Outline

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Title: Recommended practice for Coordinated Drive Systems for Electrical AC Motors Operating on Three Phase, 50 Hz or 60 Hz, 1000 V and Below for Pulp and Paper Industry Installations

Scope: This recommended practice specifies coordinated drive systems for control of three phase 50 Hz or 60 Hz electrical motors operating at 1000 VAC and below. The document addresses hardware, control, communication, performance testing, and their documentation. The document does not include:

Fractional horsepower drives
Stand-alone drives (general purpose; example pumps, fans, etc.)
Motors and specifications for motors

In the context of this recommended practice, Coordinated Drive Systems (CDSs) are defined as multiple interdependent Adjustable Speed Drive (ASD) sections that control a paper or pulp web process line.

Example usage CDSs include:

Paper Machines
Winders
Coaters – on & off machine
Extruders – on & off machine
Super Calenders
Pulp Drying

This Recommended Practice includes recommendations and rationale for:

Hardware
Control
Communication
Performance testing
Documentation

Outline

Environmental conditions in P&P (drive room)
1. Humidity
2. Ambient temperature
3. Corrosion
  1. Reference ISA air quality standards
4. Altitude
5. Seismic requirements
6. Noise
7. EMI
Power Quality Requirements (power feed to the drive system including control power)
1. Neutral grounding configurations
2. Backup power?
3. Control power conditioning
4. Drive effect on system power
  1. Upstream harmonics
  2. Downstream harmonics
  3. Power factor

Hardware
1. Protection of driven equipment
2. Personnel safety
  1. Arc flash & shock safety
    1. Arc flash protection of the DC bus
  2. Maintainability
  3. Service and repair
  4. Shipping considerations
  5. Sizing
  6. Supply unit (diode, SCR, IGBT active front end)
  7. Interface to existing drive systems
  8. Ride through capability
  9. Short circuit withstand capabilities
  10. Ergonomics
  11. Input and output power interface terminations
  12. Output isolation (motor disconnecting means)
  13. Conductor materials (copper versus aluminum, tin plating, silver plating)
  14. Rear panel access
  15. Top vs bottom entry
  16. Input Reactors, Output Reactors
  17. Hardware selection – include duty cycle (example winders)
  18. High frequency grounding for motor leads and emc considerations
3. Control (system control, hardware control – refer to other standards, not including tuning), cyber security
  1. Drive master controller vs distributed master
  2. Machine OEM vs Drive master control
  3. Drive CPU to drive ratio
  4. max CPU loading
  5. Machine safety consideration
  6. Process Control consideration
  7. Consideration of Machine Safety and Process Control applications inclusion into the same CPU with the Drive Master function
  8. Control quality requirements the drive system needs to fulfill
4. Communication (control & protection – include communication protocols and applications such as safety). Reference other standards? Cyber security, remote access.
  1. Process control to the drive system
  2. Operator interface to the drive system
  3. Individual drive sections to the drive system
  4. Machine or web transducers to the drive system
  5. Peripherals interfacing, including via wireless communication
  6. Interface to existing drive systems
  7. Machine Control System interfacing
  8. External software applications (SCADA, PIMS, Historians, etc.)
5. Site Performance Acceptance Testing – Jon Stefancik
  1. Performance Testing: Control quality requirements the drive system needs to fulfill
  2. Commissioning – (maintenance benchmarks (voltages, amps, step responses, etc.)
    1. Definition of signals – what filters for speed and tension (example encoder feedback filter)
  3. Agreed to speed and tension control radian response
    1. Mechanical considerations (backlash)
  4. Thermal performance
6. Factory Acceptance Testing
  1. Required
  2. Power up all section
  3. Communications (operator panels, PLC, DCS, diagnostics, drives, etc.)
  4. Either run a motor or simulate running of each section
  5. Functionally test operator panel
  6. Test all analog and digital inputs and outputs
  7. Verify Documentation
  8. Safety device/relay functional testing – all safety provisions
  9. Benchmark tests for:
    - A known frequency-sensitive impedance representative of probable downstream load(s)
    - A known frequency-sensitive impedance representative of the probable upstream distribution circuit (i.e. common bus)
    - Operation at multiple load points – representative of system operation (e.g. 25, 50, 75, 100 percent load or something else) against these impedances
    - Record harmonic signature at each point, out to at least 15^th harmonic (particularly necessary for active-front-end configurations with higher switching frequencies)
    - Include results in system documentation
  10. Documentation
    1. Schematics
      1. One-line
      2. Communication network topology
    2. System manual
      1. Drive manual
      2. Functional description
      3. HMI
      4. PLC
      5. PMs
      6. Fault Codes
      7. Vendor cut sheets
      8. Installation manual
      9. Maintenance and repair manual

Bill of material including manufacturer’s part number
Recommended spare parts list
Storage requirements
Electronic/paper requirements
When requested – 3D drawings cabinet layout

Training
1. Level I & Level II maintenance training
2. Operator training