HIDROENERGIA Crieff 2006
VASOCOMPACT – A EUROPEAN PROJECT FOR THE DEVELOPMENT OF A COMMERCIAL CONCEPT FOR VARIABLE SPEED OPERATION OF SUBMERSIBLE COMPACT TURBINES
Jochen BARD, Institute for Solar Energy Supply Technology (ISET), Germany Heikki PIRTTINIEMI, Waterpumps Oy, Finland Prof. Dr. Eberhard GOEDE, Inst. of Fluid Mechanics and Hydraulic Machinery, University of Stuttgart, Germany Albin MUELLER, ELMOTEC Antriebstechnik AG, Switzerland Dr. Drona UPADHYAY, IT Power, UK Martin ROTHERT, SMA Technologie AG, Germany
Funded by: European Commission, DG TREN
Institut f端r Solare Energieversorgungstechnik e.V.
Systems Technology for the Use of Renewable Energies and Efficient Energy Conversion Applications-oriented Research and Development
Wind Energy Photovoltaics Use of Biomass Hydropower, Ocean Energy Technologies Energy Conversion and Storage Hybrid Systems Energy Economy Information and Training
Executive Board: Prof. Dr.-Ing. J端rgen Schmid Dr. rer. nat. Oliver F端hrer Personnel: 75 Employees, 120 people Budget: approxim. 8 Mio. Euro Information: www.iset.uni-kassel.de
Typical low head site: SHP plant Lewitzschleuse head: 3.6 m power: 270 kW discharge: 9 m³/s Turbine: Kaplan n = 190 rpm ∅ = 1600 mm
disadvantages of gearboxes •
losses of 1-1.5% per stage (up to 5% overall)
•
vibration and noise
•
investment cost and lifetime
•
maintenance requirements and cost
•
environmental risk from oil
1 0,9
power train efficiency
0,8 0,7 0,6 PME generator
0,5
ASG+belt 0,4
old power train (ASG+ gear box)
0,3 0,2 0,1 0 0
10
20
30
40
50
60
70
80
90
Power [%]
performance curves for different drive trains
100
Example of submersible turbines with direct coupled induction generator
ITT Flygth
hydropower plant Reichenbach/Fils
VASOCOMPACT: Development of a commercial concept for variable speed operation of unregulated submersible compact turbines
• • • • •
new turbine design for runner and guide vane special PME-generator directly coupled special frequency converter scaling from 50 to 500 kW per unit installation and test of a 50 kW pilot (Tirva, Finland)
Stator windings direct flow cooling
draft tube Rotor
Permanentmagnets
fix runner fix guide vanes
Variable speed concepts in hydropower • General technical aspects • Technologies and concepts • 8 case studies 12-700 kW • Economic analysis • Data based on year 2000
available on the DGTREN homepage (8 MB pdf)
Development of a commercial concept for variable speed operation of unregulated submersible compact turbines: VASOCOMPACT
Project No. :
NNE5-349-2001
Coordinator:
Institut für Solare Energieversorgungstechnik e.V. ISET
Contractors:
Waterpumps WP Oy IT Power Ltd Institute of Fluid Mechanics and Hydraulic Machinery (IHS), University of Stuttgart Ecotools Sustainables SA, replaced by ELMOTECH SMA Regelsysteme GmbH (SMA Technologie AG)
Duration:
01.01.2002 to 31.12. 2006 (36+12 months)
Total cost:
1.380.792 €
EC-contrib.:
662.617 € (47.7 %)
Labour:
144 person month
Type:
Combined project (R&D + Demonstration)
Project Workplan Phase A: design phase 1. General specification of the new turbine design 2. Turbine design (runner, intake draft tube) 3. Generator design 4. Frequency converter development and design 5. Bearing design 6. Development of a simulation tool for site specific design
Phase B: laboratory test phase 7. Turbine model test 8. Generator manufacturing, laboratory test and optimisation 9. Frequency converter manufacturing, laboratory test and optimisation 10.Development of a control algorithm
Phase C: Installation, Testing and Monitoring 11a. Installation of complete turbine at pilot site (DEMO) 11b. Testing of the turbine 12. Co-ordination and management/workshop
Turbine design and development: IHS, Stuttgart University simulation of different runner geometries using CFD
definition of the final design
Model runner for hydraulic test
hillchart
hydraulic test
Generator with permanent magnet excitation (Elmotec, CH)
rated speed 600 rpm, 40 poles rated frequency 200 Hz design torque 840 Nm voltage 313 V, current 92 A
Frequency Converter (SMA Technologie AG) filter choke
=
G 3~
3~
Diode rectifier, DC-link with variable voltage, 50 Hz transformer G 3~
3~
Sinus Choke
= =
3~
Controlled rectifier, step-up converter Synchrongenerator
-Q2
-G2
EUPEC PowerStack 220A
-G1
EUPEC PowerStack 220A
Inenn,Netz=72A
EMC Filter
Sinusfilter
-K2 -Z2
-K1
-Z1
-Q1
=
3~
G 3~
= EUPEC-Treiber
EUPEC-Treiber U, f
Netz
ok
UGen
Adap ME earth fault monitoring
Adap BFS
Adap BFS Adap ME
U Netz
earth fault
24 V DC
24 V DC auxiliary supply
Mod5 BFS
Mod5 BFS
Betriebsführungsbaugruppe 1
Betriebsführungsbaugruppe 2
RS 485
230 V AC auxiliary supply
Sunny Central Control
RS 232
• made out of standard components • implementation of software for machine torque control (similar to vector control) • laboratory testing • modifications for field test (interfaces, start-up etc.)
Modem
RS 485
Final turbine design for demonstration site Tirva, Finland
Design head Design flow Rated speed ∅ runner Run away speed
3,5 m (2,5 to 4,5 m) 1,4 mÂł/s (but: guide vanes at 73%) 600 rpm (450 to 750 rpm) 600 mm 1500 rpm
Results from the demonstration site Tirva 40 3.37 m 3.81 m
35
4.44 m
grid power [kW]
30
25
20
15
10
5
0 400
450
500
550
600
650
700
750
speed [rpm]
84%
100% of flow
116%
800
Results from the demonstration site Tirva 50 Feb 06
45
Jan 06 Mar 06
40
Apr 06
power [kW]
35 30 25 20 15 10 5 0 1
25 49 73 97 121 145 169 193 217 241 265 289 313 337 361 385 409 433 457 481 505 529 553 577 601 625 649 673 697 721 time [h]
1200
600
1000
500
800
400
600
300
400
200
200
100
0 1
10
100 rated power [kW]
data from year 2000, today: 50-100 â‚Ź/kW
0 1000
specific cost [â‚Ź/kW]
specific cost [DM/kW]
Market evaluation of frequency converter cost
Application example for the VASOCOMPACT turbines
example design 3,18 m head 12,4 m続/s discharge 324 kW /unit
1510 mm runner 265 rpm PME-Generator
7000
0,14
6000
0,12
5000
0,10
4000
0,08
3000
0,06
2000
0,04 Euro/kW Euro/kWh
1000
0,02
Polynomisch ( Euro/kW) Polynomisch ( Euro/kWh)
0
0,00 0
5
10
15
20
25
design flow [m続/s]
30
35
40
45
Euro/kWh
Euro/kW
Cost comparison
Conclusions • commercial variable speed concept has been developed and tested successfully • scalability from 50 to 500 kW/unit • sumersible compact turbine for refurbishment or new weir integrated SHP plants • design tools are available • components are available
Î If the money is available, we are ready for commercial projects !
Multiple turbine example 10 9 8
flow [m続/s]
7 6 5 4 3 2 1 0 0
50
100
150
200
exceedance days
250
300
350