INVT GD3000 VFD for Mine Ventilation System in Australia Underground Mine

1. Project Background

Ventilation is the lifeline of underground mining operations. It is critical for ensuring a safe and breathable atmosphere for personnel, diluting hazardous gases, and controlling dust levels. In a large-scale underground mine located in Western Australia, the existing ventilation system for a key production zone was powered by fixed-speed motors. This conventional setup lacked the ability to adjust airflow dynamically based on real-time operational demands, such as the number of active equipment and personnel in different sections. The mine sought a smart, reliable, and efficient ventilation solution that could integrate seamlessly with their existing industrial control network to enhance safety, reduce energy consumption, and lower operational costs.

2. Customer Pain Points

The mine operator faced several significant challenges with the old ventilation system:

• High Energy Consumption: The fans ran continuously at full speed, leading to enormous and unnecessary electricity costs, especially during periods of low activity.

• Harsh Operating Environment: The dusty, humid, and corrosive environment in the mine required electrical equipment with robust protection to ensure long-term reliability and minimize downtime.

• Lack of Intelligent Control: The fixed-speed system could not automatically adjust to the mine's variable ventilation needs. The existing drives lacked modern communication protocols, making it impossible to integrate them into the mine's centralized monitoring and control system for data collection and remote operation.

3. INVT Solution

INVT proposed and implemented its GD3000 Series Three-Level IP54 cabinet-built VFD as the core component for the ventilation fan control system. The VFD is rated at 1140V and 315kW, and is equipped with an input reactor, an output sine filter, and an Ethernet/IP communication card. The solution offered distinct advantages:

• Three-Level Topology & Low dU/dt: The GD3000's advanced three-level technology significantly reduces the output voltage harmonic content compared to standard two-level drives. This results in cleaner power, lower dU/dt, minimizing interference with the grid, reducing motor insulation stress and extend motor life.

• Robust IP54 Protection Cabinet: The drive was housed in a dedicated IP54-rated enclosure, providing complete protection against dust and water splashes. This robust design ensured reliable operation in the harsh mine environment, reducing failure rates and maintenance needs.

• Native Ethernet/IP Industrial Ethernet Communication: The Ethernet/IP protocol allowed for seamless and high-speed integration with the mine's AB PLC-based control system. This enabled real-time monitoring of VFD parameters (speed, current, status), remote control, and fault diagnostics from the central control room.

• High reliability: Using film capacitors allows VFDs to operate reliably in high-temperature environments and has a longer lifespan than electrolytic capacitors.

Fig. On-site photos

4. Customer Benefits

The implementation of the INVT GD3000 VFD cabinet delivered substantial and measurable benefits to the Australian mine:

• Significant Reduction in Energy Costs: The variable speed control achieved by the GD3000 VFD led to energy savings of over 30% for the ventilation system, providing a rapid return on investment.

• Enhanced Safety and Operational Flexibility: The ventilation system can now be automatically and precisely controlled based on real-time data, ensuring optimal air quality and flow where and when it is needed most, thereby enhancing miner safety.

• Increased System Reliability and Uptime: The IP54 cabinet and the high-quality components of the GD3000 have proven highly resilient to the tough mine conditions, resulting in reduced unplanned downtime and lower maintenance costs.

• Intelligent, Centralized Management: Through the Ethernet/IP network, operators now have full visibility and control over the ventilation system. They can receive instant alarm notifications, perform remote troubleshooting, and optimize the entire ventilation strategy, paving the way for a smarter, more efficient mine.

5. Conclusion

INVT GD1000, GD2000, and GD3000 series VFDs are designed for the mining industry, covering voltage levels of 380V, 660V, 1140V, and 3.3kV. They are widely used in electrical equipment throughout the entire production process in the mining industry, including coal mining machines, roadheaders, scraper conveyors, belt conveyors, mine hoists, and ventilator.