h&m power conversion segmented inverter 2010 r1
DESCRIPTION
TRANSCRIPT
04/10/23 1
690 VGrid
PM Generator
690V
690VAC, 460 Amps
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3 Phase2.5MW 690 V
By: Dr. Sammy Germany
04/10/23 2
Background: To achieve low cost of energy, turbine manufacturers have
traditionally focused on: • Component cost• Component reliability• Variable speed applications to capture more low wind
speed energy
More recent industry trends have focused on • PMG - energy capture in wider wind speed range• High efficiency & Reducing O&M costs• Designs for lower class sites (Class 3)
Power System Focus – Availability + Uptime• Uptime is the key to capture more energy• Diminishing returns for
power component MTBF power component MTTR
Uptime kWh
Energy: Power & Time
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Modular Multi-MW Converters
PM Generator
690V 690V
690V Multi
Three-Phase Set Generator
35kV
High Reliability – High Availability
1. Designs are built to be reliable, tough inverters 2. Mechanical robustness to reduce O&M costs in harsh
turbine environments 3. Modularity: Operational redundancy, increasing
availability of system even under fault conditions
Cap
acity
100%
Failure event MTTR
Without redundancy
Withredundancy
time
Energy Savings w/ redundancy
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Class 4 - 30 MW Wind Farm Met Data
0
2
4
6
8
10
12
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
Win
d S
pee
d m
/s)
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
Per
Un
it T
urb
ine
Po
wer
(M
W)
Wind Speed (m/s)
Average Power
• Class 3-4 Wind farm met data used for energy harvesting case studies• Peak hourly wind speed average 80% - Optimal for parallel units. • 10 Towers, 3MW turbines
Turbine Power
Month
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What is the problem? Lost revenue from non-operation turbines increased the cost of energy in large wind farms.
• Turbine repairs occur after multiple turbines have failed (high O&M costs)• In large farms, 3-5 turbines may need to be down before serviced (up to 3 months)• Long MTTR of wind turbines impacts energy capture rates.
How significant is it for a 30MW Wind Farm?• $6.6M : Yearly energy revenue for a Class 4, 30MW wind farm (6.5 c/kW.hr)
• $330k (5%): Yearly lost revenue from 3 turbine failures with 3 months downtime.
Benefits of a DRS Power System Solution:
• If one (1) turbine failure is due to an inverter, the module remains operating and capturing energy.
• $165k Savings: 2.5% of wind farm’s yearly revenue
NPV: $0.8M – 1.8M for 1 to 2 power failures / yr over life of wind farm (20yrs)
(Considering increased energy generated due to uptime and the cost of power system modularity)
04/10/23 6
690 VGrid
PM Generator
690V
690VAC, 460 Amps
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3 Phase2.5MW 690 V
Topology Description• 500kW 690V full conversion power modules• Independent dc bus per converter stage to
maximize availability• Isolating grid and generator contactors • Integrated dynamic brake for LVRT• Suitable for medium speed and direct drive. • Optional generator dv/dt filters
Inherent Redundancy to maximize availability
Controls• Independent power module control
electronics. • No master controller with a single point of
failure.Benefits+ Lower bearing current stress+ Open winding failure on generator+ Hatchable converter for low MTTR
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690 VGrid
PM Generator
690V
690VAC, 460 Amps
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3 Phase2.5MW 690 V
DC Bus Intertie Inverters A common approach used by commercial motor drive suppliers
- No ability to isolate inverters from the shared dc bus reduces availability.
+ Lower Cost inverter controls, switchgear, filters, power module ratings ($42k delta)
Investment Project Financial Analysis Date:Unit: DRS-PCT
Project Name: 2.5 MW Wind Converter
Investment Plan 1 2 3 4 5 6 7 8Components $420,000 $0 $0 $0 $0 $0 $0 $0
Total investment $420,000 $0 $0 $0 $0 $0 $0 $0
Revenue $0 $330,000 $330,000 $330,000 $330,000 $330,000 $330,000 $330,000Income $0 $330,000 $330,000 $330,000 $330,000 $330,000 $330,000 $330,000ROS % 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%
Net Cash Flow ($420,000) $330,000 $330,000 $330,000 $330,000 $330,000 $330,000 $330,000
Cost of Capital 12.0%NPV $1,795,273.54 20 yrsIRR 76% 7 yrs
30MW Wind Farm Benefit with a DRS Power System
Net Present Value of Investment in Modularity. $0.8M – $1.8M: (1 to 2 failures / yr over 20 yrs)
Investment: $42k per turbine
$420k per wind farm.
Revenue: $165k per inverter event / yr
04/10/23 8
04/10/23 9
IP54
04/10/23 10
Full Power Conversion Systems for Wind Applications
• Power Module and cabinet system under development • Power modules: Grid & generator side inverters
Filters, protection, dynamic brake, controls, communications.• Generator Compatibility: PM, Synch., DFIG• Available: 500kW system in 2010
Major SpecificationsUtility Voltage: 690VOutput Capacity: 600kVA, 500kWGrid Freq: 50Hz or 60HzGenerator Freq. 10Hz to >150Hz depending on
generator requirementsCooling : Air or liquid cooled Location: Up-tower or down-tower
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Ethernet Fiber
Power Converter
To 690V AC Line
Gate
drive
sig
nals
an
d
cu
rre
nt
se
nsors
Thermistor
RS
23
2
Turbine controller
CA
N
Fib
er
Op
tic lin
k
Sensing and Control
Optional Discrete I/O
DRS PEMC Embedded Control Platform
Other Sensors
Grid Side FilterGrid
Contactor
DRS Full Power Conversion Block
RouterHMI
Customer Interfacing Capability
PM GEN.
General Description
• 500kW, 690V grid connection
• PM or synchronous generators compatibility
• 1700V IGBT power converter
• Integrated dynamic brake for Low voltage ride through
• Liquid cooled power converter
• Grid contactors for protection and isolation. Generator isolation optional
• IP54 Air cooled cabinet• High reliability power
module design: high MTBF: Film capacitors, low IGBT thermal stress, liquid cooling.
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DC bus capacitors
IGBTs
Gate drivers
Module Design under development
Control board
Bus plane
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Wind Farm Power (MW) 30 MW Number of Turbines 10
Number of failures per month 1Duration (months) 3Lost turbine months 6Total turbine months/ yr 120% of lost turbine months 5%
Savings - if 1st turbine failure is eliminated# turbine months saved 3% turbine months saved 2.5%
Event Description
• one turbine failure per month
• Service occurs after 3 months, 3 failures
• 1st failure is assumed to be the inverter – and mitigated.
• Savings shown.