RECTIFIER INVERTER

DC Link

1 3 5 2 6 4 SYNC.
Motor

AC Line

4 6 2 5 3 1
BRUSH
REACTOR LESS
Exciter
 415 V Power
2 6 4

Phase
controll
ed Fld.
switches Exciter Wdg

5 3 1
Exciter is an induction
frequency changer
LCI BRUSHLESS EXCITER
 100 LCI or VFD Drive
% Efficiency
80

60
Hydraulic Coupling

40 Inlet Guide Vane

20
Outlet Damper Throttling

0 20 40 60 80 100
% Speed / Flow

EFFECIENCY CURVE OF VARIOUS FLOW

CONTROL DRIVES
 CONTROL SYSTEM
•The speed reference from the process controller is a
compared to a speed feedback derived from the
integrated motor voltage & error is fed to a speed
regulator.
•The output of speed regulator is a torque command.
•This torque command is sent to the field controller and
to a current controller as a current command.
•By proper control of stator current & field excitation ,
the machine has a fairly linear torque-per-ampere
characteristic.
•The most straight forward approach is a speed
controller with a V/f controller for field excitation.
 CONTROL SYSTEM
•There are three controllable element which can
be used to control the power to the motor:
- The source side converter
- The load side converter
- the field exciter.
•All three of these use phase control of thyristor
gating angle to control output.
•Major function of load side converter control is
to maintain a minimum margin angle which will
keep the power to the motor at the highest
possible power factor.
 CONTROL SYSTEM
•A current feedback signal is derived from the
AC current into the source side power converter.
•The output of the current controller is used to
control the gate firing angle α of the source side
converter to adjust the DC link voltage
necessary to produce the commanded current.
 POWER
SOURCE

CURRENT
CONTROL SOURCE
SPEED SPEED SIDE
REFERENCE CONTROL CONVERTER

START-UP
S CONTROL LOAD
P SIDE
E CONVERTER
E
D

SYNCHRONOUS
MOTOR

VOLTS / HERTZ FIELD EXC.

CONTROL

CONTROL BLOCK DIAGRAM

 How much power saving?
Gen. ID’s Total Total power Power
MW Power (w/o (KW) by ID Saving
VFD) (KW) Fans with VFD
200 3800 850 2950
240 4150 950 3200
280 4450 1050 3100
320 4800 1250 3550
360 5050 1420 3630
400 5350 1850 3500
440 5600 2500 3100
500 5900 3000 2900
 How much power saving?

•From table it is seen that power saving

ranging from 2900 KW to 3630 KW at various
gen. Points
•Considering an average saving of 3200MW
and 300 days in operation a net saving of
Rs.288 lakhs @ generating costRs.1.25/unit
•Capital investment on VFD Rs.500 Lakhs
•Payback period less than 02 years.
 BHEL VFD
FOR ID FANS
OF 500 MW
UNITS : AN
OVERVIEW
Control Panel C&E Section Bridge LCI, Load
(all external (Control and blower & Section breaker
interlocks, excitation) Filter (Converter (VCB)
alarms, Power section & Invester
supplies bridges)
available here)

LCI Panel
Common for both chanels in one ID
Fans, but interlocking & trip relays are
seperately mounted in this panel for
each channel

Panels related to VFD in VFD room

 PSFF 70V
Power Gate
Supply Supply
module module

SEM Rack
Exciter (Microprocessor
Module & other control
cards)

IOM A
(Input / output
module)

C & E (Control & Excitation)

Panel
 AIR

FAN 1

FAN 2

Air flow
monitor
sensor

Filter Resistors
and capacitors

Fan & Filter Panel

S S
T T
M M STM - Source Thyristor Module
1 HP TK X P TN HP TK X P TN 4

S S LTM - Load Thyristor Module

T T
M M
3 HP TK X P TN HP TK X P TN 6 HPTK - Gate firing card

S S
XPTN - Attennator fead back card
T T
M M
5 HP TK X P TN HP TK X P TN 2

L L
T T
M M
4 HP TK X P TN HP TK X P TN 1

L L
T
M
6 HP TK X P TN HP TK X P TN
T
M
3
LCI (Load
L L
Commuted
T
M
2
HP TK X P TN HP TK X P TN
T
M
5
Inverter)
Thyristor
Bridge
NOTE: In each Thyristor stack there are
three Thyristors in series. Each Thyristor is
having one indication card with neon lamp.
In case of Thyristor short circuit this neon
lamp will not glow. One Thyristor short
circuit in a stack is allowed. If two
Thyristors get shorted load / source
commutation failure will arrive depending
upon which thyristors have failed and
channel will get tripped.
 Transformer
Source 11/ 2.3KV POWER CONVERTER BRIDGE Load
breaker (Ddo), 3kvA breaker
Cooling Fans Cooling Fans
UA
11kV Channel 1
BUS
INTER INTER Control
Control
FACE FACE
ID Ch # 1
REACTOR
CONTROL &
415V 3 Phase
EXCITATION
supply form ESP PANEL

BRUSHLESS
415V 3 Phase CONTROL & REACTOR SYNCHRONOUS
EXCITATION
supply form ESP MOTOR
PANEL

Source Load
breaker breaker
INTER INTER
Control
Control FACE FACE

UA
11kV
BUS Channel 2
Cooling Fans Cooling Fans
Transformer
ID Ch # 2 11/ 2.3KV POWER CONVERTER BRIDGE
(Dyn), 3kvA
 THYRISTOR FIRING

1 2 3 4 5 6 1 2 3

1 3 5 1

6 2 4 6 2

120 deg.
 I

 
DC 1 3 5
Voltage
Source
4 6 2

R Ph

Y Ph

B Ph Synchronous Motor
Stator Winding
 I

 
DC 1 3 5
Voltage
Source
4 6 2

R Ph

Y Ph

B Ph Synchronous Motor
Stator Winding
 I

 
DC 1 3 5
Voltage
Source
4 6 2

R Ph

Y Ph

Synchronous Motor
B Ph
Stator Winding
 I

 
DC 1 3 5
Voltage
Source
4 6 2

R Ph

Y Ph

Synchronous Motor
B Ph
Stator Winding
 I

 
DC 1 3 5
Voltage
Source
4 6 2

R Ph

Y Ph

B Ph Synchronous Motor
Stator Winding
 I

 
DC 1 3 5
Voltage
Source
4 6 2

R Ph

Y Ph

B Ph Synchronous Motor
Stator Winding
 I

 
DC 1 3 5
Voltage
Source
4 6 2

R Ph

Y Ph

B Ph
Synchronous Motor
Stator Winding
 1 2 3 4 5 6 1

R Ph

Y Ph

B Ph

FIRING SEQUENCE & PHASE CURRENTS

VFD Data for Motor:
kW rating - 4286 kW
Armature current - 2 X 607 Amps
Armature Voltage - 2 X 2350 V
Speed / frequency - 565 rpm / 47.08 Hz
Exciter Data:
Rated DC Current - 360 Amps
Rated DC Voltage - 100 Volts
Rated AC Current - 64 Amps
Rated AC Voltage - 345 Volts
Nominal source voltage - 2300 V AC
 POWER SUPPLIES
In control panel of VFD room there
are following supplies for different
interlocks & distribution:-
1.0 3Phase, 415 V AC supplies –
02Nos. (1st from Ch # 1 LCI Panel &
2nd from Ch # 2 LCI Panel) which in
turn fed from 415V ESP SWGR.
 415 V AC supplies stepped down to 110V
AC, 1phase and 220 V AC, 1phase supplies
through transformers.
110V supply used for control & interlock
relays of both channels in control panel
itself.
220V supply is used for space heaters of
panels, motor, reactor, cubicle illumination
lamps, door mounted printer and line
drivers, temperature scanner, reactor temp.
indicator, motor water leakage detector etc.
    24V DC: 24V AC stepped down from
415V and then rectified to 24V DC for
control panel indication lamp.

Another 24V DC supply from FSSS for

starting / stopping circuit of ID Fan
channels.

220V DC: supply from station battery

supply for source breaker tripping
interlocks & for Load breaker panels.
 Power supplies in LCI Panel: 
1.    2.3 KV main supply connected to Source Bridge in
bridge panel. 
2.    415 V 3 phase supply to C&E panel which is drawn
from ESP board (separate source for each C&E panel for
Ch # 1&2).
     415V supply stepped down to 220V & 110V AC
     220VAC UPS supply is used for fan flow indicator &
SEM rack fan.
     110V AC, 1phase is used for power supplies to all
control cards through PSFF and gate circuit 70V DC
through PS7 module.
     415V 3phase supply is also tapped for blower fans
1&2 in F&F panel.
     415V 3phase supply is tapped for exciter module in
C&E panel which gives 3-phase supply to exciter.
 Testing of ID Fan VFD’s
 Pre-commissioning tests :
-Testing of VFD Transformers
-Readiness for idle charging of VFD transformers
-Testing of Load Breaker panels for CT/PT, relays, breaker and
inter-panel wiring etc.
- Checking of all cable interconnection b/w
E&C panels to CCP
E&C panels to load breaker panels
CCP to source breaker panels (ensuring source breaker closing
& tripping from Common control panel)
E&C panels to F&F panels to converter panels
Reactor cabinet to CCP
VFD trf MB to CCP
- Testing of reactors
-Testing of CLC panels
 Site Tests/ Checks
-Testing of Synchronous motor:
 Exciter stator end lead joint below the cooling duct
found to have SS nut & washer b/w lugs is removed
 Measurement of exciter stator inductance is carried
out.
- Checking of power cables & extension of 415 AC
supply, 24 VDC supply & 220 VDC Supply, 240 VAC
UPS supply:
- Power cable screen earthing checking: IR of screen
with low voltage
 Physical verification of all components including cards
for LCI, F&F, bridge panels and control & excitation
panels including tightening check of all terminals
 Site Tests/ Checks
 Megger test of bridge SCR’s, power buses
 Continuity check of bridge cells
 Charging of auxiliary power supplies, running
of converter cooling fans
 Charging & Checking of electronic P/S, gating
P/S, signal I/P P/S
 Initialization of electronic modules and setting
up the load printer.
 Self test of SEM.
 Adjustment of the set point voltages.
 Bridge current feedback calibration.
 SCR gate test
Contd…
 Extending source voltage up to bridge converter panels

 Source no-load test at full voltage

source voltage signal phasing and balancing

set source under voltage detection
set source over voltage detection
 Load test using voltage signals from source side bridge

load voltage signal phasing and balancing

set load over voltage detection
set motor voltage and speed indication
set over speed
 Excitation tests (phase seq. & EVC power test)

 Crowbar test & Ammeter calibration, SRC_SUPP

 Uncoupled running of motor with one channel

 Uncoupled running of motor with two channels

 Commissioning tests
- verification of load CT signals with SIG
- Motor DOR & checks for DOR correction if
required
- Speed ramp test
- Excitation changeover test
- Torque signal exchange
- Verification/calibration of speed indication with
actual speed/SPD, CUR, PF, KW indication
verification & matching with both channels
- Commissioning of O&M panel.
 Voltage

0
500
1000
1500
2000
2500
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300

Speed
320
340
360
380
400
420
440
Speed vs Voltage

460
480
500
520
540
560
voltage vs speed curve
 Flux Profile

1.4
1.2
1
0.8
Flux

0.6 flux

0.4
0.2
0
0 0.5 0.8 1
Speed
TROUBLE SHOOTING

Source breaker tripping initiated through VFD

system:
(This is other than protection tripping from HT
S.W.gear)
     Source breaker tripping through an aux. relay
(hand resettable flag relay) mounted on “control
panel”. VAA13 relay for each channel.
     In case of source breaker tripping check this
relay has operated on “CCP” of VFD room. If this
relay has not operated tripping is from HT breaker
trip circuit relays & interlocks.
     Also you cannot close the source breaker if this
flag relay on “CCP” is not reset.
Contd..
VAA13 relay can operate on following
conditions:
Through LCI panel source side fault
through ‘SWGR’ relay in LCI panel.
(SUPP2, SRC_SUPP, SRC_OV, NBLF,
μP STALL, EEPROM_TRNS_FAIL,
ESTOP)
Through FLAGRY CH1/2: Oil temp. trip,
winding temperature trip & Buchholz trip.
Emergency push button is pressed.
Trip command from control panel
[CLOSE-NEUTRAL-TRIP] on VFD room.
Load breaker tripping through VFD system:
 Motor Isolator Status
 RUN Relay (Channel Selector SW,
Local/Remote etc.)
 No Channel Fault String (NSFLT, NBLF,
GNDF, SUVFLT, LD_OV, LD_SUPP, FOREGD
FAULTS, FLDL, OS, GSUV, NPSUV, BFNDR,
BFDIFSW)
 Line Breaker Status
 Field Contactor Status
 Emergency Stop
 Run permissive missing
SOME MAJOR FAULTS: VFD trips on these faults
• Loss of cooling fan (NOT-NBLF after time SQTMR2)
• Source Back up Over-current (SRC_SUPP: P900C/2)
• Load Back up over-current (LD_SUPP: P900C/5)
• Field Loss (FLD_LOSS_FLT = FLDCUR< FCLOSS
with timer SQTMR4)
• Source Over voltage (SRC_OV: P900C/0)
• Load over-voltage fault (LD_OV: P900C/4)
• Bridge differential pressure (BFDIFSW)
• Gating supply under-voltage fault (GSUV after
SQTMR1)
• P105 supply under-voltage (NOT-NPSUV)
SOME MAJOR FAULTS: VFD trips on these faults
• Over-speed (OS: P900C/7)
• Ground Fault (GNDF: NTL>0.55V)
• Fan compartment door open (NOT-BFNDR)
• Source Low line or deep under-voltage (SUVFLT after time
SQPLTIM)
• Motor Isolator not closed (MISOL_STATUS_FLT by 0.5 sec)
•Field Current Imbalance (FLTWD/0)
• Field Over current (FCLIM for FCFTIM: FLTWD/1)
• Motor Winding shorted (after TRSPD, Peak Flux value >
previous value by SWINDTOL: FLTWD/2)
• Source Over current (LKLIMS for LKOCTIM: FLTWD/3)
• Load Over current (LKLIML for LKOCTIM: FLTWD/4)
SOME MAJOR FAULTS: VFD trips on these faults
 Source commutation failure (Diff> LKLIMD for

STRHUTIM: FLTWD/5)
 Load commutation failure (Diff> LKLIMD for STRHUTIM:

FLTWD/6)
 Source PLL (SPLLTIM: FLTWD/8)

 Load PLL (LPLLTIM: FLTWD/9)

 Stack fault (FLTWD/11)

 Failure to start (FLTWD/12)

 EEPROM transfer failure (FLTWD/13)

SOME MAJOR ALARMS: Attention needed to check
 Motor Over temperature

 Link reactor Over temperature

 Cooling blower loss

 Loss of speed reference

 Gating supply under-voltage

 Microprocessor alarm

 Bridge filter fuse blown

 Source under-volts

 Transformer alarm

 Loss of speed control (Error> SRETOL for SQTMR5)

 Run Perm or Start Perm missing

 Field Exciter voltage loss

 Rotor Position start alarm

 I/O addressing Problem

START PERMISSIVES FOR THE CHANNELS (To be seen
at VFD room):
• No emergency stop pressed.
• No motor over-temperature trip persisting
• Bus supervision 24V DC & 220V DC healthy
• Heating & Illumination CB 2 ON
• No water leakage in Motor
• Water flow healthy in motor
• CB3 in control panel ON, all indication lamp circuit healthy
• No transformer alarms persisting
• No transformer trips persisting
START PERMISSIVES FOR THE CHANNELS (To be seen
at VFD room):
• No reactor alarm persisting
• No reactor trip persisting
• No Motor over temperature alarm
• No over current trip from Load Breaker
• No MTR of SRC BRK and Source breaker closed
CLOSE PERMISSIVES FOR THE SOURCE BREAKER
(To be seen at VFD room):
• No emergency stop pressed.
• No motor over temperature trip persisting
• No motor over temp alarm
• Bus supervision 24V DC & 220V DC healthy
• Heating & Illumination CB 2 ON
• No water leakage in Motor
• Water flow healthy in motor
• CB3 in control panel ON, all indication lamp circuit
healthy
CLOSE PERMISSIVES FOR THE SOURCE BREAKER
(To be seen at VFD room):
• No transformer alarms persisting
• No transformer trips persisting
• No reactor alarm persisting
• No reactor trip persisting
• Permit to close source breaker from LCI panel ( from
IOMA card : SWGR. Relay shall not be picked up
 CHANNEL RUN PERMIT (To be seen at VFD room):
• No emergency stop pressed.
• No motor over temperature trip persisting
• Bus supervision 24V DC & 220V DC healthy
• Heating & Illumination CB 2 ON
• No transformer trips persisting
• No reactor trip persisting
• No MTR of SRC BRK & Source breaker closed
• No over current trip from Load breaker
Major Problems Faced During Commissioning
 Leakage voltages in IOMA
 XPTN resistor failure
 Thyristor failure
 Card failure
 Power cable screen insulation failure
 Mal-operation of motor & reactor temperature
scanners.
 Motor exciter rotor winding coil polarity problem
 Leakage voltages appearing at the load breaker
aux. Contact terminal blocks.
 Chartless recorder
 UPS supply voltage drop in the cable.
 LIST OF COMPONENTS FAILED IN VFDs DURING/AFTER COMMG
FAILED COMPONENTS Qty VFD-5A VFD-5B VFD-6A VFD-6B VFD-7B
HMPG 02 -- -- 01 -- 01
XPTN 17 10 01 03 03 --
NSFC 02 -- 01 01 -- --
NTRF 04 -- 02 -- 02 --
PS7 COMPLETE MODULE 01 -- 01 -- -- --
PSFF COMPLETE MODULE 02 -- 01 -- 01 --
HRDD 02 -- -- 01 01 --
HPTK 08 01 -- 03 01 03
AIR FLOW MONITOR 06 02 -- 02 -- 02
IOMA COMPLETE MODULE 09 05 -- 01 02 01
REACTOR TEMP. MONITOR 03 02 -- -- 01 --
HAIA 01 01 -- -- -- --
THYRISTOR STACK 39 06 14 05 11 03
NLCB 05 03 01 01 -- --
NLIB 07 02 02 01 02 --
DLIB ( L) 06 02 01 01 01 01
DLIB ( S) 04 01 01 01 01 --
HRIA 02 02 -- -- -- --
DLCB 02 01 01 -- -- --
HLCB 01 01 -- -- -- --
 SUGGESTION FOR IMPROVEMENT
SUGGESTION REMARKS
Treated earth pit for electronic earth Implemented since start of
commg
Power cable screen insulation Implemented since start of
verification at receiving end & commg
earthing at source end
Reactor temperature scanners to be Implemented since start of
located outside reactor cubicle. commg
ACPDB REMOVED & Dedicated Implemented after Unit-5
feeder to be provided for UPS supply Commg
to ensure reliable operation; adequate
cable size to be selected to overcome
voltage drop.
Dust Collecting sieves provided on To be implemented.
bridge panel door internal to be fixed
outside
 SUGGESTION FOR IMPROVEMENT
Quality of components and These has been taken up with M/s
cards needs immediate BHEL/EDN for detailed analysis so
improvement. as to improve the quality
Providing source breaker The necessary soft ware logic
tripping instead of load modification & concurrence by M/s
breaker in the event of BHEL/EDN required.
bridge panel/fan
compartment door open
signal on safety grounds.
VFD room A/C & dust
freeness to be regularly 1. Room partitioning is being
ensured implemented to ensure effectiveness
of AC & prevent dust ingress.
2. Daily wet mopping is being ensured.
3. Room temp indication is being
provided at CCR along temp &
humidity indication at local.
THANK YOU