calculating example, working <strong>the</strong> energy back cost. to<br />

<strong>the</strong> Reference motor <strong>and</strong> 1 gives calculating examples. <strong>the</strong> energy cost.<br />

Reference 1 gives examples.<br />

Repeat <strong>for</strong> <strong>the</strong> o<strong>the</strong>r flows in <strong>the</strong> profile<br />

Repeat <strong>and</strong> total <strong>for</strong> <strong>the</strong> <strong>the</strong> energy o<strong>the</strong>r usage. flows in <strong>the</strong> profile<br />

<strong>and</strong> total <strong>the</strong> energy usage.<br />

To calculate <strong>the</strong> energy used by a<br />

To variable calculate speed <strong>the</strong> turbine energy system, used by take a <strong>the</strong><br />

variable pump chart speed <strong>and</strong> turbine load curve. system, Find take <strong>the</strong> <strong>the</strong><br />

pump horsepower chart <strong>and</strong> required load when curve. <strong>the</strong> Find pump <strong>the</strong> is<br />

horsepower running at <strong>the</strong> required reduced when speed <strong>the</strong> N2 pump <strong>and</strong>is<br />

running delivering at <strong>the</strong> reduced flow speed at B N2 in<strong>and</strong><br />

delivering Figure 4. Find <strong>the</strong> reduced <strong>the</strong> turbine flow fuel at B or insteam<br />

Figure consumption 4. Find at <strong>the</strong> this turbine speed fuel <strong>and</strong>or steam<br />

consumption horsepower, <strong>and</strong> at this calculate speed <strong>the</strong> <strong>and</strong>cost <strong>for</strong> <strong>the</strong><br />

horsepower, number of running <strong>and</strong> calculate hours. <strong>the</strong> cost <strong>for</strong> <strong>the</strong><br />

number of running hours.<br />

Repeat <strong>for</strong> <strong>the</strong> o<strong>the</strong>r flows in <strong>the</strong> profile<br />

Repeat <strong>and</strong> total <strong>for</strong> <strong>the</strong> <strong>the</strong> energy o<strong>the</strong>r usage. flows in <strong>the</strong> profile<br />

<strong>and</strong> total <strong>the</strong> energy usage.<br />

A number of free publications on this topic are available from <strong>the</strong> library at www.tmge.com , including <strong>the</strong> following:<br />

number of free publications on this topic are available from <strong>the</strong> library at www.tmge.com , including <strong>the</strong> following:<br />

1. Selecting Variable Speed <strong>Drive</strong>s <strong>for</strong> Flow Control, brochure <strong>GE</strong>A-13873 - discusses <strong>the</strong> various mechanical speed<br />

1. control Selecting systems Variable <strong>and</strong> Speed outlines <strong>Drive</strong>s <strong>the</strong> calculation <strong>for</strong> Flow Control, of energy brochure savings, <strong>GE</strong>A-13873 in particular discusses <strong>for</strong> hydraulic <strong>the</strong> various transmission mechanical speed speed control.<br />

2. control Adjustable systems Frequency <strong>and</strong> outlines <strong>Drive</strong>s <strong>the</strong> <strong>for</strong> Pump calculation <strong>Energy</strong> of energy Savings savings, Power in Generating particular <strong>for</strong> Stations hydraulic - discusses transmission pump speed energy control.<br />

2. calculations.<br />

Adjustable Frequency <strong>Drive</strong>s <strong>for</strong> Pump <strong>Energy</strong> Savings in Power Generating Stations discusses pump energy<br />

3. AC calculations. Adjustable Speed <strong>Drive</strong> Systems <strong>for</strong> Cement Kiln Induced Draft Fans - discusses large fan energy calculations.<br />

3. AC Adjustable Speed <strong>Drive</strong> Systems <strong>for</strong> Cement Kiln Induced Draft Fans discusses large fan energy calculations.<br />

Revised: 5-22-09 © 2009 TMEIC <strong>GE</strong> Automation Systems. All Rights Reserved.<br />

Page 31 of 32


65<br />

Medium Voltage Adjustable Speed <strong>Drive</strong> & Systems School<br />

TM <strong>GE</strong> Automation Systems is pleased to offer its tuition-free MV <strong>Drive</strong> & Systems School to its customers. These<br />

schools are offered regularly in Virginia <strong>and</strong> o<strong>the</strong>r cities.<br />

Course Topics:<br />

• Medium voltage [MV] induction <strong>and</strong> synchronous Motors<br />

• Fundamentals of adjustable speed drives<br />

• MV drive characteristics, payback, <strong>and</strong> specifications<br />

• MV power systems design concepts<br />

• MV switchgear, starters, trans<strong>for</strong>mers, reactors,<br />

<strong>and</strong> substations.<br />

• MV system protection<br />

• Real-world industrial application stories from <strong>the</strong> oil & gas,<br />

cement, mining, <strong>and</strong> water & waste industries<br />

• Equipment demonstrations<br />

For details <strong>and</strong> registration <strong>for</strong> our next school, visit our<br />

Web site at www.tmeicge.com.<br />

<strong>Global</strong> Office Locations:<br />

TM <strong>GE</strong> Automation Systems, LLC (USA)<br />

Office: 1325 Electric Road, Suite 200<br />

Roanoke, VA, United States 24018<br />

Mailing: 2060 Cook <strong>Drive</strong><br />

Salem, VA, United States 24153<br />

Tel.: +1-540-283-2000<br />

Fax: +1-540-283-2001<br />

Email: oilgas@tmeic-ge.com<br />

Web: www.tmeicge.com<br />

Toshiba Mitsubishi-Electric Industrial Systems Corporation<br />

Mita 43 MT Bldg.<br />

13-16 Mita 3 chome, Minato-ku Tokyo<br />

108-0073 Japan<br />

Tel.: +81-3-5444-3828<br />

Fax: +81-3-5444-3820<br />

Web: www.tmeic.co.jp/global/index.html<br />

TMEIC Industrial Systems India Private Limited<br />

Unit # 03-04, Third Floor,<br />

Block 2, Cyber Pearl, HITEC City, Madhapur,<br />

Hyderabad, 500081, Andhra Pradesh, India<br />

Tel.: +91-40-4434-0000<br />

Fax: +91-40-4434-0034<br />

Email: inquiry_india@tmeic-ge.com<br />

Web: www.tmeic.in<br />

Toshiba Mitsubishi-Electric Industrial Systems (Beijing) Corp.<br />

21/F., Building B, In.do Mansion<br />

48 Zhichunlu A, Haidian District,<br />

Beijing 100098, PRC<br />

Tel.: +86 10 5873-2277<br />

Fax: +86 10 5873-2208<br />

Email: sales@tmeic-cn.com<br />

TMEIC Europe Limited<br />

Albany House, 71-79 Station Road<br />

West Drayton, Middlesex, United Kingdom<br />

UB7 7LT<br />

Tel.: +44 870 950 7212<br />

Fax: +44 870 950 7221<br />

Email: Fowler.Gary@tmeic.eu<br />

Web: www.tmeicge.com<br />

Innovation Series is a trademark of General Electric Company.<br />

<strong>GE</strong> is a registered trademark of General Electric Company.<br />

OnSite Support is a trademark of General Electric Company.<br />

TMDRIVE is a registered trademark of Toshiba Mitsubishi-Electric Industrial Systems Corporation.<br />

TMEIC is a registered trademark of Toshiba Mitsubishi-Electric Industrial Systems Corporation.<br />

All o<strong>the</strong>r products mentioned are registered trademarks <strong>and</strong>/or trademarks<br />

of <strong>the</strong>ir respective companies.<br />

All specifications in this document are subject to change without notice. The above brochure<br />

is provided free of charge <strong>and</strong> without obligation to <strong>the</strong> reader or to TM <strong>GE</strong>. TM <strong>GE</strong> Automation<br />

Systems, LLC does not accept, nor imply, <strong>the</strong> acceptance of any liability with regard to <strong>the</strong><br />

use of <strong>the</strong> in<strong>for</strong>mation provided. TM <strong>GE</strong> provides <strong>the</strong> in<strong>for</strong>mation included herein as is <strong>and</strong> without<br />

warranty of any kind, express or implied, including but not limited to any implied statutory warranty<br />

of merchantability or fitness <strong>for</strong> particular purposes. The in<strong>for</strong>mation is provided solely as a general<br />

reference to <strong>the</strong> potential benefits that may be attributable to <strong>the</strong> technology discussed. Individual<br />

results may vary. Independent analysis <strong>and</strong> testing of each application is required to determine<br />

<strong>the</strong> results <strong>and</strong> benefits to be achieved from <strong>the</strong> technology discussed. If you have any questions<br />

regarding your project requirements, please contact TM <strong>GE</strong> at 540-283-2000.<br />

2009 U.S. © Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan<br />

All Rights Reserved<br />

<strong>GE</strong>A-14410

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