Optimizing Thermal Management in HVDC Valve Halls
Preventing Overheating of Thyristor Valves with IR Imaging Technology in High-Voltage Environments
Challenge
Thermal management in HVDC valve halls is complex due to intense heat from thyristors, restricted access during operation, and interference from electromagnetic fields. Accurate, reliable, and remote temperature monitoring is critical to prevent overheating, maintain efficiency, and ensure operational safety without physical intrusion into high-voltage areas.
Solution
Infrared thermal imaging provides non-intrusive, remote, continuous monitoring of temperature in HVDC valve halls. Thermal cameras detect hotspots and abnormal temperatures in real-time, enabling proactive maintenance and ensuring safe operation without the interference and complexity associated with traditional contact-based measurement methods.
Benefits
- Enhanced operational safety by enabling remote, risk-free temperature assessments in high-voltage environments.
- Reduced downtime through early detection of overheating and proactive, predictive maintenance practices.
- Improved reliability due to continuous monitoring and precise thermal profiling of critical equipment.
- Simplified installation with fewer measurement points needed, minimizing potential failure locations.
- Cost-efficient operation achieved by preventing costly unplanned repairs and optimizing maintenance schedules.
Optimizing Thermal Management in HVDC Valve Halls
In high-voltage direct current (HVDC) electric power transmission systems, valve halls house the critical thyristor valves of static inverters. These valves are crucial for converting AC to DC and vice versa, operating between 100 kV and 800 kV. HVDC lines are frequently employed for long-distance power transmission because they need fewer conductors and experience less power loss compared to equivalent AC lines. High voltage bushings pass through the walls of the valve hall to facilitate connections between the converter transformers on one side and the DC switchyard on the other. Adjacent to the valve hall, there is often an additional building housing control electronics, equipment for valve cooling, and valve monitoring systems.
Effective temperature regulation within these valve halls is essential to ensure the reliability and efficiency of the HVDC system. These valves are essential to ensure the reliability and efficiency of the HVDC system, as the thyristor must operate at a specific operating temperature band. The temperature control is challenging due to the substantial heat generated by the thyristors and the need for precise thermal management to prevent overheating and maintain optimal performance. Any malfunction or inefficiency in temperature regulation could lead to significant operational disruptions, costly repairs, and potential safety hazards.
Access to the valve hall is highly restricted while the static inverter is operational, necessitating remote monitoring solutions. This restricted access, coupled with the need for electromagnetic interference shielding to protect measurement systems, complicates remote temperature monitoring equipment installation and maintenance. Therefore, a reliable, non-intrusive temperature monitoring solution is imperative to ensure HVDC valve halls’ continuous, safe, and efficient operation.
IR Remote Measurement in High-Voltage Applications with Thermal Imaging Technology
Temperature measurement in high-voltage (HV) environments presents significant safety challenges. Traditional methods, such as thermocouples and resistance temperature detectors (RTDs), require highly insulated electronics and cables. This insulation can interfere with HV equipment and complicate both installation and maintenance. Thick cable insulation becomes particularly problematic in multi-channel applications within tight spaces, and sensor failures often necessitate replacing the entire unit. Electromagnetic and electrostatic disturbances can degrade signal quality, further complicating accurate temperature measurements.
In contrast, stationary thermal cameras offer a robust sensing solution for temperature monitoring in valve halls of HVDC systems. The most significant advantage of using infrared remote measurement in these applications is the lack of physical contact between high-voltage devices and the measurement system, making it intrinsically safe. The IR cameras provide continuous, real-time thermal imaging, allowing for the early detection of potential issues. By identifying hotspots and abnormal temperature variations, thermal cameras enable proactive maintenance, reducing the risk of costly unplanned outages. This capability is crucial, especially given the restricted access to valve halls while the static inverter is operational.
Remote monitoring with thermal cameras allows operators to assess equipment conditions without entering high-risk areas, enhancing safety and operational efficiency. Over time, these cameras provide detailed thermal profiles, supporting trend analysis and predictive maintenance strategies. By maintaining optimal temperature control, stationary thermal cameras ensure the continuous, safe, and efficient operation of HVDC valve halls.
Wide-Angle Thermal Imaging Reduces Installation Points by Half
In an application in Brazil, a valve hall in an electrical substation was equipped with sixty Optris infrared cameras. Optris won the project by offering a cost-effective, reliable, and robust solution tailored to the customer’s specific needs, supported by the high regard for German technology.
Implementing Optris IR cameras in high-voltage environments requires special considerations. The customer needed electromechanical housing to protect the cameras from physical interference and electromagnetic fields. Unlike other suppliers, Optris provides a range of accessories that enhance the cameras’ protection and functionality. These accessories are fundamental to a reliable industrial IR monitoring solution. A standard cooling jacket was essential, not only for temperature control but also for providing robust housing that shields the cameras from physical damage and electromagnetic interference.
The wide-angle capability of Optris thermal imaging systems allowed the customer to reduce the number of IR cameras needed, cutting down the total installation points and potential failure points by nearly half compared to other brands.
The reputation of German engineering and technology played a significant role. Direct interactions and visits reinforced this trust, enhancing customer confidence in the provided solution. Optris offered flexible connectivity options that integrated well with existing systems.
Optris offered a competitive price point. Considering all accessories and wide-angle options, Optris optimized the cost without compromising protection. This pricing strategy enabled Optris to outcompete against high-volume, low-budget competitors requiring more IR cameras and third-party housings and who were already in place.
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