PHSP FFSM UPGRADES

with fixed speed with MMC (modular with exchange

pump turbines multilevel converter) of synchronous
machine and pump
with variable speed p4
turbine
pump turbines
without exchange
p3
of synchronous
machine and pump
turbine
p6

White Paper
By Piotr Sadowski
Power Conversion Germany, Berlin

PURPOSE The water in the upper reservoir is released when the

demand for power is high. In some few cases a PHSP is
equipped with a pump and a separate turbine on the same
shaft of a motor-generator (ternary system).
As this type of PHSP topology is quite rare the focus of this
whitepaper is on fixed and variable speed systems utilizing
a so-called pump-turbine.
Introduction and background The pump-turbine is connected to a motor-generator
Pumped hydro storage plants (PHSP) have been which can be either a synchronous motor or an induction
introduced end of the 19th century and have been motor. Depending on the type of generator different power
primarily used to store energy. electronic systems are connected to the motor-generator.

Since the beginning of the 20th century the total installed

capacity of PHSP has drastically increased, also driven
by increased installation of intermittent renewable
energy sources as wind and solar. In the 1930s the first
variable speed PHSP has been developed. However, it
took more than 60 years to have a first commercial unit
commissioned [1]. The worldwide installed capacity of
pumped hydro storage plants in 2020 was 159.5 GW [2]
PHSP have been used mainly for balancing the power
production and load demand in the grid. With this it
was possible to run conventional power plants in their
maximum efficiency points even when demand for
electricity was low. In case of an over-production of the
conventional power plants the power is used to pump
water [3]. Two different topologies are mainly used in a PHSP:
• Fixed Speed PHSPs
• Variable Speed PHSPs
The structure of these topologies are described in the next
Principle chapters.
A pumped hydro storage plants (PHSP) acts as a giant
energy storage system. It contains an upper gate and
depending on the type of PHSP a second lower reserve or
a river. During periods of low power consumptions or low
cost of electricity water is pumped to an upper gate.
PHSP with fixed speed pump-turbines
Most existing PHSPs utilize fixed speed pump-turbines. These turbines are connected to synchronous motor
generators in combination with a start-up converter or so-called SFC’s.

The generator is started via the SFC and once the generator (synchronous machine) is
at rated speed and synchronized to the grid the SFC will be bypassed via a bypass switch.
The synchronous machine is connected to the grid, the pump-turbine can generate power
or consume power from the grid. As the SFC is only used for start-up of the machine,
the power rating of the SFC can be lower than the rated power of the machine.
Although the structure of this type of topology is quite simple there are some disadvantages
linked to this topology. One disadvantage is clearly that the power during pump mode
(power consumption from the grid) is limited to a fixed value at a given head of the reservoir.
Additionally, the usable head range is limited with a fixed speed.
Another disadvantage of fixed speed systems is given at deviations in the head and power
compared to rated valuta, which can lead to a significant reduction of efficiency [3].
Power adjustment in pump mode with fixed speed systems can be achieved by using
multiple smaller fixed speed systems and control the power in pump mode by activating/
deactivating several systems to adjust the power of the entire power plant.
However, this results in multiple start/stop sequences and well-balanced control of the
multiple systems [4].

PHSP with variable speed pump-turbines

Variable speed (VarSpeed) PHSP utilizes pump-turbine operating at various speed values. For this a power
electronic converter system is needed. There are two different approaches given:

1. Doubly Fed Induction Machine

VarSpeed systems based on doubly fed induction machines (DFIM) have a power
electronic converter system connected to the rotor of the DFIM. These converter systems
(also known as AC Excitation systems) are either voltage source inverters (VSIs) or
cycloconverter.
The converter rating is significantly lower than the rating of the generator as only the
required rotor current or power is provided by the converter system. Due to the lower
power rating of the converter system this topology is the preferred solution for large hydro
power plants with rated power up to 120MW.
A major drawback of this system is the use of slip rings to provide current or power to the
rotor.
As all VarSpeed PHSP, this solution provides major benefits. Firstly, power during pump
operation can be adjusted. Furthermore, a higher head range can be used which also lead
to a higher energy storage capacity. Primary frequency control during pump operation is
given for all VarSpeed PHSP [3].

3 I MMC for Hydro

 2. Fully Fed Synchronous Machine (FFSM) — the 'so-called' Fully Fed Solution
Synchronous machine (SM) with a power electronic converter system connected to the
stator of the SM are so called Fully Fed Synchronous Machine (FFSM). The first FFSM have
been put in operation in 2013.
Is it obvious that converter rating must be same as the rating of the synchronous machine.
Thus, the amount of installed power electronic components is higher compared to DFIM
solutions. However, this also means some advantages especially in starting the machine.
Compared to DFIM, FFSM can be started without dewaterimg because of the possibility to
provide significant torque at zero speed [3].
There are running FFSM based on conventional VSI topologies but the recent development
in the power electronic sector led to a change of used converter topology.

FFSM WITH
Especially high power FFSM require a stator voltage that
is typically higher than the output voltage of conventional
VSI. To achieve the desired power of the PHSP converter
currents are increased leading to a parallel connection of
several VSIs with an interconnection between converter

MODULAR MULTILEVEL and generator designed for very high currents.

Moreover, conventional VSI produce a significant amount

CONVERTER
of current harmonics on the generator side which can
lead to additional losses in the generator. This could either
be compensated by increasing the effective switching
frequency of the converter, by increasing switching
frequency of the semiconductor devices, by adding
interleaving reactors/transformers, or by implementing
appropriate filters on the output of the converter.
The Modular Multilevel Converter (MMC) was Both solutions would decrease the harmonic content in the
introduced in the early 21st century and has primarily generator current but also mean additional components or
been employed for large HVDC transmission systems. higher losses in the converter. This can be omitted when a
multilevel converter is used.
Nowadays, an increasing number of Fully Fed Synchronous
Machines (FFSMs) are being implemented using MMC
technology. The key benefit of MMC technology lies in
the modularity and scalability it offers for the converter Benefits of Multilevel Converters
system. Multilevel converters have a smoother output voltage
waveform with lower total harmonic distortion (THD)
resulting in lower harmonic content of the output or
Challenges with conventional generator current.
VSI Systems MMC converter are used in different topologies. With all
Conventional VSI Systems are designed for a specific topologies each phase leg (so-called arm) consists of
voltage and power rating. Thus, the design of the motor several identical submodules.
generator is somehow linked to the given converter
output voltage.
4 I MMC for Hydro
These can be realized either in a full-bridge configuration Due to the high scalability of such a system higher SM
with four power semiconductors (typically insulated voltage can be achieved and thus higher output power
gate bipolar transistors or integrated gate commutated ratings without the need of parallel connected converter
thyristor) together with a DC capacitor or in a half-bridge units can be reached. Converter ratings of up to 100MVA
configuration with just two semiconductor devices per can be achieved without parallel connection.
submodule and a DC capacitor.

The Modular Multilevel Matrix

Converter (M3C)
The so-called Modular Multilevel Matrix Converter
(M3C) is used for a direct AC/AC conversion.
Two AC systems, the grid and synchronous machine, are
directly interconnected without the need for AC to DC and
then DC to AC conversion. It is employed to connect two
AC systems with different frequencies, such as in newly
built Fully Fed Synchronous Machines (FFSM) PHSP or Rail
power supplies.
Due to the multilevel structure of the MM7 an almost
sinusoidal voltage waveform can be achieved.
A case study for a 60 MVA MM7 system connected to an
110kV grid has been conducted and the expected voltage
at the point of common coupling (110kV High Voltage side)
and the converter input voltage are depicted. The MM7
consists of thirteen submodules per arm and leads to
minimized total harmonic distortion (THD). The calculated
THD value on the 110kV is 0.2%.

The two AC systems must have different frequencies

to limit voltage fluctuations on the individual submodule
capacitors. This implies that also the maximum frequency
of the SM needs to be below the grid frequency.
The maximum rated SM frequency and therefore also
speed of the SM is limited to ~2/3 of the grid frequency.
It becomes obvious that this kind of topology is not
suitable for SM with rated frequencies of 50/60Hz and A similar case with a conventional VSI solution (based on
thus cannot be used for a modernization or an upgrade 3-level VSI) is also shown. It is obvious, that the THD of
of an existing PHSP with fixed speed pump-turbines. the converter voltage is significantly higher.
The calculated THD of an individual converter is
approximately 30%: Overall system THD with multiple
Enhancing efficiency and converter units in parallel can be reduced to single digit
modularity for PHSP values. However, this is still 10-times higher compared to
a modular multilevel converter. These voltage harmonics
Power Conversion introduced the MMC technology as
cause high frequency currents that produce additional
the product MM7 in 2020 for different applications. In
losses and thus lowering the overall efficiency of the
2021 MM7 for pumped hydro storage plants has been
power plant.
introduced. The MM7 for PHSP is specially designed for
high efficiency and modularity for new PHSP based on
FFSM. It utilizes the above shown topology (M3C).

5 I MMC for Hydro

UPGRADING
Generally, a potential upgrade includes several studies as
identifying system needs, hydraulic and electric study [4].
All this is not scope of this whitepaper.

EXISTING FIXED SPEED Upgrade with exchange of

synchronous machine and pump-

PUMP-TURBINES turbine
Upgrading an existing PHSP to VarSpeed operation
by replacing the synchronous machine (SM) and, if
necessary, the pump-turbine can improve the efficiency
of both components and increase the achievable output
power.[7].
Most existing PHSPs utilize fixed speed pump turbines Additionally, the selection of SM parameters (e.g., voltage
with all the known and described disadvantages (e.g., no and frequency) can be adopted to the converter resulting
power regulation in pump mode and significantly reduced in an overall optimized systems with increased efficiency.
efficiency in partial load). Selecting voltage and frequency values enables the use of
a direct AC/AC MMC topology as shown on p5. However,
Upgrading an existing fixed speed pump-turbine to
this means a major upgrade with new added components
VarSpeed eliminates these disadvantages and brings
and thus high CAPEX.
additional benefits to the power plant operator.

The operating range (Power output vs. net head) in turbine

and pump mode can be stretched (see figure [5]).
Ancillary services as frequency regulation in pump mode
or an increased Spinning reserve in generation or turbine
mode can be utilized when upgrading PHSP from fixed
Speed to VarSpeed. Frequency regulation means that the
power of the PHSP will be adjusted to keep grid frequency
in a well-defined range whereas Spinning reserve means a
spare generation capacity which can respond rapidly to a
sudden loss of the generating unit [6].
Two scenarios for upgrading an existing fixed speed
pump-turbine into an VarSpeed pump-turbine are
presented in the following sections:
• Upgrade with exchange of synchronous machine and
pump-turbine
• Upgrade without exchange of synchronous machine
and pump-turbine
6 I MMC for Hydro
Upgrade without exchange of synchronous machine and pump-turbine
Upgrading an existing PHSP to VarSpeed operation without changing the synchronous machine (SM) renders the
use of the MMC topology described on p5 (direct AC/AC conversion) impractical due to the matching frequencies of
the generator and the grid. Therefore, an alternative topology or technology must be adopted.
Generally, a conventional VSI can be used. Conventional VSI solutions do not
have the restriction of unequal frequencies and thus are suitable for this kind of
application. Due to the high harmonic content of the VSI harmonic filter (e.g., sine
filter) must be installed on the output and input of the converter.
As previously described MMC produce significantly lower harmonics and can be
used for an upgrade. A possible configuration of a MMC based solution is shown
here.
The synchronous motor has been originally designed for an operation at a grid and
thus is not optimized for operation with a variable frequency drive. Thus, stringent
requirements in terms of voltage harmonics, common mode voltages and rise times
(dv/dt) must be met by the converter.
The shown MMC topology uses a mixture of full-bridge and half-bridge submodules
to ensure start-up without the need of dewatering and to minimize common mode
voltage stress of the machine insulation [8]. Furthermore, it might be necessary to
install small filters on the converter in- and output to limit stress of the insulation of
transformer and SM.

Synchronous machines designed for direct online operation are aligned with specific voltage levels, reducing the
demand for scalability and flexibility. This allows for a simpler converter topology to be employed when upgrading
fixed-speed pump-turbines to VarSpeed operations.
A combination of a modular multilevel converter together with a conventional VSI
can reduce the complexity of the converter system.
The shown converter topology consists of a MMC Active-Front-End (AFE) and a
5-Level Machine Converter. Due to the topology of the machine converter (MC) the
AFE can be equipped with half-bridge modules. The machine converter topology is
a so-called nested NPP topology [9].
The complexity of this converter topology is notably lower when compared to
an MMC-based design (with half-bridge and full-bridge submodules), given an
assumed grid and machine voltage of 13.8kVAC. A full MMC solution (a combination
of half- and full-bridge submodules) requires nearly 60% more semiconductor
devices than a mixed MMC/VSI solution. The machine converter can achieve
equivalent torque characteristics to other conventional VSI topologies.
As the machine side converter is a 5-Level VSI, an output filter will be needed to
achieve an output voltage with similar characteristics as the grid.

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Topology Full MMC MMC-VSI combination
Type of converter AFE Full-bridge MMC Half-bridge MMC
No of arms 6 6
No of submodules per arm 9 9
Type of converter MC Half-Bridge MMC 5-level VSI
No of arms 6 3
No of submodules per arm 9 2
No of semiconductors per submodules 2 16
324 204
Total installed semiconductors 159% 100%

Power Conversion introduced this kind of mixed Conventional two or three level topologies require many
topology in 2021. The solution is called Hybrid MM7 IGBTs or IGCTs connected in series. Due to the nested NPP
and is available for machine voltages of 11kVAC and structure a series connection of only four IGBTs is needed
13.8kVAC. The machine converter consists of proven to achieve an output voltage of 13.8kV.
5-Level technology and is part of the MV7 product With the MMC topology acting as an active front end (AFE)
offering. the voltage of the AFE has low harmonic content and
The figure shows the machine converter of the hybrid harmonic filters are not needed.
MM7 utilizing a 5-Level nested NPP topology.
The 5-level inverter is built of two 3-level cells (IGBT
inverter 1 and 2). These inverter cells are connected via
a so-called flying capacitor.

Control DC capacitors IGBT inverter 1 FC capacitors IGBT inverter 2 Earth switch

8 I MMC for Hydro

CONCLUSION
Upgrading PHSP based on fixed-speed pump-turbines Glossary of terms
into variable speed enables a much wider operating
range in pump and turbine modes.
MMC: Modular Multilevel Converter
For this a converter is needed to adjust the speed of the
synchronous machine. Although this means an additional VSI: Voltage Source Inverter
CAPEX additional benefits as ancillary services can be PHSP: Pumped hydro storage plant
offered.
AFE: Active Front End
Modular multilevel converters are the best choice for
MC: Machine converter
converter-fed synchronous machine offering a modular
and thus scalable converter solution. SM: synchronous machine
Upgrades of PHSP without an exchange of the machine FFSM: Fully Fed Synchronous Machine
and the pump-turbine have the difficulty that the machine DFIM: Doubly fed induction machine
will be operated at grid frequency and that the converter
HVDC: High Voltage Direct Current
must have similar voltage characteristics as the grid.
Modular multilevel converter have the advantage of low
harmonic content. However, special converter topologies
must be used to ensure high torque at almost zero speed.
A hybrid solution combining modular multilevel converter
and conventional VSI topologies eliminates the complex
structure of a purely MMC based solution for this kind of
application.

Bibliography
[1] Toshiba, „Toshiba Science Museum,“ [Online]. Available: https://toshiba-mirai-kagakukan.jp/en/learn/history/ichigoki/1990hatuden/
index.htm. [accessed on March 30, 2022].
[2] International Hydro Association, „Hydropower status report,“ 2021.
[3] M. V. a. A. Nysveen, „Variable_speed operation of Hydropower Plants,“ IEEE Industry Applications Magazine, pp. 18-27, September/
October 2018.
[4] eSTORAGE, „Potential for conversion of classical PSP to variable speed units in EU15, Norway and Switzerland“ European Commission
– Directorate General for Research , 2016.
[5] C. Gentner und F. Maurer, „CONVERTING CONVENTIONAL PUMPED-STORAGE PLANTS TO VARIABLE SPEED“ 20th Intern. Seminar on
Hydropower Plants – Celebrating 40 Years of Industry-Academic Engagement, pp. 373-384, 2018.
[6] MWH Americas, Inc., „Pumped Storage and Wind Power Integration with Wind Power in the Pacific Northwest“ 2009.
[7] S. Antheaume, G. Darona, J.-B. Houdeline und Y. Labrecque, „Hydro Review,“ 17 February 2017. [Online]. Available: https://www.
hydroreview.com/world-regions/upgrading-two-pumped-storage-plants-to-variable-speed/#gref. [Zugriff am 30 March 2022].
[8] B. Miodrag, A. Schwery und D. Dujic, „Highly Flexible Indirect Modular Multilevel Converter for High Power Pumped Hydro Storage
Plants,“ IEEE, 2020.
[9] M. Mechlinski, S. Schröder, J. Shen und R. De Doncker, „Grounding concept and common-mode filter design methodology for
transformerless MV drives,“ IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 6,, pp. 5393- 5404, November /
December 2017.

9 I MMC for Hydro

About Power Conversion, a GE Vernova business
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obligation. GEA34919_ Multi Modular Converter_WP_MMC for Hydro_EN_20230814