FGI FD3000 High-Voltage Soft Starter Successfully Exported to a Large Russian Mining Project
his client is modernizing its long-standing main beneficiation plant. The core of the project is to equip the key equipment on its production line - multiple high-power high-voltage water pumps (10kV, 2500kW) - with high-performance soft start systems to replace the old and frequently-faulty direct-starting cabinets.
The Siberian winter is extremely cold, with the ambient temperature dropping as low as -40℃. This poses a severe test for the cold resistance of electronic components. The project space is tight, and new equipment must have a compact structure for easy installation. The internal power grid capacity of the factory is relatively limited. The sudden voltage drop caused by the direct start-up of large motors can seriously affect the operation of other precision equipment. Products for export to the Russian and Eurasian Economic Union markets must pass the strict EAC certification.
2. FGI's solution: Tailor-made FD3000 soft start system
In response to the unique requirements of the customers, the FGI engineering team proposed a customized solution centered around the FD3000-10KV/350A high-voltage soft starter.
(1). The core advantages of the FD3000 product:
It adopts a 32-bit microprocessor and advanced control algorithms, and provides precise voltage ramp, current limiting and torque control startup modes through an intelligent control platform. Key components such as high-voltage thyristor modules have been strictly selected and tested, with an extremely long Mean Time Between Failures (MTBF). The modular structure and compact cabinet design are highly suitable for space-constrained renovation projects. Built-in comprehensive system protection functions, such as overcurrent, overload, phase loss, overheating, and current imbalance, are included.
(2). Special customization for the Russian project
FGI provided the "Extremely Cold Option Package" for the FD3000, including:
Wide temperature components: All core components (such as display units, capacitors) use industrial wide-temperature grades (-40°C to +85°C).
Cabinet intelligent temperature control system: Integrated heaters and cooling fans, controlled automatically by a temperature controller, ensure the cabinet operates at the optimal temperature in any environment.
Special surface treatment: The cabinet uses anti-corrosion and cold-resistant coating processes to prevent condensation and rust.
Seamless integration solution: FGI provided interface protocols and detailed wiring diagrams with the original factory high-voltage switch cabinets to ensure seamless integration into the existing power distribution system.
Complete EAC certification: The FD3000 series of FGI has fully obtained EAC certification, meeting the requirements of TR CU 020/2011 (Electromagnetic Compatibility) and other regulations, paving the way for smooth customs clearance.
3. Project Execution: From Order to Commissioning
The local Russian technical support team of FGI had multiple rounds of communication with the customers, provided detailed bilingual (Chinese and Russian) technical materials, and arranged online video conferences where engineers from FGI's China headquarters conducted technical explanations.
After signing the contract, both parties organized production according to the customized requirements. During the production process, multiple factory inspections including low-temperature start-up tests were carried out, and the test reports were submitted for customer review. Skilled in handling export documents, including commercial invoices, packing lists, origin certificates, and the most important EAC compliance declaration. The equipment was shipped by sea to the Saint Petersburg Port, and the customs clearance process was efficient and smooth. FGI dispatched an experienced engineer to the site to guide the customer team in installation. Thanks to the friendly full-Russian-language human-machine interface and clear instructions of the FD3000, the debugging work was completed quickly, and a special training session was also conducted for the customer's operation and maintenance personnel.
4.Project outcomes and customer value
The FD3000 successfully limits the starting current of the high-pressure pump to less than three times the rated current, achieving an extremely smooth acceleration process. It completely eliminates the impact on the power grid, the factory lighting no longer flickers, and the operation of other equipment is not affected at all. After the equipment is put into operation, it has withstood two harsh winters without any failure records. Its stability has won the customers' high trust. It significantly reduces the mechanical stress on the pump impeller, bearings and pipeline system during the starting process, prolonging the equipment's lifespan. It avoids production halts caused by starting failures and ensures continuous production. It reduces the maintenance requirements caused by electrical shock and mechanical vibration.
