/ES2_Bard

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