Application of 4.8MW FGI High Voltage Power Inverter in Iran Water Pump Test Bench
1.Introduction
Iran, formerly known as Persia, has a relatively strong economy. Its economy is mainly based on the oil extraction industry and it is a major oil and gas country in the world. It is located in the Middle East, which is the region with the richest oil and gas resources in the world. Oil exports are the lifeblood of its economy. Its oil production capacity and oil export volume rank fourth and second in the world respectively. It is a member of the Organization of the Petroleum Exporting Countries. Iran has a well-developed petrochemical industry, steel industry, automotive manufacturing industry, as well as an electronics industry, nuclear industry, and computer software and hardware industry. The vast majority of Iran's territory lies on the Iranian Plateau. It is a plateau country with an altitude generally ranging from 900 to 1,500 meters, and most of its areas are covered by deserts.
Arak is a city in the central-western part of Iran, formerly known as "Sudanabad". It is located on the east side of a mountain pass in the Zagros Mountains, 120 kilometers southwest of Gum, and is the intersection of the North-South Railway of Iran and the road leading westward to Iraq. The area nearby is an agricultural zone, producing grapes, fruits and grains. There are factories for carpets, wool textiles, matches, beet sugar, etc.
2.User equipment situation
Alak Machinery Factory is a product manufacturer specializing in the sales and research and development of medium and high-end large and medium-sized pumps for Iran. The pump testing system of Alak Machinery Factory is a newly launched system. The high-voltage frequency converter is an important component of the pump testing system of Alak Machinery Factory, which is used to measure the temperature rise, vibration, flow rate, rotational speed and pressure of motors and pumps of various voltage levels and power in different frequency bands. Tests are conducted on various performance indicators such as head, and then the tested motor and water pump are sold as a set.
The main components of the water pump testing system include the water storage tank, water supply pipeline, regulating valve, booster pump, low-voltage frequency converter (controlling the booster pump), high-voltage frequency converter (controlling the pump under test), test bench, motor and water pump under test, tester and transmitter, control room, etc.
The user site of Alak Machinery Factory
After multiple investigations and repeated comparisons by the customer, the JD-BP37-4800F (4800 kW /6kW) variable frequency power supply produced by FGI Electronic Technology Co., Ltd. was finally selected as the power supply for the water pump test. Technical parameters are as follows: the input voltage of 6 kv high voltage variable frequency power supply equipment, the output voltage 1100 v to 6000 v within the scope of the automatic pressure regulating; The output current range is 0-346A. The frequency range is any voltage within the output voltage range, adjustable from 0 to 72Hz.
3.Introduction to High-Voltage Variable Frequency Power Supply System
For this renovation, one JD-BP37-4800F type variable frequency power supply was selected, with a rated voltage of 6kV, a rated current of 346A, a rated power of 4800kW, and a rated capacity of 6000kVA
The JD-BP37 series high-voltage variable frequency power supply is a new generation of vector control high-voltage variable frequency power supply system produced by FGI Electronic Technology Co., LTD. This system adopts a direct "high-high" conversion form and is a unit series multi-level topology structure. The main structure is composed of multiple power modules connected in series, thereby generating the required high-voltage output through the superposition of each group of low-voltages. It causes little harmonic pollution to the power grid, with input harmonic distortion less than 3%, directly meeting the harmonic suppression standard of IEEE519-1992. It has a high input power factor and there is no need to use input harmonic filters and power factor compensation devices. The output waveform quality is excellent, with the output voltage harmonic distortion being less than 2%. There are no additional issues such as motor heating, torque ripple, noise, output dv/dt, or common-mode voltage caused by harmonics. A common asynchronous motor can be used without the need for an output filter.
The JD-BP37 series high-voltage variable frequency power supply is composed of switch cabinets, transformer cabinets, power cabinets and control cabinets.
The on-site installation situation of high-voltage frequency converters
4.The process of transformation
First, install the variable frequency power supply system in place and carry out the main circuit line renovation. Then, debug the variable frequency power supply control system and the single-machine high-voltage system to normal. Next, fix and install the operation console, connect the wires between the operation console and the variable frequency power supply, and debug the signal transmission between the operation console and the variable frequency power supply. After it is normal, conduct unified debugging of the variable frequency power supply and the operation console. Debugging with heavy load is the key part in the transformation. The flowchart of the entire renovation project is as follows:
(1) Installation of high-voltage variable frequency power supply
(2) Connection of the main circuit of the system
(3) Electrical debugging of high-voltage variable frequency power supply control;
(4) High-voltage commissioning of single-unit high-voltage variable frequency power supply;
(5) Installation and commissioning of the operation console body;
(6) Connection and signal debugging between the high-voltage variable frequency power supply and the operation console;
(7) Preliminary unified debugging of the water pump testing system;
(8) Heavy-load commissioning of the variable frequency water pump test system;
(9) The variable frequency system of the water pump was tested and found to be operating normally.
5.The application effect of high-voltage variable frequency power supply on the water pump test bench
Since the equipment was put into operation in August 2016, the variable frequency power supply has been running stably, and the users are very satisfied. The transformation has achieved the expected goal, greatly improving the automation level of the water pump test experiment, and the test experiment is very convenient.
(1) All parts of the JD-BP37-4800 high-voltage variable frequency power supply produced by FGI Electronics are installed in the distribution cabinet and no additional equipment such as reactors and filters are required. It is small in size, compact in structure, easy to install, requires less on-site wiring, has a short commissioning period and can be put into production quickly.
(2) The operating parameters and various indications of the high-voltage variable frequency power supply are all displayed on the touch screen.
(3) The power supply is equipped with a standard communication interface, and the upper computer can fully centrally control the variable frequency power supply through communication.
(4) The variable frequency power supply is very convenient to meet the testing requirements of various motors and water pumps. Just set the corresponding parameters. It can freely drive water pumps of voltage levels such as 6kV/3kV/2300V/1100V, with a current not exceeding 450A and a range of 0-72Hz to complete various tests.
6.TAG
The successful application of the FGI JD-BP37 series high-voltage variable frequency power supply in the water pump testing system of the Arak Machinery Factory in Iran has not only created significant economic and social benefits for users, but also proved the technological advancement and quality reliability of FGI Company's high-voltage frequency converters in the field, winning more brand reputation for FGI Company. Meanwhile, the automation level of the water pump testing system has been improved, which is worthy of strong recommendation and application.
