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7/30/2019 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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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