4 metals workshop igor quintao

GE EnergyPower Conversion

We’re at work making change happen

METALS WORKSHOPBelo Horizonte18 April 2012Igor Quintão

2Team Account Planning Session

6/11/2012

Mechanical equipment

Electrical grid

Electrical machines

Variable speed drives

Automation and control

• Continuously advancing technology in critical components

• Helping to optimize the whole system architecture / system approach

• Mastering interfaces

++

Complete solution offering


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Power Conversion – Products – Automation

| 3 | 3

Level 2

AC and DC Drives

Intelligent actuators/ instrumentation

Remote I/O Remote I/O

FieldbusFieldbus

Remote access

Ethernet TCP/IP

Set-up & ModelsEngineering & Diagnostics WorkstationHMI

Level 1

Level 0

VME based High Performance Controller HPC

Standard plc

HPCip

MV drives


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Post-sale assistance / Service


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Automation: Level 1

Basic functions• Real time operating system

• Functional multitasking

• Global / Local data transfer

• Remote and local I/O

HPCi controller, MV and DC drives

Key advantages for the user:• High reliability / availability

• Optimal maintainability

• Few and simple interfaces

• Unified open platform

• Easy connection to legacy hardware systems

• Minimum installation and start-up time

• Simple training

• Reduced spares


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Automation: Level 1Engineering environment P80i – Programming Toolkit for C80-HPCi

Integrated environment for support tool• Program editors (FBD, SFC, LD), IEC-1131

compatible

• Programs and networks configuring tools

• Hardware configuration tools

• Debugging and commissioning tools

Multi-user networked access• Several P80i users can edit applications on

the same C80-HPCi


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Automation: HMIHuman Machine Interface

Typical views

(Instrumentation)


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Automation: Level 2

PDI

Supervision functions• Primary Data Input Management

o Using the main entry coil characteristics (PDI) sent by Level 3 computer (Customer)

• Product tracking & coil data sheet management

• Preset determination

• Speed optimization

• Mathematical Models

• Data collection & quality tracking

• Elaboration of reports (coil, shift, day, …)


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Process: technological controls

Hydraulic Gap Control

FeedForward

AGCGap Correction

Feed Back AGCGap Correction

MassFlow Measure

Strip Speed estimation

Entry speed Exit speed

Torque Control

Inertia Compensation

Entry GaugeExit Gauge

MassFlow Gauge

Mathematical Model Level 2 PDI

Roll Force

Tension Corrections

ForceSet-up

AGC Dynamic ModelLevel 1

Set-up and product data

Rolling Mill Measures

AGC PRINCIPLES

Speed measures Speed measures

AGC Gains Calculation

FF : to anticipate entry deviation

MF : to measure standin gap thickness and to cancel measurement delay

Dynamic adjustment of the AGC gains to compensate for changes in hardness and all rolling mill conditions

AGC - Thickness Control - Principles for single stand Mill

FB : to center exit thickness


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Process: simulationFull simulation:• Digital sensors, Absolute encoders, Thickness, Tension, Speed,

Flatness, Pulse Generators, Motor Currents…

Major advantages:• Reliability

• Shortening commissioningperiods

• Eliminating costly paralleloperation

• Training operators on the new system before the switchover


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Automation: Aid in maintenance

Display of Missing Permissives• Automatic sequences

• Line run modes

Display of faults• Grouped faults

• History events

History• Storage of variables and events

• Display of recorded data

Operator aid on HMI


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Automation: Aid in maintenance

Key features• Independent sample rates for each channel

• Recording of up to 1024 analog + 1024 digital channels

• Fastest data acquisition cycle is 1 ms for all signals

• Drivers are available for the most known PLCs in the market, including GE Energy C80-HPCi

• Acquisition from direct input or networks

• Step-wise X-Y zoom in and zoom out

• Calculations via a built-in formula editor: mathematical and logic functions

• Y/T, Y/X and FFT displays window options

• Data export to ASCII format and to databasesusing ODBC (including Excel format).

Operator aid - Process Data Acquisition


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Automation: architectureExample for Tandem Cold Mill


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Electrical and PowerLV drives – LV7000

MV drives – MV7000

Electrical rooms & pulpits

Motors100 MW

200 kW


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Electrical and Power: DrivesLow Voltage Drives: LV7000• High performance drives from 0.75 kW

to 3600 kW

• 3 AC or Common DC bus power supply

• Frequency, speed and torque control

• 4-quadrant and active front-end inverter applications available

• Air or liquid-cooled possible


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Power Conversion – Products – LV Drive

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DELTAModules

ReactorDC Link

AC Reactor

Rectifier

Fan

Inverter• Air cooled• 600kW• 440V - 690V

a.c.• 180kW ~

2.4MW


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Power Conversion – Products – LV Drive

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Inverter• Water cooled• 440V - 690V

a.c.• 600 kW ~ 3.6

MW


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Electrical and Power: DrivesLV Drives on common DC bus• Only one common DC bus

is used to feed all AC Drives for strip transport

• Any regenerating drives send their power to other motoring drives via the DC link

• Battery support allows ride through of mains power loss

• Energy saving because AC current much less than sum of individual drives

• Full regeneration readily provided

• Ride through AC supply dips while maintaining strip tension

• AC input power factor : ~1, AC harmonics reduced

M1 M2

AC supply AC

ACCB Transformer

Inductionmotors

DC COMMON BUS

PWM inverters

Input bridge

converter

220 V AC

BatteryBatteryrectifier


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Electrical and Power: Drives

Inverter-phase leg: the heart of the converter

Medium Voltage Drives: MV7000• Power range 4 up to 48 MW

• Voltage: 3.3 kV – 6.6 kV – 9.9 kV

• Powerful IGBT, based on Press-Pack technology

• Flexible design thanks to standar-dized modules, Active Front End design, DC-link configuration or stand-alone drive solutions

• Parallel connection for high ratings

• Compact design with excellent kW/m³ ratio


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Power Conversion – Products – MV Drive

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RANGE Topology Voltage (V)

Power (MW)

MV74005AC FP- AC 4160 0.5MV7401AC FP- AC 4160 0.9MV7402AC FP- AC 4160 1.8MV7403AC FP- AC 4160 3

MV7403 FP -WC 4160 2,5MV7405 FP -WC 4160 5MV7407 PP- WC 4160 7

Designed, manufactured and tested in Brazil


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MV7400-Air Cooled and Water Cooled

• IGBT based 3 Level PWM drive– Active Front End (AFE) or

Diode Front End (DFE)– IEGT devices (Transistor

type)– Quick and easy change– High efficiency


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COOLING WATER

Power Transformer

+

_

CONTROL & AUXILIARIES

NP

DC Capacitors 3-level NPP inverter (MEGAMODULE) Active Front EndControl AC out

MV73xx Drive Active Front End M 3~

Cooling unit

Pre-charge transformer

AC in

Electrical and Power: Drives

Single Line Diagram with 3-Level NPP Inverter

MV7000 up to date technology


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Electrical and Power: Energy Quality

Energy quality systems: SVC and D-SVC• Used to compensate electrical

disturbances generated by large-scale consumers with fluctuating loads, like electrical arc furnaces and large drives

• Solution based on thyristor TCR or IGBT D-SVCs linked to fixed filters

• D-SVC solution is compact with enhanced performances

• Control system based on our PECe/HPCisystem (as drives and level 1)

• Application software developed with P80i programming tools


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Electrical and Power: Energy Quality

More active power equals less tap-to-taptime equals increased production

Steel plant performances with SVCs

Power Increase = more Production • Shorter tap to tap melting time,

higher steel production

• Longer electrode life & lessrefractory material consumption

Neighbourhood disturbance & Utility• Minimum flicker perturbations

around

• No power factor penalties

• Voltage stability, less harmonics & transients


6/11/2012

GE [email protected]

Thanks!

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