Torque Report - TECO-Westinghouse Motor Company

Round Rock Factory Ships OEM Orderfor Ball Mill ApplicationThe Atacama Desert in Chile has one of the driest climates on Earth, experiencingan average rainfall of around 1 mm per year. As a result, the Atacamais rich in mineral deposits, including the world's largest natural supply of sodiumnitrate. However, the desert’s climate and extremely high altitude providenumerous hurdles for mining.Given these conditions, especially with regard to the grinding technologiesused in mining, motors employed must perform to very high standards. Of primaryimportance is the capability of the motor to consume less energy, adaptto high altitude, and maintain constant speeds. Synchronous motors havecome to represent an effective means for controlling these factors, from managingcurrents to reducing slips and improving power factors in all miningapplications. Large synchronous motors are now the flagship motors for theMining Industry.TECO-Westinghouse in Round Rock,Texas has recently completed productionon two synchronous motors for aball mill OEM, whose customer's largeiron ore mine is located in the AtacamaDesert. These 111 frame, slow-speed(200 RPM), synchronous motors arrivedat the facility in February of 2007.The two motors, both 5000 HP, representthe Round Rock facility's capabilityto manufacture large synchronous millmotors to support the mining industry.TWMC Provides Local Semi-Conductor Facility with PowerMany industrial manufacturingfacilities employ circulating waterpumps to control indoor temperature.Due to its higher density, watercan transmit heat over greater distanceswith much less volumetricflow than air. Likewise, water has ahigher specific heat capacity andmore thermal conductivity than air,both of which reduce theamount of energy needed topower such a system.Cooling towers areoften used in conjunctionwith these circulatingwater pumps tocool and re-circulatewater, while ejecting evaporatedair into the atmosphere,reducing the facility's water andenergy consumption.In November of last year, TWMCsupplied a number of Global-HDTEFC medium voltage motors andGlobal-Plus TEFC NEMA PremiumEfficiency motors to TWMCDistributor, Advanced MechanicalSystems (AMS) in San Antonio foruse on their customer's circulatingwater pumps. Additionally, TWMCsold several Max- E2 NEMAPremium Efficiency motors, withmodified space heaters, toComposite CoolingSolutions in Ft. Worth,Texas. All motorswere then sold tothe same end-user,a semiconductormanufacturer inAustin. The customer,an importantcontributor to Austin's technologysector, has recently expandedthe size of its facility, which nowhouses many large cooling towersthat support these circulating waterpumps.TWMCProduct SpotlightNew Product Release:TECO-Westinghouse has recently expanded itsAC Drives Product Line to include the EV andthe N3 series AC Drives.The EV AC Drive is a din rail mountablemicro drive that is perfectfor OEM's thatpackage individual ormultiple lower HP ACdrives in a commonenclosure. The EV isavailable in 115V,230V, and 460V ratingsfrom .25-3 HPwith dedicated singlephase and three phaseinput models. In addition,the EV includes expanded features such asPID control, 8 preset speeds and a multi-functionanalog input/output.The N3 AC Drive is a general purpose ACDrive designed to meetthe requirements ofmost constant and variabletorque applications.The PID controland sleep mode featureof the N3 makes thisAC drive a perfect fitfor fan and pumpapplications. Otherfeatures that make theN3 extremely flexibleare the keypad mounted speed potentiometer,configurable multi-functional digital and analoginput/outputs, and an optional LCD keypad thatallows the user to view programming parametersin English. The N3 is available in 230V ratingsfrom .5 - 40 HP and in 460V ratings from 1 - 75HP.Many additional options are available for boththe EV and N3 series AC drives, including aremovable parameter copy unit, RS232 andRS485 communication interfaces, and the TECOLink programming software tool that allows theusers to configure programming paramaters,record trends, and set up PID control via a personalcomputer.TORQUE REPORT 3

New Director for TWMC Design CenterIn April of 2007, TWMC announced that David D.Parkinson would be the company’s Design Center Director.David joins TWMC after a distinguished military and civiliancareer, holding positions from Senior Mechanical Engineerto Senior Vice President for leading companies in the rotatingmachinery industry. Additionally, David brings to TWMCadded experience gained during his parallel 28 year career as asenior officer in the Army Corps of Engineers.In a recent “All Hands” meeting at TWMC, David elaboratedupon his vision for the Design Center and what his initialfocus will be. He stated “The TWMC Design Center acts as abridge between the front room (Sales and Marketing) and theback room (Operations and Sourcing). In professionally executingthis function, the Design Center must be attentive,responsive, predictable, and globally-integrated as it supportsboth internal and external customers alike.”He further stated that “it’s imperative that the Design Centerprovide the most competent and cost-effective solutions thefirst time, every time. This can only be accomplished by trulylistening to the customer and then developing the internal disciplineto efficiently meet customer needs.”Additonally, David asserts, “Our primary initial goals are toimprove on-time delivery of services, minimizing errors, standardizingdocumentationandprocedures, andexpanding parametricdesignprinciples. Theenablers ofachieving andexceeding thesegoals will be theutilization ofColonel (Ret.) David Parkinson brings grand vision forcross-functionalTWMC’s future as new Design Center Director.teaming, theunderstanding and adoption of lean principles, and the empowermentof personnel through the use of continuous improvementmethodology.”Long term, David envisions the TWMC Design Center leadingthe charge toward global standards for product design andsourcing within TECO. He believes that global incorporationof “best practices” when coupled with an integrated sourcingnetwork is the key to cost effective design. David also sees anexpanded role for the Design Center in the strategic planningprocess of TWMC as it continues to diversify and to grow.TWMC to Completely Refurbish Motorsfor Largest Man-Made MineTWMC recently completed repair on the first ofseven 5500 HP, 180 RPM, 13,200 Volt synchronousmotors for Kennecott Utah Copper Corporation, amining, smelting, and refining company, whoseBingham Canyon Mine is considered the largestman-made excavation site in the world. All sevenof these large, 40 pole motors were originally manufacturedat the Round Rock plant in 1986. Eachmotor will be serviced using the manufacturer'soriginal design schematics, reducing delivery timeand ensuringthe compatibilityof theupgrade andrepair.Kennecottplans to haveT W M Crepair 1-2motors peryear, one at atime, until allThis 40 pole synchronous motor isthe first of seven large motors thatwill be repaired for the BinghamCanyon Mine, the largest manmadeexcavation site in the world.seven motors are refurbished. The first of thesemotors shipped from Round Rock in April of thisyear. The next of these large synchronous motors iscurrently in house at TWMC.TWMC Repairs Motor Generator Sets forDragline Excavation SystemsFor nearly 100 years, Bucyrus has been a leading manufacturer ofdragline excavation equipment, introducing the first crawler mounteddragline, the "Class 14," in 1911. Today, Bucyrus continues to developadvanced excavation technologies and participate in some of the largestexcavation projects around the world. In late 2006, TWMC performed acomplete overhaul of two dragline motor generator sets for BucyrusInternational.The MG sets were built at the Round Rock facility in the mid-1980'sand were in operation for nearly twenty years. Each motor generator setwas composed of six DC generators and one synchronous motor. EachDC generator's armature was completely rebuilt with new commutatorsand windings by the team at TWMC. In addition, the synchronous motorunits required both their respective stators and rotors be refurbished.TWMC, as the original manufacturer of these MG sets, was in a uniqueposition to provide timely, cost-effective service and repair. Once completed,a TWMC a fieldservice Engineer accompaniedthe MG sets toTurkey, overseeing theinstallation and startup ofthe equipment. The customerreports that bothmotor generator sets havebeen running without incidentsince their installation.4TORQUE REPORT

TWMC Provides More Horsepower for SteelTWMC recently received a large order from TATASteel for the upgrade of their Hot Strip Mill at theJamshedpur, India works.With the completion of the order, the main drivemotors in the mill will produce a total of over 62,000combined HP. These, and other, changes will allowthe mill to efficiently roll out the latest materials atan increased production rate.Tata Steel, the first private Iron and Steel Companyin India, began production in Jamshedpur, India in1907. This plant remains the largest in Jamshedpurand accounts for a significant portion of the company'sannual steel production. Westinghouse ElectricCorporation supplied the main drive motors for theoriginal mill and TECO-Westinghouse has continuedto provide main drive motors to new TATA Steel millsadded over the years.In the early 1990's, a new Hot Strip Mill was builtat the complex in Jamshedpur, utilizing TECO-Westinghouse main drive motors built at the TWMCfacility in Round Rock, Texas. The HSM was originallydesigned for one million tons/year of steel output.Refinementswere made in1995 thatincluded theaddition of asixth finishingstand anddown coiler,as well as theupgrade of theautomationsystem. These changes doubled steel coil productioncapabilities.Additional upgrades to the automation system,motor cooling refinements, and better maintenancepractices, among other things, resulted in the presentproduction rate of three times the original mill design.All of these production gains were made while stillutilizing the existing TWMC main drive DC motors.Additionally, TWMC has continued to provided technicalguidance over the years to help make the millmore productive.Drivers in the Desert MeetsIncreased Demand“Drivers”continued from Page 1To move this product along, the pipeline pump stations with electricmotors, are generally added every 30 to 60 miles. For this project,(7) 2500 HP, 3600 RPM, dual voltage, squirrel cage inductionmotors were selected by the client. These motors were uniquebecause the user specified that the motors be designed to meet allpresent needs, as well as any future conditions. For example,although these motors were used in a constant speed application forthis project, the client requested "stiff-shaft" rotors in the event variablefrequency drives were ever added to the system in the future.Furthermore, the motors were designed to start the pumps with anopen discharge valve while using a reduced auto-transformer starterwith only 65% terminal voltage. This was specified because olderlines and stations commonlyused auto-transformersas a method forreducing the inrush currentduring starting. Ifthe motors were relocatedto an existing location,the new motorswould be capable ofstarting the pump.Additonally, the motors were designed to function despite environmentalconditions. As a portion of the pipeline is located in Arizona,the motors were constructed to perform at 4000 feet ASL, which is700 feet above standard elevation. Likewise, as the motors will besubjected to extreme changes in temperature, the design of themotors included specific features that make them suitable for manyconditions.Round Rock Facility toManufacture Wind TurbineComponentsAccording to the terms ofthe Alliance, TWMC willmanufacture both the nacelleand hub components for theD8.2. As the nacelle alonehouses 90% of turbine components,the construction ofboth the nacelle and the hubat the Round Rock facilityrepresents a significant portionof the manufacturingprocess.Currently, the "D-Aisle" inTWMC's Round Rock factoryis being modified tobecome a state-of-the-artcell-based assembly line,which can be configured toproduce anywhere from onenacelle/hub per week to onenacelle/hub per day. “Theability to secure components(which we call supply-chainmanagement) will drive productionoutput," said TWMCPresident Dr. H.C. Meng.“Based on the supply-chaincurrently in place, the first“Windy”continued from Page 1units will ship from theRound Rock factory in 4thQuarter, 2007.”Dr. Meng believes thisalliance will change thefuture of the wind turbinelandscape. “By combiningDeWind's design, jointTWMC and DeWind R&Defforts, and a successfulO&M joint venture,” Dr.Meng stated, “we believethere is no limit to what canbe accomplished."TORQUE REPORT 5

TORQUE REPORTOCTOBER 2007Watch for theTECO-Westinghouse MotorCompany Ethanol Ad in:Ethanol Producer MagazineandEthanol Today MagazineEPRI Motor/Generator Rewind SeminarReaches Record AttendanceThe EPRI Motor/Generator Rewind Seminar, hosted by TECO-Westinghouse MotorCompany, in conjunction with Electric Power Research Institute and JarscoEngineering Corporation, was held, for the fourth consecutive year, at the TWMCfacility in Round Rock, Texas. With fifty-fourattendees, this year’s three-and-a-half dayseminar was the largest to date.Instructors Jim Oliver, Jim Michalec,Riccardo Covarrubias, and Elton Floyd ledthe seminar, covering many aspects of motorand generator repair and rewind, includinginduction motor design fundamentals, statorwinding insulation systems, stator coil components,coil manufacturing, motor efficiency,and much more. Designed to provideextensive information regarding motor orgenerator repairs and rewinds, this seminarattracted representatives from companiesacross the globe, including Voith-SiemensHydro, GenerationMayer Electric Supply,P&H Mine Pro Services, Tampa ArmatureTWMC’s David Briggs and Brian Kruse(top) take EPRI attendees on a tour ofthe TWMC Round Rock facility.(Bottom) A class photo includes all 54attendees and three instructors.Works, Georgia Power Company, FMCCorp, Generating Authority of Thailand,NRG Texas, Precision Electric Coil, andmany others.On Wednesday, TWMC employees led aguided tour of the 500,000 square foot motor and generator manufacturing and repairfacility. Likewise, several TWMC engineers and technicians gave presentations andfielded technical questions from seminar attendees.According to the instructors and attendees, this year’s Motor/Generator RewindSeminar was a tremendous success.5100 N. IH-35Round Rock, TX 786811-800-451-8798If you are interested in receiving futureissues of TORQUE REPORT, please visitwww.tecowestinghouse.com/torquereport.htmor send an e-mail totorquereport@tecowestinghouse.com.