Time 13 (Kiev time) 10 UTC

Improve your efficiency and equipment reliability with innovative technologies!

Agenda

Challenges

• Expenses caused by heavy start of crushers, loaded mills, and conveyors
• High maintenance costs for mechanical parts of crushers due to mechanical surges
• Loaded mill start. Risk of mill shell and guides damage
• Downtime expenses due to momentary voltage sags
• Expenses for clean locations in dusty facilities for electrical equipment
• Building cost related to equipment dimensions. Expenses for space alignment for modernization
• Double pinion mills control. Load sharing gearbox cost elimination and lifetime extension
• VFD application for old motors. Motors failures due to insulation breakdown and bearing damage
• Low energy efficiency and slurry/clearwater pump low lifetime in multi-pump configuration
• Interruption expenses due to VFD components failures

Speakers

Vasiliy Kravtsov

Business Development Manger in Europe

Nikolay Onischenko

Sales Support Engineer

What is Triol?

More than 800 employees, including 150+ design engineers and software developers;

3 factories and 11 service centers;

full production cycle

27 years of experience and more that 1700 finished projects;

Triol subsidiaries: � - Triol DWC LLС (UAE)� - Triol Trading LLC (the USA)

Triol Customers worldwide

Thousands drives were supplied all over the world

Hundreds customers worldwide

Many applications : O&G, Mining,�Elevators, HVAC

Triol manufacture capabilities

Reliable state of the art technology

Testing of 100% of products: acceptance testing, testing of each unit before assembly, thermal stress testing of each unit, NEMA tests, full load testing.

Triol Quality management system

ISO 9001:2008 since 2002

UL certificate for ESP and HPS applications CE�for VSDs and sensors

Triol major electrical components suppliers

Triol products

MV Variable Frequency Drives�3, 6, 10 kV up to 12 MW

LV Variable Frequency Drives�380-660V up to 1200 kW

Variable Speed Drives

for ESP and HPS

Downhole sensors TM01

Intake and Discharge

Linear ESP - Reciprocating Rodless pump for marginal wells

Challenge 1�Expenses caused by heavy start of crushers, loaded mills, and conveyors

Solution

Vector control provides the 200% of rated torque on zero speed with 200% of rated motor current

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Benefits

Less oversized motors and power peaks can decrease the project cost and demand charges up to 30% comparing to drives with scalar control

Challenge:

Start of heavy machines required oversized motors and leads to power consumption peaks that increases the project costs demand charges.

In common practice for mills, crushers conveyors is used motors with power rate 150-200% of constant operation power to provide enough starting torque

The start of heavy mechanism can lead to the power consumption peaks up to 275% of rated power that equivalent to demand charges

Picture represents Triol laboratory research with torque, speed and current measurements while the motor completely blocked by brake. Used 75 kW with Triol AT24-SD drive in vector control mode

Challenge 2�High maintenance costs for mechanical parts of crushers due to mechanical surges

Torque limitation algorithm

The brake application and release torque limit setpoint with shaft blocking

Challenge

If hard-to-crush material gets into the crusher, the motor produce a large torque surge that damages gears, couplings and bearings.

Solution

Torque limitation algorithm.

If the load creates a torque more than torque limit setpoint, the speed is decreasing to not exceed the torque limit.

Benefits

Decreasing maintenance cost of mechanical components avoiding it damage and wear caused by over torque.

Challenge

After a prolonged shutdown mill charge can be solidified and after jump-start it drops and destroy the mill.

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Solution

Frozen charge protection algorithm

Using the vector control mode VFD calculates the load angle and detects the frozen charge. If it detected, drive shakes the charge and try to start again while charge not be tumbled.

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Benefits

No risk of mill damage, without any additional equipment.

Challenge 3�Loaded mill start. Risk of mill shell and guides damage

Challenge 4�Downtime expenses due to momentary voltage sags

Challenge

According to researches* the average industrial site suffers from voltage sugs for 1-10 periods at 50-100% of grid voltage 10 times per year.

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Solution

The algorithm of kinetic buffering ensures stable operation of Triol VFDs in case of deep and asymmetrical supply voltage dips�for 1-10 periods at 50-100% of grid voltage.

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Benefit

To prevent the production interruption 10 times per years that eliminate losses caused by production downtime.

* Distribution System Power Quality Assessment: Phase II

Voltage Sag and Interruption Analysis. EPRI PEAC Corporation

Challenge

The most of mining facilities has the high contain of conductive dust that leads to expenses for additional clean rooms with air filtering for big size electrical equipment.

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Solution

Triol AT27 line MV with the degree of protection IP66 and AT24 line UH with the degree of protection IP55 used in with the increased dustiness of premises where there is a high content of dust, including conductive ones.

Both solutions have a separate cooling circuit, which guarantees trouble-free and reliable operation of the inverter even in the most difficult conditions.

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Benefits

VFD can be placed anywhere that eliminates additional building expenses.

Challenge 5�Expenses for clean locations in dusty facilities for electrical equipment

Challenge

During new projects implementation the building costs is proportional for space required for equipment footprint

Considering modernization there is necessary to align existing space for new VFD installation

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Solution

Due to UNICORE technology for transformer, cooling system optimization and one side maintenance Triol AT27 provides up to 30% less space than competitors

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Benefits

Less project cost related 30 % of space saving

Challenge 6�Building cost related to equipment dimensions. Expenses for space alignment�for modernization

Challenge

For mills with power rate more than 5 MW the one motor configuration has a low economical efficiency. Double motor configuration can be used if load sharing is implemented.

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Solution

Master-follower algorithm with load sharing provide the possibility of direct drive of double-pinion mill with compensation of gas oscillations.

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Benefits

Load sharing gearbox cost elimination and gears lifetime extension.

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Challenge 7�Double pinion mills control. Load sharing gearbox cost elimination and lifetime extension

Challenge

In case of modernization VFD may be applied for operation with old motor without bearing insulation and with insulation wear.

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Solutions

Multi-level PWM with algorithm of suppression of step voltage fluctuations in Triol MV VFD provides DU/DT limit for 45-50 V/us and less than 5% of THD.

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Benefits

Elimination of expenses by old motor lifetime decreasing.

Challenge 8�VFD application for old motors. Motors failures due to insulation breakdown and bearing damage

30-35% of all failures of MV motors are related to the stator winding damage

Challenge 9�Low energy efficiency and slurry/clearwater pump low lifetime in multi-pump configuration

Challenge

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The daily flow variation in some mining pump system has a wide range.

Using the multi-pump system without frequency control of all pumps always leads to asymmetric distribution of the flow between the pumps.

If flow demand is not matched with the amount of rated flows of the pumps one or more pump will operate far from Best Efficiency Point (BEP).

Challenge 9�Low energy efficiency and slurry/clearwater pump lifetime in multi-pump configuration

Pump that operates with 30-40% load factor can have 40-50% efficiency.

Challenge 9�Low energy efficiency and slurry/clearwater pump lifetime in multi-pump configuration

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Operation far from BEP can multiply a maintenance cost up to 10 times*

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* Calculations and examples for clearwater pump

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Solution

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Triol Multi-pump master-follower algorithm.

User enters the pumps curves to the master drives

Master drive receives the pressure or flow feedback from the sensor and distribute the flow between the pumps to achieve the operation point as close as possible to BEP.

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Challenge 9�Low energy efficiency and slurry/clearwater pump lifetime in multi-pump configuration

Benefits

Triol Multi-pump master-follower algorithm provides operation in range 75-115% of BEP

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For particular pump it allows increase

• Lifetime of bearing seals, casing and impeller up to 5 times
• Efficiency of particular pump operations up to 50%
• Avoid hydraulic surges that damage the pipes and valves
• Avoid electric surges

Challenge 9�Low energy efficiency and slurry/clearwater pump lifetime in multi-pump configuration

Challenge 10�Interruption expenses due to VFD components failures

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Solutions

• Semi-conductors and dry-type capacitors with MTBF up to 100 000 h
• Power cells bypass removes broken cell from operation
• Redundant power cell provides full power if one of cell is bypassed
• Redundant fan with check valve provides uninterruptible operation if one of fans is out of service
• Real-time operations system controller prevents the freezes

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* Reliability analysis of application of variable frequency drive on condensate pump in nuclear power plant John K. Avor John K. Avor & Choong-Koo Chang

Journal of International Council on Electrical Engineering, Volume 9, 2019 - Issue 1

Benefits

Operation 100% free from interruptions caused by critical VFD nodes

Challenges

• Semi-conductors failures
• DC link capacitors failures
• Cooling fans failures
• Controller freezes

Leads to production interruptions

up to 1-2 hours

Summary for Triol mining solution benefits

• Reducing expenses by motor oversizing for heavy start and demand charges up o 30%
• Decreasing maintenance cost of mechanical components avoiding it damage and wear caused by over torque
• Eliminating risks of mill damage due to frozen charge
• Avoiding downtime expenses caused by momentary voltage deeps
• Reduces the building expenses for clean facilities for VFD
• Decreasing project cost related 30 % of space saving for drive placement
• Avoiding expenses for load sharing gearbox and gears lifetime extension in double pinion mills
• Extending the lifetime of old motor
• Increasing energy efficiency and pump lifetime of multi-pump systems
• Eliminates downtime expenses for 100% of critical components failures

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Do you need something more to increase your efficiency and equipment reliability?

Thank you for attention!