HIGH POWER DRIVES

Prof.V.T.Ranganathan Dept. of Electrical Engineering Indian Institute of Science

PROF.V.T.RANGANATHAN

Medium Voltage Drives: Motor voltages: 2.3kV, 3.3kV,4.16kV, 6.3kV, 6.9kV Requirements: Availability: 99.9% Efficiency: > 97% Input PF: > 0.98 at all speeds On The Fly Start: YES Regeneration:Not always needed
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Desirable: Easy to install, minimum cabling Possibility of locating transformer outside converter room Retrofit on existing normal motors No limit on cable length to motor
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MV Drive Configurations:

Induction Motor

Synchronous Motor

Slip Ring Motor

VSI CSI

CSI LCI Cyclo Converter

CSI VSI (Kramer) Scherbius

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APPLICATION TYPES

SLOW RESPONSE
FANS PUMPS COMPRESSORS

FAST RESPONSE
CRANES HOISTS WINDERS COILERS ROLLING MILLS PAPER MILLS

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Induction Motor Drives: From 0.5 MW up to 5MW

Synchronous Motor Drives: From 3 MW up to 100MW Slip Ring Induction Motors: From 0.1MW to 10s of MW

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Information from ABB website

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Information from ABB website

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Information from ABB website

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DEVICES USED IN DIFFERENT CONFIGURATIONS

VSIs ------ IGBTs ----- up to 6.5Kv, 600A more commonly 3.3kV, 800/900A IGCTs ------ up to 5.5kV, 900A

LCIs -------- SCRs ------ up to 4.5kV,3000A

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IGBT Vs IGCT IGBT Voltage Gate drive Voltage drop Lower(<3.3 kV) Easier Higher for high voltage ratings Hard IGCT Higher Complex Smaller for similar rating Easier

Series connection

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Two Level Inverter Configuration

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SINE-TRIANGLE PWM FOR 2-LEVEL INVERTERS

Vp Vref

Vdc __ 2 Ton

__ - Vdc 2

Tc/2
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PROF.V.T.RANGANATHAN

Max. IGBT voltage rating: 3300V Max. DC Bus : 2200V Max. Motor L_L Voltage:1700V (sq. wave) 1300V (PWM) IGBT current /module :400A RMS Current of :150A
O/P KVA rating/module : 275KVA (for 1100V) For higher KVA, modules have to be paralleled.
PROF.V.T.RANGANATHAN

Motors of 1MW and above: Designed at higher voltages KV: DC Bus: 1.5 2.0 2.2 3.0 3.3 4.5 4.2 5.8

Such voltages require multiple devices in series. Direct series connection of devices is difficult; also it leads to very high dv/dt stress on motor windings. Multistepped waveform of motor voltage preferred.

This leads to multilevel inverter configurations.

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Functional equivalent of three level inverter

Pole voltage can have three levels:

+Vdc/2, 0, -Vdc/2

Motor line voltage will have 5 levels: +Vdc, +Vdc/2, 0, -Vdc/2, -Vdc
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Waveforms of Pole Voltage and Line Voltage:

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THREE LEVEL DIODE CLAMPED INVERTER

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THREE LEVEL H-BRIDGE INVERTER

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Effect Of VSI Operation on Induction Motors Nonsinusoidal voltages: lead to harmonic currents, torque pulsations. This problem is tackled by resorting to pulsewidth modulation
Voltage steps applied to motor: this leads to 1) dv/dt stress on the motor insulation; 2) bearing currents; 3) overvoltage due to reflections when long cables are used to connect motor to inverter.
PROF.V.T.RANGANATHAN

SOLUTION TO PROBLEMS DUE TO VSI OPERATION

MULTISTEP INVERTERS OUTPUT FILTER BETWEEN INVERTER AND MOTOR

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OTHER CONVERTERS FOR INDUCTION MOTOR DRIVES

A.CYCLOCONVERTERS
SIMPLE LINE COMMUTATED CIRCUIT OUTPUT FREQUENCY LIMITED TO ABOUT 20Hz LINE SIDE POWER FACTOR NOT GOOD INPUT CURRENT DRAWN FROM LINE HAS COMPLEX WAVESHAPE USED IN HIGH PERFORMANCE LOW SPEED APPLICATIONS SUCH AS ROLLING MILLS, CEMENT MILLS ETC.
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THREE PHASE CYCLOCONVERTER

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B. CURRENT SOURCE INVERTERS

RUGGED COMPARED TO VSI REGENERATION INHERENT TORQUE RESPONSE SLOW COMPARED TO VSI LOW SPEED OPERATION REQUIRES PWM WHICH IS NOT EASY
OUTPUT CAPACITOR RESONATES WITH 1. MOTOR LEAKAGE INDUCTANCE REQUIRING ELIMINATION OFTHE RESONANCE FREQUENCY THROUGH PWM 2. MOTOR MAGNETIZING INDUCTANCE, LIMITING THE HIGHEST FUNDAMENTAL FREQUENCY OF DRIVE OPERATION PROF.V.T.RANGANATHAN

CSI DRIVE CONFIGURATION

id CHOKE vi MOTOR

vr

RECTIFIER

GTO INVERTER
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CAPACITOR

FEATURES OF SLIP RING MOTORS CONNECTION CAN BE MADE TO ROTOR ROTOR RESISTANCE CONTROL WAS USED IN SOME EARLY APPLICATIONS E.G. WIND TUNNELS, PUMPS ETC. SUBSYNCHRONOUS CASCADE WAS THE FIRST COMMERCIAL APPLICATION OF ROTOR SIDE CONTROL

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SUBSYNCHRONOUS CASCADE

CHOKE

INVERTER
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RECTIFIER

FEATURES
CAN WORK ONLY AT SUBSYNCHRONOUS SPEEDS THIS IS SUFFICIENT FOR MANY APPLICATIONS SUCH AS WATER PUMPING, FANS ETC.

TRANSFORMER REQUIRED TO IMPROVE LINE SIDE DISPLACEMENT FACTOR

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FEATURES (contd.)

HARMONICS ARE INJECTED INTO THE LINE

ROTOR CURRENT IS NOT SINUSOIDAL LEADING TO TORQUE PULSATIONS

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FEATURES (contd.)
IT WAS RECOGNISED THAT IF ROTOR SIDE CONVERTER COULD HANDLE BIDIRECTIONAL POWER FLOW, SUPERSYNCHRONOUS OPERATION ALSO WOULD BE POSSIBLE CYCLOCONVERTERS WERE USED ON THE ROTOR SIDE FOR INJECTING CURRENT AT ANY REQUIRED PHASE AND FREQUENCY

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FEATURES (contd.)

RESULTING DRIVE HAD THE DRAWBACKS THAT LINE CURRENT WAS NOT SINUSOIDAL AND THE CIRCUIT WAS COMPLEX TODAY, ROTOR CURRENT CAN BE CONTROLLED BY CONNECTING VSIs IN CASCADE

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GRID CONNECTED SLIP RING MACHINE WITH ROTOR SIDE CONTROL

PR PS

STEP DOWN TRAFO.

FEC + INVERTER RATED FOR SLIP POWER

SLIP RING INDUCTION MOTOR

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FEATURES Variable speed constant frequency operation Converter power rating is fraction of system power Operation below and above the synchronous speed possible Active and reactive power can be controlled in a decoupled manner
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OPERATING REGION OF GRID CONNECTED SLIP RING MACHINE WITH ROTOR SIDE CONTROL
torque 1 p.u.
SUBSYNCHRONOUS MOTORING SUPER SYNCHRONOUS MOTORING

Inverter Rating = 1 p.u.

1 p.u. 0 p.u.
SUBSYNCHRONOUS GENERATION

2 p.u. speed

-1 p.u.

SUPER SYNCHRONOUS GENERATION

S
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DOUBLE INVERTER FED SLIP RING INDUCTION MOTOR DRIVE

GRID DIODE BRIDGE OR IGBT FRONT END

COMMON DC BUS PS PR

STATOR SIDE INVERTER

SLIP RING MOTOR

ROTOR SIDE INVERTER

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Operating region of the drive

torque 1 p.u Mode IV Mode I speed -2 p.u -1 p.u Mode III Mode II 1 p.u 2 p.u

-1 p.u

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Relationship between the speed and the frequencies of the inverters:

s stator frequency rad / sec r rotor frequency rad / sec e motor speed electrical rad / sec

e = s r
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Important Features
Proposed drive can extract 2p.u. power from 1p.u. motor Motor can run at 2p.u. speed without field weakening operation. The drive is extremely rugged at very low speed including the zero speed operation without rotor encoder. Controller depends very little on machine parameters Negligible effect of temperature variation

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Application Areas
Because of the following features: Reliable sensorless operation even at very low speed High speed with full torque operation
SUITABLE APPLICATION AREAS ARE:

ROLLING MILLS CRANES AND HOISTS HYBRID ELECTRIC BUS

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LCI DRIVE CONFIGURATION

id CHOKE

vr

vi SYNCH. MOTOR

RECTIFIER

INVERTER

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FEATURES
The rectifier works at line frequency The inverter decides the motor frequency, which can be greater than the line frequency also The choke serves to isolate the two sides Regeneration is possible by reversing the roles of the two converters
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The turn-off of the inverter thyristors is brought about by the machine back emf; hence the name Load Commutated Inverter The motor has to be operated at leading power factor for this to be possible At low speeds The back emf is not sufficient to turn off the thyristors The dc link current has to be brought to zero by phasing back the rectifier; then the new pair of conducting devices in the inverter have to be fired; the dc link current then has to be brought up again This mode of operation lasts until the output frequency reaches about 5 Hz.
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SCR BASED LOAD COMMUTATED CSI WITH ACTIVE FILTER

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FEATURES SCRs USED INSTEAD OF GTOs GATE DRIVE MUCH SIMPLER ACTIVE FILTER COMPENSATES MOTOR REACTIVE POWER AND INJECTS CONTROLLED REACTIVE POWER TO MANAGE THE COMMUTATION OF THE SCRs
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VSI OF THE ACTIVE FILTER CAN ALSO START THE MOTOR NO NEED FOR PULSING THE DC LINK CURRENT AS IN LCI ACTIVE FILTER ALSO COMPENSATES THE HARMONICS OF THE CSI MOTOR SEES SINUSOIDAL VOLTAGE AND CURRENT
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Experimental Results

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PROPOSED LCI FED SM DRIVE - CONFIGURATION

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Proposed LCI fed SM Drive - Advantages

Output machine current and therefore output machine voltages are nearly sinusoidal. Developed torque is smooth. Machine power factor can be controlled. Control is speed sensor-less. Starting procedure is easier. Can be added on as a retrofit to existing LCI drives

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NEW INDUCTION MACHINE CONFIGURATION

A new type of induction machine is proposed where torque and flux component of current flow through two separate windings, as in DC Machines and Synchronous machines. Torque component of current comes from a load commutated CSI built with SCRs, whose commutation is ensured by control. Flux component of current comes from a separate VSI which switches at lower switching frequency compared to active filter.

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ACTIVE REACTIVE MACHINE DRIVE

(11kV)

A2

A1 (2.2 kV)

3-ph SOURCE

REC1 CSI

INV1 CSI

B2

ACT-REACT B1 MACHINE C1

LC FILTER

INV2 VSI

C2

3-PH TRANSFORMER (2.2 kV)

TRANSFORMER & RECTIFIER

INV 3 VSI

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FEATURES OF THE PROPOSED DRIVE SINSUSOIDAL MOTOR VOLTAGE AND CURRENT LOAD COMMUTATED SCR CURRENT SOURCE INVERTER TOTAL REACTIVE AND HARMONIC KVA SHARED BY THE TWO VSIs

The two motor windings can be for different voltages Field weakening will be easier

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simulation results
Steady state response of winding 1 voltage and current 15 Vs1

10 Vs1(1unit=15Volt),Is1(1unit=1A)

Is1

-5

-10

-15 3.04 3.045 3.05 3.055 3.06 3.065 3.07 3.075 time(sec) 3.08 3.085 3.09

Voltage & current response of winding 1

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simulation results
Steady state voltage and current of Wdg. 2 with 10 Nm load applied 15

Vs2

Vs2(1 unit=15Volt), Is2(1 unit=1A)

10

Is2

-5

-10

-15 3.195 3.2 3.205 3.21 3.215 3.22 3.225 time(sec) 3.23 3.235 3.24

Voltage & current response of winding 2

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CONCLUSION
PRESENT MARKET IN HIGH POWER MEDIUM VOLTAGE DRIVES SHARED BWTEEN THREE LEVEL VSI DRIVES FOR INDUCTION MOTORS AND CYCLOCONVERTER OR LCI FOR SYNCHRONOUS MOTORS NEW APPROACH OF HANDLING THE MAIN POWER THROUGH SCR CIRCUITS AND THE REACTIVE/HARMONIC POWER THROUGH VSIs RESULTS IN SINUSOIDAL MOTOR VOLTAGE AND CURRENT HOLDS PROMISE FOR RETROFIT AS WELL AS NEW APPLICATIONS
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