INVT GD5000 MV VFD Retrofit for Boiler Feed Pump in Chemical Plant at Inner Mongolia

Background

At a chemical plant in Inner Mongolia, an "equipment renewal" initiative is underway. Faced with frequent failures of aging medium-voltage VFDs and difficulties in obtaining spare parts, INVT completed a "core upgrade" retrofit in just one week. The original cabinet, transformer, and cables were retained, and the equipment was transformed into a smart system with modern features such as "one-click start/stop" and intelligent control.

The upgraded system is now reliably driving the boiler feed pump, ensuring continuous production for the plant. This upgrade is not only cost-effective but also serves as a practical example of how traditional equipment can embrace smart manufacturing.

Project Challenges

The boiler feed pump at the Inner Mongolia chemical plant was originally equipped with a medium-voltage VFD (10KV, 1600KVA capacity) that had been in service for many years. In recent years, the failure rate of the VFD had significantly increased, disrupting production. Additionally, the discontinuation of spare parts made it difficult to procure replacements, and maintenance costs were high. After careful consideration, the plant decided to upgrade the equipment during the planned maintenance period in mid-2025.

The specific requirements for the retrofit were as follows:

• Retain Existing Connections: All original primary and secondary control cables should be kept to ensure the layout and connections remain unchanged.

• Partial Retention and Full Upgrade: Only the dry-type transformer and the bottom cooling fan would be retained. Other components, including control panels, modules, and cooling systems, were replaced.

• Intelligent Upgrade: Added "one-click start/stop" function to improve automation and operational convenience.

• Project Timeline Control: Retrofit completed within maintenance period to minimize production interruption.

Solution Implementation

Medium-Voltage VFD Solution

INVT customized a GD5000-based retrofit solution to replace the old VFD while retaining existing infrastructure. The implementation process included:

• Preliminary Research and Assessment: On-site data collection and system evaluation.

• Material Preparation: Customized parts and tools prepared for retrofit execution.

• On-Site Construction: Old system dismantling, new installation, wiring, and safety training.

• System Commissioning: Low-voltage tests, no-load and load testing, and functional verification.

• Acceptance and Training: Operator training and delivery of technical documentation.

Client Benefits

1. Zero Construction Cost
Retained existing cabinet and infrastructure, eliminating unnecessary civil construction costs.

2. Reduced Downtime
Faster retrofit process significantly reduced production interruption compared to full replacement.

3. Performance and Functionality Upgrades
System intelligence improved with new control features such as "one-click start/stop".

4. Stable Maintenance and Support
Upgraded to mainstream components with 24/7 INVT technical support for long-term reliability.

Conclusion

INVT has extensive experience in medium-voltage VFD retrofit solutions. Through advanced technology and professional engineering capability, INVT helps customers modernize aging equipment, reduce operational costs, and improve system efficiency. The GD5000 retrofit series provides a reliable pathway for industrial digital transformation and sustainable development.