System and Method for Minimizing Inrush of Current During Start-Up of an Electrical Power System

Abstract

A method for a method for minimizing inrush of current during start-up of an alternating current (AC) electrical power system connected to a power grid includes determining a grid voltage of the power grid. The method also includes charging an AC capacitance of a grid filter of the electrical power system from an initial capacitance value to a predetermined percentage of the grid voltage. Further, the method includes connecting the electrical power system to the power grid when the AC capacitance in the grid filter reaches the predetermined percentage of the grid voltage. Moreover, the method includes initiating start-up of the electrical power system.

Claims

1. A method for minimizing inrush of current during start-up of an alternating current (AC) electrical power system connected to a power grid, the method comprising: determining a grid voltage of the power grid; charging an AC capacitance of a grid filter of the electrical power system from an initial capacitance value to a predetermined percentage of the grid voltage; connecting the electrical power system to the power grid when the AC capacitance in the grid filter reaches the predetermined percentage of the grid voltage; and, initiating start-up of the electrical power system.

2. The method of claim 1, further comprising charging the AC capacitance in the grid filter of the electrical power system with at least one additional electrical component coupled to the grid filter, the at least one additional electrical component comprising at least one of one or more resistors or a contactor.

3. The method of claim 2, further comprising bypassing the at least one additional electrical component after connecting the electrical power system to the power grid but before initiating start-up the electrical power system.

4. The method of claim 1, further comprising charging the AC capacitance in the grid filter of the electrical power system via a power converter of the electrical power system operating in a first operating mode, the power converter configured to produce a voltage in sync with the grid voltage prior to connecting the electrical power system to the power grid.

5. The method of claim 4, further comprising charging a DC link of the power converter to a predetermined power level prior to charging the AC capacitance in the grid filter of the electrical power system via the power converter.

6. The method of claim 4, further comprising supplying a DC link of the power converter with additional power prior to charging the capacitance in the grid filter of the electrical power system via the power converter.

7. The method of claim 4, further comprising transitioning from the first operating mode of the power converter to a second operating mode after charging the AC capacitance of the grid filter of the electrical power system, the first operating mode corresponding to an AC charging mode, the second operating mode corresponding to a standard operating mode.

8. The method of claim 1, wherein the predetermined percentage of the grid voltage comprises up to about 100% of the grid voltage.

9. The method of claim 1, wherein the electrical power system comprises at least one of a wind turbine power system or a solar power system.

10. A wind turbine power system, comprising: a generator comprising a rotor and a stator; a power converter comprising a line-side converter coupled to a rotor-side converter via a DC link, the rotor-side converter coupled to the rotor; a grid filter coupled between the line-side converter and a power grid; a controller configured to control the wind turbine power system, the controller configured to perform one or more operations, the one or more operations comprising: charging the grid filter from an initial voltage value to a predetermined percentage of a grid voltage of the power grid; connecting the wind turbine power system to the power grid when the initial voltage value in the grid filter reaches the predetermined percentage of the grid voltage; and, initiating start-up of the wind turbine power system after the initial voltage value in the grid filter reaches the predetermined percentage of the grid voltage.

11. An alternating current (AC) electrical power system, comprising: a generator comprising a rotor and a stator; a power converter comprising a line-side converter coupled to a rotor-side converter via a DC link, the rotor-side converter coupled to the rotor; a grid filter coupled between the line-side converter and a power grid; a controller configured to control the electrical power system, the controller configured to perform one or more operations, the one or more operations comprising: determining a grid voltage of the power grid; charging an AC capacitance of the grid filter from an initial capacitance value to a predetermined percentage of the grid voltage; connecting the electrical power system to the power grid when the AC capacitance in the grid filter reaches the predetermined percentage of the grid voltage; and, initiating start-up of the electrical power system.

12. The electrical power system of claim 11, wherein the one or more operations further comprise charging the AC capacitance in the grid filter with at least one additional electrical component coupled to the grid filter, the at least one additional electrical component comprising at least one of one or more resistors or a contactor.

13. The electrical power system of claim 12, wherein the one or more operations further comprise bypassing the at least one additional electrical component after connecting the electrical power system to the power grid but before initiating start-up of the electrical power system.

14. The electrical power system of claim 11, wherein the one or more operations further comprise charging the AC capacitance in the grid filter via the line-side power converter operating in a first operating mode, the line-side power converter configured to produce a voltage in sync with the grid voltage prior to connecting the electrical power system to the power grid.

15. The electrical power system of claim 14, wherein the one or more operations further comprise charging the DC link of the power converter to a predetermined power level prior to charging the AC capacitance in the grid filter of the electrical power system via the line-side power converter.

16. The electrical power system of claim 14, further comprising transitioning from the first operating mode of the line-side converter to a second operating mode after charging the AC capacitance of the grid filter, the first operating mode corresponding to an AC charging mode, the second operating mode corresponding to a standard operating mode.

17. The electrical power system of claim 15, wherein the one or more operations further comprise supplying the DC link with additional power prior to charging the capacitance in the grid filter of the electrical power system via the line-side power converter.

18. The electrical power system of claim 11, wherein the predetermined percentage of the grid voltage comprises up to about 100% of the grid voltage.

19. The electrical power system of claim 11, wherein the electrical power system comprises at least one of a wind turbine power system or a solar power system.

20. The electrical power system of claim 11, wherein the electrical power system comprises a doubly-fed induction generator (DFIG).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0019] FIG. 1 illustrates a perspective view of a portion of one embodiment of a wind turbine according to the present disclosure;

[0020] FIG. 2 illustrates a schematic view of one embodiment of an electrical power system suitable for use with the wind turbine shown in FIG. 1;

[0021] FIG. 3 illustrates a block diagram of one embodiment of a controller suitable for use with the wind turbine shown in FIG. 1;

[0022] FIG. 4 illustrates a schematic diagram of one embodiment of a power converter of a wind turbine according to the present disclosure;

[0023] FIG. 5 illustrates a partial, schematic diagram of one embodiment of an electrical power system according to the present disclosure, particularly illustrating the electrical components between the line side converter and the transformer; and

[0024] FIG. 6 illustrates a flow diagram of one embodiment of a method for minimizing inrush of current during start-up of an AC electrical power system connected to a power grid according to the present disclosure.

DETAILED DESCRIPTION

[0025] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0026] In general, the present disclosure relates to pre-charging the capacitor of the grid filter in an electrical power system to the AC grid voltage to reduce electrical transients and/or inrush upon start-up of the system. Such pre-charging can be accomplished with resistors, a contactor, and/or via the power converter which produces a voltage in sync with the grid voltage prior to closing the connection to the power grid. In certain embodiments, the voltage on the capacitor can be less than 100% of the grid voltage to reduce the inrush of current. In addition, the voltage on the capacitor does not have to be perfectly aligned with the grid voltage to reduce the inrush. In further embodiments, for the power converter to effectively charge the capacitance, the DC link must be charged and/or supplied with enough power to apply an AC voltage for a sufficient time period to connect to the power grid.

[0027] Accordingly, the present disclosure provides numerous advantages over prior art systems and methods. For example, the systems and methods of the present disclosure is capable of reducing the stress on fuses, power supplies, UPSs, motors, and/or other components of the power system. Reduced stress can thereby increase component life. The systems and methods of the present disclosure can avoid catastrophic destruction due to voltage spikes occurring as a result of the inrush current.

[0028] Referring now to the drawings, FIG. 1 illustrates a perspective view of a portion of one embodiment of a wind turbine 100 according to the present disclosure that is configured to implement the method as described herein. The wind turbine 100 includes a nacelle 102 that typically houses a generator 118 (FIG. 2). The nacelle 102 is mounted on a tower 104 having any suitable height that facilitates operation of wind turbine 100 as described herein. The wind turbine 100 also includes a rotor 106 that includes three blades 108 attached to a rotating hub 110. Alternatively, the wind turbine 100 may include any number of blades 108 that facilitates operation of the wind turbine 100 as described herein.

[0029] Referring now to FIG. 2, a schematic view of one embodiment of an electrical power system 200 that may be used with the wind turbine 100 is illustrated. During operation, wind impacts the blades 108 and the blades 108 transform wind energy into a mechanical rotational torque that rotatably drives a low-speed shaft 112 via the hub 110. The low-speed shaft 112 is configured to drive a gearbox 114 that subsequently steps up the low rotational speed of the low-speed shaft 112 to drive a high-speed shaft 116 at an increased rotational speed. The high-speed shaft 116 is generally rotatably coupled to a generator 118 so as to rotatably drive a generator rotor 122 having field winding (not shown). More specifically, in one embodiment, the generator 118 may be a wound rotor, three-phase, doubly-fed induction (asynchronous) generator (DFIG) that includes a generator stator 120 magnetically coupled to a generator rotor 122. It should be understood that the electrical power system may also encompass any other suitable power generation system in addition to DFIG systems, including but not limited to permanent magnet generator (PMG) systems and/or any system connected to a power grid that includes a disconnect device, AC capacitance, and a power converter.

[0030] As such, a rotating magnetic field may be induced by the generator rotor 122 and a voltage may be induced within a generator stator 120 that is magnetically coupled to the generator rotor 122. In such embodiments, the generator 118 is configured to convert the rotational mechanical energy to a sinusoidal, three-phase alternating current (AC) electrical energy signal in the generator stator 120. The associated electrical power can be transmitted to a main transformer 234 via a stator bus 208, a stator synchronizing switch 206, a system bus 216, a main transformer circuit breaker 214, and a generator-side bus 236. The main transformer 234 steps up the voltage amplitude of the electrical power such that the transformed electrical power may be further transmitted to a power grid 243 via a grid circuit breaker 238, a breaker-side bus 240, and a grid bus 242.

[0031] In addition, the electrical power system 200 may include a wind turbine controller 202 configured to control any of the components of the wind turbine 100 and/or implement the method steps as described herein. For example, as shown particularly in FIG. 3, the controller 202 may include one or more processor(s) 204 and associated memory device(s) 207 configured to perform a variety of computer-implemented functions (e.g., performing the methods, steps, calculations and the like and storing relevant data as disclosed herein). Additionally, the controller 202 may also include a communications module 209 to facilitate communications between the controller 202 and the various components of the wind turbine 100, e.g. any of the components of FIG. 2. Further, the communications module 209 may include a sensor interface 211 (e.g., one or more analog-to-digital converters) to permit signals transmitted from one or more sensors to be converted into signals that can be understood and processed by the processors 204. It should be appreciated that the sensors (e.g. sensors 252, 254, 256, 258) may be communicatively coupled to the communications module 209 using any suitable means. For example, as shown in FIG. 3, the sensors 252, 254, 256, 258 may be coupled to the sensor interface 211 via a wired connection. However, in other embodiments, the sensors 252, 254, 256, 258 may be coupled to the sensor interface 211 via a wireless connection, such as by using any suitable wireless communications protocol known in the art. As such, the processor 204 may be configured to receive one or more signals from the sensors.

[0032] As used herein, the term processor refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. The processor 204 is also configured to compute advanced control algorithms and communicate to a variety of Ethernet or serial-based protocols (Modbus, OPC, CAN, etc.). Additionally, the memory device(s) 207 may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and/or other suitable memory elements. Such memory device(s) 207 may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) 204, configure the controller 202 to perform the various functions as described herein.

[0033] Referring back to FIG. 2, the generator stator 120 may be electrically coupled to a stator synchronizing switch 206 via a stator bus 208. In one embodiment, the generator rotor 122 may be electrically coupled to a bi-directional power conversion assembly 210 or power converter via a rotor bus 212. Alternatively, the generator rotor 122 may be electrically coupled to the rotor bus 212 via any other device that facilitates operation of electrical power system 200 as described herein. In a further embodiment, the stator synchronizing switch 206 may be electrically coupled to a main transformer circuit breaker 214 via a system bus 216.

[0034] The power conversion assembly 210 may include a rotor filter 218 that is electrically coupled to the generator rotor 122 via the rotor bus 212. In addition, the rotor filter 218 may include a rotor-side reactor. A rotor filter bus 219 electrically couples the rotor filter 218 to a rotor-side power converter 220. Further, the rotor-side power converter 220 may be electrically coupled to a line-side power converter 222 via a single direct current (DC) link 244. Alternatively, the rotor-side power converter 220 and the line-side power converter 222 may be electrically coupled via individual and separate DC links. In addition, as shown, the DC link 244 may include a positive rail 246, a negative rail 248, and at least one capacitor 250 coupled therebetween.

[0035] In addition, a line-side power converter bus 223 may electrically couple the line-side power converter 222 to a line filter 224. Also, a line bus 225 may electrically couple the line filter 224 to a line contactor 226. In addition, the line filter 224 may include a line-side reactor. Moreover, the line contactor 226 may be electrically coupled to a conversion circuit breaker 228 via a conversion circuit breaker bus 230. In addition, the conversion circuit breaker 228 may be electrically coupled to the main transformer circuit breaker 214 via system bus 216 and a connection bus 232. The main transformer circuit breaker 214 may be electrically coupled to an electric power main transformer 234 via a generator-side bus 236. The main transformer 234 may be electrically coupled to a grid circuit breaker 238 via a breaker-side bus 240. The grid circuit breaker 238 may be connected to the electric power transmission and distribution grid via a grid bus 242.

[0036] Referring particularly to FIGS. 2 and 4, alternating current (AC) power generated at the generator stator 120 by rotation of the rotor 106 is provided via a dual path to the grid bus 242. The dual paths are defined by the stator bus 208 and the rotor bus 212. On the rotor bus side 212, sinusoidal multi-phase (e.g. three-phase) AC power is provided to the power conversion assembly 210. The rotor-side power converter 220 converts the AC power provided from the rotor bus 212 into DC power and provides the DC power to the DC link 244. Switching elements 245 (e.g. diodes) used in bridge circuits of the rotor side power converter 220 can be modulated to convert the AC power provided from the rotor bus 212 into DC power suitable for the DC link 244.

[0037] The line side converter 222 converts the DC power on the DC link 244 into AC output power suitable for the electrical grid bus 242. In particular, switching elements 247 (e.g. IGBTs) used in bridge circuits of the line side power converter 222 can be modulated to convert the DC power on the DC link 244 into AC power on the line side bus 225. The AC power from the power conversion assembly 210 can be combined with the power from the stator 120 to provide multi-phase power (e.g. three-phase power) having a frequency maintained substantially at the frequency of the electrical grid bus 242 (e.g. 50 Hz/60 Hz).

[0038] It should be understood that the rotor-side power converter 220 and the line-side power converter 222 may have any configuration using any switching devices that facilitate operation of electrical power system 200 as described herein. For example, FIG. 4 illustrates a simplified schematic diagram of one embodiment of a variable frequency drive (VFD) that maintains a constant electrical frequency output on the grid side of the generator 118. As shown, the VFD configuration includes a six-switch voltage-sourced rectifier on the rotor side converter 220, a DC link capacitor 249 to minimize DC voltage variation, and a six-switch voltage-sourced inverter utilizing pulse width modulation on the grid side. Rotor-side switching elements 245 are often diodes or silicon controlled rectifiers (SCR), while the grid side-switching elements 247 are often insulated gate bipolar transistors (IGBTs). As such, the magnitude and electrical frequency of the current supplied to the generator rotor 122 through the VFD may be varied to account for changes in the rotor shaft speed and to maintain a constant output on the generator stator winding.

[0039] Further, the power conversion assembly 210 may be coupled in electronic data communication with the turbine controller 202 and/or a separate or integral converter controller 262 to control the operation of the rotor-side power converter 220 and the line-side power converter 222. For example, during operation, the controller 202 may be configured to receive one or more voltage and/or electric current measurement signals from the first set of voltage and electric current sensors 252. Thus, the controller 202 may be configured to monitor and control at least some of the operational variables associated with the wind turbine 100 via the sensors 252. In the illustrated embodiment, each of the sensors 252 may be electrically coupled to each one of the three phases of the power grid bus 242. Alternatively, the sensors 252 may be electrically coupled to any portion of electrical power system 200 that facilitates operation of electrical power system 200 as described herein. In addition to the sensors described above, the sensors may also include a second set of voltage and electric current sensors 254, a third set of voltage and electric current sensors 256, a fourth set of voltage and electric current sensors 258 (all shown in FIG. 2), and/or any other suitable sensors.

[0040] It should also be understood that any number or type of voltage and/or electric current sensors 252, 254, 256, 258 may be employed within the wind turbine 100 and at any location. For example, the sensors may be current transformers, shunt sensors, rogowski coils, Hall Effect current sensors, Micro Inertial Measurement Units (MIMUs), or similar, and/or any other suitable voltage or electric current sensors now known or later developed in the art.

[0041] Thus, the converter controller 262 is configured to receive one or more voltage and/or electric current feedback signals from the sensors 252, 254, 256, 258. More specifically, in certain embodiments, the current or voltage feedback signals may include at least one of line feedback signals, line-side converter feedback signals, rotor-side converter feedback signals, or stator feedback signals. For example, as shown in the illustrated embodiment, the converter controller 262 receives voltage and electric current measurement signals from the second set of voltage and electric current sensors 254 coupled in electronic data communication with stator bus 208. The converter controller 262 may also receive the third and fourth set of voltage and electric current measurement signals from the third and fourth set of voltage and electric current sensors 256, 258. In addition, the converter controller 262 may be configured with any of the features described herein in regards to the main controller 202. As such, the converter controller 262 is configured to implement the various method steps as described herein and may be configured similar to the turbine controller 202.

[0042] For conventional systems, during start-up of the power system, the grid filter is not connected to the grid (i.e. the line contactor is open). Therefore, once the DC link is charged, the line contactor is closed and the grid filter begins producing reactive power. Thus, a voltage spike can occur and travel through to the auxiliary power system, which generally includes an auxiliary transformer (not shown). As such, conventional systems can experience inrush of current upon start-up of the system. Accordingly, the present disclosure is directed to an improved system and method for minimizing inrush of current during start-up of an electrical power system connected to a power grid.

[0043] Referring now to FIG. 5, a partial, schematic diagram of one embodiment of the power system 200 between the line side converter 222 and the transformer 234 is illustrated according to the present disclosure. More specifically, as shown, the line filter 224 is coupled between the line side converter 222 and the transformer 234. Further, as shown, the line contactor 226 is coupled between the transformer 234 and the grid filter 224. Moreover, as shown, the power system 200 may further include a line shunt 260 and/or a line inductor 264 coupled between the grid filter 224 and the line side converter 222. In addition, the grid filter 224 may include at least one additional electrical component 268 coupled thereto for charging the AC capacitance in the grid filter 224. For example, as shown in the illustrated embodiment, the additional electrical component 268 may include one or more resistors 270. In further embodiments, the additional electrical component(s) 268 may include a contactor and/or any other suitable electrical components or combinations thereof that are capable of limiting electrical transients.

[0044] Referring particularly to FIG. 6, a flow diagram of one embodiment of a method 300 for minimizing inrush of current during start-up of an AC electrical power system connected to a power grid is illustrated. In general, the method 300 will be described herein with reference to the wind turbine 100 and power system 200 described above with reference to FIGS. 1 and 2. However, it should be appreciated by those of ordinary skill in the art that the disclosed method 300 may generally be utilized to control the operation of any other suitable power system (such as wind and/or solar power systems) having any suitable configuration, and/or systems having any other suitable system configuration. In addition, although FIG. 6 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

[0045] As shown at 302, the method 300 includes determining a grid voltage of the power grid 243. As shown at 304, the method 300 includes charging an AC capacitance of the grid filter 224 (also referred to herein as the line filter 224) from an initial capacitance value to a predetermined percentage of the grid voltage. In one embodiment, the predetermined percentage of the grid voltage may be 100% of the grid voltage. In alternative embodiments, the predetermined percentage of the grid voltage may include less than 100% of the grid voltage.

[0046] In particular embodiments, the method 300 may include charging the AC capacitance in the grid filter 224 with the additional electrical component(s) 268. In such embodiments, the method 300 may further include bypassing the additional electrical component(s) 268 after connecting the power system 200 to the power grid 243 but before initiating start-up. In alternative embodiment, the method 300 may include charging the AC capacitance in the grid filter 224 via the power converter 210, e.g. via the line side converter 222, operating in a first operating mode. In such embodiments, the line side converter 222 is configured to produce a voltage in sync with the grid voltage prior to connecting the power system 200 to the power grid 243.

[0047] In further embodiments, the method 300 may include charging the DC link 244 of the power converter 210 to a predetermined power level prior to charging the AC capacitance in the grid filter 224 via the line side converter 222. Alternatively, the method 300 may include supplying the DC link 244 with additional power prior to charging the capacitance in the grid filter 224. In several embodiments, the method 300 may also include transitioning from the first operating mode of the power converter 210 to a second operating mode after charging the AC capacitance of the grid filter 224 of the electrical power system 200. In such embodiments, the first operating mode may correspond to an AC charging mode, whereas the second operating mode may correspond to a standard operating mode. In such embodiments, the transitioning step may include detecting the contactor closure (e.g. from a change in shunt current) and subsequently stopping gating in the open-loop AC voltage mode and re-starting in standard operating mode and/or switching from one regulator topology to another.

[0048] Referring still to FIG. 6, as shown at 306, the method 300 includes connecting the wind turbine power system 200 to the power grid 243 when the AC capacitance in the grid filter 224 reaches the predetermined percentage of the grid voltage. As shown at 308, the method 300 includes initiating start-up of the wind turbine power system 200, i.e. after the AC capacitance in the grid filter 224 reaches the predetermined percentage of the grid voltage.

[0049] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.