Abb_wind Power Converter Technology Presentation

Medium Voltage Frequency Converters for MW Windturbines Introduction Power Platforms (PEBBs) Power Semiconductors PEBBs

Medium Voltage Frequency Converters for MW Windturbines

Dr. Peter K. Steimer Vice President Power Electronics and Medium Voltage Drives

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

CH - 5300 Turgi

Medium Voltage Windpower Products

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Medium Voltage Frequency Converter Medium Voltage STATCOM

Power Electronics & Medium Voltage Drives Power Electronics

Outlook

Global Center of Competence

MV Drives

Total: ~ 900 Employees

Turgi

Excitation & Synchronizing Systems UNITROL® 1000 AVR UNITROL® F or 5000 SES SYNCHROTACT® 5

Dättwil

Power Plants Industrial Plants (motors) Substations

ABB Power Electronics ABB MV Drives

High Power Rectifiers

Aluminum Smelters Copper, Zinc, Chlorine

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Power Converters Static Frequency Converter up to 100 MW BORDLINE® Converters Power Quality Systems Utilities Rolling Stock OEM's

DriveIT ACS 1000 DriveIT ACS 6000 ACS 6000c LCI

0.3 - 5 MW 3 - 27 MW 14 - 27 MW 2 - 100 MW

Cement, Mining & Minerals Chemical, Oil & Gas Marine Metals f ~ M Pulp & Paper 3~ ~ f Power n Protection Water Control Excitation Water & Waste Converter Cooling

ABB Corporate Research

Machine Cooling

1

2

Standard Scope of Supply for a Drive System

Process

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Compact Rectifier Medium Current Rectifier Thyribloc® / Rectibloc® up to 200 kA / 1500 V

Power Electronics Triangle

Lenzburg ABB Semiconductors

Medium Voltage Frequency Converters for MW Windturbines

Power platform – key technologies

Introduction Power Platforms (PEBBs)

Innovative and competitive solutions in the energy processing technology are made possible by modern power platforms (PEBBs) based on:

Power Semiconductors PEBBs

Power semiconductors and their control (IGCT, IGBT, …)

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

Converter topologies (2-Level, 3-Level, Multilevel, AC/AC, ..) Thermal design (Thermal modeling, cooler design, corrosion resistance, …)

Medium Voltage Drives Power Conditioning Products

Passive components (Capacitors, inductors, transformers …)

Medium Voltage Windpower Products

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

Outlook

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Medium Voltage Frequency Converter Medium Voltage STATCOM

Low voltage IGBT module Econopack /SKiiP/LoPak Module

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

Medium voltage IGBT module 1200 V und 1700 V

IHV / HiPak Module (E1/E2)

Maximum blocking voltage

Maximum blocking voltage

75 – 450 A

1500 A, 1200 A, 600 A

Switching frequency (fPWM)

Switching frequency (fPWM)

Maximum phase current

Maximum phase current

1200 V: Typical 3..5 kHz

3300 V: Typical 1..2 kHz

Integration

Integration

Electrical insulation

Electrical insulation Up to 2 devices (dual pack)

Up to six switching devices

Loss-optimized

Loss-optimized

Soft Punch Through or

Soft Punch Through or

Trench

Copper base plate (EconoPack) Limited in thermal cycles

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Trench ABB Schweiz AG - 7 © 2004 ABB. All rights reserved.

2500 V, 3300 V and 6500 V

AlSiC base plate Traction Turn off 3x rating current (3300V IGBT)

Medium voltage power semiconductors: IGCT presspack IGCT Presspack

Medium voltage IGBT presspack IGBT Presspack

4500 V and 6000 V

2500 V and 4500 V

Maximum blocking voltage

Maximum blocking voltage

150 – 2000 A

600 – 2000 A

Maximum phase current

Maximum phase current

Switching frequency (fPWM)

Switching frequency (fPWM)

2500 V: typical 1 – 2 kHz

Typical 0.5 – 1 kHz Ia (kA) Vdm

anode voltage Vd

4

4

Itg

3

q

anode current Ia

2 thyristor

1

x

transistor

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Gate unit Transparent Anode

2

Thyristor-based Short circuit

di/dt – snubber

gate voltage Vg

Vg (V)

1.5

2.0

2.5

3.0

Loss-optimized Soft Punch Through or Trench

Presspack

starts to block

-20

Single device

Loss-optimized

0

-10

Integration

3

1

0

4500 V: typical 0.5 – 1 kHz

Integration

di/dt of diode

3.5 t (µ s)

Turn-off Power semiconductors

Presspack

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Vd (kV)

Short circuit

Turn-off power semiconductors 200 kV

Power Scalability

IGBT Presspack

LV & MV

MV

MV & HV.

1 – 5 MW Parallel

(up to 15 kV)

(up to +/- 150kV)

5 – 100 MW

50 – 300 MW

Parallel & Series (with snubber)

Parallel & Series

Medium

Low

Medium

Costs / kVA

Low

Low

Medium

Failure type

Open (Plasma)

Short-circuit

Losses

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IGCT Presspack

LV drives Traction Power Quality

MV drives Interties FACTS

Short-circuit HVDC light

15 kV

IGCT Presspack

7.2kV

HVIGBT Module

2.3 kV ABB Schweiz AG - 12 © 2004 ABB. All rights reserved.

Application

IGBT Modul

IGBT Presspack

690 V

LVIGBT Module 0

1MVA

10 MVA

100 MVA

PEBB concepts (IEEE WG PEBB TF2)

PEBB functionality and interfaces

System control

System control

Application Control

Application control

Application control

10 µs..1ms

PLL, αβ ↔ dq Transformations id / iq current control

Converter Control

PLL, αβ ↔ dq Transformations id / iq current control

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

Application Control

1ms..1s..

- overriding control & measurements

- overriding control & measurements

1ms..1s..

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

10 µs..1ms

Serial Bus

6

A / D & D/A

A / D & D/A

Gate drives & device protection ABB Schweiz AG - 13 © 2004 ABB. All rights reserved.

VDC1 T

FB

1..6

IA/B/C VA/B/C (optional)

V

- Modulator - Converter switching logic - 2nd level protection

1..10 µs

PEBB

0.1..1 µs

- 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

Converter switching logic

2nd level protection

V

IGBT (module) PEBB

Configuration & diagnostics

2nd level protection

Modulator

PEBB Control

6

A / D & D/A

A / D & D/A

Gate drives & device protection VDC1 T ABB Schweiz AG - 14 © 2004 ABB. All rights reserved.

Configuration & diagnostics

Modulator Converter switching logic

FB

1..6

IA/B/C VA/B/C (optional)

V

- Modulator - Converter switching logic - 2nd level protection

1..10 µs

PEBB

0.1..1 µs

- 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

V

Power Plattform

IGCT (presspack) PEBB

Low-voltage IGBT module power platform

Medium voltage IGCT presspack power platform

2-Level topology, 0.6 MVA power, 400..690 VLL

3-Level topology, 9 MVA power stack, 3300..4160 VLL

1200 V and 1700 V IGBT modules, water-cooled

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

Mechanically integrated dc link

Up to two mechanically integrated phase components

Configurable regarding AC outputs (number and amperage) Integrated current and voltage measurement

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= ABB Schweiz AG - 15 © 2004 ABB. All rights reserved.

PEBB Control

IGBT (Presspack) PEBB

Innovative Technology from Wind to Grid

High voltage IGBT presspack power platform 2-Level topology, series connection up to +/- 150 kVdc 2500 V IGBT, water-cooled (de-ionized)

Conventional HVAC

Same transmission capacity

Up to 20 elements per stack

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.

HVAC with Reactive Power Compensation

HVDC

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2.5kV, 1000-1500 ARMS

Medium Voltage Frequency Converters for MW Windturbines

Innovative and competitive solutions in the energy processing technology are made possible by modern control platforms based on:

Power Semiconductors PEBBs

Digital electronics (Power PC / DSP / FPGA / ASIC …)

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

Real time operating systems (VxWorks, Linux RT, ..) Programming tools (VHDL / Matlab / Simulink / IEC 1131 /…)

Medium Voltage Drives Power Conditioning Products

Control algorithms (DTC, d/q-axes control, Observers, …) Communications and integration (Ethernet, TCP/IP, Field busses, OPC server, …)

Medium Voltage Windpower Products

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Medium Voltage Frequency Converter Medium Voltage STATCOM ABB Schweiz AG - 19 © 2004 ABB. All rights reserved.

IGBT = Integrated Gate Bipolar Transistor

Control platform – key technologies

Introduction Power Platforms (PEBBs)

Outlook

HVDC Light

AC800PEC control platform – software concept

AC800PEC control platform – hardware concept 24 Vdc safe Control platform -power supply for CPU & I/Os - CPU & basic interfaces - fast I/Os

Ethernet / TCP / IP ControlIT integration Tools / Panel Anybus Fieldbus RS232 / Modbus Low cost panel 10 MBd POF 8 MBd Modulebus Application I/Os

Engineering Application

Number of signals

Backplane and mechanical carrier

10 MBd POF Powerstage Link

Control Development

Slow Applications (IEC 61131) Fast Applications (Simulink)

Anybus-S Fieldbus module

Very Fast Applications (VHDL)

Optical module

AC800PEC control platform – control software Today…

Yesterday…

20 ADD R1, R2 CMP R1, #17 GOTO 20 ADD R2, #12

1 µs

Power Semiconductors PEBBs

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

Automatic code generation with real time workshop

Medium Voltage Windpower Products Medium Voltage Frequency Converter Medium Voltage STATCOM ABB Schweiz AG - 24 © 2004 ABB. All rights reserved.

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Execute, Test

100 µs

Introduction Power Platforms (PEBBs)

Development and Simulation with Matlab/Simulink +

Design, Simulate

Observation, optimization and monitoring

1 ms

Medium Voltage Frequency Converters for MW Windturbines

Real-Time Simulation on Control platform

Implement

Cycle time

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Controller CPU module

Outlook

Medium Voltage AC Drives

ACS 1000

DriveIT ACS 1000

315 – 5’000 kW

High reliability & availability

Air / Water 315 kW – 5 MW

DriveIT ACS 6000

High efficiency

Single Drives / Multidrives 3 – 27 MW

Retrofit ready

LCI

Small footprint

Air / Water 2 – 72 MW (or higher)

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

ACS 6000

ACS 1000 (water-cooled) 1.8 MW – 5 MW Application & motor control board with fast digital signal processor and DTC

Inverter stacks on swing frame for easy accessibility

3 – 27 MW

High reliability & availability

IGCT power semiconductors Water Cooling

High efficiency Modular design Multi-drive topology Typical applications: High power single drives: pumps, extruders

Output filter for smooth sinusoidal current and voltage waveform

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Multi-drive applications: rolling mills, conveyors

ACS 6000 (water-cooled) Line Supply Unit 6- or 12-pulse diode rectifier unit

3 – 27 MW

Power Converters

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

Capacitor Bank Unit DC capacitors for smoothing the intermediate DC voltage

PCS 500 – low voltage Water 0.5 – 2 / 4 MVA

PCS1000 – medium voltage Water 2 – 5 MVA PCS 6000 – medium voltage

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PCS 1000

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

2 - 5 MVA

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

PCS 6000

High reliability & availability

High reliability & availability

High efficiency

High efficiency

Small footprint

Small footprint

Typical applications: Wind Power, Network coupling

Typical applications: Network coupling 50 / 60 / 16.7 Hz, STATCOMs, Energy Storage and Wind Power

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Water 5 – 32 MVA

5 – 32 MVA

PCS 6000 - Railway Power Conversion

PCS 6000 - Battery Energy Storage System, Alaska

Deutsche Bahn, Limburg

The world‘s largest Battery Energy Storage System

8 x 15 MVA Standardized container modules

27 MW / 15 min 40 MW / 7 min

Platts Global Energy Award

Swiss AlpTransit, Wimmis

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4 x 20 MVA

Medium Voltage Frequency Converters for MW Windturbines

Windpower Technology - with gearbox

Introduction Power Platforms (PEBBs)

Ventilation

Brake

Propeller shaft

Power Semiconductors PEBBs

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

Medium Voltage Windpower Products

Outlook

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Medium Voltage Frequency Converter Medium Voltage STATCOM

Generator

Gearbox

Yaw Drive Source: NORDEX

Windpower Technology - gearless

Generator Types Pitch System

Yaw Bearing Yaw Drive Main Bearing Source: Lagerwey

Wind Turbines

Synchronous Generator

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Direct Drive Generator

Simple construction 2-speeds possible when using double feeded generators gearbox necessary

50 – 100 MW Windpark Requires voltage regulation on 33 kV side according applicable grid codes and fault ride through

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

Double fed induction generator in combination with STATCOM

Large cable size between generator and converter costs

Full converter with simple PM generator (or IM)

Placing of converter and transformer into the nacelle nacelle weight

U

33kV

Medium Voltage

0

1

2

3

4

5

P [MW]

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Low Voltage

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variable speed possible in combination with convertertechnology no gearbox necessary production of reactive power possible

Asynchronous - Generator

33kV

PCS 6000 – Windpower STATCOM

PCS 6000 – Windpower STATCOM

STATCOM for a 100 MW Windpark

STATCOM in TWIN topology (ABB Patent pending) Voltage Phase 1, Terminal 1

1

33kV

0

+ Wind generators

Wind generators

1 0

0.4

0.6

0.8

1

0

13.5MVA

13.5MVA

0.2

Voltage Twin, Phase 1 1

~3kV

~ VSC1 =

PCS 6000 indoor installed in substation

12.5 MVA 16 MVA PCS 6000

~

0

Harmonic Filter

VSC1 =

12.5 MVA 16 MVA PCS 6000

PCS 6000 - Grid Coupling & STATCOM

1 0

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Harmonic Filter

~3kV

0.2

0.4

0.6

0.8

Voltage Phase 1, Terminal 2

1

0

1 0

0.2

0.4

0.6

0.8

1

PCS 1000 - Medium voltage power conversion Wind turbines above 3 to 5 MW

INCO, Indonesia

Trend towards medium voltage

2 Static frequency converters

Minimum component number → High reliability

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

IGCT → best efficiency

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

Key features

Brushless → Service Offshore

STATCOM functionality

Active Rectifier Unit

Compensation of asymmetrical loads

DCLink

Inverter Unit

Flicker compensation (arc furnaces) 3

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MCB

Power transfer between the two grids

PM Gen 4.0 kV

1

PCS 1000 - 4Q Medium Voltage IGCT-Converter

PCS1000 - Wind Power Converter Cabinet

Optimized Puls Pattern 9 fold @ 50 Hz 7 fold @ 60 Hz

Standard PWM

850 Hz @ slow turbine speed 500 Hz @ fast turbine speed

Grid Converter

DC Link Clamp

Clamp

Grid Filter

Main Circuit Breaker

Generator Converter Generator Filter

3.5 kV

DC-Link

Cooling

4.0 kV

Clamp

Clamp

Blocking Frequency approx. 1410 Hz

Required Behavior during Grid Disturbances

Wind Power System Hybrid Simulator

Keep on grid as specified

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

LtG MCB

Must not result in instability

Cd

LGK

3

RGK

Feed highest possible current during grid short circuit

SG

Cd

3

Active power must resume immediately following fault clearing with specified gradient

50Hz Source

AC Grid

Transformer 50Hz

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

Feed highest possible inductive power to the grid for voltage support

Real elements Inductors / Capacitors / Resistors ABB Schweiz AG - 48 © 2004 ABB. All rights reserved.

Gradient >20%

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Converters

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Control

Gen

3

FET for power switches 4 quadrant amplifiers for sources

Converter B

DC Link

Converter A

Synchronous Generator

Synchronous Generator with Turbine Model Modeled on a real time processor for the inner voltage Real inductor for the leakage reactance

Wind Power System Hybrid Simulator

Test Results for Single Phase Voltage Sags

Generator Converter

Primary Grid Voltage [kV]

23.0

100ms/div

DC Link Grid Converter -23.0 Primary Grid Current [A]

347

-347

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

Grid Simulation

Control Panel

Generator / Turbine model

Control System

Main Processing Unit

Generator Filter Grid Transformer

Grid Filter

Test Results for 3-Phase Voltage Sag 23.0

Primary Grid Voltage [kV]

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2.0

Medium Voltage Frequency Converters for MW Windturbines 100ms/div

Introduction Power Platforms (PEBBs) Power Semiconductors PEBBs

-23.0

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

Primary Grid Current [A]

347

Medium Voltage Drives Power Conditioning Products

-347

Medium Voltage Windpower Products

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

Medium Voltage Frequency Converter Medium Voltage STATCOM

3-phase voltage sag to 0% nominal

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2.0

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Single phase voltage sag to 75% nominal

Outlook

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

2 MW wind turbines are in operation STATCOM functionality has been proven in demanding industrial environment

ABB Schweiz AG - 54 © 2004 ABB. All rights reserved.

ABB Schweiz AG - 53 © 2004 ABB. All rights reserved.

ABB has introduced the medium voltage technology to the windpower market