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Www.ld-harvest.com Beijing Leader & Harvest Electric Technologies Co. Ltd Application of Medium Voltage Variable Frequency Drive (VFD) In the Cement Industry.

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Presentation on theme: "Www.ld-harvest.com Beijing Leader & Harvest Electric Technologies Co. Ltd Application of Medium Voltage Variable Frequency Drive (VFD) In the Cement Industry."— Presentation transcript:

1 Beijing Leader & Harvest Electric Technologies Co. Ltd Application of Medium Voltage Variable Frequency Drive (VFD) In the Cement Industry

2 www. ld-harvest.com Beijing LEADER & HARVEST Electric Technologies Co., Ltd was established in August Depending on advanced technology that is from the national key lab- power electric lab of Tsinghua University, the company is a high-technology company focusing on research, development, manufacture, sales and service of the medium voltage variable frequency drive (VFD) and has got the certificates of ISO The headquarter of our company lies in Yangfang Industrial Development Zone of Changping South District. Its registered capital is RMB 40 million. Now it has 600 employees and covers the area of 50 acres. The company is the biggest domestic base of producing medium voltage variable frequency drive (VFD) at present. Company Introduction

3 www. ld-harvest.com Research and Development System The company possesses a group of high quality research and development team who are of rich experience and in pursuit of new technologies, 30% of which are technical engineers, and more than 10% of which are upper than master degree, and depends on advanced technology that is from the national key lab-power electric lab of Tsinghua University.

4 www. ld-harvest.com Production System The Building area of Production workshop is 150 arces, the production system has 300 employees, 70% of which have technology study experience in college. The productivity of the medium voltage variable frequency drive (VFD) is two thousands every year, the company has the biggest base of producing VFD at present.

5 www. ld-harvest.com Development of Technology 2000, the first HARSVERT-A 1000KW/6KV medium voltage VFD was put into use. 2001, the first 10KV medium voltage variable frequency drive in china was put into use. 2003, 1800KW/6KV medium voltage variable frequency drive was put into use. 2004, 2500KW/6KV medium voltage variable frequency drive was put into use. 2006, 3400KW/6KV medium voltage variable frequency drive was put into use. 2006, first Vector Control medium voltage variable frequency drive was put into use. 2006, synchronous motor medium voltage variable frequency drive was put into use. 2006, a great sets of medium voltage variable frequency drives are put into use in thermal power plants of 600MW. 2007, 5600KW/10KV medium voltage variable frequency drive was put into use. 2007, four-quadrant medium voltage variable frequency drive was put into use. 2008, 7500KW/10KV medium voltage variable frequency drive was produced.

6 www. ld-harvest.com Products Performance 1.The company is the biggest enterprise of producing and reseaching the medium voltage variable frequency drive (VFD). our product has been put into use in international market such as Korea, Russia, India, Kazakhstan and so on. 2.The sale is the most in domestic market, Achieve the sales of total 2300 sets of VFD by the end of 2008,market occupation near 30%. the total sales of 100 sets in the total sales of 200 sets in the total sales of 400 sets in the total sales of 1000 sets in the total sales of 800 sets in the total sales of 2000 sets in 2008.

7 www. ld-harvest.com The Honor of Company 1.August 2005, awarded as"One of 500 Best New Products " by " World Mangers Weekly". 2.December 2005, awarded as " Top Ten VFD Brand Made in China " by " VFD World ". 3.June 2006, Leader & Harvest VFD was awarded as " the most satisfactory chinese brand admitted by domestic user in 2006". 4.September 2006, Leader & Harvest was awarded as " top ten substantial growth enterprises ". 5.December 2006, Leader & Harvest was awarded as" top 100 growing Chinese small and medium-sized enterprises ". 6.February 2007, Leader & Harvest was awarded as" One of 100 Credit Chinese enterprises 7.April 2007, Leader & Harvest was awarded " One of Ten most influential national brand in Chinese Automation field in 2006 ". 8.September 2007, Leader & Harvest was awarded as " China Top Brand " by National General Administration of Quality Supervision, Inspection and Quarantine. 9.June 2008, Leader & Harvest was awarded as" Annual the most satisfactory chinese brand admitted by domestic user ".

8 www. ld-harvest.com Products Introduction Product Specification HARSVERT-A medium voltage variable frequency drive application in asynchronous motor with fans and pump in the load side HARSVERT-S medium voltage variable frequency drive application in synchronous motor voltage level 2-11kV application motor KW HARSVERT-FVA medium voltage variable frequency drive energy feedback, vector control application in asynchronous motor 4-quadrant operation

9 www. ld-harvest.com Products Introduction The HARSVERT series of variable frequency AC motor drives (voltage source inverter) include phase-shifting transformer, power cells and controller. These power cells are cascaded to provide operating voltages of 3kV(or 6kV,or10kV) directly. System Structure

10 www. ld-harvest.com Products Introduction Topology of HARSVERT –A VFD 4 cells in series-12 cells total,3kV 3KV The groups of power cells are wye connected with a floating neutral. Motor voltage 3kV can be provided directly.

11 www. ld-harvest.com Products Introduction 6KV The groups of power cells are wye connected with a floating neutral. Motor voltage 6kV can be provided directly. 5 cells in series-15 cells total,6kV Topology of HARSVERT –A VFD

12 www. ld-harvest.com Products Introduction Topology of HARSVERT –A VFD 8 cells in series-24 cells total,6kV 10KV The groups of power cells are wye connected with a floating neutral. Motor voltage 6kV can be provided directly.

13 www. ld-harvest.com The transformer secondaries that supply the power cells in each output phase are wound to obtain a small difference in phase angle between each other. This cancels most of the harmonic currents drawn by the individual power cells, so that the primary currents are nearly sinusoidal. The power factor is typically 95% at load. Products Introduction Theory-Transformer Cabinet

14 www. ld-harvest.com Power Cell Cabinet Each cell is powered by an isolated secondary winding of the integral isolation transformer. No harmonic filters required. The drives cause no additional stress to the motor insulation. Product Introduction

15 www. ld-harvest.com Waveforms of Output Voltage Products Introduction All cells are electrically and mechanically identical, so that they are interchangable. The three-phase diode rectifier, fed by the secondary, charges a DC capacitor bank. The DC voltage feeds a single-phase H-bridge of IGBTs, controlled by PWM method. Each power cell is a AC-DC-AC converter.

16 www. ld-harvest.com Hardware Overview Customer benefits: Cabinets are combination of parts, easy to production Compact in structure Fewer Spare parts Small footprint Easy to install Put into production quickly Products Introduction

17 www. ld-harvest.com Inside View of Typical Transformer Cabinet Products Introduction The Transformer Cabinet houses a dry phase-shifting transformer which cancels most of the harmonic currents. 185 Insulation Class The windings use NOMEX® insulator The transformer has three-phase temperature detector.

18 www. ld-harvest.com Inside View of Typical Cell Cabinet Products Introduction Each cell can be removed from the cabinet along the slide rails. Each cell communicates with the control system through an isolated link using fiber optic cables. The low-voltage power cells are built in high volume. Single side maintenance

19 www. ld-harvest.com Inside View of Typical Control Cabinet Products Introduction The Control Cabinet houses the controller, built- in HMI, PLC, UPS, control power source DC24V,terminals,buttons,etc. The control cabinet: Has reliable built-in processor Deals with Data & pulses Positions protection & fault Communicates by Using fiber optic cables Has friendly user interface Has Back-up battery

20 www. ld-harvest.com Products Introduction Operation Interface Main interface

21 www. ld-harvest.com Production Introduction Function interface

22 www. ld-harvest.com Production Introduction Parameter Interface

23 www. ld-harvest.com Production Introduction Operation Record Interface

24 www. ld-harvest.com Products Introduction Fault Information Inquiry Interface

25 www. ld-harvest.com Main Performance P arameter Input Frequency Hz 50±10% Rated input voltage kV kV±10% Voltage Tolerance -35% +15% Input Power Factor % Load Efficiency 0.96(Rated Load) output frequency range Hz Output Frequency Resolution Hz 0.01 Overload Capability 120% for 1min 150% for 3s 200% immediately Analog Signal Input4 20mA/0 10V Analog Signal Output4 20mA/0 10V Acceleration/Deceleration Time range S Enclosure Protection GradeIP20 Products Introduction

26 www. ld-harvest.com Production Introduction Benefits-Easy to wire

27 www. ld-harvest.com Production Introduction A variety of control mode DCS 4~20mA/0~10V analog signal RS485 Closed loop Operation box

28 www. ld-harvest.com Production Introduction The input voltage tolerance is ±10%. Under this voltage, the VFD could continue to run. When the input voltage decrease less than 35% of the rated value, the drive will run derated. Input voltage tolerance

29 www. ld-harvest.com Production Introduction High Input Power Factor HASVERT-A drives maintain a high power factor –typically better than 95%. The three-phase diode rectifier, fed by the secondary, charges a DC capacitor bank. There is nearly no phase difference between the input voltage and current.

30 www. ld-harvest.com Production Introduction Clear power input The THD of the input current is always less than 4%.

31 www. ld-harvest.com Production Introduction Multi-level PWM Output The voltage stress on the motor is dramatically reduced and the quality of the motor currents is dramatically increased. The THD of the output currents with a HARSVERT-A series drive is always less than 2 percent.

32 www. ld-harvest.com Production Introduction Advanced cell bypass Through a redundant bypass control, the drive ensures automatic bypass of a failed power cell in 10 milliseconds. Balance of line output is retained.

33 www. ld-harvest.com The VFD system is capable of automatically restarting in the event of a momentary loss of power(20s default) Production Introduction Auto-restarting

34 www. ld-harvest.com Production Introduction When we start the VFD, the motor may still rotating or even at reverse direction. The VFD, which is controlled by DSP, can automatically identify the track and drag the motor to the setting speed. Rotating start

35 www. ld-harvest.com Production Introduction Full Protections Available Output Overload Output Overcurrent Line Over voltage Line low voltage Main power supply loss DC over voltage DC under voltage Transformer overheat Loss of one phase of input power Control power source failure Drive signal failure DCS speed demand signal loss Ground failure Optic fiber fault

36 www. ld-harvest.com HARSVERT-A Product Applications The HARSVERT-A drives, the best-selling medium-voltage AC drives in China, deliver an impressive combination of benefits: Lower operating costs & maintenance costs Precise process control Increased production efficiency High performance Employed in applications ranging from power plant to oil and gas, water,and steel,the HARSVERT-A drive is a versatile performer that can help you significantly enhance energy efficiency, and reduce operating costs.

37 www. ld-harvest.com HARSVERT Product Application in cement industry Cement industry status quo Cement industry is one of the largest energy consumption area. The energy cost of medium voltage motors occupies 30% of the end product cost. Valve is widely used to control air flow in cement industry. However, the resistance caused by the valve closing waste energy.

38 www. ld-harvest.com HARSVERT Product Application in cement industry Energy saving solution The VFD can help you saving energy cost. When the medium voltage VFD is used to control the fan flow, we can save energy at the range of 30% ~ 50%. Usually the total investment will get back for less than 2 years.

39 www. ld-harvest.com HARSVERT Production Application in cement industry Till the end of 2008 HARSVERT VFD installed 151 sets in cement industry

40 www. ld-harvest.com HARSVERT Production Application in cement industry Special demands of cement industry to VFD 1 sudden change of high temperature fans load due to break down of materials accumulated, this lead to motor overload measure Use vector control, the calculation of torque needs less than 100us. When load changes, the torque of motor is restricted under rated torque. Over current would never happen.

41 www. ld-harvest.com Sensorless vector controller

42 www. ld-harvest.com HARSVERT Production Application in cement industry 2.Cement plants can present some environmental challenges for electronic equipment. Enclosure style Abundant design Rational layout of the components Several cooling types: air conditioning & air-to- water cooling & forced air cooling Special demands of cement industry to VFD

43 www. ld-harvest.com HARSVERT Production Application in cement industry 3 dealing with old liquid coupler or liquid resistor measures 1 wound rotor with liquid resistor: short circuit the resistor 2 liquid coupler: move away the liquid coupler, use a shaft to connect the motor and the fan. Special demands of cement industry to VFD

44 HARSVERT Production Application in cement industry Energy saving effect motor power volta ge adjus t power kW Moto r curre nt freq uenc y fans type kW kV % before Use VFD savin g lineVFD Hz cycling fans6306 Valve 80% % mill fans56010 Valve 80% % kiln head fan7106 Valve 70% % kiln end fan Liquid res80% % high temp fan Liquid couple r90% % cement mill fan35510 Valve 45% %

45 www. ld-harvest.com Application effect 1 energy saving 2 improve product and quality with VFD, the air volume and pressure could be adjusted more smoothly and precisely. This improves the product quality. HARSVERT Production Application in cement industry

46 www. ld-harvest.com 3 decrease the maintenance fee with the VFD, the users could save the maintenance fee of the liquid coupler. HARSVERT Production Application in cement industry Application effect 1 energy saving 2 improve product and quality

47 www. ld-harvest.com HARSVERT Production Application in cement industry with VFDs soft start, the pulse currents during start is eliminated. 4 improve the life time of motors and other machines Application effect 1 energy saving 2 improve product and quality 3 decrease the maintenance fee

48 www. ld-harvest.com HARSVERT Production Application in cement industry 5 improve the power factor of the system The cell-cascaded medium voltage VFD, with low distortion of input current, power factor higher than 0.95, compared with old speed regulating methods, greatly improves the system power factor Application effect 1 energy saving 2 improve product and quality 3 decrease the maintenance fee 4 improve the life time of motors and other machines

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