Interplay between electromechanical and solid state ... · Valve Losses Useful Work Energy Saving...

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Interplay between electromechanical and solid state switching technologies for meeting cost, sustainability, and safety demands of various applicationsThomas J. Schoepf, Eaton Innovation Center, Milwaukee (WI), U.S.A.



(In alphabetical order) Vijay Bhavaraju, Henry Czajkowski, Yakov Familiant, Werner Johler, Bin Lu, Charles Luebke, Peter Meckler, John Merrison, Peter Theisen, Ian Wallace, Gerald Witter, Peter Zeller, Xin Zhou

Special Thanks Is Due To

Thanks to the IEEE Holm operating committee for the invitation!

3 3

Basic requirements for switching devices

Closed state: connection of two conductors with least possible losses, i.e. smallest resistance possible

Open state: best isolation of both conductors possible, i.e. highest resistance and dielectric strength possible

switching state: quick and reversible transfer from one state to the other without generating too high over voltages (not to exceed the insulation limits)

4 4

Change conductivity of switching device by replacing of a very well conducting medium with a very well isolating one, and vice versa:Metal contact – arc plasma –isolating medium (e.g. gas, air)

Switching Principles

Change conductivity of switching device by controlled change of the conductivity of a medium remaining in the current path

electromechanical Solid state

MOSFET transfer characteristic

Electrical conductivity of nitrogen at atmospheric pressure

T (1000 K)

σσσσ (ΩΩΩΩ-1m-1)

5 5

• Electromechanics is dying out• Too slow interruption• Too sensitive (vibrations)• Too old-fashioned• Too noisy• Not precise enough• Standards are electromechanic

centric• …

Electromechanics vs. Solid-State Classics- prejudices

• Too expensive • Too hot• Too big• No proper isolation – leakage

current• No auxiliary contacts• Doesn’t meet the standards• Promises are not being kept –

technology development not fast enough (SiC)

• …

electromechanical Solid-state

To overcome these prejudices: Do not expect the solid-state solutions to behave like traditional electromechanical ones and vice versa.

6 6

Electromechanics vs. Solid-StateCharacteristic

Electromechanical switches

Semiconductor switches

Life 0 + +Power loss + - - Key to ratingsSize + - 0 = satisfactgoryCost + - + = goodSafe interruption + + - - + + = very goodVisible open position + - - - = unfavorableFrequency of operation 0 + + - - = very unfavorableFreedom from maintenance 0 + +Reliability 0 +Breaking capacity + -Susceptibility to overvoltage + - -Voltage drop + -Logic Connection - +Multiplicity of functions 0 +Electromagnetic compatibility + + -Interference - +Effects on environment - +Sensitivity to vibrations - + +Power amplification + 0

Source: Proc. ICEC1988

Are characteristics measured in same units (e.g. life)?

Rating depends on specific technology and application!

7 7

Applications - there are many

8 8

One Example - Comparison RF CharacteristicsFET MEMS EMR

On

StateO

FF StateC

haracteristic

Ids

Vds

Poor Linearity

G DS

Insertion loss ~ 0.43dB

2-D conduction channelSemiconductor

R = 5Ω

G DS

Isolation ~ 17dB @ 6GHz

S-D capacitive coupledSemiconductor

C = 45fF

Icontact

Vcontact

Excellent Linearity


R = 0.05Ω

Metal contactsInsulator


C = 0.015fF

Large air gapInsulator

Icontact

Vcontact

Good Linearity


R = 0.5Ω

Metal contactsInsulator


C = 0.23fF

Small air gapInsulator

Johl

erW

., IE

EE H

olm

Con

f. on

EC

, 200

3

9 9

Outline

Let’s discuss electromechanical and solid state switching technologies in the light of therapidly growing dependency on electricity.

! Global Energy Situation and GHG

! Efficiency! Impact of Soft Grids

(Safety and Power Quality)



Energy Outlook

Sources: EIA - Energy Information Administration / Annual Energy Outlook 2008, and International Energy Outlook 2008(http://www.eia.doe.gov)

World Energy-Related CO2-Emissions(Billion Metric Tons)

01020304050

1990 2000 2010 2020 2030 2005

History Projections

11 11

World Marketed Energy Consumption

Take-awayThe total world consumptionof marketed energy is projected to increase by50% from 2005 to 2030.

The largest projected increase in energy demand is for the non-OECD economies.

12 12

U.S. Primary Energy Consumption by Source and Sector, 2007

Sources: Energy Information Administration, Annual Energy Review 2007, Tables 1.3, 2.1b-2.1f and 10.3.

Take-away72% of total U.S. energy consumed by Residential, Commercial, and Industrial Sectors in 2007.

13 13

Growth of World Electricity

Take-awayOver the next 25 years, the world will become increasinglydependent on electricity to meet its energy needs.

14 14

World Electricity Generation 2005-2030

Take-away

Net electricity generation worldwide is projected to total33.3 trillion kilowatt-hours in 2030, nearly double the2005 total of 17.3 trillion kilowatt-hours.

15

8

54

0.8

7

333

1

15 15

Increase of U.S. Renewable Generation

Take-awayRenewables to increase by70% from 2006 to 2030. Wind and biomass expected to be biggest non-hydroelectric renewable electricity generators.

2006

Source: http://www.eia.doe.gov

16 16

World Energy-Related CO2 Emissions

Take-awayWorld energy-related CO2emissions projected to double from 1990 to 2030.In 2030, CO2 emissions from the non-OECDcountries are projected to exceed those from the OECD countries by 72 %.

Business as usual

17 17

Potential To Reduce World CO2 Emissions

Source: The Institute for Prospective Technological Studies (IPTS) one of the 7 scientific institutes of the European Commission's Joint Research Centre

Technologies that can reduce global CO2 emissions from energy combustion

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

1990 2000 2010 2020 2030 2040 2050

Mt C

O2

Energy savings

Fossil fuel switch

Renewable energies

Nuclear energy

Carbon sequestration

Emission of reduction case

avoi

ded

emis

sion

s

Energy Efficiency

Renewable Energies

HEV/PHEV/EVFuel Cells

H2 combustion

•Fossil Fuel Consumption•CO2 and GHG

Reduce

Business as usual

18 18

0

500

1000

1500

2000

2500

3000

3500

1990 1995 2000 2005 2010 2015 2020 2025 2030

U.S

. Ele

ctric

Sec

tor

CO

2 Em

issi

ons

(mill

ion

met

ric to

ns)

1-3% Heat Rate Improvement for 130 GWe Existing Plants46% New Plant Efficiency

by 2020; 49% in 2030

No Heat Rate Improvement for Existing Plants

40% New Plant Efficiencyby 2020–2030

Advanced Coal Generation

5% of Base Load in 2030< 0.1% of Base Load in 2030DER

10% of New Light-Duty Vehicle Sales by 2017; 33% by 2030 NonePHEV

Widely Deployed After 2020NoneCCS

64 GWe by 203015 GWe by 2030Nuclear Generation

100 GWe by 203055 GWe by 2030Renewables

Load Growth ~ +0.75%/yrLoad Growth ~ +1.05%/yrEfficiency

TargetEIA 2008 ReferenceTechnology

Achieving all targets is very aggressive, but potentially feasible.AEO2008*(Ref)

*Energy Information Administration (EIA) Annual Energy Outlook (AEO)

Technical Potential for U.S. CO2 Reductions

Rev

isJa

mes

, Nat

iona

l Ass

ocia

tion

of R

egul

ator

y U

tility

Com

mis

sion

ers

2008

Sum

mer

Mee

ting,

Por

tland

, OR

Business as usual

Energy Efficiency

Renewable Energies



Efficiency

20 20

U.S. Annual Electricity Sales per Sector

Source: Energy Information Administration, Annual Energy Outlook 2008

Take-awayCommercial Sector

(service industries continue to drive growth)

and Residential Sector(population growth

andshift to warmer regions)

dominate Electricity Demand Growth.

Slow growth in industrial production, particularly in the energy-intensive industries, limits demand.

21 21

Projected Efficiency Gains – U.S. Residential

Take-awayNew energy-efficient appliances and products, especially compact fluorescent and solid-state lighting(lighting efficiency standards in EISA2007) reduce energy use without lowering service levels. Source: http://www.eia.doe.gov

22 22

Projected Efficiency Gains – U.S. Commercial

Take-awayThe long service lives of many kinds of energy-usingequipment limit the pace of efficiency improvements.

Higher efficiency by:• improved heat exchangers

for space heating andcooling equipment

• solid-state lighting• more efficient compressors

for commercial refrigeration

Source: http://www.eia.doe.gov

23 23

SaveEnergy

Pow-R-CommandLighting Controls

According to the New Buildings Institute, lighting controls can reduce lighting energy consumption by 50% in existing buildings and by at least 35% in new construction.

• Program locally to switch loads based on automatic time schedules, analog inputs or digital inputs

• Analog outputs allow for fluorescent dimming and daylight harvesting

Pow-R-Command™Lighting and Load Control

24 24

SaveEnergy

Pow-R-Command™Lighting and Load Control

daykwh

dayhrswattslampsfixtures 256

116322250 =×××

daykwh

dayhrshrswattslampsfixtures 6.129

1)3.056.011(322250 =×+××××

Past Consumption:

New Consumption:

Percent Savings: 49.375%

Greenhouse Gases Averted:40,826 lbs. CO2

(based on eGRID 915 lbs. / MWh)

Typical Office Building Application

25 25

Motor System Energy Use by Application and Horsepower(overall Manufacturing)

0102030405060708090

100

1 - 5 hp 6 - 20 hp 21 - 50 hp 51 - 100 hp 101 - 200 hp 201 - 500 hp 501 - 1000 hp 1000+ hp

Other EnergyAir CompressorPump EnergyFan Energy

TWh/yr

Take-away

In the U.S. motors use 70% of the electrical energy (679 TWh/yr) in a typical industrial facility (≈ 23% of total U.S. electricity sold).

More than 98% of all motors are < 500 hp and they consume 15% of total U.S. electricity sold.

Industrial Motor Populations

26.4%58.8%

0.7% 0.2%2.9%1.8%

9.1%0.1% 1-5

6-2021-5051-100101-200201-500501-10001000+

1-5 hp6-20 hp

21-50 hp

Industrial/Commercial - Motor facts

Sources: DOE 2002 Industrial Electric Motor Systems Market Opportunity Assessment, US Dept of Commerce 2002 Census, Team analysis

< 500 hp

13 Million motors > 1hp

26 26

020406080

100120140160

0 10 20 30 40 50 60 70 80 90 100

Flow (%)

Pow

er (%

)Saved PowerLossesUseful Work

020406080

100120140160

0 10 20 30 40 50 60 70 80 90 100

Flow (%)

Pow

er (%

) Motor LossesPump LossesValve LossesUseful Work

Energy Saving with Solid-State Motor Control

Many motors still run at fixed speeds, power-electronics drives can control the speed of the motor to match output with the needs

• Motors consume energy 100X their cost over the lifetime; $100B annual spend in U.S. alone1

• Energy efficiency standards already in progress in most U.S. States

• 70% of industrial energy is used by electric motors –greatest efficiency opportunity after lighting

Sources: 1 Electrical Information Administration, U.S. Government2 Consortium for Energy Efficiency

Charts: Energy Efficiency-The RoleOf Power Electronics, ABB

18-25% efficiency savings with AC Drive2

Electro-mechanicalControl

Adjustable Frequency DriveControl

**No Flow Valve needed

27 27Sources: DOE 2002 Industrial Electric Motor Systems Market Opportunity Assessment, US Dept of Commerce 2002 Census, Team analysis

Motor System Energy Use (GWh/YR)

-

10,000

20,000

30,000

40,000

50,000

60,000

70,000

1-5 6-20 21-50 51-100 101-200 201-500 501-1000 1000+

CompressorPumpFan

End Users Themes1. Minimize Energy Costs2. Availability & Uptime

• Ensure equipment productivity• Optimal function with system

3. Minimize maintenance costs• Preventative maintenance & Troubleshooting• Declining Pool of Skilled Labor

Motor market perspective – many critical and power-intensive opportunities

Motor energy savings and diagnostics present a large growth potential

HP Ratings

Critical Motor Count

-

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

1-5 6-20 21-50 51-100 101-200 201-500 501-1000 1000+

Fan

Pump

Compressor

HP Ratings

Drives Employments

1.7%3.2%

7.3%

11.4%

0123456789

Pump Fan Compressor Other0%

2%

4%

6%

8%

10%

12%Total# drives% with Drives

million motors

Low Employments

28 28

0123456789

10

2003 2007 2011 2003 2007 2011

Solid-state control growth will continue to outpace electro-mechanical

Solid-State = $6.7BElectro-Mech = $4.4B

6.7% CAGR

7.9% CAGR

Global Market Size (2007 Est)

Speed control and energy savings lead the Solid-State Control and AF Drive markets to grow faster than Electro-Mechanical

B U

SD

Sources: Nema Reports, Market Studies & Product Line Estimates

29 29

Data Center Energy Usage

1.2 % of 2005 U.S.electricity sales, U$2.7 B/year

Source – Koomey Report Feb 15th, 2007, Presented at EPA Workshop Feb16th, 2007

Total U.S. and world server electricity use (including cooling and auxiliary)

Tota

l ele

ctric

ity (b

illion

kW

h/ye

ar)

U.S. world

High-end serversMid-range servers

Volume servers

2000 20052000 2005

0.8 % of estimated 2005 worldelectricity sales, U$7.3 B/year

U.S. Data Centers

• 1.2% of U.S. Electricity• 40-76% server growth

2005-2010

• ≈ 50% energy goes to cooling

• 2011 goal of 10% overall U.S. data center energy savings1 by

10.7 billion kWh

Cooling and auxiliaryequipment

20061

1DOE—The Green Grid Goal for Energy Savings, 2008

30 30

DOE—The Green Grid Goal for Energy Savings

• Goal is 10% overall U.S. data center energy savings by 2011 • 10.7 billion kWh• Equivalent to electricity consumed by 1 million typical U.S. homes• Reduces GHG emissions by 6.5 million metrics tons of CO2 per year

Green Grid - DOE Energy Savings Goal; 10.7 billion kWh/yr by 2011

31 31

Intel High Performance Data Center Airflow

Source: Intel

1.2 % of 2005 U.S.electricity sales, U$2.7 B/year

0.8 % of estimated 2005 worldelectricity sales, U$7.3 B/year

32 32

Energy Aware Provisioning - HP

Sou

rce

–K

en B

aker

, “H

P E

nerg

y A

war

e P

rovi

sion

ing

-Brid

ging

the

gap

betw

een

Faci

litie

s an

d IT

with

Dyn

amic

Sm

art C

oolin

g”,

Dat

acen

ter D

ynam

ics

Con

fere

nce

and

Exp

o -N

ew Y

ork,

New

Yor

k , M

arch

23r

d 20

07

33 33

Energy Aware Provisioning - HP

Reducing the energy required to cool a datacenter can result in significant cost savings (and reduction in CO2emissions) or the ability to deploymore IT equipment in the same space -- or a mixture of the two.

(X 1000 USD)

Source – Ken Baker, “HP Energy Aware Provisioning - Bridging the gap between Facilities and IT with Dynamic Smart Cooling”, Datacenter Dynamics Conference and Expo - New York, New York , March 23rd 2007

34 34

Electro-Mechanic – Motor StartingAC Contactors

1. Magnetic Full Voltage Motor Starters

2. Magnetic Full Voltage Reversing Motor Starters

3. AC Automatic Transfer Switches

4. Part Winding Starters5. Wye-Delta Starters6. Reduced Voltage Starters7. Multi Speed Starters8. Combination Starters9. Combination Multi Speed

Starters

700350300600300--4002001504002001506

30015015035015015012010075200100755

15075601507575100504010050404

7550407550405030255030253

4025204025202515102515102

151010151010107.57.5107.57.51

------------------5330

------------------21.51.50

460V

230V

200V

460V

230V

200V

460V

230V

200V

460V

230V

200V

NEMA

Size

StartingStartingStartingStarting

WYE - DeltaPart WindingAuto TransformerFull Voltage

Maximum HORSEPOWER 3 PHASE MOTORS

Take-awayMaximum horsepower of 3 phase motors to be started/operated with AC contactors in different configurations is limited by code. Higher powers require soft-start or drive.

35 35

Starting Motors “Across the Line”

Take-awayInduction Motors can have starting inrush currents of 10-12 times full load amps (12xFLA). These inrush currents can cause significant voltage distortions, which may require soft-starter or motor drives.

0 0.5 1 1.5 2 2.5-800

-600

-400

-200

0

200

400

600

800

Curr

ent (

A)

Time (sec)

Three-Phase Motor Currents

Starting Current

0 0.5 1 1.5 2 2.5-1000

-500

0

500

1000

1500

2000

Torq

ue (N

m)

Time (sec)

Electromagnetic Torque

Starting Torque

Voltage Distortion Tolerance of Electronic Loads

Potential voltage sag during a motor start, e.g. ≈≈≈≈20%

36 36

Soft Starter

M

L1 L2 L3

A typical soft-starter combines electro-mechanics and solid state technologies. Inrush current limit is adjustable, e.g. 3.5 - 4.5 x (Full Load Amps).

Up-stream Breaker

Bypass Contactor

SCR’s

Soft Starter

Line Voltage

Motor Voltage

Motor Current

Motor Torque

Starting at 50% load



Soft Grids- Impact of Inverter Fed Power Systems

X

House, facility, hospital

38 38

Electrical Safety and Protection- Soft Grids

Stand-by generator Applications:

• PV arrays• DC Data Center• Hybrid Vehicles• Ship Power Systems• Fuel Cells• Telecom• Soft grids

X

House, facility, hospital

fuse

Inverter-fed power systems

Grid-tied Power

Systems

39 39

feature DC and power converters

–1000Vdc for distribution, 2000Vdc for propulsion

–High fault current is not available

•Supplies current limit (e.g 2 x rated)•Long fault clearing time for conventional circuit breakers•Loads can see long outages – UPS, ABT (automatic bus transfer)

⇒ Fast acting solid state breakers offer a solution

–Current limiting and energy limiting

Circuit Breaker Technologies for Advanced Ship Power Systems

use electromechanical circuit breakers for AC and limited DC applications

–High fault current is available (e.g. 85kArms)

–DC applications generally use de-rated AC circuit breakers or fuses

Conventional power systems New power systems

Source: Slobodan Krstic, Edward Wellner, Ashish Bendre, Boris Semenov,“Circuit Breaker Technologies for Advanced Ship Power Systems”, Electric Ship Technologies Symposium, 2007. ESTS apos;07. IEEE Volume , Issue , 21-23 May 2007 Page(s):201 - 208

40 40

Arc management is a key feature of electromechanical breakers

–High energy absorption capability–Limited HVDC capability (e.g. 6kV for future ships)–Overall response time of 10 to 100 ms–Current limiting is slow relative to power converters

•Load center outages can be “long”


Solid state breakers offer fast response

–But energy absorption and voltage clamping are vital–Thermal losses are always higher

electromechanical breakers Solid state breakers

Source: Slobodan Krstic, Edward Wellner, Ashish Bendre, Boris Semenov,“Circuit Breaker Technologies for Advanced Ship Power Systems”, Electric Ship Technologies Symposium, 2007. ESTS apos;07. IEEE Volume , Issue , 21-23 May 2007 Page(s):201 - 208

41 41

Current Limiting

A

B

C D

A

B

C Dii

iiii

A

Snubber

B

Snubber

C

Snubber

Clamp

Clam

p Clamp

Line Load

Clamp

Clam

p Clamp

Military AC Solid State InterrupterDifferent types of Electromechanical

current limiting breakers

EM Breaker

SS Breaker

42 42


2000Vdc, 800A rated42 x 16.5 x 7.5 inches, 250 lbsWater cooled drawer type enclosure

electromechanical breaker Solid state breakers

Source: Slobodan Krstic, Edward Wellner, Ashish Bendre, Boris Semenov,Electric Ship Technologies Symposium, 2007. ESTS apos;07. IEEEVolume , Issue , 21-23 May 2007 Page(s):201 - 208

1800Vdc, 2300A rated35 x 25 x 10 inches, 200 lbs

High-Speed DC Circuit-Breakersfor Rolling StockType UR26, UR36 & UR40

43 43

Impact of trip current on clamp energy• Series circuit with clamp

across a fast switch• 1000 Vdc source• 1 ms time constant (L/R)• 1350 Vdc clamp

Clamp Energy vs Available Current

100 1 .103 1 .104 1 .1050.1

1

10

100

1 .103

1 .104

1 .105

Trip at 100A200A500A1kA2kA5kA10kA20kA50kA100kA

Available Current (Amps)

Ener

gy (J

oule

s)

100 1 .103 1 .104 1 .1051 .10 6

1 .10 5

1 .10 4

1 .10 3

0.01

Trip at 100A200A500A1kA2kA5kA10kA20kA50kA100kA

Available Current (Amps)

Inte

rrup

tion

Tim

e (s

ec.)

Interruption Time vs Available Current

Source: Slobodan Krstic, Edward Wellner, Ashish Bendre, Boris Semenov,Electric Ship Technologies Symposium, 2007. ESTS apos;07. IEEEVolume , Issue , 21-23 May 2007 Page(s):201 - 208

Clamp

44 44

Electronic DC Circuit Breaker.Physical Isolation at OFF-State

MOSFET Technology

Source: Meckler, P.; Ho, W.: “Does an electronic circuit breaker need electrical contacts?”,Electrical Contacts, 2004. Proceedings of the 50th IEEE Holm Conference on Electrical Contacts and the 22nd International Conference on Electrical Contacts, Volume , Issue , 20-23 Sept. 2004 Page(s): 480 - 487

45 45

Electronic Switching in a 24V DC Power Distribution System

Electronic Circuit Breakercurrent limited by electronicsSmall current peak, small i2t-valuesNo voltage sag

Mechanical Circuit BreakerHigh short circuit currentHigh i2t-valuesSignificant voltage sag

Source: Meckler, P.; Ho, W., ICEC2004

46 46

Electromechanics vs. Solid-State Trends- conclusions


! Focus on total cost of ownership

! Think system – A components play is no longer good enough

! Higher integration, closed loop controls

! Increasing number of hybrid solutions

47 47

Electromechanics vs. Solid-State Trends- conclusions


! EM and SS technologies should not be treated as competitors

! Both have there strengths and weaknesses

! Electromechanics is far from extinction

48 48

Electromechanics vs. Solid-State Trends- the good news


Over the next 25 years, the world will become increasingly dependent on electricity to meet its energy needs –We need more of Electromechanics, Solid-State-Technologies and combinations of both for new innovative solutions to meet energy efficiency, economics, sustainability and safety challenges.



Thank you very much for your kind attention

Thomas J. [email protected]

Interplay between electromechanical and solid state ... · Valve Losses Useful Work Energy Saving...

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