1. ABB Gearless Mill Drives retrofits
Mining user conference, may 3-5, 2017
ABB Gearless Mill Drives retrofits
Solutions overview and recent project experience.
Jesus Perez, Strategic Account Manager, ABB in Chile

2. ABB Gearless Mill Drives (GMD)
Ring motor
Control Block (E-house):
- Cycloconverter
- Mill control system (800xA)
- MCC
- HVAC
- Firefighting
- Advanced Condition Monitoring
Transformers
DCS
Remote
services
Agenda
ABB Gearless Mill Drives
Why retrofits?
Vision, inspiration for innovation in retrofits
Possible solutions for ABB Gearless Mill Drive retrofits
Recent project experience in Chile
Success factors and conclusions
Mining User Conference 2017, Stockholm
May 3-5, 2017

3. ABB Gearless Mill Drives (GMD)
Ring motor
Control Block (E-house):
- Cycloconverter
- Mill control system (800xA)
- MCC
- HVAC
- Firefighting
- Advanced Condition Monitoring
Transformers
DCS
Remote
services
Overview
GMDs are the workhorses of grinding operations
First GMD in 1969, delivered by ABB
Global installed base of around 170 units, of which 100 by ABB
ABB installed base rapidly growing and aging, with now 20 years of average age
ABB has developed extensive experience in effective upgrades and replacement of GMD system components
Mining User Conference 2017, Stockholm
May 3-5, 2017

4. Evolution benefits, drawbacks, solutions
Why Retrofits?
Evolution benefits, drawbacks, solutions
Product evolution has the goal to increase the drive system’s availability by:
Making equipment more reliable
Designing new features for less maintenance (at longer intervals)
Enabling innovative services to effectively support operations locally or from remote
Drawbacks of product evolution: obsolescence of previous generation
Products can reach the end of their life-cycle, typically meaning that series manufacturing has stopped and supplier’s focus is now in the next generation
As a consequence, limited or no more existing full range of life-cycle services and support such as: remote technical support, regular control software upgrades, updated spare parts inventories and preventive maintenance.
In addition, aging of equipment increases likelihood of unplanned stops
Especially valid under typical mining’s harsh operating conditions
The solution is a proactive (thus timely) retrofit of critical components in terms of life-cycle and aging with their modern version
Same functionality as before is guaranteed
In most cases, system’s features are extended to the latest available technology developments
Mining User Conference 2017, Stockholm
May 3-5, 2017

5. ABB Gearless Mill Drives (GMD)
Possible solutions for retrofits
Several retrofit and upgrade options exist for a GMD system:
Replacing SW and HW components, including parts of the ring motor
Upgrading the entire system to deliver higher power, thus achieving higher mill’s throughput
This presentation focuses on main parts with higher criticality in terms of life-cycle support, therefore products with relatively fast development life-cycles:
Microsoft Windows XP® operating system
Auxiliaries’ control system (800xA)
Cycloconverter’s controller (PSR to AC 800PEC)
Mining User Conference 2017, Stockholm
May 3-5, 2017

6. ABB Gearless Mill Drives (GMD)
Possible solutions for retrofits
Entire E-house replacement
800xA and Windows© upgrade
Cycloconverter controller
(PSR to AC 800PEC) upgrade
Complete Cycloconverter replacement
The need to retrofit Control Parts opens opportunities to replace at the same time additional parts which are critical in terms of aging but maybe less in terms of life-cycle support e.g.
Replace the complete cycloconverter or the entire E-house
This approach, under certain circumstances, can even bring advantages in terms of execution time and risk mitigation compared to the upgrade of the control parts only
These retrofit solutions can typically be executed in parallel to other long standard maintenance activities in the mine or in the concentrator plant
Mining User Conference 2017, Stockholm
May 3-5, 2017

7. ABB Gearless Mill Drives (GMD)
Additional opportunities on 800xA upgrades
integrated control system for all plant’s mills also called “Mini DCS”
Upgrade to latest operating system version (minimum recommendation)
Upgrade to a redundant server structure (maximize availability)
Separate control system for each mill
Mining User Conference 2017, Stockholm
May 3-5, 2017

8. ABB Gearless Mill Drives (GMD)
Comparison of retrofit solutions
Cycloconverter’s controller upgrade to AC800PEC.
Complete cycloconverter replacement.
Fully-equipped E-House replacement.
Accessibility to the equipment, logistic and space limitations.
No particular logistic and space requirements.
Sufficient space around the E-house to handle the cycloconverter replacement is required.
Sufficient space for the E-house handling and replacement is required.
Duration of shutdown for retrofit execution.
Similar to “cycloconverter replacement” option. Requires enough time planning for thorough point-to-point testing of control interfaces.
Similar to “controller’s upgrade” option, or faster depending on the specific site characteristics.
Strongly depending on the specific site’s characteristics in terms of logistic and space.
Trade-off between capital investment and extent of the retrofit’s scope.
Lower investment. Typically considered a fair trade-off between investment, required shutdown for execution and extent of the retrofit’s scope.
Medium investment. Typically considered a good trade-off between investment, required shutdown for execution and risk mitigation.
Higher investment. One-step implementation of all the latest design innovations for higher reliability and simpler maintenance, including the replacement of even the smaller components which – due to aging – are adding risk to the overall system availability.
Mining User Conference 2017, Stockholm
May 3-5, 2017

9. Recent project experience
SAG Cycloconverter replacement
Replacement of SAG cycloconverter in Concentrator plant in North of Chile, keeping the existing E-house.
Goal: replacement in maximum 7 days, during a long standard maintenance shutdown
Challenge:
Previous similar projects took 15 days
SAG mill is the bottleneck of the concentrator plant line 1
Team
Customer project team
ABB Chile
ABB Switzerland
Subcontractors
Mining User Conference 2017, Stockholm
May 3-5, 2017

10. Recent project experience – SAG Cyclo replacement
Overview
SAG Cycloconverter replacement
Scope:
Complete cycloconverter with latest Control HW & SW
Rotor excitation unit
Mill Local Control Panel
Interface for remote services
Interfaces:
Power cables and cooling pipes
Communication between drive controller (AC 800PEC), auxiliaries controller (800xA) and MLCP
Network connection for remote services
Key advantage: entire converter unit is factory tested, thus minimizing the quantity of functional testing required during the shutdown activities
Mining User Conference 2017, Stockholm
May 3-5, 2017

11. Recent project experience – SAG Cyclo replacement
Project phases
Phase 0 – Feasibility study (3 weeks)
Identify retrofit option, confirm possibility of 7 days only shutdown
Phase 1 – Purchase of long lead items and equipment engineering
Engineering to include learnings from feasibility and similar projects into the new equipment
Phase 2 – Site engineering (20 weeks)
Development of reliable plan for execution, required tools and infrastructure adaptations, safety and quality control plan, etc.
Phase 3 – Preparation Works (6 weeks)
Trainings, removal of interfaces, pre-commissioning of new equipment, adaptations in infrastructure, installation of tools, etc.
Phase 4 – GMD shutdown and replacement work (7 days)
Removal of old equipment, installation of new, interfaces work, electrical and control commissioning
Phase 5 – Demobilization
Removal of equipment, tools, hand over to operations, people demobilization
Mining User Conference 2017, Stockholm
May 3-5, 2017

12. Recent project experience – SAG Cyclo replacement
Phase 3 – Preparation Works (6 weeks) with SAG in operation
Scope:
Removal of interferences
Wall opening on the concentrator’s building and installation of cantilever platform
Preparation for accessing to the power cables underneath the e- house
Installation of winches
Installation of sliding rails
Placement of the new CCV unit next to the E-house and
Pre-commissioning of the new cycloconverter’s water cooling unit
Mining User Conference 2017, Stockholm
May 3-5, 2017

13. Recent project experience – SAG Cyclo replacement
Phase 4 – GMD shutdown and replacement work (7 days)
Activities
Removal and installation works:
E-house’s lateral doors lifted
Cables and cooling pipes disconnected
Old cycloconverter removed, new cycloconverter installed
Interfaces works:
Power, control, instrumentation and cooling interfaces
Electrical and control commissioning:
SAG mill ready to turn after typical commissioning tests
Mining User Conference 2017, Stockholm
May 3-5, 2017

14. ABB Gearless Mill Drives retrofits
Conclusions & Key Factors for Success
Retrofits enable the implementation of state-of-the-art hardware and software as well as the full portfolio of lifecycle services from the manufacturer.
Several solutions exist to retrofit a GMD system. If planned with expertise they can be executed in parallel to other long standard maintenance works in the concentrator plant.
Each plant has its own particular characteristics. The optimal solution is unique, specifically adapted to each site. For the same reason also the duration of the shutdown required to execute the retrofit is strongly site dependent.
Key factors for success:
Close cooperation of the project team: customer, supplier, sub-contractors
Deep knowledge of the plant and experienced personnel
Detailed, expert and innovative engineering phase
Phase 5 – Demobilization
Removal of equipment, tools, hand over to operations, people demobilization
Mining User Conference 2017, Stockholm
May 3-5, 2017

15. Thank you for Your attention
Acknowledgements & Thank you
All persons who contributed during all the phases of the SAG mill cycloconverter replacement in Concentrator plant in North of Chile
Mainly to Customer project’s team
And to all the members of the ABB’s team led by:
Yuri Villegas (ABB S.A., Chile) and
Raul Baldero (ABB Switzerland Ltd.).
Mining User Conference 2017, Stockholm
May 3-5, 2017