Enhancing the Analog Input/Output of VFD to Enable Quick Fault Finding

Abstract

Variable frequency drives are backbone of an industrial process. Their effective control and protection adds reliability to an industrial process. The present work is focused on enhancing the fault detection mechanism of variable frequency drives installed at Coastal Gujarat Power Limited (CGPL). At Costal Gujarat Power Limited (CGPL), Mundra coal is transferred from west port to generation plant which is 15 km away from the port area, where total 12 No’s of VFDs are installed for feeding the coal by using the belt conveyor. These belt conveyor motors are operated by using VFDs siemens model No: G130. These motors are running continuously for transferring the coal for generation purpose. CGPL, faces problem with fault Variable Frequency Drive (VFD). They are unable to detect without usage of Advanced operating Panel (AOP). As AOP is located at the VFD, the control room engineer is enabling to check the AOP remotely. Thus, presently fault identification is difficult due non-configuration of sub faults, displaying VFD fault available DCS panel only, thus engineer has to access the on site AOP for fault finding and rectification. The exact reason of fault identification of the drive has shown remotely available at control room, so that corrective rectification can be done within the shortest duration and will also be recorded for further analysis to have root cause analysis of defects for avoiding future trippings. In this project tripping signal of the equipments is being sensed from the equipments MPCB and send to the Allen Bradley micrologix PLC input module. This is done using Rslogix5000 software programming. To display sub-faults Intouch SCADA software is being used, also fault identification LED board is being used to display fault at VFD panel. Kepserverx software is being used for communication between PLC and SCADA. The sub faults are indicated at VFD panel as well as control room. This Enhancement of analog input of VFD helps CGPL Mundra for reduction in downtime, system reliability, improved equipment efficiency and critical equipment availability. This arrangement helps to maintain uninterrupted coal feeding operation for continuous plant generation of 4000MW.