TABLE OF CONTENTS

TABLE OF CONTENTS

Appendix R

Feeder Breaker Crusher motor ...1

R.1 Load profile...2

R.1.1

Section 21 ...2

R.1.1.1

Morning shifts ...2

R.1.1.2

Afternoon shifts ...9

R.2 Histogram ...16

R.2.1

Section 21 ...17

R.2.1.1

Morning shifts ...17

R.2.1.2

Afternoon shifts ...20

R.3 Thermal capacity ...23

R.3.1

Section 21 ...23

R.3.1.1

Morning shifts ...23

R.3.1.2

Afternoon shifts ...27

APPENDIX R

FEEDER BREAKER CRUSHER MOTOR

Typical nameplate data for the crusher motors of a Feeder breaker can be seen in

Table R-1. The crusher motors measured at both sections was a 55 kW induction

motor with a full load current rating of 39 A.

Table R-1: Nameplate data of the cutter motor on a CM.

Table R-2: Production figures for shifts that the crusher motors were

investigated.

Date

Morning

Afternoon

Morning

Afternoon

31-May-2005

1782

1716

-

-1-Jun-2005

1254

1980

-

-2-Jun-2005

1320

2145

-

-Sect 21

Sect 51

Power

55

kW

Voltage

1000 V

Duty

S1

Current

39

A

Ins class

H

RPM

1475

pf

0.87

R.1 LOAD PROFILE

The next section focuses on the load profiles of the crusher motors. Each graph

shows the line voltage and the voltage limits, the load current and full load current

capacity of the cutter motors. The morning shifts and afternoon shifts are separated as

well as the measurements made at the different sections.

R.1.1 SECTION 21

R.1.1.1 Morning shifts

Figure R.1-1: Load current and voltage for a LH crusher motor – 31 May 2005.

0 200 400 600 800 1000 1200 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-2: Load current and voltage for a LH crusher motor

– 31 May 2005 (30 minute period).

Figure R.1-3: Load current and voltage for a RH crusher motor – 31 May 2005.

0 200 400 600 800 1000 1200 12:00 12:05 12:10 12:15 12:20 12:25 12:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-4: Load current and voltage for a RH crusher motor

– 31 May 2005 (30 minute period).

Figure R.1-5: Load current and voltage for a LH crusher motor – 01 June 2005.

0 200 400 600 800 1000 1200 12:00 12:05 12:10 12:15 12:20 12:25 12:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-6: Load current and voltage for a LH crusher motor

– 01 June 2005 (30 minute period).

Figure R.1-7: Load current and voltage for a RH crusher motor – 01 June 2005.

0 200 400 600 800 1000 1200 10:30 10:35 10:40 10:45 10:50 10:55 11:00

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-8: Load current and voltage for a RH crusher motor

– 01 June 2005 (30 minute period).

Figure R.1-9: Load current and voltage for a LH crusher motor – 02 June 2005.

0 200 400 600 800 1000 1200 10:30 10:35 10:40 10:45 10:50 10:55 11:00

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-10: Load current and voltage for a LH crusher motor

– 02 June 2005 (30 minute period).

Figure R.1-11: Load current and voltage for a RH crusher motor – 02 June 2005.

0 200 400 600 800 1000 1200 8:30 8:35 8:40 8:45 8:50 8:55 9:00

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-12: Load current and voltage for a RH crusher motor

– 02 June 2005 (30 minute period).

0 200 400 600 800 1000 1200 8:30 8:35 8:40 8:45 8:50 8:55 9:00

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

R.1.1.2 Afternoon shifts

Figure R.1-13: Load current and voltage for a LH crusher motor – 31 May 2005.

0 200 400 600 800 1000 1200 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-14: Load current and voltage for a LH crusher motor

– 31 May 2005 (30 minute period).

Figure R.1-15: Load current and voltage for a RH crusher motor – 31 May 2005.

0 200 400 600 800 1000 1200 6:30 6:35 6:40 6:45 6:50 6:55 7:00

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-16: Load current and voltage for a RH crusher motor

– 31 May 2005 (30 minute period).

Figure R.1-17: Load current and voltage for a LH crusher motor – 01 June 2005.

0 200 400 600 800 1000 1200 6:30 6:35 6:40 6:45 6:50 6:55 7:00

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-18: Load current and voltage for a LH crusher motor

– 01 June 2005 (30 minute period).

Figure R.1-19: Load current and voltage for a RH crusher motor – 01 June 2005.

0 200 400 600 800 1000 1200 8:00 8:05 8:10 8:15 8:20 8:25 8:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-20: Load current and voltage for a RH crusher motor

– 01 June 2005 (30 minute period).

Figure R.1-21: Load current and voltage for a LH crusher motor – 02 June 2005.

0 200 400 600 800 1000 1200 8:00 8:05 8:10 8:15 8:20 8:25 8:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-22: Load current and voltage for a LH crusher motor

– 02 June 2005 (30 minute period).

Figure R.1-23: Load current and voltage for a RH crusher motor – 02 June 2005.

0 200 400 600 800 1000 1200 8:00 8:05 8:10 8:15 8:20 8:25 8:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

0 200 400 600 800 1000 1200 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

Figure R.1-24: Load current and voltage for a RH crusher motor

– 02 June 2005 (30 minute period).

0 200 400 600 800 1000 1200 8:00 8:05 8:10 8:15 8:20 8:25 8:30

Time (hh:mm)

Li

ne

V

ol

ta

ge

(V

)

0 25 50 75 100 125 150

C

ur

re

nt

(A

)

Voltage (V) Voltage limit (upper) Voltage limit (lower) Current (A) Full load (A)

R.2 HISTOGRAM

The next section focuses on the frequency with which a Feeder breakers crusher

motors consumed a certain load power and current. The graphs show the number of

times a certain power or current has been consumed. The tables give data about the

tonnes produced during the shift and the percentage time of the shift that the motors

were producing. The time that the motors have been over loaded or loaded within the

full load rating of the motor is given as a percentage of the actual producing time. The

morning shifts and afternoon shifts are separated as well as the measurements made

at the different sections.

R.2.1 SECTION 21

R.2.1.1 Morning shifts

Table R-3: Data for the total consumption of a LH crusher motor in section 21.

Figure R.2-1: Histogram for power consumed by a LH crusher motor.

0 1000 2000 3000 4000 5000 6000 7000 0 2 4 6 8 _{10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40}

Power bins (kW)

Fr

eq

ue

nc

y

31-May-05 1-Jun-05 2-Jun-05

31-May-05 1-Jun-05

2-Jun-05

Tonnes/CM/Shift

1782

1254

1320

% Time of shift producing

74.50%

50.27%

58.45%

% of Production time underloaded

100.00%

100.00%

100.00%

Figure R.2-2: Histogram for current consumed by a LH crusher motor.

Table R-4: Data for the total consumption of a RH crusher motor in section 21.

0 1000 2000 3000 4000 5000 6000 7000 0 1 2 3 4 5 6 7 8 9 _{10 11 12 13 14 15 16 17 18 19 20}

Current bins (A)

Fr

eq

ue

nc

y

31-May-05 01-Jun-05 02-Jun-05

31-May-05 1-Jun-05

2-Jun-05

Tonnes/CM/Shift

1782

1254

1320

% Time of shift producing

74.50%

50.29%

58.45%

% of Production time underloaded

100.00%

100.00%

100.00%

Figure R.2-3: Histogram for power consumed by a RH crusher motor.

Figure R.2-4: Histogram for current consumed by a RH crusher motor.

0 1000 2000 3000 4000 5000 6000 7000 0 1 2 3 4 5 6 7 8 9 _{10 11 12 13 14 15 16 17 18 19 20}

Current bins (A)

Fr

eq

ue

nc

y

31-May-05 01-Jun-05 02-Jun-05 0 1000 2000 3000 4000 5000 6000 7000 0 2 4 6 8 _{10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40}

Power bins (kW)

Fr

eq

ue

nc

y

31-May-05 1-Jun-05 2-Jun-05

R.2.1.2 Afternoon shifts

Table R-5: Data for the total consumption of a LH crusher motor in section 21.

Figure R.2-5: Histogram for power consumed by a LH crusher motor.

0 1000 2000 3000 4000 5000 6000 7000 0 2 4 6 8 _{10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40}

Power bins (kW)

Fr

eq

ue

nc

y

31-May-05 1-Jun-05 2-Jun-05

31-May-05 1-Jun-05

2-Jun-05

Tonnes/CM/Shift

1716

1980

2145

% Time of shift producing

74.44%

84.89%

64.34%

% of Production time underloaded

100.00%

100.00%

100.00%

Figure R.2-6: Histogram for current consumed by a LH crusher motor.

Table R-6: Data for the total consumption of a RH crusher motor in section 21.

0 1000 2000 3000 4000 5000 6000 7000 0 1 2 3 4 5 6 7 8 9 _{10 11 12 13 14 15 16 17 18 19 20}

Current bins (A)

Fr

eq

ue

nc

y

31-May-05 01-Jun-05 02-Jun-05

31-May-05 1-Jun-05

2-Jun-05

Tonnes/CM/Shift

1716

1980

2145

% Time of shift producing

74.43%

84.89%

64.34%

% of Production time underloaded

100.00%

100.00%

100.00%

Figure R.2-7: Histogram for power consumed by a RH crusher motor.

Figure R.2-8: Histogram for current consumed by a RH crusher motor.

0 1000 2000 3000 4000 5000 6000 7000 0 1 2 3 4 5 6 7 8 9 _{10 11 12 13 14 15 16 17 18 19 20}

Current bins (A)

Fr

eq

ue

nc

y

31-May-05 01-Jun-05 02-Jun-05 0 1000 2000 3000 4000 5000 6000 7000 0 2 4 6 8 _{10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40}

Power bins (kW)

Fr

eq

ue

nc

y

31-May-05 1-Jun-05 2-Jun-05

R.3 THERMAL CAPACITY

The next section focuses on the temperature of the windings of the crusher motors.

Each graph shows the temperature of the motor, the load current and rated full load

current of the motor. The morning shifts and afternoon shifts are separated as well as

the measurements made at the different sections. The thermal time constant is

45 minutes.

R.3.1 SECTION 21

R.3.1.1 Morning shifts

Figure R.3-1: Load current and motor temperature for a LH crusher motor

– 31 May 2005.

0 25 50 75 100 125 150 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)

Figure R.3-2: Load current and motor temperature for a RH crusher motor

– 31 May 2005.

Figure R.3-3: Load current and motor temperature for a LH crusher motor

0 25 50 75 100 125 150 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C) 0 25 50 75 100 125 150 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)

Figure R.3-4: Load current and motor temperature for a RH crusher motor

– 01 June 2005.

Figure R.3-5: Load current and motor temperature for a LH crusher motor

0 25 50 75 100 125 150 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30 3:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C) 0 25 50 75 100 125 150 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)

Figure R.3-6: Load current and motor temperature for a RH crusher motor

– 02 June 2005

0 25 50 75 100 125 150 6:30 7:30 8:30 9:30 10:30 11:30 12:30 1:30 2:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)

R.3.1.2 Afternoon shifts

Figure R.3-7: Load current and motor temperature for a LH crusher motor

– 31 May 2005.

0 25 50 75 100 125 150 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)

Figure R.3-8: Load current and motor temperature for a RH crusher motor

– 31 May 2005.

Figure R.3-9: Load current and motor temperature for a LH crusher motor

0 25 50 75 100 125 150 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C) 0 25 50 75 100 125 150 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)

Figure R.3-10: Load current and motor temperature for a RH crusher motor

– 01 June 2005.

Figure R.3-11: Load current and motor temperature for a LH crusher motor

0 25 50 75 100 125 150 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30 11:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C) 0 25 50 75 100 125 150 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)

Figure R.3-12: Load current and motor temperature for a RH crusher motor

– 02 June 2005.

0 25 50 75 100 125 150 3:30 4:30 5:30 6:30 7:30 8:30 9:30 10:30

Time (hh:mm)

C

ur

re

nt

(A

)

0 10 20 30 40 50 60

Te

m

pe

ra

tu

re

(d

eg

C

)

Current (A) Full load (A) Temp (deg C)