ABB INDIA LTD – 16.12.2016 , 2Nd Aluminium Work Shop at HINDALCO , HIRAKUD ABB India - High Power Rectifiers in Aluminum
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VIJAYAPRASAD.C/ ABB INDIA LTD – 16.12.2016 , 2nd Aluminium Work Shop at HINDALCO , HIRAKUD ABB India - High Power Rectifiers in Aluminum © ABB Group December 16, 2016 | Slide 1 ABB India in Aluminium Smelting n Introduction n Capabilities in Rectifiers n Achieving High Efficiencies in Rectifier Systems n ABB India Rectifiers in Aluminum Smelters n Aluminum Projects Executed n ABB CH some reference Projects © ABB Group - 216-Dec-16 - Power Electronics Global Organization Lead Center Product Responsible Unit Local Engg Center (Bangalore) India High Power Brazil Canada/USA Switzerland South Africa Poland Australia Bangalore Rectifiers Osasco St. Laurent Turgi Randhart Lodz Lilydale Static Excitation Italy-Sesto Brazil Canada/USA Switzerland South Africa Poland India Australia Systems S. Giovanni Osasco St. Laurent Turgi Randhart Lodz Bangalore Lilydale Advanced USA Switzerland Power Electronics New Berlin Turgi © ABB Group - 316-Dec-16 - ABB Bangalore Operations Drives, Motors, LT Machines , Low-Voltage Power Products Electronics, LT & HT Capacitors 3000 employees Bangalore Robotics, Control Petroleum, Paper, Minerals, Automotive & Platform & Chemical & Marine manufacturing Enterprise Construction industries Products Industries © ABB Group - 416-Dec-16 - Capabilities in Rectifier Systems since 1991 n Design, Engineering Thyristor and Diode Rectifier Systems. n Designing plant layout and execution. n Manufacturing Thyristor and Diode Rectifiers. n Design, Engineering , Manufacturing Harmonic Filters. n Retrofitting and Revamping Rectifier Jobs. n Installation and Commissioning. n Servicing & AMC of Rectifier System. © ABB Group - 516-Dec-16 - Constant Efficiency Improvements in ABB Rectiformers I. Operating Point for Rectifier for achieving better Efficiency: Operating the Rectifier at loads lower than the Rated capacity will deliver better efficiency, as the most of the losses in the Rectifier are proportional to the square of the current. II. Operating points for the Transformer: A. At a Specified value of load power factor, the efficiency will be Maximum when the variable ohmic loss [ I^2.R ( stray losses are small hence ignored) ] is equal to the fixed core loss (Pc). B. In a Transformer if the load current is kept constant, then the maximum efficiency occurs at unity power factor. © ABB Group - 616-Dec-16 - High Efficiency Concept n III. Thyristor Plant: Operating at lower loads [ I and II (A) above] implies bigger fining angle which implies less power factor and more harmonics. Efficiency will be increased as we go close to UPF [ II (B) ] hence the selected tap (OCTC) shall be close to the operating point to keep firing angle as minimum as possible i.e (Shifting of efficiency curve). n IV. Diode Plant: Fine control of voltage by Saturable reactor ( Transductor) is similar to firing angle control in Thyristor plant. Best efficiency will be achieved when the Saturable reactor is operated close to its saturation level. n V. Efficiency Curves of Transformer and Rectifier (Typical). 97.900% 97.880% 97.865% 97.860% 97.860% 97.840% 97.835% Transformer Efficiency at UPF 97.840% 97.827% Transformer Effi.8pf 97.820% Rect.Efficiency 97.831% 97.825% 97.786% 97.800% 97.810% 97.770% 97.780% Efficiency 97.780% 97.760% 97.783% 97.733% 97.740% 97.720% 97.700% 0.0% 20.0% 40.0% 60.0% 80.0% 100.0% 120.0% % Load © ABB Group - 716-Dec-16 - Reason for Higher Voltages Reduction of Losses per Million Ton (Rectifier and Transformer) © ABB Group - 816-Dec-16 - Green Field Rectifier Projects In Aluminum § Hindalco, Hirakud 4x90 kA 600 V 2014 § Balco, Korba 1x 380 kA 1560 V 2013 § Vedanta, Jharsguda 4x 380 kA 1560 V 2008 § INALUM, Indonesia 1x45 kA 800 V 2007 § Vedanta, Jharsuguda 2x 350 kA 1380 V 2006 § Hindalco, Hirakud 2x 90 kA 850 V 2005 § Balco, Korba 1x 350 kA 1300 V 2003 § Hindalco, Renukoot 3x(2x70)kA 900 V 2000 § Hindalco, Renukoot 2x 66 kA 850 V 1993 © ABB Group - 916-Dec-16 - Retrofit-Revamp Rectifier Projects Executed In Aluminum § Converting 2x 5 x 22 kA, 850 V to 2 x 3 x 55kA, 900 V at Hindalco, Hirakud in 2013-16. § Replacement of Toshiba Cooling System with ABB Cooling system of PL#3 at INALUM, Indonesia to increase the reliability & efficiency in 2016. § Replacement of Toshiba Rectifiers & controls of PL#2 at INALUM, Indonesia- 6 x 45kA, 800 V in 2014-15. § Control Revamp of ABB Analog System to Latest AC 800 PEC in PL#7 at Hindalco, Renukoot in 2013. § Control Revamp of BHEL system to Latest AC 800 PEC in PL#8 at Hindalco, Renukoot in 2012. © ABB Group - 1016-Dec-16 - GREEN FIELD PROJECTS 1. Hindalco, Renukoot – 2 X 66 KA / 850 V DC – 1995 n Scope of supply : n Incoming 132 KV AC Isolators for main and standby Bus n Incoming SF- 6 Breakers n 132 KV CT’s / PT’s n Related Switchyard. n 2 x ( 2 X 37 .15 ) MVA , 132 KV / 796 -804 V, +/- 7.5 deg Rectifier Transformers – from ABB Italy . n 2 x 66 KA / 850 V DC Thyristor Rectifiers , 12 pulse with DM Water Cooling units. Total 24 Pulse system n 2 Local Control Panels , 1 Master control panel and SCADA n Common trip and DC metering panels n DC Isolators – 40 KA / 1500 VDC © ABB Group - 1116-Dec-16 - 2. Hindalco , Renukoot – 3 X ( 2 X 70 KA / 900 ) V DC – 2000-03 Scope of supply : n Total Order for Rectifier System for potline No 9 – 11 n Incoming 132 KV AC Isolators for main and standby Bus n Incoming SF- 6 Breakers n 132 KV CT’s / PT’s and related switchyard . n 3 X ( 2 x 71.4 MVA ), 132 KV / 72.5 KV, 3 OCTC , and 17 OLTC’s Regulating Transformers– from ABB India. n 3 X ( 2 x (2 X 36.78 MVA)) , 72.5 KV / 743 V , +/- 7.5 deg Rectifier Transformer – from ABB Italy . n 2 x 70 KA / 900 V DC , 12 pulse each Diode Rectifiers with DM Water Cooling units. Total 24 pulse system . n 2 Local Control Panels , 1 Master control panel © ABB Group - 1216-Dec-16 - Hindalco, Renukoot – 3 X ( 2 X 70 KA / 900 ) V DC ( contd) n 2 Local Control Panels , 1 Master control panel n Common trip and DC metering panels n ABB Micro SCADA for supervision, monitoring and Control purposes n DC Isolators – 80 KA / 1500 VDC n Special features : n Control platform – PSR 2 introduced first time in India . n Filters on 132 KV. 5th and 11th Harmonic Filters for each Rectifier system © ABB Group - 1316-Dec-16 - 3. BALCO , Korba – 350KA / 1300 V DC 2004-05 n Scope of supply: n Complete Engineering of 350KA/1300 V DC Rectifier System including Civil Engineering and construction of Rectifier Building. n 5 Nos 137 MVA / 137MVA ( 40 MVA - tertiary ), 220 KV / 69.47(25) KV,107 taps continuous, Regulating Transformers– from ABB Turkey n 5 Nos ( 2 x 67.58 ) MVA Rectifier Transformer from Italy. n Total 60 pulse with 0 , +/- 6 deg , +/- 12 deg on 220 KV Network n 5 Nos 87.5 KA / 1300 V DC Diode Rectifiers with DM Water Cooling units. n 5 Local and remote Control Panels , 1 Master control panel n Common trip and DC metering panels © ABB Group - 1416-Dec-16 - BALCO , Korba - 350 KA / 1300 V DC ( contd) n DC Isolators – 100 KA / 1500 VDC n DC Measuring System – LKP 400 on Totalising Bus n ABB Micro SCADA for monitoring and Control purposes © ABB Group - 1516-Dec-16 - BALCO , Korba - 350 KA / 1300 V DC ( contd) n Special Features : n ABB India’s first 350KA/1300 VDC Potline n Filters connected on 25 KV tertiary winding of Regulating Transformer. n Compensation provided 24 MVAR in 5th and 7th Filters ( Filters in BALCO’s scope supplied by other vendor ) © ABB Group - 1616-Dec-16 - 4. Hindalco, Hirakud – 2 X 90 KA / 850 V DC- 2006 n Scope of supply : n 132 KV Incoming SF- 6 Breakers n 132 KV AC Isolators for main and standby Bus n 132 KV CT’s / PT’s n 2 x 97.6 MVA , 132 KV / 45 KV – 81.11 KV Regulating Transformers , 107 taps OLTC continious – from ABB India n 2 x ( 2 X 45.45 )MVA , 73 KV / 714 V Rectifier Transformer from ABB Italy, +/- 7.5 deg phase shift . n 2 x 90 KA / 850 V DC , 12 Pulse Diode Rectifiers with DM Water Cooling units . Total 24 pulse system on 132 KV Network . n 2 Local Control Panels,1 Master control panel n Common trip and DC metering panel n DC Isolators – 100 KA / 1500 VDC n ABB Micro SCADA for monitoring and Control purposes © ABB Group - 1716-Dec-16 - Hindalco, Hirakud – 2 X 90 KA / 850 V DC (contd) n DC Isolators – 100 KA / 1500 VDC n ABB Micro SCADA for monitoring and Control purposes n Special Features : n 132 KV direct input to Regulating Transformer and Rectifier Out put 850 V DC . n First time ABB India used AC 800 PEC controller as a control platform and successfully commissioned. n As a special case Totalising Busbars supplied and welding and installation done at site. n Totalising DCCT LKP 100 and measuring system n Total Order for Switchyard , Harmonic Filter and Rectifier System. © ABB Group - 1816-Dec-16 - 5. Vedanta, Jharsuguda – 2 X 350KA/ 1380 V DC 2008-9 n Scope of supply for each potline : n 2 X ( 5 x 87.5 KA ) /1380 VDC potline for 550 K Tons /Anum – Highest DC Voltage – 1380 VDC . n 5 Nos 146 MVA , 220 KV / 56.6 KV Regulating Transformers– from Chalico China n 5 Nos 2 x 4 x 36.5 ) MVA , 56.6 KV /1180 V Rectifier Transformer - from Chalico China n 5 Nos 87.5 KA / 1380 V DC Diode Rectifiers with DM Water Cooling units – ABB India n 5 Local and remote Control Panels , 1 Master control panel n Common trip and DC metering panels © ABB Group - 1916-Dec-16 - Vedanta, Jharsuguda – 2 X 350KA/ 1380 V DC (contd) n DC Measuring System Unit DC measurement by FOCS 45 n ABB Micro SCADA for monitoring and Control purposes © ABB Group - 2016-Dec-16 - Vedanta, Jharsuguda – 2 X 350KA/ 1380 V DC n Special Features : n 220 KV direct input to Regulating Transformer and Rectifier Out put ,1380 V DC .