61st MEMSA Annual Meeting Update on Conventional and

September 7, 2006
Walter Koellner / SE&A Gearless Drive Systems
Mark Johnston / Bucyrus International for Draglines

Industrial Solutions and Services

Your Success is Our Goal
Table of Content

„ History and Barriers for Static Dragline Drive Systems W

„ Major Components – Motors, AFEs, Inverters W

„ Power Factor Control and Harmonics – Methology W

„ Slide Show from 8750 Erection at Zhungeer, China W,M

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History and Barriers for Static Dragline Drive System

„ Draglines with M-G set drives are in operation for nearly one century

„ Evolutionary upgrades with analog and digital controls

„ Reliable operation but limited with respect to efficiency, productivity,

maintenance and operating costs

„ Compliance with utility requirements on voltage fluctuation at the

PCC and harmonics was major barrier for static DC or AC
systems on large draglines.

„ This can be overcome for the first time in history with AFEs
(Active Front End rectifiers)

„ In addition there is the option to install

„ Gearless AC Drives for the Hoist and Drag or

„ Conventional AC Drives with gears replacing the DC motors 1:1

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Major Components – AC Motors

„ Gearless synchronous for Hoist/Drag, induction with gears for

Swing, Propel

„ AC Induction Motor replaces DC Motor 1 : 1

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Major Components AFE / Inverter

„ Active Front End Rectifiers (AFEs) provide leading Power Factor just
like M-G sets before. This makes Static Dragline Drives for the first time
in history feasible.

„ Water cooled IGBT (Integrated Gate Bipolar Transistor) Inverters use

same technology as BI excavators and haul trucks

„ Proven, reliable traction power and control hardware (SIBAS)

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AFE Fundamentals

„ Power Circuit

IG B T M o d u le s a n d
In te rn a l D io d e s
C T 's

R + S + T +
L in e R e a c to rs
(U p p e r) (U p p e r) (U p p e r)
R
Three – phase AFE
S
Power circuit

R - S - T -
(L o w e r) (L o w e r) (L o w e r)

A F E 3 P h a s e D ia g ra m

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AFE Fundamentals

„ AFE Single Phase Diagram #1

L1

S1 S3
D1 D3
Line = 900 vac
+ =1272 peak
- +

1800
VDC
Bus
- S4
S2
L2 D2 D4

Positive Half-Cycle:
Initial State: All Switches Open

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AFE Fundamentals

„ AFE Single Phase Diagram #2

L1

S1 S3
D1 D3
+ - Line = 900 vac
=1272 peak
- +

1800
VDC
Bus
- + S4
S2
L2 D2 D4

Positive Half-Cycle:
Initial State: All Switches Open

S1 & S2 Close--Causing a large current flow through L1 & L2.

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AFE Fundamentals

„ AFE Single Phase Diagram #3

L1

S1 S3
D1 D3
Line = 900 vac
+ =1272 peak
- +

1800
VDC
Bus
- S4
S2
L2 D2 D4

Positive Half-Cycle: Initial State: All Switches Open

S1 & S2 Close--Causing a large current flow through L1 & L2.

S1 & S2 Open--L1 & L2 try and maintain the current flow in the Same Direction. As
the Voltage rises above 1800 volts, there is a current flow through D3 & D2

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AFE Fundamentals

„ AFE Single Phase Diagram #4

L1

S1 S3
D1 D3
- Line = 900 vac
=1272 peak
- +

1800
VDC
Bus
+ S4
S2
L2 D2 D4

Negative Half-Cycle:
Initial State: All Switches Open
S3 & S4 Close--Causing a large current flow through L1 & L2. The Current is
in the opposite direction compared to the positive half-cycle.
S3 & S4 Open--L1 & L2 try and maintain the current flow in the same
Direction. As the Voltage rises above 1800 volts, there is a current flow
through D4 & D1

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AFE Fundamentals

„ Control Circuit

V*dc
I*d Vd
+
-
V dc Id Vector Firing
Modulator Pulses
I*q Vq
(for P.F.=1)
+
-
Iq

Simplified control system

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AFE Fundamentals
Vinv
DC
„Motoring: The AFE supplies VARs to the line VL VDC
AC
depending on the inverter voltage amplitude Line XL
( Motoring )
AFE Power Flow
Vx Vx ( Regen )
Vx
+ VX -

VL VL I1 Vinv
VL
VL
Vinv Vinv
Vinv

I1
Motoring, Unity P.F. I1 Lagging P.F.
I1
Leading P.F.,
AFE supplies
VAR to line VAR are controlled by inverter voltage amplitude =
modulation = excitation
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AFE Fundamentals

„ Staggered Operation

Š In staggered mode the 24 AFE’s are syncronized with the firing pulses
shifted by 1 degree ( PP15, 24AFEs=360/15/24 )

Š Result:24x900 Hz=21.6KHz effective switching frequency and lowest

THD
V1 P.F. Iafe

Control Iafe1
PI voltage I*d1
+ Idc ref I*q1 PI + Feed
V *dc + d,q Vector
forward + modulator
abc
- + decoupling
Load Sharing
and reference I*d4 Id1 Iq1
Feed
Vdc generation
forward
I*q4
Control Iafe4

PI + Feed
Vdc V *dc Pinv d,q Vector
forward + modulator
abc
decoupling

Id4 Iq4

Control system for staggered AFEs

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IGBT Inverters

„ IGBT (Integrated Gate Bipolar

Transistor) Inverters

„ Common Technology with BI

Excavators & Trucks

„ Reliable Traction control system

„ Enhanced Diagnostics and

Maintenance Support

Water-cooled IGBT Phase Module same for

AFE and inverter

Proven, Reliable Technology

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IGBT Advantages

„ IGBT's utilize simple, reliable, gate drivers without

snubbers and di/dt reactors
„ IGBT's can safely turn-off overload currents without
damage (GTO's fail if overloaded even momentarily)
„ High switching frequency means smoother currents
„ Water cooled or air cooled
„ NO Fuses

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Inverter Cabinet Dragline

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Inverter Cabinet Dragline

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 Single Line Diagram Hoist / Drag

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P.F., Harmonics - Methodology of Analysis

1. Create single line diagram of distribution system and loads

2. Convert to per unit values

3. Create condensed single line diagram for analysis

4. Set voltage level at PCC to 1 (100%) with new dragline off and all
other loads present

5. Study voltage fluctuation at PCC and other network points with

new dragline peak motoring and generating loads.

6. Define leading PF for motoring and generating loads which

reduces the voltage fluctuation at PCC to 0.1% (1.001, 0.999)

7. Define THD created by the dragline drive system

8. Expand model with line and other capacitances and check for
resonance frequencies.
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Example to 1.
1. Create single line diagram of distribution system and loads

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Example to 2., 3.
2. Convert to Per Unit Values

kVA base = 100,000 kVA

kV base = 110 kV

3. Create condensed single line diagram for analysis

V0 V1 V2 V3 V4 V5

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Example to 4.
4. Set voltage level at PCC to 1 (100%) with new dragline off and all other
loads present

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Example to 5., 6.
6. Define leading PF for motoring and generating loads which
reduces the voltage fluctuation at PCC to 0.1% (1.001, 0.999)

22MW motoring
pf = 0.965
V1pu 0.9947
V5pu 0.9961

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Example to 5., 6.
6. Define leading PF for motoring and generating loads which
reduces the voltage fluctuation at PCC to 0.1% (1.001, 0.999)

13MW regeneration
pf = 0.985
V1pu 0.9990
V5pu 0.9885

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Example to 5. 6.
Evaluate Voltage Swing at PCC over complete duty cycle

DUTY CYCLE
.2 0.2

0.1

mx
0

0.1

− .2
0.2
0 10.8 21.6 32.4 43.2 54
0 x 54

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Example to 5. 6.
Evaluate Voltage Swing at PCC over complete duty cycle w/o auxiliaries

DUTY CYCLE
1.02 1.02

V0 pu ( x)
0.97
V1 pu ( x)

V5 pu ( x)
0.95

0.92

.9
0.9
0 10.8 21.6 32.4 43.2 54
0 x 54
maximum minimum delta

V1pu 1.0002 0.9970 0.0032

V5pu 1.0056 0.9940 0.0116
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Example to 8.
8. Expand model with line and other capacitances and check for resonance
frequencies.

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Example to 7.
7. THD and harmonic spectrum at primary of MPT on dragline Æ 1.17%

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Example to 8.
8. e.g. 23rd harmonic produces 20% resonance

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Photos 8750 Erection Zhungeer, China

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