Capabilities Overview for Small Hydro Power Plant

1. Energy
Capabilities Overview
For Small Hydro Power Plant
PPT2013.01.01.01EN
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2. Permanent Magnet Machines
Our Exprience and Innovation
NIDEC ASI
specific
hydraulic
conditions
= Simplifies Innovating
permanent
magnet
generators
variable
speed
better
performances
variable
frequency
drives
increased
economic
return on investment
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2

3. Variable Speed
Turbine Typical Curves
a3
Q [m3/s]
Head = H2
Head = H1
aopt1
h
a2
aopt2
a1
Qopt1
Qopt2
nopt1 nopt2
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n [rpm]
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4. Variable Speed
Variable Frequency Drives
Variable
speed
Variable
frequency
DRIVE
INVERTER
AFE
50 Hz
DC link
synchronisation
at DC bus
=
No more
sychro devices
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5. Direct Drive
~1000 rpm
~200 rpm
Direct drive
=
No GEAR
No FEAR
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6. Permanent Magnet Machines
Hydro power Application
Typical mounting
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7. Permanent Magnet Machines
Revamping
Gear box
Induction
generator
PMG’s direct driven
before
PPT2013.01.01.01EN
after
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8. Permanent Magnet Machines
Induction vs PM generator
Induction
generator
PM
generator
Weight
Kg
1700 (gearbox included)
4200
Torque
kNm
2.0
13.9
Nm/kg
1.2
3.7
%
93.5
98.1
Ratio Torque/Weight
Efficiency
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9. Permanent Magnet Machines
Design calculation methods
CFD
computational fluid dynamics
multi-objective optimization
FEMM
finite elements method magnetics
Structural Mechanics Analisys
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10. VFD Variable Frequency Drive
Static convertion cubicle
• Design and construction by NIDEC ASI S.p.a.
• Forehead cubicle as standard; back-to-back solutions on
request
• Water cooling and air conditioned available
• IP33 and IP54 degree of protection
• Customized solutions
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11. System Integration
Automation Expertise helps provide seamless integration
Process control and Automation
• Start/Stop sequences
• Auxiliary control
• Speed control
• Network parallelling and synchronization
• Power factor/Reactive Power control
• Alarm management
• Remote control, signaling and diagnostics
• Plant supervision
NIDEC ASI has a long worlwide experience in automation in a
wide range of applications, achieving a deep knowledge in process
control: metal (hot and cold lamination), rubber, cement, paper,
ropeways, hydro power plant
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12. Network Connection – Power Supply
• Substation: Turn-key
• MT/AT and MT/BT transformers
• MT and BT protection relays
• Power factor controllers / Static VAR
compensation SVC
• Electrical BoP
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13. Synchronous vs PMG+VFDdrive
PRODUCTION
energy kWh
investment
investment
VARIABLE SPEED
pmg + vfd
FIXED SPEED
Synchronous generator
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14. Better efficiency
by shifting the operating point
Efficiency [%]
Synchronous vs PMG+VFDdrive
P [MW]
Turbine driven at variable speed: main advantages
Better efficiency by shifting the operating point
Continuous variation of the shaft power
Longer life by reducing of vibrations and smooth operation
WIDER range of operation:
ratio max./min. Head - FIXED speed - approx. 1.25
ratio max./min. Head - VARIABLE speed - approx. 1.25 to 1.45
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15. VFD Variable Frequency Drive
Inverter + Active Front End (AFE)
Customized turbine control system in order to maximize the
efficiency for a wider range of operation and a maximum
exploitation of the hydraulic conditions of head/flow/speed.
The regulation operates by:
– the inverter : it manages the speed of the turbine and the
voltage on the DC bus
– the Active Front End : it manages actively the interface
with the mains by (available four quadrant operation,
bidirectional energy flow)
– Clean energy with an harmonic distortion within 1%
– Unit power factor
G
AFE
PPT2013.01.01.01EN
DC Bus
Inverter
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16. VFD Variable Frequency Drive
Inverter + Active Front End (AFE)
customized turbine control
maximize efficiency
wider range of operation
PPT2013.01.01.01EN
maximum exploitation
of the hydraulic conditions
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17. Control lay-out
f var.
Syn.
Generator
PMG
d.c.
50Hz
Generator
Side
DRIVE
Grid
Side
DRIVE
Trafo
Main
Grid
G
Hwater
Vwater
Tmec
Telec
Hydraulic
actuators

Breaking
resistor
Control Signal q
d
Distributor control
MPP Tracking
Generator side converter
Active Power control
Sensorless vector control
H cost
Q cost
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 Gen. ref
Tref
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Pref
Grid side converter
DC link voltage control
Reactive Power control
LVRT LV Ride Through
U DC ref
Q Grid ref
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18. Inverter Controlled PM Generator
Advantages
PM generator
water jacket cooling
hydraulic
conditions
ECO friendly
variable speed
power electronics
AFE control
PPT2013.01.01.01EN
low speed / high polarity
NO gear box
reduce noise level
save space and structure
reduced maintenance
high efficiency
increased
productivity
&
economic
return on investment
grid friendly (no harmonics)
NO synchro devices
wide operation range
increased global efficiency
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19. Monfalcone Porto Shpp (Italy)
Case History
The need to increase energy production and
reduce environmental impact were the driving
forces behind the decision to revamp and
reactivate the small Hydropower station at the
end of the canal.
Nidec ASI handled the complete revamping,
providing
2 x 300 kW (180…235 rpm)
permanent magnet generators connected to
Kaplan turbines
and controlled by LV inverters.
This solution allows the plant to produce energy
even at reduced water flows, optimizing power
generation.
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20. Monfalcone Porto Shpp (Italy)
Case History
2 x Kaplan S-type
single regulated
300 kW @ 230 rpm
nr 2 groups with induction generators and gear-boxes
revamped with
nr 2 VFD+PMG direct driven generators
32 poles (weight 4 tons)
=94,5%
(generator + power electronics)
Flow : 3.7 … 4.5 m3/s
Head : 3,2 … 4,5 m
Speed : 180…235 rpm
MAX tidal / min Head
min tidal / MAX Head
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21. Forte Buso Shpp (Italy)
Case History
Lake Forte Buso (m.1450) is formed
by the retention of the waters of the
River Travignolo by a high dam over
100 meters wide and 250 meters. the
reservoir contains about 30 million
cubic meters of water and it is the
most important Watershed of the
Cismon hydrological systems Cismon.
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22. Forte Buso Shpp (Italy)
Case History
1 x Pelton – Vertical 5j
New shpp on "reserved flow“ of the dam
550 kW @ 600 rpm
14 poles (weight 4 tons)
=93.5%
(generator + power electronics)
Flow : 0,4 … 0,55 m3/s
Head : 85 … 112 m
Speed : 550 … 630 rpm
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23. Bolzano Shpp (Italy)
Case History
1 x Kaplan - Vertical
New run-of-river shpp
single regulated
270 kW @ 428 rpm
18 poles (weight 3,5 tons)
=93.5%
(generator + power electronics)
Flow : 1 … 5 m3/s
Head : 6 m
Speed : 85 … 428 rpm
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24. Rhone River (Italy)
Case History
Nbr 3 Bulb turbines
3 x Bulbs
7,7 MW @ 136 rpm
64 poles (mass active parts 20
tons)
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>98%
(generator)
Rated current 2.000 A
Rated Voltage 3.250 V
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25. Synchronous vs PMG+VF Drive
Case History
FIXED
speed
Operating conditions
Q = 0,32-0,42 m3/s
H = 35-73 m
n = 750-1050 rpm
Global efficiency
52%
Average annual output
100 kW
VARIABLE
speed
700.000 kWh
hp 7.000 hr/y
-
350.000 kWh
Global eff
89%
Average annual output
150 kW
PPT2013.01.01.01EN
1.050.000 kWh
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