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1. High voltage fused disconnect switch 30 000 amp precision shunt RAPID POWER CORPORATION HIGH POWER SUPPORT EQUIPMENT APPLICABLE CODES AND STANDARDS Rapid designs manufactures and tests our power rectifiers and transformers in accordance with the prevailing specifications and the following codes and standards ANSI Standards C34 2 1968 Practices and requirements for semiconductor power rectifiers C57 12 00 amp 12 10 Standards for liquid and dry transformers C57 18 10 Standard for rectifier transformers IEC Standards IEC 76 Power transformers IEC 146 Semiconductor converters IEC 147 Essential ratings and characteristics of semiconductor devices and general principles of measuring methods IEC 148 Letter symbols for semiconductor devices IEEE Recommended Standards IEEE 519 1992 IEEE recommended practices and requirements for harmonic control in electrical power systems NEMA Standards NEMA R1 Safety code for semiconductor rectifiers NEMA R16 Electrochemical processing semiconductor rectifier requirements NFPA Standards 70 National Electric Code RAPID POWER CORPORATION 13 HG A POWER R EG TILETE R SYSTEMS R ADPID provides the best value to meet all of your application requirements FACTORY TESTING Rapid has an established high current test facility for the testing of high power transformer rectifier systems A complete line up of transformers and rectifiers are tested at rated current and ra2. HIGH POWER RECTIFIER SYSTEMS For Electrochemical Electrowinning Electrorefining Electroplating Special Applications POWER CORPORATION QUALITY AND TECHNOLOGY IN ONE PACKAGE H G H POWER REG THI FELE R SYSTEMS i APID provides the best value to meet all of your application requirements Rapid provides the best value to meet all of your application requirements Rapid Power Corporation is the largest independent manufacturer of High Power Rectifier Systems We design manufacture and test integrated high power transformer rectifier systems for use in many heavy industrial processes such as electrochemical electrowinning electrorefining electroplating and other specialized applications Our manufacturing facility is dedicated to the production of transformers oil immersed dry open wound VPI vacuum pressure impregnated varnish and cast coil epoxy resin encapsulated large phase controlled and chopper style rectifier assemblies and fully integrated control systems for all products offered by Rapid throughout the world Our multi pulse rectifier systems of various ANSI configurations are conservatively designed to provide reliable operation Rapid Power will supply a rectifier to meet your system requirements and will provide the best value in all applications Rapid s system designs may also be provided with auxiliary equipment as required by the specification including switchgear power factor corre
3. FOA FOW ANSI 45 oil filled transformer designed for a 22 500 amp 275 VDC rectifier being readied for assembly RAPID POWER CORPORATION 5 H GH POWER ese cs bt to Bk rore MS R ApID designs and builds its components and can deliver them to you quickly THYRISTOR amp CHOPPER RECTIFIERS These are available in 6 12 18 and 24 pulse sets with higher order combined systems available Each multi pulse arrangement is in an ANSI configuration that is selected for the voltage current values of the application The multi pulse criteria is selected to reduce the supply side harmonic content reduce output ripple and provide improved regulation Features of both rectifier technologies include 36 000 amp 156 VDC chopper rectifier system complete with ANSI 31 dry type transformer Features e Conservative design margins e Copper bus work e Heavy gauge construction Sub system integration High reliability and maintainability Deep hole drilled copper heat sink water cooled systems api i er it ae J0 da en S E F m 40 000 amp DC 220 VDC 12 pulse electrowinning installation with oil filled transformers and harmonic filter RAPID POWER CORPORATION HIGH POWER RECTIFIERS THYRISTOR RECTIFIER DESIGN Rapid designs and manufactures the thyristor assemblies used in our rectifiers The devices are complete with a rugged RC suppression circuit and driven by a dedicated gate driver The
4. 150 C VPI only e Copper windings e Cooling convection forced air direct water or via a heat exchanger system Epoxy vacuum cast coil transformers manufactured in Vermont USA Primary and secondary windings e Enclosures NEMA 1 3R and 4 all cast wound with copper conductors Electrical e All ANSI circuits available connectors made using tin or silver plated solid Manufactured by Dynapower Corporation See separate literature for details copper bus 14 megawatt dry type transformer 2 x 7 megawatt section rated at 67 000 amp and 425 VDC for a large electrochemical project RAPID POWER CORPORATION HIGH POWER TRANSFORMERS LIQUID FILLED TRANSFORMERS Rapid designs and manufactures a majority of its liquid filled rectifier transformers in house for application in our large industrial rectifier systems This in house capability enables Rapid to fully integrate the designs of the rectifier and transformer and take sole source system responsibility The system mechanical integration on the shop floor ensures a smooth installation on site For large kVA and greater than 34 5 kV AC input voltage systems we work with a dedicated supplier to provide completely coordinated system integrations Features e Ratings to 25 000 kVA e Primary voltages to 69 kV e Temperature rise 55 C or 65 C e Mineral oil silicone fluid and Rtemp e Copper windings All ANSI circuits available Convection cooled forced air or forced oil OA
5. extensive experience with cooling sealed dry type power rectifier systems using this method FORCED AIR COOLED Forced air cooled rectifier units incorporate finned aluminum heat sinks and may be operated continuously at full rated current at an intake air temperature of up to 40 C with custom higher ambient Water to water temperature designs available heat exchanger Liquid to air heat exchanger RAPID POWER CORPORATION 11 Ao Go H POWER RECTIFIER SYSTEMS Rapid manufactures high power rectifier systems up to 69 kV and integrates commercially available medium and high voltage components into the systems Rapid coordinates the AC switchgear for complete system integration and safety DISCONNECT SWITCH Rapid has extensive experience integrating commercially available DC disconnect switches into our systems as required JRREN IEASUREM Rapid rectifiers use precision current shunts for the control regulation and for the current measurement of our high power systems Commercially available current measurement systems for outer loop monitoring can be incorporated in accordance with the specifications of the project Rapid uses electrically pure copper bus work exclusively in our rectifier systems Bus work with plated bolted joints and flexible connections are designed to minimize bus losses and to match E the clients application requirements High current DC Switch et a i oi a ee ol p i ai pi a ain
6. guidelines contained in the service manual are followed DOCUMENTATION Rapid engineering develops a complete documentation package for each major system manufactured A full set of electrical and mechanical drawings enable the client to maintain and service the system Project documents include the description of the system control software and cut sheets of key components QUALITY CONTROL Each piece of equipment we build is rigorously tested and put through a systematic quality control examination prior to shipment Our test facilities utilize state of the art equipment to verify that the power supply you receive is exactly what you ordered Our staff of highly competent test technicians performs a full range of operational and functional testing and maintains complete documentation of all test procedures and results Prior to shipment a final quality control inspection is performed SALES ENGINEERING Our Sales Department is staffed by professional sales engineers and can help you select the appropriate piece of equipment for your specific application From the simplest rectifier to a fully integrated rectifier transformer system with harmonic filter and power factor correction Rapid s experienced sales staff can help you define your specific requirements and then provide you with the solution to your power conversion needs Contact the Rapid corporate office or your regional office or representative for your power rectifie
7. copper for cooling of the isolated modules four IGBT and four diodes maintaining low junction temperature Device Cooling Module heat sink plates are direct contact cooled by means of circulated water This water path is at ground potential and does not require special treating RAPID POWER CORPORATION Flow Protection Flow detectors Temperature Sensors Heat sink over temperature protection Number of Modules Conservative design margins with multiple parallel modules per section Parallel Devices Symmetrical assemblies with current balance controlled 5 Redundancy N 1 power module configuration is supplied Device Fuses Each IGBT has a coordinated high speed current limiting fuse with visual indication of the activated fuse Fuse Failure First IGBT fuse failure will alarm and failure of second will result in automatic current reduction or a trip signal being generated The above is a section of a 36 000 amp chopper system used on a graphite furnace application Ml GS H POWER Re Ge 1 Fo ee oR SYSTEMS systems are assembled with pride and use only the highest quality components RECTIFIER CONTROLS Rapid Power designs and manufactures the rectifier control TELL L Basic digital i systems for use in our high power rectifier systems The integration controller of this control with commercially available Programmable Logic HMI pane Controllers PLC and Personal Comput
8. ction and harmonic filters heat exchangers and free standing cooling systems Manufactured by Dynapower Corporation System Block Diagram System Block Diagram for IGBT Chopper Rectifier for Thyristor Rectifier Utility Supply Utility Supply Rapid High Power Rectifier Systems consist of the following basic sections 1 HV Switchgear Regulator 2 Rectifier Transformer 3 Thyristor Rectifier 3A Chopper Rectifier Current Measurement DC switch Regulating Controller Operator Interface Harmonic Filter and Power Factor Correction To Load To Load RAPID POWER CORPORATION NAJ l Fe l E BD aa a EIn INTR a Rapid High Power Rectifier Systems are engineered to internationally recognized Standards including ANSI IEEE IEC NEMA UL CSA JEC etc Rapid Power Corporation application and design engineers will work with the client to determine the optimum rectifier system to meet the specifications Our design capabilities include the complete High Power Transformer Rectifier System inclusive of fully integrated operator interfaces and control systems for a single unit or entire multi unit SCADA network We can evaluate the impact of the rectifier system on the incoming power grid and design power factor correction and harmonic filtering as required Rapid designs and manufactures thyristor rectifiers and fast switching IGBT chopper rectifiers for large applications With the latest techniques in b
9. ers PC is used to produce a wide range of power rectifier system designs capable of analog or digital control via a variety of serial protocols The communicat ion network and operator interface may be designed to meet your system control and monitoring requirements a KE H iy CHOPPER MODULE T To Additional Rectifiers Control amp Personal Computer driven touch screen contro running HMI software Fiber Field Optic Contacts Drivers Local amp Section Chopper Main i ki me A Controller K Remote l To Additional Rectifiers 12 3 Control Local 5 E Remote Digital Interface Operator Terminal Magelis Panel View etc _ g DC BUS Analog Control E E PT vons panel with recorders i Driver Discrete Board Signals Control l amp Field l Contacts Basic Control and i Control And Trigger Operator Trigger Board plus _ Board Panel driver circuit for analog system J Isolators Remote o i Analog Signals Thyristor Analog Control Block Diagram RAPID POWER CORPORATION HIGH POWER CONTROLS AND COOLING COOLING SYSTEMS Rapid rectifier sy
10. number of device assemblies required is a function of the configuration chosen and the total DC current required in meeting the specification Direct water cooled thyristor assemblies consist of the semi conductor mounted on deep hole drilled copper heat sinks Forced air cooled thyristor assemblies are composed of extruded aluminum with integrated blower and or fan assemblies Larger systems have baffling to ensure proper airflow Semiconductor Ratings Up to 3500 A average Up to 4500 PRV Temperature sensors Heat sink over temperature protection Clamps Spring loaded clamps ee 22 500 ADC water with insulation sleeves cooled thyristor stack in N 1 configuration Parallel Devices Current balance is maintained in accordance with ANSI C34 2 standards Redundancy N 1 configuration is available Device Fuses Coordinated high speed current limiting fuse with visual indication Fuse Failure First fuse failure will alarm and second failure in same leg results in a fault signal if N 1 redundancy is selected RAPID POWER CORPORATION 7 Four channel IGBT chopper module rated at 1 500 Amps H GH POWER RECTIFIER SYSTEMS has helpful professional service that is available when you need it CHOPPER RECTIFIERS DESIGN The chopper rectifier designs consist of high frequency switching technology in a modular design package that converts the secondary AC voltage to a regulated output DC voltage Larger
11. oth rectifier technologies Rapid application engineers can recommend the optimum rectifier configuration for your project Rapid has the experience to deliver the most reliable power conversion solutions Rapid has been manufacturing thyristor controlled transformer rectifier systems since the commercializa tion of the thyristor Today Rapid thyristor rectifiers are installed worldwide in many different applications providing high quality reliable operation All Rapid high power rectifier systems are designed manufact ured and tested in strict accordance with the latest applicable ANSI amp IEEE standards RAPID POWER CORPORATION System shown is 30 000 amp with 2x15kA choppers The chopper modules shown are rated at 1500ADC and are mounted in a 15 000A 125VDC Electrowinning Rectifier system H 1G H POWER RECTIFIER SYSTEMS VACUUM VARNISH PRESSURE IMPREGNATED EPOXY RESIN ENCAPSULATED CAST COIL Rapid dry type transformers are designed to be fully integrated with the rectifier section of the system and may be cooled by forced air direct water cooling or use of a heat exchanger system Multiple transformer systems used to meet ANSI configurations have been provided in sizes up to 28 megawatt using dry type transformers Features e Individual transformer ratings to 12 000 kVA e Primary voltages VPI 23kV cast coil 34 5 kV e Class H 220 C insulation system e Temperature rise 80 C 115 C and
12. power systems are constructed of multiple chopper modules to obtain the specified current requirements Each section of modules has a separate set of sensing and protection and receives directions from the main chopper controller This chopper conversion process has minimal effect on the incoming power system and a high power factor is maintained at the level of a fixed diode converter The transformer section is configured to optimize the harmonics The total module count usually results in a 12 pulse configuration as seen by the utility The load sees a very smooth low ripple DC over the total range due to compact high frequency output filtering Rapid designs and manufactures all the water cooled IGBT power modules used in our chopper rectifiers A full control metering monitoring and fast protection scheme is integral to all Rapid chopper rectifiers RAPID POWER CORPORATION HIGH POWER CHOPPER RECTIFIERS Additional Features for the Chopper e High power factor over full range e Low output ripple e Low harmonic distortion e Dynamic response e Modular construction Semiconductor Ratings IGBTs up to 600 A average IGBTs up to 2 000 VPRV Diodes up to 600 A average Diodes up to 2 000 VPRV Drivers Dedicated fiber optic gate driver Current Sensing Independent IGBT current sensing Buswork Laminated copper bus structure designed to maintain a low bus impedance and low voltage overshoot Heat Sinks Water cooled
13. r system requirements RAPID POWER CORPORATION Spare parts 15 HLG H POWER RECTIFIER oY S 7 MS Our main plant in South Burlington Vermont contains over 150 000 square feet of modern fully integrated manufacturing and engineering facilities as well as sales and executive offices Rapid manufactures the complete power rectifier system for a variety of applications specializing in the power transformer and the high power rectifier Rapid incorporates the latest controls conversion technologies and highest quality materials to meet the customer s exact specifications Whether your need is a catalog item or one of a kind our unique self sufficiency understanding and experience makes Rapid Power Corporation the number one choice worldwide for high power rectifier systems CORPORATE HEADQUARTERS Rapid Power Corporation PO Box 9210 85 Meadowland Drive S Burlington VT 05403 1 800 332 1111 Great product great service U S A and Canada and a state of the art facility Tel 802 652 1300 Fax 802 652 1387 info rapidpower com This is our commitment to you POWER CORPORATION ___ www rapidpower com 2003 Rapid Power Corporation RP 10 0503 2515 1K
14. stems may be designed to be cooled by a variety of cooling methods These include forced air direct water or combination of closed loop heat exchanger systems integral to the cabinet or free standing for installation external to the rectifier Air to water heat exchange in a sealed dry type transformer application Rectifier is cooled using a closed loop de ionized water to water heat exchanger while the ambient and dry type transformers are cooled by the air to water heat exchanger LIQUID COOLED The cooling water is taken from the cooling cubicle through a manifold supply tube to the base section of the rectifier to feed several parallel cooling circuits The joints in the water circuit are designed to prevent corrosion and includes pressure tested seals The heat sinks for the liquid cooled semiconductors are deep hole drilled copper and cooled by means of de ionized water which flows in a closed loop through the power circuit The water flows in a counter current pattern to obtain even temperature distribution Thermostatic proportioning valves are used to minimize plant cooling water volume based on the operating power when closed loop water to water heat exchangers are selected SEALED AIR TO LIQUID COOLED When portions of the rectifier system cannot be cooled with direct water and using external forced air is not an option they may be cooled using a sealed air to water heat exchanger Rapid has
15. ted voltage with total power levels dictated by our test area capacity FIELD TESTING Rapid Field Service Engineers have extensive experience traveling worldwide to field test commission and start up major high power rectifier systems Rapid recommends that large systems have a load capacity large enough to fully test the system parameters If this is not available Rapid engineers can usually develop a substitute load that will test the equipment to a satisfactory level Our field service technicians and system engineers are available at your request for start ups preventative maintenance emergency service and hands on training with new equipment Field testing a high power rectifier with substitute load Core and coil being tested prior to final assembly RAPID POWER CORPORATION HIGH POWER TESTING AND TRAINING TRAINING Rapid Service Engineers may instruct our customers operator and maintenance personnel during the commissioning start of the unit or during final test at our Corporate Headquarters This can be operational training and or full maintenance repair training for shift personnel SPARE PARTS Rapid maintains a multi million dollar spare parts inventory and has the appropriate factory approved spare parts on hand and ready for your use to assure maximum up time of your process Rapid s power supplies are designed for decades of trouble free use when the installation and routine maintenance
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