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Dispositivos de arranque y control para motores de media tensión
Citation preview
TM GE Automations Systems Western Mining Electrical Association
Medium Voltage DrivesOverview, Evolution &
Application
Bill Horvath, PETMGE Automation Systems
Western Mining Electrical AssociationNovember 2004
November 2004 TMGE Automation Systems - All rights Reserved 2
TM GE Automations Systems Western Mining Electrical Association
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
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TM GE Automations Systems Western Mining Electrical Association
MV Drive Materials -1• MV Drive Evolution White Paper GEZ-S1006
• Engineering Reference Manual & CDROM,GET-S1009
• Obtain from TMGE General Industrieswww.tmge.com
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TM GE Automations Systems Western Mining Electrical Association
More MV Drive Materials - 2
• Electronic MV Newsletterhttp://www.imakenews.com/getoshiba_mve-news/
• TM GE Automation Web Link:www.tmge.com
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TM GE Automations Systems Western Mining Electrical Association
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
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TM GE Automations Systems Western Mining Electrical Association
Induction Motor Speed-Torque Profile
LockedRotor Tq
Pull UpTorque
Peak[Breakdown]Torque, BDT
Rated Torque
SyncRPM
RPM
Rated SlipRPM =Sync - Rated RPM
RatedRPM
Torq
ue
Sync Rpm = 120 x Freq.#Poles
Sync Rpm = 120 x Freq.#Poles
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Motor Starting
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Motor StartingFactors 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
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TM GE Automations Systems Western Mining Electrical Association
Full-Voltage Motor Starting
Single Motor, Single Starter
Multiple Motors, SingleStarter
Torque
Amps
Full LoadTorq
ue,
Amps
RPM >
Full Voltage Amps & Torquevs Speed
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TM GE Automations Systems Western Mining Electrical Association
Reduced -Voltage Motor Starting
ReducedVoltageStarter
Bypass
Start Inrush amps ~ VoltsTorque ~ Volts2
Torque
Amps
Full Load
Torq
ue,
Amps
RPM >
Reduced VoltageMotor Amps & Torque vs Speed
1. Frequency is = line frequency2. Inrush current and torque are limited for a “soft”
start, but no true speed or torque control is possible.
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Motor on AC Adjustable Speed Drive
Motor AvailableTorque
Full LoadTorque Level
Torq
ue,
Amps
Amps
AC Adjustable Speed DriveMotor Amps & Torque vs Speed
MAdjustable
SpeedDrive
No Starting Inrush amps,Torque & Volts Controlled to
Match Load
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.
2/12/2001 VFD APPLICATION 12
TM GE Automations Systems Western Mining Electrical Association
Drive Ratings and Torques
• Variable Torque - ratings usually include 110 -115% OL rating for 60 seconds at rated Temp
November 2004 TMGE Automation Systems - All rights Reserved 13
TM GE Automations Systems Western Mining Electrical Association
Loads & Motor “Capability” Curves
TEFC
Variable Load [P
ump, F
an]
Constant TorqueLoad, Example 2
Constant TorqueLoad, Example 1
RPM -- >
Load
Tor
que
Theoretical Motor Capability
Actual Motor Capability
100% Load Point,NP RPM, Sine wave power
Induction Motor CapabilitiesUnder Variable Speed Operation
imcapab1.drw June 4, 98
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TM GE Automations Systems Western Mining Electrical Association
Pump & Fan “Affinity” Laws: 1-2-30
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
HP - %
flow - %0.00%
10.00%20.00%30.00%40.00%50.00%60.00%70.00%80.00%90.00%
100.00%
% Speed
% of Total
- 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
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Fans Fans --Things to RememberThings to Remember“Fans” have variable torque loads. “Blowers” mayhave 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
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Variable Torque Drive Applications
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Multiple Motor Pumping Application
ST1
ST2
ST3
M1
M2
M3
MTR1
MTR2
MTR3
Starting/Running Drive
4160 V
Drive
Starting/RunningContactors
PumpMotors
Across the LineContactors
4160 V
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Drive Ratings and Torques
Constant Torque [CT] rating usually includes 150% - 250% OL rating for 60 seconds when at rated Temp.
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Constant Torque –Characterized as a load curve that looks like
Variable Load [Pump,Fa
n]
Constant TorqueLoad, Example 2
Constant TorqueLoad, Example 1
RPM -- >
Load
Torq
u e
Theoretical Motor Capability
Actual Motor Capability
100% Load Point,NP RPM, Sine wave power
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TM GE Automations Systems Western Mining Electrical Association
Conveyor or Mill Loading
conveyor typical demand
Typical InductionMotor Char on 60 Hz power
TOR
QU
E
FREQ, SPEED
BREAKAWAYTORQUE
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TM GE Automations Systems Western Mining Electrical Association
Conveyor or Mill Loading
conveyor typical demand
Typical Induction Motor Char on 60 Hz power
TOR
QU
E
FREQ, SPEED
BREAKAWAYTORQUE
VFD CONTROLLED MOTOR -ENOUGH TORQUE ACROSS THE RANGE
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Crushing and Crushing and Conveying SystemsConveying Systems
TM GE Automations Systems Western Mining Electrical Association
Example MV Drive Mining Application
MINE-MOUTH TO PROCESSING PLANT CONVEYOR
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TM GE Automations Systems Western Mining Electrical Association
Application Story – Long Conveyor1. 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!
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PWM-3 1000 HP.
900 kVA13,800/2300 V
13.8kV1000 HP2.3 kV
C 1000 HP PWM-3 w/1 1000 HP Motor Basic configuration for Pulleys 4, 5, 6, 7
PWM-3. 2250 HP.
2140 kVA13,800/2400 V
13.8kV
2250 HP2.3 kV
A 2250 HP PWM-3 w/1 2250 HP Motor Basic Configuration for Pulleys 1, 2, 3
ELECTRICAL ONE LINES
2000 HP Drive CanAccommodate [2]1000 HP Motors
B 2000 HP PWM-3 w/ two 1000 HP Motors Alternate for pulley 4
PWM-3 2000 HP.
1900 kVA13,800/2300 V
13.8kV
1000 HP2.3 kV
1000 HP2.3 kV
ELECTRICAL ONE LINES
PC-2 ConveyorPlan View
10.5 miles, 16.8 kM
CONVEYOR PC-2
Elev.9,500 ft
2,400 ft
Elev.7,100 ft
2 13
Head end equip house@ 9500 feet AMSL
GRADE = Variable 5% to 1%
5%
3%
1%
GRADE = Variable 0% to 8%
CONVEYOR PC-1CONVEYOR PC-3
PC-1 ConveyorPlan View
4
Head end equip house@ 7,100 feet AMSL
PC-3 ConveyorPlan View Head end equip house
@ 9,500 feet AMSL
7
4.0 miles, 6.4 kM0.76 miles, 1.2 kM
6 5
Tail end equip house@ 9,500 feet AMSL
2 x 1000 HP 2 x1000 HP
1 x1000 HP
1 x2250 HP
2 x2250 HP
1 x2250 HP
1 x1000 HP
Application Story – Long Conveyor
8/18/97 Henpres1.ppt Slide S-21
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Application Story – Long ConveyorConveyor Mechanical Application
Considerations
Stretch, Length, Belt weight,load weight,speed
Friction
T1
T2
T3
T4
D1
D2 D3
Tension Ratios,Dynamic Response,Programmed Torque, Load Sharing
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PC-2 UPHILL CONVEYOR with PWM Drives
PC-2 ConveyorPlan View
2 13
Head end equip house@ 9500 feet AMSL
1 x2250 HP
2 x2250 HP
1 x2250 HP
PWM-3. 2250 HP.
2140 kVA13,800/2400 V
13.8kV
2250 HP2.3 kV
A 2250 HP PWM-3 w/1 2250 HP Motor Basic Configuration for Pulleys 1, 2, 3
ELECTRICAL ONE LINES
8/18/97 Henpres1.ppt Slide S-23
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PC-3 OVERLAND CONVEYOR with PWM-3 Drives
PC-3 ConveyorPlan View Head end equip house
@ 9,500 feet AMSL
7 6 5
Tail end equip house@ 9,500 feet AMSL
2 x1000 HP
1 x1000 HP
1 x1000 HP
PWM-3 1000 HP.
900 kVA13,800/2300 V
13.8kV1000 HP2.3 kV
C 1000 HP PWM-3 w/1 1000 HP Motor Basic configuration for Pulleys 4, 5, 6, 7
8/18/97 Henpres1.ppt Slide S-24
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PC-1 FEED CONVEYOR with PWM-3 Drives
PC-1 ConveyorPlan View
4
Head end equip house@ 7,100 feet AMSL
2 x 1000 HP
PWM-3 1000 HP.
900 kVA13,800/2300 V
13.8kV1000 HP2.3 kV
C 1000 HP PWM-3 w/1 1000 HP Motor Basic configuration for Pulleys 4, 5, 6, 7
8/18/97 Henpres1.ppt Slide S-22
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Application Story – Long Conveyor
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
Power Challenges
• Long power feeds
• Cable capacitance created resonance high order harmonics
Control Challenges• Precise, programmable
torque for belt tension control
• Head-to-tail tension coordination for PC3.
• Allow variable speed operation of any motor
Motor Solution
GE 2.3 kv induction motor separate
cooling air by user
Drive And Control Solution
GE Innovation PWM 2300 volt 3-level, 18 pulse rectifiers. Utilized Innovation Series Controller for torque programming & PLC Ethernet interface.
Power Solution
3-level Inverter with IEEE 519 compliant 18 pulse converters and high frequency filters to eliminate cable resonance at 19th harmonic
Challenges & Solutions
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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 endTension control of up-and-down PC3 overland with many curves
Application Story – Long Conveyor
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TM GE Automations Systems Western Mining Electrical Association
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
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Drive Output Voltage & Motor ApplicationLV 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 HPMany users select MV over 500 HP.
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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
• Why pick MV [>690v] Drive & Motor over LV?– Lower cost wiring, smaller cables– Lower power system harmonic impact– High HP LV require dual winding motors– Individual preference
• Trend: Some users select MV at >250 HPMany users select MV over 500 HP.
•• Why Pick LV [<690v] Drive & Motor?Why Pick LV [<690v] Drive & Motor?–– LV drives are lower cost / HP than MVLV drives are lower cost / HP than MV–– Reduces some safety & MV training concernsReduces some safety & MV training concerns–– HP range is small enoughHP range is small enough–– Individual preferenceIndividual preference
•• Why pick MV [>690v] Drive & Motor over LV?Why pick MV [>690v] Drive & Motor over LV?–– Lower cost wiring, smaller cablesLower cost wiring, smaller cables–– Lower power system harmonic impactLower power system harmonic impact–– High HP LV require dual winding motorsHigh HP LV require dual winding motors–– Individual preferenceIndividual preference
•• Trend:Trend: Some users select MV at >250 HPSome users select MV at >250 HPMany users select MV over 500 HPMany users select MV over 500 HP..
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MV vs LV AC Drives:Cost Factors of Various Configurations
MV vs LV AC DrivesBudgetary $ per HP
vs HP
0.0
100.0
200.0
300.0
400.0
500.0
0 500 1000 1500Horsepower
Bud
geta
ry
$ pe
r Hor
sepo
wer
LV 6-Pulse w/o Transformer
MV 4160 v 24-Pulse DB5i
LV 6-Pulse w/8% Mirus filt
LV 18 pulse incl transf
• 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
• Installed cost must be considered
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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 firingElectrical and mechanical interlocks & isolator switchesBolt on covers, warning labels
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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.
TM GE Automations Systems Western Mining Electrical Association
MV Drive Evolution
History,Topology Comparisons,& Future Trends
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Typical AC Inverter System
Transformation
UtilitySupply
Conversion
Load
Utilization
AC Inverter TechnologyUp To 97% Efficiency, including transformers
RECTIFICATION
AC TO DC
OROR
ENERGYSTORAGE
OR
SWITCHING
DC TO AC
OR
AC MOTOR
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Advances in Power
Semiconductor Technology
Lead the Way in MV Drive
Development
• The Common Threads:– All AC Drives rectify AC to DC – All AC Drives use switches to create
AC from DC• Drive topologies were created as
power rectifiers and switches grew in ratings and capabilities.
• Each new or uprated device opens up new applications
• A quick look at the device development timeline is useful
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Development Time Line of Power Semiconductors
1955 1965 1975 1985 1995 2005
Diode (D) SiliconControlled
Rectifier (SCR)
Bipolar PowerTransistor
(BPT)
Gate Turn OffThyristor(GTO)
Low Voltage InsulatedGate Bipolar Transistor
(LV IGBT)
Integrated GateCommutated Thyristor
(IGCT)
Medium Voltage InsulatedGate Bipolar Transistor
(MV IGBT)
Symmetrical GateCommutated Thyristor
(SGCT)
Injection EnhancedGate Transistor
(IEGT)
Thyristor Devices
Transistor Devices
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Gate Power Supply
GTO Gate Driver & Cell Stack EquipmentGE GTO-IMD Example
• Liquid-cooled configuration• Many discrete parts in
firing and auxiliary parts• Snubber network also
shown• Physically quite large
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GCT Gate Driver EquipmentCovers on
Gate Power Supply
Isolation Transformer
IntegratedGate Signal Unit GCT
4.5kV-4kA
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GCT & Gate Driver BoardCovers off
4.5kV-4kA4.5kV-800 A
36 Electrolytic caps21 FET Switches
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Typical IGBT & IGBT Gate Driver CircuitIGBT
400 amp 3300 volt dual packageLarger ratings have 1/package
Typical MV IGBT Dual Gate DriverEach board has 2 drivers, & fires 2 IGBT’s
Approximate Size:
4 inches x 4.5 inches
2 in,50 mm
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IEGT Gate Driver Equipment
IEGT4.5kV-4kA
Gate Drive BoardGate Drive Board
IEGT = Injection Enhanced Gate Transistor
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0
5 0 0
1 0 0 0
1 5 0 0
2 0 0 0
2 5 0 0
3 0 0 0
3 5 0 0
IC
LE D
FILM C AP AC IT O R
E LE C TR O LYT IC
R E S IS TO R (1/4)
R E S IS TO R (P W R )
D IO D E
FE T
TR ANS IS TO R
FITs
F
ailu
res
per B
illion
Hou
rs
IGCT IEGT
IGCT vs IEGT Calculated Failure Rates of Gate DriversCalculated Reliability of Gate DriversIEGT Voltage Fired vs GCT Current Fired
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Power Switching DevicesFinal 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
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• 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.
Two Basic AC Drive Topologies
A map-like diagram showing the elements of an AC drive and the relationships between them.
AC Drive Topology:
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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
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Current Source Drives
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InverterTopology
Advantages Drawbacks Practical Power Range
Current sourceLoad-CommutatedInverter
SCR = Silicon Controlled Rectifier, Thyristor
• 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.
Above 6 MW
Synchronous Motors Only
Example: GE-Innovation Series® LCIEnergy stored in
Link Inductor
Volts SyncMotor
UTILITY
SCR
SCR
Alternate: Multi-pulse/Multi-channel Converter
DC LinkInductor
LCI – Current Source Load Commutated Inverter
Primarily being offered by:
TMGE, ABB, Siemens
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InverterTopology Advantages Drawbacks Practical Power
Range
Current SourceGTO or SGCT
PWM Inverter
GTO = Gate Turn Off Thyristor
SGCT = Symmetrical Gate-Controlled Thyristor
• Low power device (GTO/SGCT) parts count
• Low motor THD• Low motor insulation
stress when input isolation transformer is used
• Requires a controlled front end – extra complexity
• Poor input power factor, with SCR front end
• Slow transient response• Narrow speed range• Potential resonance
between motor & caps• Limited availability of
power devices• Complex firing circuit
2 - 15 MW
Primarily induction motor load
Energy stored inLink Inductor
Volts InductMotor
UTILITY
GTO /GCT
SCRDC LinkInductor
Alternate: Multi-pulse/Multi-channel Converter
Example: GE-GTO IMDInduction Motor Drive
Current Source GTO / SGCT Induction Motor Drive
Primarily being offered by:
Allen Bradley
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Current Source SGCT Induction Motor DriveWith “Isolation” Reactor in Place of Transformer
Volts InductMotor*
UTILITYSCR
orGCT * non-
standard
DC LinkInductor
"Isolation"Inductor
Energy stored inLink Inductor
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Voltage Source Drives
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Voltage Source General Drive Arrangements
UTILITY 1 2 3
VoltsMotor
Alternate: Multi-pulse/Multi-channel Converter
Diode RectifierConverter Fed
Active RectifierConverter Fed 3
VoltsMotor
12
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PWM: Pulse Width ModulationA 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 WAVEPRODUCED BY 2-LEVEL
PWM INVERTER
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Example Two-Level Voltage Source Inverter
MDBR
3 PhaseDiode Bridge
ab
c
AC IncomingLine
[ + ]
[- ]
Three Phase Input
-1.3
-0.8
-0.3
0.2
0.7
1.2
0 50 100 150 200 250 300 350 400
Rectified 3-Phase
0
0.2
0.4
0.6
0.8
1
1.2
0 50 100 150 200 250 300 350 400
Rectified 3-Phase
0
0.2
0.4
0.6
0.8
1
1.2
0 50 100 150 200 250 300 350 400
DC Buss Rectified Power
PWM Motor Volts
Motor Amps
CapBank
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Fixed DCBus
Inverter(IGBT)
DiodeRectifier
LV IGBT Multi-level Voltage Source PWM Inverter
InverterTopology
Major Advantages Major Limitations Practical Power Range
Multi-level Voltage Source LV IGBT PWM Inverter
LV IGBT = Low-voltage Insulated Gate Bipolar Transistor
• Power Cell N+1 redundancy available
• 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
• 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
0.5 – 10 MW
Sync or Induction motor
Example: GE Innovation Series® Type H
Energy stored in electrolytic capsTypical Power Cell
Primarily being offered by:Robicon, Toshiba Japan
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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 workAdded parts work all the time and decrease drive component MTBF
• Traditionally, increased reliability comes from reducing parts count and conservative design.
Loadconverter
Sourceconverter
DC linkreactor
Sync MotorFeedTransformer
Added Power Devices forRedundancy
Shaded Green
LCI driveN+1 requires
12 SCR’s
Fixed DCBus
Inverter(IGBT)
DiodeRectifier
TYPICAL LV IGBT POWER MODULE FOR REDUNDANT USE
ELECTROLYTICCAPS
BYPASSSCR
LV IGBT MV DriveN+1 [3 extra power cells] adds
18 diode Rectifiers12 LV IGBTs, 15 bypass SCRs
42 electrolytic Caps, Firing circuits+ 3 added transf windings
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Fixed DCBus
Inverter(IGCT)
Diode or IGCTRectifier
AC Input
InductionMotor or
syncMotor
[req fieldexciter]
Filter
Energy stored in liquid filled caps
IGCT PWM Voltage Source Inverter
Example: GE-Innovation Series® SP IGCT Mill Drive
InverterTopology
Practical Power Range
IGCT PWM Voltage Source Inverter
Three Level
• 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
0.5 – 4.8 MVA per inverter, air cooled
4.8 – 9.6 MVA, dual channel
• 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.
Major Advantages Major Limitations
Primarily being offered by:
TM GE, ABB
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InverterTopology
Practical Power Range
Three / Five Level Voltage Source MV IGBT PWM Inverter
MV IGBT = Medium-Voltage Insulated Gate Bipolar Transistor
• Minimum parts count forvoltage 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
0.5 – 4.8 MVA per inverter, air cooled
4.8 – 9.6 MVA, dual channel
Sync or Induction Motors
• No regeneration available• Fast rise time IGBT switching
may require dv/dt output filter in some cases
• Power Device redundancy not practical
Example: TMGE Automation Systems Dura-Bilt5i® MV
MV IGBT NPC Voltage Source Drive
Ind orSyncMotor
Multi-WindingTransformer
Multi-PulseDiode Rectifier
MV-IGBTNPC Inverter
1
23
Liquid FilledPower Caps
Major Advantages Major Limitations
Primarily being offered by:TMGE Automation Systems,
Siemens
Energy stored in liquid filled caps
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MV IGBT NPC Voltage Source Drive Details
U-Phase LegAssembly
VoltageDetection
Module
OpticalLink
Module
24-PulseSource
460 Vac
V-Phase LegW-Phase Leg
24-P Source24-P Source
NM
•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
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InverterTopology
Practical Power Range
Three Level Voltage Source LV IGBT PWM Inverter
LV IGBT = Low Voltage Insulated Gate Bipolar Transistor, 1700 volt rating
• 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.
0.5 – 10 MVA using up to 4 bridges, air cooled
Sync or Induction Motors
• Power Device redundancy not practical
• 1250 volt rating limits max power
Example: TMGE Automation Systems TMdrive 30
LV IGBT NPC Voltage Source Drive
Major Advantages Major Limitations
Primarily being offered by:TMGE Automation Systems
Fixed DC3-level Bus
Inverter(IGBT)
AC Input
InductionMotor or
sync Motor[req fieldexciter]
Converter(IGBT)
Energy stored in high reliability electrolytic caps
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MV IGBT NPC Voltage Source Drive Details
• 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
0.2
0.7
1.0
0 50 100 150 200 250 300 350 400
1.08
RMS
PEAK
Red = 3-level PWM Voltage output
M
+ 900
- 900
Simulated Inverter Voltage Waveforms of 3 level NPC PWM
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Fixed DCBus
Inverter(IEGT)
AC Input
InductionMotor or
sync Motor[req fieldexciter]
Converter(IEGT)
InverterTopology
Practical Power Range
Three Level Voltage Source IEGT PWM Inverter
IEGT = Injection Enhanced Gate Transistor
• Minimum power device count – 24 for complete 8 mw regen system
• Simple firing circuit [4:1 more reliable than IGCT] and very high system MTBF.
• Low motor current THD• Fast transient response & wide motor
frequency range• High starting torque with no
significant torque pulsations• Active front end for low harmonics,
regeneration, unity or leading PF
6 to 26 MW, water cooled, one or two channelAt 3300 volts
Sync or Induction Motor
Example: TMGE Automation Systems 8 MW TM-70IEGT drive with active IEGT Source
• IEGT device limits allow 3300 volt motor output [European and Asian Standard]
• 3300 volts is not as common as 4160 volts in North American applications.
IEGT PWM Voltage Source Inverter
Energy stored in liquid filled caps•
Major Advantages Major Limitations
Primarily being offered by:TMGE Automation Systems
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IEGT PWM Voltage Source Inverter & Active Converter Circuit Details & Alternate Diode Converter Configuration
Fixed DCBus
Inverter(IEGT)
DiodeRectifier
AC Input
InductionMotor or
sync Motor[req fieldexciter]
IEGT PWM Voltage Source Inverter with Diode Converter
INDUCTIONOR SYNCMOTOR
Sync Field[If Applic]
Transformer& Feed Reactor
20% Z
8 MW IEGT Inverter with active regen-capable source
3 Level VFD Line-Line Output &Reference Sine Wave
0.2
0.7
1.0
0 50 100 150 200 250 300 350 400
1.08
RMS
PEAK
Red = 3-level PWM Voltage output
Simulated Inverter Voltage Waveforms of 3 level NPC PWM
TM GE Automations Systems Western Mining Electrical Association
A Modern MV Drive Example:
TMGE Automation Systems Dura-Bilt5i® MV
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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
200 300 400 1000 2000 4000 10000 HP
150 450 300 750 1500 3000 7500 kW
Vac4200
4000 Series
3000 Series
2000 Series
400 – 10,000 HP [300 – 7500 kW]
300 – 8500 HP [225 – 6340 kW]
200 – 5000 HP [150 – 3730 kW]
4000
3300
3000
2400
2000
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Very Compact
EST WT: 7,500 LBS 3,402 KG
300- 900 HP 3.3 & 4kV Outline
103.7[2634]
90.1 [2288]
110 [2794]
flapper clearance
43.4 [1102] 74 [1880 ]
Left Side / End View
No rear access required
300-900 HP Dura-Bilt5i MV Inverter, 3000 & 4000 series
24" fan top to ceiling for airflow clearance
ConverterSection
With IncomingConnections
Control [front]Motor Connections[Behind Control,
RH - Side]
Inverter
Front View
OptionalRedundant
Fan
StandardFan
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Dura-Bilt5i MV3300 - 4160 VoltDetailed One-Line Diagram
Dura-Bilt5i MV Control
INVERTER
Main Power7.2 kV class or below
Sensing PT's120 output
Integral12 winding
Transformer
circuit
IntegralDisconnect
Option
Hall CTCurrent
Feedback
IntegralLightningArrestor
Optionalredundant fansshown dotted
StandardE.S. Shield
M
Aux & ControlPower
460 std., others avail
33
U-Phase LegAssembly
VoltageDetectionModule
OpticalLink
Module
24-PulseSource
460 Vac
Control powerfeed option
V-Phase LegW-Phase Leg
24-P Source
CONVERTER24-P Source
OptionalDV/DT Filter
E
Incoming PowerCompartment
3
ACLM1
M2
Fan FanFan Fan
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Power System and Motor FriendlyAMPSGREEN
VOLTSBLACK
Note: traces time-shifted for clarity Utility Motor
Current Distortion: THD < 3%,Voltage Distortion: THD < 6%Line Current Distortion < 3%
Meets IEEE-519-1992 – With No Filters. With No Filters. Requires No Special Motor Thermal Rating
Operating Conditions: Full Speed, 95% LoadNOTE: Utility current trace displaced in time for clarity
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INCOMINGPOWER
BYPASSCONTACTOR
[option] TRANSFORMER & DC CONVERTER
INVERTERSECTION
Compartmentalized Design…
•Separate cooling for converter and inverter
•Control and power separated
•Voltage levels separated
•Only front access required
A Look Inside . . .
DRIVECONTROL
Typical Dura-Bilt5i MV 1850 kVA Drive
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Incoming Power Compartment
Built-in 3-phase fused disconnect, interlocked with cubicle door that can be padlocked in the open position
Integral lightning arresters for transient and surge protection
Dedicated wireways support bottom or top incoming cabling
Integral ac reactor for charging and protection of dc bus components
Built-in 3-phase MV contactor interlocked with disconnect
Fused potential transformers
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Transformer and Converter Compartment
DC cables to inverter compartment minimizes connections; thisspeeds and simplifies installation
24-pulse rectification gives power quality better than IEEE 519 recommended limits
Transformer secondaries fused with blown fuse indicators
Washable filters can be changed while drive is operational
Forced air cooled with dedicated fan. [Optional redundant fan with auto throw-over available]
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Drive Control Compartment
Optional controls for drive by-pass or other auxiliary functions
Process input-output [I/O] control board
Communication board supporting Profibus, ISBus, DeviceNet™ and Tosline S20
Separate disconnect for control power
Microprocessor control boards for drive sequencing and motor speed/ torque control
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Inverter Compartment• Easy access roll-out inverter
phase modules• Inverter module consists of:
•MV IGBT’s 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
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High Efficiency Plate Heat Exchanger for IGBTs
• 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
How it works
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• 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
High Efficiency Heat Pipe Exchanger for IGBTsAdvantages
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Inside a Typical Power IGBTThis 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
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By-Pass Contactor CompartmentRequires optional additional cubicle integrated into drive line up
Cubicle extension houses both input and output contactors
Allows full speed motor operation from utility power if drive is not available.
Contactors are interlocked to allow drive by-pass and connect motor across the power lines
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Dura-Bilt5i MV Display Unit Parameter EditingIntuitive menu interface for parameter editing
Drive StatusGraphic screen displays key variables in bar chart format with additional status icons
Status IndicatorsGive quick indication of drive operation, without requiring separate panel lamps
Control System Toolbox Interface10-100 Mbps Ethernet can be multi-drop networked -access to GE 24-7 on-site monitoring
Signal MonitorAnalog signals for test instrumentation
Local Drive ControlDedicated keys for local control of the drive for commissioning and maintenance activities
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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
Easy to UnderstandData Structure:• Drive parameters
and variables in tree structure
Animated Block Diagrams
World Class TMGE Control System Toolbox Supplied with Every Drive!
Same Toolbox as all GE System Drives and Many Exciters!
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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
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Thanks!
Bill HorvathTMGE AutomationWilliam.horvath@tmeic-ge.com540-387-8253
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