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Reference projects
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Table of contents Turbo compressor drive for a copper smelting plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ball mill drive for iron ore processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Roller press drive for iron ore processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Design and manufacturing of an electrical drive system for an NH3 screw compressor . . . . . . . . . . . . . . . . . . . 6 Delivery of explosion proof high voltage motors for frequency converter operation . . . . . . . . . . . . . . . . . . . . . . 7 Delivery of a 4,700 kW mill drive for a cement plant in Sweden . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Drive systems for a cement plant in Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 The SASREF project for an oil refinery in Saudi Arabia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Roller press drive for a copper mine in Peru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Turbo compressor drive for a copper smelting plant Customer requirements Replacement drive solution for an existing 2,500 kW synchronous motor based on a three phase variable speed drive. Adaptation of the motor to the given installation conditions Design of a concept for the physical configuration of the converter, transformer and air-conditioning system Delivery of drive components Assembly and commissioning on site Technical specifications Power consumption: 2,500 kW at 1,700 rmp Counter torque progression: M(n) ~ n2 Control range: 300 to 1,700 rpm Mains supply voltage: 4 kV and / or 6 kV Additional general conditions To be considered during concept development: Motor in water-cooled design, preferably as a slide bearing machine with circulatory oil lubrication Higher dust exposure to be considered during installation and operation
Scope of delivery DC link converter
Converter transformer HELMKE
Concrete station
Type: NSFU
Type: DGH 2,000 / 7.2 cast resin version
Power: 3,190 kVA
Rated power: 3,150 kVA
Version: Cast concrete body with two room cells
Three-phase asynchronous motor HELMKE
Connection symbol: Dy5d6
Type: DWK 560-04
UPrim / USec: 4 kV (6 kV) / 2 x 720 V
Rated power: 2,800 kW
Frequency: 50 Hz
Rated speed: 1,490 rmp
Bearing: Sliding bearing with circulatory oil lubrication
Voltage: 690 V Frequency: 50 Hz
Room cell 1: Switch room cell with raised floor and exterior door Room cell 2: Transformer cell, entry only via room cell 1 Roof construction: Separate roofs for the respective cells Dimensions: 3,020 x 9,740 x 3,560 mm Shipping weight: 48 t (incl. frequency converter)
incl. frequency converter) Shipping weight: 48 t Frequenz: 50 Hz
Dimensions: 3,020 x 9,740 x 3,560 mm
Spannung: 690 V
jeweilige Raumzelle Dachaufbau: Sep. Dächer für die
Nenndrehzahl: 1490 min-1
Lager: Gleitlager mit Ölumlaufschmierung
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Ball mill drive
for iron ore processing Customer requirements Drive concept for ball mill drives (+1 spare motor) with starter Adaptation of the motors to the given installation conditions Design of a drive concept Performance record of the drive unit Delivery of drive components Commissioning on site
Components
Technical requirements Power consumption: 5,200 kW
Three phase asynchronous motor HELMKE
Fluid starter
Counter torque progression: constant
Type: DSKK710-06
Power: 5,500 kW
Speed: 1,000 rpm Mains supply voltage: 6,300 V
Rated power: 5,500 kW Rated speed: 992 rmp Voltage: 6,300 V Cooling: IC 666
Additional general conditions Altitude of site: 2.000 m
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Type: DFA 5,500
Roller press drive for iron ore processing Customer requirements Double drive for a roller press Motors designed for high axial loads (52 kN) Frequency converter as master slave system with SPS for connection to the superior control technology via a Profibus interface Transformer for converter operation Delivery of drive components Commissioning on site Technical requirements Power consumption: 2 x 1,070 kW at 985 rpm Counter torque progression: constant Control range: 600 to 1,000 rpm Mains supply voltage: 6,300 V, motor 660 V Aditional general conditions Altitude of site 2,000 m Higher dust exposure
Components Converter transformer, oil-cooled
Frequency converter
Three phase motors, 2 pcs.
Type: DOH 3,000 / 7.2
Type: NSFU-V-69-3400-CB-12
Type: FDOR 560L-06
Rated power: 2 x 1,500 kVA (3,000 kVA)
Power: 4,000 kVA (2 x 2,000 kVA)
Power: 1,250 kW
Connection symbol: Dy5d6
Voltage: 690 V
Voltage: 660 V, 50 Hz
Transformation: 6,300 V / 2 x 710 V
Master-Slave
Bearing: Special bearing for higher axial loads Winding: Special winding for operation with frequency converter up to 690 V, 50 Hz
Frequency: 50 Hz
frequency converter up to 690 V, 50 Hz Winding: Special winding for operation with
Frequency: 50 Hz Transformation: 6,300 V / 2 x 710 V
Master-Slave
Bearing: Special bearing for higher axial loads
Connection symbol: Dy5d6
Voltage: 690 V
Voltage: 660 V, 50 Hz
Rated power: 2 x 1,500 kVA (3,000 kVA)
Power : 4,000 kVA (2 x 2,000 kVA)
Power: 1,250 kW
Type: DOH 3,000 / 7.2
Type: NSFU-V-69-3400-CB-12
Type: FDOR 560L-06
Converter transformer, oil-cooled
Frequency converter
Three phase motors, 2 pc.
Lieferumfang
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Design and manufacturing of an electrical drive system for an NH3 screw compressor We were tasked with the design and manufacturing of an electrical drive system for the infinite speed variation
of an NH3 screw compressor for the central refrigeration supply of an industrial chemical park.
Customer requirements
Execution HELMKE delivered a drive solution consisting of a converter transformer for a 12 pulse supply of a DC link converter for the speed control of a water-cooled asynchronous motor.
High level of availability of the drive unit: ≥ 8,000 h/ year Installation of the converter in an air-conditioned concrete station Motor designed as a water-cooled sleeve bearing machine
At a constant counter torque progression of the operating machine the drive remains ‚subcritical‘ in a control range of 1,500 – 3,600 rpm.
Outside installation of the motor / compressor unit (protection against weather impacts only by protective cover)
In order to fulfill the customer’s requirements, a 04-pole motor, operated at the converter with 120 Hz, was used.
Planning has to take into account the occasional occurrence of NH3 at the installation site. Connection of the drive to the customer’s 6 kV network Installation of the converter transformer atop the roof of the concrete station
The converter was delivered in an air-conditioned concrete station. A notable feature is the automatic switch to open circuit ventilation via electrically adjustable valves in case of a malfunction of the air-conditioning cell. The drive system was procedurally integrated in June 2006 and has been running to our customer’s full satisfaction ever since.
Preparation for an extension stage with an identical drive unit
Scope of delivery Development of a drive concept Project design and manufacturing of the drive components Compilation of an overview for the signal exchange with higher-level controls Check of the drive unit under comparable load conditions Delivery of the drive components and on-site assembly of the concrete station Wiring of the power cables (transformer
converter)
Three phase squirrel cage motor
DC link converter
Cast resintransformer
Type: DWK630-04
Type: ACS800-xx
Type: DGH2,000/7,2
Power: 1,700 kW
Power: 1,700 kW
Power: 2,000 kVA
Voltage: 660V, 120 Hz
Voltage: 6,000 V
Poles: 04-pole M / P / C*: IM B3 / IP55 / IC81W *Mounting / Protection / Cooling
*Mounting / Protection/ Cooling
IC81W M / P / C*: IM B3 / IP55 /
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Poles: 4 poles Voltage: 660V, 120 Hz Power: 1,700 kW
Voltage: 6,000 V Power: 1,700 kW
Power: 2,000 kVA
Delivery of explosionproof high voltage motors for frequency converter operation Customer requirements Drive for Flowserve pumps S1 operation and direct startup for mains operation Frequency control within a range of 5 – 50 Hz with cooling method IC416 Explosion proof motors Exde IIB T4: pressure-tight encapsulation with explosion group IIB (ethylene) and surface temperature up to135°C It was a special requirement to prepare the delivered motors for frequency converter operation as well as mains operation. The motors were initially operated via the power system and subsequently adapted for frequency control operation.
Scope of delivery The motors with varying output are all of the same size which helps in reducing the stock keeping of spare parts (bearings, sensors, terminal boxes). All motors are certified according to European (EN) and Russian (GOST, R, RTN) norms. Additionally, the certifications of all built-in sensors and accessories fully correspond to Russian standards.
BDEDOR560-06, Ex de IIB T4
BDEDOR560-06, Ex de IIB T4
BDEDOR560-06, Ex de IIB T4
Power: 675 kW
Power: 585 kW
Power: 365 kW
Voltage: 6,000 V
Voltage: 6,000 V
Voltage: 6,000 V
Frequency: 50 Hz
Frequency: 50 Hz
Frequency: 50 Hz
Poles: 06-pole
Poles: 06-pole
Poles: 06-pole
M / P / C*: IM B3, IP 55, IC 416
M / P / C*: IM B3, IP 55, IC 416
M / P / C*: IM B3, IP 55, IC 416
Temperature: –20 up to +45 °C
Temperature: –20 up to +45 °C
Temperature: –20 up to +45 °C
6PT 100 winding, Exe version
2PT 100 bearing, Exd version
Standstill heating, Exe version
Vibration sensor AS+BS, Exd version
Regreasing device AS+BS
Accessories
*Mounting / Protection / Cooling
*Mounting/ Protection/ Cooling
Vibration sensor AS+BS, Exd version
Regreasing device AS+BS
6 PT100 Wicklung, Exe Ausführung
2 PT100 Lager, Ex d Ausführung (Bild 2)
Zubehör
Stillstandsheizung, Ex e Ausführung
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Delivery of a 4,700 kW mill drive for a cement plant in Sweden Customer requirements Delivery of a 4,700 kW slipring motor for a Polysius ball mill; electrical and mechanical exchangeability with the existing ASEA motor, type MAEB 1,000 V, previously assembled on site. The technical specifications of the 4,700 kW motor were determined together with the operator. 100% mechanical interchangeability with the on-site ASEA motor and mounting on the foundations on-site Design in IM 1002 construction type, two shaft ends for rated torque, both shaft ends prepared for couplings with oil press fit Electrical interchangeability and design with identical rotor data in order for the existing starters to not require any modifications Ring-oil lubricated sleeve bearings instead of rolling bearings
version without terminal boxes for a direct connection via the concrete foundation 6.6 kV stator connection with a medium voltage plug system and additional mounting of a separate 6.6 kV terminal box directly at the 6.6 kV supply cable (3 meters below the motor in the concrete foundation) Delivery with separate star point terminal box and current transformers for differential protection The commissioning of the 4,700 kW slipring motor was successfully carried out in August 2004. During the commissioning, the starting process was thoroughly tested on site and wear of the starter electrodes was noticed. An immediate exchange of the electrodes and a correction of the electrolyte concentration guaranteed the safe and reliable operation of the HELMKE motor which has been running to the customer’s full satisfaction since its inception.
Additional installation of a hydrostatic system for the sleeve bearings in order to guarantee the operation of the motor at crawl speed for revision works at the mill Construction of the slipring compartment with a separate cooling air circuit (separated from the motor) with additional forced ventilation and monitoring with air-vane relay and pressure switch. Special design of the rotor and stator connection,
Scope of delivery Three phase slipring motor - HELMKE
Accessories
Type: DSWK710-06
6 PT100 winding / 2 PT100 bearing
Power: 4,700 kW
Sleeve bearing with hydrostatics
Voltage: 6,600 V, 50 Hz
Oil supply unit
Speed: 992 rmp
Anti-condensation heater 230 V for stator and slipring compartment
Rated current: 472 A
Separate starpoint terminal box with 3 current transformers 500 / 5 A
Weight: 18,500 kg M /P /C*: IM B3 / IP55 / IC81 W
Lighting and forced ventilation of the slipring compartment
Base frame for the adaption to the original foundations
Separate PT 100 for slipring compartment temperature
*Mounting / Protection / Cooling Delivery including a separate oil supply unit for the oil supply of the sleeve bearings and a separate 6.6 kV terminal box to install the 6.6 kV plug system for the stator connection Delivery including a separate oil supply unit for the oil supply of the sleeve bearings and a separate 6.6 kV terminal box to install the 6.6 kV plug system for the stator connection *Mounting / Protection / Cooling
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Base frame for the adaption to the original foundations B / S / K*: IM B3 / IP55 / IC81 W
Separater Y-Punkt Klemmenkasten mit drei Stromwandlern 500 / 5 A
Gewicht: 18500 kg
Separate PT100 für Schleifringraumtemperatur
Drive systems
for a cement plant in Russia Customer requirements Electrical and mechanical design of the drive technology consisting of transformer, frequency converter, slipring motor and starter Speed controlled drives with SPS for the registration of the engine sensors and the connection of the frequency converter to the higher-level control technology Registration of the engine sensors and control of the starters via an SPS with a connection to the control technology Testing of the frequency converters including an interface test Delivery and commissioning of the components Customer specific documentation Technical requirements
Scope of delivery High voltage slipring motors Pcs.: 8 Power: 700–6,400 kW Poles: 06–08-pole
Power consumption: 160 kW up to 3,400 kW Mains voltage: 6,000 V; 660 V; 380 V Additional conditions
Low voltage frequency converter drives with converter transformer 6 kV / 2 x 690 V Pcs.: 6 Power: 320–1,400 kW
Ambient temperature up to -40°C Motors for roller presses with bearings for higher axial loads
Poles: 04–10-pole
Low voltage frequency converters 400 V Pcs.: 2 Power: 100–250 kW Poles: 04–06-pole
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SASREF-Project
for an oil refinery in Saudi Arabia General conditions Location: Specification: Ambient conditions: Altitude: Subcontractors:
Jubail – Saudi-Arabien All motors according to Shell Dep 33.66.05.31-GEN –20 to +50 °C – (72 % humidity max. avg. monthly)
