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A Modular Direct Converter for

Transformerless Rail Interties


Manfred Winkelnkemper Arthur Korn Peter Steimer
IEEE Member IEEE Member IEEE Fellow
ABB Switzerland Ltd. ABB Switzerland Ltd. ABB Switzerland Ltd.
Austrasse, CH-5300 Turgi Austrasse, CH-5300 Turgi Austrasse, CH-5300 Turgi
manfred.winkelnkemper@ch.abb.com Arthur.korn@ch.abb.com peter.steimer@ch.abb.com

Abstract- Transformerless rail interties are of high interest A direct MMLC converter topology for power transmission
for the interconnection of the European 15kV/16.7Hz rail supply between two 3 phase grids at 25Hz and 50Hz respectively is
with the 50Hz industrial grid due to the direct connection to the presented in [5]. It is introduced as "chain link converter".
rail supply without a 16.7Hz transformer. The MMLC is an Similar converters are the MMLC for a traction converter
emerging topology which offers high blocking voltages, high presented in [6] and the chainlink matrix converter presented
modularity and very high power quality. Two transformerless in [7].
interties are presented and compared which are the "indirect In this paper the indirect MMLC and the direct MMLC for
MMLC" and the "direct MMLC". The design for a 15MVA transformerless rail interties are presented. The topologies are
intertie and the calculation of the currents and voltages are the compared based on the energy storage, the power losses, the
presented in detail. The cell capacitances are determined from utilization and the complexity in terms of the number of
the internal branch currents and voltages. Semiconductors loss applied transformers, filters and semiconductors.
calculations have been carried out in detail. The comparison of
the indirect and the direct MML shows clear advantages of the
II. TRANSFORMERLESS RAIL INTERTIES
direct MMLC.
A. Currently deployed intertie with 16.7Hz transformer
I. INTRODUCTION A common rail intertie with GTO or IGCT converters and
two transformers is shown in Fig.1. The ac filter in the dc link
One of the common rail supplies in Europe is the single compensates the 2nd harmonic power fluctuation. Additional
phase supply with 15kV at 16.7Hz. Rail interties are applied filters are needed on both ac sides in order to meet the
to connect the rail grid with the industrial 50Hz grid. Typical standards. The efficiency of the converter is very high
requirements besides the general power exchange are reactive (~0.75% semiconductor and clamp losses) but it generates
power compensation, low maintenance, high reliability and further losses in the filters and transformers.
very high efficiency. Special challenges are the pulsating
power of the single phase side, large transient overvoltages,
large current harmonics and large overloads. In general the
intertie has to be able to stabilize the rail supply.
The rail interties applied in the field are 3-level NPC
converters with GTO or IGCT with a 50Hz and a 16.7Hz
transformer and a large 2nd harmonic filter in the dc link.
Additional filters are needed to fulfill the grid codes. On the
rail side the limits of the psophometric currents are very Fig. 1. 15kV/16.7Hz rail intertie with two transformers and line filters
demanding. Especially the 16.7Hz transformer is very bulky
and costly and it causes significant power losses. Therefore a
transformerless solution is of high interest. "Transformerless" B. Indirect MMLC
however means a rail intertie without 16.7Hz transformer but The branches of an MMLC for DC/AC conversion are
with a 50Hz transformer on the 3 phase side. A challenge is equipped with unipolar cells and inductors as it is shown on
the high voltage of 15kV and the transient overvoltages of up the left hand side of Fig.2. A phase comprises two branches
to 18kV. with NC unipolar cells.
An emerging topology with a high voltage blocking An indirect converter system for a full transformerless rail
capability is the modular multilevel converter (MMLC or intertie consists of a 3-phase and a 2-phase MMLC linked at
M2LC) [1] ,[2] with unipolar cells for DC-AC conversion. its dc terminals as it is shown in Fig.3. In this paper we call
Indirect converter systems comprising two DC/AC MMLCs this system the "indirect MMLC". The rail grid is connected
are developed for fixed frequency applications like HVDC or via an air choke of 8%...15%. The single phase power
grid interties [3], [4]. fluctuation is buffered in the cell capacitors. No second
harmonic filter is applied. The branch inductors allow the

978-1-4244-6392-3/10/$26.00 ©2010 IEEE 562


rail side in order to limit short circuit currents in failure case.
Its final design depends on the protection devices inside the
MMLC but the details of the protection are out of the scope
of this paper.
The customer requirements for overvoltages and other
exceptional operation points are defining the maximum
converter output voltage. Here, a maximum transient
overvoltage of VP,max=18kVrms is assumed as it is defined in
various customer specifications. The resulting maximum
converter voltage is 25.5kV. The number of cells depends on
the maximum cell voltage. The cell design starts with the
selection of the IGBT module. Its blocking voltage (Table 1)
defines the maximum cell capacitor voltage.
TABLE I
VOLTAGE BLOCKING CAPABILITY OF HV-IGBTS
rated voltage Vce 6.5kV 4.5kV 3.3kV 1.7kV
Fig. 2. Two branches (=one phase) of the MMLC with unipolar cells for blocking voltage 4.0kV 2.9kV 2.1kV 1.1kV
DC/AC conversion (left) and one branch of the MMLC with bipolar cells for
AC/AC conversion (right).
In this paper the cell is designed with 4.5kV IGBT
control of the branch currents which is explained in the modules. Assuming a cell voltage fluctuation of +/-10% the
control section. No additional ac filters are applied due to the cell average voltage is defined to be VC,N=2600V. The
high number of voltage levels and the high output switching minimum cell voltage is 2340V. Therefore a number of
frequency resulting from the large number of cells. NC=11 cells per branch are needed to block an overvoltage of
C. Direct MMLC 25.5kV. With NC=11 cells both the indirect and the direct
The branches of a direct MMLC for AC/AC conversion are
equipped with bipolar cells and an inductor as it is shown on
the right hand side of Fig.2. A direct converter system for the
transformerless rail intertie consists of 6 branches with NC
cells each. The rail side inductor is the same as for the
indirect MMLC topology.

III. SYSTEM DESIGN


The rated power of the rail intertie is SN= 15MVA. The
rated voltage on the rail side is VPN=15kVrms at 16.7Hz and
on the grid side it is VLL=15kVrms at 50Hz. The rated
currents are IrN=1000A on the rail side and IgN=575A on the
3-phase grid side. A standard 50Hz transformer is applied on
the grid side. An air choke of 8…15% p.u. is applied on the

Fig. 4. Transformerless rail intertie with direct MMLC.

MMLC are creating a line-to-line voltage with 23 levels. The


switching frequency is fsw,IGBT=250Hz and the resulting
output switching frequency is fsw,MMLC=2.75kHz.
The cell capacitances CC are defined by the energy
fluctuation ΔEb inside the branches and the given maximum
cell voltage fluctuation ΔVC,max. The determination of CC is
described in the next section.

IV. CONVERTER CONTROL


Common control is applied for the active and reactive
Fig. 3. Transformerless rail intertie with indirect MMLC. power control and the line current control, i.e. it equals the

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control in a state of the art rail intertie. Additionally the A. Branch current control in an indirect MMLC
energy in the branches and thus the branch currents in the Fig. 6 shows a branch of an indirect MMLC connected to a
MMLCs have to be controlled. Also the individual cell dc terminal and an ac terminal. The branch power Pb is
voltages within each branch have to be stabilized. defined by the input power and output power of the branch.
Two different approaches of PWM generation for MMLCs Note that these powers are fractions of the dc terminal power
and chainlink converters can be found in literature: The first Pdc = Vdc ⋅ I dc (1)
applies a central space vector modulator (SVM) in and the ac terminal power
combination with central sorting algorithm for cell voltages in PU (t ) = vU (t ) ⋅ iU (t ) = vˆU sin(ωt ) ⋅ iˆU sin(ωt + ϕ ) . (2)
each branch [2],[8]. Considering the branch current direction
the cell with the maximum voltage or the minimum voltage is The branch power is
selected for the next switching action. An optimum cell Pb ( t ) = (Vdc − vU (t ) ) ⋅ ib ( t ) . (3)
voltage balancing is achieved with this scheme. Various pulse The branch current ib(t) comprises half the ac output current
patterns for the SVM can be found in [9]. iU(t) and an additional current iX(t) which is defined as a
A more common approach is the individual cell voltage "circulating current":
controller and the individual reference carrier modulator iU (t )
(RCM) for each cell. RCM for unipolar and bipolar cells are ib (t ) = + i X (t ) (4)
2
shown in Fig.5. Note that the cell output switching frequency It follows that the branch power comprises dc and ac parts:
is the same but the IGBT switching frequency of the unipolar Vdc iU (t ) vU (t ) iU ( t )
cell is twice compared to the IGBTs of the bipolar cell. P and Pb (t ) = − + Vdc i X (t ) + vU (t ) i X (t ) (5)
PI controllers are applied for cell voltage balancing. Various 2 2
A basic requirement is that the average value of the branch
examples for cell balancing controllers can be found for the
power is zero otherwise the cell capacitors are either
indirect MMLC [10] and the chainlink converters especially
overcharged or discharged during steady state operation. At
for STATCOMs [11],[12],[13]. P and PI controllers in
the same time the circulating current should be controlled in
conjunction with the sign of the current are applied for cell
such a way that it minimizes the energy fluctuation in the
voltage balancing.
branch without distorting the terminal currents idc and iU e.g. it
In case of ideal conditions e.g. balanced cells and equal cell
should remain inside the loops of branches. This is possible
parameters both approaches lead to the same PWM. In reality
when more than one branch is connected to each output
the first approach leads to a lower cell voltage ripple and
terminal which is the case for the indirect MMLC. The
therefore it leads to a lower branch current ripple. This has
demand for zero average branch power is fulfilled when the
not a big influence on losses and performance in case of a
circulating current is determined with the power equation
proper design of the control and a sufficiently large branch
2π 2π
inductor. iU (t )

0
(Vdc ⋅ ib ( t ) )dωt = ∫ (v
0
U (t ) ⋅
2
)dωt (6)

In contrast to (3) it is defined in (6) that the entire power


coming from the dc terminal is delivered to the ac terminal
within one fundamental period. In a 3 phase system a
circulating current of iX(t)=Idc/3 cancels the dc parts of (6). But

Fig. 5. PWM generation in the indirect MMLC with unipolar cells (top)
and in the direct MMLC with bipolar cells(middle) and the resulting cell
output voltage (bottom). Fig. 6. Currents and voltages in a branch of an indirect MMLC.

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such a current does not minimize the branch energy second subfigure shows the phase output voltage VU and the
fluctuation. A minimum branch power fluctuation is achieved branch voltage Vb. Third harmonic injection is applied to the
when the fraction of Idc which flows into the branch is voltages. Note, that the branch current is at its minimum
weighted with the instantaneous output power pU(t) referred to when the branch voltage is at its maximum. The third
the total power: subfigure shows the unequal current distribution in the IGBT
vU (t ) iU ( t ) modules of a cell which leads to a relatively low utilization of
i X (t ) = ⋅ I dc (8) the modules in general. The bottom subfigure shows the sum
2 ⋅ Vdc ⋅ I dc
of the NC cell voltages ΣVC. The cell capacitor for a voltage
The result is a circulating current which comprises a dc part
fluctuation ΔVC=+/-10%VC,N is CC=1.3mF. The minimum
equal to Idc/3 and an ac part which cancels the 2nd harmonic
voltage is about 25700V. Note that the maximum achievable
power fluctuation:
blocking capability is a function of the load angle.
vˆ iˆ vˆ iˆ Fig.8 shows the equivalent current and voltage waveforms
i X (t ) = U U cos(ϕ ) − U U cos(2ωt + ϕ ) = i X ,dc − i X ,ac (9)
4 ⋅ Vdc 4 ⋅ Vdc for the 2-phase MMLC. The branch current ib,rail in the top
In case of symmetrical 3-phase systems the ac parts of iX(t) subfigure comprises half the phase output current and a dc
in the 3 phases of the MMLC add up to zero because they are current. It is in phase with the branch voltage Vb,rail in the
shifted by 0, -2/3π and 2/3π i.e. these circulating currents second figure i.e. the energy fluctuation in the branches is not
remain inside the 3 phase MMLC without affecting the minimized. The entire power fluctuation from the grid side is
terminal currents. buffered in the cell capacitors. Consequently a very large cell
In a 2-phase MMLC these currents are shifted by 0 and 2π capacitance CC,rail=10.6mF is needed. Note that the main
and therefore it is not possible to add such a circulating power fluctuation in the cells has a frequency of 16.7Hz
current for minimization of the power fluctuation without which results from the first and the last terms in (5). This low
appearing in the dc terminal current. It means that it is not frequency power fluctuation requires the large cell
possible to cancel the branch power fluctuation inside the 2- capacitances.
phase MMLC. It is a major drawback of the indirect MMLC There are different possibilities to reduce the cell
for rail interties that the single phase power fluctuation from capacitance. Either each cell is equipped with a 16.7Hz filter.
the rail cannot be compensated by circulating currents. Or the fluctuating power is shifted to the dc link by adding a
The currents and voltages of a branch in the 3-phase circulating current iX(t) to the branch currents. A 33Hz filter
MMLC are shown in Fig.7. The top subfigure shows the could be applied in the dc link as in other state of the art rail
phase output current iU and the branch current ib and the interties. Another possibility is to shift the fluctuating power

Fig. 7. Waveforms of the 3-phase MMLC for DC/AC conversion: Top: Phase Fig. 8. Waveforms of the 2-phase MMLC for DC/AC conversion: Top: Phase
output current iU and branch current ib; 2nd from top: Phase output voltage VU output current iU and branch current ib; 2nd from top: Phase output voltage VU
and branch voltage Vb; 2nd from bottom: Currents through the top IGBTs and and branch voltage Vb; 2nd from bottom: Currents through the top IGBTs and
diodes of a cell; bottom: Sum of all cell voltages ΣVC diodes of a cell; bottom: Sum of all cell voltages ΣVC

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to the 3-phase MMLC. Its cell capacitance has to be increased that the branch current is at its minimum when the branch
in this case. However it requires a large effort to reduce voltage is at its maximum. The cell capacitance is 2.6mF
energy storage in the 2-phase MMLC. only. The third subfigure shows the currents through the
IGBT modules. They are equally shared in contrast to the
B. Branch current control in a direct MMLC
unequal current sharing in the indirect MMLC.
The calculation of the branch currents and voltages in a
The bottom subfigure shows the sum of the cell voltages of
direct MMLC for AC/AC conversion is similar to that of the
a branch. Note that the lowest frequency of power fluctuation
indirect MMLC. The dc terminal in Fig. 6 is replaced by
is 33.3Hz. Other frequencies are 66.7Hz and 100Hz. These
another ac terminal with an ac voltage vR(t) and an ac current
frequencies are obtained from (11).
iR(t). The branch power equation becomes
Pb (t ) = (v R (t ) − vU ( t ) ) ⋅ ib ( t ) . (9)
The ac terminal R is connected to three branches and the ac V. COMPARISON OF THE INDIRECT AND THE DIRECT
MMLC
terminal U to two branches (see Fig.4). Therefore the
terminal currents are weighted with the average fraction of A. Energy Storage
the terminal powers which have to pass each branch. These From the previous calculations the cell capacitances in the
are PU(t)/2 and PR(t)/3. For given terminal voltages vU(t) and indirect MMLC are CC,3ph=1.3mF on the 3-phase side and
vR(t) the resulting branch current is CC,2ph=10.6mF on the 2-phase side. Adding up the stored
iU (t ) i R (t ) energies in the 6 branches of the 3-phase side and the 4
ib (t ) = + (10)
2 3 branches of the 2-phase side at rated cell voltage CC,N=2600V
The resulting branch power is gives a total stored energy of Etot, indirect/SN=124Ws/kVA.
v R (t ) iU (t ) vU (t ) iU (t ) v R (t ) i R (t ) vU ( t ) i R (t ) The cell capacitance of the direct MMLC is 2.6mF. Adding
Pb (t ) = − + − (11)
2 2 3 3 up the stored energies in the 6 branches gives a total stored
Calculating the dc parts of the power and substituting energy of Etot,direct/SN=38.7Ws/kVA only. The direct MMLC
VR=√3·VU and iR=1/2·√3·iU proves that the dc part of the requires less than 1/3 of the stored energy compared to the
branch power is zero. indirect MMLC. Moreover all its cells are operated under
Fig.9 shows the currents and voltages of the direct MMLC. same conditions while the cells in the indirect MMLC are
The top subfigure shows the terminal currents iU and iR and operated under two different conditions. Two different types
the branch current ib. The second subfigure shows the of cells are required for the indirect MMLC which is a severe
terminal voltages VU and VR and the branch voltage Vb. Note disadvantage for production and maintenance.
B. Semiconductor losses
A further advantage of the direct MMLC is the equal
current sharing of the cell currents in the IGBT modules. This
leads to a better utilization of the IGBT modules.
In the indirect MMLC the semiconductors of the 3-phase
and the 2-phase side are loaded with very different rms
currents (ratio of 1:0.62) and similar peak currents (retio of
1:0.76). This means that the same or at least similar types of
semiconductors have to be applied in the entire indirect
MMLC. A bad utilization cannot be avoided.
In general the semiconductor losses are dominated by the
conduction losses because the switching frequency of a single
IGBT module is very low with fsw,IGBT=250Hz in the unipolar
cells of the indirect MMLC and fsw,IGBT=125Hz in the bipolar
cells of the direct MMLC.
Extensive loss calculations have been carried out. Results
are presented for the 4.5kV/900A Mitsubishi CM900HB-90H
module in Table II for an operation point with 15MVA and
unity power factor on both sides of the converter. The
switching losses of the direct MMLC and the indirect MMLC
are 1.1% in both cases even though the direct MMLC
contains 20% more semiconductors than the indirect MMLC.
Fig. 9. Waveforms of the direct MMLC for AC/AC conversion: Top: Phase The reason is the lower cell current and the better utilization
output currents iU and iR on the rail side and branch current ib; 2nd from top:
Phase output voltages VU and VR and branch voltage Vb; 2nd from bottom:
of the IGBTs in the direct MMLC. The losses in the 2-phase
Currents through the top IGBTs and diodes of a cell; bottom: Sum of all side are much higher than that in the entire 3-phase side due
cell voltages ΣVC to the large average and peak currents as it is shown in Table

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II. In general the switching losses are dependant on the power The comparison of the indirect and the direct MML shows
factor but the relation between the losses of the indirect and clear advantages of the direct MMLC. It requires only 1/3 of
direct MMLC remain in the same order. the stored energy compared to the indirect MMLC and it has
Both the direct and the indirect MMLC have higher a much better utilization of the semiconductors. Moreover the
semiconductor losses than the GTO or IGCT converters current sharing of the semiconductors inside the cell is equal
applied in the field. But the overall rail intertie has higher in contrast to the heavily unequal current sharing in the
losses compared to the presented transformerless rail interties indirect MMLC. The semiconductor losses of the direct
due to the losses of the 33Hz filters and the 16.7Hz MMLC are 1.22% compared to 1% in the indirect MMLC but
transformer. this is caused by the higher number of semiconductors in the
TABLE II direct MMLC.
SEMICONDUCTOR LOSSES IN THE MMLC AT UNITY POWER FACTOR The overall losses of the transformerless rail intertie based
direct indirect indirect on the MMLC are less than the losses of the common interties
MMLC MMLC MMLC applied in the field.
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