The Drive had a massive failure within a U phase IGBT, causing damage to the IGBTs, IGBT Control Board and the Bus distribution plate and insulators. VeeArc will clean and repair the IGBT and IGBT Control Board assembly, rebuild the Bus distribution plate Insulators and perform a full functionality test to save the end user the cost of a New Drive replacement and get their motor back up and spinning like a ballerina on a merry-go-round.
When the drive arrived we performed an evaluation and formulated a failure analysis. Their failure was due to an improperly placed IGBT within the U phase:
An IGBT’s Heatsink Mounting plate (It’s Backside) is convexly parabolic in shape. This means that to make flat contact when mounted it will require even pressure from the outer edges of the device. Torqueing down all six mounting screws is essential to a flat mount and proper thermal linkage of the device to the Drive chassis heatsink. Heat transfer compound must also be applied to the IGBT to further improve thermal linkage.
The major arc flash event was due to the IGBT over-heating, due to improper thermal linkage, and venting. The IGBT momentarily shorts when over-heated which creates a direct path for the Positive and Negative Bus Voltage causing all the energy stored in the Bus Capacitor banks to discharge instantaneously in an explosive Arc-Flash event. This event caused several other component failures within the drive due to the massive electrical surge, the heat generated by the blast and/or the blast concussion.
The unit was from a Tissue manufacturer and was covered in dust and Lint. The drive had to be totally disassembled and cleaned before any replacement components could be installed. We pressure washed the Heatsink and Chassis, washed all circuit boards, disassembled and cleaned sub-assemblies, polished off any corrosion on the Copper Buswork and remade all damaged Voltage Isolation Insulators.
Once all this work was performed the drive was fully reassembled and tested in a controlled environment at our testing lab. This Drive is now back at the customer facility happily spinning out copious amounts of tissues so our homes can be effectively TP’d this Halloween!
Quad Plus LLC has completed their installation portion of the 45 million dollar Electrical Distribution revamp of The City of Chicago’s South Water Purification Plant. This first phase of the project was to install 9 new PCP’s (Pump Control Panels), for 7 synchronous and 2 induction motors. These panels completely changed how the motors were started from the existing systems installed in the late 1940’s. The installation team consisted of MG Electric (general contractor), Quad Plus (provided 7 Synchronous Motor Field Applications Systems), Siemens Industry, Inc. Switchgear Division (supplied new Switchgear and motor starters), and Allen ICS (Supplied SCADA equipment and programming). One of the challenges was that the Plant could not be shut down to accomplish this retrofit.
We were given one pump system every 6 weeks to complete the transformation. The motors ranged from 350hp to 1000hp at 2300vac. During the design phase of the project Quad Plus and the supplier of the synchronous equipment Kinetics (Trenton, NJ) were able to engineer a package that had the range in field currents so that one system could do all 7 motors, which only required a small amount of tuning at start up. The customer was very happy with this, since the spare parts were all interchangeable. The success of this start up gained Quad Plus the ability to quote and win the next project at The City of Chicago’s Jardine Water Purification Plant. We will be supplying a total of 8 new Synchronous Motor Field Application Systems following the same design criteria as done on the South Water Plant project.
The University of Illinois at Urbana-Champaign’s Center for Plasma-Material Interactions (CPMI) looked to Quad Plus Senior Engineer Kent Wegley for expertise in safely installing a toroidal plasma device known as HIDRA.
Combining capabilities of a tokamak and a stellarator, HIDRA provides scientists a valuable and unique testbed for plasma/fusion experimental research, the type of science that could one day lead to viable energy production from fusion reactors. HIDRA was transported from its original home at the Max Planck Institute for Plasma Physics (IPP) in Germany in 2014 and is now safely running at CPMI.
Cooper & Associates designed 100% of this factory for IKO. We worked with IKO to engineer all elements from soil samples (expansive clay), site layout for rail and truck, foundations, steel, tanks, silos, material delivery, machine foundations, piping, and thermal systems.