real-life design project approach to teaching renewable energy design project... · (engineering...

S

Real-Life Design Project Approach

to Teaching Renewable Energy

Dr. Elena Brewer, Anthony Dalessio

Erie Community College

2013 Sustainability Conference, Alfred State

SUNY College of Technology, June 7, 2013

Existing PV Systems course

(since 2011)

S Examinations

S Homework assignments: - theoretical - practical (load analysis using kill-a-watt meter, shading analysis using Solar PathFinder, solar irradiance analysis with PV Watts calculator or solar irradiance tables, etc.

S Comprehensive Group Design Project

S Assessment



Design Project

New Wind Power course: Some of the Topics Covered

S Wind turbine site analysis

S Wind resource analysis (Rayleigh distribution, Weibull

distribution, etc.)

S Turbine power output / energy output estimates

S Blades aerodynamics

S Mechanical and Electrical aspects



System Needs and

Requirements

S The EET department presently has a need for an off-grid

power system to power lights and power tools for the

college’s overhead construction and climbing facility for

Energy Utility Technology program:

- overhead climbing class runs 3 or 6 weeks every summer,

5 days a week, 8 hours per day;

- no electricity on site;

- hot temperatures.



Superwind 350

Wind Turbine • The turbine was installed at

south campus during summer 2012 climbing school.

• The department was going to complete the stand-alone wind/PV system for data acquisition purposes and to run lights in the trailer for the climbing school.

• Budgetary issues prevented us from completing this project in 2012.

2013 Sustainability Conference, Alfred State SUNY

College of Technology, June 7, 2013

Installation of

Wind Turbine



ASEE ETD (Engineering Technology Division)

Mini-Grant

S In the Fall of 2012, ASEE ETD division announced the competition for mini-grants (up to $5,000) for partial funding on project which will benefit ETD or a segment of the engineering technology community.

S ETD gave as much latitude as possible to ETD members in the choice of projects. The project should benefit ETD itself or a significant portion of the engineering technology community. It may focus on a single discipline and/or be of use to a particular college or system, so long as the results will benefit the larger ETD community.

S EET department applied and won one of three mini-grant awards.



Budgetary Constraints

S ASEE ETD mini grant - $4,200 for equipment, $800 for

conference

S ECC matching costs:

- $2,500 Superwind 350 24V wind turbine

with wind charge regulator and dump load,

- available assortment of PV charge controllers ($400 -

$1,500)

- available 140W solar panels (if students choose to use them)

- 10 available AGM 105 Wh batteries (if students choose to use

them)

- up to $1,000 from EET department budget

- installation of the pole ($1,400) plus pole cost ($600)



Design Competition

S Several students groups (2-3 students each) competed for the best design of the system within current specifications (energy audit, wind resource analysis, shading analysis, customer load requirements, customer system requirements, budgetary constraints, already existing equipment, NEC requirements, etc.) during Spring 2013 semester.

S Design competition provided students with real life experience designing actual renewable energy system.

S The combination of PV Systems course and Wind Power course (electives) provided students with unique background for possible design of the hybrid PV-Wind system.



Design Competition

S Deliverable – design of the viable PV/Wind/hybrid stand alone system with battery back up: - PowerPoint presentation - Portfolio with supporting materials (wind resource and shading analysis, load specs, major system components specs, array and battery bank sizing calculations, wire sizing calculations, etc.)

S The competition judging panel consisted of PV/wind industry representatives, customers (instructor from National Grid teaching the climbing school), ECC faculty



Design Competition

S 4 student group designs were presented ranging from

systems utilizing only PV array to hybrid systems with wind

turbine and PV panels.

S The winning project was determined based on judging panel

scores.

S The grade for the student design project was determined

based on judging panel scores, portfolio with system

specification, presentations performance, student self-

evaluation.



Design

Competition:

Judging

Criteria



EL 264 PV/Wind System Design Competition

Project: ______________________________________________________________

Assign a rating of each relevant criteria based on a 10 point scale (10 rated the highest and 1 rated the

lowest rating)

Technical Aspects

Criteria Rating (1 to 10) Comments

Load analysis

Were minimum load

requirements met?

Were space requirements

met?

Shading analysis

Available wind energy

analysis (if applicable)

PV Array / Wind turbine

sizing

Charge controller and

battery bank sizing

Inverter sizing

BOS sizing (disconnects,

wiring)

System components

completely priced out

Was project cost kept under

budget?

Were specs for all system

components provided?

Sources for all components

How complete the proposal

is

Room for expansion

Presentation aspects:


Eye contact

Team work (everybody

presents)

Appropriate use of

PowerPoint

Technical content

Timing (15-20 min)

Elocution and appropriate

audio level

Design

Competition:

Presentation

Evaluation



EL 264 PV/Wind System Design Competition

Project: ______________________________________________________________

Assign a rating of each relevant criteria based on a 10 point scale (10 rated the highest and 1 rated the

lowest rating)

Technical Aspects


Load analysis

Were minimum load

requirements met?

Were space requirements

met?

Shading analysis

Available wind energy

analysis (if applicable)

PV Array / Wind turbine

sizing

Charge controller and

battery bank sizing

Inverter sizing

BOS sizing (disconnects,

wiring)

System components

completely priced out

Was project cost kept under

budget?

Were specs for all system

components provided?

Sources for all components

How complete the proposal

is

Room for expansion

Presentation aspects:


Eye contact

Team work (everybody

presents)

Appropriate use of

PowerPoint

Technical content

Timing (15-20 min)

Elocution and appropriate

audio level

Design

Competition:

Peer

Evaluation



Peer Teamwork Assessment Rubric NAME: ____________________________________

Student Outcome (f): Demonstrate the ability to work cooperatively in teams

To be completed by each team member: For each of the other members of your project team, assign a

rating of the team member on each of the 10 criteria listed in the table below. Indicate the extent to which

you agree, or disagree, with each assertion about each of your team members.

Rating scale: 5 – strongly agree

4 – agree

3 – not sure

2 – disagree

1 – disagree strongly

Criterion Team Member 1:

Team Member 2:

Roles were clearly defined and executed

1: Had a clear understanding of what was expected of them

2: Maximized the use of her/his individual skill set for the

benefit of the team

Followed a schedule for timely completion

3: Complied with mechanisms to track the progress of the

project

4: Could be expected to complete assignments in a timely

fashion

Negotiated consensus when needed

5: Showed respect for the opinions of the other team

members

6: Showed willingness to negotiate and compromise

Equitable participation by team members

7: Contributed her/his own ideas and viewpoints

8: Did their fair share of the work

Shared responsibility for success and failure

9: Actively sought and shared information from/with other

team members

10: Was flexible/adaptable to changing requirements

Design

Competition:

S Teamwork rubric

S Behavior rubric

S Organization rubric

S Time Management rubric Self

Evaluation



System

Requirements • Lighting inside the 40 ft.

trailer (on 20A circuit)

• Portable ice maker (on 20A

circuit)

• Small monitoring/data

logging system

• Wireless access point



Inside the

Trailer View

Potential

Additional

Loads

• Larger PLC-based data

logging system

• Flood lights / sign lighting

• Small refrigerator

• Weather station



Pole Yard

Aerial View

Additional

System

Requirements

• Low maintenance batteries:

either AGM or gel

• 30-40 ft. from the trailer to

the poles

• Poles are 40 ft. high



Pole Yard side

View

Site

Characteristics

• Good wind resource (throughout the whole year)

• Low shading

• During winter – heavy snow (poor solar generation)

• Low winter temperatures: - average low -8C - record low – 29 C (poor battery performance in winter)



Shading

Analysis • 4 groups of students did

laboratory experiment for

shading analysis at the site

of future installation using:

- Solar Pathfinder

- Solmetric SunEye

• Different possible PV array

locations were tested:

- pole mount

- ground mount (south end)

- on top of the trailer

- on the south side of the

trailer



Wind Resource Analysis for

Superwind 350 24V turbine

S There is no detailed wind data for the site.

S Data for average wind speeds from weather station at Buffalo International airport were used to determine Rayleigh wind speed distribution and projected turbine generated energy output.



S

The Winning Student

Design Project Hybrid System



ECC South Campus

Stand Alone PV System

Presented by:

Mathew Hawley

Louis Schiumo

Eric Sturm

4x High efficiency light bulbs inside

conex box (LED 15W, 25,000hr lifespan)

Portable ice maker (Ice under 10 min)

Flood light – ECC sign

Outlet in conex box for charging cell

phones.

Inverter

PM-100-D PentaMetric

Proposed Load

Load Requirements

Load Watts Estimated

Daily Use

Watt hours per

day

4x Light Bulbs 60 (15 ea.) 6 hrs 360

ECC Sign 24 12 hrs 288

Ice Maker 230 2 hrs 460

Inverter 12 24 hrs 288

PM-100-D PentaMetric ½ 24 hrs 12

Cell Phone charging

outlet

10.5 2 hrs 21

Total 337 --- 1429

Critical Design Month Analysis Month Daily Power

Consumption

(Wh/day)

Insulation (-15

degree fixed) (PSH)

Critical Design

Ratio

January 588 2.17 271

February 588 2.95 199

March 588 4.25 138

April 588 4.85 121

May 588 5.57 106

June 1429 6.19 231

July 1429 5.88 243

August 588 5.38 109

September 588 4.62 127

October 588 3.31 178

November 588 2.08 283

December 588 1.82 323

120W solar panel

24V SuperWind 350 Micro turbine

Inverter

Charge Controller

8x 105Ah Batteries

Proposed Design

Proposed Design Design is simple and

low cost. It is a 120W solar panel mounted on the utility pole in conjunction with a 24V Superwind micro-turbine. Design is backed by a large battery bank which is positioned at the base of the pole.

Circuit Diagram

Based on Rayleigh wind distribution curve the

turbine is expected to produce 1kWh/day.

Superwind Micro-turbine

Proposed PV panel is a 120 Watt Solarland High efficient

Multicrystalline at 28º tilt for maximum summer output.

Array

For example the 120W array during the month of June:

120W x 6.19 PSH x (de-rates)

( 0. 95 X 0.98 X 0.96 X 0.9x0.85 ) = 507.87W

Connected Load 1429 Wh With the superwind turbine average daily

output is 1KW So 1429 – 1000 = New connected load is 429Wh De – rates : battery charging/discharging – 0.90

• Array to cc – 0.96 • wiring losses – 0.98 • Elevated temp, soiling, mismatch – 0.95 • Tilt and azimuth angle, shading – 1.00 • Inverter efficiency – 0.85

Array must generate 429Wh/(0.9)*(.96)*(.98)*(.95)*(.85)= 628W

Array

Array must generate 628Wh

Array tilt to maximize

summer output

performance -15 degrees

July – PSH = 5.88

Array minimum rating :

628Wh / 5.88 PSH = 107 W

Array

1.5 Days of Storage ( Worst Case Scenario, no power generation )

24 V system Loads between June and July B out = 1429Wh x 1.5 days / 24V = 90 Ah

Loads Between August to May B out = 588Wh X 1.5/ 24V = 37 Ah

How much stored energy will be

necessary?

De – Rates 0.98 – wiring losses 0.30 – DOD 0.76(Aug-may), - Temp & discharge rate 0.875(June-July)

0.85 – Inverter inefficiency Battery Storage for June and July B rated = 90Ah / ( 0.98 x 0.30 x 0.875 x 0.85 )= 411 Ah at 24 V Battery Storage for August to May B rated = 37Ah / ( 0.98 x 0.30 x 0.76 x 0.85) = 195 Ah at 24 V

Battery Storage

B rated = 411 Ah at 24 V

Marine / RV Intimidator AGM 12 V, 105 Ah ( ECC supplied with 10 )

Need 2 in series and 4 in parallel = Total of 420 Ah

Battery Specifications

Proposed battery

enclosure is

48W”x24L”x16H” and

can hold up to 9

batteries.

Battery Enclosure

Proposed design

has 8 batteries. 4

strings of 2 batteries

in parallel to

produce 420Ah at

24V.

Battery Setup with Enclosure

I out = ( P array + P turbine / V bat ) * C.C

efficiency

I out = (120 + 350 / 24V ) * 0.96 = 18.8A

Need 20A or higher , 24V charge controller

Charge regulator SCR 24 Marine 40A , 24V ,

96% efficiency, Max Voc = at least 55 V,

Charge Controller

Required power 107 W

Module: 120 Watt Solarland High efficienct Multicystalline PV Isc = 3.86A

Imp = 3.49A

Voc = 43.2V

V mp = 34.4V

Cv = -.080 V/°C

V max = 43.2 V + (-.080 V/°C ) (-28.9°C - 25°C ) = 47.51V

V min = 34.3 V + (-.080 V/°C ) ( 37.2°C +30°C -25°C ) = 30.92V

Imp = 3.49A x 1.25 = 4.36A + turbine current 14.58A = 18.94A < 40A

Factor of 1.25 accounts for the period of higher than STC insolation

Array Configuration

Excluding June and July the load will only be 558W, the turbine produces on average 1 kW of energy a day, therefore there is an adequate amount of energy to supply the load during those months.

Comparison of daily loads (Wh) and energy

availability (Wh) for stand alone system

For the 120W array - June : 120 W x 6. 19 PSH X de-rates ( 0. 95 X 0.98

X 0.96 X 0.9x0.85 ) = 507.87W+ 1000 W from turbine = 1507.87W ,

required is 1429 Watts

Samex America PST – 2000 – 24

2000W 24 V inverter

85% peak inverter efficiency

Continuous output power of

2000 W

Surge Output power 3500 W

Inverter

DPW Solar Panel Side of the Pole Mount SPM3-C

Features: Mounts three solar panels Solar Panel can be sized at W 22 - 27

inches and L 56 - 63 inches (panel is 27 inches wide by 59 inches

long) Flexible array tilt angle Easy to install

Includes: Standard solar mounts designed to

withstand 90 MPH wind zones Stainless steel module mounting

hardware High strength stainless steel band clamps

Mounting Hardware

Batteries – Supplied by ECC

Flood Light –supplied by ECC

Inside Conex box lights - $87.52 for four

Solar panels - 120 Watt array - $ 445.20

Charge Controller – Supplied by ECC

Wind Turbine – Supplied by ECC

Battery enclosure – $796.32 for 8 batteries

Inverter - $665.15

Disconnect box –4 @ $60 for 30 A box Mount – $240

Penta metric – Supplied by ECC

Portable Ice maker - $110

*AC wire – 250 ft 14 gauge $43.84

*DC wire – 50 ft , 10 gauge $78.62

Wire Conduit – 80 ft @ $13.95 per 10 ft , Total - $111.60

Total = $2578.25

Cost

*Wiring specification calculation

sheet included in folder

ECC South Campus – Stand Alone PV System

Spec. Sheets & Pricing Options

(portfolio)

1. Operation Manual and Average Daily output of Superwind 350 turbine 2. Solar Pathfinder Site Report with PSH for utility pole location 3. Buffalo, NY Record Low and Record High temps. (ºC) 4. Gel Battery capacity ( % rated capacity) vs. Temperature 5. Angle and Azimuth De-rate factor

6. 120 W High efficiency Multicrystalline PV module spec. sheet 7. Charge Regulator SCR 24 Marine Spec. sheet 8. Marine/RV Intimidator AGM 12v, 105 AH Spec. sheet 9. Samalex America PST 2000W 24V inverter, Spec. sheet and pricing 10. GE General Disconnect Box pricing

11. Battery Enclosure, Spec. sheet and pricing 12. Solar Panel Mount, Spec. sheet and pricing 13. LED light Bulb, 15 Watt 25,000 hour lifespan pricing 14. Koldfront Ultra Compact Portable Ice Maker pricing 15. AC and DC wiring sizing calculations 16. AC wire pricing

17. DC wire pricing 18. Wiring conduit pricing

Project Discussion

S Students did not present/consider:

- additional power generation to charge batteries and run

full loads at the same time,

- calculations to determine proper cables for the battery

bank,

- specs and prices for the conduites,

- specs and prices for the blocking diode for the solar panel.



Conclusions

S Designed hybrid system met load requirements and specified system requirements

S The system (with minimum modifications) can be installed within the budget constraints

S Students received valuable experience designing real-life hybrid stand-alone system

S EET and EUT students will gain more experience during installation of the system (late June 2013)



Conclusions

S The installed system will be utilized to power lights, ice maker, and other small loads during summer climbing school

S The rest of the year, the system will provide power for monitoring/ data collection system allowing us to collect data pertinent to solar and wind power production at the site. EET department has plans of offering this site as a testing site for various small turbines in the future.

S Generated data can also be used in the various courses related to renewable energy generation.





Questions??

Operation Manual

Superwind 350

December 2007

real-life design project approach to teaching renewable energy design project... · (engineering...

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