VARIABLE FREQUENCY DRIVE CABINET VENTILATION SYSTEM, APPARATUS AND METHOD
20180249595 ยท 2018-08-30
Assignee
Inventors
- Ryan Bridwell Ashbaugh (Tulsa, OK, US)
- Tyler Clay Courtwright (Glenpool, OK, US)
- Casey Laine NEWPORT (Tulsa, OK, US)
- David Reagan Manen (Tulsa, OK, US)
- Thomas John Gottschalk (Houston, TX, US)
Cpc classification
H05K7/206
ELECTRICITY
H05K7/20918
ELECTRICITY
H05K7/20909
ELECTRICITY
International classification
Abstract
A variable frequency drive (VFD) cabinet ventilation system, apparatus and method is described. A VFD cabinet includes an internal air circulating closed circuit that extends through an inside of an air-to-air heat exchanger and an external air open circuit extending around an outside of the heat exchanger. The circulating internal air closed circuit extends through a chamber closed to ingress of external air, the chamber including electrical components of a VFD system. The external air open circuit makes a turn from downwards to upwards before flowing through a VFD chassis including a drive of the VFD system. A VFD cabinet ventilation method includes turning a flow of cabinet ventilation air from downwards to upwards to separate dirt from the ventilation air, passing the separated ventilation air through a VFD chassis, and circulating internal cabinet air through a closed circuit including an inside of a heat exchanger.
Claims
1. A variable frequency drive (VFD) cabinet comprising: portions defining an outside air flow path, the outside air flow path extending: from outside the VFD cabinet into the VFD cabinet through an air intake fan, from the air intake fan downwards around an outside of heat exchanger pipes between a wall of a housing of the VFD cabinet and a first vertical plate, the first vertical plate above and proximate to a floor of the VFD cabinet, flowing underneath the first vertical plate before turning upwards through a channel formed by the first vertical plate and a second vertical plate inside the housing, continuing upwards from the channel into and through a VFD chassis, and out of the VFD cabinet through a curved exit vent; and portions defining an internal air closed circuit, the internal air closed circuit extending: from a chamber within the VFD cabinet downward through a first plenum, from the first plenum through an inside of the heat exchanger pipes, from the inside of the heat exchanger pipes upward through a second plenum, and from the second plenum returning into the chamber, the chamber closed from ingress of outside air.
2. The VFD cabinet of claim 1, wherein the portions defining an outside air flow path comprise a shrouded plenum fluidly coupling an inside of the VFD chassis and the channel between the first vertical plate and the second vertical plate.
3. The VFD cabinet of claim 1, wherein the outside air flow path passes by VFD cooling fins as the outside air flow path continues upwards into and through the VFD chassis.
4. The VFD cabinet of claim 1, wherein the curved exit vent has an inlet opening that receives outside air vertically from the VFD and an exit opening that expels outside air horizontally.
5. The VFD cabinet of claim 1, wherein the curved exit vent curves about 90.
6. (canceled)
7. The VFD cabinet of claim 1, wherein the air intake fan is between the wall of the housing of the VFD cabinet and the first vertical plate.
8. The VFD cabinet of claim 7, wherein the air intake fan creates positive pressure proximate the portion of the cabinet defining the turn upwards between the first vertical plate and the second vertical plate.
9. The VFD cabinet of claim 1, wherein the chamber comprises a VFD controller and a VFD user interface, and the VFD chassis comprises a drive.
10. The VFD cabinet of claim 9, wherein the drive comprises a series of heat exchange fins exposed to the outside air flow path.
11. The VFD cabinet of claim 9, wherein the drive is operably coupled to an electric submersible pump motor.
12. The VFD cabinet of claim 1, comprising a lower chamber below the closed chamber, the lower chamber open to outside air and comprising a potted inductor and a booster fan.
13. The VFD cabinet of claim 12, wherein the booster fan is a resistor bank booster fan.
14. (canceled)
15. A variable frequency drive (VFD) cabinet comprising: an internal air closed circuit inside the VFD cabinet that extends through an inside of an air-to-air heat exchanger; an external air open circuit extending through a positive pressure fan and then around an outside of the air-to-air heat exchanger; the internal air closed circuit circulating through a chamber closed to ingress of external air, the chamber comprising electrical components of a VFD system; the external air open circuit making a 180 degree turn from downwards to upwards as the external air circuit flows underneath a vertical plate above and proximate to a floor of the VFD cabinet before flowing through a VFD chassis comprising a drive of the VFD system.
16. The VFD cabinet of claim 15, wherein the VFD chassis is fluidly coupled to a curved exit vent.
17. (canceled)
18. The VFD cabinet of claim 15, wherein the internal air flows around an outside of the VFD chassis in the chamber.
19. The VFD cabinet of claim 15, wherein the external air open circuit flows downwards through a first channel and upwards through a second channel, wherein the first channel and the second channel are separated by the vertical plate.
20. The VFD cabinet of claim 19, wherein external air flows underneath the vertical plate to travel from the first channel to the second channel.
21. The VFD cabinet of claim 19, wherein the second channel is defined by the vertical plate and a second vertical plate, the second vertical plate and a horizontal plate defining the chamber.
22. A variable frequency drive (VFD) cabinet ventilation method comprising: flowing outside air downwards through a booster fan into a VFD cabinet; boosting a pressure of the downwards flowing outside air with the booster fan; passing the downwards flowing outside air passed an outside of a heat exchanger inside the VFD cabinet; turning a flow of the downwards flowing outside air to upwards flowing outside air, the turn causing the separations of dirt from the outside air; moving the upwards flowing outside air through a VFD chassis comprising a drive before sending the upwards flowing outside air out of the VFD cabinet by guiding the outside air from an upwards flow to a horizontal flow through a curved exit vent; and circulating internal cabinet air through a closed circuit extending from a chamber and then through an inside of the heat exchanger to cool the internal cabinet air, the chamber sealed from the outside air and comprising portions of a VFD system.
23. The VFD cabinet ventilation method of claim 22, wherein turning the flow of outside air from downwards to upwards separates dirt from the outside air before the outside air moves through cooling fins within the VFD chassis.
24. The VFD cabinet ventilation method of claim 22, wherein turning the flow of the downwards flowing outside air from downwards to upwards comprises guiding the outside air around vertical plates that create air channels.
25. (canceled)
26. The VFD cabinet ventilation method of claim 22, further comprising operating an electric submersible pump (ESP) motor with the drive.
27. The VFD cabinet ventilation method of claim 26, wherein the ESP motor is downhole in a production well.
28. The VFD cabinet ventilation method of claim 26, wherein the VFD system operates the ESP motor, stores information from downhole sensors coupled to the ESP motor and interfaces with an operator of the ESP motor.
29. The VFD cabinet ventilation method of claim 22, further comprising operating a horizontal surface pump motor with the drive.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings in which:
[0016]
[0017]
[0018]
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[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the embodiments described herein and shown in the drawings are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
[0027] A variable frequency drive (VFD) cabinet ventilation system, apparatus and method is described. In the following exemplary description, numerous specific details are set forth in order to provide a more thorough understanding of embodiments of the invention. It will be apparent, however, to an artisan of ordinary skill that the present invention may be practiced without incorporating all aspects of the specific details described herein. In other instances, specific features, quantities, or measurements well known to those of ordinary skill in the art have not been described in detail so as not to obscure the invention. Readers should note that although examples of the invention are set forth herein, the claims, and the full scope of any equivalents, are what define the metes and bounds of the invention.
[0028] As used in this specification and the appended claims, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a chassis includes one or more chassis.
[0029] As used in this specification and the appended claims, coupled refers to either a direct connection or an indirect connection (e.g., at least one intervening connection) between one or more objects or components. The phrase directly attached means a direct connection between objects or components.
[0030] As used in this specification and the appended claims, outside air or external air means air that originates outside the VFD cabinet and flows from outside the VFD cabinet into the VFD cabinet during normal operation of the VFD system.
[0031] As used in this specification and the appended claims, inside air or internal air means air that originates within the VFD cabinet and remains within the VFD cabinet while the VFD system is operating, except for instances when the VFD cabinet may be opened for maintenance or repairs.
[0032] As used in this specification and the appended claims, sand, dirt, and particulates are used interchangeably to mean any solid contaminant carried by outside air.
[0033] Illustrative embodiments are described in terms of a VFD packaged system operating a downhole motor of an electric submersible pump (ESP) assembly. However illustrative embodiments are not so limited and may be applicable where a VFD system operates inside a cabinet and is subject to damage from overheating and/or contamination from dirt. For example, illustrative embodiments may be employed in horizontal pumping applications, drilling applications, hydraulic pumps, extruder drive controls and/or active front end regenerative solutions.
[0034] Illustrative embodiments provide a VFD cabinet ventilation system that may reduce the risk of overheating of electrical components of a VFD system while reducing contamination from sand, dirt, and dust. Illustrative embodiments may provide a VFD cabinet that remains on average 6 F. cooler during VFD operation than conventional VFD cabinets. Illustrative embodiments may improve the flow path of air circulating through a VFD cabinet by providing a ventilation flow that simultaneously improves cooling of a VFD system inside the cabinet, employs indirect cooling within a sealed chamber and removes particulates from the ventilation flow before the air passes by sensitive VFD electrical components that may be exposed to outside air.
[0035] Illustrative embodiments include a VFD cabinet partitioned into sections by plates. The plates may isolate a clean chamber containing drive electronics and other electronics, such as DIN rails, contactors, power supplies, relays, auxiliary contacts, transformers and programmable logic controllers (PLC). The isolated chamber may be sealed, isolated and/or closed from outside air and indirectly cooled by an air-to-air heat exchanger. To create the sealed chamber, a horizontal plate may partition a VFD chassis from a potted inductor inside the cabinet housing. In addition, a pair of parallel, vertical plates may separate the VFD chassis from an air intake fan. An air-cooled heat exchanger and a set of plenums creates a closed circuit of clean air within the sealed chamber of the cabinet.
[0036] Illustrative embodiments may include a distinct flow path for outside air. The pair of vertical plates may direct outside air to flow downwards and first make a 180 turn from downwards to upwards before the outside air enters the VFD chassis. The turn from downward flow to upward flow may cause sand, dirt and other particulates to separate from the ventilating air before the outside air passes through a shrouded plenum and into the VFD chassis. Once inside the VFD chassis, the outside air may continue through a passageway in the drive that routes the air through VFD cooling fins. After passing through the VFD chassis, the outside air may exit the cabinet through a curved exhaust vent that may encourage laminar flow. A booster fan at the cabinet's intake may create positive pressure between the pair of vertical plates, assisting the air to flow upwards against gravity and create the turn that may cause particulates to be removed from the outside air. The bottom of the cabinet may include a pallet that can be used to easily lift the cabinet with a forklift or pallet jack for easy positioning.
[0037]
[0038]
[0039] A VFD system may reside inside cabinet 230 on well surface 225 and/or proximate horizontal surface pump assembly 275 in an outdoor, hot and/or sandy location.
[0040]
[0041] Second vertical plate 425 may extend parallel to first vertical plate 420 from ceiling 495 towards floor 430, but stop a few inches short of floor 430, such as by hovering one, two or a few inches above floor 430. Second vertical plate 425 may be supported by, support and/or attach to sides of housing 455 adjacent wall 400, ceiling 495, horizontal plate 440 and/or shroud 445 surrounding VFD chassis 450. Second vertical plate 425 may include apertures to allow one or more exhaust vents 480 to extend through second vertical plate 425. Horizontal plate 440 may extend between second vertical plate 425 and the front side of housing 455 and/or the side of housing 455 opposite housing wall 400. Together housing 455, horizontal plate 440, floor 430 and second vertical plate 425 may define lower chamber 460. Lower chamber 460 may include potted inductor 465 and booster exit fan 470. Air circulated by booster exit fan 470 may exit cabinet 230 through exit booster fan vent 710 (shown in
[0042] Shroud 445 may be polycarbonate or another material with similar heat conduction, strength and/or toughness properties, and may be optically transparent. Shroud 445 may surround or partially surround VFD chassis 450.
[0043] Turning to
[0044]
[0045] Outside air 300 may then flow upwards between first vertical plate 420 and second vertical plate 425 through upward air channel 475 (shown in
[0046] A distinct channel for inside air may also be formed within packaged VFD cabinet 230. Internal air 320 may remain separated from outside air 300 during normal operation of VFD system 700 (i.e., other than during setup, breakdown, or in maintenance or repair periods). As shown in
[0047]
[0048] Illustrative embodiments may improve cooling within a VFD cabinet, while reducing contamination from dirt inside the cabinet. Illustrative embodiments may provide an isolated clean chamber that houses a VFD controller, VFD user interface, PLCs and other electrical components of the VFD system. Air within the clean chamber may circulate in a closed circuit in heat exchange with cooling outside air. Outside air may be directed through a labyrinth of one or more turns that causes sand, dirt and other particulates to be removed from outside air before the outside air flows through the VFD chassis that contains the drive, to cool the drive. The drive may include a passageway of fins exposed to the outside air that cool the drive. After flowing through the VFD chassis, outside air may be guided out of the cabinet through curved exhaust vents that encourage laminar flow of outside air through the cabinet.
[0049] A VFD cabinet ventilation system and apparatus has been described. Further modifications and alternative embodiments of various aspects of the invention may be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the scope and range of equivalents as described in the following claims. In addition, it is to be understood that features described herein independently may, in certain embodiments, be combined.