High Speed Motors The Theory Hasn’t Changed . . . But The Product Has Unrestricted © Siemens 2016 usa.siemens.com/oil-and-gas The Theory - Maxwell’s Equations (c. 1862) d B.ds ∫∫ dt s c d = H . dl D.ds + ∫∫ J .ds ∫c ∫∫ dt s s ∫ E.dl = − (Faraday’s law) (Maxwell-Ampère law) ∫∫ D.ds = ∫∫∫ ρdv (Gauss’s law) ∫∫ B.ds = 0 (Gauss’s law - magnetic) v s s 1866 – Ernst Werner Siemens First “dynamo machine” Unrestricted © Siemens 2016 Page 2 . . . And The Rotor Turned Three phase winding in the stator Rotating magnetic field Rotating magnetic field Induces current to flow in the rotor Induced current produces second magnetic field Rotor ‘chases’ rotating magnetic field Synchronous motor Add ‘additional’ electromagnets so it catches up and synchronizes! Unrestricted © Siemens 2016 Page 3 Confused By Standards? 500 kVA ≥500kVA Synchronous machines API 546 4th Edition Annex I – 2017? High Speed Motors API 546 3rd ‘Custom’ API 541 5th 2 pole WPII 2 pole TEFC ‘Standard’ ≥500HP API 547 1st Vertical 250 – 3000HP 4/6/8p “Non-critical” IEEE 841 2009 ≤500HP, ≤4kV, TEFC H & V, A/F brgs HP 1 kW Unrestricted © Siemens 2016 Page 4 250 185 500 375 800 1250 600 930 3000 2240 10000 Now metric 100000 Design Objectives Flexible designs suited to most direct drive applications Simple installation Reliable Reduced maintenance Low operating costs Environmentally friendly Unrestricted © Siemens 2016 Page 5 Applications Compressors Gas pipeline Process Gas injection Pumps Boiler feed pump Water injection Pipeline Unrestricted © Siemens 2016 Page 6 Expanders Generators Motor/generators Others Traditional motor (3,600rpm or slower) gear driven Traditional gas/steam turbine direct drive Why High Speed? Physically smaller motor Footprint and mass Eliminates gearbox Smaller footprint Reduced (or eliminated) lube oil requirements Eliminates low speed/high torque coupling Improved reliability Fewer components (vs. conventional ASD) Higher efficiency (vs. conventional ASD) Replace direct drive gas turbines, steam turbines or expanders Reduced emissions/improved efficiency/reduced maintenance Unrestricted © Siemens 2016 Page 7 Defining the Envelope Speed Mechanical stresses Rotor dynamics Shaft/rotor dia Rotor length Rotor volume Torque Power Unrestricted © Siemens 2016 Page 8 Cooling system Motor Capabilities 2 - 90MW Induction 2-30MW Synchronous 15-60MW, 6,400rpm max Synchronous 60-90MW, 3,600rpm max 18,000 Speed (rpm) 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 10 20 30 40 50 Power (MW) Unrestricted © Siemens 2016 Page 9 60 70 80 90 Conceptual Design Application-specific cooling (open, air-air, air-water) Flange mounted bearings sleeve or magnetic Cage induction rotor solid forged shaft Stator designed for Drive converter operation Unrestricted © Siemens 2016 Page 10 Shaft-mounted fans or auxiliary blowers Cage Induction Rotor Special rotor designs required for above 170 m/sec Patented technology up to 250 m/sec Diffusion bonding/hot isostatic pressing (HIP) Unrestricted © Siemens 2016 Page 11 Mechanical Design Minimum number of individual components 100% bonding of copper/solid steel to form a solid body Unrestricted © Siemens 2016 Page 12 Attention to Detail Lightweight Kevlar blades maximum efficiency Optimum setting with bayonet connection Unrestricted © Siemens 2016 Page 13 Electrical Design Complete motor-converter system is optimized Components optimized for high frequency Demanding technical requirements utilizing established production technologies and standard modules where practical Combined testing BEFORE arriving at site Unrestricted © Siemens 2016 Page 14 Rotor Balance is Key Unrestricted © Siemens 2016 Page 15 Power HS-Modyn Product Family Unrestricted © Siemens 2016 Page 16 rpm ‘Conventional’ Enclosures Self-ventilated with shaft-mounted fans Force-ventilated with blower-motors mounted on the motor Customized versions Unrestricted © Siemens 2016 Page 17 FCCU @ US Refinery 3,4 MW, 6,300rpm TEWAC Class I Division 2 2R AMBs API 541, NEMA Inconel coated rotor H2SO4 atmosphere Unrestricted © Siemens 2016 Page 18 Gas Pipeline 12 MW constant 7,000 to 9,500 rpm Ducted (TEPV) Class I, Division 2 Sleeve bearings API 541, NEMA Torsional analysis for the complete string by Siemens Unrestricted © Siemens 2016 Page 19 Alky Compressor - Hawaii 3,75 MW, 5,300 rpm TEAAC Class I, Division 2 Sleeve bearings API 541, NEMA Unrestricted © Siemens 2016 Page 20 Integrated Options Canned solution Liquid-cooled stator Gas-cooled rotor Liquid-tolerant HV insulation Inconel rotor coating ∆P compensation across can Single shaft 7.5MW 12,200rpm Delivered 2006 2R+1A AMB Process gascooled solution Gas-cooled stator Gas-cooled rotor Gas-tolerant HV insulation Inconel rotor coating Closed loop cooling Flexible coupling 4R+1A AMB Unrestricted © Siemens 2016 Page 21 10MW 10,000rpm Delivered 2013 ASDs for High Speed Induction Motors SINAMICS PERFECT HARMONY GH180 SINAMICS PERFECT HARMONY GH150 180 kVA – 15.5 MVA 4 MVA - 13.3 MVA Output voltage 2.3 - 11 kV Output voltage 4.16 - 7.2 kV Multi-cell voltagesource DC link converter Multi-cell voltage-source inverter (VSI) LV IGBT air-/ water cooled LV-IGBT water-cooled Unrestricted © Siemens 2016 Page 22 SINAMICS GM150 SINAMICS SM150 1 - 13 MVA (IGBT) 3.4 – 7.2 MVA (IGBT) 5 - 21 MVA (IGCT) 5 – 31.5 MVA (IGCT) Output voltage 2.3 – 4.16 kV Output voltage 3.3 kV (IGCT & IGBT) 4.16 kV (IGBT) SINAMICS SM120 CM SINAMICS GL150 SINAMICS SL150 7.2 / 6.5 MVA 2.8 - 85 MVA per unit (higher power ratings on request) 3 - 40 MVA Output voltage 4.16 kV / 6,6 kV Output voltage 1.4 – 10.3 kV Output voltage 1.5 – 4 kV Load-commutated inverter (LCI) Cycloconverter (CSI) Thyristor air/water cooled Thyristor air/water cooled M2C 3 level NPC / 3-level NPC voltage- 3-level NPC voltagediode bridge voltagesource DC link source DC link source DC link converter converter converter HV IGBT (air/water cooled) IGCT (water cooled) HV IGBT (air/water cooled) IGCT (water cooled) LV / HV IGBT water cooled Synchronous Based on conventional solid cylindrical 2 pole rotor Solid cylindrical 4 pole option available when dictated by rotor dynamics Outboard exciter for easy maintenance Excitation control managed by ASD Unrestricted © Siemens 2016 Page 23 Conventional AC-Fed Exciter Exciter Field Exciter Armature Motor Field Winding D1 D2 D3 Varistor D4 D5 D6 Stationary Unrestricted © Siemens 2016 Page 24 Rotating LNG Compressor Motor 79MW, 3,000rpm 4 pole solid cylindrical 120 T Full load back-to-back test Size Mass Pulsating torques Interharmonics Rotor dynamics Unrestricted © Siemens 2016 Page 25 Back-To-Back Testing Unrestricted © Siemens 2016 Page 26 Double-Ended Motor 23 MW, 600 to 6,300rpm TEWAC EExP II B T3 IEC & DEP Sinamics GL150 8 x AMBs 6R + 2A Compressor #1 Unrestricted © Siemens 2016 Page 27 Motor Compressor #2 ASDs for High Speed Synchronous Motors SINAMICS PERFECT HARMONY GH180 SINAMICS PERFECT HARMONY GH150 180 kVA – 15.5 MVA 4 MVA - 13.3 MVA Output voltage 2.3 - 11 kV Output voltage 4.16 - 7.2 kV Multi-cell voltagesource DC link converter Multi-cell voltage-source inverter (VSI) LV IGBT air-/ water cooled LV-IGBT water-cooled Unrestricted © Siemens 2016 Page 28 SINAMICS GM150 SINAMICS SM150 1 - 13 MVA (IGBT) 3.4 – 7.2 MVA (IGBT) 5 - 21 MVA (IGCT) 5 – 31.5 MVA (IGCT) Output voltage 2.3 – 4.16 kV Output voltage 3.3 kV (IGCT & IGBT) 4.16 kV (IGBT) SINAMICS SM120 CM SINAMICS GL150 SINAMICS SL150 7.2 / 6.5 MVA 2.8 - 85 MVA per unit (higher power ratings on request) 3 - 40 MVA Output voltage 4.16 kV / 6,6 kV Output voltage 1.4 – 10.3 kV Output voltage 1.5 – 4 kV Load-commutated inverter (LCI) Cycloconverter (CSI) Thyristor air/water cooled Thyristor air/water cooled M2C 3 level NPC / 3-level NPC voltage- 3-level NPC voltagediode bridge voltagesource DC link source DC link source DC link converter converter converter HV IGBT (air/water cooled) IGCT (water cooled) HV IGBT (air/water cooled) IGCT (water cooled) LV / HV IGBT water cooled SIMOTICS Active Magnetic Bearings (AMB) Available on both induction and synchronous AMB’s levitate a rotating shaft and permit relative motion without friction or wear Consist of an electromagnet assembly, a set of power amplifiers and a controller Gap sensors provide feedback to control the position of the rotor Each is equipped with a back-up bearing for emergency operation Unrestricted © Siemens 2016 Page 29 AMB Features Standard electronics 300,000 units per year Customized HMI Wide range of bearings and inverters Easy purchasing/replacement of standard drive hardware Extensive built-in system diagnostics Conformity to relevant ISO, DIN, IEC and API standards Unrestricted © Siemens 2016 Page 30 ‘Conventional’ High Speed Induction only Sleeve or anti-friction bearings Aluminum die cast or copper bar Forced cooling for higher speeds 500 frame – max 1,500 HP, max 6,000 rpm 12½ inch center height 580 frame – max 2,600 HP, max 5,300 rpm 14½ inch center height 680 frame – max 3,700 HP, max 4,200 rpm 17 inch center height Unrestricted © Siemens 2016 Page 31 WPII, 508 frame 6.5rpm – 5,600rpm ‘Conventional’ High Speed Conventional cast iron frame Unrestricted © Siemens 2016 Page 32 Modified ventilation/cooling circuit Modified end bracket Modified bearing design ‘Conventional’ High Speed Light-weight die cast aluminum core Solid aluminum die cast end rings eliminated traditional fan blades and balance lugs Unrestricted © Siemens 2016 Page 33 Separate balancing planes close to the core Eliminated shaft mounted fans – separate auxiliary cooling “Not-So-Conventional” High Speed Custom fabricated end bracket Custom fabricated frame 2 or 4 lobe or tilting pad bearings Small HIP rotor Unrestricted © Siemens 2016 Page 34 Proven Experience Induction Synchronous 18,000 Speed (rpm) 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 10 20 30 40 50 Power (MW) Unrestricted © Siemens 2016 Page 35 60 70 80 90 Thank You For Your Time Mark Chisholm Principal Business Developer Chemicals & Air Separation Large Drives 500 Hunt Valley Road New Kensington, PA 15068 USA Mobile: +1 (412) 389-7469 [email protected] siemens.com Unrestricted © Siemens 2016 Page 36