ZHUHAI SINOPAK ELECTRIC LTDacdriveelectric.com/upload/3922/download/1/pdf/... · Set by host computer via RS485 port; Multi-speed set, suitable for the working conditions in cyclic

ZHUHAI SINOPAK ELECTRIC LTD

Zhuhai Sinopak Electric LtdanihC ,ecnivorP gnodgnauG ,ytiC iahuhZ ,nwoT niqgneH ,egalli V nahsihS ,08 .oN ,A kcol B,202 mooR :sserddA

Postcode: 519031

Tel: +86-756-7755124

Email: [email protected] [email protected]

75623082931-68+ :ppAstahW &tahceW

Website: www.sinopakelectric.com

Skype: zhwld08

www.sinopakelectric.com

Storage & Transprtation

Type Description

Type Description 12

The Cassical Solutions 17

16

14

Typical Applications 18

Zhuhai Sinopak Electric Ltd is a professional one-stop solution supplier for motor drives and power quality correction equipment; We mainly supply Medium voltage and low voltage variable frequency drives, Mine use flameproof and intrinsically safe drives, Medium voltage magnetically controlled reactor typed soft starter, Medium voltage and low voltage Static synchronous compensator (STATCOM), Act ive harmonic filter etc. With years of exporting experience, we have cooperative partners in Bangladesh, Pakistan, Vietnam, Iran, Turkey, Poland, Russia, Mongolia, etc. Up to now, our products cover about 20 countries and regions from the South-east Asia and Eastern Europe to Middle East and Africa.

Sinopak will follow the principle of “customer first” , focus on pre-sale and after sales technical support service, continue to spare no efforts to help our customers improve production efficiency, save energy consumption and fulfill its social responsibilities.


ZHUHAI SINOPAK ELECTRIC LTD-02- -03-

Application FieldsSinopak medium voltage inverter is widely used for speed regulation, energy saving, soft startup and intelligent control of the medium voltage motors in such industries as thermal power plant, petroleum, chemicals, faucet water, mining and metallurgy.

1) Control cabinet: includes the main low-voltage control unit like controller,PLC，etc, isolating and communicating

with the high voltage part by optical fiber.

2) Power units cabinet: used to install the power unit, as the main link of energy conversion and storage.

3）Power module: the main part of the inverter, implementing rectification, energy storage and inverse;

4）Transformer cabinet: installation space of phase-shifting transformer, transforming high-voltage to low-voltage,

and effectively filtering input harmonic.

Thermal power plant: Air blower, draft fan, dust exhaust fan, circulation pump, feed pump, condensate pump, water supply pump for heat-supply network, return water pump for heat-supply pump, coal pulverizer, etc.

Urban water supply: Water delivery pump, water intake pump

Petroleum: Water injection pump, crude oil pump, etc.

Chemicals: Compressor, fan, circulation pump, icemaker, etc.

Mine: Slurry machine, ventilation blower, belt conveyer, etc.

Metallurgy: Water supply pump, dust collection pump, draft fan, oxygen generator, etc.

Cement: Water pump, draft fan, air blower, dust collection pump, grinding machine, etc.

Others: Loads such as fan, pump and compressor in pharmaceutical, paper making and sewage treatment industry.

Product Structure

Power Cabinet Control Cabinet

Signal acquisition, Power device driver, Optical fiber communication, Protection and so on


5）Bypass cabinet(optional): through cooperation of the knife-switch, contactor or breaker to form the standard

modes "manual one-drive-one "," manual one-drive-two" " manual two-drive-three "," automatic one-drive-one",

"automatic one-drive-two" or other non - standard circuit.

6）Resistance cabinet(optional):optional for large capacity systems, used for charging current limiting or energy

consumption, etc.

7）Synchronization cabinet(optional):optional for non standard contract, achieving grid connection switching or

energy feedback.

Remark: Not all of the above are independent cabinet.

-04- -05-

Working Principle of VFD

Topology Structure of Main Circuit (Take 6kV and 10kV for examples)

6kV Series: 5/6 power cells per phase, total 15/18 power cells, three phases Y-Connected.

10kV Series: 8/9 power cells per phase, total 24/27 power cells, three phases Y-Connected.

Sinopak series medium voltage VFD adopts AC-DC-AC mode, the electronic switch component is IGBT. It is highly reliable by means of the power cells connected in series and voltage overlapping method.

6kV Asynchronous Motor

B5A5

C5

B4A4

C4

B3A3

C3

B2A2

C2

B1A1

C1

Input three-phase 6kV

power supply

Isolated

Transformer

Power Cell

Bypass Cabinet Transformer cabinet

M

ZHUHAI SINOPAK ELECTRIC LTD ZHUHAI SINOPAK ELECTRIC LTD

-06- -07-

Voltage Overlapping Method

Sinopak medium voltage VFD has a number of power connected in series, the independent phase-shift power is supplied to each power cell by the isolated transformer. By changing the power cells number in each phase, the customer can get different output voltage conveniently without the limitation for the components’ withstand voltage. For example, 6kV series VFD has 5 power cells in each phase, the rated voltage of each power cell is 690V, the phase voltage is 3460V (The corresponding line voltage is 6kV).

Power Cell Topology

Rated Voltage Cell Quantity per Phase

Phase Voltage

(V)

Line voltage (kV) Levels of Voltage

3.3kV 3 1900 3.3 7 4.16kV 4 2400 4.16 9 6kV 5 3460 6 11 6.6kV 6 3810 6.6 13 10kV 8 5770 10 17 11kV 9 6350 11 19

Sinopak medium voltage VFD consists of a number of power cells connected in series, the power cell adopts AC-DC-AC mode, equivalent to a low-voltage voltage-source inverter with three-phase input and single phase output. All power cells are fully same in electrical and mechanical features, thus very easy for maintenance and replacement.

The power cell receives the signals via optic fiber and adopts space vector sine wave pulse width modulation (PWM) to control the conductivity and disconnection of Q1~Q4 IGBT, outputting single-phase pulse width modulation waveform. Each cell only has three possible output voltage statuses. When Q1 and Q4 are conducted, the output voltage status between L1 and L2 will be “1”; when Q2 and Q3 are conducted, the output voltage status between L1 and L2 will be “-1”; when Q1 and Q2 are conducted, or Q3 and Q4 are conducted, the output voltage status between L1 and L2 will be “0”.

Fuse Diode Rectifier DC Link Inverter Output

R

+

+

+Q3

Q1 Q2

Q4

L2

L1S

T

690

690

690

690

690

690 690

690

690

690

690

690

690

690

690

6000VLine Voltage

3450VPhase Voltage

10kV Asynchronous or

Synchronous MotorM

A8B8

C8A7

B7C7

A6B6

C6A5

B5C5

A4B4

C4A3

B3C3

A2B2

C2A1

B1C1

Input three-phase

10kV power supply

Isolated

Transformer

Power Cell


Product Characteristics

High-quality Power Input Section

Sinopak MV VFD adopts isolated transformer with the phase-shifted secondary windings, which can provide independent power supply for the power cells with multi-pulse diode rectifier (30 pulses for 6kV, 54 pulses for 11kV), the harmonic current of power cells can be effectively reduced.

Perfect Power Output Section

Sinopak MV VFD adopts voltage overlapping method (i.e. Power cells multi-level cascade technology); it can output the perfect PWM sinusoidal waveform. It has the following advantages:◎ No need for the additional output filter.◎ Directly driving general synchronous or asynchronous motor◎ No de-rating operation on the motor.◎ No dV/dt stress on the insulation of motor and cables.◎ No torque ripple, extending service life of motors and mechanism.◎ No cable length restriction within the acceptance voltage drop.

Flexible Control Options

Sinopak Series Medium voltage VFD adopts multi-level cascaded power cells technology, all power cells in each phase are connected in series.

Sinopak Medium voltage VFD is complied with IEEE 519-1992 and GB/T 14549-1993. They do not require the additional input filter and reactive power compensator, saving the cost for harmonic filter and reactive power compensator.

-08- -09-

External system Diagram

Local Control: Direct control from the button on cabinet door or the keypad. This is the main control method.

Remote I/O Control: Realize remote control by connecting to the remote switch signal via the I/O board.

Host Control: Isolated RS485 port and adoption of standard MODBUS RTU communication protocol. Able to connect with host system like DCS for optimized coordination control.

A

B

C

3-phase MV Input Main PowerL1

L2

L3

U

V

WM

Three Phase Induction Motor

485_A

485_B

Control Power Supply A

B

C/L

N

+_

_

A

B

C/L

N

+_

_

FAVOFACOFACM

CAVOCACOCACM

Communication Signal

HV Emergency Trip

HV Closing Permission

V/F Running

Mini Fault

Heavy Fault

Standby

Backup

Backup

Output Frequency Analog Voltage OutputOutput Frequency Analog Current Set Output

Output Frequency Command End

Output Current Analog Voltage OutputOutput Current Analog Current Set Output

Output Current Command End

AVI

ACI

ACM

AVI

ACI

ACM

Fault Reset

HV Closing

HV Opening

HVF Start

HVF Stop

Emergency Stop

Backup

Backup

DCM

Backup

Backup

Fault Reset

HV Closing

HV Opening

HVF StartHVF Stop

Emergency Stop

Analog Voltage Set

Analog Current Set

Analog Set Command End

Analog Voltage Feedback

Analog Current Feedback

Analog Feedback Command End


Protection functions and other features:

◎ Overload and over-current◎ Phase loss and grounding◎ Over voltage◎ Overheat◎ Redundant control power supply◎ Power cell bypass◎ Cabinet door alarm◎ Phase-lock function◎ Wide range of input voltage;◎ Synchronous switching between VFD

◎ Direct command from main interface;◎ Set by analog signal (0~10V or 4~20mA signal);◎ Set by host computer via RS485 port;◎ Multi-speed set, suitable for the working conditions in cyclic change;◎ In event of closed-loop operation, it will be automatic set by built-in PID via computation

-10- -11-

Five Options of Frequency Set

According to output voltage feedback, the inverter can automatically adjust the output voltage to make it free from the influence caused by the change of grid voltage and loads, and protect the motor from insulation damage due to long overvoltage or core overheating due to high magnetic density.

AVR (Automatic Voltage Adjustment) Function

Built-in full digital PID is provided for closed-loop control upon the user ’ s requirements and for realization of operation under constant press or constant fluid flux. PID parameters can be adjusted online.

PID Function

In event the output current of the inverter exceeds the preset value, the inverter will automatically limit the current output to avoid over current protection incurred during acceleration or deceleration or due to sudden change of the loads, thus to minimize the stop times of the machine.

Current Limiting Function

Sinopak inver ter is provided wi th complete self-diagnosis capability to monitor the system status online. In event of any fault, the inverter will be automatically activated to take protective actions and save the time, cause and location of the fault. This will help the maintenance personnel find the cause and eliminate the fault quickly.

Self-diagnosis Function

Instantaneous Power Loss Tracing Function

Technical Specification

and Grid system (Optional)◎ Soft starter of motor◎ High efficiency>98% (VFD at full load)◎ Electrical isolation by optic fiber.◎ Built-in PID regulator◎ Rich in communications modes.◎ Faults history record◎ Compact structure and layout, customized design is available.

In event the electric grid is incurred to instantaneous power loss, the inverter will control the motor to be unde r powe r -gene ra t i ng s t a tus and keep decelerated operation. If the electric grid resumes to normal, the inverter will immediately return to original operating status. The keeping time is 100ms and typical value of the fan load is 3s.

Overload capacity 100% In in a row,130% In 1minute/10 minutes, 180% In Immediate protection

Voltage SPWM Phase shift superimposed waveforms, 0~Un（nominal rated voltage output) continuously adjustable

Frequency 0~50Hz or 0~60Hz adjustable Frequency resolution 0.01Hz

Output Voltage class 2.3kV，3kV，3.3kV，6kV，6.6kV，10kV，11V

Current Less than 2% (At full load) Phases, frequency Three-phase: 50/60Hz Permissible frequency fluctuation Frequency: -5 ~ +5% Fluctuations in voltage Voltage: normal operation within -15 ~ +15%; derating

operation within -15 ~ -35%. Power factor >0.96 ( more than 20% load)

Input

Current harmonic THD Meet national standards GB14549-93 and power quality standards IEEE519-1992

System controller TI's DSP chip dedicated for high-speed motor control Controller power supply AC380V,three-phase, 10kVA Start frequency 0.1 ~10Hz (settable) Input/output interface 16 digital input / 16 digital output

2 analog input / 2 analog output (4 ~20mA or 0 ~10V) Above is the basic configuration; more are available as per the order technical agreement

Communication interface RS232, RS485, CAN, Modbus, Profibus Signal isolation mode Photoelectric isolation Control signal transmission Optical fiber transmission, Trans-coding Accuracy Frequency stability accuracy 0.1%; voltage accuracy ±2% Efficiency When rated load > 97%,when 20% rated load > 95% Torque boost 0 ~ 10% rated voltage (settable) Accel/Decel time 0 ~ 3000s (settable) Instantaneous power-off restart Restart modes are selectable, waiting time 0.1 ~ 30s (settable) PID in PLC Manually set parameter values：P : 2 ~850%; I: 0.5 ~350s ;

D: 1 ~200s Auto-tuning PLC uses adaptive fuzzy control with intelligent regulation, fast

system response , high precision and good stability. PID parameters are automatically adjusted, greatly simplifying the on-site commissioning work.

Minimum resolution The sensor range 1%

Control

Steady-status accuracy Determined by the set accuracy tolerance and the sensor accuracy

LED Display Operational status, Signal indication Digital Display Output of the frequency, voltage, current, power（one selected）

Display

LCD Display Input/output: frequency, voltage, current, power, power factor; Fault / alarm and recording; Parameters setting

Running operation Panel buttons, Instructive control of remote switch Frequency setting Panel setting, Analog control of remote current

Run

Operating status export Fault,Alarm output Protection function Over-current ,short-circuit,ground fault, overvoltage,

under-voltage,overload, overheat,motor overload,open-phase,IGBT breakdown or short-circuit, unit fault and so on.

Failover system bypass switching and unit bypass. Protective measures Five type of protection in electricity ; Atresia Safe Guarding Internal grounding resistance ≤0.1Ω


Attention

Notice

The Sinopak general MV VFD has 3kV, 3.3kV, 4.16kV, 6kV, 6.6kV, 10kV and 11kV ratings, and Sinopak also can supply customized VFD to meet special ratings.

In case of the special load or special motor or special operation environment, in addition to consider the rated power and rated current of the motor, the selection of Sinopak MV VFD should also refer to the following:

The advice above does not include the cases of special loads and special motors, please contact with Zhuhai Sinopak Electric Ltd. To confirm the selection of the Sinopak general MV VFD.

-12- -13-

Type Description Power Specifications

◎ For the load with the high torque ripple such as compressor, vibrating machine and kneader, the rated current of the selected VFD should be larger than the maximum current of motor at the industrial frequency based on the practical operation condition.

◎ For the submersible pump with higher than the rated current of the general motor, the rated current of the selected VFD should be larger than the rated current of the motor.

◎ For the asynchronous motor with multiple poles, the rated current of the selected MV VFD should be enlarged according to the rated current of the motor and the practical working condition.

◎ When the roots fan with large starting current, the rated current of the selected VFD should be enlarged accordingly.

◎ For the Sinopak general MV VFD driving several motors in parallel, the rated current of the selected VFD should be larger than the total current of these motors.

◎ For the oil pump with peak current, the rated current of the selected MV VFD should be enlarged properly.

◎ Under the extreme environments, such as high temperature or high altitude (>1000m), the Sinopak general MV VFD should be de-rating and the VFD power should be enlarged accordingly.

◎ If the required working condition is explosion-proof, the Sinopak general MV VFD should be installed at safety site because it is not the explosion-proof design.

Adapted Motor Power(kW)Voltage Level(kV)High Voltage Frequency Inverter Abbreviate(HVF)Company Name Abbreviate(SPK)

The total length The total depth

The

tota

l hei

ght


-14- -15-

Type Description

10kV Selection Table

Model Rated Capacity(kVA)

Power(KW)

Output current(A)

Dimension(WXDXH)mm

SPK-HVF-0400-10B 400 315 25.0

2700*1586*2675

SPK-HVF-0450-10B 450 355 36.0

SPK-HVF-0500-10B 500 400 36.0

SPK-HVF-0560-10B 560 450 36.0

SPK-HVF-0630-10B 630 500 36.0

SPK-HVF-0700-10B 700 560 50.0

SPK-HVF-0800-10B 800 630 50.0

SPK-HVF-0900-10B 900 710 60.0

SPK-HVF-1000-10B 1000 800 60.0

SPK-HVF-1150-10B 1150 900 75.0

SPK-HVF-1250-10B 1250 1000 75.0

SPK-HVF-1400-10B 1400 1120 105.0

SPK-HVF-1500-10B 1500 1250 105.0

SPK-HVF-1750-10B 1600 1400 105.0

105.0SPK-HVF-1800-10B 1800 1500

SPK-HVF-2000-10Y 2000 1600 120.0

5500*1386*2675SPK-HVF-2250-10Y 2250 1800 150.0

SPK-HVF-2500-10Y 2500 2000 150.0

SPK-HVF-2800-10Y 2800 2200 180.0

5700*1386*2675SPK-HVF-3100-10Y 3100 2500 180.0

SPK-HVF-3500-10Y 3500 2800 216.0

SPK-HVF-3750-10Y 3750 3000 216.0

SPK-HVF-4000-10Y 4000 3150 250.0 6500*1386*2675

SPK-HVF-4500-10Y 4500 3550 250.0 6700*1386*2675

SPK-HVF-5000-10Y 5000 4000 270.07780*1386*2675

SPK-HVF-5600-10Y 5600 4500 300.0

SPK-HVF-6300-10Y 6300 5000 360.08580*1586*2910

SPK-HVF-6750-10Y 6750 5400 400.0

SPK-HVF-7800-10Y 7800 6300 480.0 9800*1586*2910

SPK-HVF-8900-10Y 8900 7200 540 11410*1586*2910

SPK-HVF-10000-10Y 10000 8000 600 13410*1586*2910

SPK-HVF-11250-10Y 11250 9000 720.0 13410*1586*2910

SPK-HVF-12500-10Y 12500 10000 720.0 13810*1586*2910

SPK-HVF-14000-10Y 14000 11200 810.0 20100*1586*2910

SPK-HVF-15500-10Y 15500 12500 900.020700*1586*2910

SPK-HVF-17500-10Y 17500 14000 1050.0

ModelRated Capacity

(kVA)Power(KW)

Output current(A)

Dimension(WXDXH)mm

SPK-HVF-280-06B 280 220 36.0

2250**1586*2675

SPK-HVF-315-06B 315 250 36.0

SPK-HVF-350-06B 350 280 36.0

SPK-HVF-400-06B 400 315 50.0

SPK-HVF-450-06B 450 355 50.0

SPK-HVF-500-06B 500 400 50.0

SPK-HVF-560-06B 560 450 60.0

SPK-HVF-630-06B 630 500 60.0

SPK-HVF-700-06B 700 560 75.0

SPK-HVF-800-06B 800 630 105.0

SPK-HVF-900-06B 900 710 105.0

SPK-HVF-1000-06B 1000 800 105.0

SPK-HVF-1150-06B 1150 900 120.0

3100**1586*2675

SPK-HVF-1250-06B 1250 1000 120.0

SPK-HVF-1400-06B 1400 1120 150.0

SPK-HVF-1550-06B 1550 1250 150.0

SPK-HVF-1800-06B 1800 1400 180.0

SPK-HVF-2000-06B 2000 1600 216.5

SPK-HVF-2250-06B 2250 1800

2000 250.0

216.5

SPK-HVF-2500-06B 2500

SPK-HVF-2800-06Y 2800 2250

4500 540.0

270.06360*1386*2675

SPK-HVF-3150-06Y 3150 2500 300.0

SPK-HVF-3500-06Y 3500 2800 350.0 6400*1386*2675

SPK-HVF-4000-06Y 4000 3150 400.0 7200*1386*2675

SPK-HVF-4500-06Y 4500 3550 480.0

8400*1586*2910SPK-HVF-5000-06Y 5000 4000 480.0

SPK-HVF-5600-06Y 5600

SPK-HVF-6300-06Y 6300 5000 600.0

SPK-HVF-7000-06Y 7000 5600 720.0 8600*1586*2675

SPK-HVF-8000-06Y 8000 6300 800.010200*1586*2910

SPK-HVF-9000-06Y 9000 7100 900.0

SPK-HVF-10000-06Y 10000 7800 1050.0 12200*1386*2675

6kV Selection Table


-16- -17-

Storage & Transportation The Classical Program

≤60°

Top lifting point Top lifting point

The bottom lifting point of the U-bar The bottom lifting point of the U-bar

Special spreader

Lifting angle ≤60°

功率柜Gong Lv Gui



电缆柜Dian Lan Gui

F14 F13 F12 F11

电阻柜DianZu Gui

Tteel pipe

Tteel pipe

Foundation

K1

M1

K2

HVF

M1

K3

K1

J1

J3

QF3

M2

K03

K01

J01

J03

QF4

K01

M2

K02

K1

M1

K2

QF2 QF1

HVF HVF

M

K3

K1

J1

J3 J2

K4 K2

HVF

K1 K2

M1 M3

F1 F4 F3

#1 HVF

K01K02

M2

F5 F2

#2 HVF

Manual bypass one-drive-one

Manual bypass one-drive-two

Automatic bypass one-drive-one

Automatic bypass one-drive-two

Manual bypass two-drive-three

After years of field practice and application, Sinopak Electric has accumulated mature system application programs. 1) Manual one-drive-one: suitable for load which has less demand for switching speed of the power frequency and variable frequency 2) Manual one-drive-two: suitable for site with two motors, one for work, one for preparation, such as condensate pump of thermal power plant etc. During regular operation, one motor is in variable frequency operation, and the other one is for power frequency standby;3) Automatic one-drive-one: suitable for load in need of fast power frequency switching. 4) Automatic one-drive-two: suitable for site with two motors, one for work, one for preparation,such as condensate pump of thermal power plant etc. During regular operation, one motor is in variable frequency operation, and the other one is for power frequency standby. When the inverter needs maintenance or inverted pump operation, it can rapidly switch to power frequency operation. 5) Manual two-drive-three: suitable for site with three motors, two for use, one for preparation and one for use, two for backup; usually in demand for higher stability, such as blast furnace blower or steel plant electric water pump of thermal power plant and so on. Under regular operation, two motors are in variable frequency operation; when one motor bursts, the standby fan (pump) will be started immediately, ensuring the continuity of production; and it will switch to variable frequency operation after maintenance.


Sinopak series high voltage frequency conversion speed regulating system can be transported by the car, train, ship, and any other modes of transportation. The products in transportation must be carefully handled and protected from rain, sun, violent vibration, impact and upside down storage.▲ Transport and storage temperature(within four weeks): - 40 ～ +70°C; long-term storage: - 5 ～ +55°C. ▲ Relative humidity: Less than 95% and no condensation. ▲ Vibration(storage): maximum 0.3mm(2 ～ 9Hz ),maximum 0.1g. ▲ Vibration(earthquake): maximum 9mm(5 ～ 35Hz ),maximum 2g. ▲ Impact(storage and transportation): maximum 10g. ▲ Hoisting and positioning should be strictly in accordance with the hoisting guidance documents.

Note:Top lifting(left picture above) is confined to separate control cabinet, bypass cabinet and other cabinets specified to be top lifting feasible. Bottom lifting (right picture above ) is suitable for most cabinets with ring at the bottom. During the positioning process , multiple pieces of 70-100mm diameter steel pipes need to be laid below the U-steel, with interval less than 500mm and rolling steel assisting in positioning (below):

1.The Project Brief

2. The Frequency Conversion Transformation Program

-18- -19-

Typical Applications

In recent years, the economic situation and government policy are forcing steel enterprises to implement energy-saving emission

reduction to reduce the energy consumption of production. As one of the largest single equipment of sintering production lines,

the main sintering fan can largely reduce the energy consumption of sintering single production by energy saving frequency

conversion transformation.

Main sintering fan is the key equipment of the sintering production line and its energy saving frequency transformation needs

solving the following six problems:

▲The larger sintering production line is equipped with main exhaust fan with power more than 5000KW, so it demands an inverter

with larger power.

▲As the core equipment, the running of the Main sintering fan request high stability. Not only does the inverter needs work

stability and a low failure rate, but it also needs rapidly restarting the power production mode after the inverter fails, so as not to

affect the operation of the product line. Thus, the frequency conversion transformation of the double main exhaust fan usually

adopt mutual standby mode, which asks for a high technology of combing frequency conversion and power grid.

▲Large power inverter producing much heat has high request for working environment temperature and cleanliness, which

contradicts with the dusty environment of the steel plant.

▲As a lot of main fans are driven by large power synchronous motor, the control of synchronous motor inverter is more

complicated and requires higher technology than that of the asynchronous motor inverter.

▲Driven by the synchronous motor, not only does the main fan require the cooperation of the inverter and excitation device in

variable working condition, but also it requires the the rapid switch to excitation working mode at the same time when the motor

switches between power driving mode and variable frequency mode. The excitation device must have a variety of optional

operation modes and can flexibly and conveniently switch between different working modes.

▲As the main fan system is with a lot of device, its monitoring system must monitor and protect the power supply system, air

volume, air pressure,vibration and oil system and have the capability of fast and reliable communication to send timely feedback

of the working state of the equipment to the production lines and control system.

The following frequency conversion transformation program instruction is for the main sintering fan driven by dual

synchronous motors. For the main exhaust fan driven by the asynchronous motor or the main exhaust fan system driven by a

single motor, the transformation program is simple , so it is not described here.

Project 1. The Variable Frequency Transformation of the Main Exhaust Fan In the Sintering Production Line In Metallurgy.

Synchronous motor blower

QF301

10kV I

QF101

10kV II

QF202

GNQF0

QF201 QF102 QF302

DC Panel

PT2 QF2QF1QF401 PT1

M

3~

M

3~

QF10

TF1

Inrush current cabinet

QF111 QF212

QF11

QF112

QF20

QF211

TF2QF21

Reactor cabinet

2.1 Main exhaust fan power supply system

Inrush current cabinet

Reactor cabinet

1# H

igh

volta

ge in

vert

er

10kV I#

Pow

er s

uppl

y Th

e ac

cess

term

inal

pow

er s

uppl

y

10kV I#

Pow

er s

uppl

y Th

e ac

cess

term

inal

pow

er s

uppl

y

1# Synchronous motor blower 2# Synchronous motor blower

2# H

igh

volta

ge in

vert

er

Not only can the above two inverters in the power supply system be the inverter driven device of the corresponding main fan, but they

can also be the frequency conversion soft start device of another main exhaust fan. When any one of the inverters breaks down, the

other inverter will rapidly switch the motor to power frequency operation without disturbance, which will not affect the continuity of

production.

2.2 High Voltage Frequency Conversion Speed Regulating System

Sinopak large power synchronous motor special frequency conversion speed regulating system, using the synchronous motor special

control technology, can achieve precise control of synchronous motor and "flying start". The regulation system can switch the

motor to power frequency operation without disturbance; during the switching, there is no mutation impact of the motor current; with

design redundance, in the primary unit bypass state, the system can still be in full load variable frequency operation or switch the

operation mode power frequency operation without disturbance.

2.3 High Voltage Inverter Chamber Cooling System

These two high voltage inverters adopt a closed environment external circulation forced air cooling system. Automatically controlling the

operation of the cooling device according to the operation conditions of the inverters and environmental temperature, the system

can save equipment investment and operation cost with small maintenance workload, good heat dissipation and low temperature

rise of device. Thus, it guarantees the operation stability of the high voltage inverter.

The special speed control system of the main sintering fan driven by the dual synchronous motor, consists of five subsystems,

including air fan power supply system, super large capacity special high-voltage inverter, high voltage inverter chamber cooling

system, synchronous motor and ventilation frequency excitation system, main fan centralized monitoring system etc. The

subsystems can respectively solve the above problems we come across in the frequency converter transformation of the main

exhaust fan.


3、Classic Program

-20- -21-

Main exhaust fan monitoring screen

High Voltage Inverter Chamber Cooling System

The Current Wave of the Switching Process From Variable Frequency Operation to Power Frequency Operation

This project was carried out on the sintering main exhaust fan system driven by dual brushless synchronous motors of the new

sintering production line in the 430m2 large iron and steel production base of Bao Steel Group. Two Sinopak inverters, used for two

7800kV Siemens synchronous motors, were one time through acceptance and put into operation. Then the program was put into

production smoothly and steadily. The operation successfully proved the economy, efficiency and reliability of the program.

According to the energy-saving evaluation for nearly two months after the two sets of high voltage frequency conversion speed

regulating system were put into operation, the average energy saving rate reached as high as 40%. Calculated in accordance with

operation of 7000h a year, the two sets of high voltage frequency conversion speed regulating system could save annually

90000000 degrees of power.

During the project acceptance process, test of main fan rapidly switching from variable frequency operation to power frequency

operation without disturbance was carried out on site. The following waves recorded in the test proved that this project could

ensure the main fan rapidly and softly switched to power frequency during inverter fault , which would not affect the continuity of

production.

Sinopak sintering main exhaust fan special centralized monitoring system can control and real-time monitor the parameters of the

sintering main exhaust fan, operation of the motor, auxiliary equipment, wind turbine and auxiliary equipment, power supply

system of the main exhaust fan, inverter, excitation device, throttle, variable frequency chamber cooling system and other main

device; the system can communicate data with the central control station of the sintering production line. Further more, the

monitoring system can provide powerful and full protection to the fan, motor and inverter, ensuring the safe and reliable running

of the process load of the product line.

2.4 Synchronous Motor Excitation Frequency Control System

Synchronous motor excitation frequency control system, has two controllers that mutually standby( automatically switch to standby

machine to operate when host faults ), to ensue the operation reliability of excitation system. What’s more, the system has constant

firing angle, constant voltage, constant current, constant power factor control and a variety of control modes, which can

automatically switch the control modes according to the operating condition of the motor. The operation is simple and running is

reliable.

2.5 Main Exhaust Fan Centralized Monitoring System


The subcritical thermal power generating unit with 2X330MW capacity of a thermal power plant in West North China was put into

operation in 2005. In 2011, in order to improve operation efficiency and reduce operation consumption, the plant decided to carry

out variable frequency transformation on the feed water pump system which takes up 20-33% of the power of the plant.

R15K551.1 hydraulic coupler was a compact design with precise manufacture and accurate adjustment. Working oil and lubricating oil from different types of pump, gear pump and centrifugal pump respectively, was concentric stacked, driven with a shaft, adjusted speed to 3000rpm, installed in the hydraulic coupler shell, powered by the water pump motor and connected with gears. VOITH R15K551.1 and other domestic TOT51 series hydraulic coupler used for 300MW units was largely different in structure and technology. In order to avoid vibration increase, larger noise, momentum imbalance and other undesirable phenomenas after transformation of the R15K551.1 hydraulic coupler, and to assure the system function and performance after transformation consistent with the original design, it was pragmatic and prudent to choose the technique “Original pump out, Cardiopulmonary bypass” . That is, after transformation, the hydraulic coupler would still use the original centrifugal/ gear and pump, match suitable motor and gear, keep the working speed at 3000rpm and make the same working environment as that before transamination. Correspondingly, external fuel tank, pump, instrumentation and safety protection device were needed. Only in this way, the original technical index and long term safe operation of the VOITH R15K551.1 hydraulic coupler could be guaranteed.

Analysis of Variable Frequency Transformation Effect:After variable frequency transformation, the feed water pump kept operating in the mode of two for working, one for backup and the hydraulic coupler opened to 99%. Two Sinopak high voltage inverters adjusted the frequency and speed of the pump motor, and another inverter was for the power frequency backup. Effect contrasted as follows :

As the load of the thermal power plant could not always keep at a high level, the energy saving effect of the feed water pump frequency conversion speed regulation is much more better than that of the hydraulic coupler, with energy-saving rate up to 35~ 40%. Technically speaking , after the upgrade of the pump, the plant power could achieve soft start of generator without impact and avoid the same bus device making protection in error. It took only 20-30s to reach rated speed and achieve stable water supply and the speed regulation was precise, ensuring the safe and stable operation of the generator unit.

-22- -23-

The type and parameters of the feed pump:

The type and parameters of the motor of the feed pump:

Project 2. Variable Frequency Transformation on Feed Water Pump for a 300MW Thermal Power Plant

Type Double casing multistage segmental centrifugal pump

Head 2353m

Model CHTC5/6SA Shaft power 4460kW Quantity 3 Efficiency 83% Running mode Two for working and one for backup Speed 5830rpm Manufacturer Shenyang Pump Co., Ltd.

Type YKS5500-4 Rated speed 1491rpm Rated power 5500kW Rated frequency 50Hz Rated voltage 6000V Stator terminal Y Rated current 611A Manufacturer Harbin Electric Factory

The type and parameters of hydrodynamic coupling:

Type R15K551.1 Maximum output speed 6100rpm Spoon pipe control Hydraulic servo Slip ratio 3.12% Output power 4500kW Working oil pump KP144 Motor speed 1490rpm lube oil pump MZP450 Gear ratio 131/31 Auxiliary lube oil pump ZP350

Principal axis speed 6296rpm Auxiliary oil pump M2QY1324A

Pre-feed pump:

Rated power 110kW Efficiency 83%Rated speed 1490 Head 46m

Variable Frequency Transformation Program

Diagram before and after variable frequency transformation:

Motor load rate % Inverter

efficiency %

Speed regulation type

coupler %

Fluid coupling efficiency %

The efficiency difference %

90 97 93 87 6 80 97 93 78 15 70 96 93 67 26 60 95 92 58 34 50 94 91 49 42

Booster pump

Feed pump

Self-

deae

rato

r

Water pump motorSpoon pipe

Fluid coupling

Spee

d in

crea

sing

ge

arW

orki

ng o

il pu

mp

Lube

oil

pum

pA

uxili

ary

oil

pum

p

Go

Boile

rs

Booster pump motor

Self-

deae

rato

r

Booster pump

Water pump motorSpoon pipe

Fluid couplingFeed pump

Go

Boile

rs

Delivery pump

Working oil pump

Lube oil pump

Auxiliary oil pump

Fuel tankInverter


Under the background of vigorous promotion of energy saving and emission reduction in our country, many thermal power plant were taking action in technique transformation, such as desulfurization, denitration etc. During the transformation, if the original fan and booster fan of the unit adopted the discrete program, there would be some difficulty in the regulation of operation. A better way was to combine the booster fan with the original fan to be a united fan so that the operation regulation was simpler and more convenient after transformation. As the power of the united fan was higher than the original fan, thus, to achieve more efficient and economic operation of the motor of the united fan at different load and to reduce the power consumption rate of the plant, it is particularly important for the united fan to adopt the frequency conversion energy saving technique. The domestic largest capacity 600MW united fan frequency conversion transformation program (500KW/6KV ), carried out by Sinopak Electric for a power plant of Datang Power Generation Group, had been put into production in 2012 and achieved remarkable energy saving success.

Through public bidding, the plant finally chose Sinopak high voltage frequency conversion speed regulating system for the energy conservation transformation, which was the first time domestic inverter was used in 6KV/6500KW power high voltage motor for energy conservation transformation. One of the key technique of the transformation of this project was technology and quality insurance of high voltage frequency conversion equipment; the other key was the design of the cooling system of the equipment on site. During the implementation of the project, with leading R & D and manufacturing technology of large capacity frequency conversion equipment in this industry and rich experience in power industry, Sinopak overcame various kinds of difficulties such as difficult site construction, complex system and so on, and the project was one time put into production successfully.

Two one-drive-one high voltage frequency conversion speed regulating systems were configured to two induced draft fans of #1 unit and controlled induced draft fan A and B separately. The primary connection diagram after high voltage frequency control system transformation was as below:

United fan of thermal power plant could obtain both technological and economic benefits after frequency conversion transformation. 3.1 Improvement on the Unit Process by the Variable Frequency Transformation ◆ Effect on the power plant: motor starting current of the united fan was significantly reduced, avoiding the huge current impact on the plant power caused by the full voltage start of the motor and avoiding the mis-operation of relay protection;◆ Effect on the motor: the motor could start up smoothly, preventing damage to the insulation of the motor from full pressure start. ◆ Effect on the fan and other mechanical equipment: the smooth start of the motor could prevent the fan and other machines from transient strong pressure and prolong the service life of the equipment. ◆ Effect on the flue gas system: As damper was no longer used to regulate the airflow, the transformation would ensure the smooth change of wind pressure, reduce the noise of the network and avoid mechanical wear caused by frequent adjustment of the throttle.

A power plant of Datang Group built 3X600MW subcritical thermal power generating units in central China. In accordance with the overall planning for power plants, energy-saving emission reduction transformation was carried out on #1 unit firstly. Two original 6.3KV/3600KW fans were removed, and two 6.3KV/3600KW united fans were modified while desulfurization and denitrification equipment and production technology were newly added. The operating parameters of the united fan were as follows:

-24- -25-

Project 3. Variable Frequency Transformation on United Fan of the 600MW Unit of a Thermal Power Plant

1. Project Overview Introduction

2.The Variable Frequency Transformation on the Induced Draft Fan of 600MW Unit

Type Rated voltage 6kV Rated power 6500kW Rated current 748A Power factor > 0.8

Motor nameplate parameters

Rated speed 995rpm Insulation class F Type HA46236-8Z Shaft power 6221kW Rated speed 995rpm Rated airflow 560.36m3/s Full pressure 9847Pa Stator blade adjustment range

Designed medium temperature

140°C

Fan nameplate parameters

Efficiency 86% Rated moment of inertia

Users switchgear HVF

Motor Fan

Main wiring diagram of the high-voltage frequecy conversion speed regulating device

High Voltage Frequency Conversion Speed Regulating System Transformation Program

3. Analysis of the Frequency Conversion Transformation Effect of the 600MW Induced Draft Fans.

On site operation of High Voltage FrequencyConversion Speed Regulating System

Induced Draft Fan Controlled by High Voltage Frequency Conversion Speed Regulating System


3.2 Economic Benefit of Variable Frequency Speed Regulation.Variable frequency speed regulation was a highly effective speed control technology. Not only did it improve the production technology of the thermal power plant but it also saved energy and reduced emission; it reduced the power consumption rate of the power generation plant, and had considerable economic benefits. The economic benefits were particularly remarkable when the thermal power units operated at low low load. The average energy saving rate was up to 20-40%; energy-saving effect would be more remarkable when the unit was in peaking operation.

In 2012, under the unified arrangements of the corporation, the Tibet branch took the lead in variable frequency transformation on the main fan of the1000T/D production line. As the company was located in plateau, at an altitude of 4000m, where air was thin and average annual temperature was 8 °C, there was no precedent high voltage variable frequency operation before. Therefore, it had higher requirements for the overall strength of the high-voltage inverter manufacturer.The main object of the transformation was kiln head EP fan, kiln tail exhaust fan and ID fan; the specific parameters of the motor and the matched inverter were as below:

The stable operation of the Sinopak high voltage frequency conversion speed regulating system on the 4000 meters altitude plateau, created tangible economic benefits for the enterprise and made due contributions in the field of energy saving for the Tibet autonomous region.

Combing the on-site operation, Sinopak developed high voltage frequency conversion speed regulating system specially for plateau. The system adopted mature manual one-drive-one program:

The Tibet branch of a large cement enterprise, located in Tibet autonomous region Shannan Area, had built a new dry process cement clinker production line with 1000 ton a day capacity and another line with 2500 ton a day capacity, which could annually produce 1200000 tons high quality cement. The company ranked among the top 10 industrial enterprises in Tibet autonomous region and made great contributions to the economic construction for Tibet regions during the 10 years operation of the factory.

-26- -27-

Project 4. Sinopak HVF Running at an Altitude of 4000m.

Operation frequency (Hz)

Input current (A) Output current

(A) De-dustingair- pressure(Kpa)

Generator units load (MW)

A United fan

B United fan

AUnited fan

B United fan

A Unitedfan

B Unitedfan

A United fan

B Unitedfan

Remark

315.77 26.91 26.96 82 79 227.69 225.12 -1.2 -1.12 404.39 30.56 30.39 110 105 256.2 254.07 -1.51 -1.35 465.3 32.84 32.83 158 163 293.86 294.68 -1.73 -1.58 491.31 33.69 33.66 167 163 299.5 298 -1.62 -1.66 563.34 36.23 36.24 217 215 340.48 339.8 -1.92 -1.91 614.55 40.47 40.41 293 294 398.76 403.72 -2.28 -2.24 313.55 27.46 27.89 82 83 227.69 228.5 -1.2 -1.13 406.49 30.06 30.29 105 113 251.38 255.95 -1.39 -1.32 466.26 34.24 34.46 130 135 268.67 275.44 -1.5 -1.39 506.66 36.23 35.78 198 205 326.95 334.47 -1.81 -1.82 559.16 37.12 37.12 218 227 343.04 351.76 -1.96 -1.9 601.33 40.66 40.29 343 353 432.52 447.64 -2.63 -2.48

The data acquisition time was 2012-12-19，denitration had not been put into operation

Users switchgear HVF

Motor Fan

10KV

Load name ID Fan Kiln tail exhaust fan Kiln head EP fan Type YRKK560-4 YRKK500-6 YKK450-6 Rated power (kW) 1120 500 220 Rated voltage (V) 10000 10000 10000 Rated current (A) 75.01 34.92 16.14 Rated speed (r/min) 1486 987 992 Rated power factor 0.9 0.875 0.83 Rotor open circuit voltage

885 723 --

Rated rotor current (A) 774 430 --

Load motor

manufacturer Lanzhou motor Lanzhou motor Lanzhou motor Type A9H1750/10Y A8H750/10Y A8H400/10Y Rated current (A) 100 50 25 Rated voltage (kV) 10.5 10.5 10.5

Matched inverter

Remark Plateau type Plateau type Plateau type

After transformation, the operation data of various load motors with the same production capacity were as below:

Load Frequency power kW Variable frequency power kW Average energy saving rate ID Fan 1006 750 25.4% Kiln tail Exhaust fan 461 362 21.5% Kiln head EP fan 176 54 69.3%


For a number of large industrial enterprises, the smooth start of high voltage high power motor was very important, as the load of these high voltage motors was usually the key equipment of production. For example, compressor of chemical enterprise, oxygen machine of iron and steel enterprises, generator sets of LNG (Liquefied Natural Gas ) and high concentration grinding machine of paper-making enterprises. The smooth start of the motor was directly related to smooth production. The power of this type of motor was usually large, smaller power was thousand kilowatts,and larger up to dozens of thousands of kilowatts. The power could suddenly reach several times of the rating power when the motor started at full voltage. Even if it was fractional load or no-load start, the power system with limited capacity would be weak, which would lead to mis-operation of relay protection , abnormal operation of other equipment, or worse, collapse of power grid of the factory.It had been a long time since the study of the soft start of large power motors at home and abroad, from the star delta starter, rotor resistance starting (water) at the beginning to thyristor soft start device later. With the development of power electronic technology in recent years and widespread application of high voltage frequency conversion speed regulating system, the soft start of high voltage inverter, as a new soft start device, was gradually getting more and more recognition.

The second period of the project of a big paper manufacturing enterprise integrating forest, pulp and paper in Guangxi, could reach an annual output of 1500000 tons pulp and 2500000 tons paper. The enterprise had two large power high consistency refiner, with 10 kV/20MW brushless excitation synchronous motors made in Shanghai motor factory. In order to achieve efficient use of resources, after on-site inspection of numerous Sinopak technical experts, a one-drive-two program of applying Sinopak high voltage inverter on large capacity synchronous motor was suggested to achieve the soft start of the two motors,(as pictured on the right), with the coordinated control of excitation system during startup process at the same time. When 1# high consistency refiner needed to start, #1 bus was charged and all circuit breakers were off. After preparation before start, closed QF01, the inverter was charged and entered the standby mode. Closed QF30, QF12, connected the excitation cabinet,sent out current, and started the inverter. When reaching

Take a 6kv/10000kw wound asynchronous motor driving compressor load as an example. When the motor rotor series resistance (water) starts, the valve of the compressor was fully closed. The motor was in fractional load, with starting current up to about 3600A and start time about 43S. 2.1 High Voltage Variable Frequency Soft Start ProgramAs a soft start device, the high voltage inverter needed to operate to smoothly control the output current when the motor started with QF01,QF02 closed, and QF1, QF2 off. When the output of the inverter reached 50HZ and the motor reached the rated speed, there was a sync switching. The switching process was as follows: Firstly QF1 was closed, QF02 was off after a few seconds, the inverter stopped running, then QF01 was off, and the frequency conversion stopped; after a few seconds, QF02 was off, sync reactor was short, and the motor completed soft start. 2,.2 The Advantage of High Voltage Variable Frequency Soft Start

The soft start of the motor could actually be achieved by a high voltage inverter. Compared with the traditional soft start device, the inverter was with obvious advantages as below: ◆Truly no impact current when the motor starts : Current changed smoothly when the motor started, and the maximum value was strictly controlled below the rated current of the motor, which protected the insulation of the motor and prolonged the service life of the motor. ◆No impact on the power grid: As the output power of the high voltage inverter increased gradually and usually didn’t exceed 50% of the motor rated power, there would be no effect on the grid, which avoided the possible interference on the equipment operation at the same bus and avoided mis-operation of relay protection. ◆Achieve the switching between the frequency conversion output and power frequency grid without disturbance: sync switching technology could realize the switching completely without impact and would not have any impact on the motor and load equipment operating at high speed.

-28- -29-

Project 5. High Voltage Variable Frequency Soft Start of the Large Capacity Motor

1.Brief Introduction

QF01

QF2

QF1

QF02

M

10KV high-voltage bus

sync switchgear

HVFL

2.Variable Frequency Soft Start Program

3、Program Implementation

QF101

L1QF11

QF201

10KV 2

QF102

QF12 QF22

M1

10KV 1

QF21

QF202

QF30

M2

L2HVF

50HZ after some time, the Sinopak high voltage inverter automatically locked the frequency, phase and amplitude of #1bus, adjusted the output to keep the it consistent with the bus voltage. Then closed QF201, cut off QF12 and QF30 after a few seconds, stopped frequency conversion operation, closed QF11 after a few seconds, cut off QF101 and the start was finished. The starting of #2 high consistency refiner could be referred to that of the #1 refiner. At present, Sinopak high voltage inverter on site had successfully realized the soft start of two high consistency refiners. During the starting, current change of the motors was steady and operation of the motor was normal without abnormal heat, movement or other problems. At the same time, the power system of the factory also ran well, without abnormal operation and mis-operation of relay protection of equipment due to interference.


Documents

ZHUHAI SINOPAK ELECTRIC LTDacdriveelectric.com/upload/3922/download/1/pdf/... · Set by host computer via RS485 port; Multi-speed set, suitable for the working conditions in cyclic