ABB_Wind Power Converter Technology Presentation

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Medium Voltage Frequency Converters for MW Windturbines

Dr. Peter K. SteimerVice President

Power Electronics and Medium Voltage Drives

CH - 5300 Turgi

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� Introduction� Power Platforms (PEBBs)

� Power Semiconductors� PEBBs

� Control Platforms (Power Electronics Controller)� Medium Voltage Drives and FACTS Products

� Medium Voltage Drives� Power Conditioning Products

� Medium Voltage Windpower Products� Medium Voltage Frequency Converter� Medium Voltage STATCOM

� Outlook

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Power Electronics & Medium Voltage Drives

ProcessMM

3 ~3 ~

f1

f2

~

~

ConverterCooling

MachineCooling

ProtectionProtection Control Control ExcitationExcitation

n

ProcessMM

3 ~3 ~

f1

f2

~

~

ConverterCooling

MachineCooling


n

Standard Scope of Supply for a Drive System

ProcessMM

3 ~3 ~

f1

f2

~

~

ConverterCooling

MachineCooling


n

ProcessMM

3 ~3 ~

f1

f2

~

~

ConverterCooling

MachineCooling


n

Standard Scope of Supply for a Drive SystemStandard Scope of Supply for a Drive System

Power Electronics MV Drives

Excitation & Synchronizing Systems

High Power Rectifiers

Power Converters

� UNITROL® 1000 AVR� UNITROL® F or 5000 SES� SYNCHROTACT® 5

� Power Plants� Industrial Plants (motors)� Substations

� Compact Rectifier� Medium Current Rectifier� Thyribloc® / Rectibloc®

up to 200 kA / 1500 V

� Aluminum Smelters� Copper, Zinc, Chlorine

� Static Frequency Converterup to 100 MW

� BORDLINE® Converters� Power Quality Systems

� Utilities� Rolling Stock OEM's

� DriveIT ACS 1000 0.3 - 5 MW� DriveIT ACS 6000 3 - 27 MW� ACS 6000c 14 - 27 MW� LCI 2 - 100 MW

� Cement, Mining & Minerals� Chemical, Oil & Gas� Marine� Metals� Pulp & Paper� Power� Water & Waste Water

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Global Center of CompetenceTotal: ~ 900 Employees

ABB Power ElectronicsABB MV Drives

Turgi

ABB Corporate Research

Dättwil

ABB Semiconductors

Lenzburg

Power Power ElectronicsElectronics

TriangleTriangle

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.Medium Voltage Frequency Converters for MW Windturbines






� Outlook

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Power platform – key technologies

� Innovative and competitive solutions in the energy processing technology are made possible by modern power platforms (PEBBs) based on:� Power semiconductors and their control (IGCT, IGBT, …)

� Converter topologies (2-Level, 3-Level, Multilevel, AC/AC, ..)

� Thermal design (Thermal modeling, cooler design, corrosion resistance, …)

� Passive components (Capacitors, inductors, transformers …)

� Mechanical design (Module, stray inductances, busbars, leakage paths, …)

� Insulation coordination and design (Partial discharges, leakage paths,…)

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Low voltage IGBT module� Econopack /SKiiP/LoPak Module � 1200 V und 1700 V

Maximum blocking voltage

� 75 – 450 AMaximum phase current

� Switching frequency (fPWM)� 1200 V: Typical 3..5 kHz

� Integration� Electrical insulation

� Up to six switching devices

� Loss-optimized� Soft Punch Through or

� Trench

� Copper base plate (EconoPack)� Limited in thermal cycles

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Medium voltage IGBT module� IHV / HiPak Module (E1/E2)

� 2500 V, 3300 V and 6500 VMaximum blocking voltage

� 1500 A, 1200 A, 600 AMaximum phase current

� Switching frequency (fPWM)� 3300 V: Typical 1..2 kHz

� Integration� Electrical insulation

� Up to 2 devices (dual pack)


� Trench

� AlSiC base plate� Traction

Turn off 3x rating current (3300V IGBT)

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Medium voltage power semiconductors: IGCT presspack

� IGCT Presspack� 4500 V and 6000 V

Maximum blocking voltage


� Switching frequency (fPWM)� Typical 0.5 – 1 kHz

� Integration� Gate unit

� Loss-optimized� Transparent Anode

� Thyristor-based

� Presspack� Short circuit

� di/dt – snubber� di/dt of diode

4

1

Ia (kA)

Vdm

Itgq

4

3

2

1

0

-10

-20

Vg(V)

2

3

0

anode voltage Vd

anode current Ia

gate voltage Vg

thyristor transistorx

starts to block

Vd(kV)

2.01.5 3.02.5 3.5 t (µ s)

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Medium voltage IGBT presspack� IGBT Presspack

� 2500 V and 4500 VMaximum blocking voltage


� Switching frequency (fPWM)� 2500 V: typical 1 – 2 kHz

� 4500 V: typical 0.5 – 1 kHz

� Integration� Single device


� Trench

� Presspack� Short circuit

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IGBT Presspack

Medium

Turn-off Power semiconductors

Costs / kVA

IGCT Presspack

LowLow

Application MV & HV.(up to +/- 150kV)

MV(up to 15 kV)

LV & MV

MediumLosses LowMedium

IGBT Modul

Scalability Parallel & SeriesParallel & Series (with snubber)

Parallel

Short-circuitFailure type Short-circuitOpen (Plasma)

LV drives MV drives HVDC lightTraction IntertiesPower Quality FACTS

50 – 300 MWPower 5 – 100 MW1 – 5 MWA

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IGBTPresspack

Turn-off power semiconductors

0 1MVA 10 MVA 100 MVA

200 kV

15 kV

7.2kV

2.3 kV

690 VLVIGBTModule

HVIGBTModule

IGCTPresspack

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.PEBB concepts (IEEE WG PEBB TF2)

IA/B/C VA/B/C

(optional)

1..6VDC1 T

V

V

Gate drives &device protection

FB

PEBB Control - Modulator- Converter switching logic- 2nd level protection

PEBB - Stack or module assembly- Snubbers for safe commutation- Gate drives & feedbacks - 1st level device protection- A/D & D/A conversion- Gate drive power supply - Current and voltage sensors- AC/DC power terminals- Thermal management

A / D & D/A

Converter switching logic

2nd level protection

Modulator

PLL, αβ ↔ dq Transformationsid / iq current control

Application control

Converter Control - PLL synchronization- αβ ↔ dq Transformations- id- and iq current control

Application Control - overriding control & measurements

A / D & D/A 0.1..1 µµµµs

1..10 µµµµs

10 µµµµs..1ms

6

Con

figur

atio

n&

dia

gnos

tics

1ms..1s..

System control

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Power Plattform

IA/B/C VA/B/C

(optional)

1..6VDC1 T

V

V

Gate drives &device protection

FB

PEBB Control - Modulator- Converter switching logic- 2nd level protection

PEBB - Stack or module assembly- Snubbers for safe commutation- Gate drives & feedbacks - 1st level device protection- A/D & D/A conversion- Gate drive power supply - Current and voltage sensors- AC/DC power terminals- Thermal management

A / D & D/A

Converter switching logic

2nd level protection

Modulator

PLL, αβ ↔ dq Transformationsid / iq current control

Application control

Converter Control - PLL synchronization- αβ ↔ dq Transformations- id- and iq current control

Application Control - overriding control & measurements

A / D & D/A 0.1..1 µµµµs

1..10 µµµµs

10 µµµµs..1ms

6

Con

figur

atio

n&

dia

gnos

tics

1ms..1s..

System control

SerialBus

PEBB functionality and interfacesA

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IGBT (module) PEBB

� Low-voltage IGBT module power platform � 2-Level topology, 0.6 MVA power, 400..690 VLL

� 1200 V and 1700 V IGBT modules, water-cooled

� Mechanically integrated dc link

� Configurable regarding AC outputs (number and amperage)

� Integrated current and voltage measurementA

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IGCT (presspack) PEBB

� Medium voltage IGCT presspack power platform � 3-Level topology, 9 MVA power stack, 3300..4160 VLL

� 4500 V and 6000 V IGCTs, water-cooled (de-ionized)

� Up to two mechanically integrated phase components

=

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.IGBT (Presspack) PEBB

� High voltage IGBT presspack power platform � 2-Level topology, series connection up to +/- 150 kVdc

� 2500 V IGBT, water-cooled (de-ionized)

� Up to 20 elements per stack

2.5kV, 1000-1500 ARMS

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Innovative Technology from Wind to Grid

HVDC Light

HVDC

HVAC with Reactive Power Compensation

Conventional HVAC

Sam

e tra

nsm

issi

on c

apac

ity

With High Voltage Direct Current Systems (HVDC Light) and IGBT Power Electronics we are able to connect large windfarms to even weak grids at maximum efficiency and minimum costs.

IGBT = Integrated Gate Bipolar Transistor

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� Outlook

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Control platform – key technologies

� Innovative and competitive solutions in the energy processing technology are made possible by modern control platforms based on:� Digital electronics (Power PC / DSP / FPGA / ASIC …)

� Real time operating systems (VxWorks, Linux RT, ..)

� Programming tools (VHDL / Matlab / Simulink / IEC 1131 /…)

� Control algorithms (DTC, d/q-axes control, Observers, …)

� Communications and integration (Ethernet, TCP/IP, Field busses, OPC server, …)

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.AC800PEC control platform – hardware concept

Optical module

Backplane and mechanical carrier

Controller CPU module

Anybus-S Fieldbus module

24 Vdc safe Ethernet / TCP / IPControlIT integrationTools / PanelAnybusFieldbusRS232 / ModbusLow cost panel10 MBd POF 8 MBd ModulebusApplication I/Os

10 MBd POFPowerstage Link

Control platform-power supply for CPU & I/Os

- CPU & basic interfaces- fast I/Os

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AC800PEC control platform – software concept

Fast Applica-tions(Simulink) Very Fast

Applications(VHDL)

Slow Applications(IEC 61131)

Cycle time

Numberof signals

1 ms 1 µs100 µs

Control DevelopmentEngineering Application

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AC800PEC control platform – control software

� Today…

Automatic code generation with real time workshop

Development and Simulation withMatlab/Simulink +

Real-Time Simulationon Control platform

Observation, optimization and monitoring

20 ADD R1, R2CMP R1, #17

GOTO 20ADD R2, #12

� Yesterday…

Design, Simulate

Implement

Execute, Test

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� Outlook

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.Medium Voltage AC Drives

� DriveIT ACS 1000

� Air / Water 315 kW – 5 MW

� DriveIT ACS 6000

� Single Drives / Multidrives 3 – 27 MW

� LCI

� Air / Water 2 – 72 MW (or higher)

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ACS 1000 315 – 5’000 kW

� High reliability & availability

� High efficiency

� Retrofit ready

� Small footprint

� Typical applications: pumps, fans, conveyors, extruders, mixers, compressors, grinding mills

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ACS 1000 (water-cooled) 1.8 MW – 5 MW

Inverter stacks onswing frame for easyaccessibility Water Cooling

Application & motor controlboard with fast digital signalprocessor and DTC

IGCT power semiconductors

Output filter for smoothsinusoidal current andvoltage waveform

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ACS 6000 3 – 27 MW


� High efficiency

� Modular design

� Multi-drive topology

� Typical applications: High power single drives: pumps, extruders

Multi-drive applications: rolling mills, conveyors

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.ACS 6000 (water-cooled) 3 – 27 MW

Line Supply Unit 6- or 12-pulse diode rectifier unit

Terminal and Control Unit Contains the power terminalsand the control swing frame

Inverter UnitSelf-commutated, 6-pulse, 3-level voltage source inverter with IGCT PEBB technology

Capacitor Bank Unit DC capacitors for smoothing the intermediate DC voltage

Water Cooling Unit Supplies the closed cooling system withdeionized water for the main power components

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� PCS 500 – low voltage

� Water 0.5 – 2 / 4 MVA

� PCS1000 – medium voltage

� Water 2 – 5 MVA

� PCS 6000 – medium voltage

� Water 5 – 32 MVA

Power ConvertersA

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PCS 1000 2 - 5 MVA


� High efficiency

� Small footprint

� Typical applications: Wind Power, Network coupling

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PCS 6000 5 – 32 MVA


� High efficiency

� Small footprint

� Typical applications: Network coupling 50 / 60 / 16.7 Hz,STATCOMs, Energy Storage andWind Power

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.PCS 6000 - Railway Power Conversion

� Deutsche Bahn, Limburg

� 8 x 15 MVA

� Standardized container modules

� Swiss AlpTransit, Wimmis

� 4 x 20 MVA

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PlattsGlobal Energy

Award��

� ��

PCS 6000 - Battery Energy Storage System, Alaska

� The world‘s largestBattery Energy Storage System

� 27 MW / 15 min

� 40 MW / 7 min

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� Outlook

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Windpower Technology - with gearbox

Generator Gearbox

Propeller shaftVentilation

Yaw DriveSource: NORDEX

Brake

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.Windpower Technology - gearless

Yaw Drive

Direct Drive Generator Pitch System

Main BearingYaw BearingSource: Lagerwey

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Generator Types

Synchronous Generator Asynchronous - Generator

� variable speed possible in combination with converter-technology

� no gearbox necessary� production of reactive power

possible

� Simple construction� 2-speeds possible when using

double feeded generators� gearbox necessary

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Wind Turbines

Low Voltage disadvantages for the upper power range� Parallel connection of converters

� space

� Large cable size between generator and converter� costs

� Placing of converter and transformer into the nacelle � nacelle weight

0 1 2 3 4 5

U

P[MW]

Medium Voltage

Low Voltage

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50 – 100 MW Windpark

33kV 33kV

� Requires voltage regulation on 33 kV side accordingapplicable grid codes and fault ride through� Double fed induction generator in combination with STATCOM

� Full converter with simple PM generator (or IM)

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.PCS 6000 – Windpower STATCOM

� STATCOM for a 100 MW Windpark

VSC1

~

=

Wind generators

12.5 MVAPCS 6000

33kV

Wind generators

~3kV

VSC1

~

=12.5 MVAPCS 6000

~3kV

indoorinstalled insubstation

HarmonicFilter

13.5MVA 13.5MVA

HarmonicFilter

PCS 6000

16 MVA 16 MVA

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PCS 6000 – Windpower STATCOM

� STATCOM in TWIN topology (ABB Patent pending)

+

-

0

Voltage Phase 1, Terminal 1

0 0.2 0.4 0.6 0.8 1

1

0

1

Voltage Phase 1, Terminal 2

0 0.2 0.4 0.6 0.8 1

1

0

1

Voltage Twin, Phase 1

0 0.2 0.4 0.6 0.8 11

0

1

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PCS 6000 - Grid Coupling & STATCOM

� INCO, Indonesia

� 2 Static frequency converters

� Combination of STATCOM (32 MVA)and Grid coupling (18 MVA)

� Key features

� STATCOM functionality

� Compensation of asymmetrical loads

� Flicker compensation (arc furnaces)

� Power transfer between the two grids

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PCS 1000 - Medium voltage power conversion

� Wind turbines above 3 to 5 MW� Trend towards medium voltage

� Minimum component number → High reliability

� IGCT → best efficiency

� Trend towards full power converter� Weak grids → reduced stress on the gear box

� Brushless → Service Offshore

3

MC

B

Active RectifierUnit

InverterUnit

PMGen

DC-Link

4.0 kV

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.PCS 1000 - 4Q Medium Voltage IGCT-Converter

Standard PWM850 Hz @ slow turbine speed500 Hz @ fast turbine speed

Optimized Puls Pattern9 fold @ 50 Hz7 fold @ 60 Hz

3

Main CircuitBreaker

ClampClamp

Clamp Clamp

GeneratorFilter

Gen

GeneratorConverterDC LinkGrid

Converter

4.0 kV3.5 kV

GridFilter

Blocking Frequencyapprox. 1410 Hz A

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PCS1000 - Wind Power Converter Cabinet

Control DC-Link CoolingConverters

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Required Behavior during Grid Disturbances

� Keep on grid as specified

� Must not result in instability

� Feed highest possible current during grid short circuit

� Active power must resume immediately following fault clearing with specified gradient

� Feed highest possible inductive power to the grid for voltage support

Gradient >20%

Gradient >5%

Voltage limit curve of a grid fault to keep on grid

Source: E.ON Netz GmbH, Grid code for high and extra high voltage, Bayreuth, Germany, 09.01.2003

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Wind Power System Hybrid Simulator

� Based on 50 VA level with ±100V dc link voltage

� Real elements� Inductors / Capacitors / Resistors

� FET for power switches

� 4 quadrant amplifiers for sources

� Synchronous Generator with Turbine Model� Modeled on a real time processor

for the inner voltage

� Real inductor for the leakage reactance

LtG

RGK

LGK

Cd

Cd

3

MCB

SG3

SynchronousGeneratorDC LinkConverter B

Transformer50HzAC Grid50Hz Source Converter A

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.Wind Power System Hybrid Simulator

Grid Simulation

Generator / Turbine model

Control Panel Control System

Main Processing Unit

Generator Converter

Grid Converter

DC Link

Grid Transformer Grid Filter

Generator Filter

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Test Results for Single Phase Voltage Sags

Single phase voltage sag to 75% nominal

-347

Primary Grid Voltage [kV]

Primary Grid Current [A]

Grid Active Power [MW]Grid Reactive Power [MVAr]

23.0

347

2.0

-23.0

100ms/div

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Test Results for 3-Phase Voltage Sag

3-phase voltage sag to 0% nominal

Primary Grid Voltage [kV]

Primary Grid Current [A]

100ms/div

23.0

347

2.0

Grid Active Power [MW]Grid Reactive Power [MVAr]

-23.0

-347A

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� Outlook

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.Outlook

� ABB has successfully applied IGCT based medium voltage converter technology to multiple applications, i.e.� Medium Voltage drives� Power Converters for Grid Coupling,

Energy Storage and STATCOMs

� Windpower applications will benefit from this high volume medium voltage technology for� STATCOMs for Windparks� Full converter solutions

� ABB has introduced the medium voltage technology to the windpowermarket� 2 MW wind turbines are in operation� STATCOM functionality has been

proven in demanding industrial environment

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ABB_Wind Power Converter Technology Presentation

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Transcript of ABB_Wind Power Converter Technology Presentation