Robicon VFD Perfect Harmony Theory

Folie 1Proven Scalable Technology
Large Drives Applications
ROBICON Perfect Harmony
21.06.2007 * © Siemens AG 2007 - We reserve the right to make changes
ROBICON Perfect Harmony Family
ROBICON Perfect Harmony Topology
Beginnings in 1992
The ease of system integration
The Solution:
True sinusoidal Motor Waveform
Product Features and Benefits
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Harmony Today
Since Then …
Highest Output Power Built – 60 MW / 80,000 HP
Maximum Cable Length Run – 22 Miles / 35 KM
Energy Business – 75%
Applied to Induction, Wound Rotor, Synchronous, Permanent Magnet and Super-conducting Motors
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Core Features
Low Harmonic Input
97% or Better Above 20% Load
Line Disturbance Immunity
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No Need to Waste Energy or Capacity
Core Features
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&LRobicon Proposal P340&CSection 5 Page PD-18&RJANUARY 28, 2003
VFD Efficiency
Load
&C&"Arial,Bold"&14&A
&L Robicon Proposal P340&CSection 5 Page PD-19&RFEBRUARY 28, 2003
VFD Efficiency
Motor Efficiency
System Efficiency
Load
An Integrated VFD System
Easy to Engineer – One Line-Up – Lower Installed Cost
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A Fully Tested System
Fast and safe commissioning at customer site
In-factory test
Tested as complete systems in our plant Comprehensive proof of performance Enhances reliability by weeding out early failures
Presentation ROBICON Perfect Harmony robicon-perfect-harmony-theory-e.ppt
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1994
1996
1997
1999
2000
2001
2002
2003
Harmony HV - First MV drive to directly run 13.8 kV motors
2004 LNG System
1000th Unit Installed
1995
2008
GenIVe
Market Leadership Award
1998
First IGBT-based drive above 10,000 horsepower
(7.5 MW)
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Air-Cooled
300 kW to 6.7 MW
2300 ~ 7200 V Motors
Full-featured ROBICON Perfect Harmony
110” high x 66” wide x 42” deep
2.8 M high x 1.68 M wide x 1.07M deep
1000HP / 750 kW @ 4160V
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Water-Cooled
Single bridge to 20,000 HP / 15 MW
Four bridges in parallel to
80,000 HP / 60 MW
Water to water and
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High Voltage
Single bridge to 43,500 HP / 32.5 MW
Four bridges in parallel to 174,000 HP / 130 MW
Water to water and
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400 to 40,000 HP / 300 kW to 30 MW
and a Single Control
Automatic motor/drive auto-tuning
State-of-the-art Sensorless Flux-vector Control
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The following DCS Protocols are supported as standard options from the ROBICON Perfect Harmony VFD system control.
Modbus and Modbus Plus
Ethernet IP
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Built-in Input/Output Power Monitoring
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Typical Power Schematic of a ROBICON Perfect Harmony Drive
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AVAILABLE
VAC
VBA
VCB
A
B
C
120o
TYP.
N
A 4,160 volt supply can be assembled from 750 volt sources.
Equivalent circuit of 9-cell Harmony drive with all cells in service.
A3
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6.0~7.2 kV Drive (750 V Cells), or 11 kV Drive (1375 V Cells)
Typical Power Schematic of a ROBICON Perfect Harmony Drive
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AVAILABLE
VAC
VBA
VCB
A
B
C
120o
TYP.
N
A 6,600 volt supply can be assembled from 750 volt sources.
Equivalent circuit of 15-cell Harmony drive with all cells in service.
A3
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A
A 14,400 volt supply can be assembled from 1,375 volt sources.
Equivalent circuit of 18-cell HV Harmony drive with all cells in service.
100% VOLTAGE
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Induction or Synchronous Motor
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Very Large Power / High Availability Applications
The standard ROBICON Perfect Harmony control allows the connection in parallel of up to four individual line-ups.
If one of the line-ups requires maintenance, it can be disconnected and serviced while the system continues operating.
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Input Power Quality Claim
Input Power Quality
“Clean power” sinusoidal converter Near zero harmonics P.F. > .95
Meets all IEEE 519 1992 requirements No need to do harmonic analysis Eliminates the costly and troublesome harmonic filters No need to add P.F. Correction Capacitors or Extra Bus Capacity
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Six-Pulse Rectifier
Input Power Quality
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30-Pulse Rectifier
Input Power Quality
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No Need to Waste Energy or Capacity
Good Power Factor at any Speed
Input Power Quality
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&LRobicon Proposal P340&CSection 5 Page PD-18&RJANUARY 28, 2003
VFD Efficiency
Load
&C&"Arial,Bold"&14&A
&L Robicon Proposal P340&CSection 5 Page PD-19&RFEBRUARY 28, 2003
VFD Efficiency
Motor Efficiency
System Efficiency
Load
Why Limit the Options?
Procuring a new motor can increase the project implementation cost.
The number of existing motors exceeds the number of new motors built each year by 30 to 50 times (average 40).
Existing or new motors could be:
Induction (asynchronous)
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Retrofits?
Existing motors do not have special insulation systems.
Existing cables that run to motors are not designed for voltage spikes associated with non-sinusoidal power loads.
Long cable runs can result in voltage doubling.
Harmonics from non-sinusoidal loads can increase:
Motor heating
Motor Compatibility
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Harmony Motor Compatibility Claims
Drive is compatible with both new and existing motors
No motor embedded RTD insulation failures
Overall induced torque ripple 1% or less on driven load for any given frequency
No additional VFD induced motor heating
Drive can be safely applied to 1.0 service factor motors
Harmonic Voltage Factor < 0.02, well below MG1 limit = 0.03
No dV/dT problems
No Problem with Harmony’s Output Power Quality
Motor Compatibility
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Harmony Motor Compatibility Claims
Isolation transformer guaranties common mode elimination
With Harmony, the isolation transformer is standard, and integrated into the single VFD lineup
An almost perfect sinusoidal motor voltage waveform,
… with an order of magnitude smaller voltage steps
... and a high overall PWM switching frequency
Motor Compatibility
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Three Series Cell-Seven-Level PWM Solution Shown
Harmonic Cancellation in Output Voltage
Motor Compatibility
CELL 3
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Motor Compatibility
1,945 Volts
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Effective Modulation Frequency
Output Voltage Modulation Frequency
A higher effective modulation frequency means a lower motor current distortion.
The effective modulation frequency for the Harmony family of products (based on a cell switching frequency of 600 Hz) becomes:
3 Cell System – 3,600 Hz
With the Harmony Concept the modulation frequency is maintained throughout the motor speed/frequency range.
Motor Compatibility
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Harmonic Voltage Factor
US NEMA Standard MG 1-30 defines requirements for motor de-rating based resulting from harmonic injection from a VFD.
The Harmonic Voltage Factor (HVF) is calculated based on the motor voltage waveform harmonics, reflecting the combined heating effect on the motor stator windings which caused the current harmonics to be induced by a distorted voltage waveform.
The standard states that if the calculated HVF is greater than 0.03,
a motor must be thermally de-rated.
HVF for Harmony VFD outputs are:
For a 3 Series Cell Solution < 0.020
… and Hence No Motor De-rating is Needed
Motor Compatibility
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9-Level Line-to-neutral Voltage Waveform (4 cells per phase)
The Line-to-Line Voltage Waveform Would Show 17 Levels
Harmony Output Voltage and Current
Motor Compatibility
Motor Voltage
Motor Current
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True Adjusted Voltage Output
Wave Forms Remain High Quality at Lower Speeds
Due to Multi-level PWM Output
Motor Compatibility
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150% Current Motor Current @ 1.6 Hz
Motor Voltage (Vln)
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Output Harmonics Induced Heating?
Results Are Proven From Field Testing
Motor Compatibility
(based on 3 hour averages)
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0
10
20
30
40
50
60
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
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Each recirculation pump and motor has a Bentley-Nevada vibration system
Vibration data with M-G set and VFDs compared
No impact on vibration levels from VFD operation
Output Harmonics Induced Torque Pulsations?
Motor Operating from
Motor Compatibility
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Extended Cable Length Applications
Output Filters for Long Cables?
ROBICON Perfect Harmony VFD systems have been applied for solutions where the cable length between the VFD output and motor connection have exceeded 35 kilometers (22 miles).
In general, no motor filters are required. When cable lengths exceed 2 kilometers (6,500 feet), a calculation of the output system should be completed to insure that a filter is not required.
Motor Compatibility
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The Five Pillars of High Availability
Features
ProToPS™ Control Strategy
Extended under-voltage operation
Power loss ride-through
The vast majority of power incidents only last a few cycles
Virtually no single points of failure
High System Availability
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Advanced Cell Bypass
Automatic Bypass of a Failed Cell in Less Than 450ms
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Advanced Cell Bypass Results
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Keeping in mind …
The % of available voltage is calculated based on the VFD maximum output voltage, which is larger than the motor rated voltage.
A motor operating at a lower voltage can still maintain the required speed by increasing the stator current, which is done automatically by the drive up to the motor/vfd set current limit.
100% Output Current is Always Available.
Advanced Power Cell Bypass
VFD Output Voltage Available with All Cells Working
Percent of Original Voltage / Speed
Available after One Failure
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Advanced Power Cell Bypass
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N+2 at Process Rated Power Minimum
Six Series Cell Solution Example: 6,900 V Motor
Redundancy for the Power Electronics
Maximum Output Voltage Available
5,553
4,860
4,165
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Four Series Cell Solution Example: 4,160 V Motor
N+2 at Process Rated Power Minimum
Maximum Output Voltage Available
2,777
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ProToPS™
Process protection versus VFD protection
Allows the user to decide when and how to respond to an
alarm or possible trip situation
Provides time for a smooth transition of process
Communicates, if required, via a hierarchical service of
messages
Alarms - Something is wrong, no process impact
Process alarms - Advisory not to increase process
Trip alarms - VFD will initiate a trip if process action not taken
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Air-cooled ISO Transformer
VFD Trip – only if:
Loss of Cooling Pump
Alarm - One pump lost
Trip Alarm - Loss of cooling or of all pump control power
VFD Trip – only if:
All pumps are lost
cabinet Temp Alarm
Process Protected from
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Input VFD Voltage Within +/- 10% of Rated Value:
100% VFD continuous output power available.
Input VFD Voltage Falls Within 90% to 65% of Rated Value:
VFD output power is rolled-back linearly from 100% power @ 90% input voltage down to 50% power @ 65% input voltage.
During roll-back, the highest available voltage will be sourced to the motor.
The output power is reduced by limiting the available motor torque.
The VFD can operate continuously in this mode.
Input VFD Voltage Falls Below 65% or Disappears All Together:
The VFD will “ride-through” without tripping for at least five cycles.
During “ride-through” the motor voltage is maintained but no torque is produced until input VFD voltage is re-established.
If input voltage is not re-established before the energy stored in the power cells is depleted, the VFD will trip.
Input MV Availability
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5 Cycle Power Loss Ride-through @ 100% Voltage
Input MV Availability
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Redundancy Options with
VFD Control
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System Availability Results
Single points-of-failure remaining include:
Process Availability – Based on a Two-year “Breaker-to-Breaker” Run
> 0.9999+ Moving to 0.99999
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VFD Sizing
Gen IV – 70, 100, 140, 200 and 260 Amps
Gen IIIe – 315, 375, 500 and 660 Amps
WC III – 880 and 1250 Amps
HV – 500, 800 and 1400 Amps
The second criteria is momentary overload
GEN IV – 150%
Gen IIIe – 110%
WC III – 110%
Sizing for Required Current Ratings
System Application & Integration Options
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VFD Sizing
“V-Available” is the maximum voltage the VFD can produce. It is based on the cell rated voltage and number of working cells.
“V-Required” is the motor rated voltage or the process required voltage.
Note: A process may operate at a speed less than the motor 50 or 60 Hz rated speed.
“V-Available” margin is important when:
Considering the implications of long cable runs
Dealing with applications that required closed transition synchronous transfer
The process rating needs to be stable during a line voltage excursion
Special requirements are placed on power electronics redundancy
Example – Power Generation Applications are commonly sized for N+2 cell redundancy at rated motor voltage
Understanding and Applying “V-Available”
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VFD Sizing
As an Isolation Transformer is always included the input voltage can be set independently from the VFD System output voltage.
Input voltages to 13.8 kV and input frequencies of 50 or 60 Hz are supported in standard designs.
Input voltages above 13.8 kV should be referred to the factory for proper sizing.
For WCIII and HV solutions, primary voltages above 20 kV require the application of an Air-cooled primary winding.
Transformer cubicle sizing may be impacted by the primary voltage rating. Refer to the sizing tables.
Sizing for Input Voltage and Frequency
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VFD Sizing
… above 40oC (104oF) and/or 3300 feet (1000 meters)
factory must be consulted
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Two Coil Design
N+1 Fan Redundancy
Copper Pipe
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Liquid-to-Air HEX Solution
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100% Redundant Construction
Full Isolation Valves
In Place Serviceable
Water-to-Water Heat Exchanger
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2 x 4000 HP (2.8 MW) Air-to-Air HEX
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2 x 6500 HP (4.8 MW) Air-to-Air HEX
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A Power Distribution Center (PDC) is commonly supplied as part of a VFD System Solution.
The term PDC is used, as opposed to control house, for tax and depreciation reasons.
For VFD solutions to 10,000 HP (7.5 MW) is common to locate up to two VFDs in a single PDC.
VFD cooling is commonly handled on PDC solutions as follows:
GEN IV - Wall Mounted HVAC
GEN IIIe – Air-to-Air Heat Exchangers
WCIII – Liquid-to-Air or Water-to-Water Heat Exchangers
HV – Water-to-Water Heat Exchangers
Note: As more than 96% of all heat is transferred to the heat exchanger. GEN IIIe, WCIII and HV PDCs have very low supplementary HVAC requirements.
PDC Solutions
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Pad or Pier Mounted As Standard
Two doors required for ingress and egress
Aisle ways to meet safety and clearance (NEC Common)
Walls and ceilings are insulated, floor optional
Lighting and emergency lighting
Panic Hardware and Automatic Re-closers on Doors
Equipment Removal Panel Above Equipment Door
Transformer Rear Access Panels for WCIII and HV Systems
Two grounding provisions on PDC base (diagonal sides)
Roof slope
Walls and ceilings sized for wind, seismic and snow loads
Building HVAC N+1 design
Low voltage and lighting distribution Included
Low voltage feed from distribution to VFD included
PDC over-temperature common alarm
PDC common fire alarm
Common PDC Features and Options
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Options Common For High Availability Installations
Provision to receive dual low voltage feeds to PDC
Automatic transfer switch
Double-conversion UPS
Indication of UPS fault or “on battery” to each VFD
ProToPSTM Options for PDC
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Documents

Robicon VFD Perfect Harmony Theory