Power Electronic Grid Simulator

1 Power Electronic grid SimulatorPlatform of drives and Power qualityproducts for wind-turbine testingEster Guidi, Pieder J rg, abb medium voltage Drives, Switzerland ABBM onth DD, YYYY | Slide 1 Outline Teststand applications for drives and Power electronics Modular drives and Power -electronics platform ACS6000 Power Electronic grid Simulator based on platform Design considerations following windturbine testingrequirements ABB GroupJune 11, 2013 | Slide 2 ABB GroupJune 11, 2013 | Slide 3 Teststand applications for drives and Power electronicsTest stand applicationssingle-drivemulti-driveDevic e under testACDCDCACMDCACGARUACDCDCACM motoring OR generatingmotoring AND generating ABB GroupJune 11, 2013 | Slide 4fixed installationTeststand applications for drives and Power electronicsTest stand applicationssingle-drivemotored device testingACDCDCACMACDCDCACMDUTD evice under test ABB GroupJune 11, 2013 | Slide 5 Gearbox Electrical generator Electrical motor grid simulation Wind turbine.

2 ABB s areas of activityTest stand applicationsSingle driveMulti driveDevice testing Compressor & turbo charger Pump Balancing plant Jet engine Gas Turbines Motor Generator set, ..Fix installations Wind tunnel Human centrifuge (pilot training) Soft starters for high energy labsTeststand applicationsTypical requirements towards electrics/automation High dynamic electric motor control over wide speed range capability to control induction and synchronous motors base speed of electrical motor:1Hz .. 75Hz / few rpm .. 3600rpm wide field-weakening range (.. 1:5) high torque over-loadability (.. 275%) air-gap-torque control bandwidth (.. 400Hz) flexible automation integration (PLC, FB, fast I/O ..) Versatile Power Electronic building blocks load-cycling capable (reliability) parallelable and multi-terminal capable (scalability) ABB GroupJune 11, 2013 | Slide 6 Outline Teststand applications for drives and Power electronics Modular drives and Power -electronics platform ACS6000 Power Electronic grid Simulator based on platform Design considerations following windturbine testingrequirements ABB GroupJune 11, 2013 | Slide 7 ACS 6000 Modular drives and Power -electronics platform voltage range kV Power range MVA continuous and 36 MVA short term Output frequency range Hz (higher on request) Field weakening point Hz (lower / higher on request) Field weakening range 1:5 ACS 6000 focus.

3 Demanding applicationsChemical, Oil & GasPowerWaterMarinePulp & PaperSpecial applications, wind tunnelsMetalsCement, Mining &MineralsInverter Unit Power Stack(s)Pre-definedinterfacesfor Power ,cooling &controlconnectionsACS 6000: Some building blocksActive RectifierINU1 5 MVAI nverter UnitCapacitor BankCBULSUD iode RectifierWater 9 MVAARU5 9 MVA ABB GroupJune 11, 2013 | Slide 113 BHT490558R0001 Rev. ATerminal and Control UnitContains the Power terminalsand the control swing frameInverter UnitSelf-commutated, 6-pulse,3-level voltage sourceinverter with IGCT technologyCapacitor Bank UnitDC capacitors for smoothingthe intermediate DC voltageWater Cooling UnitSupplies the closed cooling systemwith deionized water for the mainpower componentsACS 6000 water cooled3 36 MWActive Rectifier Unit (ARU)Self-commutated, 6-pulse,3-level voltage source inverterwith IGCT technology ABB GroupJune 11, 2013 | Slide 123 BHT490558R0001 Rev.

4 AInverter topology 3-level voltage source inverter IGCT technology for maximal loadabilityin combination with minimal part count Fuseless design, ACS 6000 uses IGCT sfor fast and reliable protection of powercomponents instead of unreliablemedium voltage Power fuses12-pulse LSU single drive6-pulse ARU single drive ABB GroupJune 11, 2013 | Slide 133 BHT490558R0001 Rev. ACommon DC bus Several motors (induction andsynchronous) can be connected to thesame DC bus optimized energy flow Braking energy generated in onemotor can be transferred to otherinverters via common DC buswithout Power consumption fromsupply network Optimum configuration can bereached by combining different inverterand rectifier modules within one driveOptimized energy flowwith common DC bus, cold reversingsteel millACS 6000: INU 9 MVA unit=~~=~~=~~=~~=~~ of two of three units=~~=~~=~~=~~=~~Parallel connection of inverter units:9, 18, 27, 36 MVA as of four units=~~=~~=~~.

5 ACS 6000: Flexible solutions from 2Q single ..440010002200290020004400 :700mmforbetterserviceavailability& DCDC ACMINU5 MVAACS 6105_L12_1a5 ACS 6000: .. to 4Q multi driveACM 6209_A12_1s9_1s9_1s9169001000 ARU1500750 ARU1500750 INU2100750 TEU4200400022002000 TEUCOU1000500 INU2100750 TEUCOUINU2100750 TEUCOUWCU20001000 VLU6006004300 EXU800800 EXU8008004400 EXU800800 CBU800800 CBU800800AC DCDC ACMAC DCDC ACMDC ACMINU9 MVAINU9 MVAINU9 MVAARU2x9 MVAO utline Teststand applications for drives and Power electronics Modular drives and Power -electronics platform ACS6000 Power Electronic grid Simulator based on platform Design considerations following windturbine testingrequirements ABB GroupJune 11, 2013 | Slide 17 ACS 6000 grid simulatorOverview ABB GroupJune 11, 2013 | Slide 18 Main benefit: Enables tests to becarried out off-line in a cost- and time-efficient manner Flexibility: suitable for any kind ofelectrical equipment that needs to beconnected to the grid Wind and Tidal Turbines PV systems Solar Power Fuel cells Motor Gensets Energy storage systemsACS 6000 grid simulatorCombined functionality ABB GroupJune 11, 2013 | Slide 19 Project example test stand for wind turbineCombined functionality drive train and grid Simulator ABB GroupJune 11, 2013 | Slide 20 Integrated allin one line-upbased onACS6000platformACS 6000 grid simulatorExample of a layout and dimensions ABB GroupJune 11, 2013 | Slide 21 ACS 6000 grid simulatorLayout possibilies U-shape, L-shape.

6 ABB GroupJune 11, 2013 | Slide 22 Outline Teststand applications for drives and Power electronics Modular drives and Power -electronics platform ACS6000 Power Electronic grid Simulator based on platform Design considerations following windturbine testingrequirements ABB GroupJune 11, 2013 | Slide 23 ACS 6000 based grid simulatorControl and transformer engineered to application ABB GroupJune 11, 2013 | Slide 24 grid Simulator inverter control and theoutput transformer are dedicated( engineered ) for the grid simulatorapplication Everything else is off the shelf Power Electronic hardware Hardware protection Mechanical design and cooling Supervisory control and sequencing Supply from public grid ..engineeredengineered ABB GroupJune 11, 2013 | Slide 25 ACS 6000 grid simulatorControl hardware overviewACS6000AC800 PECAMCAMCPUBPUBINT(INU1)INT(INU2)INT(INU 3)INT(INU4)INT(ARU)PFFPECIOMeasPFFS upervisiorModbusModbusModbusVref3 VPCCIPCC33 RBUO ptical link pairAnalogueFieldbusProtectionIODigitale ngineered ABB GroupJune 11, 2013 | Slide 26 ACS 6000 grid simulatorControl hardware features Main controller - PP D113 36 Optical fiber modules (25us) DDCS (DriveBus Comm) Communication to the upper control viaAnybus-Modules or CEX Profibus-DPV1 Master CANopen Slave ControlNet Slave DeviceNet Slave Modbus-RTU S, -TCP S Profibus-DP S, -DPV1 S, EtherCAT S Profinet RTI - IO Fast IO UA D149 PowerLink (native protocol 25 us) 32 DI (24V) 16 DO (24V) 12 AI ( 10V, 20mA) Isolated in groups of 3 4 isolated AO ( 10V, 20mA)ACS 6000 grid simulatorFunctional diagram ABB GroupJune 11, 2013 | Slide 27engineeredOverview.

7 Configurations of matching transformer Match the converter voltage to the desired testbus- voltage Sum-up the Power (resp. currents) of the different inverters, of 4 inverters Cancel inverter harmonics to improve THDv Provide galvanic insulation between DUT and Simulator forsimpler test-design and protectionWhat is the function of the transformer ABB GroupOverview: Configurations of matching transformer What doesn t work 3 winding transformer ( 12-pulse ) circulating currents Parallel transformers circulating currents What basically works Series connection of HV winding for summing up Y configuration of LV winding with starpoint to NP Delta configuration of LV winding 3 single phase trafos with H-bridge driven LV windingWhat works and what not ABB GroupOverview: Configurations of matching transformer Series connection allows summation of voltages withcancellation of harmonic voltages This turns the separate inverter units into a multi-level/multi-cell converter Tapings are relatively easy to implement The star-point is accessible and can be freely treated (hardgrounded, soft-grounded)HV side configuration.

8 Series connection ABB GroupWhat you get as result3 independent floating voltage sources Lab setup option 1 Lab setup option 2 or any other configuration of 1, 2 or 3 sourcesHow does the voltage source look likePotential and achievable short-circuit Power inverter is idealvoltage source withno internalimpedanceit can run up to amaximum currenttransformer leakageinductance is visiblegrid impedance duringnormal operationminimum is ~5% ofrated transformer powertransformer thermalrating defines the short-circuit currents, that thegrid Simulator can reallysink or sourcemaximum is installedpower Electronic 2000A11 MVA per unit44 MVA for 4 cont. rating5% 320 MVAshort-circuit will limitshort-circuit at44 MVAC onclusion ABB builds the grid simulators on a platform, which iswidely used in demanding industrial applications The grid Simulator is enabled by an application specificcontrol hardware and software, and a dedicated matchingtransformer Compatibility with drives allows setups which include thedynamometer on the same DC-bus, thus isolating it fromthe local lab supply grid The used hardware and its configurations have been(partly widely) used since the launch of ACS 6000 in 1998 Dynamometer: High- Power rolling-mill drive, direct drivemine-hoist grid Simulator : Static VAR compensator, grid -interties(16 2/3 Hz <-> 50Hz) and for large energy storage ABB GroupJune 11, 2013 | Slide 33