Amtech-Variable-Frequency-drive-Motor-Control.pdf
- 1. Total Solution in Motor Control GAIN TOTAL CONTROL
- 2. Power Conservation Best Uptime Customization Improved Maintenance Quality Production Creating an edge The important process parameters for any manufacturing industry are pressure, flow and temperature. For an industry with specific needs there is an endowment of options that is centered on choices of control depending on accuracy, flexibility, energy saving and price. This is where Amtech has an edge over others. Amtech provides complete motor control solutions competent to meet the production trends and requirements resulting in efficient production at mass scale. Motor Control - Customised At Amtech, we have a proven expertise in customised motor control. Since 1987, we have designed and manufactured the highest and most accurate motion control solutions for an array of industries around the world. Our customised Variable Frequency Drives (also known as AC Drives) and motor control products provide critical performance for today’s demanding applications in markets requiring high precision and high throughput motor control solutions. We, with our engineered systems, offer our clients a full range of services tailored to their specific needs. Right from replacing a system component, to dedicating a complete team of Amtech professionals to implement projects of varying scales, we do it all. 2
- 3. We have been the pioneers in state-of-the-art motor control technology in India. Our team of seasoned experts completely understands your process to offer optimized solutions. They continuously innovate and provide the finest motor control systems at par with global standards. Fully equipped with design and development aids such as CAD tools, Simulation softwares, DSP design & development tools, PCB design software and experienced technical professionals, we are able to cater to customized requirement in power electronics & automation. Our in-house R&D department has earned recognition by successfully developing state-of-the-art products like VFDs, Soft starters and many other Power Electronics products at par with the Global Standards. Our motor control products, services and solutions are user-friendly and highly reliable. They not only increase your production efficiency, but also reduce manual dependence and production cost. Accelerating Production Efficiency 3
- 4. Reliable Drives Since inception, Amtech has been working with the energy sectors. Our well-built, user-friendly Variable Frequency Drives ensure efficient and reliable functioning of your pumps, fans/blowers and cranes. They not only save energy, maintenance and downtime costs but also provide precise control over the process. Minimise wear & tear and save energy Accurate speed control of our VFDs maximise output of your pump and fan systems and reduce mechanical wear & tear, vibrations and leakages. Each of your operation is continuously modified to demand, maintaining the required pressure as per the flow or the volume to be handled. Further, a sleep mode function in our VFDs saves energy by stop- ping the motor when it is not required to run. Optimise cost Smooth start reduces rush currents and mechanical or hydraulic stress in pipes and gaskets. Linear stops eliminate the risk of water hammer in your pumps, without the need for costly motor-controlled valves to reduce pressure spikes. Starting a fan that is rotating in the reverse direction is handled safely with a speed search function securing the correct direction and function before full speed operation. • Rolling Mills / Roller Table • Wire / Sheet Drawing Machine • Cranes / Stacker - Reclaimer • Fume / Dust Exhaust Fan / Blower • Lifter / Pusher / Charging Car Metal Industry • Drilling Rig • Mud / Submersible / Progressive Cavity Pump • GCS Heater • Artificial Lift (Pump Jack) • Compressor / Fracking Oil & Gas • Kiln Drive • Grinder / Crusher • Cranes / Stacker - Reclaimer • Separators • Cooler Fans / ESP Fan Cement Industry • ID / FD / PA / SA Fan • BF Pump • Cooling Tower Fan / Pump • Wagon Tippler • Stacker / Reclaimer Power Industry • Centrifuge • Agitator / Mixer / Fermentor • Dozing Ammonia Pumps • Process & Supply Pumps • Chiller / Lube Compressors Chemical & Pharma • Sugar Mill Drive Automation • Sugar Centrifuge Automation • Cane unloader hoist drive • Feeder table automation • Cane carrier Sugar Industry 4 DRIVINGTHE GROWTH
- 5. Dynamic performance for demanding applications Our VFDs offer high accuracy in dynamic applications, for example in cranes used for material handling. Efficient and precise control minimises cycle times and mechanical wear. Precise torque control handles abrupt load changes and overcomes initial peak loads. Efficient operations Our VFDs and soft starters are well equipped for applications such as pumps, blowers, mixers, scrapers and centrifuges. Designed to meet harsh environment challenges, we help you to install them close to the controlled equipment. A built-in load monitor protects the process from damage and downtime, if a pump is running dry, a pipe is blocked, a mixer blade is broken or a scraper is jammed. Our VFDs and Electronic Soft Starters prevent water hammer in your pump systems and extend equip- ment lifetime. Well proven for harsh operations Working in mining, chemical, rayon and cement production always means harsh operating and environmental conditions - heavy loads, abrasive dust & dirt, extreme weather and temperatures; remote locations with poor power supply conditions. Amtech products are well proven in material handling applications around the world. Amtech can handle your heavy operations in a reliable and efficient way, whether they are crushers, conveyors, hoists or centrifuge. • Paint Booth / Shop • Grinding • Hobbing Machine • Shower Application • Conveyor Automobile • Sectional Automation • Line Shaft Drives • Pulper / Refiner • Vacuum Pumps • Winder / Rewinder Paper Industry • Chiller Compressors • Butter Churner • Condensor Automation • Hydroflow System • Homogeniser Food & Beverages • Raw Water Supply Pumps • ETP Pumps • DM Water Pumps • Sewage Supply Pumps • Decanter Centrifuge Water & Waste Water • Ring Spinning / Speed Frame • Winder • Jet Dyeing Pump / Printing • Stenter & Sizing Machine • Autoconer Machine Textile • Elevator • Conveyor • Bulk Material Handling • Cranes • Pumps / Fans Mining 5 OF DIVERSE SECTORS
- 6. • Solution provided without replacement of existing AC Motor and VFD system • Speed of kiln increased to the desired speed, 4 RPM, resulting in higher productivity • Smooth speed control of kiln through two VFDs and motor of different ratings Benefits: Scenario For the kiln application, DC motor and drive are used due to their excellent torque speed attributes, but the maintenance of dc motor is a big issue. Customer replaced DC Motor and Drive with AC Motor and our VFD to run the kiln. But, they could not increase the speed of kiln due to wrong sizing of the AC Motor and VFD. Solutions Without replacing the entire AC Motor and VFD system, we installed additional auxiliary AC motor and VFD along with the additional controller which is used for load sharing. We assist our customer to size the VFD and motor system when replacing the existing DC Drive system. Retrofit Solutions for EOT (Electric Overhead Travelling) Grab Crane Scenario The most common but very challenging type of overhead crane, found in most factories is electrically operated. But the old system has many limitations like, maintaining differential gear, slip-ring motor and mechanical brakes for EOT Crane and are extremely expensive and time consuming. Solutions Amtech offers retrofit solution for EOT crane having grab unit for material handling like coal, gypsum, sand, limestone, clinker etc. We provided solutions in Cement Industry for EOT Cranes having 6 ton capacity, located at 35 feet above ground level, cross travelling 70 feet and long travelling 330 feet. The differential gear replaced by high resolution encoders to monitor the position of grab/hoist travel. Crane controller used to ensure proper synchronization of grab/hoist mechanism. Used high performance VFDs, control- ler and automation system with squirrel cage induction motor with special function of VFD for smooth start/stop. Benefits: • Smooth crane operation through VFD without any jerk • No maintenance of brake system, as the brakes are used only for holding • Precise closing of grab results in increased productivity and reduced pollution • Energy saving as the total system efficiency improves 6 APPLICATIONS VFD Solutions for Kiln Application
- 7. VFD with Active Front-end Converter for Centrifuge Machines Scenario Many utilities have centrifuge machines with stand-alone system and mechanical brakes. All this wastes a large amount of energy during the stop and start operations. More so, the machines start with mechanical jerks and draw large current from the utility, reducing the equipment's lifespan and increasing pollution in the utility. Solutions To resolve these issues Amtech offers Active Front-end Convertor (AFC) to feed the regenerative energy back to the mains rather than dissipating it in resistors. This not only helps in power saving but also enables smooth and efficient working of the machines. Benefits: Total Turnkey Solution for Roller Table Scenario Since the roller table requires high torque, the slip ring motors have been the preferred choice for many years. But the slip-ring motors come with inherent disadvantages like high maintenance and heavy jerks during start and stop. More so, if the bloom piles-up on roller table, the existing motor is unable to drive the bloom resulting in heavy produc- tion loss. Solutions Roller table drive systems are composed by multiple motors, where synchronised operation of each motor play crucial role for the rolling process quality. Also, the load sharing by each motor is equally improtant for the trouble free opera- tion. Roller tables are designed to operate with variable speed demand constant torque even when running at low speeds. Amtech has successfully provided "Total turn key solutions" to meet the demanding performance in roller table applica- tion. We supply cabels, motors, engineered system with VFDs and automation system. Benefits: • 15% increase in energy saving • AFC feeds the regenerative energy back to the mains • The current harmonics at input of VFDs are limited to 4 % THD and power factor is unity • Smooth start/stop operation through VFD • Reduced mechanical jerks • Smooth start of bloom in all conditions • Precise braking due to electronic brake, hence roller table can stop within a second • The productivity increased by 20% • Load shring and synchronised speed results in smooth operation 7 APPLICATIONS
- 8. Amtech offers highly reliable drive systems for most critical applications. We have successfully installed Medium Voltage Variable Frequency Drives on Boiler ID, FD, PA, SA fans and Feed Water pumps in power plants. The ID fan sucks the gases out of the furnace and throw them into the stack by creating sufficient negative pressure in the furnace (5-10 mm wc) in the balanced draft units. They are located in between the ESP and Chimney in the flue gas path. Radial Fans-double suction-backward curved vane with inlet guide vane (IGV) control and VFD control is used in all boilers. They handle large volumes of hot dust/ash laden flue gas (temp up to 150 deg C) from furnace and all leakages occurring in the system till the inlet of the fan. ID fans overcome the pressure drop inside the furnace, Super heater, Preheater, Econ- omiser, Gas ducting & ESP. Consumes maximum power in all boiler auxiliaries as it handles the large volume and heavy pressure drop of the flue gas. The PA fans supply high pressure primary air through APH, needed to dry & transport coal directly from the coal mills to the furnace. Primary air for mills is divided into cold & hot primary air. Axial fan-double stage-reaction type with blade pitch control is used in the Pulverized fired boiler (210/250/500 MW). 8 VFDs for Sugar Mill ID/PA Fans for Boiler APPLICATIONS The torque requirement is very high at low speed during sugarcane milling. In the existing older systems the steam used in the turbines cannot be controlled during variable load. Though the turbine takes input as per its design capacity, it is unable to give optimum output due to poor efficiency. Moreover, steam turbine prolongs the start and stop timing to 25-30 minutes and makes reverse operation difficult. Amtech's innovative & efficient drives deliver much higher torque at variable speeds. Also, the squirrel cage induction motor installed in place of turbine accelerates the overall efficiency and reduces the start/stop time by 75%. • Smooth start/stop operation through VFD without any jerks • Very low speed operation is possible through VFD • Energy saving as the VFD consumes power based on the requirement and the steam saved is utilised to generate power • Smooth operation provides more life to mechanical parts • Precise control of flow enables fuel saving and quality operations • More than 20% energy saving • Full motor protection Benefits: Benefits:
- 9. 9 Master Follower Operation VFDs for Wagon-Tippler APPLICATIONS • The wagon tippler can be startedwithout any problem in any condition • Precise current balancing of both motors as compare to old system • Dynamic yet precise braking system enables smooth up and down tippler operation • Highly reliable VFD with trouble free operation • Minimised production losses and prevented penalty to Indian Railways • Jerk free stopping of the tippler Wagon Tippler is a mechanism used for emptying loaded wagons or railroad cars such as hopper cars, gondolas or lorries (tipplers). It holds the rail car to a section of track and rotates the track and car together to unload the contents. At Amtech, our experts first look into the type of tippler, tipping requirements, marshalling equipment, wagon inhaul/out-haul and tipping operations and then suggest required VFDs for the smooth operation of the tippler. We offer solutions for the new machines as well as retrofit requirements. Sectional paper machine has many variants based on the operating speed, GSM, mechanical design etc. If sections are designed to rotate with the help of two motors in common felt, then care must be taken to choose the load demand of each motor. Otherwise it may impact on stretching of the Wire/Felt, resulting in breakage of Wire/Felt. This results in costly replacement and shutdown of the machine affecting valuable production. VFD, which is synchronizing the speed of the motor, must also take care of load sharing of each motor. This requires precise Tension/Torque control. For example, Wire is rotated with Couch roll and Turning roll, then both motor should share the equal load depending on the size of the motor and dimension of the roll and gearbox. Also the combined effect of speed on wire should get synchronized with rest of the machine. Same phenomena will be applicable for Press and Felt driven Dryer sections • Increased life of Wire, Felt etc • Provides smooth higher speed operation • Increased production gain by reducing paper breakage • Improved paper quality • Jerk less operation improves life of mechanical parts Benefits: Benefits:
- 10. DRIVING THE GROWTH Axpert series variable frequency drives are designed for wide-varying tropological and power conditions. The drives are easy to configure, control and monitor. Also, they are highly reliable and are resilient in harsh industrial conditions. Power Capacity 0.75...2100 kW (1...2815 HP) Voltage Range 380...480 V, 500...600 V, 601...690 V, 3-Phase, 50/60 Hz AXPERT-HIVERT Medium Voltage Drive is widely used for speed regulation, energy saving, soft start-up and intelligent control of the medium voltage motors in industries such as thermal power plants, petroleum, chemicals, mining and metallurgy. Power Capacity 200...12500 kW (270...16750 HP) Voltage Range 3, 3.3, 4.16, 6, 6.6, 10, 11 kV, 3-Phase, 50/60 Hz The Axpert-Opti torque series Electronic Soft starters are very high performance and offers a complete package of advanced features in start/stop control, protections, monitoring, diagnostics and communication for motors. Its advanced digital control eliminates the need for thermal and electronic motor protection relays, meters, transducers etc. Power Capacity 15...1065 A, 3.7...1000 kW (5...1340 HP) Voltage Range 200...480 V, 200...690 V, 3-Phase, 50/60 Hz Variable Frequency Drive Soft Starter Medium Voltage Drive Engineered System 10 Amtech’s vertically integrated Engineered System packages comprise VFD modules with customer specific switchgear & protection, enclosure requirements and cooling arrangements. The seamless integration guarantees that performance specifications are adhered to as per the ratings, enclosure types, environmental issues and power supply conditions. The engineered systems are designed as per the global standards and engineered with efficiency & affordability in focus. DRIVING THE GROWTH
- 11. 11 Always ready to serve you We have an expansive area of 25,000 sq. m. located at the Electronic Zone, Gandhinagar, with state-of-the-art infrastructure, hi-tech production and testing facilities to innovate and customise Motor Control solutions for your need. Our team of more than 300 highly qualified management professionals, engineers, R&D specialists, quality assurance and customer support professionals work round the clock to support our customers across the globe. Amtech Advantage • Innovative solutions by in-house R&D • Core competence in VFD and customised solutions • Highly qualified and experienced professionals • Approval of renowned consultants in various industries • Manufacturing excellence and fast turnaround capacity • Quality system certified as per ISO 9001:2015 standard • Wide installation base with major industry coverage • Strong understanding of the Indian and global market • Competitive pricing • Dealers/system house network across the country • Prompt customer service support network
- 12. CAT.NO. : AEIL/MC/10-21 Our Network: E-6, GIDC Electronics Zone, Gandhinagar - 382028, Gujarat, India. Phone: +91-79-23289101, 23289102, 23289103 | Fax: +91-79-23289111 Email: info@amtechelectronics.com | Website: www.amtechelectronics.com Specifications in this catalogue are subject to change without notice. With over 35 years of field experience, our team of technical experts can help design custom solutions that will make your equipment more efficient, reliable and cost effective. And that's the bottom-line! INNOVATIVE Products People Solutions Services For the Industry Gandhinagar Atlanta Gandhinagar Ahmedabad Mumbai Surat Muzaffarnagar Delhi (Gurgaon) Vadodara Indore Jamnagar Udaipur Kolkata Nagpur Pune Hyderabad Vapi Raipur Bhopal Jamshedpur Jaipur Lacknow Vizag Bangalore Chennai Belgaum Coimbatore Pondicherry Trichy Head Office Branch Office Dealer System Integrator Resident Engineer Global Distribution Aurangabad Nasik Chandigarh Veraval