NEWS n 5 First speed-controlled MV motor is ‘a new way of creating motion’ ABB has announced what it describes as the world’s rst speedcontrolled medium-voltage motor, claiming that it represents “a new way of converting electricity into motion”. The system – called MV Titanium – combines a 1-5MW MV motor with a frequency converter in a single package. It is designed to power loads such as pumps, compressors and fans, reducing the need for equipment such as transformers, switchgear and MV motor cables, and cutting infrastructure costs. It is aimed at both retro t and new applications, and could cut energy use by up to 40%, paying for itself in less than a year in some applications. ABB has been developing the system for about two years. It is currently testing prototypes and hopes to begin pilot trials soon, before starting the rst commercial installations in 2026. The motors have a new design topology (aspects of which have been patented), but the accompanying drives are slightly modi ed and reprogrammed versions of existing frequency converters. Although variable-speed control is well-established for smaller motors, “large motors have so far been left behind, due to initial cost and complexity, with only 10-15% currently connected to a drive,” explains Heikki Vepsäläinen, president of ABB Large Motors and Generators. “But that is set to change with our new MV Titanium concept that makes it cost-eective and straightforward to install a suitable matched motor, with increased control, monitoring, and connectivity in a single package. “The potential savings in energy costs and CO2 emissions are huge,” he adds. “If we retro tted the entire installed base, it would be like taking just over 1,000 coal- red power stations oine.” At present, there are around one million MV motors in use around the world, accounting for about 10% of global electricity consumption. Each year, about 50,000 new MV motors are installed worldwide, typically with 20-year design lifetimes. Although these motors operate with eciencies of around 98%, there is still scope to save energy by controlling their speed. But varying the speed of the MV motors has traditionally been regarded as challenging because of the complexity and costs of designing and installing separate motors and controllers, and the need to build electrical plant rooms, often needing ventilation. Most users therefore opt for simpler DOL (direct on-line) xedspeed installations. ABB argues that its new concept will overcome these issues, saving the space and costs of a plant room, and eliminating the need to install heavy-duty cables between the controls and the motor. The purchase price of the new system will be similar to that of a separate motor and drive, but energy and other savings could recoup the cost of the new system within 1-3 years, depending on the application. There will also be substantial savings compared to using nonelectronic forms of control. Compared to throttling and valve controls, for example, the savings could be up to 54%; compared to on/o controls, they could be up to 42%; and compared to hydraulic controls, the savings could be up to 17%. Initially, ABB plans to oer the new technology in ratings from 1-2MW and to target pump and fan/blower applications, in particular. The range could later be expanded from around 500kW to 5MW and be aimed at other applications in sectors such as water and wastewater, pulp and paper, metals, cement, power, and minerals and mining. ABB is talking to pump manufacturers about adopting the technology. Initially, Vepsäläinen wants to focus on the retro t market, rather than the smaller market for new installations. ABB estimates that around 80% of MV motor installations between 2024 and 2027 will still be DOL applications. Although ABB is the rst motor manufacturer to be oering this “new way of de ning electromechanical powertrains”, Vepsäläinen says he would welcome other suppliers oering similar technologies to help reinforce the concept. He believes that the biggest challenge to establishing this “disruptive” technology will be to make users aware of its potential. “Beyond its technical progress, this next-generation motor concept represents a signi cant step towards productivity in a low-carbon world,” he concludes. “It puts ABB well on the road to support changing large, xedspeed motors to fully electrically controlled motors, one by one.” www.drivesncontrols.com July/August 2024 ROCKWELL AUTOMATION HAS issued a security notice urging all of its customers to take “immediate” action to assess whether they have industrial control devices facing the public Internet and, if so, to remove that connectivity “urgently” for devices not designed for public Internet connectivity. It says it is issuing the advice “due to heightened geopolitical tensions and adversarial cyberactivity”. The advice does not refer to any speci c cyberthreats or vulnerabilities. Rockwell adds that users should never con gure their ICSs (industrial control systems) to connect directly to the public Internet. “Removing that connectivity as a proactive step reduces attack surface and can immediately reduce exposure to unauthorised and malicious cyberactivity from external threat actors,” it explains. As well as disconnecting items from the Internet – or if this is not feasible – Rockwell is also urging users to follow its Security Best Practices document. Rockwell warns ICS users to cut Internet connections ‘immediately’ ABB’s speed-controlled medium-voltage motor could cut energy use by up to 40%
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