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Overland Conveyor
Change in Market demand
Environmental friendly transport of material Increased length e.g. concentrator plant on lower altitudes Increased length reduce number of flights and transfer stations Higher conveying capacity
Gear power for angular gears limited to approx. 3000 kW @ ~ 70 min-1 New drive concept with new equipment needed
Overland Conveyor
Conventional Drive Configuration
Pulley 1 (twin drive) 2 x 1045 kW, 1793 min-1, 4kV Coupling Brake Angular Gearbox Pulley with antifriction bearings Frequency Converter ACS1000
Pulley 2 (single drive) 1 x 1045 kW, 1793 min-1, 4kV Coupling Brake Angular Gearbox Pulley with antifriction bearings Frequency Converter ACS1000
Overland Conveyor
Change to gear- & bearing-less drive solution
Overland Conveyor
Longer belts with higher capacity
Gearless Drives
New Drive Configuration allows a equipment reduction by 50%, means only one:
Driven Motor shaft per pulley Motor, Frequency Converter, Transformer, MV-breaker in case of single drives per pulley or smaller Multidrive system.
New Drive Configuration allows a component reduction of 50%, means only one:
Driven Motor shaft per pulley Motor, Frequency Converter, Transformer, MV-breaker in case of single drives per pulley or smaller Multidrive system. Max. belt tension might be higher (to be checked for each project)
Tail: 1 x 2500 kW
Tail: 1 x 5000 kW
Head: 2 x 5000 kW
Avoiding limiting Gears (max.3 MW), the new Gearless Drive Configuration allows:
Longer Overland Conveyors due to new Belt and Reduction of number of Flights and Transfer-Stations
Maintenance
Gear Reducer
Gear reducers: - limited to ~ 3 MW - intensive maintenance required - life time ~ 10 years The bearings of the gear reducer (failures on input bearings are most common) have a life time of down to 3 - 4 years. The change of the bearings is linked to a major overhaul. High focus on lubrication is required. Common issues: - Water contamination - Inadequate oil supply to individual bearings - Defective or unsuitable shaft seals The life time of gear reducers of approx. 10 years are not matching the life time expectations of the conveyor and need to be replaced.
Motor 1
Motor 2
Benefits:
2 main wear & tear parts MTBF > 30 Years
(MTBF = Mean Time Between Failures)
Load
2.5 MW
2.5 MW
High efficiency
Motor 1
5 MW
Load
Preferred solution
Cooling : typical IC37, IC666, IC86W, others on request Protection class up to IP55 PT100s for winding Space heater Speed and position encoder Sole plates, anchor bolts and shim
Make up filters are not accepted due to high dust content in ambient air. Protection class at least IP55 (preferred IP65)
Motor with bearings limited life time of bearings reduced reliability additional supervision for bearing higher Capex & Maintenance Costs larger size and higher weight (transport, crane capacity) longer drive train (higher tendency to oscillations)
Motor without bearings much higher reliability almost maintenance free motor design, means: - excitation-, earthing-brushes & cooling device only Air gap sensors to keep air gap in tolerance no maintenance required on the heavy components
Transportation
After test run motor is dismantled and stator and rotor are mounted on steel supports and enclosed with wooden boxes
Transportation
Rotor inside transportation cage is uncrated and turned to vertical position. Lifting ring is mounted around the rotor at factory.
2300
4600
Efficiency (typical)
System HSS/LSS 2 x 2500 kW / LSS 1 x 5000 kW
Efficiency vs Motor Load (IEC)
2 x 2500kW to 1 x 5000 kW Motor @ 100% speed
98 96
SM 1 x 5000 kW
94
SM 2 x 2500 kW
92 Efficiency [%] 90 88 86 0.3 0.4 0.5 0.6 0.7 Motor Load [T/Tn] 0.8 0.9 1.0 1.1 1.2
VSD with Squirrel Cage (SCIM) + Gear Slip Ring Motor (WRIM) + Gear VSD with Synchronous Motor (SM) VSD with Synchronous Motor (SM)
No load operation example @ 35% of nominal motor load SM Efficiency (5 MW): + 6.2% higher than SCIM + 5.8% higher than WRIM
Operation at nom. conveying capacity Eff. design point for equipment: Over sizing factor: 125 135% approx. 75% of nominal motor load of nominal motor load SM Efficiency (5 MW): + 4.3% higher than SCIM + 4.3% higher than WRIM
Lifecycle Costs
CAPEX (2 x 2.5 MW, 1 x 5.0 MW, 20 years)
High Speed Geared Drive
VSD HSS 2x12-p. VSD HSS 24-p.
2 x 2.5 MW
100 % (142 %)
2 x 2.5 MW
114 % (158 %)
2 x 2.5 MW
146 %
2 x 2.5 MW
133 %
1 x 5.0 MW
96 %
Motor ACS Trafo
Investment Costs
80 % 60 % 40% 20 %
Trafo Trafo Motor ACS Motor ACS ACS ACS
0%
Trafo
Trafo
Investment costs (3-stage gear box, 1 add. Coupling) Investment costs (drive system), Price adder for high efficiency EUR 50000 / 2500 kW Motor Excluding mechanics, foundations & control (not available yet) Gear overhaul or replacement after approx. 10 years operation required
ABB Group September 28, 2012 | Slide 22
2 x 2.5 MW
100 % 100 %
2 x 2.5 MW
101 %
2 x 2.5 MW
97.7 %
2 x 2.5 MW
95.9 %
1 x 5.0 MW
93.1 %
100 % 90 % 80 % 70 %
> 7.0%
Lifecycle Costs
88.2 %
85.9 %
85.9 %
60 % 50 % 40 %
9.8 %
6.6 %
8.0 %
5.8 %
20% 10 %
5.6 %
0%
Investment costs (3-stage gear box, 1 add. Coupling) Investment costs (drive system) Maintenance & Service Costs Operation, Energy Costs (EUR 0.065 / kWh)
ABB Group September 28, 2012 | Slide 23
1.8 %
6%
2%
6%
2%
30 %
100 %
88.2 %
85.7 %
Same drive technology used for mine hoist drive Power demand up to 8000 kW @ 50 min-1 Drive System consisting of: - Synchronous Motor - Frequency Converter ACS6000 - Converter Transformer - Control System - etc.
~ 1000 systems
~ 100 systems
Operation conditions harder compared to conveyor applications: - High number of start / stop cycles - Change from motoric to regenerative operation
Number of overland conveyor with ACS6000 drive installations high speed solution with gear box: 9 drives - 3 ACS6000 Multi-Drive uphill - 1 ACS6000 Multi-Drive downhill Active Front End - 1 ACS6000 Single-Drive uphill 3 x 2 x 2000 kW 3 x 2000 kW 1 x 2000 kW
Other conveyor installations: - 32 projects since the year 2000 with approx. 120 LV- & MV-Drives
Actual Projects
Gear- & Bearing-less Conveyor Drive
Gearless Conveyors with several 12 x 2500 kW Drives Gearless Conveyor with 3 x 7000 kW, Design study with several solutions Power range 2000 kW . 7000 kW
Summary
Gear- & Bearing-less Conveyor Drive
Compact and simple design less space High efficiency, better than induction motor (no slip losses) No gearbox losses Less components less interfaces, engineering, project management and spare parts Drive train free of oscillation Almost maintenance free drive system No gearbox cooling, monitoring, supervision, oil coolers / heaters No back lash during oscillations and at load reversals Less installation and commissioning Higher availability & reliability