SOLAR PUMPING March 7th2013

1 2 3 4 5 6 7 SD700 SP Introduction Operation modes Hydraulics Submersible pumps 5 SD700SP LCoW 6 SD700SP Ordering Info 7 SD700SP Sample

01 Introduction/ ¿What is Solar Pumping? SOLAR PANELS PUMPING SYSTEM PUBLIC GRID OR DIESEL GENERATOR Solar Pumping consists in supplying water pumps with the energy generated by a PV Solar Plant.

01 Introduction/ SD700SP Topology

01 Introduction/ SD700SP Topology AC on-load disconnector DC On-load disconnector DC Fuses AC Fuses DC terminals (+) and (-)

02 Operation Modes 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: SOLAR ASSISTED & GRID CONNECTED

OPERATION MODE: RENEWABLE ENERGY SELF- SUFFICIENT 02 Operation Modes / Renewable Energy Self-sufficient OPERATION MODE: RENEWABLE ENERGY SELF- SUFFICIENT Minimum System Required Power (30Hz-50Hz) Maximum System Power (50Hz)

03 Hydraulics 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%.

THROTHLING CONTROL VS VARIABLE SPEED DRIVE - OVERVIEW 03 Hydraulics THROTHLING CONTROL VS VARIABLE SPEED DRIVE - OVERVIEW 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 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 Head in m H2O FLOW Static height 20 meters 100% 60% 90% 80% 70% 50% H-Q curves 10 100% 50% 20 30 Q Flow m3/min 10 100% 50% 20 30 H-Q Curves System curves

BOTH SYSTEM AND PUMP CURVES DEFINE THE MINIUM START REQ. 03 Hydraulics BOTH SYSTEM AND PUMP CURVES DEFINE THE MINIUM START REQ. Q (m3) Height (bar) Q (m3) Height (bar) CURVE -A CURVE -B 50 Hz 50 Hz 40 Hz 40 Hz Min Height. 30 Hz 30 Hz 20 Hz Min Height. Curves with high angled slopes offer optimal regulation Curves with low angled slopes offer poor regulation Better regulations deliver higher savings Energy savings are restricted by the regulation range INDIVIDUALIZED SYSTEM ANALYSIS 11

PUMP’S PERFORMANCE DEPENDING ON SPEED VARIATION 03 Hydraulics PUMP’S PERFORMANCE DEPENDING ON SPEED VARIATION 50% 60% 70% 80% 85% 88% 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 N = 1480 RPM Efficiency curves Curve H – Q System curve Q flow m3/min 12

MINIMUM FEED IN POWER AND VINIMUM MFT VOLTAGE 03 Hydraulics MINIMUM FEED IN POWER AND VINIMUM MFT VOLTAGE Q (m3) Height (bar) Q (m3) Height (bar) CURVE -A CURVE -B 50 Hz 50 Hz 40 Hz 40 Hz Min Height. 30 Hz 30 Hz 20 Hz Min Height. Curves with high angled slopes offer optimal regulation and lower starting frequencies Curves with low angled slopes offer poor regulation and higher starting frequencies Better regulations deliver higher savings Energy savings are restricted by the regulation range INDIVIDUALIZED SYSTEM ANALYSIS 13

SUBMERSIBLE PUMP TOPOLOGY 04 Submersible pumps SUBMERSIBLE PUMP TOPOLOGY Water impulsion Pump Shaft Pump Impellers Cooling jacket Water intake Motor Shell Motor Thrust bearing 14

SUBMERSIBLE PUMPS & VSD CONSIDERATIONS MOTOR CABLES TYPE AND LENGHT PUMP COOLING THRUST BEARING COOLING VSD OPERATION & SETTINGS 15

SD700 – RECOMMENDED CABLE TYPE 04 Submersible pumps SD700 – RECOMMENDED CABLE TYPE Desired - Up to 300m Compatible - Up to 150m

VOLTAGE FLANGE WAVE FORM ALL DRIVES ARE NOT THE SAME 04 Submersible pumps VOLTAGE FLANGE WAVE FORM ALL DRIVES ARE NOT THE SAME Competitors dV/dt values SD700 STANDARD

04 Submersible pumps ADMISSIBLE PEAK VOLTAGE LIMIT CURVES IN AC MOTORS TERMINALS:

PUMP COOLING 04 Submersible pumps 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 Well intake T (ºC) Cooling Speed - V (m/s) Q (m3/s) INCREASE COOLING CAPACITY REDUCE HEAT LOSSES Lower water temperature (ºC) Lower motor load (AP) Higher pump flow (Q) Pump speed reduction (Hz) Wider motor Diameter (mm) Dp Higher convection factor (W/mm2) Dw Water stream distribution Low factor between motor diameter and well diameter 19

THRUST BEARING COOLING 04 Submersible pumps 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 20

VSD OPERATION AND SETTINGS 04 Submersible pumps VSD OPERATION AND SETTINGS How long it takes to empty the pipe? - Soft start after the empty time - Soft stop to reduce water hammer YES Is there water release holes in the pump? YES NO Start and Stop with water-filled pipe settings (Maximum head)- CASE 1 1 Is a Check Valve integrated in the pump? Start with empty pipe but it needs a fast speed transient - CASE 3 3 YES Is there a check valve on the top of the hole ? NO 2 NO Soft start and stop – CASE 2 21

START AND STOP WITH WATER-FILLED PIPE 04 Submersible pumps START AND STOP WITH WATER-FILLED PIPE Q (m3) Time (s) Pump Speed (Hz) Head (bar) 1 Min Head 50Hz 40Hz 30Hz 20Hz Min Head - AP 10Hz Q min (thrust bearing cooling) Pump Installation Slow ramp Flow control range Reduce sand impulsion Slow ramp Water Hammer Control 50 40 30 20 Fast ramp Pump stop Fast ramp – Min Flow 10 2s 4s- 7200s 30s 1s 22

SOFT START AND STOP 04 Submersible pumps 2 Head (bar) Q (m3) Pump Time (s) Pump Speed (Hz) Head (bar) 2 Min Head 50Hz 40Hz 30Hz 20Hz Min Head - AP 10Hz Q min (thrust bearing cooling) Pump Installation Slow ramp Flow control range Reduce sand impulsion Slow ramp Water Hammer Control 50 40 30 20 10 Fast ramp – Min Flow 4s- 7200s 4s- 7200s 1s 1s 23

SOFT START AND STOP WITH FAST TRANSIENT 04 Submersible pumps Q (m3) Time (s) Pump Speed (Hz) Head (bar) SOFT START AND STOP WITH FAST TRANSIENT 3 Inst. Head Min Head 50Hz 40Hz 30Hz 20Hz Min Head - AP 10Hz Q min (thrust bearing cooling) Pump Installation Slow ramp Flow control range Reduce sand impulsion 50 Slow ramp Water Hammer Control 40 Fast transient ramp – Checkvalve opening 1s 30 4s- 7200s 20 10 Fast ramp – Min. Flow 4s- 7200s 1s 4s- 7200s 1s 24

SD700SP Grid Connected system 05 SD700SP LCoW / Grid connected SD700SP Grid Connected system Hydraulic System: Pump power: No restriction Pump/line voltage: From 230Vac to 440Vac. Min frequency (Hz): No restriction Min Power (kW): No restriction Solar PV system Sizing: Max DC Voltage: 1000Vdc MPP tracking: No, fixed DC voltage MPPt range: Vmppt = sqrt(2) · Vac + 5V Vmppt_230Vac= 1.41 · 230 +5V = 329V Vmppt_400Vac= 1.41 · 400 +5V= 569V Start feed-in power: No restriction Results: Energy Savings: kWh/ per year Fuel/ Electricity cost: € 25

05 SD700SP LCoW / Self Sufficient SD700SP Self Sufficient Hydraulic System: Pump power: From 2.2kW up to …. (feasibility limit) Pump/line voltage: From 230Vac to 440Vac. Min frequency (Hz): Required. Hydraulic system modeling Min Power (kW): Required. Hydraulic system modeling Solar PV system Sizing: Max DC Voltage: 1000Vdc MPP tracking: Yes MPPt range: Vmin (Min.Hz) ….1000V Start feed-in power: Min Power (kW) Results: Power (kW): kW Hourly data ( PV sys tool) Pumping ratio : Multiple values - Pump curve dependant 26

SD700SP Self Sufficient / Hydraulic Sizing- Deep Well to storage 05 SD700SP LCoW / PV sizing SD700SP Self Sufficient / Hydraulic Sizing- Deep Well to storage Power PCA - Work flow Min. Frequency. (42.5Hz) Min. Power (25kW) Rated flow, head and power Pump and SD700SP Selection 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 50% 60% 70% 80% 85% 88% 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 N = 1480 RPM Efficiency curves Curve H – Q System curve Q flow m3/min Assumptions 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. 27

SD700SP Self Sufficient / PV sizing 05 SD700SP LCoW / PV sizing SD700SP Self Sufficient / PV sizing PV Sys – Work flow 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. P out Eff (%) 0% 10% 96.5% 30% 98.0% 50% 98.2% 70% 98.6% 90% 98.5% 100% 28

SD700SP Self Sufficient / PV performance 05 SD700SP LCoW / PV sizing SD700SP Self Sufficient / PV performance Radiation Sensor Minimum Voltage Minimum Power 29

06 SD700SP Ordering Info SD700SP Ordering Info 30 Project Solar Pumping Project   Pump Submersible pump Location Egypt Application 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 : -10ºC Max. Ambient Temperature : +45ºC Degree of Protection : IP54 Indoor installation Units :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_ A PV plant Data  First Level Panel type : BYD 255 6C Nº PV panels in series : 24 Nº of String per combiner box : 22 ON-load disconnection : YES Combiner box fuse rating : 12A  Second Level Number of combiner boxes : 3 Fuse protection 50A ON-load disconnector AC Power Supply Protections (if needed) AC On load disconnector AC Semiconductor Protection Fuses Irradiation Sensor :  :Included  I/O signals 6 DI, 3 DO, 2 AI, 2AO, 1 PTC, 1 PT100. (Other available under request)  Communication  : RS485 – Modbus RTU Door Pushbuttons : Optional Door Pilots Heating Resistors Hygrostat 30

07 SD700SP Sample SD700SP Case Study 31 Pump: 2x Sulzer 75kW SD700SP: 1x SD7SP Frame 4 Accessories: AC Disconnector DC ON-load manual disconnector DC fuses according to PV sizing 31

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