SOLAR PUMPING March 7 th 2013

Transcription

1 SOLAR PUMPING March 7 th 2013

2 1 SD700 SP Introduction 2 Operation modes 3 Hydraulics 4 Submersible pumps 5 SD700SP LCoW 6 SD700SP Ordering Info 7 SD700SP Sample

3 01 Introduction/ What is Solar Pumping? SOLAR PANELS WHAT IS SOLAR PUMPING? PUMPING SYSTEM PUBLIC GRID OR DIESEL GENERATOR Solar Pumping consists in supplying water pumps with the energy generated by a PV Solar Plant.

4 01 Introduction/ SD700SP Topology SD700 SP TOPOLOGY

5 01 Introduction/ SD700SP Topology SD700 SP TOPOLOGY SD700SP AC on-load disconnector DC On-load disconnector AC Fuses DC Fuses DC terminals (+) and (-)

6 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.

7 02 Operation Modes / Solar assisted & Grid Connected OPERATION MODE: SOLAR ASSISTED & GRID CONNECTED

8 02 Operation Modes / Renewable Energy Self-sufficient Minimum System Required Power (30Hz-50Hz) OPERATION MODE: RENEWABLE ENERGY SELF- SUFFICIENT Maximum System Power (50Hz)

9 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%.

10 03 Hydraulics THROTHLING CONTROL VS VARIABLE SPEED DRIVE - OVERVIEW Head in m H 2 O 1 X n P = kW 40 3 P40 = P50 = 51. 2kW 50 FLOW Head in m H 2 O 1 X n 35 P35 P = 50 = 34.3kW X n 0.8 X n 0.7 X n 0.6 X n Static height 20 meters 100% 80% 70% 90% 60% 50% X n 0.8 X n 0.7 X n 0.6 X n X n 0.4 X n X n 0.4 X n 10 H-Q curves Q Flow m 3 /min 50% 100% H-Q Curves System curves % 100%

11 03 Hydraulics BOTH SYSTEM AND PUMP CURVES DEFINE THE MINIUM START REQ. Height (bar) 50 Hz 40 Hz 30 Hz CURVE -A CURVE -B Height (bar) Min Height. 50 Hz 40 Hz 30 Hz Min Height. 20 Hz Q (m 3 ) Curves with high angled slopes offer optimal regulation Better regulations deliver higher savings Q (m 3 ) Curves with low angled slopes offer poor regulation Energy savings are restricted by the regulation range PP 2 = PP = PP PP 2 = PP INDIVIDUALIZED SYSTEM ANALYSIS = PP

12 03 Hydraulics PUMP S PERFORMANCE DEPENDING ON SPEED VARIATION X n 30% 50% 60% N = 1480 RPM 70% 80% 85% X n 0.8 X n 0.7 X n 87% 88% 87% 85% 80% X n X n 0.4 X n Efficiency curves Curve H Q System curve Q flow m 3 /min

13 03 Hydraulics MINIMUM FEED IN POWER AND VINIMUM MFT VOLTAGE Height (bar) 50 Hz 40 Hz 30 Hz CURVE -A CURVE -B Height (bar) Min Height. 50 Hz 40 Hz 30 Hz Min Height. 20 Hz Q (m 3 ) Q (m 3 ) Curves with high angled slopes offer optimal regulation and lower starting frequencies Better regulations deliver higher savings PP 2 = PP Curves with low angled slopes offer poor regulation and higher starting frequencies Energy savings are restricted by the regulation range = PP PP 2 = PP INDIVIDUALIZED SYSTEM ANALYSIS = PP

14 04 Submersible pumps SUBMERSIBLE PUMP TOPOLOGY Water impulsion Pump Impellers Pump Shaft Cooling jacket Water intake Motor Shell Motor Thrust bearing

15 04 Submersible pumps SUBMERSIBLE PUMPS & VSD CONSIDERATIONS MOTOR CABLES TYPE AND LENGHT PUMP COOLING THRUST BEARING COOLING VSD OPERATION & SETTINGS

16 04 Submersible pumps SD700 RECOMMENDED CABLE TYPE Desired - Up to 300m Compatible - Up to 150m

17 04 Submersible pumps VOLTAGE FLANGE WAVE FORM ALL DRIVES ARE NOT THE SAME Competitors dv/dt values SD700 STANDARD

18 04 Submersible pumps ADMISSIBLE PEAK VOLTAGE LIMIT CURVES IN AC MOTORS TERMINALS: Peak voltage (kv) m 30m 50m 100m IEC Curve B (without filters for motors up to 690V AC) NEMA MG1 Pt31 in grids of 600V IEC Curve A (without filters for motors up to 500V AC) 200m IEC NEMA MG1 Pt31 in grids of 400V 2.15kV 1.86kV 1.56kV 1.35kV 1.24kV m 0.4 Examples of the test results, SD700 using reinforced copper wires at 415V rated voltage Rise time of the voltage pulse (µs)

19 04 Submersible pumps Well intake Cooling Speed - V (m/s) Q (m3/s) T (ºC) PUMP COOLING Keep a minimum speed of the surrounding water. Vc = m/s ( Consult Manufacturer) 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) Higher pump flow (Q) Lower motor load (AP) Pump speed reduction (Hz) Wider motor Diameter (mm) Dp Dw Higher convection factor (W/mm 2 ) Water stream distribution Low factor between motor diameter and well diameter

20 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

21 04 Submersible pumps VSD OPERATION AND SETTINGS YES Is there water release holes in the pump? YES How long it takes to empty the pipe? - Soft start after the empty time - Soft stop to reduce water hammer NO Start and Stop with water-filled pipe settings (Maximum head)- CASE 1 1 Is a Check Valve integrated in the pump? YES Start with empty pipe but it needs a fast speed transient - CASE 3 3 NO Is there a check valve on the top of the hole? NO Soft start and stop CASE 2 2

22 04 Submersible pumps START AND STOP WITH WATER-FILLED PIPE 1 Head (bar) Min Head 50Hz Min Head - AP Q min (thrust bearing cooling) Pump Installation 10Hz 40Hz 30Hz 20Hz Q (m 3 ) Pump Speed (Hz) Slow ramp - Flow control range - Reduce sand impulsion 2s Fast ramp Min Flow 4s- 7200s 30s Slow ramp Water Hammer Control 1s Fast ramp Pump stop Time (s)

23 04 Submersible pumps SOFT START AND STOP 2 Head (bar) Min Head 50Hz Min Head - AP Q min (thrust bearing cooling) Pump Installation 10Hz 40Hz 30Hz 20Hz Q (m 3 ) Fast ramp Min Flow Pump Speed (Hz) s Slow ramp - Flow control range - Reduce sand impulsion 4s- 7200s Slow ramp Water Hammer Control 4s- 7200s 1s Time (s)

24 04 Submersible pumps SOFT START AND STOP WITH FAST TRANSIENT Head (bar) 3 Inst. Head Min Head 50Hz Min Head - AP Q min (thrust bearing cooling) Pump Installation 10Hz 40Hz 30Hz 20Hz Q (m 3 ) Fast ramp Min. Flow Pump Speed (Hz) Slow ramp - Flow control range - Reduce sand impulsion Slow ramp Water Hammer Control 1s 4s- 7200s 1s Fast transient ramp Checkvalve opening 4s- 7200s 4s- 7200s 1s Time (s)

25 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= V = 329V Vmppt_400Vac= V= 569V o Start feed-in power: No restriction Results: Energy Savings: kwh/ per year Fuel/ Electricity cost:

26 05 SD700SP LCoW / Self Sufficient Hydraulic System: o Pump power: o Pump/line voltage: o Min frequency (Hz): o Min Power (kw): Solar PV system Sizing: o Max DC Voltage: o MPP tracking: o MPPt range: o Start feed-in power: SD700SP Self Sufficient From 2.2kW up to. (feasibility limit) From 230Vac to 440Vac. Required. Hydraulic system modeling Required. Hydraulic system modeling 1000Vdc Yes Vmin (Min.Hz).1000V Min Power (kw) Results: Power (kw): Pumping ratio : kw Hourly data ( PV sys tool) Multiple values - Pump curve dependant

27 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 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 X n 0.9 X n 0.8 X n 0.7 X n 0.6 X n 0.5 X n 0.4 X n Min. Frequency. (42.5Hz) Min. Power (25kW) 30% 50% 60% N = 1480 RPM 70% 80% 85% 87% Rated flow, head and power Pump and SD700SP Selection 88% 87% 85% Min flow: (5 m3/min) Depend on pump cooling. 80% Efficiency curves Curve H Q System curve Q flow m 3 /min

28 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%

29 05 SD700SP LCoW / PV sizing SD700SP Self Sufficient / PV performance Radiation Sensor Minimum Voltage Minimum Power

30 06 SD700SP Ordering Info SD700SP Ordering Info Project Solar Pumping Project Pump Submersible pump Location Egypt Application and control [Deep well to storage, lake/river to storage, pressurization] Other information [Attach PV sys reports, pump manufacturer curves, Power PCA report, other studies] Min. Ambient Temperature : -10ºC Max. Ambient Temperature : +45ºC Degree of Protection : IP54 Indoor installation Units :4 Reference number SD7SP 55 S Nominal Current _A Power Motor up to _kw AC Power Supply YES : [Diesel Genset, Grid-connected ] Motor Data Power : 75 _ kw Voltage : 380 _ Vac Current : 165_ A PV plant Data First Level 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 Second Level Number of combiner boxes : 3 Fuse protection 50A ON-load disconnector : YES AC Power Supply Protections (if needed) AC On load disconnector : YES AC Semiconductor Protection Fuses : YES Irradiation Sensor : :Included I/O signals 6 DI, 3 DO, 2 AI, 2AO, 1 PTC, 1 PT100. (Other available under request) Communication : RS485 Modbus RTU Door Pushbuttons : Optional Door Pilots : Optional Heating Resistors : Optional Hygrostat : Optional

31 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

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