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GE EnergyPower ConversionWe’re at work making change happenMETALS WORKSHOPBelo Horizonte18 April 2012Igor Quintão
Complete solution offering                                 +                +  Electrical        Electrical       Variable...
Power Conversion – Products – Automation                                                    Engineering &           Set-up...
Post-sale assistance / Service                                                             4                              ...
Automation: Level 1                                           HPCi controller,                                          MV...
Automation: Level 1Engineering environmentP80i – Programming Toolkit for C80-HPCi                         Integrated      ...
Automation: HMIHuman Machine Interface    Typical views                  (Instrumentation)                                ...
Automation: Level 2Supervision functions• Primary Data Input Management    o Using the main entry coil      characteristic...
Process: technological controlsAGC - Thickness Control - Principles                                                       ...
Process: simulationFull simulation:• Digital sensors, Absolute encoders, Thickness, Tension, Speed,  Flatness, Pulse Gener...
Automation: Aid in maintenance                      Operator aid on HMI                  Display of Missing Permissives   ...
Automation: Aid in maintenanceOperator aid - Process Data AcquisitionKey features• Independent sample rates for each chann...
Automation: architecture                     Example for Tandem Cold                     Mill                             ...
Electrical and Power                                       MV drives – MV7000LV drives – LV7000                           ...
Electrical and Power: DrivesLow Voltage Drives: LV7000• High performance drives from 0.75 kW  to 3600 kW• 3 AC or Common D...
Power Conversion – Products – LV Drive                                            Inverter                                ...
Power Conversion – Products – LV Drive   Inverter   •   Water cooled   •   440V - 690V       a.c.   •   600 kW ~ 3.6      ...
Electrical and Power: DrivesLV Drives on common DC bus• Only one common DC bus                             220 V          ...
Electrical and Power: DrivesMedium Voltage Drives:MV7000• Power range 4 up to 48 MW                 Inverter-phase leg:• V...
Power Conversion – Products – MV Drive   RANGE        Topology Voltage         Power (MW)                           (V)  M...
MV7400-Air Cooled and Water Cooled•   IGBT based 3 Level PWM drive      – Active Front End (AFE) or         Diode Front En...
Electrical and Power: Drives                                                   MV7000 up to date technology Control       ...
Electrical and Power: Energy Quality Energy quality systems: SVC and D-SVC • Used to compensate electrical   disturbances ...
Electrical and Power: Energy QualitySteel plant performances with SVCs                             Power Increase = more P...
Thanks!GE Energyigor.quintao@ge.com                                                 25                      Team Account P...
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4 metals workshop igor quintao

  1. 1. GE EnergyPower ConversionWe’re at work making change happenMETALS WORKSHOPBelo Horizonte18 April 2012Igor Quintão
  2. 2. Complete solution offering + + Electrical Electrical Variable speed Automation Mechanical grid machines drives and control equipment• Continuously advancing technology in critical components• Helping to optimize the whole system architecture / system approach• Mastering interfaces 2 Team Account Planning Session 6/11/2012
  3. 3. Power Conversion – Products – Automation Engineering & Set-up & Models Diagnostics HMI Workstation Remote accessLevel 2 Ethernet TCP/IP Standard plc VME basedLevel 1 High HPCip Fieldbus Performance Controller HPC FieldbusLevel 0 Intelligent AC and Remote I/O actuators/ DC Drives Remote I/O instrumentation MV drives 3 Team Account Planning Session |3 |3 6/11/2012
  4. 4. Post-sale assistance / Service 4 Team Account Planning Session 6/11/2012
  5. 5. Automation: Level 1 HPCi controller, MV and DC drives Key advantages for the user: • High reliability / availability • Optimal maintainability • Few and simple interfaces • Unified open platform Basic functions • Easy connection to legacy hardware • Real time operating system systems • Functional multitasking • Minimum installation and start-up time • Global / Local data transfer • Simple training • Remote and local I/O • Reduced spares 5 Team Account Planning Session 6/11/2012
  6. 6. Automation: Level 1Engineering environmentP80i – 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 6 Team Account Planning Session 6/11/2012
  7. 7. Automation: HMIHuman Machine Interface Typical views (Instrumentation) 7 Team Account Planning Session 6/11/2012
  8. 8. Automation: Level 2Supervision functions• Primary Data Input Management o Using the main entry coil characteristics (PDI) sent by Level 3 computer (Customer) PDI• Product tracking & coil data sheet management• Preset determination• Speed optimization• Mathematical Models• Data collection & quality tracking• Elaboration of reports (coil, shift, day, …) 8 Team Account Planning Session 6/11/2012
  9. 9. Process: technological controlsAGC - Thickness Control - Principles Dynamic adjustment of the AGC gainsfor single stand Mill to compensate for changes in hardness and all rolling mill conditions AGC PRINCIPLES Set-up and product data Mathematical AGC Dynamic Model Model Level 1 PDI Level 2 Force Set-up AGC Gains Calculation Tension Corrections Rolling Mill Measures Roll Force FB : to center exit thickness FF : to anticipate Feed Feed Back entry deviation Forward Gap Correction Hydraulic Gap Gap Correction AGC MassFlow Gauge AGC Control Exit Gauge Entry Gauge Inertia Compensation MassFlow Measure MF : to measure stand in gap thickness and to cancel measurement delay Torque Control Speed measures Strip Speed Speed measures estimation Entry speed Exit speed 9 Team Account Planning Session 6/11/2012
  10. 10. Process: simulationFull simulation:• Digital sensors, Absolute encoders, Thickness, Tension, Speed, Flatness, Pulse Generators, Motor Currents…Major advantages:• Reliability• Shortening commissioning periods• Eliminating costly parallel operation• Training operators on the new system before the switchover 10 Team Account Planning Session 6/11/2012
  11. 11. Automation: Aid in maintenance Operator aid on HMI 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 11 Team Account Planning Session 6/11/2012
  12. 12. Automation: Aid in maintenanceOperator aid - Process Data AcquisitionKey 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 databases using ODBC (including Excel format). 12 Team Account Planning Session 6/11/2012
  13. 13. Automation: architecture Example for Tandem Cold Mill 13 Team Account Planning Session 6/11/2012
  14. 14. Electrical and Power MV drives – MV7000LV drives – LV7000 Motors 100 MW Electrical rooms & pulpits 200 kW 14 Team Account Planning Session 6/11/2012
  15. 15. 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 15 Team Account Planning Session 6/11/2012
  16. 16. Power Conversion – Products – LV Drive Inverter • Air cooled Fan • 600kW • 440V - 690V a.c. • 180kW ~ 2.4MW DELTAModules AC ReactorReactorDC Link Rectifier 16 Team Account Planning Session | 16 6/11/2012
  17. 17. Power Conversion – Products – LV Drive Inverter • Water cooled • 440V - 690V a.c. • 600 kW ~ 3.6 MW 17 Team Account Planning Session | 17 6/11/2012
  18. 18. Electrical and Power: DrivesLV Drives on common DC bus• Only one common DC bus 220 V Battery Battery AC rectifier is used to feed all AC Drives AC supply AC DC COMMON BUS for strip transport ACCB Transformer• Any regenerating drives send Input bridge their power to other motoring converter drives via the DC link PWM inverters Induction M1 M2• Battery support allows ride through motors 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 18 Team Account Planning Session 6/11/2012
  19. 19. Electrical and Power: DrivesMedium Voltage Drives:MV7000• Power range 4 up to 48 MW Inverter-phase leg:• Voltage: 3.3 kV – 6.6 kV – 9.9 kV the heart of the converter• 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 19 Team Account Planning Session 6/11/2012
  20. 20. Power Conversion – Products – MV Drive RANGE Topology Voltage Power (MW) (V) MV74005AC FP- AC 4160 0.5 MV7401AC FP- AC 4160 0.9 MV7402AC FP- AC 4160 1.8 MV7403AC FP- AC 4160 3 MV7403 FP -WC 4160 2,5 MV7405 FP -WC 4160 5 MV7407 PP- WC 4160 7 Designed, manufactured and tested in Brazil 20 Team Account Planning Session | 20 6/11/2012
  21. 21. 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 21 Team Account Planning Session 6/11/2012
  22. 22. Electrical and Power: Drives MV7000 up to date technology Control AC in Active Front End DC Capacitors 3-level NPP inverter (MEGAMODULE) AC out Pre-charge transformer + CONTROL & AUXILIARIES Cooling unit NP COOLING WATER _ MV73xx Drive Active Front End M 3~ Power Transformer Single Line Diagram with 3-Level NPP Inverter 22 Team Account Planning Session 6/11/2012
  23. 23. 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/HPCi system (as drives and level 1) • Application software developed with P80i programming tools 23 Team Account Planning Session 6/11/2012
  24. 24. Electrical and Power: Energy QualitySteel plant performances with SVCs Power Increase = more Production • Shorter tap to tap melting time, higher steel production • Longer electrode life & less refractory material consumption Neighbourhood disturbance & Utility • Minimum flicker perturbations around • No power factor penalties • Voltage stability, less harmonics & transients More active power equals less tap-to-tap time equals increased production 24 Team Account Planning Session 6/11/2012
  25. 25. Thanks!GE Energyigor.quintao@ge.com 25 Team Account Planning Session 6/11/2012

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