ELECTRIC POWER SOLUTIONS FOR PIPELINE APPLICATIONS

1. Oil & Gas
ELECTRIC POWER
SOLUTIONS FOR PIPELINE
APPLICATIONS
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2. Pipeline Applications Experience
NIDEC ASI provides electric power solutions for pumps and compressors in oil and gas
pipelines, guaranteeing the best technology and the best operational conditions along the
entire process: from extraction to distribution.
Our engineering team fully realizes your dreams and desires, designing customized solutions
which meet our client’s need in terms of: power quality, network connection, power and
frequency flexibility, low maintenance costs and time, machine durability, optimization of
capital expenditure, best allocation of available space.
With over 40 years of experience we work in close collaboration with End Users, Engineering
and OEM in order to develop the best global solutions for pipeline field operations.
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3. Electric Power Solutions
Meeting the operational needs
Meeting the operational needs for oil & gas pumps and compressors in terms of operational
speed range is a primary issue, specific to these applications. The cost, complexity, and
reliability of the drive train will be impacted as more components are added.
To guarantee maximum reliability, uptime and performance in terms of efficiency, electric
motor-drive systems for pump and compressor applications require specific studies
considering all the different operating requirements.
This will affect the motor type, motor size, system configuration, power requirements,
network power connection, costs and losses, coupling and operational methodologies.
We meet requirements and desires of our customers, in the selection of the electric motor
and drive train configuration, through a customized approach.
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3

4. Traditional Approach
Application up to 5 MW
In these types of solutions 2 or 4 poles fixed frequency machines are traditionally used, but
the interest in VFD technologies is steadily growing.
Electric Utility or
Other Generated
Power
Constant 50 or 60 Hz,
AC ~ Voltage
Softstarter
Electric
Motor
N
1
N
1
Gas
Pump or
Compressor
Compressor
Softstarter + Motor Directly Driving Pump or Compressor
The traditional approach is usually applied to compressors and centrifugal pumps on oil and
gas pipelines where substations are near or else in derivation plants. The motor operates
Direct on Line (DOL) at constant speed and torque.
Today, in order to increase plant longevity and maintain simplicity and costs, the preferred
option for the drive train is to install a softstarter to ramp up the motor to its nominal rated
operating conditions.
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5. Softstarter
By starting a motor at a low
effective frequency and then
ramping up the speed, motor
current and torque can be limited
to near full load values.
The Softstarter can provide a
motor soft-start while providing
full load torque, also helping to
reduce the motor current
requirements for start-up.
Advantages in using a Softstarter:
• Least severe option for torsional
load and current demand by
motor upon start up means less
wear on equipment
• Guarantees motor can be
started on virtually any electrical
grid
Medium Voltage Softstarter
3,3 KV up to 15,000 KV
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6. Softstarter
One Line Diagram
Incoming line
By pass switch
Softstarter
M
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7. VFD Solutions
Flexibility & Life Cycle Management
Another option would be to use a VFD as a softstarter. This solution requires a higher intial
capital investment but guarantees maximum flexibility for future operation.
M
Pump
or
Compressor
VFD
M
Pump
or
Compressor
N° motors
Plant Phase 1: start up – full efficiency:
Plant Phase 2: changes in conditions
The VFD System technologies can be
used as Softstarter. With this configuration
it is possible to activate a X number of
motors with a gradual increase of power.
This solution permits to optimize
frequency flow, without bearing upon the
external electrical network and increasing
life span machines.
In this second phase Flexibility and
Optimization of initial investiment are key needs.
PPT2013.01.01.08EN
In this phase the drive is used not only to
start the motors but also to adjust the
speed to the required load, thus saving
energy.
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8. Silcovert S
Principle one line diagram for one Softstarter system
11 kV – 50 Hz Line Power
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9. Silcovert TN
Principle one line diagram for one Softstarter system
13,2kV-60Hz Power Supply line
NIDEC ASI SCOPE
OF SUPPLY
3a
By_pass
Circuit
Breaker
1
Input
line
Circuit
Breaker
3b
By_pass
Circuit
Breaker
SILCOVERT
SVTN
Synchronization
Unit
Mot.
Protect.
Mot.
Protect.
2b Output
Circuit
breaker
2a Output
Circuit
breaker
M
1
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M2
Asynchronous Motor 1-2
One run. the other is
Stand-by (reserve)
9

10. VFD Solutions
Investment planning
We support the installation of the Variable Frequency Drive System both as a new build
and through retrofitting. This allows our customers a choice in their investment planning.
Retrofitting can be handled in one of two ways:
•
•
TN VFD in Container
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Control - room space management. The
station can easily be designed from the
beginning to accomodate the future
installation of the VFD. In this case NIDEC
ASI can act as consultants, providing the
engineering team with the Dimensions and
Electrical schemes to size the original
station.
Or
NIDEC ASI can provide the installation of
the complete solution in container ready to
be connected to the existing plant.
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11. VFD Packages
Application up to 30 MW
Some applications will require the use of a Variable frequency drive (VFD) from the beginning
to vary the pump or compressor speed. Typically, these are higher power applications or
installations where the flow rate is not constant throughout the year. The VFD works to vary
the input frequency and voltage supplied to the electric motor.
NIDEC ASI supplies VFD Technologies in
complete Fully Integrated Packages
consisting of:
• Switchgear
• Drive Transformer
• VFD
• Disconnectors (supplied by a third part)
• Electric Motor or Motor/Generator
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12. VFD Solutions
Life Cycle Cost Evaluation
 the highest efficiency on the market today (lower energy consumption)
 the Lowest Maintenance Costs
 the Highest reliability (no down time means higher productivity)
Load
%
VFD
Efficiency %
VFD+Transf+motor
Efficiency %
Power Factor
%
100
98.6 – 98.0
97.3 – 96.1
0.96
75
98.5 – 97.5
97.7 – 95.8
0.97
50
98.0 – 97.0
97.5 – 95.0
0.98
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13. Optimize Electric Motors Efficiency
To reduce component losses eliminating Gearbox
To optimize the elecrtic motor’s efficiency the installation of tailor – made
solutions is a primary need
Electric Utility or Other
Generated Power
Constant 50 or 60 Hz,
AC ~ Voltage
Variable
speed
Variable freq
AC ~
Electric
Electric
Motor
Motor
VFD
VFD
N
N
1
1
1
Gas
Gas
Compressor
Compressor
Single motor Directly Driving a Gas Compressor with VFD (without Gearbox)
Electric Utility or Other Constant 50 or 60 Hz,
Generated Power
AC ~ Voltage
Fixed Speed Ratio,
Variable
freq AC ~
VFD
VFD
Variable Speed
Electric
Electric
Motor
Motor
N1
Gearbox
N2
Gas
Gas
Compressor
Compressor
Electric Motor with VFD (with Gearbox)
Efficiency of the electric motor drive train will be determined by the losses. The gearbox is
one of the main significant causes of drive train component losses. Typically, these are on
the order of 5 to 8 %(*).
(*) “Application guideline for electric motor drive equipment for natural gas compressors”, Gas Machinery Research Council Southwest Research
Institute, Jan 2008
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14. Integrated Engineering Approach
Typical Electric Drive System
EM
~
~
=
=
Electric Drive
Grid Side connection
• Current & voltage distortion
• Power factor
• Filters
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Motor Side connection
• Torque distortion
• Motor thermal stresses
• Train dynamics
• Train operability
Subsystems
• Transformers
• Power Converters
• Control system
• Auxiliaries
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15. Integrated Engineering Approach
Integrated Mechanical & Electrical Design
Torque Input from VSDS
Drive Control
Torsional Mode Analysis
Drive
Steadfast Drive
FR9
FR9E
FR9
EM
MCL1402
3MCL1403
EM
Optimizing Max Ripple at Torsional Modes in Speed Range…
torque spectrum at 3300 rpm and 33 MW
1000
900
1000
|Fsw - 15f0|
800
600
|Fsw - 21f0|
400
200
0
1st torsional mode
700
2nd torsional mode
600
500
400
300
200
100
20
25
30
35
40
Fundamental frequency, Hz
45
Speed/fundamental frequency (Hz)
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torque harmonic in Nm
T o r q u e A m p l it u d e , N m
@ R ip p le f r e q u e n c ie s …
800
0
0
20
40
60
80
100
120
frequency in Hz
140
160
180
200
Damping torque response by control algorithms
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15

16. Integrated Engineering Approach
Mechanical Design For Electric Motors
Our engineering team performs specific studies to develop customize concept based on the
characteristics of each plant.
Integrated engineering approach regards all aspects related to all technology selection
process, taking into consideration thermal and mechanical performance under diverse
operating conditions to minimize harmonics and identify the optimal trade off between
Voltage and Current to guarantee maximum stability of the system:
Operating
performance
Site
Conditions
Shaft Line &
Vibration
• Reduce Complexity
• Guarantee Maximum
Reliability & Availability
• Maximize Overall
Performance
• Optimize Auxiliary
Systems
• Maximize Flexibility
• Optimize device
response & Stress
• Optimize Maintainability
• Optimize choice of motor
Technology
• Minimize Costs
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• Optimize choice of Motor
Technology
Cooling &
Maintenance
• Improve System Design
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17. Integrated Engineering Approach
Motor Design – Operating parameters
The load features
• Quadratic load Vs. speed are in
general required for the VSDS
design.
• Speed range must be well defined
from the beginning – critical speeds
must be avoided – maximum
operating speed and the over-speed
(120%) shall be mechanically verified
– lower speed shall be compatible
with motor cooling and bearings
design.
• In case of an operational speed
margin (example 110% speed),
constant power will be considered
according to the rated power of the
VSDS. Otherwise, with quadratic
torque load, the VSDS should be
oversized and rated accordingly
(example 133% power).
• Compressor load can be highly
influenced by the process (gas
pressures/temperatures), so proper
margins must be considered.
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Motor Power Vs. Speed
speed m argin @ const. pow er
cubic pow er (quadratic torque)
rated speed
compressor load points
Motor Torque Vs. Speed
speed m argin
quadratic torque
rated speed
com pressor load points
Motor Voltage & Current Vs. Frequency
voltage
V/Hz = const
current
rated speed
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18. Integrated Engineering Approach
Motor Design – Site Conditions
Russia - Sakhalin Island LNG Plant
High Power Traditional Solution 4 poles
Sakhalin is a large Russian island in the North
Pacific and is crossed by the one most important
pipeline of Russia.
Technology: Shell / JGC
Scope Of Supply:
n.2 21 MW LCI drives Silcovert S
n.2 motors plus 4 MW fixed speed
motors for Overhead Stabilizer
Compressors
PPT2013.01.01.08EN
The strong cold and the other extreme weather
conditions, constantly wear out the electrical and
mechanical equipment of the pipeline
Due the site conditions, NIDEC ASI provided the
best solution for the customer, choosing the critical
components to guarantee proper performance
at -50°C.
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19. Integrated Engineering Approach
Motor Design – Site Conditions
Qatar - Ras Laffan Re-injections Plant
High Power Induction motor + PWM-NPC Solution
Ras Laffan Industrial City is the Qatar's main site for
production of liquefied natural gas and gas-to-liquid.
In the desert (Ambient temperature +54°C) and in the
maritime environment, structural integrity is vulnerable
to wind blown sand and to saline of the sea, therefore
the equipment had to be sealed against the elements
and positioned in areas where they were least at risk.
NIDEC ASI supplied the right equipment and the best
solution, resolving the problems of its customers
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Scope Of Supply:
n.3 CR 1000 Y 4 – 13.7 MW 11 kV 50 Hz
dual shaft end for gas re-injections
compressors
n.2 CR 900 X 4 9.6 MW Silcovert GN 2
x 3300 V for NGL 4 & NGL 5
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20. Integrated Engineering Approach
Motor Design – Shaft Line & Vibrations
Example of Rotor Dynamics Analysis
y
z
x
Shaft Model
Example of Prediction of
Rotordynamic Response
Unbalance Response
Deflection Shape
Dynamic Couple Unbalance
Speed = 6060 rpm
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21. Integrated Engineering Approach
Motor Design – Shaft Line & Vibrations
Traditional LCI approach - Gas turbine driver - Large compressors:
Propane
Mixed Refrigerant
Nitrogen
G/T
LP Comp
HP Comp
High speed
LCI
driven motor
LCI Electric system
Note to the traditional approach




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LCI machines have longer shaft line
Complex mechanically
Torque pulsations from the electric system
Only low pressure restart
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22. Integrated Engineering Approach
Motor Design – Shaft Line & Vibrations
4 Pole Solution - Gas turbine driver - Large compressors:
Propane
Mixed Refrigerant
Nitrogen
Parallel drive driven
motor/generator
G/T
LP Comp
HP Comp
High speed
4 pole motor w/Parallel Drive Electric System
Note to the 4 Pole approach






Shorter shaft lines to reduce vibrations
Power compensation for high temperature turbine derate
No torque pulsations from the electric system
Full pressure restart (Higher starting torque)
Regenerative to the network independent from the speed
Power factor correction and/or filters are not necessary
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23. Integrated Engineering Approach
Motor Design – Cooling
Rotor Winding Head Ventilation
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24. Integrated Engineering Approach
Motor Design – Cooling
Internal Ventilation
NCVC2: Number of
radial ventilation
slots in central
chamber
NCVC1: Number of
radial ventilation
slots in end
chambers
Stator
Rotor
Stator end windings
Rotor retaining rings
Rotor fans
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25. Integrated Engineering Approach
Motor Design – Maintenance
Critical Components for Maintenance
Level I components
• bearings and bearing seals
• air-to-water heat exchangers
• pressurizing system
Level II components
• windings (stator & rotor)
• excitation system windings
• shaft seals
• instrumentation
Level III Components
Bearings supplied by Top manufacturers, designed according
to our specifications to maximize up time.
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• gaskets and seal on fixed components
• hold-down bolts and alignment shims
• painting
• terminal box components
• soundproof insulation
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26. Integrated Engineering Approach
Drive System
The same care is taken in the choice of Drive Topology and overall
system design
Switching
Device
• Assure device reliability
• Minimize
Costs
Drive
Topology
Control
Strategy
• Reduce Complexity
• Maximize Overall
Performances
• Optimize Auxiliary
Systems
• Optimize Maintainability
• Reduce Parts count
• Optimize device response &
Stress
• Maximize Flexibility
• Optimize choice of Drive
Technology
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Packaging
• Improve System Flexibility
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27. Integrated Engineering Approach
Drive System – Switching Devices
Thyristor/SCR
IGBT/IEGT
IGCT
• Current controlled device
• Voltage controlled device
• Current controlled device
• Semi-controlled (turn-on only)
• Fully controlled
• Fully controlled
• Highest V-I rating @ lowest
cost
• Faster switching
• Lower conduction loss
• Press-pack packaging
• Mature technology
• Module (mature) or
press-pack (emerging)
• Proven technology
• Proven technology
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28. Integrated Engineering Approach
Drive System – VFD Circuit Topology
LCI
VSI (3-Level NPC)
VSI (Stacked H-bridge)
• Distortion
• Extensively adopted in Steel industry
• Complexity @ high power
• More subsystems to get high
performances
• Easy & flexible to control
• Complex failure modes
• Use IGBT, IGCT, IEGT
• Use IGBT and IGCT
NIDEC ASI has significant knowledge in drive topologies and can offer customers the
right choice for their application
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29. Our MV Products
Drive Topology
Silcovert S
Thyristor based LCI
for synchronous
motors provides
speed regularity,
monitoring and
braking torque
regulation
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Series N
Air cooling: up to 10400
KVA
Water cooling: up to
24000 KVA (higher
power on request)
Voltage: up to 3300 V
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Series H
Air cooling: up to 8100 KVA
Water cooling: up to 18700
KVA (higher power on
request)
Voltage: up to 7200 V
(12000 V on request)
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30. High Speed Solutions
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31. High Speed Capability
Motors Types and Ratings
A
80
70
60
Recent projects update
50
Consolidated
New
MW
A
Exxon / QatarGas – RasGas
HS 4-pole turbo motor-generator
Under discussion
Delivered
40
B
30
20
B
10
Petrocanada
HS 2-pole turbo motor
C
C
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
24000
rpm
Transco / Tenneco
HS 2-pole induction motor
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32. High Speed Solutions
Main Advantages
HS motors vs. conventional
motors with gear boxes
• Reduction of power losses
in the drive system
• Smaller size
• Higher reliability
• Lower maintenance (time - cost)
• Lower noise
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HS Motors vs gas
Turbine
• Higher efficiency
• Lower cost
• Smaller size
• Lower noise
• No air pollution
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Electrical Solutions
• Best flexibility
• Lower noises
• Lower maintenance costs
(> 10 years continuous field operation
demonstrated)
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33. Economic Comparison
3700 kW (5000 hp) System
Parameter
Recip.
Turbine
Electric
Total Installed Cost
1.00
0.65
0.52
Space Requirement
1.00
0.75
0.65
Maintenance
1.00
0.60
0.15
Spare Parts
1.00
0.60
0.40
Environmental
1.00
0.80
0.10
Availability
96%
98%
99%
Fuel Efficiency
31-40%
21-36%
35-45%
Electric Motor Driven Compressor Stations: $10/hp/yr
Gas & Steam Turbine Driven Stations: $35/hp/yr
Transco 205:
Operating and
Maintenance Cost
Comparison
Gas Reciprocating Engine Driven Stations: $55/hp/yr
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34. High Speed Applications
One Line Diagram SVTN 24 Pulses
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35. References High Speed Motors
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36. Machines & System Testing Capabilities
Up to 10 MW
NIDEC ASI works in close collaboration with Project engineering management and End
users and the OEM supplier to guarantee that equipment is fully tested
before being shipped on site.
 Routine tests (according to IEC & IEEE standards);
 up to 10 MW @ 9000 r/min: no load tests at motor speed range supplied by a
motor-generator set.
 Factory facilities, no job equipment needed;
 greater than 10 MW @ 9000 r/min: no load tests at motor speed range.
 Job transformer, converter, capacitors and other equipment needed;
 Main Testing Area for Drives: 2500 kVA
Extra power if needed for PCS testing: 1300 kVA
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37. PDS System Testing Capabilities
Convertitore frequenza SVGN
SVGN Frequency Converter
Cabina stabilmento 20 kV / 20 kV Plant Cabin
/
IPT1 (T1)
M
SG
CR 630 Y4
IPT2
Trasformatore abbassatore 10/3,3 kV /
10/3.3 kV Step-down Transformer
G2
IG2 (T2)
10 kV /
415 V
G1
SG1
SIG 10 Z4
Nuovo interruttore / breaker
new
Back to Back - Full Load Testing Up to 75 MW
10 kV /
380-220V
GSCR1000Z4
IPT4
IPT3 (T3)
“Turning-gear” & “pre-charge”
10 kV / 415 V
Autotrasformatore di prova 10/33 kV /
10/33 kV Tool Autoransformer
In order to meet the challenges of de-risking large
powered motors we can provide full load machine
testing in back-to-back full load configuration at
our Monfalcone Italian facility if 2 or more machines
have been ordered.
We are able to support our customer with complete
test in back to back configuration (IEEE 112) for
applications up to 75 MW.
S/S Generazione Potenza / Power generation S/S
Perdite / losses
Unità di commessa / Job Units
Quadro interruttori 33 kV / HV Switchgear
Q+P
Q+P
Trasformatori VFD /
VFD Transformers
1
2
3
4
5
6
7
8
Convertitori
frequenza / VFD
“Perfect
harmony”
Ecc / exc
Q+P
Q+P
4
MGSCR1120Z
Motore / motor
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4
MGSCR1120Z
Generatore /
Generator
Q+P
Back to back testing is a complete
test which gives our customer
additional assurance about
machine’s efficiency.
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38. Active Partener in String Tests
String test at OEM facility
MV Switchgear
Thread 1
Thread 2
33kV / 3 kV
Thread 3
M
G
Thread 4
Test stand layout
back-to-back test: electric motor
coupled with a generator and 30
MW resistor banks
We work closely with the compressor suppliers to conduct complete string tests at their facilities.
This guarantees the final end user that there will be no surprises or risks in the field.
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39. Remote Diagnostics System
Remote connection
Ethernet
Local network USB
Data signals:

Inputs for vibration probes (mechanical data)

Input for speed sensor (mechanical data)

Inputs for line current / voltage (electrical data)

Excitation current (synchronous machines)

Inputs for Pt100 (thermal data)

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Outputs (alarm, trip, status)
Stand alone unit capability:

Data log

Basic analysis

Ethernet communication

Re configurable acquisition tasks

Customizable / expansible

Available for Hazardous area
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40. Remote Diagnostics Demostration
On this project, for example, diagnostics were managed from Japan via internet from our
factory in Italy using our drive’s remote diagnostics capabilities.
Our drive control system can be easily integrated and interfaced with existing Control
Systems.
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