© ABB ATAP - 1
MV Drives North America
Randy Huebner
MV Drives North America
Outline
1. World Market size & growth
2. ABB specific data
3. Applications in Utilities
4. ABB MV Drive Products
© ABB ATAP
ABB North America ATAP - 2
5. North America – Competitors
ATAP Growth!
World Market size and growth 00-04
MV Drives development World Market
Index yr 2000
200%
180%
160%
140%
USD CAGR: 15%
CHF CAGR: 6%
Unit CAGR 14%
kUSD
120%
kCHF
100%
# Conv
USD/Conv
80%
CHF/Conv
© ABB ATAP
ABB North America ATAP - 3
60%
40%
20%
0%
ATAP Growth!
2000
2001
2002
2003
2004
World Market 2004 Industry Segments
World Market [400 MUSD] Industry Segments
Others
5%
Metals
23%
Power
21%
Marine
6%
© ABB ATAP
ABB North America ATAP - 4
Water & Waste
12%
ATAP Growth!
COG
23%
Cement Mineral
& Mining
8%
Pulp & Paper
2%
World Market 2004 geographically (end-user MUSD)
World Market Geographically
ROW
11%
North America
23%
© ABB ATAP
ABB North America ATAP - 5
China
37%
ATAP Growth!
Europe
29%
ABB’s position world wide # drives
Unit market shares 2004 Rockwell/AB
16.8%
ABB
16.2%
ASI Robicon
15.0%
GE-Toshiba
12.5%
Siemens
9.8%
TMEIC Toshiba/Mitsubishi
7.6%
Chinese - Harvest
5.6%
Alstom /GECELEC /AEG / GEC
3.2%
2.9%
Fuji
2.7%
© ABB ATAP
ABB North America ATAP - 6
Others (L&T, CTQ, WEG, BHEL)
Hitachi
1.5%
Chinese - AriTime
1.4%
Chinese - Tried
1.4%
Yaskawa
1.3%
Chinese - Mingyang, Dongfan & other
1.1%
GE (Industry)
0.9%
ATAP Growth!
0.0% 2.0% 4.0% 6.0% 8.0% 10.0 12.0 14.0 16.0 18.0
%
%
%
%
%
ABB’s position world wide (USD) in 2004
Market shares in kUSD - Market size ~400 MUSD
ABB
26.3%
ASI Robicon
17.9%
Siemens
13.2%
Rockwell/AB
12.4%
GE-Toshiba
6.2%
TMEIC Toshiba/Mitsubishi
6.0%
Alstom /GECELEC /AEG / GEC
4.5%
Others (L&T, CTQ, WEG, BHEL)
3.2%
2.3%
© ABB ATAP
ABB North America ATAP - 7
Chinese - Harvest
GE (Industry)
1.7%
Chinese - AriTime
1.5%
Chinese - Tried
1.5%
Fuji
1.3%
Hitachi
0.8%
Yaskawa
0.6%
Chinese - Mingyang, Dongfan & other
0.5%
ATAP Growth!
0%
5%
10%
15%
20%
25%
30%
ABB Drives USA

ABB US Drive Headquarters New
Berlin, WI

180M Sales 2004

330 Employees

ISO 9001 Facility

LV & MV Drives & Motors

Power Electronics

Ratings: 3 - 135,000HP
© ABB ATAP
ABB North America ATAP - 8
ABB MV Drive Headquarters
Turgi Switzerland
ATAP Growth!
MFG Location for MV Drives
Products
Turgi
World leader in MV Drives
ATAP Projects Business – North America
ATAP
President
Greg Scheu
Instrumentation
LV Drives / LV Control
Bernard Lafrance
Rick Hepperla
Dane Maisel
Pat Hogan
Projects
Chuck Clark
Excitation
Mike Wallin
Bernard Lafrance
Joe Maloni
© ABB ATAP
ABB North America ATAP - 9
MV Motors / Generators
Jan-Anders Bergman
Toronto
ATAP Growth!
MV Drives
Randy Huebner
Houston
Advanced Power Electronics
Kevin Dennis
New Berlin
Project Businesses – U.S. / New Berlin
Project Businesses
Chuck Clark
Business Controller
Jaana Suvanto
Executive Assistant
Diane Hermann
Marketing
Heather Flanagan
North American
Factory Support Team
Chuck Clark
Olli Mansikka
Douglas Crock
Jeff Freisleben
Stephane Levesque
Bob Smon
Rick Walmsley
Advanced Power
Electronics - N.A.
Kevin Dennis
© ABB ATAP
ABB North America ATAP - 10
Bill Hejdak
Hans Krattiger
Chris Larsen
Tor-Eivind Moen
ATAP Growth!
Low Voltage
Motors - U.S.
Jim Clark
Carol Campbell
Duane Hoernemann
Tom Klenner
Marko Kukkamaa
Arlene Mandery
Sandy Mitchell
Lars-Erik Thand
Bryan Wethered
Medium Voltage
Motors - U.S.
Ray Doran
Richard Matonich
MV Motors / LV Motors
ABB Canada
Jan-Anders Bergman
John Dulas
Robert Nelson
Tim Trumbo
Aaron Wood
LV Motors
Dominique Binet
Dominic Colameo
Medium Voltage
Drives
Randy Huebner
Operations
Anders Troedson
Deepika Kothembaka
Adrian Guggisberg
Benjamin Magwe
Canada (Open)
Steve Schefus
David Tiller
Project
System & Design
Business Development
Management
Engineering
(Open)
Anders Troedson
Peter Reindl
Calgary (Open)
Houston (Open)
Chandreka Ballmick
Brian Baldwin
R&D (Open)
David Banks
Tom Harper
Ravi Dodballapur
Michael Kirschner
Bruce Heard
Dale Nemitz
Ravi Kureti
Brian Ong
Beau Lowerr
Erik Martensson
Gary Morris
Ali Nilchian
Bob Schmidt
Joe Von Sebo
© ABB ATAP
ABB North America ATAP - 11
Fields of Application
Cement, Mining and Minerals
Conveyors, crushers, mills, fans and
pumps
Chemical, Oil and Gas
Pumps, compressors, extruders, mixers
and blowers
Metals
Pumps and fans
Pulp and Paper
Fans, pumps, refiners and chippers
Power Generation
Fans, pumps, conveyors and coal mills
Water and Waste Water
Pump applications, fresh water and
waste water
Other Applications
Test stands and wind tunnels
ATAP Growth!
Large Motors Applied in Power Generation
Circulating and Cooling Water
Pumps

Boiler Feed Water Pumps

Fans

Compressors

Coal Mills

LCI Starters for Generators

Any of these Motors
can use a Drive!!
© ABB ATAP
ABB North America ATAP - 12

ATAP Growth!
Fans
Chimney
Boiler
Cooling tower fan
© ABB ATAP
ABB North America ATAP - 13
Desulfurization
ATAP Growth!
Electric precipitator
ID Fan
Primary fan
Air preheater
Secondary fan
© ABB ATAP
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Visualization of power flow
Source: Hugo Stadler, Lohr GmbH
ATAP Growth!
Common Applications

ID Fans and Scrubber
Upgrades

Scrubber upgrade requires
larger ID Fan

Power supply is not large
enough to start motor
Matched ID fans to to balance
the load

ID fans and FD Fans on swing
plants help turn down ratio of
the plant
© ABB ATAP
ABB North America ATAP - 15

ATAP Growth!
MV Drives Portfolio (standard converters)
P (kW)
50’000
10’000
9’000
ACS 6000c
7’000
LCI
ACS 5000
16’000
ACS 6000
Motor Power
27’000
5’000
2’000
ACS 1000
Step-Up
ACS 1000
© ABB ATAP
ABB North America ATAP - 16
315
ATAP Growth!
U (kV)
1.0
1.5
1.8
2.4
3.3
4.16
Motor Voltage
6.0
6.9
8.0
13.8
ACS 1000, ACS 5000 , ACS 6000
Reliability and Availability

Robustness and Performance

Efficiency

Compatibility
© ABB ATAP
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
ATAP Growth!
Reliability - Semiconductors
IGCT semiconductors and 3-level VSI design
© ABB ATAP
ABB North America ATAP - 18

ATAP Growth!

Low part count

Least complex and most robust
design

No series or parallel connection
of power semiconductors
Reliability – 3 level VSI
Ls1
Vcl1
V1u
V1v
V1w
V2u
V2v
V2w
Rs1
Cdc1
Ccl1
V1Nu
V3u
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Cdc2
ATAP Growth!
Ccl2
V4u
Vcl2
Ls2
V3w
V3v
V2Nw
V2Nv
V2Nu
Rs2
V1Nw
V1Nv
V4v
V4w
Reliable Components

Fuseless design


Faster and better protection than medium voltage power fuses
Long-life capacitors

Advanced, self-healing, environmental friendly,
foil capacitors have a substantially longer
lifetime than electrolytic capacitors

© ABB ATAP
ABB North America ATAP - 20

Lower lifetime costs
Built-in input surge protection

Surge arresters at the isolation transformer primary side

Tolerant to network disturbances
ATAP Growth!

Increased reliability
© ABB ATAP
ABB North America ATAP - 21
Worldwide Service and Support
ATAP Growth!

Installation and commissioning

Training

On-board diagnostics

Remote diagnostics

Customized service programs

Local technical support

Local service support

Spare parts and logistics
network

24 x 365 support line
Robustness and Performance - DTC

Direct Torque Control (DTC)
© ABB ATAP
ABB North America ATAP - 22

Most powerful control platform

Power loss ride-through of one second

Flying start and automatic restart

Flux optimization

Critical speed avoidance bands
Typical torque response (t) of a DTC drive,
compared with flux vector control and
open loop pulse width modulation (PWM)
ATAP Growth!
Robustness and Performance – Power Ride Through
n
T
t
ride through
Input
section
Input
transformer
Rectifier
DC-link
Vs1
Inverter
Output filter
Motor
Udc
I_s
S1
M
U_in
Vs2
magnetizing
current
U
I
© ABB ATAP
ABB North America ATAP - 23
U
ATAP Growth!
t
t
t
ride through
ride through
ride through
load current
Compatibility – Input / Network

24-pulse or 12-pulse diode rectifiers, fulfilling IEEE 519

No active switching elements on line side interface (only
for 4 Q operation)

No filter at the line side
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ABB North America ATAP - 24


No oscillation problems
No power factor compensation
ATAP Growth!
Compatibility – Fieldbus adapters

Control System
Connection to higher-level process controllers
© ABB ATAP
ABB North America ATAP - 25

ATAP Growth!

Flexible hardware I/Os for remote control, allowing easy
customization

Large variety of available fieldbus interfaces

Profibus

Modbus

DeviceNet

LonWorks

CANopen

InterBus-S

Ethernet
ACS 1000 Main Features

Inverter design
3-level
Voltage Source Inverter (VSI)
Sine Wave
Filter
Standard
AC Induction
Motor
© ABB ATAP
ABB North America ATAP - 26
DC
Link
ATAP Growth!
Legend
IGCT with integrated gate driver and freeweeling diode
NPC Diode (Neutral Clamping Diode)
ACS 1000

Sine Filter
Output sine filter

Actively controlled LC low pass filter

Eliminates virtually all inverter switching harmonics to the motor

Keeps motor and bearings common mode voltage free
Output Sine Filter
© ABB ATAP
ABB North America ATAP - 27
Inverter
Side
Inverter output voltage
ATAP Growth!
Motor
Side
Drive output voltage to the motor
Compatibility – Common Mode
Input transformer
Output sinefilter
Cable
MCB
Motor
Grounding network
Converter
Normal common mode current path
Stray capacitance to ground of:
•Transformer
•Cables
•Converter
I_Cfuvw_G
A
35
30
25
© ABB ATAP
ABB North America ATAP - 28

The produced common mode
voltage is only seen by the
transformer secondary windings
against ground
20
15
10
5
0
-5
-10
-15
-20
-25
-30
0

The Common Mode is keept inside
the Drive System
ATAP Growth!
5
10
15
20
25
30
ms
ACS 1000
© ABB ATAP
ABB North America ATAP - 29
Air cooled
ATAP Growth!
or
Water cooled
ACS1000 Air Cooled
Front View
Air Cooled Range:
0.4 - 2 MVA;
2.3, 3.3 and 4kV;
© ABB ATAP
ABB North America ATAP - 30
6.5ft
excl.
air outlet
cover
ATAP Growth!
3ft
10ft
ACS1000 Water Cooled
Front View
15ft
© ABB ATAP
ABB North America ATAP - 31
6.5ft
3ft
ATAP Growth!
Water Cooled Range:
2 - 6 MVA;
3.3 and 4kV;
© ABB ATAP
ABB North America ATAP - 32
ACS 1000 Water Cooled
ATAP Growth!
Cooling Circuit Overview
ACS 1000i
Three cables in – three cables out!
© ABB ATAP
ABB North America ATAP - 33

Special features:

Full integrated solution, including
transformer, input switch and
disconnector

Easy to install

Standard 24-pulse rectifier bridge

Small footprint

No auxiliary power required
ATAP Growth!
General overview ACS 1000i
© ABB ATAP
ABB North America ATAP - 34
Input
section
ATAP Growth!
Input
transformer
Rectifier
DC-link
Inverter
Output filter
Motor
M
ACS 5000 and ACS 6000

High power drives (5000HP – 40’000HP)


Suitable for induction, synchronous and permanent magnet motors
ACS 5000

General drive for pump, fan and compressor applications
 6.0 – 6.9kV output voltage

ACS 6000
© ABB ATAP
ABB North America ATAP - 35

High performance drive
 Active front end or diode bridge input
 Reactive power compensation
 Single drive and Multi drive topology
ATAP Growth!
Power
ACS 6/5000
Inverter Unit
Motor Voltage
ACS 5000 and ACS 6000 Common Platform
3MVA
3kV
INU
5MVA
7MVA
Power
Stack(s)
ATAP Growth!
6kV
© ABB ATAP
ABB North America ATAP - 36
9MVA
12MVA
Technology Basis
3 level IGCT phase
To motor
To motor
To “converter
starpoint”

ACS 6000:
© ABB ATAP
ABB North America ATAP - 37

ATAP Growth!
One 3 level phase module per motor
phase
-> 3.3kV output voltage

ACS 5000:

two 3 level phase modules per
motor phase (in series)
-> 6.9kV output voltage
ACS 6000
VSI
”System topology”
Power flow
2Q drive
LSU
Line Supply Unit
Motoring mode
INU
Inverter Unit
CBU
DC (+)
Motor
DC (NP)
DC (-)
© ABB ATAP
ABB North America ATAP - 38
Supply
transformer
ATAP Growth!
Clamping circuit
Resistor Braking
Unit (RBU)
Phase modules
EMC Filter
ACS 5000
VSI - MF
”System topology”
Main Power Supply
Auxiliary Power Supply
MCB (Standard)
(Pre)Trip
Open/Close
Control Interface Options:
- Oil level Alarm
- Overtemp /FLT/Alarm
- Gas relay /FLT/Alarm
- Transformer supervision
FLT/Alarm
UPS Power
Supply
WCU
COU
Auxiliaries
Control
Cooling Water
© ABB ATAP
ABB North America ATAP - 39
Scope of ACS 5000
ATAP Growth!
Motor
1U 1V 1W
IM
Converter Starpoint
Options for
control Interface:
T
- Tacometer
- Winding Temp /FLT/Alarm
- Bearing Supervision /FLT/Alarm
- Cond. Water Det.
- Space Heater FB
- Cooling Fans FB
© ABB ATAP
ABB North America ATAP - 40
ACS 5000
ATAP Growth!
12 MVA unit
North American Market
Market Size

Competitors
© ABB ATAP
ABB North America ATAP - 41

ATAP Growth!
North America – Sales Channel values
DOMESTIC

GE

GE-Toshiba

Rockwell

Robicon
NA Market - Sales Channel values ~ 150 MUSD
(Domestic+Export)
ABB
Other
8%
© ABB ATAP
ABB North America ATAP - 42
IMPORTED DRIVES

ABB

Siemens

Alstom

Other marginal players
(WEG..)
ATAP Growth!
ASI Rob
30%
2%
Siemens
2%
Rockwell
30%
TMEIC&GE
26%
Alstom
2%
This is our perception of the North
American Market.
North America – the main players
NORTH AMERICA End-User ~100 MUSD (Domestic only)
DOMESTIC

GE

GE-Toshiba

Rockwell

Robicon
Other
2%
© ABB ATAP
ABB North America ATAP - 43
IMPORTED DRIVES

ABB

Siemens

Alstom

Other marginal players
(WEG..)
ATAP Growth!
ABB
4%
ASI Rob
34%
Alstom
2%
Siemens
3%
Rockwell
32%
TMEIC&GE
23%
This is our perception of the North
American Market.
© ABB ATAP
ABB North America ATAP - 44
A closer look at the individual competitors
ATAP Growth!
Main Competitors
ASI Robicon

AB Rockwell

GE Toshiba
© ABB ATAP
ABB North America ATAP - 45

ATAP Growth!
© ABB ATAP
ABB North America ATAP - 46
Robicon

Fighting for time and money

Expressed strategic focus: COG – (Exxon projects)

New HV IGBT module with less parts

New capacitors of “self-healing” film type (developed and
used by ABB for 10 years)

We are eagerly waiting for news on who will buy them.
Until then – customers are taking a certain risk dealing
with them. (Many want to bail out)
ATAP Growth!
ASI Robicon

Main Products:


Baby Harmony and Perfect Harmony
Messages:

Company Under chapter 11

Availability

© ABB ATAP
ABB North America ATAP - 47
ACS 1000 reduces the maintenance required on the drive. There are no
components in the power circuit to be changed and maintained.
 Robicons Harmony drives requires extensive maintenance work. According
to the user manual:
ATAP Growth!

This results in 8 inspections in the first year, taken 8 to 12 hours per
shut-down (increased maintenance and lost production output).
ASI Robicon

Reliability and Lifetime cost:

ACS 1000 is designed to minimize lifetime cost. There are for
example no electrolyte capacitors used in the power circuit of the
drive.

Robicon use electrolyte capacitors, which have to be changed all 5
years according to their manual.
© ABB ATAP
ABB North America ATAP - 48

ATAP Growth!
Capacitors
By changing the capacitors the core of the drive (inverter) has
to be disassembled. This brings a high risk of failure (No burne
in after reassembly).
ASI Robicon
Reliability and Lifetime cost:
© ABB ATAP
ABB North America ATAP - 49

ATAP Growth!
Fuses / Fuseless

In ABB medium voltage drives are no power fuses to protect the
converter. The converters are based on a fuseless design.

In Robicon’s Harmony drives all the power cells are protected with
fuses.
Fuses
ASI Robicon


ACS 1000 offers a ride through of at least 1s due to DTC. In many
practical situations a ride through of at least 500ms is required
(Example: main bus transfers).

Harmony offers a ride through capability of only 6 cycles. -> see
flyer
Common tools
© ABB ATAP
ABB North America ATAP - 50

Ride Through
ATAP Growth!

ABB offers a wide range of automation products. For the different
product, the same tools are used to monitor and configure. ABB’s
medium voltage drives use exactly the same tools as ABB’s low
voltage drives.

Robicon is only offering a small range of products with automation
technologies. This means that product specific tools and skills are
required.
Rockwell


Growing steadily with good profit
Rockwell Control Systems
MUSD
Increasing
push into COG (Bohai Bay)
4500

projected based on
Q1 -2005
25.0%
Control Systems Sales
Earnings
Will4000be increasing
power of PowerFlex 7000 by
% margin
20.0%
3500
paralleling
drives
3000

15.0%
Trend-setter in trafo-less drives.
2500
2000
10.0%
© ABB ATAP
ABB North America ATAP - 51

1500
Their
technology limits their applications to “less
1000
5.0%
demanding”
types
like
pumps,
fans,
compressors..
But
500
this is
a large market still.
0
0.0%
ATAP Growth!
2002
2003
2004
2005Q1
AB Rockwell

Main Product:


PowerFlex7000
Messages:
VSI versus CSI
© ABB ATAP
ABB North America ATAP - 52

ATAP Growth!

ABB uses voltage source inverters, which allows to use diode rectifiers at
the line side.

AB use current source inverters, which requires always active front end
(Thyristors or SGCTs).

Today’s state of the art is voltage source inverters -> just consider low
voltage

Diodes are much more reliable than thyristors (or SGCTs).

Diode rectifiers are causing much less harmonics -> no filter is required,
where for CSI’s always a filter is required (harmonics + power factor)
AB Rockwell
Active front end
© ABB ATAP
ABB North America ATAP - 53

ATAP Growth!

An active front end is used to regenerate power to the network – 4Q
operation. Therefore ABB uses active front end drives only if
regeneration is required.

AB is pushing active front end also for 2Q operations.

Active front end requires in connection with CSI always a line
filter.

The reliability of the active front end is much lower than the
reliability of a diode bridge.
AB Rockwell

Transformer less design

© ABB ATAP
ABB North America ATAP - 54

ATAP Growth!
ABB uses an insulation transformer on the drive input in order to:

Keep the common mode voltage within the drive system (not
seen by the motor and the network)

Cancel harmonics by phase displacement
AB is promoting transformer less design. AB’s topology requires:

Special insulations on the motor, due to high common mode
voltage stress.

An input inductor, which has approximately the same
impedance like an input transformer.

Higher insulation levels and overvoltage withstand within the
converter, because there is no galvanic separation to the
network.
AB Rockwell
SGCT versus IGCT
© ABB ATAP
ABB North America ATAP - 55

ATAP Growth!

IGCT (Reverse Conducting)

SGCT

The SGCT has an integrated diode in series to the GCT, where the IGCT has
an integrated diode in parallel to the GCT

It follows that the SGCT has higher on state losses due to the fact that tha
current pass through the GCT and the diode.

It is expected that the SGCT creates 20% more losses than the IGCT
GE/Toshiba

A competitor to consider – growing fast in the low
powers. Durabilt, T300MVi and “Built for X-tremes”

States 16 year MTBF – an unrealistic figure in our
opinion. Customers need education on this subject

Bench-mark on prices up 3000 HP

Also active in Rolling Mill and high power applications
© ABB ATAP
ABB North America ATAP - 56

Their service network may not be as strong as they
claim. Not all GE offices are capable.
ATAP Growth!
GE/Toshiba

Product:


Dura-Bilt 5iMV or Tosvert T300MVi
Messages:


ACS 1000 offers a ride through of at least 1s due to DTC. In many practical situations a
ride through of at least 500ms is required (main bus transfers).

Dura Built has a ride through capability of only 100ms.

See flyer
Tacho / Speed encoder
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
Ride through
ATAP Growth!

ACS 1000 doesn’t require speed encoders. DTC is a very powerful control scheme,
proved in many thousands of installations worldwide.

Dura-Bilt requires tachometer for several applications. This is due to poor control
accuracy and stability. Torque control without encoder has only an accuracy of +- 30%

See application guide, flyer
GE/Toshiba

Cooling

ACS 1000 offers water cooled and air cooled drives. Water and air doesn’t
cause any hazard.

Dura-Bilt 5iMV use heat pipes for the air cooled drives in order to get a lower
thermal resistance. As cooling medium Fluorinert is used.

Fluorinert gets poisonous in case of overheating. Overheating may
occur in case of a semiconductor failure.


The air “cooled” Dura-Bilt lose the
big advantage of air cooled drives:
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
ATAP Growth!

Risk for humans
There remains a risk of a leaking
Check home page of GE -> Dura-Bilt presentations
GE/Toshiba

Overvoltage protection:

ACS 1000i has always a transformer primary overvoltage protection (surge arrestors in
front of the transformer). This protects the drive and especially the transformer from
overvoltages caused in the network and caused by the input main switch.

Dura-Bilt has surge arrestors only in front of the main switch. This means the
transformer is not protected against overvoltages caused by the switch.

The transformer gets a higher insulation stress, which can cause short circuits of
the transformer windings.
T1
ACS 1000i
Protection Relay
300/5A
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S2
ATAP Growth!
Dura-Bilt
S1
F1 [u, v, w]
Ft(u,v,w)
Surge Arrestors of ACS 1000
Between switch and transformer
ATAP Growth!
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