Current Electromagnetic Compatibility Problems of High-Power Industrial Electric Drives with Active Front-End Rectifiers Connected to a 6-35 kV Power Grid: A Comprehensive Overview

Today, electric drive systems based on frequency converters with active front-end rectifiers (FC-AFEs) are widespread across industries. In the course of the upgrade of production facilities, such systems replace the conventional converters with thyristor- and diode-based rectifiers. FC-AFEs have the following advantages: the capacity to regenerate the power to the grid and the capacity to operate at the set power factor. The manufacturers of FC-AFEs also claim that their products have the best electromagnetic compatibility (EMC) with the power grid. The best EMC shall be achieved via a multilevel FC-AFE topology and specialized pulse-width modulation (PWM) algorithms for AFE rectifiers. However, the experience of operating mid-voltage high-power electric drives with an FC-AFE in 6-35 kV factory distribution grids with non-linear frequency response due to resonant phenomena refutes the claims of the FC-AFE manufacturers. Resonant phenomena in 6-35 kV grids are caused by the interaction of the inductance of grid components (transformers, reactors) and the capacitance of output cable lines. If the resonance frequency at a sufficient amplitude corresponds to the harmonic frequency of the current consumed by the FC-AFE, the distribution grid will feature high-frequency voltage distortions. This may lead to failures in voltage quality-sensitive electrical consumers. This problem recurred at various metallurgical companies. The purpose of this research is to make a comprehensive overview of the EMC problems during the operation of FC-AFEs at active production facilities, as well as the analysis of the technical solutions aimed at the improvement of the EMC of high-power FC-AFEs with the power grid.