…… ……… Joint-Stock Company “PLUTON” JSC “Pluton” 5 Novostroyek st. Zaporozhye 69076 Ukraine tel.: +38(061) 220-48-11, +38(061) 220-48-13; fax: +38(061) 220-48-12; www.pluton.zp.ua; e-mail: deo@pluton.zp.ua MAIN PARAMETERS OF RECTIFIERS _ Table 1 Name of parameter В-ТПЕД- 1.6к-825М1 В-ТПЕД- 2.5к-825М1 В-ТПЕД- 1.6к-825М2 В-ТПЕД- 2.5к-825М2 В-ТПЕД- 1.6к-825-12П В-ТПЕД- 2.5к-825-12П 1. Rated output active power, kW 1320 2062.5 1320 2062.5 1320 2062.5 2. Rated output voltage, V825 3. Rated output current, A 1600 2500 1600 2500 1600 2500 4. Rated input voltage, kV: 6; 6,3; 10; 10,5 5. Rated input frequency, Hz 50 (60) 6. Number of rectifier input voltage phases 3 7. Number of phase connections of converter section 3 6 8. Type of converter section cooling Air, natural 9. Voltage of auxiliary circuit, V 220 10. Capacity coefficient (design), r.u. no less than 0.95 11. Efficiency coefficient (design), no less % 98 12. Standard power of converting transformer, kVA 1600 2500 1600 2500 1600 2500 13. Rated power of converting transformer, kVA 1470 2315 1470 2315 1470 2315 14. Type of converter transformer RESIBLOC®, ТСЗП-1600/10- МУ3 RESIBLOC®, ТСЗП-2500/10- МУ3 RESIBLOC®, ТСЗП-1600/10- МУ3 RESIBLOC®, ТСЗП-2500/10- МУ3 RESIBLOC®, ТРСЗП- 1600/10- МУ3 RESIBLOC®, ТРСЗП- 2500/10-МУ3 15. Ratio of current overload tolerance, once and during permissible overloads, s 1.25 –7200 s, twice in 24 hours* 2.0 – 40 s, with 75s. cycling** 3.0 – 10 s. with 75s. cycling** 1.5 –7200 s, twice in 24 hours* 2.0 – 40 s. with 75s. cycling** 3.0 – 10 s, with 75s. cycling** 16. Converter section overall dimensions, no more than, mm length depth height 1000 600 2200 2000 600 2200 1000 600 2200 2000 600 2200 1000 600 2200 2000 600 2200 17. Weight of converter section, kg, no more than 400 800 400 800 400 800 *Mean-square current value per any 8 hours during 24 hours shouldn’t exceed rated current. ** Mean-square current value per any 75 seconds must not exceed 1.25 of rated current for rectifiers В-ТПЕД-1.6к-825М1, В-ТПЕД-2.5к-825М1 and 1.5 of rated current for rectifiers В-ТПЕД-1.6к-825М2, В-ТПЕД-2.5к-825М2 OUTLINE DRAWING OF В-ТПЕД CONVERTER SECTIONS _ а) В-ТПЕД-1.6к-825М1, В-ТПЕД-1.6к-825-12П б) В-ТПЕД-2.5к-825М1, В-ТПЕД-2.5к-825-12П Rectifiers Series В-ТПЕД For Metro Traction Substations AC busbars "plus" busbar "minus" busbar 1006 605 2360 2220 AC busbars busbars "-825 V" busbars "+825 V" 2006 605 2360 2220 Fig. 1 CS В-ТПЕД- 2.5к-825М1 Fig. 2 Industrial controller PP41with visualization function Fig. 3 RESIBLOC® Transformer As rectifiers for metro traction substations complete set of converting sections series В-ТПЕД manufactured by JSC “Pluton” and RESIBLOC® dry transformer manufactured by ABB company (Germany) or NOMEX transformer produced domestically is applied. Rectifiers are produced according to 12-pulse and 6-pulse “bridge” rectification circuits. В-ТПЕД CONVERTER SECTIONS _ In development and production of В-ТПЕД converter sections (further CS) modern technologies, materials and components of world-leading companies were used. CS are constructed on power pill diodes 1600…2500А, 25 th grade, produced by INTERNATIONAL RECTIFIER company. CS cooling is natural air. CS power part is made with application of maintenance-free contact joints technology. Special German compensating devices, which fix clamps on contact joints, irrespective of temperature and thermal diurnal and seasonal oscillation, are applied. When assembling CS each bolted contact joint is crimped with torque wrench with certain torque force in accordance with standards, and stated force remains during whole operation life. Due to this fact, there is no need in periodical retorque, stripping of contact joints during operation. Contact joint stabilization increases fire safety of switchgears and substation as a whole. Current division in parallel paths is forced and made with effective inductive dividers providing current division between parallel paths no worse than 5%. Thus, during operation of converters, in case of power diode replacement, there is no need to match diodes by direct and reverse voltage drop. Evenness of current division is preserved also during operation at natural degradation of power diodes parameters. It is important criterion of reliability and absence of necessity in periodic monitoring of equipment during operation. There is power semiconductor devices protection against internal and external switching overvoltage in rectifier. Diodes are protected against internal switching overvoltage by RC circuits, against external - by RC circuits and varistors (overvoltage protection panel). CONTROL AND DIAGNOSIS MICROPROCESSOR SYSTEM _ В-ТПЕД CS are equipped with microprocessor control and diagnosis system. Control and diagnosis microprocessor system is made on the basis of industrial controller with PP41 visualization function and allows: - to provide supervision of each diode condition in 4 criteria: “normal operation”, “parameters degradation” (loss of class), “breakdown” and "fault”, and also to control diodes temperature with information issue to visualization panel. Diagnosis according to these criteria allows to increase sufficiently time of trouble-free operation over 80000 hours (9 – 10 years). At the same time during operation information about parameters of each diode is taken in dynamic; - to provide control of some parameters of traction transformer. Visualization panel represents module type industrial controller with LCD display and feather-touch control. Notation conventions of rectifier diodes condition, diagrams of reverse voltage distribution between diodes and paths temperature are displayed in mnemonic form. Signals displayed in main window: • transformer overheating (I stage); • transformer overheating (II stage); • diagnosis failure; • ground protection; • connection absence; • doors; • CS overheating; • diode breakdown; • diode failure; • diode parameters; In case of diodes parameters alteration to the level corresponding to critical one for the given circuit (for applied diodes), power diode can be replaced in no-current pause, without rectifier emergency break coming from diode breakdown, which can happen in case of further degradation of unit parameters (class reduction). Information about rectifier condition and its elements can be observed on visualization panel or on PC monitor by means of specialized program. In CS there is possibility of communication with upper level control system (central substation panel installed in complete set of РУ-825 switchgear, medium voltage switchgears protection units, operator’s desk (telemechanics) both by standard multi-wire system through terminal block and also by double-wire communication through RS-485 port for the distance up to 1200m. RESIBLOC® TRANSFORMERS _ As converter transformers JSC “Pluton” applies modern dry transformers manufactured by RESIBLOC® technology with power of 1000kVA to 40000kVA with different combinations of voltage HV and LV (up to 45kV). RESIBLOC® transformers are certified by State Standard of Russia and successfully operated in metros of Europe, Kiev, Kharkov, Minsk, etc. Transformer is connected with converter section by busbar bridge supplied in complete set. Transformers have original design of primary and secondary windings made of copper wire and aluminum foil. Windings are capsulated by fiber-glass string soaked in epoxy. Owing to original design of windings and epoxy application technology RESIBLOC ® transformers are able to withstand maximum temperature fluctuations without damage of epoxy surface and formation of microcracks. These are the only transformers able to operate at temperatures up to -60 0 С. Transformers operate under conditions of 100% humidity, water vapor condensation and chemical pollution. Transformers may be equipped with radial ventilators wit low noise level. Cooling system allows to increase transformer rated capacity up to 40%. Transformer windings resistance to mechanical loads is 650 – 750 N/mm 2 , than its closest competitor - GEAFOL transformers. Described parameter is especially important for converting transformers functioning in rapid starting current mode. All components of transformers were tested for toxicity absence. All materials are non-inflammable and do not support burning. Transformers protection level is IP00, IP21, IP23, IP54 acc. to GOST 14254-96. RESIBLOC® transformer allows overload until the hottest heating point of transformer reaches 155°С. By customer’s request transformers are supplied with electronic unit of temperature control. Unit is provided with two settings: for 140 0 С – alarm signal, for 155 0 С – load trip. There is a possibility of third setting – for 130 0 С – forced ventilation activation. Owing to described technological and design features RESIBLOC® transformers perfectly fit in maintenance-free substation concept. SYMBOLS STRUCTURE _ В - Т П Е Д - ХХХ - 825 ХX - УХЛ 4 climatic version & location category in acc. with GOST 15150-69 ; modification code 1 or 2 acc. to table 1 rectification circuit: М - bridge; 12П - bridge 12-pulse; value of rated output voltage in volts ; value of rated output current : 1,6 kА; 2,5 kА, type of applied main semiconductor units of power circuit: diodes ; cooling: air natural; output current type: constant; feeding line current type: three-phase ; rectifier Fig. 1 CS В-ТПЕД- 2.5к-825М1 Fig. 2 Industrial controller PP41with visualization function Fig. 3 RESIBLOC® Transformer As rectifiers for metro traction substations complete set of converting sections series В-ТПЕД manufactured by JSC “Pluton” and RESIBLOC® dry transformer manufactured by ABB company (Germany) or NOMEX transformer produced domestically is applied. Rectifiers are produced according to 12-pulse and 6-pulse “bridge” rectification circuits. В-ТПЕД CONVERTER SECTIONS _ In development and production of В-ТПЕД converter sections (further CS) modern technologies, materials and components of world-leading companies were used. CS are constructed on power pill diodes 1600…2500А, 25 th grade, produced by INTERNATIONAL RECTIFIER company. CS cooling is natural air. CS power part is made with application of maintenance-free contact joints technology. Special German compensating devices, which fix clamps on contact joints, irrespective of temperature and thermal diurnal and seasonal oscillation, are applied. When assembling CS each bolted contact joint is crimped with torque wrench with certain torque force in accordance with standards, and stated force remains during whole operation life. Due to this fact, there is no need in periodical retorque, stripping of contact joints during operation. Contact joint stabilization increases fire safety of switchgears and substation as a whole. Current division in parallel paths is forced and made with effective inductive dividers providing current division between parallel paths no worse than 5%. Thus, during operation of converters, in case of power diode replacement, there is no need to match diodes by direct and reverse voltage drop. Evenness of current division is preserved also during operation at natural degradation of power diodes parameters. It is important criterion of reliability and absence of necessity in periodic monitoring of equipment during operation. There is power semiconductor devices protection against internal and external switching overvoltage in rectifier. Diodes are protected against internal switching overvoltage by RC circuits, against external - by RC circuits and varistors (overvoltage protection panel). CONTROL AND DIAGNOSIS MICROPROCESSOR SYSTEM _ В-ТПЕД CS are equipped with microprocessor control and diagnosis system. Control and diagnosis microprocessor system is made on the basis of industrial controller with PP41 visualization function and allows: - to provide supervision of each diode condition in 4 criteria: “normal operation”, “parameters degradation” (loss of class), “breakdown” and "fault”, and also to control diodes temperature with information issue to visualization panel. Diagnosis according to these criteria allows to increase sufficiently time of trouble-free operation over 80000 hours (9 – 10 years). At the same time during operation information about parameters of each diode is taken in dynamic; - to provide control of some parameters of traction transformer. Visualization panel represents module type industrial controller with LCD display and feather-touch control. Notation conventions of rectifier diodes condition, diagrams of reverse voltage distribution between diodes and paths temperature are displayed in mnemonic form. Signals displayed in main window: • transformer overheating (I stage); • transformer overheating (II stage); • diagnosis failure; • ground protection; • connection absence; • doors; • CS overheating; • diode breakdown; • diode failure; • diode parameters; In case of diodes parameters alteration to the level corresponding to critical one for the given circuit (for applied diodes), power diode can be replaced in no-current pause, without rectifier emergency break coming from diode breakdown, which can happen in case of further degradation of unit parameters (class reduction). Information about rectifier condition and its elements can be observed on visualization panel or on PC monitor by means of specialized program. In CS there is possibility of communication with upper level control system (central substation panel installed in complete set of РУ-825 switchgear, medium voltage switchgears protection units, operator’s desk (telemechanics) both by standard multi-wire system through terminal block and also by double-wire communication through RS-485 port for the distance up to 1200m. RESIBLOC® TRANSFORMERS _ As converter transformers JSC “Pluton” applies modern dry transformers manufactured by RESIBLOC® technology with power of 1000kVA to 40000kVA with different combinations of voltage HV and LV (up to 45kV). RESIBLOC® transformers are certified by State Standard of Russia and successfully operated in metros of Europe, Kiev, Kharkov, Minsk, etc. Transformer is connected with converter section by busbar bridge supplied in complete set. Transformers have original design of primary and secondary windings made of copper wire and aluminum foil. Windings are capsulated by fiber-glass string soaked in epoxy. Owing to original design of windings and epoxy application technology RESIBLOC ® transformers are able to withstand maximum temperature fluctuations without damage of epoxy surface and formation of microcracks. These are the only transformers able to operate at temperatures up to -60 0 С. Transformers operate under conditions of 100% humidity, water vapor condensation and chemical pollution. Transformers may be equipped with radial ventilators wit low noise level. Cooling system allows to increase transformer rated capacity up to 40%. Transformer windings resistance to mechanical loads is 650 – 750 N/mm 2 , than its closest competitor - GEAFOL transformers. Described parameter is especially important for converting transformers functioning in rapid starting current mode. All components of transformers were tested for toxicity absence. All materials are non-inflammable and do not support burning. Transformers protection level is IP00, IP21, IP23, IP54 acc. to GOST 14254-96. RESIBLOC® transformer allows overload until the hottest heating point of transformer reaches 155°С. By customer’s request transformers are supplied with electronic unit of temperature control. Unit is provided with two settings: for 140 0 С – alarm signal, for 155 0 С – load trip. There is a possibility of third setting – for 130 0 С – forced ventilation activation. Owing to described technological and design features RESIBLOC® transformers perfectly fit in maintenance-free substation concept. SYMBOLS STRUCTURE _ В - Т П Е Д - ХХХ - 825 ХX - УХЛ 4 climatic version & location category in acc. with GOST 15150-69 ; modification code 1 or 2 acc. to table 1 rectification circuit: М - bridge; 12П - bridge 12-pulse; value of rated output voltage in volts ; value of rated output current : 1,6 kА; 2,5 kА, type of applied main semiconductor units of power circuit: diodes ; cooling: air natural; output current type: constant; feeding line current type: three-phase ; rectifier …… ……… Joint-Stock Company “PLUTON” JSC “Pluton” 5 Novostroyek st. Zaporozhye 69076 Ukraine tel.: +38(061) 220-48-11, +38(061) 220-48-13; fax: +38(061) 220-48-12; www.pluton.zp.ua; e-mail: deo@pluton.zp.ua MAIN PARAMETERS OF RECTIFIERS _ Table 1 Name of parameter В-ТПЕД- 1.6к-825М1 В-ТПЕД- 2.5к-825М1 В-ТПЕД- 1.6к-825М2 В-ТПЕД- 2.5к-825М2 В-ТПЕД- 1.6к-825-12П В-ТПЕД- 2.5к-825-12П 1. Rated output active power, kW 1320 2062.5 1320 2062.5 1320 2062.5 2. Rated output voltage, V825 3. Rated output current, A 1600 2500 1600 2500 1600 2500 4. Rated input voltage, kV: 6; 6,3; 10; 10,5 5. Rated input frequency, Hz 50 (60) 6. Number of rectifier input voltage phases 3 7. Number of phase connections of converter section 3 6 8. Type of converter section cooling Air, natural 9. Voltage of auxiliary circuit, V 220 10. Capacity coefficient (design), r.u. no less than 0.95 11. Efficiency coefficient (design), no less % 98 12. Standard power of converting transformer, kVA 1600 2500 1600 2500 1600 2500 13. Rated power of converting transformer, kVA 1470 2315 1470 2315 1470 2315 14. Type of converter transformer RESIBLOC®, ТСЗП-1600/10- МУ3 RESIBLOC®, ТСЗП-2500/10- МУ3 RESIBLOC®, ТСЗП-1600/10- МУ3 RESIBLOC®, ТСЗП-2500/10- МУ3 RESIBLOC®, ТРСЗП- 1600/10- МУ3 RESIBLOC®, ТРСЗП- 2500/10-МУ3 15. Ratio of current overload tolerance, once and during permissible overloads, s 1.25 –7200 s, twice in 24 hours* 2.0 – 40 s, with 75s. cycling** 3.0 – 10 s. with 75s. cycling** 1.5 –7200 s, twice in 24 hours* 2.0 – 40 s. with 75s. cycling** 3.0 – 10 s, with 75s. cycling** 16. Converter section overall dimensions, no more than, mm length depth height 1000 600 2200 2000 600 2200 1000 600 2200 2000 600 2200 1000 600 2200 2000 600 2200 17. Weight of converter section, kg, no more than 400 800 400 800 400 800 *Mean-square current value per any 8 hours during 24 hours shouldn’t exceed rated current. ** Mean-square current value per any 75 seconds must not exceed 1.25 of rated current for rectifiers В-ТПЕД-1.6к-825М1, В-ТПЕД-2.5к-825М1 and 1.5 of rated current for rectifiers В-ТПЕД-1.6к-825М2, В-ТПЕД-2.5к-825М2 OUTLINE DRAWING OF В-ТПЕД CONVERTER SECTIONS _ а) В-ТПЕД-1.6к-825М1, В-ТПЕД-1.6к-825-12П б) В-ТПЕД-2.5к-825М1, В-ТПЕД-2.5к-825-12П Rectifiers Series В-ТПЕД For Metro Traction Substations AC busbars "plus" busbar "minus" busbar 1006 605 2360 2220 AC busbars busbars "-825 V" busbars "+825 V" 2006 605 2360 2220 . any 75 seconds must not exceed 1.25 of rated current for rectifiers В-ТПЕД-1.6к-825М1, В-ТПЕД-2.5к-825М1 and 1.5 of rated current for rectifiers В-ТПЕД-1.6к-825М2, В-ТПЕД-2.5к-825М2 OUTLINE. pause, without rectifier emergency break coming from diode breakdown, which can happen in case of further degradation of unit parameters (class reduction). Information about rectifier condition. current type: three-phase ; rectifier Fig. 1 CS В-ТПЕД- 2.5к-825М1 Fig. 2 Industrial controller PP41with visualization function Fig. 3 RESIBLOC® Transformer As rectifiers for metro traction