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S. D. Jang1. J. S. Oh1, Y. G. Son1, J. H. Suh1, S. J. Kwon1, W. W. Lee1, D. E. Kim1. Ch. H. Chun1, C. W. chung1, K. S. Han1, J. S. Hwang2, J. Y. Ryu2, O. J. Kwon3, G. W. Park3, H. J. Kim3 PoWER-C/PAL, POSTECH San 31 Hyojadong, Namgu, 790-784, Pohang, Korea Phone: +82.54.2791146 Fax: +82.54.2791199. e.mail: sdjang@postech.ac.kr 2 Unison Co., LTD 803, Jangsan-ri, Sooshin-myun Cheonan City, Chung-nam, Korea 3 PLASPO Co., LTD 1005, Ilsan Techno Town, Baekseok-dong, Ilsan-gu, Gyeonggi-do, Korea Abstract :Wind turbines require an electromechanical converter in order to convert the rotary motion of the blades into electrical power. The converter system is connected to between a generator system and a grid network. The fluctuation of power output can be reduced applying torque control through the electrical power converter. The use of permanent magnets (PM) for the magnetic field system in the rotor of the synchronous power generator allows for reduction of loss in electrical power and enables for high efficiency operation. A variable speed gearless synchronous wind turbine employing a PM type synchronous generator has been being developed to achieve this task. Pohang Wind Energy Research Center (PoWER-C) is developing a 750-kW inverter system for KBP-750D wind turbine in this year. This system includes an IGBT based electronic converters. Its design specifications are as follows; a rated grid voltage of 690 V with a output frequency of 60 Hz, a maximum output current of 643 A, a rated DC link voltage of 1250 V, an inverter efficiency of over 94%. In this paper, a principle of a power conversion, a basic design and initial test results of the inverter system are presented. Keywords: 750-kW Inverter System, Permanent Magnet (PM), IGBT Based Electronic Converters
1
1.
Introduction
Nowadays, several technologies may be used for the electromechanical conversion in wind turbines. The electromechanical converter may be generally referred to as a component or group of components, which converts the rotary motion created by the blades, into electrical power. In most cases, this electrical power must be compatible with the requirements of the public electricity company. Wind turbines require an electromechanical converter, in order to convert the rotary motion of the blades into electrical power. Several technologies have been developed to achieve this task, and the development continues. The latest developments include a permanent magnet direct-drive generator, connected to an IGBT based electronic converter. The direct-drive technology, using a permanent magnet generator is especially interesting for wind turbines that are erected in cold countries. The absence of a gearbox indeed excludes the need for lubricating oil, which in gearbox systems may contribute to the early failure of the gears, for such cold environments [1]. Even though the direct-drive technology offers several advantages over the geared technologies, it has not yet achieved competitiveness in terms of selling price. Progress in the development of permanent magnet of the rare earth has brought the feasibility of PM generators for lager-sized wind systems. Our wind turbine systems also have employed such generators. The loss of flexibility in the PM generator can be compensated for largely with semiconductor power processing. Through the use of variable speed control technology, we have designed highly efficient power generation capable of supplying stable power even when wind velocity fluctuates. Pohang Wind Energy Research Center is developing a 750-kW inverter system for KBP-750D gearless PM wind turbine. The average power rating of Wind Turbine Inverter Systems for the KBP-750D is 750 kW. This system includes an IGBT based electronic converters connected to the electric grid. And also, a 10-kW small-scale simulator is developed to study the control dynamics of the inverter for the 750-kW wind turbine. The rotor blades torque of the winds is simulated by a torque control of a DC motor. The torque controller evaluates equivalent torque according to the wind speed, wind direction, blade-pitching angle. In this paper, a basic design and initial test results of the inverter system will be presented together with the test results of the simulator.
2.
variable-frequency output of a wind machine to direct current and then reconverting it to utility-quality ac power can be realize by power semiconductor converters. Figure 1.depicts a simplified system overview for a gridconnected wind energy conversion system with IGBT converter and inverter. The converter system that includes inverter is connected to between a generator system and a grid network.
PWM converter
PWM inverter
Reactor
PM synchronous generator
Incoming panel Fig.1: Simplified system overview for a grid-connected wind energy conversion inverter system
Electronic power converter consists of AC/DC/AC power converter, reactor and protection panel. AC/DC/AC power converter consists of AC/DC conversion module (PWM converter), capacitor bank (Cd), DC/AC conversion module (PWM inverter), dynamic braking module (DBM) and cooling module. AC/DC conversion module provides the maximum power of generator within variable speed range with torque control and PWM technology. The DC/AC conversion module provides the high quality power to grid and soft grid connection. Dynamic braking module provides protection from rotor over-speed with abnormal condition in the event that a large amount of energy is regenerated back into the DC bus. Regenerated energy is dissipated as heat in the resistor. Above rated rotor speed, the generator torque is controlled in order to keep constant power output. DC/AC converting is performed by PWM technology. During DC/AC controlling, some control method is performed for satisfying the condition for parallel operation with gird and getting high power quality such as DC link voltage, AC voltage control, AC current control, power factor control. Power converter maintains DC link voltage higher than grid voltage for transmitting the power to grid. It uses D-Q coordinate method for controlling the voltage as well as the current. It controls power factor in order to improve the power efficiency.
Table 1. Design philosophy and Implementation of an inverter The power converter for Wind Turbine Systems of the KBP-750D is designed by the design parameters described in Table 2. It operates within the specifications.
Description Grid voltage Output power DC link voltage Output current Input power Input voltage Rated RPM Input current Switching frequency
Description Collector Emitter Voltage DC Collector Current(at 80 degree) Repetitive peak Collector Current Collector-Emitter Saturation Voltage Gate Charge Turn-off energe loss per pulse Turn-on energe loss per pulse Gate-emitter peak voltage Thermal resistance, juction to case Thermal resistance, case to heatsink
Symbol Vces Ic nom Icrm Vce sat Qg Eoff Eon Vges Rthjc Rthch
Value 3300 1200 2400 3.4 22 1300 1400 +/-20 8.5 6.0
I c 2 I inv ripple OL
(1)
Where Iinv: a rated RMS current of an inverter, ripple: the ripple current factor due to PWM (=1.1), OL: over load (=1.2). From above equation, a rated current of IGBT is 1200 A. In addition, the power loss and heat transfer conditions should be considered in the design stage [2]. For optimum operation of the IGBT, the total switching losses have to be minimum. Power loss analysis is carried out using commercial tools. Through the calculations, the ratings of IGBT stack, DC link capacitors are estimated. IGBT module (EUPEC FZ1200R33KF2C, 1200A, 3300V) was selected for a safe and reliable operation. Table 3 describes its specification.
Degree
Fig.3: Power Loss of IGBT Switch Also, the temperature analysis of heat sink and the specification of IGBT water-cooling system are resulted in Figure 4.
1,10 m x 0,70 m, with a built in water-cooling, where the hot water is led into a radiator. The basic cooling circuit diagram for inverter power cubicle is shown in Figure 5.
Item Symbol Dimension Material Heat Sink Hydraulic Liquid Heat Power Delta T Flow Rate Pressure Drop Dimension Capacity Radiator Water Delta T Flow Rate Pressure Drop Value 273 x 187 x 18 CU Water 3500 12 21.7 38 692 x 720 x 1716 1.34 1.9 260 2.1 W Degree l/min kPa mm kW/degree Degree L/min bar Unit mm
Fig.5: Basic cooling circuit diagram for cooling system The components specification of the cooling system was totaly reviewed before assembly. The components specification and design result of radiator cooling system is listed in Figure 6. The radiator used to cool the coolant is based on the Hyundai Olaer model SQI44-4. The dependence of the cooling power of the various radiators is shown in Figure 6 varying coolant flow rate. In our case, the coolant flow should be greater than 260 liters/min to maximize the cooling capacity. For further details, please consult specification sheet from Hyundai Olaer that describe parameters for all radiators.
M o d e l: H yu n d a i O la e r S Q I4 4 -4 F an M o to r: A C 3 p h a se, 4 p o les, 3 8 0 V 6 0 H z M ax im u m W o rk in g P ressu re: 2 1 b ar M ax im u m O il F lo w : 3 5 0 /m in C o o lin g C ap acity ( T = 4 0 C ): 5 8 4 8 0 k cal/h M ax im u m O il In let T e m p e ra tu re: 1 2 0 C
D esig n V a lu es
P ressu re D ro p : 2 .4 b ar W ater F lo w : 2 6 0 /m in C o o lin g C ap ac ity : 1 .7 k W /C W ater In let T e m p eratu re: 6 0 C
3.
T =
, Where is air density, R is blade radius, opt is optimum tip-speed ratio at the maximum torque coefficient CP, max. 400
350
The controller distinguishes three different control zones. These control zones are zone I, II and III in figure 3.1. The control zones I and II are active in partial load conditions and control zone III is active in full load conditions (rated power). In the control zones I and II, the pitch controller is not active. In the control zone III, the rotor speed is kept at rated speed in a range of about 10 % by the pitch and torque controller. The rotor speed difference is used as a control input for the pitch controller. Because of the non-linear interaction between change of pitch angle and change in output power for different wind speeds, a correction factor is used in the pitch controller. Above rated rotor speed in region III, the generator torque is controlled in order to keep constant power output. DC/AC converting is performed by PWM technology. During DC/AC controlling, some control method is performed for satisfying the condition for parallel operation with gird and getting high power quality such as DC link voltage, AC voltage control, AC current control, power factor control. The converter torque control scheme of a PI controller for the torque control is well demonstrated according to a predefined torque vs. rotor speed curve in figure 8. The minimum torque below 26 rpm is no-load torque due to frictions at the bearings or gearbox. Due to the system inertia, the measured values show little amount of overshoot or hysteresis. The overall pattern is well controlled and is similar to figure 7.
total power losses of an inverter system including a 10-kW reactor loss are approximately 43-kW. The dependence of the temperature rise on the peak output current change is shown in Figure 9. This graph shows the temperature characteristics at the overload conditions. Through the above estimation of power losses, the efficiency has been evaluated as the ratio between the output power from a generator and the output power on grid network (excluding an losses of auxiliary equipment such as pumping and control power, etc.). If input power from the PM generator is 805 kW, an inverter system gives the efficiency of 94.6% when the power factor is actively controlled.
45 40 35
Temperature
30 25 20 15 10 5 0 0 0 283 424 424 495 566 566 566 636 707 707 778 778 849 891
4.
Conclusions
The 750-kW converter system has been designed with an engineering discipline in accordance with reorganized industrial standards and it will function reliably throughout its specified life. The engineering design efforts and some results for wind turbine converter equipment and assemblies that will be used for KBP-750D WEC are discussed in this paper. It features direct drive and PM excitation for higher energy yield and less maintenance demands. The power loss and heat transfer conditions of the system should be considered in the design stage. For optimum operation, the ratings of IGBT stack, DC link capacitors and other devices are analyzed. For the calculation of cooling capacity, the power loss and thermal analysis of IGBT switch and other devices were investigated to estimate the temperature rise at the rated and overload conditions respectively. The initial test results of a 750-kW converter system for the wind turbine are complied with the designed one. A 10-kW small-scale simulator is developed to study the control dynamics of the inverter for the 750-kW wind turbine. A PI controller is used for the torque controller. The torque speed curve is chosen in order to operate the turbine at the optimum tip speed ratio of the rotor, which gives maximum efficiency. It was demonstrated to limit the output of the torque controller according to a predefined torque vs. rotor speed curve in medium wind conditions. Now, the 750-kW converter system has been fully assembled. We are on the way to set-up this system to test the operational performance according to prepared test procedure [4]. Our goal in the test operation during the next fiscal year is to demonstrate and improve the reliability of main combined wind turbine system as well as an inverter system for a real site application, together with the research effort to improve the power efficiency through the understanding of the nonlinear characteristics of the WEC system. Future developments are aimed at improving their efficiency and power development for a stable system.
5.
References
[1]. M. R. Dubois, H. Polinder, J. A. Ferreira Generator Topologies for Direct-Drive Wind Turbines, an Adapted Technology for Turbines Running in Cold, Delft University of Technology, Lab. of Electrical Power Processing, The Netherlands, m.dubois@its.tudelft. [2]. R. S. Ramshaw, Power Electronics Semiconductor Switches, First Edition, 1993. Published by Chapman & Hall. [3]. D. E. Kim, J. H. Chung, J. S. Hwang, J. Y. Ryu, D. H. Kim, Development of 20 kW Class PM Direct Drive Synchronous Generator, Proceeding of the KIEE Summer Annual Conference 2003, pp. 1398-1400. [4]. International Standard, IEC 146-1-1, Third Edition, 1991-03 Semiconductor convertors, General Requirements and Commutated convertors.