100 MW Full Size Converter Hans Schlunegger

100 MW full-size converter in the
Grimsel 2 pumped-storage plant
H. Schlunegger and A. Thöni

Oberhasli Hydroelectric Power Company
Grimselstrasse 19
CH-3862 Innertkirchen
Switzerland
Existing storage pumps can be operated at variable speed by adding a frequency converter. This not only enables the
optimal adaptation of power plant group output to the loading schedule, but also the generation of primary and
secondary control energy. A storage pump at the Oberhasli Hydroelectric Power Company Grimsel 2 pumped
storage plant was recently equipped and successfully commissioned with a full-size converter. This article describes
the type of converter and its integration in power plant operation.
1. Oberhasli Hydroelectric Power Company (KWO)

The nine KWO power plants have a total installed capacity of 1125 MW and generate an annual energy output of
2200 GWh. Annual inflow amounts to 700 million cubic metres, and storage reservoir capacity totals 200 million
cubic metres.
Grimsel 2 pumped storage plant, built between 1974 and 1980, incorporates four 90-MW ternary machine sets. Each
of them comprises a horizontal-axis motor/generator, a Francis turbine and a pump, all three of which are
permanently connected. During turbine operation the pump runner rotates in the dewatered housing, and vice-versa.
The turbine is used for starting both in pump and turbine operating modes. The main technical data of Grimsel 2
pumped storage plant are as follows:
Power output in turbine operation 4 x 80 MW
Power input in pump operation 4 x 90 MW
Average head 400 metres
Average water flow rate 4 x 22 m3/sec
Synchronous speed 750 rpm
Oberhasli Hydroelectric Power System, longitudinal section

■ power stations in operation ■ power stations under construction
1. high pressure shaft
2. low pressure shaft
3. manifold
4. butterfly valves
5. spherical valves
6. turbine
7. pump
8. motor/generator
One 90 MW machine group comprising generator motor, Francis turbine and pump
2. Reasons for installing a frequency converter

An important task of KWO is to provide control energy, but so far this has only been possible in turbine operation.
Above all with low water inflow in winter and during low-load periods, control energy has to be generated with
storage reservoir water. The value of this water for subsequent peak load coverage is therefore lost. In order to solve
this problem by generating control energy in pumping mode, the “Varspeed Grimsel 2” project was launched.
One of the four machine sets was modified thereby to enable variable-speed operation. According to the state of
technology in 2008, it would have been possible to convert the existing synchronous machine into a double-fed
asynchronous motor. For various reasons this was not followed up, and the only remaining solution was a full-size
converter.
Hydraulic short-circuit mode was not considered, on the one hand for flow dynamics reasons, and on the other hand
due to the low efficiency of the Francis turbine in partial load operation.
3. Evaluation of a suitable frequency converter
The largest existing frequency converter capacity for synchronous machines is 100 MW. This load-commutated
inverter (LCI) type was not however suitable for the present purpose, because the high harmonic distortion and the
voltage curve of the load-commutated inverter would seriously overload the existing machine. Furthermore, the line-
side power factor of such converters is inductive and cannot be influenced. For this reason the only possibility was a
voltage-sourced converter with a motor voltage curve acceptable for the existing machine.
ABB and Siemens responded to the public call for tenders in 2009. The contract was awarded to ABB due to the use
of IGCT (Integrated Gate-Commutated Thyristor) semiconductors and the better, more controllable line-side power
factor.
4. Full-size frequency converter
4.1. Converter design
The converter is configured in two blocks, each with 50 MW capacity, on the line and motor sides. The respective
block input and output voltages are added by the converter transformers on the line and motor sides. Each converter
block comprises double-phase modules made up of two 3-phase three-level units in parallel. The converter system
incorporates 24 double-phase modules in total.
bypass switch
M
220 kV 13,5 kV
generator step-up 50 Hz bypass mode (750 U/min)
circuit breaker transformer
lineside 3 point DC link voltage 3 point motorside
transformers bridges limitator bridges transformers
2 x 50 MVA 2 x 50 MVA
50 Hz 46 - 51 Hz
converter mode
(680 – 765 rpm)
start-up transformer
converter
singleline diagram
4.2. Power range
The pump can be operated over a power range of 60 to 100 MW, the minimum power being defined by the
cavitation limit, and the maximum power by the frequency converter and admissible torque on the pump shaft.
line side power diagram pump characteristics

4.3. Starting procedure
In turbine operation and in unregulated pumping mode, the machine set is started up with the turbine. The block
transformer is magnetized by the generator and switched to 220 kV level after reaching synchronization conditions.
In regulated pumping mode, the block transformer and the two line-side converter transformers would have to be
switched in directly, thereby causing very high inrush current peaks. To avoid this, the frequency converter DC link
is energized by the start-up transformer through the converter diodes on the motor side. The transformers are then
magnetized by the line-side converter and afterwards synchronized. The entire starting procedure takes only about
10 seconds, after which the machine is accelerated by the converter to 600 rpm with the watered pump operating
against the closed spherical valve. After opening the spherical valve, the speed is adjusted to approximately 690 rpm
according to the minimum power required by the current operating head.
converter control loops
4.4. Power control
The active power is either set manually or by the higher-ranking plant control system, which adjusts the output of all
KWO power plants to comply with the loading schedule. The line-side regulation setpoint is added to the loading
schedule setpoint. The converter power and speed control are configured in cascade, the active power being limited
by the current pumping head and the maximum converter power capacity.
Reactive power is regulated by a voltage control loop, either set manually or by the higher-ranking 220 kV line
voltage control system. Active power takes preference to reactive power.
total power output KWO and power output/input 3 pumps in operation,

PSP Grimsel 2 during one night 2x 88 MW constant, 1 x 60-100 MW variable
variable-speed pump in two different control modes total power output KWO and power output/input
PSP Grimsel 2 during a weekend
5. Operating modes
Operation is possible in the following modes:
 Turbine mode
 Pumping mode without converter (at constant speed)
 Pumping mode with converter (at variable speed)
 Synchronous condenser mode with converter
Turbine operation with converter was not considered, because adjusting the Francis turbine speed to the relatively
small head range would not compensate the converter losses.
6. Project schedule
The converter delivery and erection schedule was adjusted to the refurbishing work taking place at the same time.
This covered: overhaul of the hydraulic machinery, spherical valve and butterfly valve, renewal of the
instrumentation and control systems, replacement of the turbine governor and excitation equipment, and replacement
of the 220-kV switchgear.
Enough space was available in the existing cavern for the entire converter system. The four transformers were
installed at machine room floor elevation and the converter units in the basement, where the cooling system
connected to the existing plant cooling water network is also installed.
7. Operating experience
This plant has been operating since May 2013, and accumulated 1000 hours in regulated pumping mode by the end
of July. Teething troubles occurred as with all projects, but they were mainly limited to some control system
optimization requirements.
8. Prospects
New pumped storage plants with pump-turbines are almost exclusively equipped for variable-speed operation, using
double-fed asynchronous motors according to the state of technology. There are serious drawbacks to this type of
motor, however: the complex rotor is subject to design limits that restrict speed increase to comply with the optimal
speed of the pump-turbine. Furthermore, the starting procedure is much more complicated, sometimes even
requiring pump-turbine dewatering, and compliance with Grid Code requirements is more difficult. For these
reasons the trend in future will be more toward synchronous machines with full-size converters. Fitting an existing
pumped storage plant with a full-size converter therefore offers an ideal way of testing this future-oriented
technology in actual practice. Experience so far with the full-size converter at Grimsel 2 pumped storage plant is
very promising.
References
1. G. Sydnor, ABB, Medium Voltage Drives Project Manager, New Berlin, Wi, USA, R. Bhatia, NASA, Investment
Manager, Aeronautics Test Program, ARMD, Hampton, Va, USA, H. Krattiger, ABB, Director, Business Development,
New Berlin, Wi, USA, J. Mylius, ABB, MV Power Converter Systems Sales Manager, Turgi, Switzerland, D. Schafer,
Energie Wasser Bern, CEO, Berne, Switzerland „FIFTEEN YEARS OF OPERATION AT NASA’S NATIONAL
TRANSONIC FACILITY WITH THE WORLD’S LARGEST ADJUSTABLE SPEED DRIVE“, archive Nasa
2. Johann Hell, ANDRITZ HYDRO, Penzinger Strasse 76, A-1141, Vienna, AUSTRIA, Markus Egretzberger, ANDRITZ
HYDRO, Wienerberger Strasse 41, A-1120 Vienna, AUSTRIA, Robert Schürhuber, ANDRITZ HYDRO, Penzinger
Strasse 76, A-1141 Vienna, AUSTRIA, Alois Lechner, ANDRITZ HYDRO, Penzinger Strasse 76, A-1141 Vienna,
AUSTRIA, Yves Vaillant, ANDRITZ HYDRO AG, Hardstrasse 319, CH-8021 Zuerich, SWITZERLAND. „Full Size
converter solutions for Pumped Storage Plants, A promising new technology“, Hydro2012
The Authors
Dr. Hans Schlunegger graduated in electrical engineering at the Swiss Federal Institute of Technology (ETH Zurich) and
worked as assistant at ETH's Institute of power electronics and electrical measuring technology. After gaining his doctorate in
power electronics he was deputy head of the Traction and Workshop Department at BLS Lötschbergbahn Railway Company. For
16 years he was Technical Director of the Jungfrau Railway Company. Since his retirement in 2006 he has been a consulting
engineer and visitors' guide at Oberhasli Hydroelectric Power Company (KWO), and project manager for the 100 MW Full Size
Converter.
Andreas Thöni graduated in mechanical engineering at the Swiss Federal Institute of Technology (ETH Zurich). He joined the
Oberhasli Hydroelectric Power Company KWO two years ago.

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100 MW full-size converter in the

Grimsel 2 pumped-storage plant

H. Schlunegger and A. Thöni

1. Oberhasli Hydroelectric Power Company (KWO)

Oberhasli Hydroelectric Power System, longitudinal section

2. Reasons for installing a frequency converter

line side power diagram pump characteristics

total power output KWO and power output/input 3 pumps in operation,

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