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LEARNING CENTER MINING, ALUMINIUM AND CEMENT

Gearless Mill Drive – Operation and Maintenance

800xA control system
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Agenda

800xA control system

Process control
Dual controller principle
General overview
Control block (E-house)
Cycloconverter cooling system
Ring motor
Brake supervision
Lube system
Network connection
Questions

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March 13, 2018 Slide 2
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

Process control
ABB’s System 800xA Minerals Library is a suite of object-oriented
software control modules, which make it possible to design
process control and power applications in an efficient and fully-
parameterized manner. Successfully operating in more than 400
cement and mining sites worldwide, the technology increases
standardization, functionality and quality of process control
software over the complete life cycle of a production facility. This
minimizes downtime caused by abnormal situations and allows to
operate and maintain the production process and assets most
efficiently.

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 3
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

Dual controller principle

Drive controller: AC800PEC DCS
Auxiliary controller: AC800M (800xA control system)
Profibus DP / MMS / Modbus TCPIP
Time critical tasks required for controlling the drive are processed OPC MMS
Auxiliary Controller Drive Controller
in AC 800PEC drive controller due to fast cycle time HMI
AC800M AC800PEC
The auxiliary system is controlled by the AC800M controller
Signals between the AC800M auxiliary controller and the Profibus DP CombiIO / PowerLink
AC800PEC drive controller are exchanged by means of the MMS MCC
LIN / …
(Manufacturing Message Specification) communication protocol Profibus DP
IO Modules Profibus DP IO Modules
S800 S800
Modbus RTU DriveBus
HVAC DCS800
Modbus RTU OPC
UPS CCT

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March 13, 2018 Slide 4
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

HMI – General overview

800xA control system
– Transformer supervision
– Stator OLDS control and supervision
– Rotor OLDS control and supervision

From AC800PEC drive controller (MMS)

– Medium voltage breaker status
– Line voltage
– Excitation converter input / output voltage
– Cycloconverter output current
– Stator voltage
– Motor power

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 5
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

HMI – Control block (E-house)

800xA control system
– HVAC control & supervision
– E-House temperature supervision
– Fire-fighting supervision
– MCC main breaker supervision
– UPS supervision
– E-house overpressure fan control
– Fault and alarm status of auxiliary panel (+F03)
– Fault and alarm status of network panel (+F04)
– Fault and alarm status of RET 670 panel (+F16)

From AC800PEC drive controller (MMS)

– Fault and alarm status of cycloconverter panels
– Status of excitation converter

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
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express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
—
GMD – Operation and Maintenance
800xA control system

HMI – Cycloconverter cooling system

800xA control system
– Cooling pump control

From AC800PEC drive controller (MMS)

– Pressure supervision
– Internal cooling water temperature supervision
– External raw water temperature supervision
– Regulating valve control
– De-ionized water conductivity supervision
– Water leakage supervision

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 7
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

HMI – Ring motor I

800xA control system
– Stator winding temperature supervision
– Warm air temperature supervision
– Cold air temperature supervision
– Water temperature supervision
– Water flow supervision
– Water leakage supervision
– Water pressure supervision
– Humidity supervision
– Dust sealing system supervision
– Vibration supervision
– Pole winding temperature supervision

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 8
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

HMI – Ring motor II

800xA control system
– Cooling fan control
– Overpressure (make-up) fan control
– Space heater control

From AC800PEC drive controller (MMS)

– Stator winding insulation against ground
– Rotor winding insulation against ground
– Static airgap measurements

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 9
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

HMI – Brake supervision

800xA control system
– Brake pump(s) control
– Oil heater control
– Brake pressure supervision
– Brake calipers supervision
– Brake valves supervision
– Filters supervision
– Oil temperature supervision
– Oil level supervision

From AC800PEC drive controller (MMS)

– Brake valve status

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 10
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

HMI – Lube system I

800xA control system
– Low pressure circulation pumps control
– High pressure circulation pumps control
– Accumulator circuit pumps control
– Oil heaters control
– Water cooling valve control
– Flow dividers supervision
– Valves supervision
– Accumulator pressures supervision
– Oil level supervision
– Oil pressures and flows supervision
– Oil temperature supervision
– Oil filters supervision

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 11
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
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GMD – Operation and Maintenance
800xA control system

HMI – Lube system II

800xA control system
– Table style listing of bearing values
– Bearing temperatures supervision
– Bearing pressures supervision
– Bearing flows supervision
– Thrust bearings supervision

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March 13, 2018 Slide 12
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
—
GMD – Operation and Maintenance
800xA control system

HMI – Network connection

800xA control system
– Status of 800xA and the process controller
– Status to client DCS link
– Status of MCC modules

From AC800PEC drive controller (MMS)

– OPC alarms
– OPC events

OPC (Open Platform Communications)

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March 13, 2018 Slide 13
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property
—
GMD – Operation and Maintenance
800xA control system

Questions

We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without
March 13, 2018 Slide 14
express authority is strictly forbidden. © ABB (Switzerland) Ltd. 2018 property