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Lci Brochure
Lci Brochure
Large adjustable-speed
synchronous motor drives
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MEGADRIVE-LCI system
Inverter
Thyristors in the inverter electronically switch 12-pulse circuit
the DC current such as to produce a three- To minimise both the harmonic
phase AC system of variable frequency and influence of the drive on the supply
voltage for supplying the motor. The design system and the ripple on the motor
of the inverter is basically the same as that of torque, rectifier and inverter normally
the rectifier with the exception that the inverter operate in a 12-pulse mode. This
phase currents are commutated by the motor technique eliminates harmonics of
voltage. An inverter of this type is referred to the series 5th, 7th, 17th and 19th etc.
as a load-commutated inverter (LCI). At very A synchronous motor for this kind of
low speeds (0…5 % of rated speed), the operation is equipped with two sets of
motor voltage is too low to guarantee reliable windings electrically displaced by 30°.
commutation and pulse mode commutation Similarly, the supply transformer also
has to be employed. has two secondary windings shifted
by 30°.
World-wide references
ABB has installed more than 150 installed to transport natural gas. Another
MEGADRIVE-LCI units with a total power of noteworthy project was for a converter-fed
1140 MW for applications in power plants, high-speed synchronous motor (14 MW at
the oil, gas and chemical industries, in water 6,400 rpm) to replace a steam turbine driving
pumping stations and in test bays. For the a five-stage compressor in an ethylene
most part, they are driving compressors, production plant in Italy.
blowers, pumps and extruders efficiently and Over 50 of the units supplied for driving
reliably under extremely adverse ambient boiler feed pumps in electricity power plants
conditions (corrosive atmospheres) or in and operate in the high-speed range up to
hazardous areas (oil platforms etc.). The 6000 rpm. They have ratings between 3 MW
largest drives supplied up to the present and 15 MW.
were for a hydroelectric power plant in the These together with approximately 360 LCI.ST
PR of China (pump rated at 60 MW) and for units supplied for soft start of synchronous
the Troll project in Norway, where five com- machines, make ABB a leading supplier of
pressor drives each with a rating of 41 MW this kind of drive technology.
and a maximum speed of 3750 rpm are
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Design and function
of the MEGADRIVE-LCI
control system
Structure
As can be seen from the block diagram
below, the control system is divided into three
parts for:
• interface modules
• programmable controller
• standard modules
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Closed-loop control
Speed controller
The speed controller (1) and the current
controller (2) form a conventional cascade
feedback circuit. The speed controller provides
the current controller with the set-point value
necessary to attain and maintain the required
speed. It may be assumed that the torque
developed by the motor is approximately
proportional to the motor current, flux and
power factor. Thus the current controller
indirectly adjusts the torque exerted on the
shaft of the motor by varying the DC voltage
at the output of the line converter.
ß angle control
ß angle control (3) is a forward control
function which determines the instant of firing
Communication and interfaces of the thyristors in the machine converter. The
The programmable high-speed controller angel ß is adjusted as a function of current and
communicates with the other control speed such as to ensure correct commutation
system modules via a parallel bus capable of the inverter.
of transferring the control function data at
the required rate. Communication with other Voltage controller
units of the drive and with any higher level The voltage controller (4) and the current
control system or remote control centres controller (5) also form a conventional cascade
takes place via corresponding interfaces feedback circuit. The voltage controller provides
controlling either parallel or fast serial links. the excitation current controller with the set-
point value it needs to attain and maintain
the required voltage at the motor terminals.
The ability to ride through Basically, the motor voltage is adjusted in
short supply interruptions is proportion to the motor speed which is
one of the most important equivalent to maintaining the motor flux at its
features of MEGADRIVE-LCI rated value. The current controller (5) adjusts
Usually, your process just carries the current of the brushless exciter by varying
on without noticing anything. its stator voltage via a three-phase AC controller.
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Protection and diagnostics
Reliability is a must!
Reliability and availability are of the utmost Also components are conservatively rated and more than adequate
importance in power plants and industrial safety margins are allowed.
processes. As a leading supplier of drive Where appropriate, functions are physically isolated from each
systems, ABB achieves the highest reliability other in the interest of greater reliability.
by ensuring that it complies with the quality
standards and procedures specified in ISO A special design feature of MEGADRIVE-LCI is its ability to ride
9001. Tests are performed at various stages through brief supply interruptions so that in most cases they pass
during production in addition to the extensive unnoticed by the process. Should the drive fail in spite of all these
final tests (heat run, combined, and burn-in precautions, fault location and corrective action are made easy by
tests are conducted on request). Redundancy the failure indication system which points to the precise component.
of crucial components (e.g. cooling pump or Attention has also been paid to the simple replacement of all
fan and essential parts of the control system) components,units and assemblies. For example, a thyristor can be
can be provided which enormously increases replaced without having to interrupt the cooling water circuit. All the
reliability and availability while enabling measures incorporated should achieve repair times of just minutes
maintenance intervals to be extended to and an MTBF of more than 4 years.
4 years and more.
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Applications
Boiler
feed pumps
in a thermal power
plant driven by
MEGADRIVE-LCI
Continuous rating :
10 MW, 500 … 5222 rpm
Short-time rating:
13 MW, 5700 rpm
Compressor hall
with 3 reciprocating
compressors
equipped with
MEGADRIVE-LCI in a
natural gas pumping
station
Speed range:
0 … 375 rpm
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Applications
Polyethylene
extruder drive
with
MEGADRIVE-LCI
Continuous rating :
5.5 MW
Speed range:
120 … 1185 rpm
Wire
block drive
with
MEGADRIVE-LCI
Continuous rating:
5 MW
Speed range:
900 … 1500 rpm
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Converter design and cooling
Water-cooled
MEGADRIVE-LCI
Rated power: 5 MW
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Efficient cooling means
higher reliability
Air-cooling Air-cooled
MEGADRIVE-LCI driving
• Open-circuit: a boiler feed pump in a
Fans force the cooling air through the nuclear power plant
thyristor heat sinks. Rated power: 3.4 MW
This method is suitable in plants with Operating
clean air conditions. mode: 12/12-pulse
• Closed-circuit:
The cooling air circulates in a closed
circuit inside the converter cubicles. The
air in the closed cooling circuit is cooled
by an air-to-air or air-to-water heat
exchanger.
This method is necessary in plants with
dusty and/or aggressive atmospheres.
The advantages of air cooling are:
• simplicity
• overload capability for short duty cycles
• permits converters to be installed where
cooling water is not available.
Water-cooling
Deionised water flows in a closed-circuit Water-cooled
MEGADRIVE-LCI driving a
through the thyristor heat sinks and around
natural gas compressor
the snubber circuit resistors and is cooled by
Rated power: 41 MW
either a water-to-water or water-to-air heat
Operating
exchanger. This method is necessary for high- mode: 12/12-pulse
power applications and in plants with dusty
and/or aggressive atmospheres. Circulation
pump, monitoring devices for flow, temperature
and conductivity are part of the converter
assembly. No cooling water pipes have to be
disconnected or drained in order to replace
a thyristor. Walk-in outdoor enclosure
for two MEGADRIVE – LCI’s
driving boiler feed pumps in
The advantages of water cooling are: a power plant
• space-saving layout
• losses easily conveyed from control room Walk-in enclosure
• higher ambient temperature permissible For outdoor erection, the converter complete
• less noise with auxiliaries, switchgear, reactors and air-
• fully enclosed cubicle with protection conditioning plant can be installed in a fully
class up to IP55 (protection against dust sealed enclosure which can be supplied for
and splash water) for noise reduction and varying severities of ambient conditions.
severe ambient conditions available All components are wired and the system
tested at the works prior to delivery which
considerably reduces the time required for
erection and commissioning on site.
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High-speed synchronous motor drives
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Motor design
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MEGADRIVE-LCI.ST
Starter for synchronous machines
Main features
Starting a large synchronous machine on-line • starting current limited to the rated
can prove problematical either because of machine current or less
the inrush current or because of the thermal • provides facility for braking the machine
stress at hot spots on the rotor surface while • sequential starting of several machines
running up. These problems can be overcome possible with a single soft starter
with the aid of solid-state «soft» starting • microprocessor control system
equipment which for this reason is being used
in an increasing number of applications. Technical data
Typical power range: 2 … 80 MW
Maximum speed: 3600 rpm (+5 %)
Output frequency: 0…60 Hz (+5 %)
Operation
The synchronous machine is started with
a variable frequency by the converter in
the same way as a converter-fed variable
speed motor (see MEGADRIVE - LCI). At
rated speed, the machine is automatically
synchronised to the power system and the
circuit-breaker for direct connection to the
supply is closed. The motor is excited from
standstill.
Typical applications
Starting of
• gas turbines
• synchronous compensators
• refiner motors
• motor/generators in pump storage
power plants
• large compressors and blowers for:
chemical processes
wind tunnels
blast furnaces
References
World-wide, ABB has installed more than
360 solid-state converters as starters with
ratings between 1 MW and 60 MW. These
are in use in a variety of applications and
the technique has proved highly reliable for
over 20 years.
Gas turbine starting
converter Type LCI.ST 3.8
Rated power: 3.8 MW
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MEGADRIVE-LCI.ST
MEGADRIVE-LCI.ST
Solid-state frequency converter
for starting motor/generator sets
in pump storage power plants
Rated power: 24 MW
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Engineering a MEGADRIVE-LCI-system
A MEGADRIVE
system – the
total solution
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Standard converter types
Motor design criteria
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MEGADRIVE-LCI under test
Back-to-back testing of
two high-speed (6000 rpm)
10 MW MEGADRIVE-LCI
drives at ABB’s motor works
at Birr in Switzerland.
The associated converter
cubicles and supply
transformers can be seen
behind the two motors.
Combined tests efficiency of the item concerned (segregated
For newly developed systems or at the loss method).
customer's request, the frequency converter
is tested in combination with a motor at the Special and performance tests
works to verify its performance and that it At the customer’s request, special tests on the
conforms to the design data. complete drive system can be carried out to
check the noise level, short-circuit capability,
Large units are tested «back-to-back»
electromagnetic compatibility (EMC) etc.
(see picture above), i.e. one converter/motor
combination drives a similar combination in
a generation mode. ABB has adequate
Routine tests
Every component or sub-system of a drive
Routine testing of a facilities to perform all these tests.
frequency converter.
is tested as part of the normal production
process. They are carried out in accordance
Load tests
with international standards (e.g. IEC) and
Major components,
ABB quality assurance procedures (ISO 9001).
sub-systems or the
complete drive are
Every component of a drive is subjected
tested on load to
to thorough testing to verify that quality
verify power or
standards and customer requirements are
current output at
fully met. Routine tests and functional tests
rated and overload
form an integral part of the scope of supply
operating points
of a MEGADRIVE system. Where additional
under defined
tests such as load tests, combined tests or
cooling conditions.
special tests are considered necessary,
If desired these tests
they should be agreed as early as possible.
can also verify the
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At your service… ABB after-sales
Training
On-site training in the operation and mainte-
nance of MEGADRIVE equipment is provided
by the people who know it best – our service
engineers. Training courses are also held at our
engineering centres in Switzerland, Finland
and other countries throughout the world.
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MEGADRIVE-LCI – Scope of Supply
* optional
Request information on other adjustable speed drives and further information on the
MEGADRIVE series from your local ABB company or agent.
Printed in Switzerland (1203-1000-0)