Variable Frequency Drives-Induced Torsional Stresses in Pumped Hydropower Storage Applications

Abstract

Despite consistent maintenance and monitoring equipment installed in pumped storage hydropower (PSH) facilities, many shafts and electrical component failures are reported, possibly resulting from undetected sources. These sources include undetectable vibrations or, in certain conditions, high-frequency mechanical or electrical harmonics. This paper presents a direct method for plotting Campbell diagrams of large motors supplied by variable frequency drives (VFDs) for torsional analysis purposes in PSH systems. These diagrams display the precise locations where torsional stress components induced by VFDs can interfere with shaft resonance modes. The method simplifies the determination of the magnitude of stimulus forces in the motor airgap that may threaten the shaft. The method has been successfully applied to two-level, three-level neutral-point clamped, and seven-level cascaded H-bridge multilevel inverters, which are commonly used industrially available VFD topologies for pumped PSH plants. The paper also discusses the theoretical motor-pump voltage, current, and torque spectra when driven by a cascaded H-bridge multilevel converter operating with bypassed and faulty cells. The accuracy of the theoretical developments is supported by selected simulations results at different operating points and different fault conditions. Hybrid experimental-numerical VFD-induced harmonic stress analysis is also performed to demonstrate the relevance of the proposed study.

Keywords

• Airgap torque
• hydropower
• pulse-width modulation
• resonance
• torsional analysis
• torsional stress