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ABB Machine with
Variable Speed Drive
Business Unit - Machines

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Content
What is VSD
Machines with VSD
Design
Feature
Benefits
EX- motors with VSD
Electrical protection
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What is a Variable Speed Drive (VSD)?
The most efficient way to control
the process is to control the
speed, and the most efficient way
to control the speed is to use an
electric variable speed drive
a frequency converter
A VSD controls the speed, torque
or power on the shaft of an
electric motor by converting the
fixed voltage, fixed frequency at
the network, into a variable
voltage, variable frequency on the
output to the motor
In this way the drive can control
the variables of a process, such
as flow, by controlling the speed
of a pump
ACS 5000 VSI-MF topology
Converter
Converter with integrated input transformer
ACS 5000 VSI-MF topology

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Why variable speed drives?
60 - 65% of industrial electrical energy is consumed by electric
motors
For each 1 USD spent to purchase a motor, 100 USD are spent for
energy cost during its lifetime
Today, only 5% of these motors are controlled by variable speed
drives
30% of existing motors can be retrofitted with variable speed drives
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The installed base of ABB drives saves more than 120 TWh
of energy per year, the equivalent of 15 nuclear power plants.
ABB drives reduce CO
2
emissions by approx. 60 million tons per year.

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T T
n n
P P T T
n n
n n
T T
Typical applications
Pumps
Quadratic load
Compressor
Quadratic or
constant torque
Extruders
Constant torque

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VSD system
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What is a VSD system?
4 4 2 2 3 3
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1 1
The application (1), driven by a drive system, can be a pump, a
compressor, an extruder
A motor (2) is needed to drive it.
The most efficient way to control the process is to control the speed, and
the most efficient way to control the speed is to use an electric variable
speed drive a frequency converter (3).
A transformer (4) is usually necessary to adapt to the network and to
isolate the network and drive or to relieve the motor from common mode
voltages.

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Benefits of VSD system control
Energy savings
Improved product quality
through better process control
Reduced process equipment
wear and longer lifetime of
equipment
Soft start and stop reduce
waste and save raw material
Noise reduction
Improved process efficiency
time
speed
Soft Start
Production rise
Energy saving
Best quality

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Critical parts of Motor designs for VSD
application
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Rotor design for VSD system
Strong construction
Rotor bars mechanical locking
Welded or brazed joint for end
rings
Balancing
Two-plane dynamic method
Nominal speed
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Rotor design for VSD system - Critical speed
20 % safety marginal needed
Stiff shaft design move critical
speed above normal speed
range
Benefit; hole speed range
can be used
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[
m
m
/
s
]Critical
speed
Speed range in
VFD operation
6000 4000 2000
Rotation speed [rpm]
5,0
4,0
3,0
2,0
1,0
0,0

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Stator design for VSD system
Factors affecting the design of
insulation systems:
Electrical stress
Voltage peaks
Thermal stress
Higher temperature rice
Solid Insulation system
A proven system with the origin
more than 30 years back and tens
of thousands of machines
successfully in use by customers
all over the world (Midacur)
Dedicated design tools
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Bearings design in vsd system
Bearing currents
The VSD might generate high
frequency current in the bearings
Bearing current might create
sparks in the bearings and
outside the frame
Sparks may damage the
bearings, lubrication or they can
ignite explosive gas around the
motor
ABB prevent that phenomena
Bearing insulation
N-end insulation
Both side insulation + grounding
cable in D-end
Worst conditions for the test
Hybrid bearings
Spark test
apparatus
No ignition
acc. to
EN 50020
Shaft
Insulated bearing Motor frame

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Cooling
Force ventilated cooling
Constant torque for hole speed
range
Available for all machines
types
IC 416
IC616/IC666
IC86W

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Ex Motors with Converter supply
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Ex Safety with motors fed by VSDs
Electrical protection
Sparks
Bearing current
Stator insulation
Terminal box
Thermal sensor for electrical
overload protection
Surface temperature
protection
Dimensioning
Thermal sensor for surface
temperature
VSD current limit

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Ex Motors with Converter supply
Generic requirements
(IEC 60079-0/EN 50014ATEX 95)
No requirements
Installation rules
(IEC/EN 60079-14ATEX 137)
TT supply:
A residual current device shall be used
IT supply:
An insulation monitoring device shall be
provided to indicate the first earth fault
Protection devices:
Short-circuit and earth-fault protection
devices shall prevent auto-reclosing
under fault conditions
Isolation:
To allow work to be carried out safely,
isolation (for example isolators, fuses and
links) shall be provided
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Ex Motors with Converter supply
Maintenance
(IEC/EN 60079-17ATEX 137)
An initial inspection.
During operation either
a) regular periodic inspections
(the interval of three years), or
b) continuous supervision by
skilled personnel
A history of maintenance
activities
Isolating all incoming
connections. (Isolation can be
implemented by withdrawal of
fuses and links or the locking off
of an isolator or switch)
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Ex motors with converter supply / requirements
Installation Requirements / ATEX 137 Product Requirements / ATEX 95 Protection
EN / IEC 60079 -14
The combination shall be tested as a unit with
the associated protective device.
To prevent any over-voltage spikes and higher
temperatures in the motor and bearing currents.
EN 50019 / IEC 60079 -7
The combination shall be tested as
a unit with the associated protective
device.
e
Increased
Safety
EN / IEC 60079 -14
To prevent any over-voltage spikes and
higher temperatures in the motor.
EN 50021 / IEC 60079 -15
The motors shall be tested for this
duty with the converter specified.
In exceptional cases the
temperature class may be
determined by calculation.
n
Non Sparking
2.4 Explosion protection measures
equipment,and any associated connecting
devices must only be brought into service if the
explosion protection document indicates that
they can be safely used in an explosive
atmosphere.
EN/ IEC 60079-0/EN 50014
Precaution shall be taken to guard
against any effect due to the
presence of circulating currents
Minimum
requirements
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Ex motors with converter supply / requirements
Installation Requirements / ATEX 137 Product Requirements / ATEX 95 Protection
EN 50281-1-2
The IP65 protection seals shall be inspected on a
regular scheduled basis, the period of which will
depend on the general environment, the amount of use
and the manufacturers recommendations.
EN 50281-1-1
Temperature rise shall be measured using
U
nom
+/- 5%.
DIP
Dust Ignition
Proof
EN / IEC 60079-14 10.5
a) Either a direct temperature control by embedded
temperature sensors or other effective measures. The
action of the protective device shall be to cause the
motor to be disconnected. The motor and converter
combination does not need to be tested together; or
b) the motor shall have been type-tested for this duty
as a unit in association with the converter and with the
protective device provided.
EN 50018 / IEC 60079 1
No specific requirements
NB Clarification sheet 00/02/059/CS
The combination shall be design and tested always as
a unit with converter parameters listed, or direct
thermal protection with sufficient margin to protect
bearings or rotor.
Analysis of converter control electronic according to
IEC 61508 or duplication of protection.
d
Flame Proof
EN / IEC 60079-14
No specific requirements.
EN 50016 / IEC 60079 -2
The safety of the combination shall be shown by
calculations or other measures. The operational speed
range must determine the position and pressurisation
of the minimum pressure point within the enclosure.
Electronic safety control equipment must be certified or
duplicated two independent faults.
p
Pressurized
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End user has several possibilities such
as, and not limited to, examples
below:
Select ATEX certified packages of
motor and associated converter
The Motor vendor shall issue the
Declaration of Conformity according to
ATEX 95
Buy a complete machine which is itself
certified as an ATEX equipment
The Machine vendor shall issue the
Declaration of Conformity by according
to its own ATEX 95 requirements
Proceed to the compliance with the
Minimum requirements of the
ATEX 137
The whole unit is the certified as a
work place
Solutions for Motors with Converter supply
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References
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MEGADRIVE-LCI
Ormen Lange, Norway
Compressor drives
Worlds longest export pipeline
Motor power 3 x 48 MW
Project
Example
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Reference Case 1
Variable Speed Control of Oil Pump
Project : Ras Tanura, KSA
End customer : Aramco
Driven equipment : Oil pump
Drive System : 2 x 4500kW, 4 kV
Speed : 3600 RPM (30-105%)
Application : Shipping pumps
Order received: December 1999
First adjustable speed drive for Aramco, KSA

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Reference case 2
KOC Crude Oil Export Pumps
3 * ACS5000 13,000 kW each
Scope to ABB, Transformers VSDs Chillers, project
management
Sold to Sulzer UK (EPC Hyundai)
Ras Laffan, Qatar
18 * ACS6000 7,500 kW each.
Scope to ABB Transformers, Drives, Motors and Pump Control
Panels
k+
Slide 25
k4 Ras laffan is WWW case ?
Juha.Kytaja@fi.abb.com, 5f19f2007

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References Oil, Gas and Petrochemicals
Pump
Soft-starter
Gas compression
Agitator
Pump
Extruder
Pump
Pump
Extruder
Compressor
Compressor
Extruder
Compressor
Soft-starter
Extruder
Segment
2
2
6
2
2
2
5
4
4
1
2
1
4
3
2
Motor
10,60
15,00
95,82
4,30
1,90
10,00
3,00
3,80
6,20
4,25
9,50
5,35
23,80
29,63
2,40
Total
(MW)
5 300
7 500
15 970
2 150
950
5 000
600
950
1550
4250
4750
5 350
5 950
9 875
1200
Power
(kW)
F-Conventer Application Project name Country
ACS 1000 Oil & Gas Ras Tanura SA
LCI.SO Oil & Gas Yanbu SA
LCI.DR Oil & Gas Ras Laffan QA
ACS 1000 Petrochemicals LG Oman PP OM
ACS 1000 Oil & Gas Huwaila AE
ACS 1000 Petrochemicals Sidpec Petrochemical EG
ACS 1000 Oil & Gas Bangestan NISOC IR
ACS 1000 Oil & Gas MHI ADCO AE
ACS 1000 Petrochemicals Petrokemiya SA
ACS 1000 Oil & Gas AMOC Lube Oil EG
ACS 1000 Oil & Gas GSI ST
ACS 1000 Petrochemicals JSW Arak HDP IR
ACS 1000 Oil & Gas South Pars IR
LCI.SO Oil & Gas Darquiain Oil Filed IR
ACS 1000i Oil & Gas Sabic Sharg SA

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ABB benefits
Operating applications at variable speed has advantages
which can have a direct impact on a companys profits
Energy savings
Improved process control
One supplier
Better product quality
Less stress on equipmentreduced maintenance cost
Elimination of mechanical equipment (e.g. valves, gearboxes)
Smooth start up of motors/generators

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Sparks / Bearing Current
Phenomena Description
The VSD might generate high
frequency current in the bearings
Bearing current might create sparks
in the bearings and outside the
frame
Sparks may damage the bearings,
lubrication or they can ignite
explosive gas around the motor
ABB documents indicates how to
prevent that phenomena
Bearing insulation
Cabling, grounding
Filtering
ABB test results
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Stator insulation
Safe voltage peaks
Orange curve is valid for ABB Form wound low voltage machines
MV Drives and sparks tests & studies to check that they are not causing sparks
or aging due to high risk of PDs.
Limiting curves for impulse peak voltage in frequency
converter operation, phase-to-phase at motor
0,80
1,00
1,20
1,40
1,60
1,80
2,00
2,20
0,00 0,20 0,40 0,60 0,80 1,00 1,20
Rise time 10-90 %, s
IEC TS 60034-17
IEC TS 60034-25 A
IEC TS 60034-25 B
ABB Special Insul.
Limiting curves for impulse peak voltage in frequency
converter operation, phase-to-phase at motor
0,80
1,00
1,20
1,40
1,60
1,80
2,00
2,20
0,00 0,20 0,40 0,60 0,80 1,00 1,20
Rise time 10-90 %, s
IEC TS 60034-17
IEC TS 60034-25 A
IEC TS 60034-25 B
ABB Special Insul.
ABB
Form
wound
ABB
Form
wound