VFD High Current output

Status
Not open for further replies.
Hello, I have a VFD that when hooked up to a transformer runs 98 amps phases A B Phase C is 23. Its a ESP ( Electrical Sub Pump) for an oil well.
Meggerd everything all is good. No load on drive runs Hertz, volt, just fine. As soon as I put the Transformer in line I get those reading. Any ideas
how to test transformer? Randy
 

GoldDigger

Moderator
Staff member
Location
Placerville, CA, USA
Occupation
Retired PV System Designer
The transformer is on the AC input to the VFD, right? And is three phase?
Is the input winding of the transformer delta or wye? The output winding? What input is the VFD specified to use (most likely grounded wye)?
Are there taps on the individual windings of the transformer? Are they set identically?

Since the AC input to almost all VFDs goes into a bridge rectifier to produce DC on the VFD internal bus, the most likely reason for drawing less current from a single hot wire is that the voltage from that wire to neutral is lower than the other two for some reason.
Possibly a lower open circuit voltage (measure it) or a higher voltage drop resulting in a lower voltage under load. (Measure the peak or RMS voltage on each wire with the VFD loaded.)
 

Ingenieur

Senior Member
Location
Earth
Is it an isolation cfmr?
with no transformer all phases balanced?
vfd output balanced?

insert transformer
phases become unbalanced on xfmr sec
did you measure xfmr primary?
vfd output?
 

Jraef

Moderator, OTD
Staff member
Location
San Francisco Bay Area, CA, USA
Occupation
Electrical Engineer
Often times on oil field ESPs, the transformer is on the OUTPUT side, because the motor is hundreds or maybe thousands of feet down-hole, so they need to boost it to a higher voltage to keep the VD down and the cable weight from being so much that it can't support itself. Going from 480V to 4000V is not unheard of.

I know that a lot of ESP suppliers pay no attention to the step-up transformer design, but I was always taught it was critical because at the variable frequencies, the transformer saturation curve is different. At the very least, the acceptable eddy current loss tolerances should be much tighter, which means top quality silicon steel made for transformers, not recycled Hyundais. I always quoted building them with custom made transformers designed for the variable frequencies, but I usually lost out to the cheap-o guys who didn't care. So if it was the cheapest transformer they could find, it might be that it was just so far off the deep end of being out of tolerance for this use that you ended up with it not working.

But for sure, check your transformer windings with a megger (disconnect the drive!) just like you would the motor. You may have blown through the insulation. A basic off-the-shelf distribution transformer used in this way is subject to the same stresses on the output of the VFD as a motor is; high DV/DT, standing wave generation and corona discharge breakdown of the winding insulation.
 
Often times on oil field ESPs, the transformer is on the OUTPUT side, because the motor is hundreds or maybe thousands of feet down-hole, so they need to boost it to a higher voltage to keep the VD down and the cable weight from being so much that it can't support itself. Going from 480V to 4000V is not unheard of.

I know that a lot of ESP suppliers pay no attention to the step-up transformer design, but I was always taught it was critical because at the variable frequencies, the transformer saturation curve is different. At the very least, the acceptable eddy current loss tolerances should be much tighter, which means top quality silicon steel made for transformers, not recycled Hyundais. I always quoted building them with custom made transformers designed for the variable frequencies, but I usually lost out to the cheap-o guys who didn't care. So if it was the cheapest transformer they could find, it might be that it was just so far off the deep end of being out of tolerance for this use that you ended up with it not working.

But for sure, check your transformer windings with a megger (disconnect the drive!) just like you would the motor. You may have blown through the insulation. A basic off-the-shelf distribution transformer used in this way is subject to the same stresses on the output of the VFD as a motor is; high DV/DT, standing wave generation and corona discharge breakdown of the winding insulation.

Oh yes cheap and 30 years old. 1000 Vac secondary 3000' down hole Baker Hughes Centrilift Drive 20+ years on that.
Thanks
 
Is it an isolation cfmr?
with no transformer all phases balanced?
vfd output balanced?

insert transformer
phases become unbalanced on xfmr sec
did you measure xfmr primary?
vfd output?

With just primary on transformer no load. Thats the high unbalaced current. Off transformer no load volts and hertz are as should be
and 0 current
 

LMAO

Senior Member
Location
Texas
Hello, I have a VFD that when hooked up to a transformer runs 98 amps phases A B Phase C is 23. Its a ESP ( Electrical Sub Pump) for an oil well.
Meggerd everything all is good. No load on drive runs Hertz, volt, just fine. As soon as I put the Transformer in line I get those reading. Any ideas
how to test transformer? Randy

So it is a submersible pump? And transformer is there because cable running between the down-hole pump and VFD is too long?

It may sound obvious but the transformer is probably bad. I don't know of a good "passive" way to test a transformer; your best bet is to put a low voltage on each phase and see if voltage ratio holds up. Like, apply 24VAC to AB, BC and AC separately and measure corresponding secondary.

You may also measure resistance between each phase on primary and secondary to see if the numbers are close. Or measure the inductance of you have anything that would measure inductance.
 
Status
Not open for further replies.
Top