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Medium Voltage Multilevel Converters for Ship

Electric Propulsion Drives


Kalpani Thantirige, Student Member, IEEE Gamini Jayasignhe, Member, IEEE
Akshay Kumar Rathore, Senior Member, IEEE Michael Adam Zagrodnik
Sanjib Kumar Panda, Senior Member, IEEE Amit Kumar Gupta, Senior Member, IEEE
Department of Electrical & Computer Engineering Rolls-Royce Singapore Pte Ltd, Singapore
National University of Singapore, Singapore E-mail: Gamini.Jayasinghe@Rolls-Royce.com,
E-mail: kalpani.thantirige@nus.edu.sg MichaelAdam.Zagrodnik@Rolls-Royce.com and
eleakr@nus.edu.sg and eleskp@nus.edu.sg Amit.Gupta@Rolls-Royce.com

Abstract—An increasing number of ships are being integrated increases complexity and total cost of the ship power
with electric propulsion systems and a significant proportion of distribution system. Consequently, there is a growing interest
these require variable frequency drives in the multi-megawatt on MVAC solutions for marine power systems particularly
range. At such large power, medium voltage AC (MVAC) drive above 6MW in size. Reduced copper losses and simplification
offers numerous advantages over low voltage AC (LVAC) of the distribution cabling are some of the advantages attained
solution. This paper examines the state-of-the art MV drives and with MVAC ship power systems. Reduced load current
their development trends for marine applications. Further, a enables the use of smaller conductor size for the same power
review is carried out on multilevel converter (MLC) topologies rating. Therefore, MVAC distribution systems have become
suitable for high power ship propulsion drives. A variety of
an attractive solution to electrical power distribution in both
topologies are evaluated for marine applications based their
commercial and naval vessels [5].
specific requirements. From the review, it is concluded that
hybrid solution seems the most attractive option for the specified Power electronics and variable frequency drives (VFDs) are
application. key components of the electric propulsion system. The
majority of vessels have installed power capacity of less than
Keywords—Marine electric propulsion; Medium voltage; Multi- 10MW with individual drives rated at less than 3MW [4].
level converter; Variable frequency drives Systems of such size are traditionally designed using LVAC,
typically 690V. The success of LV marine systems is partly
I. INTRODUCTION due to the availability of LV power semiconductor devices and
Traditional mechanically coupled ship propulsion maturity of the technology developed for land based industrial
mechanisms are gradually being displaced by all electric or applications.
hybrid-electric drive systems. Systems featuring electric drives Marine propulsion systems of installed capacity greater
for ships are evolving technology and they are customized to than 15MW benefit greatly from MV distribution systems and
meet demands in order to obtain high performance and cost the motor drives designed for medium voltage (eliminating the
effective solution. Not only do electric drives help improve the use of step down transformers). High power MVAC drives
fuel efficiency, but they also improve dynamic response, have already been well established in heavy industries and in
reliability and reduce the space requirements on the vessel. A other areas such as wind energy conversion [6], [7]. In the
typical marine electrical power system consists of prime marine industry, however, the adoption of MVAC systems
movers, generators, transformers, distribution cables, power over LVAC system has taken a longer time for both technical
converters, electrical machines and energy storage systems and non-technical reasons. Comparison between LV and MV
[1]. Typically, power generation and distribution systems are drives in terms of cost and other performance metrics have
developed with fixed frequency 60Hz 3-phase systems. been reported in the literature [7], [8], and [9]. According to
Voltage levels of the distribution system vary depending on these comparisons, the use of MV converters in electric ship
the power level and the types of vessels [2]. For example, a propulsion is often more expensive, costlier to maintain and
large liquefied natural gas (LNG) tanker may utilize a 6.6- has lower reliability mainly due to the immaturity of the
11kV medium voltage AC distribution system, while an technology. Therefore, for a fair evaluation, one must consider
offshore supply vessel may utilize a 480V or 690V LVAC various MV converter topologies and compare against marine
system [3], [4]. requirements and system performances.
With the increase in electric power demand on vessels, LV In general, the MVAC power conversion system is
AC distribution systems are reaching their limits. The core considered to extend from 2.3kV to 13.8kV. Presently, 6.6kV
issue is contending with high currents. Installation cost systems appear to be particularly popular. Traditional two-
increases as high currents require larger conductors and level converters are not capable of meeting this voltage level.
frequently necessitates the use of parallel cables. This Therefore, multi-level converter (MLC) topologies capable of

978-1-4799-7400-9/15/$31.00 ©2015 IEEE


delivering the required power at MV levels have been A. MV MLCs in Ship Propulsion Drives
developed. Moreover, MLCs demonstrate high dynamic Substantial research efforts have recently been proposed a
performance and have the potential to meet power quality variety of MV MLC drives for land based industrial
requirements in marine applications. MLCs have experienced applications [6]-[8]. Most of the drive manufacturers offer a
high market penetration over the last decade [7]. However, the variety of MLC topologies to suit different application
design of a MV drive system is challenging due to selection requirements. MLCs are generally configured as three or five-
of: (1) appropriate topology; (2) appropriate power level topologies. Table I shows commercially available MV
semiconductor devices; and (3) converter control methods [9]. industrial products for marine drives that cover power ratings
Consequently, the selection of the appropriate MLC topology from 0.4MW-40MW. These MV drive technologies have their
is fundamental to performance and this is achieved through individual unique features and limitations.
evaluation of the contending alternatives. This paper presents
a comparative evaluation of the most relevant MLC topologies Among the advantages offered by MLCs are the improved
suitable for MV marine AC drive applications. The objective power quality and lower dv/dt (reducing common mode
of this study is to provide an insightful review of suitable current and EMI problems) [9]. However, with the increase in
MLCs for ship propulsion drive application, in order to number of output voltage levels, the power semiconductor
establish the current state of the art and trends of the marine device count also increases. According to ‘part count’ mean
technology. This paper is organized as follows. Section II time before failure (MTBF) reliability modeling, this larger
introduces the state-of-the art in MV drives for ship number of components reduces the reliability of the converter.
propulsion. Potential candidate topologies suitable for MV Other factors such as losses, complexity and ease of
high power drives are identified in Section III. In Section IV, maintenance are to be considered when selecting converter
the selected MLC topologies are studied and evaluated based topologies [9].
on specific drive requirements. Finally, conclusions of this
study are presented in Section V. B. Requirements and Challenges
The technical challenges for the high power marine MV
II. STATE OF THE ART MV DRIVES FOR SHIP PROPULSION drives are interrelated to the input power quality, converters
This section presents the state-of-the-art in MVAC drives topology, switching device limitations and the drive system
for shipboard power systems. A single line diagram for a requirements. Typical ship propulsion drive system
typical MV ship electric power system is shown in Fig. 1. requirements are listed as follows [8];
• Low implementation and maintenance cost
Turbine Diesel Diesel Turbine • High reliability and efficiency
• Safety and continuous availability
• Spatial design flexibility to enhance ship utilization
• Sinusoidal input/output waveforms with low harmonic
Generator Generator Generator Generator content – compliant with marine standards[8]
• Availability of power semiconductor devices and
MV bus
replacement parts
• Regenerative operation and/or dynamic braking
(depending on prime mover and balance of plant)
• Compatibility with system voltage and power levels
• Compliance with international standards such as
Lloyd's Register, DNV, ABS and BV [10]
• Demanding environmental operating conditions
Propulsion Drive
An important constraint on line-side converter is the need
to minimize the current harmonic distortion. LC resonance
Motor Motor
filter, if used, must be carefully designed so as to avoid
undesired oscillations in the distribution network. Another
LV bus
important constraint with high power MV MLCs is the
LV bus
Propulsion Loads Propulsion Loads inverter switching speed (time to turn-on or turn-off the
Variable Speed Drive
device) which leads to high dv/dt and high common mode
(CM) currents, EMI and deterioration of motor bearings and
Converter motor insulation [9]. Higher switching frequency increases the
Supply side Machine side
device switching loss and excessive temperature rise is often
M LOADS compensated by a reduction in the switching frequency.
Therefore, the main challenge and objective are to reduce the
Rectifier Inverter
drive output waveform distortions while using a very low
device switching frequency [11], [12].
Fig. 1. A single line diagram for a typical MV shipboard power system
TABLE I. OVERVIEW OF COMMERCIALLY AVAILABLE MV DRIVE PRODUCTS BY MARINE APPLICATIONS [10], [13]- [17]

System specifications
Manufacturer
Voltage and Power level Drive topology
• Diode clamped VSI – Voltage Source Inverter (3-level or 5-level
[10] Power range: 3 – 36 MW
ACS 6000 output waveform)
ABB Output voltage: 3.0 – 3.3 kV
• Diodes: 6/12/24-pulse rectifier or IGCT: 6/12/18-pulse active rectifier
• Type of motor: Induction, synchronous and/or PMSM
[13] Power range: 0.2–20 MVA • PWM current source with Symmetrical SGCT
Allen Power Flex 7000
Voltage 4.16, 6.6kV • 18-Pulse and Transformerless Active Front End (AFE) Recti¿er
Bradley

MV7000
[14] Power range: 3 – 81 MW • Load side inverter 3-level NPC VSI; IGBTs
General
Input voltage: 3 to 10 kV • Line side converter DFE 12 to 36-pulse / AFE IGBT 6-pulse
Electric
Output voltage up to 10 kV
• 3-level inverter (PWM) in NPC topology with IGCT or HV- IGBTs
SINAMICS GM150 Power range: 10–27 MW
• 12-pulse or optional 24-pulse diode rectifier without regenerative
[15] Voltage: 3.3 kV
feedback
• Motor type Induction and synchronous motors
Siemens Power range: up to 13.3
MVA • Line side: diode rectifier; 36-pulse rectifier
SINAMICS GH150
Input voltage: 0.9 - 2.4 kV • Motor side: Modular multi-level topology with LV IGBTs
Output voltage: 4.0 - 7.2 kV • Drive two-quadrant operation

[16] • Multi-level SCHB VSC; LV IGBT


ASI Perfect Harmony Power: 7.5-MW
• Line-side converter 18- to 36-pulse diode rectifier (standard)
Robicon Voltage: 4.16-kV
• Driving: 2 directions of rotation (2 quadrant), 4 quadrant option
• 3 level PWM, IGBT
[17] Power: 9 .4 MVA • 12, 18 and 24 pulse configurations
MVPD800066 Supply voltage 6.6kV • Direct with low loss concept or propulsion transformer
Wärtsilä
• Motor type asynchronous, synchronous and PMSM

been widely used in conventional high-power ac motor drive


Although most of the MVAC propulsion drive systems applications. The merits of this topology are (1) single DC-
utilize transformers, which increase the total drive cost with voltage source, (2) higher efficiency compared to two level
additional cabling, cooling and installation, etc. counterparts and (3) possibility to employ the same NPC
Transformerless MV drives for ship propulsion applications topology for a back-to-back operation [18], [19].
are an attractive solution due to cost reduction and substantial Additional voltage levels can be used to further exploit the
energy savings. However, additional measures are then advantages offered by the NPC-technology. Fig. 2(a) shows a
required to reduce CM circulating current. For the MLC, CM single-phase of a 5-level NPC converter with clamping diodes
voltage elimination methods continue to be of research interest and four capacitors with common DC-bus configuration.
and significant contributions to research may be found in [6], Currently, this topology has limited practical attention due to
[7], and [9]. The aforementioned system requirements and the higher device count and drive system complexity. In
challenges need to be well considered when selecting suitable particular, there is a need to actively balance the voltages on
MLC topologies and control solutions for high power AC the dc-link [19]. The other drawbacks associated with 5-level
drive applications. NPC topology are lack of modularity and unequal loss
distribution over the different power semiconductor devices.
III. POTENTIAL MLC TOPOLOGIES
However, it is still a feasible option for high power propulsion
In this section, the most feasible MV MLC topologies for motor drives due to its superior output waveform quality, low
marine electrical drive system are studied. Neutral point- dv/dt and relatively high efficiency.
clamped (NPC), Cascaded H-Bridge (CHB), Hybrid topology
and Modular Multilevel Converter (MMC) are selected as B. Cascaded H-Bridge Topology
potential topologies. MV propulsion drives need to comply
Fig. 2(b) shows 5-level cascaded H-bridge (CHB)
with marine regulatory requirements. Although most of these topology which is composed of multiple configured with
topologies have already been fielded in the industries, they are series connected H-bridge modules per phase. They are fed by
increasingly being adapted to satisfy marine requirements and isolated DC-voltage sources. By controlling each module
are making their way into the commercial marine sector. individually, 2n+1 voltage levels can be generated in the
There topologies are discussed next: output. The converter itself is highly modular since no extra
A. Neutral Point Clamped Topology devices are needed in order to connect the modules together.
Switching state redundancy gives great flexibility for this type
The Neutral Point Clamped (NPC) or diode-clamped of topology [20]. Utilization of low voltage switching devices
inverter is considered to be a mature MLC topology and has
and the usage of standard motors without output filters are topology nor the power semiconductor device technology is
some of the merits of CHB topology based MLCs. However, straightforward. Therefore, it is rather challenging task to
disadvantages of this topology include the need for multiple select the most appropriate solution that satisfies all the
isolated DC sources which in turn requires complicated application requirements at the best. Most manufacturers look
transformers with multiple phase shifted transformers [16]. to find an acceptable compromise between performance,
Therefore it limits the number of output levels in drive reliability and cost.
applications. The CHB topology is also not practicable to use
in back to back connection [20]. The following sub-section summarizes the key aspects that
should be considered during topology comparison.
Subsequently, a conclusion is reached as to which topologies
C. Hybrid Topology are to be shortlisted for further research in high power ship
Basic MLC topologies may be further modified by propulsion drives.
combining two or more different topologies in a series or
parallel connections i.e. hybrid topologies [21]. Fig. 2(c) 1) Output Voltage Level and Availability
shows conventional 2-level inverter connected in series with
H-bridge inverter. The voltage across the capacitors of the In case of MV applications, the capability to handle high
floating H-bridge cells needs to be half of the DC-bus voltage. DC-bus voltage (without direct series connection of devices)
The required number of DC sources may be reduced. High becomes an important factor because reliability and efficiency
power quality and low device count are main advantages with tend to decrease with increasing number of power
this particular hybrid topology. Furthermore, the devices of semiconductor devices. Owing to the advancement of power
the lower 2-level voltage source converter may be controlled semiconductor device technologies, switching devices which
to switch at a lower frequency compared to the floating cells. can withstand voltage up to 6.5kV have been developed. This
This enables switching losses to be reduced significantly. suggests that high DC-bus voltage may be obtained with fewer
devices rated at higher voltage. Unfortunately, the lower
Therefore, the hybrid MLCs can be considered as an appealing
solution for future ship propulsion drives. number of output levels results in the need large and
expensive LC output filters. A strategy to use high voltage
An alternative hybrid configuration involves cascading of devices would nonetheless be appropriate for use with 5-level
the 3-level NPC inverter with H-bridge cells [21]. This hybrid inverters together with suitable control techniques and filters.
structure further improves the output power quality and
efficiency. However, it introduces additional conduction and 2) Fault tolerance
switching losses and larger capacitors are required for high The converter topology should include provision to
power motor drive applications. The complexity of the control continue operation in spite of faults to ensure continuous
system increases; as it is required to address the problems operation of the marine vessel. Fault tolerance through
associated with capacitor voltage regulation [22], [23]. redundancy has been reported in the literature to improve the
redundancy of the NPC converter by adding an extra leg to the
D. Modular Multilevel Converter Topology converter [22]. In hybrid topologies, fault tolerant capability
Fig. 2(d) shows modular multilevel converter (MMC) can be incorporated by adding a redundant power cells. The
topology which is currently being explored as a promising CHB topology offers high fault tolerant capability as cells may
candidate for MV drive applications. In this topology, each be bypassed if faulty with little degradation of performance.
sub module contains a floating capacitor instead of an isolated The MMC converter likewise offers high fault tolerance as
DC source. Higher modularity, redundancy and fault tolerant redundant modules may be added at low additional expense.
capability offer significant benefits to the MMC topology [24]. [30].
However, the main challenge facing the use of the MMC
topology as drive converter is the AC fluctuation of the sub- 3) Efficiency
module voltages. This is particularly severe at low speed high
Among various performance and design criteria for MV
torque operation. Therefore, more complicated control
drive systems, the overall system ef¿ciency is one of the most
strategies are required to solve DC-voltage balancing issues
and to control the flow of circulating currents within the cells signi¿cant factors due to the growing concern for energy
[25]. savings and cost. In high power applications, the switching
losses contribute significantly towards the total device losses.
IV. EVALUATION OF MLC TOPOLOGIES However, not to be overlooked are the losses associated with
ac ¿lter inductances, motors and transformers. When
A. Preliminary Remarks conducting topology evaluation studies, it is therefore
Several comparison studies have been reported in the necessary to consider the total efficiency of the system.
literature for various types of industrial MV drives [26]-[29].
Reliability, cost-effectiveness of power semiconductor devices 4) DC-link voltage balance
and the drive performance are the key criteria considered for
topology evaluation. As mentioned in [26], topology The DC link voltage balancing problem is well known for
evaluation can be performed either based on the comparison of 3-level NPC topologies that use for active power transfer. In
the most suitable application or comparison of the most [19] various solutions are offered for voltage balancing in
suitable power semiconductor device. Neither the converter back to back designs. However, for 5-level NPC converter the
DC link balancing problem is more difficult to solve. For CHB
S1a
S1a S3a a
+ Vdc/4
Vdc/4 C1 S2a S2a S4a
-
+ S3a S5a S7a
Vdc/4
Vdc/4 C2
- S6a S8a
S4a n
+ a
S5a (b)
Vdc 0
-
+
S6a
Vdc/4 C3
-
+ S7a
Vdc/4 C4
- S8a
+
Vdc/2 C
(a) -
Sub-module
+ a
Vdc 0
S1a S2a a
-
Ca
S3a S4a S1 +
+
Vdc/2 C + Vc
- C-
Vdc/2 C1 VSM
+ S1
S2
Vdc 0 -
- Vdc/2 C2
S2
(c) (d)

Fig.2. Topology configurations: Single phase of a 5-level (a) NPC (b) Cascaded H-bridge (c) Hybrid Topology (2L inverter cascaded with H-bridge cells) and
(d) Modular Multilevel Converter with half bridge modules

converters DC-balancing is not a problem since it depends on modulation techniques and control complexity for the selected
the isolated power sources. Hybrid topology (2-level with H- MLCs.
bridge cells) with single DC-source usually requires additional
control methods to regulate the H-bridge cell capacitor B. Basis of Comparison
voltages and then balance the voltages between them. In
MMC topology, the DC-bus balance of each sub module can The circuit configurations of the 5-level NPC VSC, the 5-
be obtained by applying a proper control algorithm [30]. level CHB VSC, 5-level Hybrid and 5-level MMC are
illustrated in Fig. 2. It can be seen that all the MV converter
5) Modulation and Control solutions have the same voltage levels. For illustration purpose
6.6 kV, 7MW propulsion motor drive application, using the
Particularly for high power MV drives, reducing the commercial HV IGBT modules is used to conduct the
switching frequency while maintaining a reasonable power topology comparison. Basic converter data and total
quality is an important requirement and it has become a main component count for the selected MV MLCs are given in
challenge for the drive manufactures. Moreover, significant Table III and Table IV respectively. The comparison shows
efforts have been proposed to enhance the performance of that 5-level hybrid topology needs the least number of power
MLCs by harmonic elimination methods with pre-calculated semiconductor devices. However, consideration should be
switching functions and using new control strategies [31]. given to the semiconductor utilization factor to minimize the
However, selecting an appropriate modulation scheme is very high share of costs in MV drive systems. The minimum DC
much a trade-off between switching frequency and harmonic link voltage necessary to obtain an output line to line voltage
distortions. Table II, summarizes the most commonly used of 6.6kV can be calculated from (1). To determine the nominal
DC link voltage of the converter, a voltage reserve of 6% is
assumed as shown in (2), which is considered for dynamic MV Drive System 5-level 5-level 5-level 5-level
processes and filter voltage drops. Table V summarizes the Topologies NPC CHB Hybrid MMC
Total device count 64 30 29 80
possibilities of the power semiconductors for the converter
specifications given in Table III.
TABLE V. POWER SEMICONDUCTOR SPECIFICATIONS [26], [28]-[29]

Vdc, min = ¥2 ×Vll (rms) (1) MV Drive System Topologies


5-level 5-level 5-level 5-level
Vdc, n = 1.06×Vdc (min) (2) NPC CHB Hybrid MMC
DC link voltage Vdc, n 9894V 2474V 9894V 9894V
Commutation voltage 2L - 4947V
of respective 2474V 2474V H-bridge - 2474V
TABLE II. MODULATION AND CONTROL OF MLCS [11], [12], [19], [20], commutation cell, Vcom 2474V
[30]-[33]
2L -
Drive System specifications Rated device voltage, 2×4.5kV
Topology 4.5 kV IGBT 4.5 kV
Modulation schemes Control complexity VCE,n H bridge -
4.5 kV
- Level shifted PWM Vcom @100FIT 2800V
Control complexity is
- Multicarrier PWM
higher Device voltage
5-level - Space vector PWM
- DC bus voltage balancing utilization factor 0.88 0.88 0.88 0.88
- Selective Harmonic
NPC - Control methods to (Vcom/Vcom@FIT)
Elimination (SHE)
balance the switching
- Synchronous Optimal
losses
Pulsewidth Modulation
The above evaluation criteria are mainly focused on the
- Multilevel Carrier-Based
reliability and cost-effectiveness of power semiconductor
PWM devices. CHB topology can achieve higher number of levels
Control complexity is with less device count. However, it requires phase shift
5-level - Multilevel SVM
relatively lower compared
CHB - Phase Shifted Method
to other topologies transformers to provide isolated DC sources. Hence, it
- Level shifted PWM increases the overall cost, complexity and cooling
- Multilevel SHE method
requirements of the drive system. Even though MMC offers
- Fundamental and PWM Control complexity is low cost options for implementing redundancy, the control
modulation scheme higher: system complexity and components count are higher than the
- SHE PWM method - Capacitor voltage rest. In addition, NPC topology is also feasible for above five
5-level - Selective Harmonic stabilization levels but other topologies may obtain better performance
Hybrid Mitigation method - Power balancing by
- Synchronous Optimal varying the common mode
while attaining higher voltage levels. Based on the identified
Pulsewidth Modulation voltage application specification, the hybrid topology can be
considered as the most feasible topology for this MV
More advanced control propulsion drive application. It offers high reliability,
- Space vector PWM schemes are required for:
- Staircase modulation - DC bus voltage control
simplifies the front-end converter complexity and offers
- Phase shifted PWM - Circulating current improved performance of the converter as compared to other
5-level selected topologies.
method control
MMC
- Modulation with - Overall sub-module
Fundamental switching capacitor voltage control Alternatively, there is a trend in the recent advancement of
frequency - Sub-module capacitor the power semiconductor devices imposed by the market
voltage balancing demand has been the increase of their voltage and current
rating. For an example, insulated gate bipolar transistor
TABLE III. BASIC CONVERTER DATA (IGBT) modules and integrated gate commutated thyristors
(IGCTs) have experimentally demonstrated with blocking
Converter line to line voltage Vll (rms) 6.6 kV voltages of 8kV and 10kV respectively [34]. The introduction
Minimum DC link voltage Vdc (min) 9334V of such technology with new voltage and current ratings
Nominal DC link voltage Vdc (n) 9894V enables the requirements of high power industrial applications
Phase current Iph (rms) 772 A to be met with few devices while increasing their reliability
Apparent output power Sc 8.825 MVA and modularity.

V. CONCLUSIONS
TABLE IV. COMPONENT COUNT OF MV MLCS [27], [29]
In this paper, the current trends in MLC technology for
MV Drive System 5-level 5-level 5-level 5-level MV high power ship propulsion drives are studied and
Topologies NPC CHB Hybrid MMC
discussed. Several promising MLC topologies are reviewed
Main switches 24 24 24 48
with regards to complexity of control, reliability, availability
DC bus capacitors 4 6 2 2 and technological maturity. However, other evaluation criteria
Clamping diodes 36 0 0 0 considering drive system cost, efficiency, semiconductor loss
Floating capacitors 0 0 3 24 distribution and output waveform quality have not been
Inductors 0 0 0 6 considered as part of this study. This review shows that,
hybrid cascade topology can offer comparative advantages [17] Wärtsilä (2014), “Wärtsilä MV Power Drive” Available:
over the other topologies for the specified MV propulsion http://www.wartsila.com/en/power-electric-systems/power-
drives/mediumvdrive#_0_Articles__undefined
drive application. In future, hybrid topology can be targeted to
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