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Enha nced P ow er Tr ak S ync Ex cit at io n S ys t em Slide 1 Western Mining Electrical Association - November 200 9 We Drive Industry Power Trak Pro- Ac tion Syn c Exc ita ti on System Power Trak Pro-Ac ti on Sync Exc it ati on System P resent ed b y Bill Horv at h, TM GE Automation Syst em s At Western Mining Electrical Association San Antonio, Texas November 2009 Presented b y Bill Horv at h, TM GE Autom at ion System s At Western Mining Electrical Association San Antonio, Texas November 2009  TMGE A u t om at ion Sy stems  TMGE Au t omation Sy stems

5 WMEA Nov 2009 Power Trak Plus r2

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Enhanced Power Trak Sync Excit at ion System 

Slide 1

Western Mining Electrical Association - November 2009 We Drive Industry

Power Trak Pro-ActionSync Excitation SystemPower Trak Pro-ActionSync Excitation System

Presented by Bill Horvath, TM GE Automation Systems

At Western Mining Electrical Association

San Antonio, Texas

November 2009

Presented by Bill Horvath, TM GE Automation Systems

At Western Mining Electrical Association

San Antonio, Texas

November 2009

 TMGE Automation Systems TMGE Automation Systems

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Enhanced Power Trak Sync Excit at ion System 

Slide 2

Western Mining Electrical Association - November 2009 We Drive Industry

Dragline Sync Excitation Enhancements

• What is needed for good draglineoperation?

• Maintaining Dragline Trail CableVoltage

• Sync Motor Basics and Operation

• Sync Field Excitation Evolution & Issues

• Sync Field Excitation SystemPerformance

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Enhanced Power Trak Sync Excit at ion System 

Slide 3

Western Mining Electrical Association - November 2009 We Drive Industry

• Voltage must be held torange of 

Plus 10% to -5%• High Side range limit

due to motor voltagestress

• Low side range due tosync torque loss withvoltage drop: pull out!

Good Dragline Operation

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Enhanced Power Trak Sync Excit at ion System 

Slide 4

Western Mining Electrical Association - November 2009 We Drive Industry

Why Use Sync Motors?REACTIVE POWER VOLTAGE CONTROL!

NO SYNCHRONOUS MOTOR WITH SYNCHRONOUS MOTOR

RESULT: L ARGE VOLTAGE SWINGS AT BUS 2 & 3

RESULT: GREATLY REDUCED VOLTAGE SWINGS AT BUS 2 & 3

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Enhanced Power Trak Sync Excit at ion System 

Slide 5

Western Mining Electrical Association - November 2009 We Drive Industry

Challenge:Pit Conditions Changing

• When Draglines are moved to new diggingareas, Z3 [pit distribution impedance] changes.

• Field Excitation Control set up for best voltagecontrol at Bus 3 may have to change to keep Bus3 volts within -5% + 10% motor limits.

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Enhanced Power Trak Sync Excit at ion System 

Slide 6

Western Mining Electrical Association - November 2009 We Drive Industry

Dragline Real & Idealized Power Cycle

Sync Motor Loading

Peak Hoist DC kw+Peak Swing DC kW/ effic./ 2.5 pull out margin

@95% volts

Max Regen 60% xpeak motoring

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Enhanced Power Trak Sync Excit at ion System 

Slide 7

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motor SizingDC MG Set PEAK POWER CALCS Master Sheet MGPKPOWER-2.xls Rev 12-06/07

This Sheet 8750-Billiton-POWER-1.xlx Rev 12-06/07

Fill in values in Blue - otherS are calculated.

BHP Billiton NUMBER OF SETS: 4Billiton 8750

MOTION Mot Qty Motor Pk Volts P eak Amps Max DC KwKW to Include

in DL Pk KWMOTION Motor

Gen NP

KW

Gen Pk

Volts

Amps at

Pk volts#GENS

PEAK DC

KW

Percent

Contrib

 Tot Contrib

kW to MG

Motor @

Peak power

HOIST 8 MD824 660 2610 13781 13781 HOIST MD824 1254 660 2610 2 3445 100% 3445

DRAG 8 MD824X 660 2610 13781 0 DRAG MD824X 1254 660 2610 2 3445 0% 0

SWING 8 MD824 600 2610 12528 12528 SWING MD824 1045 600 2610 2 3132 100% 3132

DC DRIVES

KW TOTAL 26309

DIV BY .95*.95 EFFIC 0.9025  TOTAL DC GEN KW 6577

DRIVES AC TOT KW 29151 GEN EFFIC 0.93

+AUXIL KW 2500 SHAFT KW [TOT/EFF] 7072

DRAGLINE TOT PK KW 31651 SHAFT HP [KW/.746] 9480

DRAGLINE RMS KW 15192

DRAGLINE AVG KW 9495 TQ AVAIL 2.5

AUX LOAD = 2500 KW MIN VOLTS 0.95

AUX PF = 0.8 LAG 3992

 AUX KVA = 2500 + J 1875

MIN SYNC N.P. HP

REQU =

[HP/(PK TQ*MIN VOLTS)]

MOTOR SELECTION AND TOTAL DL POWER

MG SYNC MOTOR LOADINGAND MARGIN CALCULATION

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Enhanced Power Trak Sync Excit at ion System 

Slide 8

Western Mining Electrical Association - November 2009 We Drive Industry

After Synchronizing – With DC Field• Rotor follows stator

magnetic wave at syncRPM

• Magnetic Couplingbetween Stator &Rotor:Like an elastic band

 Torque “stretches” bandand rotor trails stator byan angle called the

torque angle

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Enhanced Power Trak Sync Excit at ion System 

Slide 9

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motor ModelFully Running

Effect of DC Field

•Sync Motor KVAR

Exported with strong DCfield [leading pf]

Imported with weakerfield [lagging pf]

•Increases torquecapability [power output]

R1 Xd

MagnetizingCurrent

POWER

SOURCESingle Phase Synch Motor Model

LAM

RAM

Amort.

Ef 

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Enhanced Power Trak Sync Excit at ion System 

Slide 10

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motor Reactive Power• Motors are rated both in

kVA and HP [or kW] and PF

• Typically 1.0 PF or 0.8 leadPF

• Excavator MG sync motors:NNNN HP, 0.8 pf 

250% pullout torque at 0.95

volts6-pole, 1200 RPM [1000 RPM

on 50 Hz]

Power kW]

  K   V A

      K      V      A      R

Power factor = Cos

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Enhanced Power Trak Sync Excit at ion System 

Slide 11

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Rotor Power Curve•Curve applies to aparticular level of fieldgenerated volts [Ef ] and

 Terminal Volts [V1]•Stronger Ef or changing V1

affects max power

•Power [torque] past 90

deg will result in de-sync

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Enhanced Power Trak Sync Excit at ion System 

Slide 12

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motors & Torque Production

S N

FLUX LINES FLUX LINES

      F      L      U      X

      L      I      N      E      S

F L   UX 

L  I    NE  S       F

      L      U      X

      L      I      N      E

      SF 

L   UX 

L  I    NE  S 

      F      L      U      X

      L      I      N      E      S

Rotor 

Rotation

 Torque

angle

N

S

STATOR FIELD

N

S

Motoring Torque

Rotor Trails Stator Wave

S N

FLUX LINES FLUX LINES

      F      L      U      X

      L      I      N      E      S

F L   UX 

L  I    NE  S       F

      L      U      X

      L      I      N      E

      SF 

L   UX 

L  I    NE  S 

      F      L      U      X

      L      I      N      E      S

Rotor 

Rotation

 Torque

angle

N

S

STATOR FIELD

N

S

Regen Torque

Rotor Leads Stator Wave

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Enhanced Power Trak Sync Excit at ion System 

Slide 13

Western Mining Electrical Association - November 2009 We Drive Industry

Summary

• Sync Motor provides kW to

generators but can independentlygenerate KVAR [reactive power]

• Reactive power flow opposite of kW

helps hold voltage at DL steady.

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Enhanced Power Trak Sync Excit at ion System 

Slide 14

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motor MG Set 2-3 Hz Natural Frequency•Sync Motors all have a natural

frequency – like a spring and mass•Natural frequency f n of a connected

motor is approximately:

•For Dragline MG sets [sync motorplus DC gens] this natural frequencycalculates to 2-3 Hz

•Increasing field strength “stiffens” the

spring, but does not change thenatural f n.•Impact loading on motor can

“bounce the spring”.

f n 35200RPM

Pr x f WK 2

=

S N

FLUX LINES FLUX LINES

      F      L      U      X

      L      I      N      E      S

F L   UX 

L  I    NE  S       F

      L      U      X

      L      I      N      E

      SF 

L   UX 

L  I    NE  S 

      F      L      U      X

      L      I      N      E      S

Rotor 

Rotation

 Torque

angle

N

S

STATOR FIELD

N

S

Swing from Motor to Regen Power 

Stimulated 2 Hz with Low Damping

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Enhanced Power Trak Sync Excit at ion System 

Slide 15

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motors 2 Hz Example

S N

FLUX LINES FLUX LINES

      F      L      U      X

      L      I      N      E      S

F L   UX 

L  I    NE  S       F

      L      U      X

      L      I      N      E

      SF 

L   UX 

L  I    NE  S 

      F      L      U      X

      L      I      N      E      S

Rotor 

Rotation

 Torque

angle

N

S

STATOR FIELD

N

S

Swing from Motor to Regen Power 

Stimulated 2 Hz with Low Damping

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Enhanced Power Trak Sync Excit at ion System 

Slide 16

Western Mining Electrical Association - November 2009 We Drive Industry

2 Hz Rotor Power – Where Can It Go?

• Disturbance power flows into power

system, swinging AC volts!• Amortiseur winding provides damping

torque.

POWER SOURCE

One Phase Model

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Enhanced Power Trak Sync Excit at ion System 

Slide 17

Western Mining Electrical Association - November 2009 We Drive Industry

2 Hz MG Set Resonance Effects

• Sudden load impacts shift sync motorpower [torque] angle

• Rotor overshoots, swings back and forth.

• Rotor angle pushes watts and vars in andout of dragline sometimes in huge swings

• Voltage swings can trip off dragline andnearby equipment

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Enhanced Power Trak Sync Excit at ion System 

Slide 18

Western Mining Electrical Association - November 2009 We Drive Industry

Notes & Experience with 2 Hz Problems• All sync MG sets have 2-3 Hz resonance!

• Amortiseur windings of low starting current motors[400-450% vs standard 600%] have low damping

and prone to worse 2 Hz problems.• Weak pit feeder gives low damping – worsens 2Hz.

• Using DC kW as field amps reference has shownto be best in 2 Hz performance and voltage stability

• High forcing [ratio of exciter max volts to sync fieldhot drop] helps.

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Enhanced Power Trak Sync Excit at ion System 

Slide 19

Western Mining Electrical Association - November 2009 We Drive Industry

Example Traces of 2 Hz Phenomenon[before analog regulator modifications]

 Thanks to Monte WilkeWestern Energy Co

Coalstrip, MT DL3124

1. Freq = 1/0.467 = 2.14 Hz

2. kW Transducer is notlying! Rotor oscillationsare really causing wildpower swings

Large power swings show upat trail cable as measuredby PTs

Rotor amps follow kWfeedbback with 2 hz

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Enhanced Power Trak Sync Excit at ion System 

Slide 20

Western Mining Electrical Association - November 2009 We Drive Industry

Example Traces of 2 Hz Phenomenon[after regulator modifications]

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Enhanced Power Trak Sync Excit at ion System 

Slide 21

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motor Excitation Hardware

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Enhanced Power Trak Sync Excit at ion System 

Slide 22

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Excitation Control Hardware Evolution• Rotating Exciters with

Fixed Field - resistor off 120 volt house exciter

Multi-step Contactors & Resistors off 120 volt house exciter

Dedicated 230 volt sync exciter with Saturable Reactor fieldcontrol

• Solid State op-amp & direct analog thyristor exciter

• Digital thyristor exciter with reactive power control infirmware.

• PLC based field excitation reference control• IGBT based exciters

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Enhanced Power Trak Sync Excit at ion System 

Slide 23

Western Mining Electrical Association - November 2009 We Drive Industry

Notes on Voltage “Forcing” on Sync Excitation

• Inductance and resistance of sync DCfield gives natural time constant of 2-3sec

• Min source volts must provide peakamps @ hot voltage drop

• Higher available source volts allowsfaster change of current to desired levelto follow duty cycle, hold excitation

 TimeConstant

 TypicalL/Rhot =2-

3 sec

L

RSync

MotorDC

Field

DCExcitation

SourceRatings:

* Peak Volts,

* RMS Amps* Peak Amps* Response

 Typical Hot-Drop =90-120 volts

Rated Field

Max Field [@ peak kW]

300 V Exc. Volts

600 V Exc. Volts

~4-6 sec

~1 sec >

~0.6 sec

Min Exc Volts =180=120 v x 150%

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Enhanced Power Trak Sync Excit at ion System 

Slide 24

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Motor Excitation Control

Schemes

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Enhanced Power Trak Sync Excit at ion System 

Slide 26

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Reactive Regulating Schemes

 A. POWER FACTOR REGULATORSingle PF setting with minimum field clamp.

B. WATT-VAR REGULATORMultiple break slope VAR vs Input KW

C. FIELD CURRENT VS KW [POWER TRAK] REGULATORMultiple break slope Sync Field Amps vs AC kW

D. ENHANCED POWER TRAK REGULATORMultiple break slope Sync Field Amps vs DC kW with ACkW fixed offset

[+] MOTORING KW[-] REGENERATING KW

    S    Y    N    C    F    I    E    L    D

    C    U    R    R    E    N    T

C. POWER TRAK

REGULATOR

Rx3i Controller ReferenceShaping

[+] MOTORING KW

    K    V    A    R    [  -    ]

 A. POWER FACTOR

REGULATOR

[-] REGENERAT ING KW

[+] MOTORING KW

    K    V    A    R    [  -    ]

B. KW VS KVARREGULATOR

[-] REGENERATIN G KW [+] DC MOTIONPOWER KW

    S    Y    N    C    F    I    E    L    D

    C    U    R    R    E    N    T

D. ENHANCED POWER

TRACK REGULATOR

Rx3i Controller ReferenceShaping

[-] DC MOTIONPOWER KW

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Enhanced Power Trak Sync Excit at ion System 

Slide 27

Western Mining Electrical Association - November 2009 We Drive Industry

Power Factor RegulatorSimplified Representation

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Enhanced Power Trak Sync Excit at ion System 

Slide 28

Western Mining Electrical Association - November 2009 We Drive Industry

Pure “Power-Factor” RegulatorCalculated Performance

Es = 1.075

Z = .06 + j .16

+ P.U. POWER- P.U. POWER

PF=0.936

Q / P = R / X

P  F   =  0  .9  1  

CONSTANT

REGULATED

POWERFACTOR ONLY

CREATES

SYMETRICAL

VOLTAGE

DROP OR RISE!

VOLTAGE DROP VS POWER

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Enhanced Power Trak Sync Excit at ion System 

Slide 29

Western Mining Electrical Association - November 2009 We Drive Industry

Watt-VAR [KVAR vs Kw] RegulatorSimplified Representation

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Enhanced Power Trak Sync Excit at ion System 

Slide 30

Western Mining Electrical Association - November 2009 We Drive Industry

kW vs Field Current [Power-Trak] RegulatorSimplified Representation – Any technology

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Enhanced Power Trak Sync Excit at ion System 

Slide 31

Western Mining Electrical Association - November 2009 We Drive Industry

Sync Field Current vs Kw Regulator [Power-Trak]Advantages vs PF or WATT-VAR Regulators

• Lower Overall Cost

• Easier to understand, easier to adjust• Better voltage regulation from:

Independent regulation of motoring andregen allows lower field amps at light load

As line voltage from utility side drops, syncmotor automatically produces morecompensating kVARs to hold voltage.

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Enhanced Power Trak Sync Excit at ion System 

Slide 32

Western Mining Electrical Association - November 2009 We Drive Industry

Details on TraditionalAC kW Ref Power Trak[with DC-EXX

Implementation]

[+] MOTORINGAC KW

[-] REGENERATINGAC KW

      S      Y      N      C

      F      I      E      L      D

      C      U      R      R      E      N      T

TRADITIONAL

POWER TRAK REGULATORSYNC FIELD CURRENT

VS AC DRAGLINE KW

Rx3i Controller ReferenceShaping

D

PLC Based orDiscreteWATT

 TRANSDUCER

SM1SM2

Trail Cable

Voltage

6.6 kv Nom

AUXLoads

Nom 435

Rx3iController

T h   yr i   t   e

T   y  pi    c  al   

 9 Wx

2  0 H

X 1 2 D

 3  0  0 A 

    k    W

    F   e   e    d

    b   a   c    k

[+] KW

    I    f    i   e    l    d

Reference shapingFunction within

Controller

Sync

mot field

 Typical DC-EXX Field controlEach Motor

AC Utility Amps and Volts

CT

PT

 A

C

B

F

E

F

kWkVar

MotoringPower Flow

kWkVar

RegeneratingPower Flow

Trail

Cable

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Enhanced Power Trak Sync Excit at ion System 

Slide 33

Western Mining Electrical Association - November 2009 We Drive Industry

OVERVIEW:

Traditional

System with

 AC kW and or Kvar 

Transducer 

SignalsG

G

MM

SYNCMOT

MGINERTIA

ROTORANGLE

STATOR

KW Transducer

WATT VAR orPower TrakRegulator

Exciter

Sync field

2 sec timeconstant

[+] MOTORING KW

       K       V       A       R

       [   -       ]

B. KW VS KVAR

REGULATOR

[-] REGENER ATING KW

REF SHAPER

UTILITYPOWER

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Enhanced Power Trak Sync Excit at ion System 

Slide 34

Western Mining Electrical Association - November 2009 We Drive Industry

Traditional Sync

Excitation SystemOperation

G

G

MM

SYNC

MOT

MGINERTIA

ROTORANGLE

STATOR

KW Transducer

WATT VAR or

Power TrakRegulator

Exciter

Sync field

2 sec timeconstant

[+] MOTORIN G KW

       K       V       A       R

       [   -       ]

B. KW VS KVAR

REGULATOR

[-] REGENERATI NG KW

REF SHAPER

UTILITYPOWER

1. Load Change [A Rock]

2. Torque on Motor & Gen

3. Delay from MG inertia

4. Torque angle increase

on sync5. AC Line torque [real]

amps increases

6. Watt Transducercreates kw signal

7. Ref shaper create ref 

8. Regulator9. Exciter creates field

volts

10.Field amps increases

11.Torque angle shrinks

1. BIGRock!

2. Torque

4. IncreaseTorque Ang le

7. Ref 

Shaper 

3. Delay

5. Torque Amps

8.Regulator 

6. KWSignal

9. VoltageOutput

10. Field Amps

11. ReduceTorque Angle

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Enhanced Power Trak Sync Excit at ion System 

Slide 35

Western Mining Electrical Association - November 2009 We Drive Industry

Traditional Power Trak System Limitations• Inherent delays in feedback quantities

themselvesAC kw is a response to digging loads after MG

inertiaAC kW changes AFTER need for more excitation

• Transducers are slow• Allows more rotor movement and increases

chance of 2 Hz trouble

• A 2 Hz AC kW component shows up on fieldcurrent reference!

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Enhanced Power Trak Sync Excit at ion System 

Slide 36

Western Mining Electrical Association - November 2009 We Drive Industry

Sync SystemDelays

Rotor Angle

 ACPower 

Dig Cycle

DCPower 

 ACVoltage

PitDistrib

Utility

Rotor Angle

 ACPower 

Dig Cycle

DCPower 

 ACVoltage

PitDistrib

Utility

 APPLY FIELDCORRECTION AFTER ACFEEDBACK

 APPLY FIELDCORRECTION ASSOON AS DC KW

CHANGES

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Enhanced Power Trak Sync Excit at ion System 

Slide 37

Western Mining Electrical Association - November 2009 We Drive Industry

G

G

MM

SYNC

MOT

MGINERTIA

ROTORANGLE

STATOR

KW Transducer

WATT VAR or

Power TrakRegulator

Exciter

Sync field

2 sec timeconstant

[+] MOTORIN G KW

       K       V       A       R

       [   -       ]

B. KW VS KVAR

REGULATOR

[-] REGENERATI NG KW

REF SHAPER

UTILITYPOWER

1. BIGRock!

2. Torque

4. IncreaseTorque Ang le

7. Ref 

Shaper 

3. Delay

5. Torque Amps

8.Regulator 

6. KW

Signal

9. VoltageOutput

10. Field Amps

11. ReduceTorque Angle

Improving the“traditional”

system• AC kW shows up

too late!•Inertia slows the

feedback more!

•Torque angle

overshoots•kW transducers

are slow

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Enhanced Power Trak Sync Excit at ion System 

Slide 38

Western Mining Electrical Association - November 2009 We Drive Industry

Details on DC kW Ref Pro-Action Power Trak

[with DC-EXXImplementation]

[+] DC MOTIONPOWER KW

    S    Y    N    C    F    I    E    L    D

    C    U    R    R    E    N    T

ENHANCED POWERTRACK REGULATOR

Rx3i Controller ReferenceShaping

[-] DC MOTIONPOWER KW

SM1SM2

Trail Cable

Voltage

6.6 kv Nom

AUXLoads

Rx3iController

T h   yr i   t   e

T   y  pi    c  al   

 9 W

x

2  0 H

X 1 2 D

 3  0  0 A 

Motion kW

Summation

[+]KW

    I    f    i   e    l    d

Profibus

Syncmotfield

Field Control Sameas SM1

 Typical DC-EXX Field controlEach Motor

Field CurrentReference to

each exciter 

 A

C

D

F

E

F

kWkVar

MotoringPower Flow

kWkVar

RegeneratingPower Flow

Trail

Cable

Utility Source

HoistDC Arm Volts

& Amps

Drag/PropelDC Arm

Volts & Amps

Swing DC ArmVolts & Amps

DC PowerSummation

CT

Aux Watt &Var Trans[option]

AuxKW Bias

PT

Profibus

B

Reference

shaping

Function

within

Controller 

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Enhanced Power Trak Sync Excit at ion System 

Slide 39

Western Mining Electrical Association - November 2009 We Drive Industry

DC V &AmpsIsol

SWING

DC V &AmpsIsol

DRAG

DC V &AmpsIsol

HOIST

Power TrakField CurrentReference

Exciter

Sync field

2 sec timeconstant

RX3i

Prrocessor [<10 ms scan]

PLC Analog I-O& DC Power Calc &

DC KW Summer

[+] DC MOT IONPOWER KW

      S      Y      N      C

      F      I      E      L      D

      C      U      R      R      E      N      T

ENHANCED POWER

TRACK REGULATOR

Rx3i Controller Reference

Shaping

[-] DC MOTIONPOWER KW

OVERVIEW:

Power Trak

Excitation

System with DCKw Reference –

ProAction

G

M M

100 mVshunt

G

SYNCMOT

MG

INERTIA

ROTOR

ANGLE

STATOR

UTILITY

POWER

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Enhanced Power Trak Sync Excit at ion System 

Slide 40

Western Mining Electrical Association - November 2009 We Drive Industry

DC V &AmpsIsol

SWING

DC V &AmpsIsol

DRAG

DC V &AmpsIsol

HOIST

Power TrakField CurrentReference

Exciter

Sync field

2 sec timeconstant

RX3i

Prrocessor [<10 ms scan]

PLC Analog I-O& DC Power Calc &

DC KW Summer

[+] DC MOT IONPOWER KW

      S      Y      N      C

      F      I      E      L      D

      C      U      R      R      E      N      T

ENHANCED POWER

TRACK REGULATOR

Rx3i Controller Reference

Shaping

[-] DC MOTIONPOWER KW

Power Trak

ProAction SystemOperation

1. Load Change [A Rock!]

2. Torque on Motor & Gen

3. Armature amps & voltsfeedback

4. PLC Calcs & Sums allDC kW

5. Ref shaper creates fieldamps reference

6. Exciter applies fieldvolts

7. Field amps increases8. Torque angle minimized

G

M M

100 mVshunt

G

SYNCMOT

MG

INERTIA

ROTOR

ANGLE

STATOR

UTILITY

POWER

1. BIGRock!

2. Torque

8. Torque Angle

5. Ref Shaper 

7. Field Amps

3. Arm V& Amps

4. PLCCalc &Sum

6. FieldVolts

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Enhanced Power Trak Sync Excit at ion System 

Slide 41

Western Mining Electrical Association - November 2009 We Drive Industry

Summary of Benefits fromChanges

• Take field strength action based onreal digging load – pro-actively

• Eliminate delays frominertia, ACkW feedback.

• Reduce voltage swings atAC feed

or upstream.

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Enhanced Power Trak Sync Excit at ion System 

Slide 42

Western Mining Electrical Association - November 2009 We Drive Industry

Example Performance Traces

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Enhanced Power Trak Sync Excit at ion System 

Slide 43

Western Mining Electrical Association - November 2009 We Drive Industry

Case 1: Watt-Var SystemPartial Step of Replacing AC Kw

Reference with Total DC kW

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Enhanced Power Trak Sync Excit at ion System 

Slide 44

Western Mining Electrical Association - November 2009 We Drive Industry

Case 1: Watt-Var System on 4 Set Machine

“BEFORE”

• Watt-Var regulator• Existing DL with 4

sets, two exciters• Two different Sync

motors• 2nd exciter slave to first• Two Hz Swings

HUGE: even causedtrips

• Tune-ups did not fixproblem

 Thyristor Non-Reversing

Plugging Exciter

435 VAC3-ph

 T1

300 - 550VDC

 Thyristor Non-Reversing

Plugging Exciter

 T2

300 - 550VDC

Master

Slave

SyncMotor

#1 & #2

Fields

Sync

Motor#3 & #4Fields

435 VAC3-ph

[+]MOTORING KW

      K      V      A      R

      [   -      ]

B. KW VS KVARREGULATOR

[-]REGENERATING KW

Field CurrFollower Ref 

AC Kw

AC KVAr

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Enhanced Power Trak Sync Excit at ion System 

Slide 45

Western Mining Electrical Association - November 2009 We Drive Industry

•Red trace = Totalmachine kW

•Two Hz ringing onAC kW is about 8MW peak to peak!

•Blue Trace = TotalDC kW

Case 1: Watt-Var System on 4 Set Machine

“BEFORE”

DRE03 June 2008

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Enhanced Power Trak Sync Excit at ion System 

Slide 46

Western Mining Electrical Association - November 2009 We Drive Industry

Case 1: Watt-Var System on4 Set Machine

“ AFTER”

• 2nd exciter still slave tofirst

• Configuration set upwith DC Motion kWreplacing AC kW

• Rest of Watt-Var

regulator stayed thesame

 Thyristor Non-

ReversingPlugging Exciter

435 VAC3-ph

 T1

300 - 550VDC

 Thyristor Non-Reversing

Plugging Exciter

 T2

300 - 550VDC

Master

Slave

SyncMotor

#1 & #2

Fields

Sync

Motor#3 & #4Fields

435 VAC3-ph

[+]MOTOR INGKW

    K    V    A

    R    [  -    ]

B. KW VS KVAR

REGULATOR

[-]REGENERATING KW

Field CurrFollower Ref 

AC KVAr

DC V &

AmpsIsol

SWING

DC V &Amps

Isol

DRAG

DC V &

AmpsIsol

HOIST

PLC Analog I -O

& DC Power Calc &DC KW Summer

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Enhanced Power Trak Sync Excit at ion System 

Slide 47

Western Mining Electrical Association - November 2009 We Drive Industry

Case 1: Watt-Var System on 4 Set Machine“ AFTER” – DC Power Reference Components

 AC Vol ts22.4 kv +/- 500 v

DragDC kW

SwingDC kW

HoistDC kW

Total

DC kW

•DC kW reference issum of each motionDC power

•Heavy double-traces are MG ACkw with slight 2-Hzringing

•DL trail cable volts+/- 2.5% - good!

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Enhanced Power Trak Sync Excit at ion System 

Slide 48

Western Mining Electrical Association - November 2009 We Drive Industry

Case 1: Watt-Var System on 4 Set Machine

“ AFTER”

•Red trace = Totalmachine kW

•Blue Trace = TotalDC Motion kW

•Green Trace = TotalMachine KVAR

•Two Hz ringing onkW and KVAR isessentially gone.

DRE03 June 2008

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Enhanced Power Trak Sync Excit at ion System 

Slide 49

Western Mining Electrical Association - November 2009 We Drive Industry

Case 2: Power Trak Plus Pro-action

SystemReplacing AC Kw Reference

with Total DC kW vsSync Field Current Function

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Enhanced Power Trak Sync Excit at ion System 

Slide 50

Western Mining Electrical Association - November 2009 We Drive Industry

Hoist Amps

HoistVolts

Drag Amps

DragVolts

Swing Amps

Swing

Volts

 ACWatts

 ACVARS

•Traces are of loopamps and volts, all 3motions

•Volts and amps aremultiplied and added togive DC Motion kW

•Total Machine AC kWand KVAR shown

•AC kW used for field

reference•Two Hz ringing on both

kW and KVAR

Power Trak Pro Action Power Traces

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Enhanced Power Trak Sync Excit at ion System 

Slide 51

Western Mining Electrical Association - November 2009 We Drive Industry

DC Machine kW vs Sync Field Amps ReferenceTotalDC kW

SyncField Ref 

      3      5      5      0

200

100

      7      1      0      0

   -      3      5      0      0

      8      8      7      5

   F   i  e   l   d   A  m  p  s   R  e   f

Total DC kW [+]Total DC kW [-]

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Enhanced Power Trak Sync Excit at ion System 

Slide 52

Western Mining Electrical Association - November 2009 We Drive Industry

Actual Field Current Feedbacks Two Field Sync System

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Enhanced Power Trak Sync Excit at ion System 

Slide 53

Western Mining Electrical Association - November 2009 We Drive Industry

Effect of Changing From AC to DC kW Sync Reference Input

 AC Watts[Not used as ref!]

DC TotalWatts Ref 

DC Field AC kVAR

•Top trace is DC MotionkW – sync field ref 

•Total Machine AC kWshows 2-Hz ringing

•Switching to DC kW forPower Trak Ref:

 Two Hz ringing on KVARcompletely gone

•AC line volts at DL morestable – pit feed is 2.5:1

reactive•AC line volts at utility

muchmore stable – pitfeed is highly [6:1] reactive

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Enhanced Power Trak Sync Excit at ion System 

Slide 54

Western Mining Electrical Association - November 2009 We Drive Industry

Example Calc of Voltage Swing

• 30% kw swing • 30% kVAR swing

•Power delivery Equation:Es2 = Er2 +I2{R2 + X2}+ 2{PR + QX}

LOAD

XErEs R

I, P, Q .

“ TYPICAL” DL FEED Zpu = .06 + j0.16

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Enhanced Power Trak Sync Excit at ion System 

Slide 55

Western Mining Electrical Association - November 2009 We Drive Industry

DifferentSystem: Ehsham#1

 AC DLWatts[Red]

DC TotalWatts Ref [Gray]

•Top [grey] trace is DCMotion kW

•AC Aux Power [fans, etc]

is added to DC kW asoffset

•DC kW + Offset is inputto sync field function gen

•Total Machine AC kW[red] trace – NO 2 Hzringing

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Enhanced Power Trak Sync Excit at ion System 

Slide 56

Western Mining Electrical Association - November 2009 We Drive Industry

DC kW and Sync Field Ref For Ehsham#1•Multiple DL Cycles

•Grey trace is DC Motion kW,used as sync field reference

•Red trace – total DL kVAR

•kVAR compensation followsfunction in PLC regulator.

•Min field for low kW andregen modes

DC TotalWatts Ref 

 AC kVAR

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Enhanced Power Trak Sync Excit at ion System 

Slide 57

Western Mining Electrical Association - November 2009 We Drive Industry

 Total System Performance – Ehsham#1

•Multiple DL Cycles

•DC Motion kW with ACaux offset used as sync

field reference

•AC kW shows NOstimulation of MG 2 Hzoscillation

•Line volts held to +/-300 volts out of 6600

volts: good!

 AC kW

DC kW[w AC Offset]

Sync FieldRef 

 AC Vol tsIncoming

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Enhanced Power Trak Sync Excit at ion System 

Slide 58

Western Mining Electrical Association - November 2009 We Drive Industry

Power Trak ProAction Regulator  Take field strength action based on

real digging load – pro-actively

Sum of DC Motion kw used asreference

Reduces stimulation of 2 – 3 HzSync-MG oscillations

More accurate VAR control

Eliminate kW and Var transducer

Optional long term [10 minute T.C.]integration of actual variations insystem – to compensate forchanges

Faster response to match sync fieldstrength to digging needs

Eliminate delays from inertia, AC kWfeedback.

Better operation & less impact onmine and utility

Reduce voltage swings at AC feed orupstream

Reduce parts count

Adapt to changing utility or pitconfiguration

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Enhanced Power Trak Sync Excit at ion System 

Slide 59

W Mi i El i l A i i N b 2009 W D i I d

 Thanks!

Office Location:

TM GE Automation Systems, LLC

1325 Electric Road Roanoke, VA 24018 [Office]2060 Cook Drive Salem VA, 24153 [Mailing]

USA

 TEL: +1-540-283-2000; FAX: +1-540-3283-2005www.tmeicge.com