Retrofit Variable Speed Drive (VSD) Panel

di
Maros Cement Plant
Oleh:
Ir. MUHAMMAD ILYAS, ST, IPM
PT. Semen Bosowa Maros

Knowledge Sharing BKTF PII

Rabu, 28 Juli 2021
Outline

● Cement Plant Operation

● VSD Basic
● VSD in Maros Cement Plant
● Equipment Life Cycle
● Retrofit solution for Obsolete Equipment
● VSD Retrofit Planning
● VSD Retrofit Installation
● Commissioning and test run
Cement Plant Operation
● Raw material i.e limestone are crushed and mixed with clay in crusher area and
stored in mixed storage.
● Mixed limestone and clay together with additives such as silica sand, iron ore or
other material are mixed with certain proportioning into raw mill, grinded to get raw
mix powder product, stored in blending silo
● Raw mix heated and calcined in preheater before going into kiln where the
temperature up to 1450 degC produces black granular material called clinker,
then air cooled and stored in clinker silo
● The clinker then mixed with small proportion of gypsum and some other additives,
fed into cement mill, grinded to fine product, produce cement.
● Cement dispatched and distributed in bulk cement or bagged in cement packing
plant.
Typical Cement Plant Flow Diagram
The need of variable speed drives in cement plant

● Cement plant need precise control of its equipment to get the optimum
operation and to meet the standard quality cement product.
● Some equipment such as material feeder for dosing proportioning, separator,
process fans, kiln, grinding mill, and pumps need adjustable speed control to
regulate the flow of raw material, fuel, and air needed in operation.
● Most of variable speed drives (VSD) application includes AC induction motor
and AC drive panel, while some old specific application use DC motor and DC
drive panel. In newer plant, DC motor and DC drive has been replaced by AC
motor and drives.
Type of VSD drives used in Maros Cement Plant

● Line 1 (Start operation in 1999): ABB Sami Star (Raw Mill EP Fan and
Separator), ABB ACS600 (Apron Feeder), ABB ACS800 (Preheater Fan),
ABB DCS500 (Kiln), ABB Cycloconverter (Cement Mill)

● Line 2 (Start operation in 2016): ABB MV ACS2000 (Preheater, Raw Mill and
Coal Mill Fan), ABB ACS800 (Kiln and Clinker Cooler Fan), ABB ACS550
(Apron Feeder and other) and ABB ACS355 (Weighfeeder and other),
Schneider ATV71 (Cement Mill Classifier)
Features of ABB Sami Star VSD (Existing)

● Installed in Plant Line 1 years 1999

● Mains voltage supplied from 11kV/0.69kV converter transformer
● Connected to 0.69kV induction motors (capacity 1200kW, 1250kW, 800kW,
500kW and 400kW)
● Pulse width modulation (PWM) based
● Use Gate Turn Off (GTO) thyristor
● Electrolytic Capacitor in Capacitor Bank Unit
● Digital Control and microprocessor based
● Serial data communication
● Scalar (most of application ) and vector control
Layout panel VSD Sami Star

CTU LCU CBU INU INU

(ret.) (ret) (ret)

Outside view Inside view

Schematic diagram of ABB Sami Star VSD

CTU: Contactor Unit

LCU: Line Converter Unit
CBU: Capacitor Bank Unit
INU: Inverter Unit
CP: Control Panel
Contactor Unit (CTU)
● Function: Connecting the frequency
converter to mains voltage source
● Consist of:
○ Disconnector and Contactor
○ Main Fuses
○ Control and supervision board
○ Control of Charging resistor to Capacitor
Bank
○ Auxiliary Power Supply to other modules
Line Converter Unit (LCU)
● Function: forms DC voltage source for the
frequency converter to intermediate DC
circuit
● Consist of:
○ Diode bridge (6 pulse)
○ RC snubber circuit
○ DC choke
○ Cooling Fans
Capacitor Bank Unit (CBU)
● Function: Eliminate current ripple in
intermediate DC circuit
● Consist of:
○ Bank of capacitors connected in series and
parallel
○ Compensating resistor
○ Supervision board
○ Cooling Fans
○ Temperature monitoring
Inverter Unit (INU)
● Function: forms three phase voltage for
the motor from DC intermediate circuit
● Consist of:
○ GTO Thyristor with freewheeling diode
○ Choke for di/dt protection
○ Snubber Capacitor for du/dt protection
○ DC Chopper
○ Power Supply Card
○ Pulse Amplifier Card
○ Chopper Control Card
○ Main Control Card
○ Interface Card (I/O)
○ Terminal Block Card
○ Current Measurement
○ Control Panel
VSD Sami Star Major Failure dalam 5 tahun terakhir

1. Raw Mill EP Fan (431.FN1-M01) mengalami major failure 4 kali dalam waktu
5 tahun dan harus diganti beberapa komponen
2. Raw Mill Classifer (361.RM1-M02) mengalami major failure 3 kali dalam
waktu 5 tahun dan harus diganti beberapa komponen
3. Clinker Cooler Vent Fan (471.FNF-M01) mengalami major failure 3 kali dalam
waktu 5 tahun dan harus diganti beberapa komponen

Komponen yang sering failure di bagian inverter unit (INU), GTO thyristor, dioda
snubber, capacitor snubber , pulse amplifier card, DC chopper thyristor, dioda dan
capacitor
ABB drive product life cycle
VSD Sami Star Life Cycle Statement
Life Cycle Assessment year 2020
Some results for Maros Plant Line 1 VSD assessment by PT. ABB Sakti Industri:

● 1. Raw Mill Classifier VSD (Status Obsolete, Criticality 1)

● 2. Raw Mill EP Fan VSD (Status Obsolete, Criticality 1)
● 3. Coal Mill Fan VSD (Status Obsolete, Criticality 1)
● 4. Kiln VSD (Status Limited, Criticality 1)
● 5. Clinker Cooler Fan VSD (Status Obsolete, Criticality 1)
● 6. Ball Mill VSD (Status Obsolete, Criticality 1)
● 7. Cement Mill Separator VSD ( Status Obsolete, Criticality 1)

• Criticality 1 : High business impact, high failure probability

• High failure probability based on environment (ambient temperature and humidity, frequent
stoppage)
• Recommendation is to retrofit, upgrade or replacement with the Active phase equipment
Some critical equipment life cycle status (1)
Some critical equipment life cycle status (2)
VSD performance and reliability over drive life time
Benefit of Retrofitting VSD
Retrofit Option
Retrofit example (1)
Retrofit example (2)
Retrofit example (3)
ABB drive evolution
Features of ABB ACS880 VSD

● Direct Torque Control (DTC) for higher precision motor control

● Uses Insulated Gate Bipolar Transistor (IGBT) Inverter
● Redundancy modules with parallel connected module
● Integrated safety with Safe Torque Off (STO)
● Longer life time for cooling fan and capacitor
● Control unit connected with all parallel connected modules such as rectifier
and inverter modules
● Programmable and extendable input and output
● Removable memory unit for maintenance
Schematic diagram drive ACS880 (complete unit)
1. Main Switch Disconnector
2. AC fuses
3. Main Contactor
4. Supply Modules
5. DC bus
6. Inverter DC fuses
7. Inverter module
8. Motor
9. Brake chopper DC fuse
10. Brake chopper
11. Brake resistor
12. Auxiliary voltage supply
13. Auxiliary voltage transformer
Schematic diagram drive ACS880 (inverter unit)
1. DC supply
2. DC switch / disconnector
3. Charging switch
4. Charging resistor
5. DC fuses
6. Common Mode Filter
7. Inverter Module
8. Motor
Retrofit Sami Star VSD with ACS880 Retrofit Kit

● Converter Transformer still used

● Induction Motor and cable still used
● Contactor Unit (CTU) still used
● Line Converter Unit (LCU) still used
● Capacitor Bank Unit (CBU) removed
● Inverter Unit (INU) removed and replaced with ACS880 Inverter Unit
● Control Panel (CP) removed and replaced with ACS880 Control Unit
Planning and Implementation Timeline

● Technical Discussion: Beginning of 2019

● Request for Quotation: July 2019
● Quotation from ABB (For 3 units VSD): September 2019
● Purchase Order (For 3 units VSD): October 2019
● Retrofit Kit Delivery : March 2020
● EP Fan VSD Retrofit Kit Installation: October 2020
● Clinker Cooler Fan and Raw Mill Classifier VSD Retrofit Kit Installation:
January – February 2021
● Coal Mill ID Fan and Cement Mill Separator VSD Retrofit Kit has also been
ordered
Retrofit Work Implementation Sequence
● Disconnect motor cable at drive output terminal
● Disassemble existing Sami Star obsolete control board, inverter module (INU)
and capacitor bank module (CBU)
● Install frame for new modules
● Install DC bus bar
● Install new ACS880 inverter modules
● Install new ACS880 control module
● Wiring control for new installed modules
● Connect cable to motor
● Install DC fuse
● Energize drive and test running
● Tuning speed control
Retrofit kit Installation Step
● Support plate, Connector assembly, and ● Fuse and shroud, I/O connector, and
bottom frame assembly cooling air guide assembly
Retrofit kit Installation Step
● Inverter Module, Common Mode Filter, ● Finished assembly
Panel Door and Control Panel Assembly
Installation Pictures (1)

Disconnect existing cables Pulling out existing inverter modules and

capacitor bank unit
Installation Pictures (2)

Installation of new frames Installation of control and

communication module
Installation Pictures (3)

Installation of new inverter module Test run actual parameter with motor at 95%
speed setting
Commissioning and Test Run

● Checklist prior to test run:

○ Mechanical and electrical installation done according to retrofit manual
○ Insulation resistance measurement good (no short circuit)
● ID run test for obtaining induction motor model
● Start up of the drive according to manual
○ Drive control mode set to Speed Control
○ Operation mode set to DTC (Direct Torque Control)
● Parameter back-up files saved
● Data logger for fault event configured
● Safety related test performed
Results and next planning

● EP Fan VSD has been run continuously since October 2020 with better
reliability and speed control
● Clinker cooler fan and raw mill classifier has been run continuously since
February 2021 with better reliability and speed control
● Coal mill fan VSD to be retrofit
● Cement mill separator VSD to be retrofit
● Kiln DC VSD to be replaced
● Apron Feeder VSD to be replaced
THANK YOU