solar pumping march 2014. 1 sd700 sp introduction 2 operation modes 3 hydraulics 4 submersible pumps...

SOLAR PUMPINGMarch 2014

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?

Solar Pumping consists in supplying water pumps with the energy generated by a PV Solar Plant.

¿ WHAT IS SOLAR PUMPING?

SOLAR PANELS

PUBLIC GRID OR DIESEL GENERATOR

PUMPING SYSTEM

01 Introduction/ SD700SP Topology

SD700 SP TOPOLOGY

SD700 SP TOPOLOGY

01 Introduction/ SD700SP Topology

SD700SP

AC Fuses

AC on-load disconnector

DC On-load disconnector

DC Fuses

DC terminals (+) and (-)

OPERATION MODES

02 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.

OPERATION MODE: SOLAR ASSISTED & GRID CONNECTED

02 Operation Modes / Solar assisted & Grid Connected

OPERATION MODE: RENEWABLE ENERGY SELF- SUFFICIENT

02 Operation Modes / Renewable Energy Self-sufficient

Minimum System Required Power (30Hz-50Hz) Maximum System Power

(50Hz)

PHOTOVOLTAIC PANEL

03 Photovoltaic Introduction

MANUAL DESIGN- PHOTOVOLTAIC FIELD

03 Photovoltaic Introduction

Serie Panels - Define Maximum Open Circuit Voltage VCA y VMPPT

Parallel panels - Set Maximum Current Short Icc:

Open Circuit Voltage MaxVca : < 900Vcc MPPt Max Voltage: < √2 · 400V =

565Vcc V CA = #Serie x Vca (25ºC) x [1+ At (TminºC - 25ºC ) x Coef Vca (Tº))]

V CA = 17x 45VCA +[1+ ((- 33ºC) x ( - 0.0033/ºC))] = 898 Vcc < 900Vcc

Tmin (location) = -8ºC

V MPPt = 17x 35.5VCA +[1+ ((- 33ºC) x ( - 0.0045/ºC))] = 733 Vcc > 565Vcc ¡Alerta! [1]

V MPPT = #Serie x VMPPT (25ºC) x [1+ At (TminºC - 25ºC ) x Coef VMPPT (Tº))]

Current Max CC: < 200A (Talla 3 SD700SP-CU)

ICC = #String x ICC (25ºC) x [1+ At (TmaxºC - 25ºC ) x Coef ICC (Tº))]

Tmax (location) = 42ºC

ICC = 22 x 8.35A x [1+ (20ºC) x ( 0.0006/ºC))] = 185A < 200A

Power Peak Park PMPPT:

Peak Power Max(kWp): 1.5 PAC (SD7SP0115 5) = 75kW

PMPPT = #String x #Serie x PMPPT = 17 x 22 x 280 = 104kWp

AC:DC = 104kWp/75kW = 1.38

[1] high Vmppt can cause motor damage, consult Power Electronics

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

Stat

ic h

eigh

t 20

met

ers

0

Head in m H2O

H-Qcurves

System curves

10 20 30 Q Flow m3/min

FLOW

100%50%0

Head in m H2O

70

60

50

40

30

20

10

80

1 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

10 20 30100%50%

100%90%80%70%60%50%

H-Q Curves

70

60

50

40

30

20

10

80

1 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

THROTHLING CONTROL VS VARIABLE SPEED DRIVE - OVERVIEW

kWP 10050 kWPP 25150

403

5040 .

3

35 50

3534.3

50P P kW

03 Hydraulics

PUMP’S PERFORMANCE DEPENDING ON SPEED VARIATION

50% 60%70%

80%85%

80%

88%87%

85%

87%

30%1 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

80

70

60

50

40

30

20

10

0

N = 1480 RPM

Efficiency curves

Curve H – Q

System curve

10 20 30 40Q flowm3/min

03 Hydraulics

Q (m3)

Hei

ght

(bar

)

Q (m3)

Hei

ght

(bar

)

MINIMUM FEED IN POWER AND VINIMUM MFT VOLTAGE

CURVE -A CURVE -B

Min Height.

Min Height.

50 Hz

40 Hz

30 Hz

20 Hz

50 Hz

40 Hz

30 Hz

Curves with high angled slopes offer optimal regulation and

lower starting frequencies

Better regulations deliver higher savings

Curves with low angled slopes offer poor regulation and higher

starting frequencies

Energy savings are restricted by the regulation range𝑃2 = 𝑃1 ·൬2050൰3 = 𝑃1 · 0.064 𝑃2 = 𝑃1 ·൬4050൰3 = 𝑃1 · 0.512

INDIVIDUALIZED SYSTEM ANALYSIS

03 Hydraulics

SUBMERSIBLE PUMP TOPOLOGY

Pump Impellers

Water intake

Pump Shaft

Motor

Thrust bearing

Water impulsion

Cooling jacket

Motor Shell

04 Submersible pumps

SUBMERSIBLE PUMPS & VSD CONSIDERATIONS

MOTOR CABLES TYPE AND LENGHT

PUMP COOLING

THRUST BEARING COOLING

VSD OPERATION & SETTINGS


SD700 – RECOMMENDED CABLE TYPE

Desired - Up to 300m Compatible - Up to 150m


VOLTAGE FLANGE WAVE FORM

Competitors dV/dt values

SD700 STANDARD

ALL DRIVES ARE NOT THE SAME


ADMISSIBLE PEAK VOLTAGE LIMIT CURVES IN AC MOTORS TERMINALS:

10m

20m30m

50m

Rise time of the voltage pulse (µs)0.1 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.20.40.30.2

0.4

0.8

1.2

1.6

2.0

2.4

Examples of the test results, SD700 using reinforced copper wires at 415V rated voltage.

IEC 60034-25 Curve B(without filters for motors

up to 690V AC)

NEMA MG1 Pt31 in grids of 600V

IEC 60034-25 Curve A(without filters for motors up to 500V AC)

IEC 60034-17

NEMA MG1 Pt31 in grids of 400V

2.15kV

1.86kV

1.56kV

1.35kV

1.24kV

Pea

k vo

ltage

(kV

)

100m 200m


PUMP COOLING

Keep a minimum speed of the surrounding water.

Vc = 0.08…0.5 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

Low factor between motor diameter and well diameter

Well intake

Coo

ling

Spe

ed -

V (

m/s

)

Wider motor Diameter (mm)

Higher convection factor (W/mm2)

Water stream distribution

REDUCE HEAT LOSSES

Lower water temperature (ºC) Lower motor load (AP)

Pump speed reduction (Hz)

Dw

Dp

Higher pump flow (Q)

Q (

m3/

s)T (ºC)


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


VSD OPERATION AND SETTINGS

Is a Check Valve integrated in the pump?

YES

NO

Is there water release holes in the pump?

YES

NO

How long it takes to empty the pipe?

- Soft start after the empty time - Soft stop to reduce water hammer

Start and Stop with water-filled pipe settings (Maximum head)- CASE 1

1

Is there a check valve on the top of the hole ?

YES

NO

Start with empty pipe but it needs a fast speed transient - CASE 3

Soft start and stop – CASE 2

3

2


START AND STOP WITH WATER-FILLED PIPEM

in H

ea

d -

AP

Q (m3)

Time (s)

Pum

p S

pee

d (H

z)

Hea

d (b

ar)

50

40

30

20

10

0

Pump Installation

50Hz

40Hz

30Hz20Hz

10Hz

Q min (thrust bearing cooling)

Min Head

Fast ramp – Min Flow

2s 4s- 7200s

Slow ramp Water Hammer

Control

1s30s

1

Slow ramp - Flow control range- Reduce sand impulsion

Fast ramp Pump stop


SOFT START AND STOPM

in H

ea

d -

AP

Q (m3)

Time (s)

Pum

p S

pee

d (H

z)

Hea

d (b

ar)

50

40

30

20

10

0

Pump Installation

50Hz

40Hz

30Hz20Hz

10Hz


Min Head

Slow ramp - Flow control range- Reduce sand impulsion

4s- 7200s

Slow ramp Water Hammer

Control

1s

2

Fast ramp – Min Flow

1s

4s- 7200s


Q (m3)

Time (s)

Pum

p S

pee

d (H

z)

Hea

d (b

ar)SOFT START AND STOP WITH FAST TRANSIENT

Min

He

ad

- A

P

50

40

30

20

10

0

Pump Installation

50Hz

40Hz

30Hz

20Hz

10Hz


Min Head

Slow ramp - Flow control range- Reduce sand

impulsionSlow ramp

Water Hammer Control

1s

3

Fast ramp – Min. Flow

1s

4s- 7200s

Inst. Head

4s- 7200s

Fast transient ramp – Checkvalve opening

1s 4s- 7200s


SD700SP Grid Connected system

05 SD700SP LCoW / Grid connected

Hydraulic System:

oPump power: No restriction

oPump/line voltage: From 230Vac to 440Vac.

oMin frequency (Hz): No restriction

oMin 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: €

Hydraulic System:

oPump power: From 2.2kW up to …. (feasibility limit)

oPump/line voltage: From 230Vac to 440Vac.

oMin frequency (Hz): Required. Hydraulic system modeling

oMin 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 / Self Sufficient

SD700SP Self Sufficient

05 SD700SP LCoW / PV sizing

SD700SP Self Sufficient / Hydraulic Sizing- Deep Well to storage

50% 60%70%

80%85%

80%

88%87%

85%

87%

30%1 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

80

70

60

50

40

30

20

10

0

N = 1480 RPM

Efficiency curves

Curve H – Q

System curve

10 20 30 40Q flowm3/min

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

Power PCA - Work flow

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. Min flow: (5 m3/min)

Depend on pump cooling.

Min. Frequency. (42.5Hz)Min. Power (25kW)

Rated flow, head and powerPump and SD700SP Selection


SD700SP Self Sufficient / PV sizing

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.

PV Sys – Work flow

P out Eff (%)

0% 0

10% 96.5%

30% 98.0%

50% 98.2%

70% 98.6%

90% 98.5%

100% 98.5%


SD700SP Self Sufficient / PV performance

Minimum Voltage

Minimum Power

RadiationSensor

06 SD700SP Ordering Info

SD700SP Ordering InfoProject Solar Pumping Project Pump Submersible pump Location EgyptApplication 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 : -10ºCMax. Ambient Temperature : +45ºCDegree of Protection : IP54 Indoor installationUnits :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_ APV plant Data First Level Panel type : BYD 255 6C

Nº PV panels in series : 24Nº of String per combiner box : 22ON-load disconnection : YESCombiner box fuse rating : 12A

Second Level Number of combiner boxes : 3Fuse protection 50AON-load disconnector : YES

AC Power Supply Protections (if needed) AC On load disconnector : YESAC 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 RTUDoor Pushbuttons : OptionalDoor Pilots : OptionalHeating Resistors : OptionalHygrostat : 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 ELECTRONICSAppreciates your time

For more information please visit:

www.power-electronics.com

For more information please visit:

www.power-electronics.com

solar pumping march 2014. 1 sd700 sp introduction 2 operation modes 3 hydraulics 4 submersible pumps...

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