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Smarter Process Altivar Process

Discover the first smart, connected, services-oriented drives

Presentado por Harold R Oliveros

Confidential Property of Schneider Electric

 Powering the

Economy

Improve your power quality for greater plant reliability and efficiency
What is a variable speed drive and its benefits
Where will the variable speed drive be used?

Often not visible as they are hidden within systems, but on energy bills !

Buildings* Industrial & Infrastructure*

36%
of energy
consumed
by motor
69 %
of energy
consumed
by motor
HVAC Processes
Water distribution/slurry

Gas compressors Refinery

Pumps Fans
Conveyors/Mixer
*Building environment : HVAC, pumping, etc *Ind. & Infra. : utilities & processes
Confidential Property of Schneider Electric | Page 3
 What is a variable speed drive and its benefits
How can a variable speed drive benefit pump/fan systems

Output flow
Needed by the process
Power consomption
With valves
Power consomption
with speed drives
Energy saving
100% 100% 100% 0% 1
80% 90% 60% 30% 2
50% 75% 15% 60% 2

1 Valves controlling pump 2 Variable speed drive controlling pump

Motor running full speed : Control valve Motor speed controlled by variable speed drive to
regulates the flow regulate the flow

Example 1
Confidential Property of Schneider Electric | Page 4
The evolution of motor controlled processes needs in industry
From control/command to business insight

New Customer Values

going towards IIOT
Huge Expansion of VSD Drive & Digital Offers provide

• Electronics regulation
intelligence on Application, Process
Direct On Line Motors
& Maintenance optimization
•

• E.E & better process control

• Regulations is Mechanical (valves)

• Automation on control/command
• First Drive intelligence mainly on motors
From Now !
• Maintenance moves to proactive approaches
• Poor protection of motors & syst.

• Reactive Maintenance From 2000 -2020

More than 20 years ago

1998 2000 2017 2020

Complete range of AC drives and drive systems

Soft Starter Machines Building Process Process & Utilities

0-500kw 0-75kw 0-75kw 0-1500Kw 260 -16,000kW

ATS22
ATV1200

ATV312

ATV32 ATV212
ATS01 ATS48
ATV12

ATV6000
ATV600 ATV900

Altistart Altivar Altivar Altivar Altivar

Soft starters Machine Building Process Process

Confidential Property of Schneider Electric | Page 6

The Altivar Process family
LV and Medium Voltage Drives

Altivar ATV6000 ATV6x0, 9x0 and

MV Drive Systems ATV990 LV
convergence to drive systems
Altivar Process 400 V
family 0.75 kW – 1000 kW
2.4 kV – 13.8 kV
0.3 MW – 20 MW
ATV630 and
ATV950 LV drive
products
200 – 400 V
The Altivar Process range features innovations to boost 0.75 kW – 315 kW
connectivity and user experience, including:
• Fieldbus connections
ATV600 and ATV900
• DTM library for process automation integration Modules for cabinet
• SoMove software integration
380 – 690 V
• EcoStruxure™ compatibility 110 kW – 1200 kW
• Cyber security
Confidential Property of Schneider Electric | Page 7
It’s the first ever Services Oriented Drives, a drive that
Collects business insights from the application

Monitoring of KPIs on
Pump curve embedded
energy and on
process performance
(eg: Pump effiency,
KW/m3…)

Accurate mechanical Sensors feedback:

power measurement Flow , Head
Drift detection (alarm
on threshold)

Asset protection
(indicate clearly the
danger zones…)
Confidential Property of Schneider Electric 8
ATV 680/980
product high light’s

1. 3 level concept (grid inverter)

> 4 Q operation in modern 3 Level design
> Total current distortion factor THD(i) ~2%
> Pass IEEE519 even in distorted networks
> Extended motor life-time due to reduction of
isolation stress on factor 2
> Enhanced efficiency compared to the classic 2
Level AFE design
losses for the whole
> Compact dimensions due to optimized filter – 14% Low Harmonic drive
components
voltage stress for the
ost – 25%
m motor increases lifetime
l y the w
us o
bvio cient L rive! – 22% footprint compared to ABB
O
effi onic D
m
Har
Confidential Property of Schneider Electric 9
ATV 680/980 3-Level architecture
with common mode suppression
+Ud / 2
0
+Ud
S 1 S 3 S 5
RBS 1 RBS2

RBS3 RBS 4
L1

L2

L3 Ud
0
RBS 5 RBS 6

S2 S 4 S 6

C
F

- Ud
- Ud / 2
0

10
Standard drive with diode rectifier
dv/dt and common mode voltage is known and accepted

Due to the PWM modulation

of the drive the motor
windings gets stressed by
high dv/dt values and voltage
spikes. Common mode
voltages lead to bearing
current

This effects are well known

and gets considered by motor
design and adfditoionally
dv/dt filters on the drive

Confidential Property of Schneider Electric 11

Classic 2-Level Technology
additional stress for the motor

The traditional 2 Level AFE

design creates due its line
sides IGBT´s high frequency
common mode voltages on
the DC link. They get overlaid
with the common mode
voltage from the motor side
IGBT´s.

By this the motor winding

stress and bearing current
rise by the factor of 2

Confidential Property of Schneider Electric 12

Unique 3-Level Technology
used in ATV980 and ATV680 Drive Systems

Only our AFE 3-Level

architecture with common
mode suppression filter
technology avoid this effects
and help to increase motor
lifetime

This new architecture is

actually ONLY available on
Schneider ATV drives!

Confidential Property of Schneider Electric 13

4Q - Low Harmonic Drives ATV680/980
ATV660/960 size 1p
ATV680/980 size 1a

dv/dt filter choke

Inverter module

AFE module

Rectifier module
AFE capacitors
48V DC Fan module

AC choke module
Line filter module
14
MVD Offer Panorama
new
ATV1200 ATV1260
ATV6000
High Altitude CE/UL
Utility/Process
+ Seismic

Integrated transformer Separated transformer

Integrated transformer
AC, 2Q AC/WC, 2/4Q
AC, 2Q

Optimum Market

Medium Market
Confidential Property of Schneider Electric | Page 15
Targeted segments and applications

Mining, Minerals, Water and Oil & Gas Power plants

and Metals Wastewater
Material handling Water extraction Upstream Gas turbine power plants
Processing Water transportation Midstream Steam generating boilers,
waste incinerators
Grinding Water treatment Downstream
Fuel handling
Typical applications: Typical applications: Typical applications:
• Long-distance conveyor • Raw water pump • ESP Typical applications:
• Slurry pump • Lifting station • Crude oil transfer pump • Boiler/Feed Water Pump
• SAG/ball mill • Blower/compressor • Pipeline compressor • ID/FD fans
• HPGR • Booster pump • ID/FD fans • Coal mill
• ID/FD fans • High-pressure pumps • FPSO • Cooling water circulation pump
• Mixer • Fuel gas compressor

Confidential Property of Schneider Electric | Page 16

Drive Systems
World wide

• Schneider Electric, your reliable partner

• SE Drive Systems engineering teams assist
you in in everything relating to your needs
• Your Drive Systems is produced at Schneider
sites in Europe, China and USA
• We have more than 30 years experience in
Drive Systems business in all segments
(Metal, Mining, Minerals, Oil & Gas, Water, …)
• Local field service teams assist you for
commissioning and after sales topics
• Factory Acceptance Tests are possible Production
in all our production sites
SE Sales
• To drive innovation we invest 7% of our
revenue in R&D

Confidential Property of Schneider Electric | Page 17

 9 of the 10 largest Mining, Minerals and Metals
companies in the world use products and solutions from Schneider Electric

Confidential Property of Schneider Electric

Confidential Property of Schneider Electric | Page 18
Altivar Process ATV6000
Discover the first services-oriented drive for medium voltage

Presented by: Harold Ricardo Oliveros

Confidential Property of Schneider Electric

Schneider Electric Value proposition
A1 B1 C1

Maintenance
Disa
bled
pow
er
cell
A2 B2 C2

A3 B3 C3
Bypa
ss Contract
Web Server
A4 B4 C4

M
- 75% of voltage
- 100% of current

By pass
(N+1) Augmented
Reality
Digital Services
Offer

HMI 10
Spares
QR Code

Confidential Property of Schneider Electric | Page 20

Virtual Demo

Industry – IC&D – LoB Drive Systems – R. Holzer, R. Kapeller, Leo Fuchs 2015
Virtual Demo

Industry – IC&D – LoB Drive Systems – R. Holzer, R. Kapeller, Leo Fuchs 2015
Virtual Demo

Industry – IC&D – LoB Drive Systems – R. Holzer, R. Kapeller, Leo Fuchs 2015
Realidad Aumentada

Industry – IC&D – LoB Drive Systems – R. Holzer, R. Kapeller, Leo Fuchs 2015
 Realidad Aumentada
An industrial and ergonomic solution

Fans
Visualization contextual data in real time,
without open doors & in run mode
(information, events, alarms, temp ...)
Controle
Inverter
Protection Access to data by points of interest:
technical documents, video tutorials ...

Transformator

Securing operators by opening virtual

cabinet door or machine housing

POINTS OF INTEREST (POI):

5 DIFFERENT WAYS TO ACCESS Ability to deposit operator notes on the
INFORMATION application

Confidential Property of Schneider Electric | Page 25

MINING – Applications – References
Schneider Electric - Drive Systems LoB 26
Mining process

Open-pit or Underground mining

Stockpiling / Homogenization

Concentration /
Mineral seperation

Solid-Liquid-Separation

Final handling / Transport

Schneider Electric - Drive Systems LoB 29

Mining process – drive applications
Open-pit or Underground
Mining

Bucket wheel excavator

Conveyor
Spreader
Stone/Ore Crusher
Shaft elevator
Compressor
Drainage pump
Mine ventilation
...

Schneider Electric - Drive Systems LoB 30

Mining process – drive applications

Homogenization

Conveyor
Stacker
Reclaimer
...

Schneider Electric - Drive Systems LoB 31

Mining process – drive applications

Mineral seperation

Crusher
Mill
Compressor
Pump
Seperator
Conveyor
...

Schneider Electric - Drive Systems LoB 32

Mining process – drive applications

Solid-Liquid Separation

Pump
(Decanter) centrifuge
Mixer
Compressor
Conveyor
Dryer fan
...

Schneider Electric - Drive Systems LoB 33

Mining process – drive applications

Final handling

Crane
Ship loader
Conveyor
...

Schneider Electric - Drive Systems LoB 34

FQM-Mina De Cobre
Panama
End User : First Quantum Minerals, Australia
Customer : Process E&I, Australia

76 MV drives
Scope : MV Drives + Design of E-room Cooling System
KEY Points ;

- Excellent collaboration between SE Industry, Segment and Drives Activity

teams during the 3 years of pre-sales - tendering – sale – execution
- Heavy consultancy job provided to EPC:
- Optimized product solution
- POE (*) function to replace output circuit breakers -> 50 linear meters of cubicles saved
- Adaptation of power cell: 710+ to deliver 1000 A -> higher drive compacity
- Design of E-rooms cooling
- Tremendous support provided by RAC on start up plan (30 pages detailed
commissioning plan)
- Strong after sales support provided to FQM on running project in Zambia
- Strong project execution:
- Competition: ABB, Siemens, WEG
(*) POE: Power Output Removal

Confidential Property of Schneider Electric | Page 35

 Stone crusher

Place: Swizerland / Lötschberg, Gotthard

Customer: Strabag

Application: Stone Crushers

Competition: ABB, Siemens

Customer requirement: high starting torque,

Vibrations, shock loads

Schneider Electric - Drive Systems LoB 36

 Reference
China Guizhou Jinfeng Gold mine SAG Mill <Grinding Mill>

10KV 3400KW SAG Mill MVD

Serviced in 2007

Schneider Electric – BALL MILL MV VSD SOLUTION 42

 Reference
China Tiandiwangpo coal mine belt conveyor <belt conveyor>

Belt Conveyor MVD drives (2×1400kW), both motors are

allocated at head part.
Belt Conveyor Parameters:
Capacity of belt Q =1800t/h ； Length =1160m ； inclination of
belt θ =17° ；
Width B =1200mm ； Belt Velocity V =4.5m/s ； Safety factor
m =7.34 ；
Output Power = 1400×2 kW ； Maximum tension S =653570 N.
Motor Parameters:
Frequency 5-50HZ; Power 1400kW; Voltage 6kV; Current
159.5A.
Control way: Droop

Schneider Electric – BALL MILL MV VSD SOLUTION 46

20 MW Drive Aplicación de compresor de gas
Application Focus For Mining
 Go  To be checked  No Go

Application Power Range Focus

IPCC – In Pit Crushing and Conveying 200kW – 2500kW 
Bucket wheel excavators 110kW – 400kW 
Mine Hoist 75kW – 2000kW 
Crushing and Screening 75kW – 630kW 
Grinding Mills (Ball Mills, SAG and AG Mills) 400kW – 2000kW 
Flotation and Thickening 5kW – 110kW 
Spiral and Magnetic separators 5kW – 110kW 
Dewatering and Filtration 15kW – 200kW 
Mine Shaft Pumps 500kW – 2000kW 
Reclaimers and Stackers 15kW – 200kW 
Ship Loaders 75kW – 630kW 
Tunneling Machines/Mobile Miner 110kW – 400kW 
Mining Truck 75kW – 500kW 
Shovel Excavator 75kW – 500kW 

Confidential Property of Schneider Electric Page 61

Application Focus For Minerals
 Go  To be checked  No Go

Application Power Range Focus

Crusher 110kW – 400kW 
Long Belt conveyor 250kW – 800kW 
Grinding Mills 400kW – 2000kW 
IDFan (Prehater fan) 800kW – 3000kW 
Kiln waste gas fan 400kW – 2000kW 
Cooler exhaust fan 800kW – 3000kW 
Kiln Main Drive 250kW – 500kW 
Separator for VRM 200kW – 1500kW 
Pump for water supply 15kW – 110kW 

Confidential Property of Schneider Electric Page 62

 7. Preguntas y respuestas

Confidential Property of Schneider Electric | Page 63

 THANK YOU

Confidential Property of Schneider Electric | Page 64