Gearless Mill Drive - Operation and Maintenance

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LEARNING CENTER MINING, ALUMINIUM AND CEMENT
Gearless Mill Drive – Operation and Maintenance

Drive system overview
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Agenda

Maximum availability and productivity
Process and operational benefits / maintenance benefits
Medium voltage switchgear
Transformers
Control Block (E-House)
Off load disconnect switch
Ring motor
Questions
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
May 15, 2018 Slide 2
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
Maximum availability and productivity

ABB’s GMD is the most powerful mill drive system in the market to
power semi-autogenous (SAG), ball and autogenous (AG) mills.
This ‘workhorse’ for grinding operations combines a robust,
service-friendly and fit for purpose design to provide highest
throughput, reliability and availability for your processing plant.
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Process and operational benefits Maintenance benefits

Provides maximum throughput Easy maintenance due to direct communication with the drive via
Provides highest availability mill local control panel (MLCP)
Robustness of the system allows for operation under the worst Quick return to operation with frozen charge remover
and extreme environmental conditions (high altitudes, varied Minimized unplanned downtime due to advanced monitoring and
climates, remote locations) remote service features
Operator can react to changes in ore characteristics due to
variable-speed
Process optimization leads to a more efficient use of grinding
power
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Power circuit of the GMD system (6 pulse cycloconverter)

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Main components of the GMD system power circuit:
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1. Medium Voltage Breaker
2. Transformer
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3. Cycloconverter – positive bridge
4. Cycloconverter – negative bridge
5. Off Load Disconnect Switch 4
6. Stator winding
7. Rotor winding
5
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Medium voltage switchgear

Switchgear:
– MV air insulated switchgear
– MV gas insulated switchgear
– Fused contactor (rotor only)
Functionality:
– Connect / disconnect drive system to / from the main supply
– Electrical short circuit protection and overload protection
– Hardwired and exclusively controlled from drive controller
AC800 PEC
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Converter transformers
The GMD system is equipped with three converter transformers
and one excitation (converter) transformer.
Cycloconverter transformer:
– 3 winding transformers for 12 pulse application
– 4 winding transformers for 18 pulse application
Cycloconverter and excitation transformers are typically mineral
oil-cooled, with alternatives like silicon oil, bio degradable oil. Dry
type transformers can also be used.
Cycloconverter transformers are typically supervised by ABB
transformer protection relays for differential current,
instantaneous overcurrent and time inverse overcurrent.
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Control block (E-house)

Contains electrical equipment's such as:
– Motor Control Center (MCC)
– Drives (Cycloconverter)
– Auxiliary control panel (PLC)
– Network panel
– HVAC system
– Fire-fighting system
– Transformer protection panel
– UPS, ….
E-house in container design is pre-fabricated, pre-tested, pre-
commissioned and transportable
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Off load disconnect switch

OLDS is an equipment to isolate electrical power to the motor.
OLDS shall be operated only in de‐energized condition (drive not
modulating).
Lock out / tag out isolation for a mill can be done at stator & rotor
OLDS. Drive main circuit breaker can be in closed condition.
Makes the isolation procedure considerably simpler & shorter.
Transformer need not to be isolated which will reduce additional
stress on the them by reducing unnecessary switching operations
of the transformer feeder.
May 15, 2018 Slide 10
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Ring motor
GMD eliminates all mechanical components of a conventional mill
drive system, such as ring-gear, pinion, intermediate gearbox,
coupling, motor shaft and motor bearings.
By mounting rotor poles directly on the mill body, the mill itself
becomes the rotor of the gearless motor.
May 15, 2018 Slide 11
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GMD – Installed bases

108 units installed (136 cycloconverter built)
– 16 units in Europe
– 8 units in North America
– 7 units in Central America
– 42 units in South America
– 5 units in Africa
– 27 units in Asia
– 3 units in Australia
May 15, 2018 Slide 12
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Questions
May 15, 2018 Slide 13

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LEARNING CENTER MINING, ALUMINIUM AND CEMENT

Gearless Mill Drive – Operation and Maintenance

Drive system overview

Maximum availability and productivity

Process and operational benefits Maintenance benefits

Power circuit of the GMD system (6 pulse cycloconverter)

Medium voltage switchgear

Control block (E-house)

Off load disconnect switch

GMD – Installed bases

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