April 2010
Medium voltage drives
Overview
© ABB Group
February 18, 2011 | Slide 1
3BHT490546R0001, Rev. G
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 2
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 3
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
Medium voltage drives
Manufacturing locations
Lodz, Poland
New Berlin, WI, USA
Turgi, Switzerland
Beijing, China
Bangalore, India
© ABB Group
February 18, 2011 | Slide 4
3BHT490546R0001, Rev. G
Turgi, Switzerland

ABB’s global headquarters for
Power Electronics and MV Drives

Location: Turgi, Switzerland

Total number of employees: more than 1200
Responsibilities
 Research and development
 Sourcing
 Manufacturing & assembly
 Engineering & project management
 Sales and marketing
 Product support & services
 Training
© ABB Group
February 18, 2011 | Slide 5
3BHT490546R0001, Rev. G
Global center of competence (Switzerland)
ABB Power Electronics
& MV Drives, Turgi
Power
Electronics
Triangle
ABB Corporate
Research, Dättwil
ABB Semiconductors,
Lenzburg
© ABB Group
February 18, 2011 | Slide 6
3BHT490546R0001, Rev. G
R&D for drives is highly innovative
© ABB Group
February 18, 2011 | Slide 7
3BHT490546R0001, Rev. G
Beijing, China
© ABB Group
February 18, 2011 | Slide 8
3BHT490546R0001, Rev. G
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Chinese headquarters for LV and
MV drives

Manufacture, development and sourcing
for MV drives for the Chinese market:

air-cooled ACS 5000

ACS 2000

Location: Beijing, China

Total number of employees:
more than 800
Bangalore, India
© ABB Group
February 18, 2011 | Slide 9
3BHT490546R0001, Rev. G

Indian headquarters for drives, power
electronics, low voltage breakers
and switches

Short circuit testing facility

Assembly of MV general purpose drives
for the Indian market:

air-cooled ACS 5000

ACS 2000

Location:
Nelamangala, Bangalore, India

Total number of employees:
more than 800
Lodz, Poland
© ABB Group
February 18, 2011 | Slide 10
3BHT490546R0001, Rev. G

Module assembly for MV drives, power
electronics and traction converters

Location: Lodz, Poland

Total number of employees: 135
New Berlin, WI, USA
© ABB Group
February 18, 2011 | Slide 11
3BHT490546R0001, Rev. G

US headquarters for Discrete
Automation and Motion division and
Low Voltage Products division, including
MV Drives

R&D center for North American focused
products

Location: New Berlin, Wisconsin, USA

Total number of employees: 450
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 12
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
What is a Variable Speed Drive (VSD)?
ACS 5000 VSI-MF
topology
© ABB Group
February 18, 2011 | Slide 13
3BHT490546R0001, Rev. G
The most efficient way to control the
process is to control the speed, and the
most efficient way to control the speed is
to use an electric variable speed drive –
a frequency converter

A VSD controls the speed, torque or
power on the shaft of an electric motor
by converting the fixed voltage, fixed
frequency at the network, into a
variable voltage, variable frequency on
the output to the motor

In this way the drive can control the
variables of a process, such as flow, by
controlling the speed of a pump
Why variable speed drives?

60 - 65% of industrial electrical energy is consumed by
electric motors

For each 1 USD spent to purchase a motor, 100 USD are
spent for energy cost during its lifetime

Today, only 5% of these motors are controlled by variable
speed drives

30% of existing motors can be retrofitted with variable
speed drives


© ABB Group
February 18, 2011 | Slide 14
3BHT490546R0001, Rev. G
The installed base of ABB drives saves
more than 190 TWh of energy per year.
ABB drives reduce CO2 emissions by
approx. 80 million tons per year
Benefits of variable speed control
Speed Production rise
Best quality

Energy savings

Improved product quality through better
process control

Reduced process equipment wear and
longer lifetime of equipment

Soft start and stop reduce waste and
save raw material

Noise reduction

Improved process efficiency
Energy saving
Soft Start
© ABB Group
February 18, 2011 | Slide 15
3BHT490546R0001, Rev. G
Time
Control methods
© ABB Group
February 18, 2011 | Slide 16
3BHT490546R0001, Rev. G
Throttling
Bypassing
On/off control
Variable speed
Power requirement for various control methods
Throttling
Cyclic control
AC Drive
Pump / fan
Saving
potential
Power Required
Recirculation
100
90
80
70
60
50
40
30
20
10
00
20
40
Flow
© ABB Group
February 18, 2011 | Slide 17
3BHT490546R0001, Rev. G
60
80
100

Process equipment often runs at partial
load, resulting in unnecessary high
energy bills

Many businesses find that a 20% cut in
energy costs gives the same benefit to
the bottom line as a 5% increase
in sales
How much energy do you save?
ABB has developed the following tools to assist in the
calculation of energy savings:
 FanSave – for comparison of energy consumption
between different fan control methods

© ABB Group
February 18, 2011 | Slide 18
3BHT490546R0001, Rev. G
PumpSave – for comparison of energy consumption
between different pump control methods
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 19
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
Medium voltage AC drives for ...
Cement, Mining &
Minerals
Chemical, Oil & Gas
Marine
Metals
Power
Pulp & Paper
Water
Special applications,
e.g. wind tunnels
© ABB Group
February 18, 2011 | Slide 20
3BHT490546R0001, Rev. G
Applications
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© ABB Group
February 18, 2011 | Slide 21
3BHT490546R0001, Rev. G
Blowers & fans
Conveyors
Compressors
Crushers, rolling mills
Extruders, mixers
Marine propulsion
Mine hoists
Pumps
Refiners
Gas & hydro turbine starters
Soft starters for large machines
Test stands, wind tunnels
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 22
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
What is a drive system?
Standard scope of supply for a drive system
© ABB Group
February 18, 2011 | Slide 23
3BHT490546R0001, Rev. G

A drive system is used to control speed, torque and power
of an electric motor in an application

It consists of transformer, variable speed drive and motor
What is a medium voltage drive?

For motor voltages from 1,000 V to 20,000 V

Power range 300 kW to 100 MW

Motor speed 0 to ± 12,000 rpm
Why medium voltage?
© ABB Group
February 18, 2011 | Slide 24
3BHT490546R0001, Rev. G
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For a given power, current is lower compared to LV drives

Smaller cables, lower current rating for breakers

Lower losses

As the power increases, it is the only practical solution
Motor
Purpose of motor
 The motor is driving an application
M
3~
High-voltage motors


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Air- or water cooled
Designs for harsh environmental
conditions or hazardous areas
Types
 Induction motors
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Synchronous motors
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© ABB Group
February 18, 2011 | Slide 25
3BHT490546R0001, Rev. G
Power range: up to 18 MW
Power range: up to more
than 100 MW
With brushes, brushless or
permanent magnet
ABB induction cast iron motors
Process performance motor
 Power: 110 – 530 kW
 Frame sizes: 315 – 400
 Standard high voltage motor
 Based on proven platform
 For serial OEM’s
 Short delivery times
Engineered cast iron motor HXR
 Power: 100 – 2,250 kW
 Frame sizes: 315 to 560
 High efficiency levels, even at partial load
 Low noise levels
 Fixed speed and variable speed use
© ABB Group
February 18, 2011 | Slide 26
3BHT490546R0001, Rev. G
ABB induction modular motors
© ABB Group
February 18, 2011 | Slide 27
3BHT490546R0001, Rev. G
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Built from the basic design by using
modular construction

Complete range of enclosures and
cooling arrangements

Optimal weight to power ratio

Power: 160 – 20,000 kW

Frame sizes: 315 – 1,120
ABB synchronous motors
© ABB Group
February 18, 2011 | Slide 28
3BHT490546R0001, Rev. G

DOL and variable speed motors

Very high voltage motors

For pumps, fans, compressors, refiners,
expanders, extruders, blowers etc.

Power: 0.5 – 60 MW

Frame sizes: 710 – 2,500
ABB permanent magnet motors and generators
Applications
© ABB Group
February 18, 2011 | Slide 29
3BHT490546R0001, Rev. G

Azipod propulsion motors
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Wind turbine generators
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Direct drive motors
Input transformer
Purpose of transformer
 Adapt the network voltage to that of
frequency converter



Reduce the fault level of the network to
a level that the converter can handle in
case of a short circuit
Galvanic isolation of the drive from the
network to simplify the
protection system
Relieve the motor and/or network from
common mode voltages
Types of transformers
 Air cooled

© ABB Group
February 18, 2011 | Slide 30
3BHT490546R0001, Rev. G
Oil-immersed
ABB oil-type transformers
Power range
 Up to 137 MVA
Primary voltage

Up to 170 kV
Temperature rise
 Class A
Insulation liquids

Mineral oil
Silicone oil

Synthetic ester

© ABB Group
February 18, 2011 | Slide 31
3BHT490546R0001, Rev. G
ABB dry-type transformers
Power range
 50 kVA up to 30 MVA
(vacuum cast-resin dry-type
transformer)

30 kVA up to 40 MVA
(Resibloc® dry-type transformer)
Primary voltage
 Up to 52 kV
Climate class

C2 (IEC 60076-11)
Insulation class
 220°C (AINSI/IEEE)
© ABB Group
February 18, 2011 | Slide 32
3BHT490546R0001, Rev. G
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 33
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
© ABB Group
February 18, 2011 | Slide 34
3BHT490546R0001, Rev. G
MV drives
ACS 1000, ACS 1000i

Cooling: air / water

Power range: 315 kW – 5 MW

Output voltage: 2.3 – 4.16 kV

Air-cooled ACS 1000 available with
integrated input transformer and input
contactor (ACS 1000i)
ACS 2000
© ABB Group
February 18, 2011 | Slide 35
3BHT490546R0001, Rev. G

Cooling: air

Power range: 315 – 800 kW

Output voltage: 6.0 – 6.9 kV

Suitable for use with or without input
isolation transformer
MV drives
ACS 5000

Cooling: air / water

Power range: 2 – 22 MW

Output voltage: 6.0 – 6.9 kV

Air-cooled ACS 5000 available with
integrated input transformer
ACS 6000
© ABB Group
February 18, 2011 | Slide 36
3BHT490546R0001, Rev. G

Cooling: water

Power range: 3 – 27 MW

Output voltage: 3.0 – 3.3 kV

Available as single or multidrives
MV drives
MEGADRIVE-LCI
© ABB Group
February 18, 2011 | Slide 37
3BHT490546R0001, Rev. G

Cooling: air / water

Power range: 2 – 72 MW
(higher on request)

Output voltage: 2.1 – 10 kV
ACS 1000 air cooled
315 kW – 1.8 MW
Integrated fan for low
noise level
IGCT power
semiconductors
Application & motor
control board with
fast digital signal
processor and DTC
Output filter for smooth
sinusoidal current and
voltage waveform
© ABB Group
February 18, 2011 | Slide 38
3BHT490546R0001, Rev. G
ACS 1000 water cooled
1.8 – 5 MW
Inverter stacks on
swing frame for easy
accessibility
Application &
motor control
board with
fast digital
signal processor
and DTC
Water cooling
Output filter for
smooth sinusoidal
current and voltage
waveform
© ABB Group
February 18, 2011 | Slide 39
3BHT490546R0001, Rev. G
IGCT power semiconductors
(behind swing frame)
ACS 1000i air cooled
315 kW – 2 MW
Control electronics
mounted on swing
frame for easy access
Input isolator for safe
de-energization
3-level voltage source
inverter using IGCT
power semiconductors
Power cable connection
section for top and
bottom entry
24-pulse input bridge
as standard for
stringent harmonic
mitigation
© ABB Group
February 18, 2011 | Slide 40
3BHT490546R0001, Rev. G
Output filter for smooth
sinusoidal current and
voltage waveform,
supplied
to the motor
24-pulse input
isolation transformer
for lowest line
harmonics
ACS 2000 air cooled
315 – 800 kW
Control unit
Inverter Unit (INU)
Cable connection
section for top and
bottom entry
Withdrawable phase
modules
Active Front End (AFE)
© ABB Group
February 18, 2011 | Slide 41
3BHT490546R0001, Rev. G
ACS 5000 air cooled
2 – 7 MW
Fan
ACS 5000 air cooled with
integrated transformer
Input/output cable
connection section
DC Capacitors
Inverter unit
Control Unit
© ABB Group
February 18, 2011 | Slide 42
3BHT490546R0001, Rev. G
ACS 5000 water cooled
5 – 22 MW
Inverter unit
Control unit
Auxiliary power for
control hardware
36-pulse diode
rectifier
Water cooling unit
with stainless
steel piping
DC-link capacitors
Transformer cable
connection
section for top
and bottom entry
© ABB Group
February 18, 2011 | Slide 43
3BHT490546R0001, Rev. G
Motor cable connection
section for top
and bottom entry
ACS 6000 water cooled
3 – 27 MW
Line Supply Unit
6- or 12-pulse diode
rectifier unit
Capacitor Bank Unit
DC capacitors for
smoothing the
intermediate DC voltage
Water Cooling Unit
Supplies the closed
cooling system with
deionized water for
the main power
components
Terminal and Control Unit
Contains the power terminals
and the control swing frame
© ABB Group
February 18, 2011 | Slide 44
3BHT490546R0001, Rev. G
Inverter Unit Self-commutated,
6-pulse, 3-level voltage source
inverter with IGCT technology
MEGADRIVE-LCI air cooled
2 – 31 MW
Air outlet
Motor cable
connection section
Control cubicle
- Control panel
Air-cooled
DC reactor
© ABB Group
February 18, 2011 | Slide 45
3BHT490546R0001, Rev. G
Transformer cable
connection section
- Power terminals
- Current transformer
(CT) and potential
transformer (PT)
Air-cooled converter
- Air-cooled thyristor stacks
- Fans
MEGADRIVE-LCI water cooled
7 – 72 MW (higher on request)
Water-cooled
DC reactor
Control cubicle
- Control panel
- Excitation
Water
cooling
unit
Water-cooled converter
- Water-cooled thyristor stacks
- Transformer cable connection section
© ABB Group
February 18, 2011 | Slide 46
3BHT490546R0001, Rev. G
Water-cooled converter
- Water-cooled thyristor stacks
- Motor cable connection section
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 47
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
Technology
Cornerstone of success
AC drive
development
started
1969
Direct
Torque
Control
(DTC)
© ABB Group
February 18, 2011 | Slide 48
3BHT490546R0001, Rev. G
Megastar
3-level PWM
MV drive
with vector
control
1985
Integrated
Gate
Commutated
Thyristors
(IGCTs)
ACS 1000
first IGCTbased MV
drive
ACS 6000
first MV
multidrive
with PEBB
technology
Self-healing
capacitors
1993
1995
1997
1999
Extension
of PEBB
technology
(3 – 27
MVA)
ACS 5000
first MV drive
with VSI-MF
topology
2003
2005
2009
ACS 2000
MV drive
for directto-line
connection
MV drives evolution 1994 - 2006
1. Motor voltage

1994

2006
10
8
6. Faster switching
6
2. Motor friendliness
4
2
0
5. Network friendliness
3. Efficiency
4. Reliability
© ABB Group
February 18, 2011 | Slide 49
3BHT490546R0001, Rev. G
Cornerstone technologies

Integrated Gate Commutated
Thyristors (IGCTs)

High Voltage Insulated Gate Bipolar
Transistors (HV IGBTs)

Direct Torque Control (DTC)
 Common hardware and
software platforms

Reduced number of different parts
Reduced cost

Guaranteed reliability

© ABB Group
February 18, 2011 | Slide 50
3BHT490546R0001, Rev. G
Core ideas of DTC

Direct control of the motor electro-magnetic state
 Torque and stator flux are controlled at every control
cycle and so is the selection of inverter switching;
there are no pre-determined switching patterns

Exact calculation of the flux vector


© ABB Group
February 18, 2011 | Slide 51
3BHT490546R0001, Rev. G
Using an adaptive motor model, based on motor
nameplate data
Torque control by using hysteresis control
Benefits
Direct Torque Control
Typical torque
response (t) of a DTC
drive, compared with
flux vector control and
open loop pulse width
modulation (PWM)
© ABB Group
February 18, 2011 | Slide 52
3BHT490546R0001, Rev. G

Provides fast, accurate and stepless
control from zero to full speed

Full torque with optimal speed accuracy
over the whole speed range

Negligibly low torque ripple

Minimal inverter switching losses at
maximal control performance

No speed encoders needed
Overview
MV Drives
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© ABB Group
February 18, 2011 | Slide 53
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
VSI routine test
Example ACS 1000
Test bay at MV drives
factory in Switzerland
1.
High voltage
insulation test
2.
Testing of
controls
3.
Testing of
power part
4.
a) Motor load test 1 h
b) Full current test 2 h
c) Overvoltage test 10 min
© ABB Group
February 18, 2011 | Slide 54
3BHT490546R0001, Rev. G
VSD system test
Example of 48 MW BtB test installation
Three 48 MW / 3600
rpm export
compressor drives for
Ormen Lange
delivered 2005
Converter 2
Converter 1
Drive to be tested
Drive as load
Motor 2
© ABB Group
February 18, 2011 | Slide 55
3BHT490546R0001, Rev. G
Motor 1
Project-specific testing
Source: Burkhardt
Compression
© ABB Group
February 18, 2011 | Slide 56
3BHT490546R0001, Rev. G

On customer-request, tests of the whole
drive system (transformer, converter,
motor) and the application
(e.g. compressor) can be arranged

String tests are performed at the
customer site to test the mechanicalelectrical interaction of the whole
drive train
Overview
MV Drives

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

© ABB Group
February 18, 2011 | Slide 57
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
Complete life cycle management
Performance
Upgrade,
retrofit or
replacement
Preventive
maintenance
Reliability
Overhaul
© ABB Group
February 18, 2011 | Slide 58
3BHT490546R0001, Rev. G
Aging
Corrective
maintenance
ABB drive life cycle management model

The drive with
complete life cycle
services is available
for purchase.


The drive with
complete life cycle
services is available
for plant extensions
and spare part.
Some product
enhancements can be
made.
Complete life cycle services
© ABB Group
February 18, 2011 | Slide 59
3BHT490546R0001, Rev. G

Spare parts and repair
services are available
as long as materials
can be obtained.

Migration to a new
ABB drive is
recommended.

ABB cannot guarantee
availability of life cycle
services for technical
reasons or within
reasonable cost.

Migration to a new ABB
drive is recommended.
Limited life cycle services
Global MV drives service presence
Regional Service
Center
Asia Pacific:
Australia
India
Malaysia
Philippines
Taiwan
Spare Parts Center
Americas:
Argentina
Brazil
Canada
Chile
Mexico
United States
© ABB Group
February 18, 2011 | Slide 60
3BHT490546R0001, Rev. G
Europe & MEA:
Austria
Finland
Ireland
Norway
South Africa
United Kingdom
Belgium
France
Italy
Poland
Spain
Czech Republic
Germany
Latvia
Portugal
Sweden
Denmark
Greece
Netherlands
Slovakia
Switzerland
China
Korea, Republic
New Zealand
Singapore
Thailand
DriveMonitorTM
Intelligent monitoring and control
DriveMonitorTM is an intelligent diagnostic
system consisting of
 Hardware module (installed in- or
outside of drive)

Software layer (collecting and analyzing
selected drive signals and parameters)
Functions
 Monitoring of drive’s performance,
and, if required, other shaft line
components (main circuit breaker,
transformer, motor)

© ABB Group
February 18, 2011 | Slide 61
3BHT490546R0001, Rev. G
Fast fault finding process
Overview
MV Drives









© ABB Group
February 18, 2011 | Slide 62
3BHT490546R0001, Rev. G
Global presence
Variable speed drives and their benefits
Industries and applications
What is a variable speed drive system?
MV drives product portfolio
Technology
Testing
Services
References and case studies
References (shipments)
42'000
VSI
37'000
Cyclo
32'000
CSI (Cascade,
LCI)
MVA
27'000
22'000
17'000
12'000
7'000
2'000
1995
© ABB Group
February 18, 2011 | Slide 63
3BHT490546R0001, Rev. G
1997
1999
2001
2003
2005
2007
2009
© ABB Group
February 18, 2011 | Slide 64
3BHT490546R0001, Rev. G
Water industry
© ABB Group
February 18, 2011 | Slide 65
3BHT490546R0001, Rev. G

The Metropolitan Waterworks Authority
of Thailand, replaced the eddy current
coupling drives that controlled the speed
of its water pumps with AC drives from
ABB

The treatment plant‘s system efficiency
increased by 15 – 30%

Energy saving:
about 180,000 kWh/month

Reduction of CO2 emissions:
about 90,000 kg/month

Other benefits
 Reduced maintenance cost
 Increased system reliability
 Longer lifetime of motor & pump
Water industry
© ABB Group
February 18, 2011 | Slide 66
3BHT490546R0001, Rev. G

Ten ACS 1000 variable speed drives,
each of 3,500 kW, control pumps at the
Changi influent pumping station in
Singapore.

The Changi Water Reclamation plant
will initially treat 176 million gallons of
used water per day.

Benefits:

Soft starting of motors with 11 m
long shafts

Elimination of water hammering

Flow regulation of used water inflow

Integration with automation system
Cement industry

A Mexican cement plant replaced the
existing damper fan control of two
1,000 hp fixed speed ID fans with
AC drive control (VSD) from ABB

Energy saving:
about 5,500,000 kWh/year

Reduction of CO2 emissions:
about 2,750,000 kg/year

Other benefits
 Revenue up by USD 900,000
through increased productivity


© ABB Group
February 18, 2011 | Slide 67
3BHT490546R0001, Rev. G
Maintenance reduced by 97%
Payback period: 6 months
Chemical, oil & gas industries
© ABB Group
February 18, 2011 | Slide 68
3BHT490546R0001, Rev. G

A refinery in Saudi Arabia was upgraded to
meet Saudi Arabia‘s future demand for
refined products

It replaced the fixed speed control of its
shipping pumps with variable speed drives
(VSD) from ABB

Designed for a capacity of 4.5 MW, it is now
operating at 1-1.5 MW

Estimated energy saving:
about 18,700,000 kWh/year

Reduction of CO2 emissions:
about 9,350,000 kg/year

Other benefits
 Reduced maintenance
 Better process control
 Easier operation
 Short payback period
Power industry

An US university power plant installed
a 1,000 hp AC drive from ABB for its
scrubber booster fan

Energy efficiency improved by 25%
against that of inlet vanes

Energy saving:
about 1,460,000 kWh/year

Reduction of CO2 emissions:
730,000 kg/year

Other benefits
 Better process controllability


© ABB Group
February 18, 2011 | Slide 69
3BHT490546R0001, Rev. G
Less maintenance by soft starting
No more start-up problems
Coal-fired power plant
© ABB Group
February 18, 2011 | Slide 70
3BHT490546R0001, Rev. G

A German coal-fired power plant
replaced the hydraulic couplings, which
were regulating two boiler feed-water
pumps of 5.8 MW each with ABB AC
drives

Estimated energy saving:
about 12,000 MWh/year

Reduction of CO2 emissions:
about 10,000 tonnes/year

Other benefits
 Improved efficiency of pump drive
system
 Short payback period
Metals industry
© ABB Group
February 18, 2011 | Slide 71
3BHT490546R0001, Rev. G

A Taiwanese steel company had used a
mechanical return (bypass) valve, controlled
by an external PID controller, to regulate the
pressure of the water being fed to the
descaling pumps of the hot rolling mill. By
retrofitting ABB AC drives to the fixed speed
booster pump motors, energy and water
costs could be reduced considerably

Energy saving: about 2,930,000 kWh

Reduction of CO2 emissions:
about 1,465,000 kg

Other benefits
 Reduced water costs (savings of about
65,000 tons of water/year)
 Reduced maintenance cost
 Improved product quality
Mining industry

A Mexican iron mining company
installed an AC drive from ABB,
replacing the existing constant speed
1,250 kW cooling fan motor

Energy savings of 23% were achieved

Energy saving:
about 2,300,000 kWh/year

Reduction of CO2 emissions:
1,150,000 kg/year

Other benefits
 Better process controllability


© ABB Group
February 18, 2011 | Slide 72
3BHT490546R0001, Rev. G
Lower motor noise and vibration
Reduced maintenance cost
Pulp & paper industry
An Estonian paper mill uses a variable
speed drive from ABB to start up a
3,500 kW refiner motor
By operating the motor with a VSD, no
disturbances are caused to the existing
automation equipment and practically no
voltage drops can be detected at the
supply lines
© ABB Group
February 18, 2011 | Slide 73
3BHT490546R0001, Rev. G

Start-up of refiner motor without voltage
drop in supply network

Reduction of maintenance costs

Other benefits
 Minimized total investment
 Increased availability
 Extended lifetime of equipment
Marine

© ABB Group
February 18, 2011 | Slide 74
3BHT490546R0001, Rev. G
Oasis of the Seas, the world‘s largest
cruise ship, is equipped with ACS 6000
medium voltage drives to control the
ship’s Azipod propulsion motors
Wind tunnel
© ABB Group
February 18, 2011 | Slide 75
3BHT490546R0001, Rev. G

With the successful delivery of a
101 MW variable speed drive for a
135,000 hp synchronous motor in a
NASA wind tunnel, ABB has set a
world record for size and power

The drive is needed for simulated flight
testing of large supersonic aircrafts