A

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B

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1
-

2
0
0
2

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B
B
.

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Medium Voltage
Frequency Converters
for MW Windturbines
Dr. Peter K. Steimer
Vice President
Power Electronics and
Medium Voltage Drives
CH - 5300 Turgi
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Medium Voltage Frequency Converters for MW Windturbines
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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-

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Power Electronics & Medium Voltage Drives
Process
MM
3 ~ 3 ~
f1
f2
~
~
Converter
Cooling
Machine
Cooling
Protection Protection Control Control Excitation Excitation
n
Process
MM
3 ~ 3 ~
f1
f2
~
~
Converter
Cooling
Machine
Cooling
Protection Protection Control Control Excitation Excitation
n
Standard Scope of Supply for a Drive System
Process
MM
3 ~ 3 ~
f1
f2
~
~
Converter
Cooling
Machine
Cooling
Protection Protection Control Control Excitation Excitation
n
Process
MM
3 ~ 3 ~
f1
f2
~
~
Converter
Cooling
Machine
Cooling
Protection Protection Control Control Excitation Excitation
n
Standard Scope of Supply for a Drive System Standard 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
MediumCurrent Rectifier
Thyribloc

/ Rectibloc

up to 200 kA / 1500 V
Aluminum Smelters
Copper, Zinc, Chlorine
Static Frequency Converter
up to 100 MW
BORDLINE

Converters
Power Quality Systems
Utilities
Rolling Stock OEM's
Drive
IT
ACS 1000 0.3 - 5 MW
Drive
IT
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 Competence
Total: ~ 900 Employees
ABB Power Electronics
ABB MV Drives
Turgi
ABB Corporate Research
Dttwil
ABB Semiconductors
Lenzburg
Power Power
Electronics Electronics
Triangle Triangle
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.
Medium Voltage Frequency Converters for MW Windturbines
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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4
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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 A
Maximum phase current
Switching frequency (f
PWM
)
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 V
Maximum blocking voltage
1500 A, 1200 A, 600 A
Maximum phase current
Switching frequency (f
PWM
)
3300 V: Typical 1..2 kHz
Integration
Electrical insulation
Up to 2 devices (dual pack)
Loss-optimized
Soft Punch Through or
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
150 2000 A
Maximum phase current
Switching frequency (f
PWM
)
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
I
a
(kA)
V
dm
I
tg
q
4
3
2
1
0
-10
-20
V
g
(V)
2
3
0
anode voltage V
d
anode current I
a
gate voltage
V
g
thyristor transistor x
starts to block
V
d
(kV)
2.0 1.5 3.0 2.5 3.5 t ( s)
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Medium voltage IGBT presspack
IGBT Presspack
2500 V and 4500 V
Maximum blocking voltage
600 2000 A
Maximum phase current
Switching frequency (f
PWM
)
2500 V: typical 1 2 kHz
4500 V: typical 0.5 1 kHz
Integration
Single device
Loss-optimized
Soft Punch Through or
Trench
Presspack
Short circuit
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IGBT Presspack
Medium
Turn-off Power semiconductors
Costs / kVA
IGCT Presspack
Low Low
Application
MV & HV.
(up to +/- 150kV)
MV
(up to 15 kV)
LV & MV
Medium
Losses Low Medium
IGBT Modul
Scalability Parallel & Series
Parallel & Series
(with snubber)
Parallel
Short-circuit Failure type Short-circuit Open (Plasma)
LV drives MV drives HVDC light
Traction Interties
Power Quality FACTS
50 300 MW Power 5 100 MW 1 5 MW
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IGBT
Presspack
Turn-off power semiconductors
0 1MVA 10 MVA 100 MVA
200 kV
15 kV
7.2kV
2.3 kV
690 V
LVIGBT
Module
HVIGBT
Module
IGCT
Presspack
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PEBB concepts (IEEE WG PEBB TF2)
I
A/B/C
V
A/B/C
(optional)
1..6 V
DC1
T
V
V
Gate drives &
device protection
FB
PEBB Control
- Modulator
- Converter switching logic
- 2
nd
level protection
PEBB
- Stack or module assembly
- Snubbers for safe commutation
- Gate drives & feedbacks
- 1
st
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
2
nd
level
protection
Modulator
PLL, dq Transformations
id / iq current control
Application control
Converter Control
- PLL synchronization
- dq Transformations
- id- and iq current control
Application Control
- overriding control & measurements
A / D & D/A
0.1..1 s
1..10 s
10 s..1ms
6
C
o
n
f
i
g
u
r
a
t
i
o
n
&

d
i
a
g
n
o
s
t
i
c
s
1ms..1s..
System control
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Power Plattform
I
A/B/C
V
A/B/C
(optional)
1..6 V
DC1
T
V
V
Gate drives &
device protection
FB
PEBB Control
- Modulator
- Converter switching logic
- 2
nd
level protection
PEBB
- Stack or module assembly
- Snubbers for safe commutation
- Gate drives & feedbacks
- 1
st
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
2
nd
level
protection
Modulator
PLL, dq Transformations
id / iq current control
Application control
Converter Control
- PLL synchronization
- dq Transformations
- id- and iq current control
Application Control
- overriding control & measurements
A / D & D/A
0.1..1 s
1..10 s
10 s..1ms
6
C
o
n
f
i
g
u
r
a
t
i
o
n
&

d
i
a
g
n
o
s
t
i
c
s
1ms..1s..
System control
Serial
Bus
PEBB functionality and interfaces
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IGBT (module) PEBB
Low-voltage IGBT module power platform
2-Level topology, 0.6 MVA power, 400..690 V
LL
1200 V and 1700 V IGBT modules, water-cooled
Mechanically integrated dc link
Configurable regarding AC outputs (number and amperage)
Integrated current and voltage measurement
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IGCT (presspack) PEBB
Medium voltage IGCT presspack power platform
3-Level topology, 9 MVA power stack, 3300..4160 V
LL
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 A
RMS
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Innovative Technology from Wind to Grid
HVDC Light
HVDC
HVAC with Reactive
Power Compensation
Conventional HVAC
S
a
m
e

t
r
a
n
s
m
i
s
s
i
o
n

c
a
p
a
c
i
t
y
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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Medium Voltage Frequency Converters for MW Windturbines
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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B
B
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0
-

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0
0
4
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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 / IP
Control
IT
integration
Tools / Panel
Anybus
Fieldbus
RS232 / Modbus
Low cost panel
10 MBd POF
8 MBd Modulebus
Application I/Os
10 MBd POF
Powerstage 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
Number
of
signals
1 ms 1 s 100 s
Control Development Engineering Application
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AC800PEC control platform control software
Today
Automatic code
generation with real time
workshop
Development and
Simulation with
Matlab/Simulink +
Real-Time Simulation
on Control platform
Observation,
optimization
and
monitoring
20 ADD R1, R2
CMP R1, #17
GOTO 20
ADD R2, #12
Yesterday
Design, Simulate
Implement
Execute, Test
A
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Medium Voltage Frequency Converters for MW Windturbines
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
A
B
B
S
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w
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2
5
-

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0
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4
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Medium Voltage AC Drives
Drive
IT
ACS 1000
Air / Water 315 kW 5 MW
Drive
IT
ACS 6000
Single Drives / Multidrives 3 27 MW
LCI
Air / Water 2 72 MW (or higher)
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ACS 1000 315 5000 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 on
swing frame for easy
accessibility
Water Cooling
Application & motor control
board with fast digital signal
processor and DTC
IGCT power semiconductors
Output filter for smooth
sinusoidal current and
voltage waveform
A
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B
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ACS 6000 3 27 MW
High reliability &
availability
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 terminals
and the control swing frame
Inverter Unit
Self-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 with
deionized water for
the main power
components
A
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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 Converters
A
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PCS 1000 2 - 5 MVA
High reliability &
availability
High efficiency
Small footprint
Typical applications:
Wind Power, Network coupling
A
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B
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PCS 6000 5 32 MVA
High reliability &
availability
High efficiency
Small footprint
Typical applications:
Network coupling 50 / 60 / 16.7 Hz,
STATCOMs, Energy Storage and
Wind Power
A
B
B
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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
A
B
B
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Platts
Global Energy
Award
Energ, Eng|neer|ng
Proecr ol rne Year
PCS 6000 - Battery Energy Storage System, Alaska
The worlds largest
Battery Energy Storage System
27 MW / 15 min
40 MW / 7 min
A
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Medium Voltage Frequency Converters for MW Windturbines
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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Windpower Technology - with gearbox
Generator Gearbox
Propeller shaft
Ventilation
Yaw Drive
Source: NORDEX
Brake
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Windpower Technology - gearless
Yaw Drive
Direct Drive Generator Pitch System
Main Bearing Yaw Bearing
Source: 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 according
applicable 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 MVA
PCS 6000
33kV
Wind generators
~3kV
VSC1
~
=
12.5 MVA
PCS 6000
~3kV
indoor
installed in
substation
Harmonic
Filter
13.5MVA
13.5MVA
Harmonic
Filter
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 1
1
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
M
C
B
Active Rectifier
Unit
Inverter
Unit
PM
Gen
DC-
Link
4.0 kV
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PCS 1000 - 4Q Medium Voltage IGCT-Converter
Standard PWM
850 Hz @ slow turbine speed
500 Hz @ fast turbine speed
Optimized Puls Pattern
9 fold @ 50 Hz
7 fold @ 60 Hz
3
Main Circuit
Breaker
Clamp Clamp
Clamp Clamp
Generator
Filter
Gen
Generator
Converter
DC Link
Grid
Converter
4.0 kV
3.5 kV
Grid
Filter
Blocking Frequency
approx. 1410 Hz
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PCS1000 - Wind Power Converter Cabinet
Control DC-Link Cooling Converters
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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
L
tG
R
GK
L
GK
C
d
C
d
3
MCB
SG
3
Synchronous
Generator DC Link Converter B
Transformer
50Hz
AC Grid 50Hz 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 GridVolt age [kV]
Primary GridCurrent [A]
GridActive Power [MW]
Grid React ive 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 GridVolt age [kV]
Primary GridCurrent [A]
100ms/div
23.0
347
2.0
GridAct ive Power [MW]
Grid React ive Power [MVAr]
-23.0
-347
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Medium Voltage Frequency Converters for MW Windturbines
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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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 windpower
market
2 MW wind turbines are in operation
STATCOM functionality has been
proven in demanding industrial
environment
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