ABB CI546 3BSE012545R1 Industrial Control ABB Series Advantage System Metering Board

Description

A wind farm in the northwest of Huadian has an installed capacity of 200 MW, 134 doubly fed doubly fed units have been installed and operated in CI546, and the project was put into operation in 2016. After the project was put into operation, converter IGBT overheating shutdown failures frequently occurred, causing certain power loss to the wind farm.

1.1 High IGBT temperature of the unit
Analysis of the operation condition of WTG037 # unit: the IGBT temperature of WTG037 # unit is too high (102.92 ℃ picture) during normal operation (Figure 1.1). During on-site inspection, CI546 found that the cooling fan stopped (secretly stopped) during operation of the inverter module at the side of the unit when the fan power board and control board were normal.
1.2 Backtracking of unit failure
CI546 analyzed the historical operation data of the unit damaged by the converter one by one from the point of finding that the unit had high IGBT temperature. WTG037 #, WTG067 # and WTG039 # units had damage records of machine side or grid side inverter modules in January, March and July respectively. WTG037 # unit damaged the grid side inverter module in January, during which the IGBT temperature corresponding to its active power is shown in Figure 1.3. It can be seen that the IGBT temperature of the unit under the working condition of 600KW was higher in January. The inverter module of WTG067 # unit was damaged in March, during which the IGBT temperature corresponding to its active power is shown in Figure 1.4. It can be seen from the figure that the IGBT temperature of the unit was higher under the working condition of 800KW in March. WTG039 # unit damaged the unit side and grid side converter modules on July 4. Figure 1.5 shows the IGBT temperature corresponding to the active power of the unit from May to August. Before July 4, the unit frequently encountered the problem of high IGBT temperature (blue scattered points). After the inverter module was replaced on July 5, the IGBT temperature returned to normal (dark red scattered points). According to the above operating temperature changes, it can be determined that the damage of the inverter module is directly related to the high IGBT temperature. picture
1.3 Cause analysis of high IGBT temperature
High heating power, heat dissipation factor, cooling fan, air duct, filter screen, control program.
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2. Technical transformation measures
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During the seven periods in 2019, five units (see Table 2-1 for unit number) were selected for the technical transformation of air-cooled ABB frequency converter. The selected technical transformation was based on the pictures of IGBT temperature greater than 90 or IGBT modules damaged in the last three months.
The technical transformation specifically includes the transformation of heat dissipation and power supply mode of frequency converter, the optimization of air duct, the transformation of filter screen, the addition of fan power supply control devices, the optimization of PLC program, the transformation of filter cotton, and the sealing of tower door seam.
3.1 Transformation in TBC100 cabinet
The TBC100 cabinet is powered off as a whole (400VAC, 230VAC UPS, 24VDC), and the power is checked to ensure that X100.2 terminals in the cabinet are not charged, and the 230VAC UPS and 24VDC stop working.
Install new components such as guide rail, circuit breaker, contactor and terminal, and the setting value of motor starter is 8A.
The wiring between TBC100 and CC100 cabinets shall be arranged close to the side of the tower, and binding shall be carried out every two beams.
Wire according to the wiring interconnection table or drawing.
Calibrate the wiring to ensure correct wiring.
3.2 Transformation in CC100 cabinet
Power supply wiring of cooling fan. The ISU has one cooling fan and the INU has two cooling fans. The left side is the ISU module, and the right side is the two modules of the INU

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