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MTG-16-03-5580 / 6595 - 1

R E S E A R C H & D E V E L O P M E N T

Creare LLC Copyright © 2017 An unpublished work. All rights reserved.

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MTG-17-09-6263A / 6596 - 1

Sandia National Laboratories is a multimission laboratory managed and operated by National Technology and Engineering Solutions of Sandia LLC, a wholly owned subsidiary of Honeywell International Inc. for the

U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Creare LLC Bruce R. Pilvelait October 11, 2017

Phase I & Phase II SBIR: DOE Energy Storage Program, Dr. Imre Gyuk and Technical POC Dr. Stan Atcitty, Sandia National Laboratories

2017 EESAT Conference

Feasibility Analysis and Testing of a Utility Grade Advanced Power Inverter (API)

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Copyright © 2017 Creare LLC An unpublished work. All rights reserved.


U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. MTG-17-09-6263A / 6596 - 2

• Motivation: What can SiC do for me? • Opportunity: Improving existing MV inverters • Topology: DAB 3LNPC • Status Update: Last year; this year; next year • Testing Results • Development Plan

Contents

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Objective: Greater Power Density & Revenue

Our long-term objective is to provide the API to improve existing products.

Existing 500 kVA Grid Tied Energy Storage Container (Dynapower)

Eliminate Add Key:

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Motivation: SiC Is an Enabling Technology

• Use SiC WBG technology to improve the value proposition for Grid Tied Energy Supplies: – SiC high voltage rating enables direct connection to medium

voltage grids (3θ, 12.47 kV) (this is the enabling technology) – Eliminates 60 Hz transformer (reduces size) – High operating temperature eliminates liquid cooling (reduces

size, improves reliability) – Creates modular building block for 500 kW to MW+ (expands

markets) – Achieves >4x power density improvement (customer benefit) – Reduces audible noise (customer benefit)

Proposition: SiC devices can improve the value of grid tied energy

supplies by reducing size and cost and improving reliability and end user satisfaction.

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Creare’s API Meets or Exceeds All Objectives Parameter Requirement Creare’s API

Semiconductor Type Silicon Carbide Silicon Carbide Output Voltage (kV) >12.47 12.47

Output Power (kW) 100 500

(can be combined for MW+ class power)

Power Density Improvement 2X 4.3X

60 Hz Transformer Eliminate Eliminated

Cooling Eliminate liquid cooling Forced air convection

Power Flow Bidirectional Bidirectional

Program Objectives

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Opportunity for Improvement

Typical DC-AC Inverter:

Battery MV Transformer 480 : 12.47 kV

LV Inverter

Filter

1 kV 12.47 kV

Limitations of this design: • Requires 480 : 12.47 kV transformer for grid connect. • Silicon MOSFETs or IGBTs require liquid cooling (~50°C). • Filter is large and also requires liquid cooling. • 60 Hz transformer emits acoustic noise.

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SiC Enables Direct Grid Connection Battery MV Grid Tied Inverter (3LNPC) DAB Creates (2) 10 kV buses

Filter

1 kV

12.47 kV

HF Transformer

Improvements: • SiC MOSFETs enable direct grid connection to 12.47 kV. • 60 Hz transformer replaced with (2) smaller (10X) high frequency transformers. • Transformer is quieter. • Liquid cooling is eliminated. • Filter faces lower current, reduces losses, and eliminates liquid cooling.

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• Presented Last Year: – Described objective, opportunity, and topology – Illustrated that power density of SiC is ~ 4X Si, and cost

is about the same • This Year:

– Completed a preliminary design – Completed low voltage testing of SiC devices – Completed testing of controller and 480 V operation of

Si surrogate topology – Designed and fabricated 250 kW HF transformer and

inductor • Next Year:

– Refine design details – Fabricate and test high voltage SiC topology at 125 kW – Demonstrate 12.47 kV grid interface

2017 Status Update

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Inverter Package Design: SiC Inverter

• Total rack volume for electronic components and cooling system is 1.125 m3. • Total space claim is about 1.75 m3 including bus work and components mounted

to the back of the rack. • Substantial reduction is achieved by elimination of liquid cooling and transformer.

Heat Sink

Caps Controller Boards

SiC Modules

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Low Voltage Bridge Testing – Low Power

• A full bridge, with Creare custom 1:1 transformer and resistive load

• RLoad = 10Ω • fs = 20 kHz • Voltage on the load for different

values of input voltage:

Vin=15V Vin=20V Vin=30V

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Silicon IGBT Prototype

Part number Description CHK-7-005011500 CHOKE, 500A, 480V, 115 uH CAP-1-300906000 CAP, 90.00 uFD, 600 VAC FFVE6B0107K- DC CAP metallized polypropylene , 100uF, 800VDC CM600HA-24A IGBT module (4X per leg) – 1200V, 600A FRS400CA120 Diode module for neutral clamp ( 2X per leg), 1200V, 400A

• Low voltage prototype developed with Si IGBTS to assist controls development

• Includes two dual-active bridges with high frequency transformers and 3-level neutral point clamp inverter

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Si IGBT Prototype

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3LNPC Inverter – Standalone (UF) Mode

Yellow = High voltage ramping from 0 to 800 VDC (two series DAB secondaries, 400 VDC Each)

Red and Blue = Output Voltage Phases = 480 Vrms, 60 Hz

Standalone Mode Startup

Green = Inverter Inductor Current = +/- 50 Apk, 60 Hz

Yellow = High voltage 800 VDC (two series DAB secondaries, 400 VDC Each)

Red and Blue = Output Voltage Phases = 480 Vrms, 60 Hz

Standalone Mode Steady State

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Grid Tied (PQ) Mode

Yellow = DC Bus Voltage = 800 Vdc Ramps up at startup

Blue = Grid Voltage = 480 Vrms, 60 Hz

Grid Tied Mode Startup

Red = Inverter Output Voltage = 480 Vrms, 60 Hz

Green = Grid Current

Yellow = DC Bus Voltage = 800 Vdc Contactors opened, then inverter gated to discharge bus

Blue = Grid Voltage = 480 Vrms, 60 Hz

Grid Tied Mode Shutdown


Green = Grid Current

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Grid Tied (PQ) Mode

Blue = Grid Current = 16 Arms, 60 Hz

Grid Tied Mode Steady State, 10 kW


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250 kW High Frequency Transformer

Nanocrystalline Core

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High Voltage AC Filter Inductor

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Technology Deployment Plan

10 Year Plan for Deploying the API Development

Phase Time Frame Objectives/Technical Focus

SBIR Phase I 2015–2016 • Develop proof-of-concept system • Feasibility testing

SBIR Phase II 2016–2018

• Full-scale prototype demonstration • Refine business plan • Marketing to existing and new customers • Evaluate peak shaving, energy shifting,

ramp rate mitigation, frequency regulation, active VAR management, voltage control

Commercialization 2018–2025 • Conduct initial demonstrations • Low volume production • Obtain safety certification

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• Finalize plan for high voltage converter components – select power scale and components

• Complete design for high voltage converter • High power testing of low voltage SiC devices • Begin fabrication of mechanical components • Begin fabrication of rack mountable modules

for low voltage components • Characterize high voltage / high frequency

transformer

Near-Term Plans

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• DOE Office of Electricity • Dr. Imre Gyuk • Dr. Stan Atcitty

Acknowledgements

Thank you! Bruce R. Pilvelait [email protected] www.creare.com

mailto:[email protected]

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