GE Medium Voltage Drives

TM GE Automations Systems
Western Mining Electrical Association
Medium Voltage Drives Overview, Evolution & Application

Western Mining Electrical Association November 2004
Bill Horvath, PE TMGE Automation Systems
MV Drive Session Overview

Provide links to more reference materials. Review the benefits of ASDs in motor starting and control Cover basic drive application Cover basic tradeoffs between MV & LV drives Review one recent mining conveyor MV drive application Trace the Evolution of MV drives & circuit configuration
Compare each historical and current major MV drive topology Compare each drive topology's major strengths and weaknesses.
Review the TMGE Dura-Bilt5i MV IGBT Drive as an example of current technology

November 2004 TMGE Automation Systems - All rights Reserved 2
MV Drive Materials -1
MV Drive Evolution White Paper GEZ-S1006 Engineering Reference Manual & CDROM, GET-S1009
Obtain from TMGE General Industries www.tmge.com

More MV Drive Materials - 2 Electronic MV Newsletter

http://www.imakenews.com/getoshiba_mve-news/
TM GE Automation Web Link:

www.tmge.com
AC Motors & Control Overview

Induction Motor Basic Characteristics Load Types
Starting and Running Torque-Speed Profiles Typical Applications
Starting and Running Control Methods Variable Frequency Drives

Low Voltage vs Medium Voltage MV Drive Evolution TMGE Automation Systems Dura-Bilt5i MV Overview
Induction Motor Speed-Torque Profile

Peak [Breakdown] Torque, BDT Locked Rotor Tq Torque Pull Up Torque Rated Torque
Rated SlipRPM = Sync - Rated RPM
Sync Rpm = 120 x Freq. Sync Rpm = 120 x Freq. #Poles #Poles
RPM
Rated RPM Sync RPM
November 2004
TMGE Automation Systems - All rights Reserved
Motor Starting
November 2004
Motor Starting
Factors That Apply
Inrush Amps and Duration Motor Limit on Number of Starts Per Hour Motor Connected Inertia Limits Load Mechanical Issues
Pumps, Piping & Hydraulic issues Coupling Stress
Starting Torque vs Load Requirements

Full-Voltage Motor Starting

Full Voltage Amps & Torque vs Speed
Amps
Torque, Amps
Single Motor, Single Starter
Torque
Full Load
Multiple Motors, Single Starter
RPM >
November 2004
Reduced -Voltage Motor Starting

Reduced Voltage Motor Amps & Torque vs Speed
Reduced Voltage Starter
Amps
Torque, Amps
Torque
Bypass
Full Load
Start Inrush amps ~ Volts Torque ~ Volts2
RPM >
1. Frequency is = line frequency 2. Inrush current and torque are limited for a soft start, but no true speed or torque control is possible.
Motor on AC Adjustable Speed Drive

AC Adjustable Speed Drive Motor Amps & Torque vs Speed
Torque, Amps
Adjustable Speed Drive
Motor AvailableTorque
No Starting Inrush amps, Torque & Volts Controlled to Match Load
Full Load Torque Level

s Amp
1. Frequency and voltage are controlled. 2. Line current, motor voltage torque regulation provide true speed and torque control. 3. KEY: Process and energy use can be optimized.
Drive Ratings and Torques

Variable Torque - ratings usually include 110 -115% OL rating for 60 seconds at rated Temp
2/12/2001
VFD APPLICATION
12
Loads & Motor Capability Curves

TEFC
Induction Motor Capabilities Under Variable Speed Operation
Theoretical Motor Capability 100% Load Point, NP RPM, Sine wave power Constant Torque Load, Example 1
ab ility A ctual Mo to r C ap
Load Torque
Constant Torque Load, Example 2
Va
b r ia
le
a Lo
u [P
RPM -- >
imcapab1.drw June 4, 98
November 2004
p,
Fa
n]
13
Pump & Fan Affinity Laws: 1-2-3

- 1 Flow Rate Varies 1st power of Speed [Proportional] - 2 Pressure & Load Torque Varies as the 2nd power [square] of Speed - 3 Horsepower at Motor Shaft varies as the 3rd power [cube] of Speed
100.00% 90.00% 80.00% 70.00% 60.00% 50.00% 40.00% 30.00% 20.00% 10.00% 0.00%
10%
20%
flow - %
30%
40%
50%
60%
70%
80%
HP - %
% of Total
90%
% Speed
November 2004
100%
14
Fans -Things to Remember

Fans have variable torque loads. Blowers may have constant torque or variable torque loads. Load torque goes up as the square of the speed. Horsepower load goes up as the cube of the speed. Torque needed to run an Induced Draft fan increases significantly as gas temperature decreases. Fan Motor sizing greatly effected by across the line
November 2004
16
Variable Torque Drive Applications
November 2004
17
Starting/ Running Drive

4160 V
Drive
4160 V
M1
Starting/Running Contactors
Pump Motors
ST1
MTR1
ST2 M2 ST3 M3
MTR2
MTR3
Across the Line Contactors
Multiple Motor Pumping Application
November 2004
18
Drive Ratings and Torques

Constant Torque [CT] rating usually includes 150% - 250% OL rating for 60 seconds when at rated Temp.
November 2004
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Constant Torque Characterized as a load curve that looks like

Theoretical Motor Capability 100% Load Point, NP RPM, Sine wave power Constant Torque Load, Example 1 Constant Torque Load, Example 2
bility Actual Motor C apa
Load Torque
b ria a
le
a Lo
u [P
RPM -- >
November 2004
p,
Fa
n]
20
Conveyor or Mill Loading

Typical Induction Motor Char on 60 Hz power
BREAKAWAY TORQUE
TORQUE
mand r typical de conveyo
FREQ, SPEED
November 2004
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Conveyor or Mill Loading

VFD CONTROLLED MOTOR ENOUGH TORQUE ACROSS THE RANGE Typical Induction Motor Char on 60 Hz power
BREAKAWAY TORQUE
TORQUE
mand r typical de conveyo
FREQ, SPEED
November 2004
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November 2004
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Crushing and Conveying Systems
November 2004
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Example MV Drive Mining Application

MINE-MOUTH TO PROCESSING PLANT CONVEYOR
Application Story Long Conveyor

1. Underground Molybdenum Mine in Colorado had 15 mile long train to take ore from mine tunnel to processing plant 2. Train equipment became obsolete, unreliable 3. Three segment conveyor at variable speed was winning concept to replace train 4. Total length of conveyors over 15 miles! One section over 10 miles!
November 2004
26

0.76 miles, 1.2 kM
10.5 miles, 16.8 kM Elev. 9,500 ft
4.0 miles, 6.4 kM
CONVEYOR PC-1
CONVEYOR PC-2
E GRAD
% iable 5 = Var 1%
to 1%
CONVEYOR PC-3
2,400 ft
3%
8% % to ble 0 Varia DE = GRA
5%
Elev. 7,100 ft
PC-1 Conveyor Plan View
Head end equip hous e @ 7,100 feet AMSL
Head end equip hous e @ 9500 feet AMSL
Tail end equip hous e @ 9,500 feet AMSL
PC-3 Conveyor Plan View Head end equip hous e

@ 9,500 feet AMSL
4
2 x 1000 HP
3
1x 2250 HP
1x 1000 HP
2x 1x 2250 HP 2250 HP
2x 1x 1000 HP 1000 HP
ELECTRICAL ONE LINES

2140 kVA 13,800/2400 V

1900 kVA 13,800/2300 V
1000 HP 2.3 kV
900 kVA 13,800/2300 V
PWM-3. 2250 HP.
2250 HP 2.3 kV
PWM-3 2000 HP.
13.8kV
13.8kV
2000 HP Drive Can Accommodate [2] 1000 HP Motors
1000 HP 2.3 kV
PWM-3 1000 HP.
13.8kV
1000 HP 2.3 kV
2250 HP PWM-3 w/1 2250 HP Motor Basic Configuration for Pulleys 1, 2, 3
2000 HP PWM-3 w/ two 1000 HP Motors Alternate for pulley 4
1000 HP PWM-3 w/1 1000 HP Motor Basic configuration for Pulleys 4, 5, 6, 7
8/18/97
November 2004
Henpres1.ppt Slide S-21
27

Conveyor Mechanical Application Considerations
Stretch, Length, Belt weight, load weight, speed Friction T1 T2
D1 D3
D2
T3 T4
Tension Ratios, Dynamic Response, Programmed Torque, Load Sharing
November 2004
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PC-2 UPHILL CONVEYOR with PWM Drives

Head end equip hous e @ 9500 feet AMSL
1x 2x 1x 2250 HP 2250 HP 2250 HP

2140 kVA 13,800/2400 V
PWM-3. 2250 HP.
2250 HP 2.3 kV
13.8kV
2250 HP PWM-3 w/1 2250 HP Motor Basic Configuration for Pulleys 1, 2, 3
8/18/97
November 2004
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PC-3 OVERLAND CONVEYOR with PWM-3 Drives

PC-3 Conveyor Tail end equip hous e Plan View Head end equip hous e
@ 9,500 feet AMSL @ 9,500 feet AMSL
1x 1000 HP
1x 2x 1000 HP 1000 HP
900 kVA 13,800/2300 V
PWM-3 1000 HP.
13.8kV
1000 HP 2.3 kV
8/18/97
November 2004
30
PC-1 FEED CONVEYOR with PWM-3 Drives

Head end equip hous e @ 7,100 feet AMSL
4
2 x 1000 HP
900 kVA 13,800/2300 V
PWM-3 1000 HP.
13.8kV
1000 HP 2.3 kV
8/18/97
November 2004
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Application Story Long Conveyor Challenges & Solutions

Motor Challenges High Starting Torque for PC3
Two sizes: 1000 HP & 2250 HP each wide speed range
Drive Challenges 24/7 Reliable

Energy Efficient Low Maintenance High overload torques in winter on PC3
Control Challenges
Precise, programmable torque for belt tension control Head-to-tail tension coordination for PC3. Allow variable speed operation of any motor
Power Challenges Long power feeds Cable capacitance created resonance high order harmonics
Power Solution Motor Solution GE 2.3 kv induction motor separate cooling air by user
November 2004
Drive And Control Solution GE Innovation PWM 2300 volt 3-level, 18 pulse rectifiers. Utilized Innovation Series Controller for torque programming & PLC Ethernet interface.
3-level Inverter with IEEE 519 compliant 18 pulse converters and high frequency filters to eliminate cable resonance at 19th harmonic
32
Application Story Long Conveyor Customer Benefits

Train system replacement with conveyor has proven to be very reliable. Variable speed operation on the conveyor resulted in added energy savings, reduced friction and belt wear. Biggest risks and failure potentials were avoided by careful design:
Slippage and stretch of long strand 20 mile total length PC2 with 4 x 2250 HP at head end Tension control of up-and-down PC3 overland with many curves
All AC Drive Selection Factors

Load type: CT, VT, CH, Regen or non-regen Physical Environment at drive location Power system compatibility Precision of control needed Overload ratings needed Operator control & digital communication needed Drive Output Voltage & Motor Application
Drive Output Voltage & Motor Application

LV drives: defined as having output volts <690 volts Why Pick LV [<690v] Drive & Motor? Why pick MV over LV? Trends: Some users select MV at >250 HP Many users select MV over 500 HP.
Drive Output Voltage & Motor Application

Why Pick LV [<690v] Drive & Motor?
LV drives are lower cost / HP than MV Reduces some safety & MV training concerns HP range is small enough Individual preference Lower cost wiring, smaller cables Lower power system harmonic impact High HP LV require dual winding motors Individual preference
Why pick MV [>690v] Drive & Motor over LV?
Trend:
November 2004
Some users select MV at >250 HP Many users select MV over 500 HP. HP.
TMGE Automation Systems - All rights Reserved 36
MV vs LV AC Drives:
Cost Factors of Various Configurations
MV drive $ / HP decreases with HP Harmonic content can be important:
MV data is 24 pulse TMGE Automation Systems DB5i MV LV data is GE-Fuji AF300 P11
MV vs LV AC Drives Budgetary $ per HP vs HP
500.0
Budgetary $ per Horsepower
LV 6-Pulse w/o Transformer MV 4160 v 24-Pulse DB5i
400.0 300.0 200.0 100.0 0.0 0 500
LV 6-Pulse w/8% Mirus filt LV 18 pulse incl transf
Installed cost must be considered

November 2004
1000
Horsepower
1500
37
Safety, Training & MV Drives

Different level of training and personnel for MV vs LV equipment Different procedures MV vs LV Local maintenance staff may not be comfortable with MV equipment MV drive include many safety features:
Optical control isolation: feedbacks and firing Electrical and mechanical interlocks & isolator switches Bolt on covers, warning labels
MV vs LV Drives: Some Conclusions

For drives > 1000 HP, MV makes sense For long cable runs, MV makes sense For drives < 500 HP, LV makes sense. If low system harmonics are required, LV filter or multi-pulse expense can favor MV over LV. In the range 500 to 1000 HP the various application & installation factors apply.
Final choice may boil down to user preference.
MV Drive Evolution
History, Topology Comparisons, & Future Trends
Typical AC Inverter System

Transformation
AC TO DC
OR OR OR OR
Conversion
DC TO AC
Utilization
Load
AC MOTOR
Utility Supply
RECTIFICATION
ENERGY STORAGE
SWITCHING
AC Inverter Technology Up To 97% Efficiency, including transformers
November 2004
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The Common Threads:

All AC Drives rectify AC to DC Advances in All AC Drives use switches to create Power AC from DC Semiconductor Technology Drive topologies were created as Lead the Way in power rectifiers and switches grew MV Drive in ratings and capabilities. Development
Each new or uprated device opens up new applications A quick look at the device development timeline is useful
November 2004
Development Time Line of Power Semiconductors

Transistor Devices
Bipolar Power Transistor Low Voltage Insulated Gate Bipolar Transistor Medium Voltage Insulated Gate Bipolar Transistor Injection Enhanced Gate Transistor
(BPT)
(LV IGBT)
(MV IGBT)
(IEGT)
1955
1965 Silicon Controlled Rectifier (SCR)
1975
1985 Gate Turn Off Thyristor (GTO)
1995 Integrated Gate Commutated Thyristor (IGCT)
2005 Symmetrical Gate Commutated Thyristor (SGCT)
Diode (D)
Thyristor Devices
November 2004
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GTO Gate Driver & Cell Stack Equipment

GE GTO-IMD Example
Gate Power Supply
Liquid-cooled configuration Many discrete parts in firing and auxiliary parts Snubber network also shown Physically quite large
November 2004
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GCT Gate Driver Equipment

Covers on
Isolation Transformer Gate Power Supply
Integrated Gate Signal Unit
GCT
4.5kV-4kA
November 2004
45
GCT & Gate Driver Board

Covers off
4.5kV-4kA 4.5kV-800 A
36 Electrolytic caps 21 FET Switches

Typical IGBT & IGBT Gate Driver Circuit

IGBT
400 amp 3300 volt dual package Larger ratings have 1/package
Typical MV IGBT Dual Gate Driver

Each board has 2 drivers, & fires 2 IGBTs
2 in, 50 mm
Approximate Size: 4 inches x 4.5 inches
November 2004
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IEGT Gate Driver Equipment

Gate Drive Board
IEGT
4.5kV-4kA
IEGT = Injection Enhanced Gate Transistor
November 2004
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Calculated Reliability ofRGateof G ate D rivers Drivers IG C T vs IEG T C alculated Failure ates
IEGT Voltage Fired vs GCT Current Fired
Failures per Billion Hours
3500 3000 2500 2000 1500

IC
LE D
F IL M C AP AC IT O R
E L E C T R O L YT IC
R E S IS T O R (1 /4 )
R E S IS T O R (P W R )
D IO D E
FET
FITs
1000 500 0
T R AN S IS T O R
IG C T
November 2004
IE G T
49
Power Switching Devices

Final Comparisons & Conclusions
Current switched devices [SGCT, IGCT] require many more parts in firing / gate control than voltage switched devices [IGBT, IEGT]. Voltage switched devices [IGBT, IEGT] have MUCH lower switching losses than current switched. Conduction losses are nearly equal for equivalent volt & amp-rated device SGCT, IGCT vs IGBT, IEGT Voltage switched devices allow higher switching rates and can give better output waveforms
AC Drive Topology:
A map-like diagram showing the elements of an AC drive and the relationships between them.
Two Basic AC Drive Topologies

Current source drive: ENERGY STORAGE section between converter and inverter consists of an inductor. Voltage Source Drive: ENERGY STORAGE section between converter and inverter consists of capacitors.
Comparing Topologies
Current Source Drives
LCI Load Commutated Inverter GTO/SGCT Current Source Induction Motor Drive
Voltage Source Drives

LV IGBT Paice Multilevel PWM MV IGCT PWM Diode or Active Source MV IGBT PWM Integrated package MV IEGT PWM Active or Diode Source
November 2004
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Current Source Drives
November 2004
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LCI Current Source Load Commutated Inverter

SCR SCR
Volts
UTILITY
DC Link Inductor
Sync Motor
Alternate: Multi-pulse/ Multi-channel Converter
Example: GE-Innovation
Inverter Topology Current source Load-Commutated Inverter SCR = Silicon Controlled Rectifier, Thyristor

Series LCI
Advantages Drawbacks

Energy stored in Link Inductor
Practical Power Range Above 6 MW Synchronous Motors Only
Low Parts Count Full Regen is inherent Rugged ultra reliable Economical High HP N+1 SCR device redundancy possible
Requires a controlled front end High motor current THD Slow transient response Narrow motor frequency range Reduced Starting Torque Limited starting performance Poor PF at low motor speeds High harmonics unless multiple channels used; filters may be needed.
November 2004
Primarily being offered by: TMGE, ABB, Siemens 54
Current Source GTO / SGCT Induction Motor Drive

GTO / GCT
Volts
UTILITY
SCR
DC Link Inductor
Induct Motor
Example: GE-GTO IMD Induction Motor Drive

Inverter Topology
Current Source GTO or SGCT PWM Inverter GTO = Gate Turn Off Thyristor SGCT = Symmetrical Gate-Controlled Thyristor

Practical Power Range
Advantages
Low power device (GTO/SGCT) parts count Low motor THD Low motor insulation stress when input isolation transformer is used
Drawbacks
Requires a controlled front 2 - 15 MW end extra complexity Poor input power factor, Primarily with SCR front end induction Slow transient response motor load Narrow speed range Potential resonance between motor & caps Limited availability of power devices Primarily being Complex firing circuit
November 2004
offered by: 55 Allen Bradley
Current Source SGCT Induction Motor Drive With Isolation Reactor in Place of Transformer
Volts
UTILITY
"Isolation" Inductor
SCR or GCT
DC Link Inductor
Induct Motor*
* nonstandard
November 2004
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Voltage Source Drives
November 2004
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Voltage Source General Drive Arrangements

Volts
Diode Rectifier Converter Fed
Motor
UTILITY
Volts Motor
Active Rectifier Converter Fed
November 2004
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PWM: Pulse Width Modulation

A method of varying voltage by changing the average ON time of switches between source and load.
Example Pulse-Width-Modulated [PWM] Waveform

Voltage: The Average of the time the Voltage is on Plus the time the Voltage is Off.
Current: The Motor tends to smooth the resulting current
PEAK DC SOURCE VOLTAGE
EXAMPLE SIMULATED SINE WAVE PRODUCED BY 2-LEVEL PWM INVERTER

Example Two-Level Voltage Source Inverter

Rectified 3-Phase
1.2
1
0.8
0.6
0.4
3 Phase Diode Bridge
PWM Motor Volts

0 50 100 150 200 250 300 350 400
0.2
[+] AC Incoming Line

Three Phase Input
1.2
DC Buss Rectified Power
Cap Bank
DBR
a b c
0.7
0.2 0 -0.3 50 100 150 200 250 300 350 400
-0.8
-1.3
[- ]
Motor Amps
November 2004
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LV IGBT Multi-level Voltage Source PWM Inverter
Example: GE Innovation Series Type H

Diode Rectifier
Fixed DC Bus Inverter (IGBT)
Typical Power Cell
Energy stored in electrolytic caps

0.5 10 MW Sync or Induction motor
Inverter Topology
Major Advantages
Major Limitations
No regen or DB possible Large parts count lowers base MTBF N+1 redundancy adds parts and decreases MTBF Large footprint in high HP Electrolytic capacitors are sensitive to over temp & overvoltage
Multi-level Voltage Power Cell N+1 redundancy Source LV IGBT PWM available Inverter Low motor current THD Fast transient response LV IGBT = Low-voltage Wide motor frequency range Insulated Gate Bipolar No significant torque pulsations Transistor High starting torque. Multi-pulse converter for very low AC line harmonics High true pf over all speeds
November 2004
Primarily being offered by: 61 Robicon, Toshiba Japan
Power Cell N+1 Redundancy

N+1 redundancy originated in LCI drive design, defined as having an extra SWITCHING DEVICE per leg, with no other added parts. One Robicon method re-defines N+1 as including a complete extra cell transformer secondary & SCR bypass switch:
Cell must be intact and control 100% functional to work Added parts work all the time and decrease drive component MTBF
Traditionally, increased reliability comes from reducing parts count and conservative design.
DC link reactor Load converter
Source converter
LCI drive
N+1 requires 12 SCRs
LV IGBT MV Drive
N+1 [3 extra power cells] adds 18 diode Rectifiers 12 LV IGBTs, 15 bypass SCRs 42 electrolytic Caps, Firing circuits + 3 added transf windings
TYPICAL LV IGBT POWER MODULE FOR REDUNDANT USE
Feed Transformer
Sync Motor
Fixed DC Bus
Added Power Devices for Redundancy Shaded Green
BYPASS SCR
Diode Rectifier
ELECTROLYTIC CAPS
Inverter (IGBT)
November 2004
62
IGCT PWM Voltage Source Inverter

Fixed DC Bus AC Input Diode or IGCT Rectifier Inverter (IGCT)
Filter
Induction Motor or sync Motor [req field exciter]
Example: GE-Innovation Series SP IGCT Mill Drive

Inverter Topology
IGCT PWM Voltage Source Inverter Three Level
Energy stored in liquid filled caps

0.5 4.8 MVA per inverter, air cooled 4.8 9.6 MVA, dual channel
Major Advantages
Low power switch device count for voltage rating Fast transient response & wide motor frequency range High starting torque High power levels with largest IGCT devices Regen possible with active IGCT converter
Major Limitations
Complex high parts count firing circuit 3-level output above 3.3 kV requires output filter for low motor current distortion. Potential for electrical and mechanical resonance between load and filter.
November 2004
Primarily being offered by: 63 TM GE, ABB
MV IGBT NPC Voltage Source Drive

Multi-Winding Transformer
1
Ind or Sync Motor
Example: TMGE Automation Systems Dura-Bilt5i MV

Inverter Topology
Multi-Pulse 2 Diode Rectifier Liquid Filled MV-IGBT Power Caps NPC Inverter

0.5 4.8 MVA per inverter, air cooled 4.8 9.6 MVA, dual channel Sync or Induction Motors
Major Advantages
Minimum parts count for voltage rating & waveform Simple firing circuit. High efficiency Low motor current THD Fast transient response Wide motor frequency range No significant torque pulsations High starting torque. Multi pulse converter for very low AC line harmonics High true pf over all speeds
Major Limitations
No regeneration available Fast rise time IGBT switching may require dv/dt output filter in some cases Power Device redundancy not practical
Three / Five Level Voltage Source MV IGBT PWM Inverter MV IGBT = MediumVoltage Insulated Gate Bipolar Transistor
Primarily being offered by: TMGE Automation Systems, Siemens

64
November 2004
MV IGBT NPC Voltage Source Drive Details

24-P Source 24-P Source
W-Phase Leg V-Phase Leg
24-Pulse Source
U-Phase Leg Assembly
Neutral Point Clamped [NPC] reduces voltage to ground 5 / 9 level waveform < 3% motor current distortion 24 pulse diode converter <2% line current distortion, better than IEEE 519 limits
Example 5/9 level motor voltage & current waveforms
460 Vac
Voltage Detection Module
Optical Link Module
November 2004
65
LV IGBT NPC Voltage Source Drive

Fixed DC 3-level Bus AC Input
Converter (IGBT)
Inverter (IGBT)
Example: TMGE Automation Systems TMdrive 30

Inverter Topology
Three Level Voltage Source LV IGBT PWM Inverter LV IGBT = Low Voltage Insulated Gate Bipolar Transistor, 1700 volt rating
Energy stored in high reliability electrolytic caps

0.5 10 MVA using up to 4 bridges, air cooled Sync or Induction Motors
Major Advantages
With High reliability design and component selection, measured MTBF of > 50 years is possible. Simple firing circuit. High efficiency Low motor current THD Fast transient response No significant torque pulsations High starting torque. Active Front End for full regen, Harmonic, and PF control.
Major Limitations
Power Device redundancy not practical 1250 volt rating limits max power
Primarily being offered by: TMGE Automation Systems

66
November 2004
MV IGBT NPC Voltage Source Drive Details

+ 900
Simulated Inverter Voltage Waveforms of 3 level NPC PWM

- 900
Neutral Point Clamped [NPC] reduces voltage to ground 3 level waveform ~ 3% motor current distortion Active PWM front end better than IEEE 519 guideline limits
November 2004
1.08 1.0
PEAK RMS Red = 3-level PWM Voltage output
0.7
0.2 0 50 100 150 200 250 300 350 400
67
IEGT PWM Voltage Source Inverter

AC Input Fixed DC Bus
Converter (IEGT)
Inverter (IEGT)
Example: TMGE Automation Systems 8 MW TM-70 IEGT drive with active IEGT Source
Inverter Topology
Three Level Voltage Source IEGT PWM Inverter IEGT = Injection Enhanced Gate Transistor

Major Advantages
Major Limitations
Minimum power device count 24 for IEGT device limits allow 6 to 26 MW, complete 8 mw regen system 3300 volt motor output water cooled, Simple firing circuit [4:1 more reliable [European and Asian one or two than IGCT] and very high system Standard] channel MTBF. At 3300 volts 3300 volts is not as Low motor current THD common as 4160 volts Sync or Fast transient response & wide motor in North American Induction Motor frequency range applications. High starting torque with no significant torque pulsations Primarily being offered by: Active front end for low harmonics, regeneration, unity or leading PF TMGE Automation Systems
November 2004
IEGT PWM Voltage Source Inverter & Active Converter

Circuit Details & Alternate Diode Converter Configuration
Fixed DC Bus Diode Rectifier Inverter (IEGT)
3 Level VFD Line-Line Output & Reference Sine Wave
1.08 1.0
8 MW IEGT Inverter with active regen-capable source

Transformer & Feed Reactor 20% Z
IEGT PWM Voltage Source Inverter with Diode Converter

AC Input
PEAK RMS Red = 3-level PWM Voltage output
0.7
0.2 0 50 100 150 200 250 300 350 400
Simulated Inverter Voltage Waveforms of 3 level NPC PWM

Sync Field [If Applic] INDUCTION OR SYNC MOTOR
November 2004
69
A Modern MV Drive Example:
TMGE Automation Systems Dura-Bilt5i MV
Dura-Bilt5i MV Overview
An AC Fed Medium Voltage Drive Featuring:
Compact/compartmentalized design Integral incoming fused disconnect Integral converter transformer 24 pulse IEEE 519 compliant ac to dc converter Advanced user interface and system features
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Covering a Broad Range of Medium Voltage Drive Applications

Vac
4200
400 10,000 HP [300 7500 kW]
4000 Series
4000 3300
3000 Series
3000 2400 2000
300 8500 HP [225 6340 kW]
2000 Series
200 150 300 450 400 300
200 5000 HP [150 3730 kW]
1000 750
2000 1500
4000 3000
10000 HP 7500 kW
November 2004
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300- 900 HP 3.3 & 4kV Outline

24" fan top to ceiling for airflow clearance
Very Compact
Optional Redundant Fan
Standard Fan
110
300-900 HP
No rear access required

43.4 [1102] Left Side / End View
[2794] flapper clearance
Inverter
103.7 [2634]
Converter Section With Incoming Connections
90.1 [2288]
Control [front] Motor Connections [Behind Control, RH - Side]
Front View
74 [1880 ]
Dura-Bilt5i MV
EST WT: 7,500 LBS
Inverter, 3000 & 4000 series

3,402 KG
November 2004
73
Integral 12 winding Transformer
CONVERTER
24-P Source 24-P Source 24-Pulse Source
INVERTER
W-Phase Leg V-Phase Leg U-Phase Leg Assembly
Main Power
7.2 kV class or below
circuit Incoming Power Compartment ACL M1
Optional DV/DT Filter
3
E
M2
Integral Lightning Sensing PT's Arrestor 120 output Integral Disconnect Option
Standard E.S. Shield
Hall CT Current Feedback

460 Vac Voltage Detection Module Optical Link Module
Control power feed option
Aux & Control Power

460 std., others avail
Fan
Fan
Fan
Fan
Optional redundant fans shown dotted
Dura-Bilt5i MV 3300 - 4160 Volt Detailed One-Line Diagram
Dura-Bilt5i MV Control
November 2004
74
Power System and Motor Friendly

AMPS GREEN VOLTS BLACK
Note: traces time-shifted for clarity
Utility
Motor
Line Current Distortion < 3%
Current Distortion: THD < 3%, Voltage Distortion: THD < 6%
Meets IEEE-519-1992 With No Filters. Requires No Special Motor Thermal Rating

NOTE: Utility current trace displaced in time for clarity
Operating Conditions: Full Speed, 95% Load

75
November 2004
A Look Inside . . .
Compartmentalized Design
INCOMING POWER BYPASS CONTACTOR [option] INVERTER SECTION
TRANSFORMER & DC CONVERTER DRIVE CONTROL
Separate cooling for converter and inverter Control and power separated Voltage levels separated Only front access required
Typical Dura-Bilt5i MV 1850 kVA Drive

Incoming Power Compartment

Integral ac reactor for charging and protection of dc bus components Built-in 3-phase fused disconnect, interlocked with cubicle door that can be padlocked in the open position Built-in 3-phase MV contactor interlocked with disconnect Integral lightning arresters for transient and surge protection
November 2004
Dedicated wireways support bottom or top incoming cabling
Fused potential transformers

77
Transformer and Converter Compartment

DC cables to inverter compartment minimizes connections; this speeds and simplifies installation 24-pulse rectification gives power quality better than IEEE 519 recommended limits Transformer secondaries fused with blown fuse indicators Forced air cooled with dedicated fan. [Optional redundant fan with auto throw-over available]
November 2004
Washable filters can be changed while drive is operational

78
Drive Control Compartment

Separate disconnect for control power Optional controls for drive by-pass or other auxiliary functions
Process input-output [I/O] control board Microprocessor control boards for drive sequencing and motor speed/ torque control
November 2004
Communication board supporting Profibus, ISBus, DeviceNet and Tosline S20

79
Inverter Compartment
Easy access roll-out inverter phase modules Inverter module consists of: MV IGBTs and heat sinks Liquid-filled capacitors Snubbers Gating power supplies Gate driver board Air cooled heat plate cooling system High efficiency, low fan noise Low device temperature rises and temperature cycling Optional redundant fan with auto throw-over available
November 2004
80
High Efficiency Plate Heat Exchanger for IGBTs

How it works
Devices are mounted to side of plates Current flow generates heat in devices With only a few degrees of temperature rise, coolant is vaporized within the plate Vapor rises to the top condensing unit passages Heat is removed by airflow over fine fins, which liquefies coolant Coolant returns to base of chill plate for next cycle
High Efficiency Heat Pipe Exchanger for IGBTs

Advantages
Liquid-cooled performance is achieved with air-cooled simplicity! Low IGBT-to-plate thermal resistance keeps IGBTs cool Minimized temperature fluctuations during operation maximize IGBT life up to 10x Sealed system is maintenance free Like the proven GE Innovation Series heat pipe design, but even more effective, with a larger active surface
Inside a Typical Power IGBT

This example: 400 amp, 1700 Volt.
Inside the package, many individual devices paralleled with bonding leads. Thermal cycling from wide load cycle can cause fatigue failure of bonds due to expansion and contraction Heat plate, like liquid cooling, keeps mounting plate surface more even during load cycles. Minimized temperature fluctuations during operation maximize IGBT life up to 10x
November 2004
83
By-Pass Contactor Compartment

Requires optional additional cubicle integrated into drive line up Contactors are interlocked to allow drive by-pass and connect motor across the power lines Cubicle extension houses both input and output contactors
Allows full speed motor operation from utility power if drive is not available.
Dura-Bilt5i MV Display Unit

Drive Status Graphic screen displays key variables in bar chart format with additional status icons Status Indicators Give quick indication of drive operation, without requiring separate panel lamps Control System Toolbox Interface 10-100 Mbps Ethernet can be multi-drop networked access to GE 24-7 on-site monitoring
Parameter Editing Intuitive menu interface for parameter editing
Signal Monitor Analog signals for test instrumentation
Local Drive Control Dedicated keys for local control of the drive for commissioning and maintenance activities
85
November 2004
Integrated Trend Window

Drag and drop variables Real time trending or archiving to buffer for historical trending Auto scaling Zoom in/out function Different views by using variable hide feature Analyze specific time with cross hair Frequency-based analysis of trend with fast Fourier transform function
World Class TMGE Control System Toolbox Supplied with Every Drive!
Easy to Understand Data Structure:

Drive parameters and variables in tree structure
Animated Block Diagrams
Same Toolbox as all GE System Drives and Many Exciters!

Summary & Conclusions

ASDs offer superior motor control MV Drives can make sense at even modest HP levels MV Drives have come a long way MV drives using MV IGBTs have simplest control MV Drive Reliability needs to be built in, not added on
Thanks!
Bill Horvath TMGE Automation William.horvath@tmeic-ge.com 540-387-8253

GE Medium Voltage Drives

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GE Medium Voltage Drives

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TM GE Automations Systems

Western Mining Electrical Association

Medium Voltage Drives Overview, Evolution & Application

Bill Horvath, PE TMGE Automation Systems

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MV Drive Session Overview

Review the TMGE Dura-Bilt5i MV IGBT Drive as an example of current technology

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Obtain from TMGE General Industries www.tmge.com

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