Professional Documents
Culture Documents
Keywords
«AC/AC converter», «Converter circuit», «Current source inverter (CSI)», «Cyclo converter (CC)»,
«Drive», «Multilevel converters», «Variable speed drive», «Voltage Source Inverters (VSI)»
Abstract
The paper gives an overview over high power medium voltage drive inverters in the range between
one and one hundred megawatts. First the applications and their key requirements are summarized.
Then the available power semiconductors and the different inverter circuit topologies with their diffe-
rent properties, advantages and drawbacks are presented. The key features are compared and suitable
converter types for the applications and industry branches are identified. Finally, future trends of
technology, manufacturing and market are outlined.
Introduction
Medium voltage inverters in the megawatt range are not just standard products but - together with
further components - parts of drive systems or of energy conversion systems. The applications in va-
rious industry sectors require different performance features from the drive system and from the power
converter. The converter circuit also has to fit to the specific motors, like dc motor, induction motor or
synchronous motor - with permanent magnets or separately excited. Therefore different circuit topolo-
gies, like cycloconverters, matrix inverters, voltage source inverters, cellular inverters, current source
inverters, load commutated inverters have been established to fulfill the requirements in an economic
way.
Requirements on MV Drives
If we look at the variable speed drive applications in the megawatt range, we find them mainly in the
basic material industry sector, that is mainly process industry, energy and ship propulsion and traction.
Table I shows a list of converter applications according industry branches and the respective power
ranges. This table includes the non-rotating converter applications for power grid energy conversion,
but not the traction applications.
To understand the different requirements for the drives we look at the type of business that is usual
within that high power range. It is not a product or system business, but rather a project, solution or
plant business.
Business Customer
The drive inverter is not directly sold to the
Product: System: Project: Solution: Plant: Factory:
operating company, but instead to a system
integrator, a plant constructor or a Inverter, Inverter, Drivepackage Industry Mechanical
Inverter, Inverter,
Complete - Industry sector Mech. sys., Building,
Control Control, with erection sector System,
cl.-loop ctrl, and
cl.-loop ctrl Motor, drive, technology electrical, plant,
machinery OEM. There is no company that motor
Technolog
with comm. Control
. Electrical
auxiliaries logistics
Transf. Commission. Auxiliaries
can supply the complete equipment from its
own manufacturing. That means, that the System integrator, plant builder
Opera-
decision for or against a specific drive Drive inv.
manufacturer ting
technology is made jointly between the com-
Machinery OEM pany,
parties involved, each having different process
priorities, including not only technical industry
The different key-requirements of the main applications in the industry sectors are listed in Table II.
Those requirements lead to the different main application fields for the specific circuit topologies that
fulfil the requirements (s. Tab. VI).
Power Semiconductors
The available power semiconductors are mainly turn-off devices up to high power ratings. The ultra
high power area is still covered by the thyristors, which can only turn-on and need commutation by the
power circuit (s. Fig. 3).
GTO
IGCT
HV-IGBT
where no. 1 and 5 to 8 are state of the
art for medium voltage converters.
1000 LV-IGBT
15 MW
1. SCR line- and load-commutated
7 MW
2. SCR pulsed with commutation 4 MW
in 1 MW
circuit y
nc z)
e 0.01
3. LV-IGBT (replacing SCR up to qu (kH
fre es 100 1000 10 000
e iv 0.1
some MW) ls dr
Pu he
4. GTO, S-GTO (replacing SCR) t
1
Current that can be
5. HV-IGBT (replacing SCR, GTO, Trend turned-on/turned-off (A)
10
LV-IGBT)
6. IGCT (replacing GTO) Fig. 3: Power Semiconductors
7. SGCT (replacing SCR and S-GTO)
8. IEGT, PPI (competing with IGCT)
HV-IGBT
low control Insulated Gate main stream
energy, high Bipolar Transistor
switching PPI Press Pack IGBT Press Packed Yes Low High
frequency (single source)
IEGT Injection High ratings No Medium Medium
Enhanced IGBT (single source)
Current driven GTO Gate Turn Off Needs big No High Low
turn-on/-off Thyristor snubber
technology, IGCT Integrated Gate High ratings, No Medium Low
high ratings, Commutated main stream
Thyristor
low Thyristor
conducting SGCT Symmetrical Gate Reverse block- No Medium Low
losses Commutated ing, for CSI
Thyristor
Only turn-on, SCR Silicon Controlled Needs No Low Low
very high Rectifier commutation
ratings (= Thyristor)
*) including snubber circuit losses
Current Source Inverters have inductive Star Open [M3] TFE AFE DFE AFE TFE
energy storage by a dc current link between
the input converter and the output inverter.
Fig. 4: Types of AC Drive Inverters.
Voltage Source Inverters have capacitive TFE: Thyristor Front End, AFE Active Front End,
energy storage by a dc voltage link between DFE: Diode Front End. [Matrix]: Not a MV Product.
the input converter and the output inverter.
Cycloconverters (CC)
A cycloconverter consists of 3
antiparallel connected SCR-bridges
that work like dc converters and vary •
the output voltage according to a sine
wave with the desired fundamental
frequency. By this maximum output
frequencies of 45 % of the line
frequency are possible with a toler-
able harmonic content. 4-quadrant
operation is obligatory. Reactive motor current
current from the line is required 0,12 0,14 0,16 0,18 0,20 0,22
The dynamic behaviour of the cycloconverter is excellent. The rated voltage designs of transformer,
converter and motor have to be considered as a system design.
The open circuit needs more motor cables but only one transformer and has design advantages at high
dynamic and overload applications. High
overload systems are realized air cooled,
steady state applications above 5 MW with a
water cooling system. So the cycloconverter is
used best for low speed applications. The
efficiency is very high due to the direct energy Thyristors
There is no additional voltage stress on the motor winding and virtually no limitation of cable lengths
– like it is at Voltage Source Inverters (VSI). For increasing the rated power many SCRs can easily be
connected in series – with additional elements for redundancy – and two complete circuits are
operated in parallel – getting lower harmonics in line and motor currents.
Again the efficiency and the reliability are extremely high due to the simple and high rated power
elements. The LCI is used best for general purpose 2Q and 4Q applications and for extremely high
power ratings up to 100 MW. In some cases line filters are necessary to reduce the current harmonics
and to supply the needed reactive line power.
The air cooled version of the LCI is used to start up synchronous machines and power generators that
are normally operated directly at the power grid. The start-up inverters are rated from 3 to 15 MW, the
respective motors about three times higher.
Pulsed Current Source Inverters (CSI)
The pulsed current source inverter is equipped
with turn-off elements that operate with a M
pulse-width modulation to generate sinusoidal
output currents. Therefore filter capacitors are
necessary at the inverter output. Since the
semiconductor elements must block reverse
voltage, S-GTOs and SGCTs are used. The
input converter feeding the dc inductor can be
Motor
either a SCR-bridge (TFE) like with the LCI or Current
a pulsed bridge (AFE) like the motor side
inverter, which implicates additional input
filter capacitors. Motor
Voltage
The pulsed CSI is best used for general purpose 2Q and 4Q applications together with a standard
induction motor. Thanks to the sinusoidal motor voltage and current there is no additional voltage
stress on the motor, long cables are allowed
and torque ripple and motor losses are low. line-side 3-level
inverter
rectifier dc link
Using a TFE there are the line side
disadvantages as known from dc converters. +
Cellular Inverters M
The cellular inverter has only a 2-quadrant Fig. 11: Cellular Inverter
capability, but features a good harmonic
behaviour at the power grid, due to the multi phase shift of the input transformer, which has to be
specially designed. The motor losses are low with no need of an output filter.
The cellular inverter is used best for general purpose and high speed applications in a power range of 1
– 15 MVA however it is promoted also for much higher power ratings. While a proper reliability is
only achieved with the redundance equipment for the high component count, the cost for replacing
failed cells has to be taken into account.
past: 1-20 MVA
Comparison of the Inverter LCI (SCR)
today 10–100 MVA
CSI (SCR)
Concepts Cellular (LV-IGBT)
Looking back over the past 25 years we NPC (GTO)
see that inverter concepts have been CSI (GTO) 1 – 15 MVA
developed according to the availability of NPC (HV-IGBT, IGCT)
improved power semiconductors (s. Fig.
CSI (SGCT)
12, Fig. 13).
today time
Table V shows a comparative overview Fig. 12: History of General Purpose inverters
over medium voltage inverter concepts. It
is obvious that the elder, simpler and long DC (SCR)
improved concepts LCI and CC with SCRs CC (SCR)
are cost effective and most reliable, but they NPC (GTO) 3 – 30 MVA
have disadvantages concerning the line NPC (IGCT, IEGT)
reactions, that however are either not
relevant having a strong power grid or can today time
be effectively cleared by a line filter. The Fig. 13: History of High Dynamic 4Q inverters
Manufacturing Trends: As said above, the suppliers will go on standardizing their product portfolio by
reducing the variety of platforms and technologies built, this by cooperating with partners, since the
absolute quantities of sold pieces are still low, compared with the increasing R&D and engineering
cost.
Market Trends: The market demands ultra high reliability and availability in operation at reduced
invest cost. There is an increasing demand for inverters with no line reactions on the power grid,
which means the inverters with turn-off devices (mainly VSI, also CSI) will replace the thyristor
inverters (LCI and CC) to a certain extent, coming from low power upwards. There are upcoming
markets by new applications, for instance gearless high speed drives are replacing gas turbines for gas
compression (pipelines, LNG stations). Furthermore power conversion applications are coming up
using medium voltage inverters (wind turbines, line coupling, static var compensation). Future
challenges are sub-sea sataions for gas compressors and pumps.
Conclusions
Because of different requirements of the various applications and the different performance properties
of the power electronic topologies, there are still several different medium voltage drive concepts in
the market. However all applications can be covered by a certain selection of topologies.
The voltage source inverters are coming up to higher power ratings, but the thyristor inverters are still
state of the art for low speed (cyclo converter) and very high power applications (LCI inverter). The
SCR-inverters are most cost effective and most reliable.
The drive system consisting of motor, inverter, transformer / filter, cables and auxiliaries, has to be
carefully integrated and adapted on the application by a competent supplier or system integrator. In
case of competing inverter types not only the properties of the circuit topology, but also the overall
project items incl. price decide which solution gets chosen.
References
[1] F. Kleiner, B. de Wit, B. Ponick: "Choosing Electric Turbocompressor Drives", IEEE Industry Applications
Magazine, Vol. 7, No. 4, Jul/Aug 2001, pp 45-52
[2] M. Ruff, R. Sommer, G. Zaiser: "Voltage source inverter in the medium voltage range", EPE-PEMC 2002,
Dubrovnik & Cavtat
[3] ASI-Robicon Industrial Power Control: Brochure on “Perfect Harmony Series”
[4] Rockwell Automation: Brochure on “PowerFlex 7000”
[5] R.-D.Klug, A.Mertens: „Reliability of Megawatt Drive Concepts“, ICIT2003, Maribor, Slovenia, pp.636-641
[6] U.Putz, W. Schulz, Alstom: “Mehrstufen-Wechselrichter in der Leistungselektronik”, ETG-Info 2003
E P E 2 0 0 5 - D r eI Ss dB eN n : 9 0 - 7 5 8 1 5 - 0P 8. -1 50