大功率整流系统综合节能理论与新技术研究
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摘要
在国家上调工业企业用电价格及强制性实施节能减排的双重背景下，高耗能行业的节能改造势在必行。在需要大功率直流电解的冶金、化工行业，整流系统存在节能改造的空间。论文对目前常规的二极管及晶闸管整流方式进行了分析，提出了一种基于感应滤波技术的新型大功率整流系统，分析了感应滤波的机理及实现条件，结合工程实际中存在的直流大电流准确计量与系统及部件的运行效率监测等难题，提出了一个基于感应滤波的大功率整流系统综合节能理论及新技术。工程实测结果验证了新型大功率整流系统在谐波抑制及节能方面的优越性。
针对提出的综合节能理论及新技术，本文主要开展了以下几个方面的基础研究工作，并取得相应的创新成果：
1、建立了大功率整流系统的等值电路模型、变压器谐波传递数学模型
分析了计及换相过程及直流脉动的整流器谐波特性，根据常规的大功率整流系统及其滤波功补方法，在阐述感应滤波理论与方法的基础上，提出了一种基于感应滤波技术的大功率整流系统及其阀侧滤波功补方法，给出了大功率整流系统的主电路拓扑结构，依据其工作原理和数学模型，建立了系统等值电路模型、变压器谐波传递模型及系统能耗模型，进行了系统能耗分析，并对谐波功率进行研究，探讨了谐波功率与系统基波电能计量的关系。
2、提出了一种直流大电流的间接测量方法
鉴于目前测量方法及设备存在的问题，根据变压器耦合瞬态模型的交流阀侧及直流电流关系、开关函数及其拓展与理论解析，推导了变压器阀侧交流电流与直流电流的对应关系。在此基础上，根据整流变压器阀侧交流的波形，通过变压器所有输出母排交流电流的叠加得到直流电流的波形，并获得国家发明专利。优点是此方法计算简单，摒弃了体积庞大的直流传感器，且不受直流强磁场的影响。
3、提出了一种大功率整流系统各部件运行功耗及效率的监测方法
大功率整流机组由变压器(含整流与调压变压器)、整流柜及滤波功补装置三大部分组成，通过交流网侧、滤波侧、低压阀侧及直流侧的同步测量，提出一种能耗部件运行功耗监测与系统效率分析方法，并进行了工程测试研究。同时，对工程测试中遇到的电力整流设备运行效率测试问题、传感器精度问题、同步测量问题、晶闸管损耗工程测试问题进行分析与研究，并根据国家制定的电力整流设备运行效率的在线测量标准，对测试结果进行了分析及误差修正。此方法可实现整流系统的电能质量及效率分析，解决目前系统及部件效率无法核算的难题，为系统的节能评估提供数据支持。
4、分析了绿色节能直流电站的综合节能技术
根据前述研究，探讨了基于感应滤波技术的绿色节能直流电站的感应滤波节能(在接近谐波源处进行谐波抑制与无功补偿)、系统参数优化设计节能、基于节能的关键部件优化设计节能及基于部件损耗监测系统优化运行节能等综合节能技术，可有效解决目前大功率整流系统谐波污染严重及效率低下的问题。
5、对基于感应滤波的6脉波及12脉波大功率整流系统的工程实践进行了研究
对感应滤波构建的直流输出415V，22kA的6脉波大功率整流系统及直流输出640V，16kA的单体12脉波大功率整流系统进行了工程测试研究。介绍了新型大功率整流系统的主拓扑结构、新型6脉波及12脉波带自耦调压的整流变压器的原理接线及其配套全调谐滤波装置的实物图、变压器与滤波装置的主要设计参数、以及实际调试后滤波支路的主要参数；分别对上述2套新型整流系统的运行效率进行了工程测试。测试结果表明：感应滤波的实施使得系统的谐波抑制效果优良，变压器及系统的效率高，具有良好的节能效果。
The industrial application of large-power rectifier system based on the AC/DCenergy convention has become an important part of the national industry. Under thebackground of high electricity price and mandatory implementation of energy saving forindustrial enterprises, the high energy-consuming industries must face the problem ofenergy saving. In this thesis, the conventional diode uncontrolled rectifiers and thyristorphase-controlled industry rectifiers system are analyzed, and a new DC power supplysystem based on an inductive filtering technology is presented. The inductive filteringmethod and its implementation condition are analyzed. According to the followingpractical problems: accurate measurements of the large direct current and efficiencymonitor of the system and key equipments, a synthesis energy saving theory and newmethod of the large-power rectifier system is presented. The projective test results showthe technical superiority of the new rectifier system on harmonic suppression and energysaving.
For the synthesis energy saving theory and new method, the performed fundamentalresearch and the related innovative achievement in this thesis are summarized asfollows:
(1) The equivalent-circuit model of the large-power rectifier system and theharmonic-transfer mathematical model of the transformer are established. Theharmonic characteristic of the rectifier with the commutation and finite link inductanceis analyzed. Based on the conventional large-power rectifier system and its harmonicsuppression and reactive power compensation methods, a new industry rectifier systembased on inductive filtering technology is presented. Furthermore, its main-circuittopologies are analyzed, and the equivalent-circuit model of the rectifier system,harmonic transfer mathematical model of the transformers and the system loss model areestablished to analyze harmonic transfer characteristics and key equipments’ loss.Moreover, the harmonic power and its influence on electric energy measurement isdiscussed.
(2) A new indirect measuring method of large direct current is presented.Considering the conventional measuring method and related problems, the relationshipbetween the current of valve side and DC side are deduced and analyzed by theelectromagnetic coupling transient model, switch function method and classic analytic calculation approach. Then, considering the effect of the valve pressure drop, loss andresistor-condenser circuit on the DC, a detailed measuring scheme is presented from thewaveforms measuring of transformer valve currents to direct current inversion andcalculation, and had obtained the national invention patent. This method has theadvantages of simple calculation, rejecting the bulky dc sensor, and no the influence ofthe DC strong magnetic field.
(3) Real-time monitoring and analysis method of the key equipments andsystem loss and efficiency on the larger-power rectifier system is proposed. Thelarger-power rectifier system consist of regulating and rectifier transformer, rectifier andfilters. Therfore, a monitoring method for the rectifier system’s real-time loss ispresented by the simultaneous measurement of the voltage and current of the AC gridside, filtering side, valve side, and DC side. Then, the engineering testing is developed.Meantime, the problems of operating efficiency testing of the power rectifier equipment,sensor accuracy, synchronous measurement and rectifier loss engineering testing areanalysed and researched. Finally, according to the corresponding national standards of P.R. China, the testing results and their error correction are processed. It can be used tosolve the problems of power supply equipments and system’s efficiency accounting, andprovide date for the assessment of energy saving.
(4) A synthesis energy saving scheme of the non-harmonic pollution and energysaving DC power supply system is analyzed. In the basis of the prior study, the energysaving technology are researched as follows: inductive filteing method energy saving,including harmonic suppression reactive power compensation nearby harmonic andreactive power sources; energy saving of the system parameters optimum design; energysaving of the key equipments optimum design and system operations control energysaving based on the real-time monitoring of the key equipments’ loss. It is expected tosolve the existing problems of serious harmonic pollution and larger losses on thelarge-power rectifier system.
(5) The projective application of inductive filtering in6-pulse and12-pulselarge-power rectifier system is researched. The inductive filtering method has beenapplied in a6-pulse industrial rectifier system (DC voltage is415V, DC current is22kA),and a12-pulse industrial rectifier system (DC voltage is640V, DC current is16kA). Inthis thesis, the electric wiring scheme of the two industrial rectifier system, theconfiguration and the main design parameters of the inductive filtering rectifiertransformers and their related full-tuned branches are introduced, respectively.Furthermore, the practical characteristic harmonic impedance parameters of full-tuned branches are presented. Finally, the field test on the two large-power rectifier systemsare performed respectively to verify the effectiveness of harmonic suppression andenergy saving.
针对提出的综合节能理论及新技术，本文主要开展了以下几个方面的基础研究工作，并取得相应的创新成果：
1、建立了大功率整流系统的等值电路模型、变压器谐波传递数学模型
分析了计及换相过程及直流脉动的整流器谐波特性，根据常规的大功率整流系统及其滤波功补方法，在阐述感应滤波理论与方法的基础上，提出了一种基于感应滤波技术的大功率整流系统及其阀侧滤波功补方法，给出了大功率整流系统的主电路拓扑结构，依据其工作原理和数学模型，建立了系统等值电路模型、变压器谐波传递模型及系统能耗模型，进行了系统能耗分析，并对谐波功率进行研究，探讨了谐波功率与系统基波电能计量的关系。
2、提出了一种直流大电流的间接测量方法
鉴于目前测量方法及设备存在的问题，根据变压器耦合瞬态模型的交流阀侧及直流电流关系、开关函数及其拓展与理论解析，推导了变压器阀侧交流电流与直流电流的对应关系。在此基础上，根据整流变压器阀侧交流的波形，通过变压器所有输出母排交流电流的叠加得到直流电流的波形，并获得国家发明专利。优点是此方法计算简单，摒弃了体积庞大的直流传感器，且不受直流强磁场的影响。
3、提出了一种大功率整流系统各部件运行功耗及效率的监测方法
大功率整流机组由变压器(含整流与调压变压器)、整流柜及滤波功补装置三大部分组成，通过交流网侧、滤波侧、低压阀侧及直流侧的同步测量，提出一种能耗部件运行功耗监测与系统效率分析方法，并进行了工程测试研究。同时，对工程测试中遇到的电力整流设备运行效率测试问题、传感器精度问题、同步测量问题、晶闸管损耗工程测试问题进行分析与研究，并根据国家制定的电力整流设备运行效率的在线测量标准，对测试结果进行了分析及误差修正。此方法可实现整流系统的电能质量及效率分析，解决目前系统及部件效率无法核算的难题，为系统的节能评估提供数据支持。
4、分析了绿色节能直流电站的综合节能技术
根据前述研究，探讨了基于感应滤波技术的绿色节能直流电站的感应滤波节能(在接近谐波源处进行谐波抑制与无功补偿)、系统参数优化设计节能、基于节能的关键部件优化设计节能及基于部件损耗监测系统优化运行节能等综合节能技术，可有效解决目前大功率整流系统谐波污染严重及效率低下的问题。
5、对基于感应滤波的6脉波及12脉波大功率整流系统的工程实践进行了研究
对感应滤波构建的直流输出415V，22kA的6脉波大功率整流系统及直流输出640V，16kA的单体12脉波大功率整流系统进行了工程测试研究。介绍了新型大功率整流系统的主拓扑结构、新型6脉波及12脉波带自耦调压的整流变压器的原理接线及其配套全调谐滤波装置的实物图、变压器与滤波装置的主要设计参数、以及实际调试后滤波支路的主要参数；分别对上述2套新型整流系统的运行效率进行了工程测试。测试结果表明：感应滤波的实施使得系统的谐波抑制效果优良，变压器及系统的效率高，具有良好的节能效果。
The industrial application of large-power rectifier system based on the AC/DCenergy convention has become an important part of the national industry. Under thebackground of high electricity price and mandatory implementation of energy saving forindustrial enterprises, the high energy-consuming industries must face the problem ofenergy saving. In this thesis, the conventional diode uncontrolled rectifiers and thyristorphase-controlled industry rectifiers system are analyzed, and a new DC power supplysystem based on an inductive filtering technology is presented. The inductive filteringmethod and its implementation condition are analyzed. According to the followingpractical problems: accurate measurements of the large direct current and efficiencymonitor of the system and key equipments, a synthesis energy saving theory and newmethod of the large-power rectifier system is presented. The projective test results showthe technical superiority of the new rectifier system on harmonic suppression and energysaving.
For the synthesis energy saving theory and new method, the performed fundamentalresearch and the related innovative achievement in this thesis are summarized asfollows:
(1) The equivalent-circuit model of the large-power rectifier system and theharmonic-transfer mathematical model of the transformer are established. Theharmonic characteristic of the rectifier with the commutation and finite link inductanceis analyzed. Based on the conventional large-power rectifier system and its harmonicsuppression and reactive power compensation methods, a new industry rectifier systembased on inductive filtering technology is presented. Furthermore, its main-circuittopologies are analyzed, and the equivalent-circuit model of the rectifier system,harmonic transfer mathematical model of the transformers and the system loss model areestablished to analyze harmonic transfer characteristics and key equipments’ loss.Moreover, the harmonic power and its influence on electric energy measurement isdiscussed.
(2) A new indirect measuring method of large direct current is presented.Considering the conventional measuring method and related problems, the relationshipbetween the current of valve side and DC side are deduced and analyzed by theelectromagnetic coupling transient model, switch function method and classic analytic calculation approach. Then, considering the effect of the valve pressure drop, loss andresistor-condenser circuit on the DC, a detailed measuring scheme is presented from thewaveforms measuring of transformer valve currents to direct current inversion andcalculation, and had obtained the national invention patent. This method has theadvantages of simple calculation, rejecting the bulky dc sensor, and no the influence ofthe DC strong magnetic field.
(3) Real-time monitoring and analysis method of the key equipments andsystem loss and efficiency on the larger-power rectifier system is proposed. Thelarger-power rectifier system consist of regulating and rectifier transformer, rectifier andfilters. Therfore, a monitoring method for the rectifier system’s real-time loss ispresented by the simultaneous measurement of the voltage and current of the AC gridside, filtering side, valve side, and DC side. Then, the engineering testing is developed.Meantime, the problems of operating efficiency testing of the power rectifier equipment,sensor accuracy, synchronous measurement and rectifier loss engineering testing areanalysed and researched. Finally, according to the corresponding national standards of P.R. China, the testing results and their error correction are processed. It can be used tosolve the problems of power supply equipments and system’s efficiency accounting, andprovide date for the assessment of energy saving.
(4) A synthesis energy saving scheme of the non-harmonic pollution and energysaving DC power supply system is analyzed. In the basis of the prior study, the energysaving technology are researched as follows: inductive filteing method energy saving,including harmonic suppression reactive power compensation nearby harmonic andreactive power sources; energy saving of the system parameters optimum design; energysaving of the key equipments optimum design and system operations control energysaving based on the real-time monitoring of the key equipments’ loss. It is expected tosolve the existing problems of serious harmonic pollution and larger losses on thelarge-power rectifier system.
(5) The projective application of inductive filtering in6-pulse and12-pulselarge-power rectifier system is researched. The inductive filtering method has beenapplied in a6-pulse industrial rectifier system (DC voltage is415V, DC current is22kA),and a12-pulse industrial rectifier system (DC voltage is640V, DC current is16kA). Inthis thesis, the electric wiring scheme of the two industrial rectifier system, theconfiguration and the main design parameters of the inductive filtering rectifiertransformers and their related full-tuned branches are introduced, respectively.Furthermore, the practical characteristic harmonic impedance parameters of full-tuned branches are presented. Finally, the field test on the two large-power rectifier systemsare performed respectively to verify the effectiveness of harmonic suppression andenergy saving.
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