Report

SOLAR PUMPING March 7th2013 1 SD700 SP Introduction 2 Operation modes 3 Hydraulics 4 Submersible pumps 5 SD700SP LCoW 6 SD700SP Ordering Info 7 SD700SP Sample 01 Introduction/ ¿What is Solar Pumping? ¿ WHAT IS SOLAR PUMPING? SOLAR PANELS PUMPING SYSTEM PUBLIC GRID OR DIESEL GENERATOR Solar Pumping consists in supplying water pumps with the energy generated by a PV Solar Plant. 01 Introduction/ SD700SP Topology SD700 SP TOPOLOGY 01 Introduction/ SD700SP Topology SD700 SP TOPOLOGY SD700SP AC on-load disconnector DC On-load disconnector AC Fuses DC Fuses DC terminals (+) and (-) 02 Operation Modes OPERATION MODES SOLAR ASSISTED SYSTEM: SD700SP is connected to the PV farm and to the grid simultaneously. The PV power is prioritized. RENEWABLE ENERGY SELF-SUFFIENCENT: SD700SP is only connected to the PV field, generating the necessary power to start and speed-up the pump. The motor start will depend on the systems minimum power required. GRID CONNECTED: SD700SP is operated as a regular VSD, hence it allow to run the pump during night hours and during PV farm maintenance seasons. In no event will the PV farm (DC) and the electric grid (AC) interact, due to the unidirectional thyristor-diode rectifier bridge in between them. 02 Operation Modes / Solar assisted & Grid Connected OPERATION MODE: SOLAR ASSISTED & GRID CONNECTED 02 Operation Modes / Renewable Energy Self-sufficient Minimum System Required Power (30Hz-50Hz) OPERATION MODE: RENEWABLE ENERGY SELF- SUFFICIENT Maximum System Power (50Hz) 03 Hydraulics VSD CONTROL The variable speed pump’s control provides unique regulation and performance features. The variable speed drive modifies the performance curve of the pump in order to meet the system requirements. The centrifugal pump performance is modeled by the affinity laws. In theory, the power reduction is proportional to the cubic of speed, for example a 20% speed reduction cause a power saving greater than 47%. 03 Hydraulics THROTHLING CONTROL VS VARIABLE SPEED DRIVE - OVERVIEW P50 100kW 80 P40 P50 40 50 3 3 51 .2kW Head in m H2O P35 80 Head in m H2O 1Xn 1Xn FLOW 70 50 40 30 0.9 X n Static height 20 meters 60 0.8 X n 0.7 X n 0.6 X n 90% 80% 70% 60% 50% 100% 70 60 50 40 30 0.5 X n 0.9 X n 0.8 X n 0.7 X n 0.6 X n 0.5 X n 20 20 0.4 X n 0.4 X n H-Q curves 10 0 35 P50 34.3kW 50 20 10 50% H-Q Curves 30 100% System curves 10 Q Flow m3/min 0 10 50% 20 100% 30 03 Hydraulics Height (bar) Height (bar) BOTH SYSTEM AND PUMP CURVES DEFINE THE MINIUM START REQ. CURVE -A 50 Hz 40 Hz Min Height. 30 Hz CURVE -B 50 Hz 40 Hz 30 Hz 20 Hz Min Height. Q (m3) Q (m3) Curves with high angled slopes offer optimal regulation Curves with low angled slopes offer poor regulation Better regulations deliver higher savings Energy savings are restricted by the regulation range 20 2 = 1 · 50 3 = 1 · 0.064 40 2 = 1 · 50 INDIVIDUALIZED SYSTEM ANALYSIS 3 = 1 · 0.512 03 Hydraulics PUMP’S PERFORMANCE DEPENDING ON SPEED VARIATION 80 1Xn 30% 50% 70 60% N = 1480 RPM 70% 80% 0.9 X n 85% 87% 60 50 88% 87% 85% 0.8 X n 80% 0.7 X n 40 30 20 0.6 X n 0.5 X n Efficiency curves 0.4 X n Curve H – Q System curve 10 0 10 20 30 40 Q flow m3/min 03 Hydraulics Height (bar) Height (bar) MINIMUM FEED IN POWER AND VINIMUM MFT VOLTAGE CURVE -A 50 Hz 40 Hz Min Height. 30 Hz CURVE -B 50 Hz 40 Hz 30 Hz 20 Hz Min Height. Q (m3) Curves with high angled slopes offer optimal regulation and lower starting frequencies Curves with low angled slopes offer poor regulation and higher starting frequencies Energy savings are restricted by the regulation range Better regulations deliver higher savings 20 2 = 1 · 50 Q (m3) 3 = 1 · 0.064 40 2 = 1 · 50 INDIVIDUALIZED SYSTEM ANALYSIS 3 = 1 · 0.512 04 Submersible pumps SUBMERSIBLE PUMP TOPOLOGY Water impulsion Pump Shaft Pump Impellers Cooling jacket Water intake Motor Shell Motor Thrust bearing 04 Submersible pumps SUBMERSIBLE PUMPS & VSD CONSIDERATIONS MOTOR CABLES TYPE AND LENGHT PUMP COOLING THRUST BEARING COOLING VSD OPERATION & SETTINGS 04 Submersible pumps SD700 – RECOMMENDED CABLE TYPE Desired - Up to 300m Compatible - Up to 150m 04 Submersible pumps VOLTAGE FLANGE WAVE FORM ALL DRIVES ARE NOT THE SAME Competitors dV/dt values SD700 STANDARD 04 Submersible pumps ADMISSIBLE PEAK VOLTAGE LIMIT CURVES IN AC MOTORS TERMINALS: Peak voltage (kV) 2.4 IEC 60034-25 Curve B (without filters for motors up to 690V AC) 2.0 NEMA MG1 Pt31 in grids of 600V 1.6 1.2 20m 0.8 100m 50m 30m 2.15kV 1.86kV IEC 60034-25 Curve A (without filters for motors up to 500V AC) 1.56kV IEC 60034-17 1.35kV 200m 1.24kV NEMA MG1 Pt31 in grids of 400V 10m Examples of the test results, SD700 using reinforced copper wires at 415V rated voltage. 0.4 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Rise time of the voltage pulse (µs) 1.0 1.1 1.2 04 Submersible pumps PUMP COOLING Well intake Keep a minimum speed of the surrounding water. Vc = 0.08…0.5 m/s ( Consult Manufacturer) T (ºC) Q (m3/s) Cooling Speed - V (m/s) Cooling flow depends on: • Water temperature and properties • Pumps geometry and Motor Shell • Motor and pump load • Well geometry INCREASE COOLING CAPACITY REDUCE HEAT LOSSES Lower water temperature (ºC) Lower motor load (AP) Higher pump flow (Q) Pump speed reduction (Hz) Wider motor Diameter (mm) Dp Higher convection factor (W/mm2) Dw Water stream distribution Low factor between motor diameter and well diameter 04 Submersible pumps THRUST BEARING COOLING Thrust bearings needs a minimum water flow (15-30% of Qn) to create a thin lubrication layer. The layer ensures bearing cooling and reduce friction between fixed parts. Lubrication layer 04 Submersible pumps VSD OPERATION AND SETTINGS YES YES How long it takes to empty the pipe? - Soft start after the empty time - Soft stop to reduce water hammer Is there water release holes in the pump? Start and Stop with water-filled pipe settings (Maximum head)- CASE 1 1 YES Start with empty pipe but it needs a fast speed transient - CASE 3 3 NO Soft start and stop – CASE 2 2 NO Is a Check Valve integrated in the pump? NO Is there a check valve on the top of the hole ? 04 Submersible pumps START AND STOP WITH WATER-FILLED PIPE Head (bar) 1 Min Head 50Hz Min Head - AP 40Hz 30Hz 20Hz 10Hz Q min (thrust bearing cooling) Pump Pump Speed (Hz) 50 Q (m3) Installation Slow ramp - Flow control range - Reduce sand impulsion Slow ramp Water Hammer Control 40 30 20 10 Fast ramp Pump stop Fast ramp – Min Flow Time (s) 0 2s 4s- 7200s 30s 1s 04 Submersible pumps SOFT START AND STOP Head (bar) 2 Min Head 50Hz Min Head - AP 40Hz 30Hz 20Hz 10Hz Q min (thrust bearing cooling) Pump Pump Speed (Hz) 50 Fast ramp – Min Flow Slow ramp - Flow control range - Reduce sand impulsion Q (m3) Installation Slow ramp Water Hammer Control 40 30 20 10 4s- 7200s Time (s) 4s- 7200s 0 1s 1s 04 Submersible pumps SOFT START AND STOP WITH FAST TRANSIENT Head (bar) 3 Inst. Head Min Head 50Hz Min Head - AP 40Hz 30Hz 20Hz 10Hz Q min (thrust bearing cooling) Pump Pump Speed (Hz) 50 Fast ramp – Min. Flow Q (m3) Installation Slow ramp - Flow control range - Reduce sand impulsion Slow ramp Water Hammer Control 40 Fast transient ramp – Checkvalve opening 30 20 10 Time (s) 4s- 7200s 0 1s 4s- 7200s 1s 4s- 7200s 1s 05 SD700SP LCoW / Grid connected SD700SP Grid Connected system Hydraulic System: o Pump power: No restriction o Pump/line voltage: From 230Vac to 440Vac. o Min frequency (Hz): No restriction o Min Power (kW): No restriction Solar PV system Sizing: o Max DC Voltage: 1000Vdc o MPP tracking: No, fixed DC voltage o MPPt range: Vmppt = sqrt(2) · Vac + 5V Vmppt_230Vac= 1.41 · 230 +5V = 329V Vmppt_400Vac= 1.41 · 400 +5V= 569V o Start feed-in power: No restriction Results: Energy Savings: kWh/ per year Fuel/ Electricity cost: € 05 SD700SP LCoW / Self Sufficient SD700SP Self Sufficient Hydraulic System: o Pump power: From 2.2kW up to …. (feasibility limit) o Pump/line voltage: From 230Vac to 440Vac. o Min frequency (Hz): Required. Hydraulic system modeling o Min Power (kW): Required. Hydraulic system modeling Solar PV system Sizing: o Max DC Voltage: 1000Vdc o MPP tracking: Yes o MPPt range: Vmin (Min.Hz) ….1000V o Start feed-in power: Min Power (kW) Results: Power (kW): kW Hourly data ( PV sys tool) Pumping ratio : Multiple values - Pump curve dependant 05 SD700SP LCoW / PV sizing SD700SP Self Sufficient / Hydraulic Sizing- Deep Well to storage Power PCA - Work flow Determine the static head (m) of the system. Determine the desired flow of the system (m3/min) Select the pump considering Head and flow Select SD700SP according to pump rated power. Create new project in Power PCA Select High Accuracy mode Introduce pump curves points (P vs Q) Introduce efficiency pump curves ( Eff vs Q) Select Variable flow and constant height Determine the Q min Introduce different Q values (including Q min) Save Data as XLS Min. Frequency. (42.5Hz) Min. Power (25kW) 80 1Xn 30% 50% 70 60% Rated flow, head and power Pump and SD700SP Selection N = 1480 RPM 70% 80% 0.9 X n 85% 87% 60 50 88% 87% 85% 0.8 X n 80% 0.7 X n 40 30 20 0.6 X n 0.5 X n Efficiency curves 0.4 X n Assumptions Pipes, valve losses are dismissed. Pump performance according to affinity laws. Constant height, no well level variation are considered Further accuracy requires specific hydraulic SW. Curve H – Q System curve 10 0 10 20 30 Min flow: (5 m3/min) Depend on pump cooling. 40 Q flow m3/min 05 SD700SP LCoW / PV sizing SD700SP Self Sufficient / PV sizing PV Sys – Work flow Select Project Design – Grid connected system Open an existing inverter Introduce Vmin in Minimum MPP Voltage, depending on the hydraulics limitations ( see next slide) Introduce Pmin in Power Threshold. (error may appear) There are no limitations on nº of DC inputs or DC/AC ratio. Select efficiency = f(P out) and check that efficiency curves are ready Select the appropriate string distribution to maximize the PV production. P out Eff (%) 0% 0 10% 96.5% 30% 98.0% 50% 98.2% 70% 98.6% 90% 98.5% 100% 98.5% 05 SD700SP LCoW / PV sizing SD700SP Self Sufficient / PV performance Radiation Sensor Minimum Voltage Minimum Power 06 SD700SP Ordering Info SD700SP Ordering Info Project Pump Location Application and control Solar Pumping Project Submersible pump Egypt [Deep well to storage, lake/river to storage, pressurization] Other information [Attach PV sys reports, pump manufacturer curves, Power PCA report, other studies] : -10ºC : +45ºC : IP54 Indoor installation :4 SD7SP _ _ _ _ 55 S _ _ _A _ _ _kW YES : [Diesel Genset, Grid-connected ] Power : 75 _ kW Voltage : 380 _ Vac Current : 165_ A Min. Ambient Temperature Max. Ambient Temperature Degree of Protection Units Reference number Nominal Current Power Motor up to AC Power Supply Motor Data PV plant Data First Level Second Level AC Power Supply Protections (if needed) Irradiation Sensor I/O signals Communication Door Pushbuttons Door Pilots Heating Resistors Hygrostat Panel type : BYD 255 6C Nº PV panels in series : 24 Nº of String per combiner box : 22 ON-load disconnection : YES Combiner box fuse rating : 12A Number of combiner boxes :3 Fuse protection 50A ON-load disconnector : YES AC On load disconnector : YES AC Semiconductor Protection Fuses : YES : :Included 6 DI, 3 DO, 2 AI, 2AO, 1 PTC, 1 PT100. (Other available under request) : RS485 – Modbus RTU : Optional : Optional : Optional : Optional 07 SD700SP Sample SD700SP Case Study • Pump: 2x Sulzer 75kW • SD700SP: 1x SD7SP Frame 4 • Accessories: • AC Disconnector • DC ON-load manual disconnector • DC fuses according to PV sizing POWER ELECTRONICS Appreciates your time For more information please visit: www.power-electronics.com