1510 brosur elc eng

ELECTRONIC LOAD CONTROLLER (ELC) DIGITAL SYSTEM TECHNOLOGY

STATE OF THE ART CONTROL SYSTEM FOR SMALL

HYDRO POWER & MICRO HYDRO

Jl. Awibitung No.40 Ciawitali Selatan, Cimahi 40512, Jawa Barat. Indonesia

Tel/fax : +62 22 6631608, www.pme-bandung.com

http://www.pme-bandung.com

PROTEL MULTI ENERGY – www.pme-bandung.com

Electronic Load Controller (ELC) is a controller used in small hydro power generation to

control the frequency of generator by diverting excess power to dummy/ballast load, thus

the speed, frequency and voltage of generator will be maintained.

Excess power normally happened during low power consumption on main load/villagers

during day or midnight. On the plant without ELC or appropriate governor, this condition will

lead to higher generator speed, high frequency and voltage which will destroy most of

electrical appliances and even generator it self due to runaway speed. In most large hydro

power generation, control is done by adjusting flow entering turbine through guide vane to

match the power output required and maintain the speed. This will be too complicated and

costly for small hydro power, especially for rural electrification that required simple and

affordable system.

Power diversion to dummy load is done electronically through thyristor as electronic switch

which controlled by ELC main board. It will keep the frequency at set point with smooth and

steady operation without the need of operator interferences. Our ELC panel is integrated

with standard protection for main load and generator and metering to monitor the plant

operation at real time.

Installation of an ELC on Micro hydro power plant, Indonesia

Pgenerator = Pload + Pballast 20.000 Watt = 15.000 Watt + 5.000 Watt

ELC DEFINITION


1. Constant frequency and voltage generated by the system, thus preventing the damaged on electronic appliances due to high frequency/voltage

2. Avoid damage on generator due to runaway speed when the main load is switched off or decreased

3. No water hammer risk on the penstock, since no need of sudden flow closing when full load rejection

4. No frequent turbine opening adjustment needed to regulate the power during the operation. Once turbine opening position is possible for long period of operation, thus operator work is simpler

5. Easy in installation, operation and maintenance as well as longer life time expectancy. Standard components are used and widely available

6. Fast recovery time upon sudden load change. Frequency will be recover to set point less than 2 second (adjustable)

7. Affordable price compared to any other control system type

8. ELC panel is integrated with standard protection and metering, as well as customized system for data monitoring and logging, no more cubicle required

9. Customized metering and protection, based on customer requirements and applied national standard

10. Suitable for synchronous generator, on/off grid application and can be integrated with existing control system as back up.

11. Suitable for remote data monitoring system (RMS) to view the data of the plant through web interface and mobile phone (SMS) (on demand)

Typical Single Line Diagram of Small hydro power with ELC – off grid

ADVANTAGE OF ELC


Working Principles

ELC Protel Multi Energy use microcontroller chip and thus based on digital technology where all the controller parameter is set from the software. It is ensure the high performance, accuracy and steady operation of the controller. No need of trimmer or potentiometer setting to adjust the control parameter during commissioning of the plant like analog based ELC.

ELC works based on frequency signal, microcontroller will continuously measure and calculate the generated AC signal every half cycle (10 ms) or 100 times per second and will trigger the Thyristor at certain angle according to measured error. It will continuously adjust the triggering angle until set point is reached (50 Hz). Frequency will be keep at set point (50/60 Hz) with accuracy 0.1-0.2 Hz. Recovery time required takes ±2 seconds, which means in case of load change/disturbance the frequency will be back to set point at around 2 seconds. Controller response can be adjusted through provided dip switch on main board, it is possible to make slow, medium and fast response controller according to plant and load characteristics, but in most cases default setting are appropriate for most plant set up.

Two Step Systems

Thyristor triggering is based on phase angle system, which will vary the voltage and power diverted to ballast load from 0-100% according to triggering angle. The disadvantage of phase angle control is current/voltage distortion or harmonic. Total harmonic distortion will correspond to the amount of power diverted to ballast load which based on phase angle switching degree. The effect of harmonic might disturb the motor, transformer or any sensitive appliances. But in most cases the effect are not significant especially to standard electric appliances. To minimize and reduce the harmonic we use two step methods by modifying the switching of ballast into 2 steps. Only 50% of ballast capacity will be connected if the power diverted less than 50%, and the second capacity will only be connected if more than 50% power diverted to ballast load.

WORKING PRINCIPLES OF ELC


Under Frequency and Voltage Control

Please notice that ELC will only regulate the Frequency when the power generated bigger than consumed by main load. In the condition where consumers draw more power than generated, frequency will falls below 50 Hz and ELC can not help to increase it. ELC will cut off the main load connection with under frequency relay trip (if included) in case frequency falls below threshold <47.5 Hz. When these conditions happen, it is suggested to increase the flow into the turbine or reduce the consumption in case the turbine is already at its full power. Some peoples think that ELC will stabilize the frequency at any circumstances, which in fact its not. Following is the working condition of ELC;

EXAMPLE OF ELC WOKRING CONDITIONS

ELC works to detect and regulate the frequency and not the voltage! Generator voltage is controlled by Automatic Voltage Regulator (AVR) which normally included on generator. Brushless generator with AVR normally will be able control the voltage output when frequency between 47.5 - 52.5 Hz. In most cases generator without AVR will have uncontrolled voltage output, even when the frequency is 50 Hz the generator voltage can reach up to 250 Volt or even more. Therefore the use of brushes generator without AVR should be avoided to get the better quality of electrical power output.

Ballast load or dummy load basically is a resistive load (resistance) used to dump the excess power. We normally used tubular air heater type, industrial standard which have good quality to ensure long life time expectancy. It’s normally used in industrial process for heating and drying purpose. Air heater doesn’t need forced air for cooling, natural water flow should be sufficient to cool the heater, thus placement of ballast load on the good air ventilation is recommended. We also use water heater resistance made from stainless steel tubing if customer required the hot water for other purpose. But water heater system require appropriate tank and maintain water availability to prevent overheating and damage.

Considering that voltage applied to ballast load is not sinusoidal waveform, it is recommended not to use any normal appliances to be used as ballast load. Replace the ballast load resistance immediately in case of any damage occurring, to avoid over speed of generator. Ballast load capacity is recommended to be ±20% higher than designed power output to compensate thyristor waveform and expected higher output of the turbine. If Ballast load is too small the generator speed and frequency might increase when all power dumped, it is mean that generated power are bigger than ballast load capacity.

TURBINE CONSUMER BALLAST FREQUENCY ACTION

25 kW 10 kW 15 kW F = 50 Hz ELC WORKING UNDERLOADReduce turbine opening

25 kW 18 kW 7 kW F = 50 Hz ELC WORKING NORMAL

25 kW 26 kW 0 kW F < 50 Hz ELC NOT WORKING OVERLOADincrease flow or reduce load

CONDITION

BALLAST LOAD


Air Heater Ballast Load Water Heater Ballast Load

Our ELC panel is provided with standard metering to monitor the electrical output and electrical consumption by load, thus no additional panel required. Customer can request additional metering system if standard version is not sufficient. Digital or analog version is available on request. Following is our standard ELC metering;

1. Pilot lamps generator, 3 phase

2. Ampermeter ballast, 3 phase

3. Ampermeter konsumen, 3 phase

4. Voltmeter generator, 1 Phase

5. Frequency generator, 1 Phase

6. Hour counter, 1 unit

Standard metering is analog type with 72x72 mm display dimension.

ELC METERING


Besides metering, ELC panel is integrated with standard protection to protect generator, main load and ELC for standard application. Some additional protection might be added upon customer requirements especially for other application such as grid connected and parallel operation with other generator. Following are the included standard protection of ELC;

1. Main load MCCB for overload and short circuit

2. Main load Contactor for on/off consumer

3. Protection Fuse/MCB

4. Grounding terminal

5. Under/over frequency relay (optional)

6. Lightning arrester (optional)

7. Exhaust fan for ELC>30 kW

Main board ELC is equipped with dip switch setting to change some parameter of the controller like controller PI response, frequency setting and so on. In most cases dip switch default setting will serve basic system characteristic and no need to change, but some parameter can be adjusted for certain cases. Following are general function of dip switch on ELC main board.

Detailed setting of dip switch is provided on ELC manual operation come with ELC unit.

DIP SWITCH NO DEFAULT POSITION STATUS VALUEDIP 1 OFFDIP 2 OFFDIP 3 OFFDIP 4 OFFDIP 5 OFF 50 HzDIP 6 OFF 50 HzDIP 7 OFF 50 HzDIP 8 OFF Disable

FUNCTION

Proportional Value 3

Integral Value 3

Set Point -1 = 49 HzSet Point +1 = 51 HzSystem freq. (50/60 Hz)Droop setting (52Hz)

ELC PROTECTION

DIP SWITCH SETTING


1. ELC Type : Digital system with microcontroller 2. Control method : phase angle control with PI algorithm, two steps. 3. Switching method : Double Thyristor (SCR), 6 units – 2 units per phase 4. Power : 1 – 500 kW 5. Voltage : 220/380 V, 230/400 Volt 6. Phase : 1 and 3 Phase 7. Frequency : 50 / 60 Hz 8. Freq. accuracy : <± 0.2 9. Freq. sensing ; every half cycle or every 10 ms or 100 times/second at 50 Hz 10. Recovery time : ±2 seconds 11. Standard protection

- Main load MCCB - Main load contactor - Fuse/ MCB protection - Over/Under Frequency relay (optional) - Lightning arrester (optional)

12. Standard metering - Pilot lamps generator, 3 phase - Ampermeter ballast, 3 phase - Ampermeter consumer, 3 phase - Voltmeter generator, 1 Phase - Frequency generator, 1 Phase - Hour counter, 1 unit

13. Ballast load : tubular air heater, 6 units (2 units / phase) STANDARD CUBICLE LAYOUT

ELC TECHNICAL SPECIFICATIONS


5-10 kW 11-20 kW 21-30 kW 31-40 kW 41-50 kW

METERING

Pilot lamp - 3P Yes Yes Yes Yes Yes

Ampermeter ballast load - 3P DIRECT 30A CT 50/5 A CT 50/5 A CT 75/5 A CT 100/5 A

Ampermeter main load - 3P CT 50/5 A CT 50/5 A CT 50/5 A CT 75/5 A CT 100/5 A

Voltmeter generator - 1P 0-300 V 0-300 V 0-300 V 0-300 V 0-300 V

Frequency meter generator - 1P 45-55 Hz 45-55 Hz 45-55 Hz 45-55 Hz 45-55 Hz

Hour Counter 6 digit 6 digit 6 digit 6 digit 6 digit

Digital multi meter CVM NRG (V,I,Hz,kW,kWh,PF,kVA,etc)

- - - - -

PROTECTION

MCCB main load 20A 20/30A 50/60A 80A 100A

Contactor main load 20A 20/30A 50/60A 80A 100A

Fuse/MCB protection 3x2A 3x2A 3x2A 3x2A 3x2A

Over/underfrequency relay - Optional 47.5/52.5 Hz 47.5/52.5 Hz 47.5/52.5 Hz

Cooling fan - - 12 cm fan 12 cm fan 12 cm fan

Lightning arrester - - - - -

Grounding PEN PEN PEN PEN PEN

CABLES & DIMENSION

Main load cable size 4 mm² 6 mm² 10 mm² 16 mm² 25 mm²

Ballast load cable size - x2 1.5 mm² 2.5 mm² 4 mm² 6 mm² 10 mm²

THYRISTOR Size 3xSKKT42 6xSKKT42 6xSKKT42 6xSKKT57 6xSKKT57

Cubicle dimension (cm) 40x60x20 40x60x20 50x70x20 50x70x20 50x70x20

Generator cables size - 4 pcs 4x6 4x10 4x16 4x25 4x35

Approximate Weight ±15 kg ±20 kg ±24 kg ±31 kg ±38 kg

BALLAST LOAD

Rated Voltage 220 or 230 220 or 230 220 or 230 220 or 230 220 or 230

Ballast amount (pcs) 6 6 6 6 6

Ballast capacity per element 1.5 - 2 kW 2 - 4 kW 4 - 6 kW 6 - 8 kW 8 - 10 kW

Ballast cables size - 7 pcs 4x2.5 4x2.5 mm2 4x4 mm2 4x6 mm2 4x10 mm2

Approximate Weight ±7 kg ±15kg ±22 kg ±28 kg ±35 kg

SPECIFICATIONSDESCRIPTIONS

ELECTRONIC LOAD CONTROLLER SIZING


v Only for guidance! Specification might change anytime with/without notice

51-60 kW 61-70 kW 71-80 kW 81-90 kW 91-100 kW

METERING

Pilot lamp - 3P Yes Yes Yes Yes Yes

Ampermeter ballast load - 3P CT 100/5 A CT 150/5 A CT 150/5 A CT 200/5 A CT 200/5 A

Ampermeter main load - 3P CT 100/5 A CT 150/5 A CT 150/5 A CT 200/5 A CT 200/5 A

Voltmeter generator - 1P 0-300 V 0-300 V 0-300 V 0-300 V 0-300 V

Frequency meter generator - 1P 45-55 Hz 45-55 Hz 45-55 Hz 45-55 Hz 45-55 Hz

Hour Counter 6 digit 6 digit 6 digit 6 digit 6 digit

Digital multi meter CVM NRG (V,I,Hz,kW,kWh,PF,kVA,etc)

Included Included Included Included Included

PROTECTION

MCCB main load 100A 125A 160A 200A 200A

Contactor main load 100A 125A 160A 200A 200A

Fuse/MCB protection 3x2A 3x2A 3x2A 3x2A 3x2A

Over/underfrequency relay 47.5/52.5 Hz 47.5/52.5 Hz 47.5/52.5 Hz 47.5/52.5 Hz 47.5/52.5 Hz

Cooling fan 12 cm fan 12 cm fan 12 cm fan 12 cm fan 12 cm fan

Lightning arrester 3P+N 3P+N 3P+N 3P+N 3P+N

Grounding PEN PEN PEN PEN PEN

CABLES & DIMENSION

Main load cable size 25 mm² 35 mm² 35 mm² 50 mm² 50 mm²

Ballast load cable size - x2 10 mm² 16 mm² 16 mm² 25 mm² 25 mm²

THYRISTOR Size 6xSKKT57 6xSKKT92 6xSKKT92 6xSKKT132 6xSKKT132

Cubicle dimension (cm) 60x80x30 60x80x30 60x80x30 80x120x40 80x120x40

Generator cables size - 4 pcs 4x35 4x35 4x50 4x50 4x50

Approximate Weight ±45 kg ±53 kg ±58 kg ±80 kg ±80 kg

BALLAST LOAD

Rated Voltage 220 or 230 220 or 230 220 or 230 220 or 230 220 or 230

Ballast amount (pcs) 6 6 6 6 6

Ballast capacity per element 12 - 14 kW 14 - 16 kW 16 - 18 kW 18 - 20 kW 19 - 21 kW

Ballast cables size - 7 pcs 4x10 mm2 4x16 mm2 4x16 mm2 4x25 mm2 4x25 mm2

Approximate Weight ±40 kg ±47kg ±54 kg ±68 kg ±73 kg

ELECTRONIC LOAD CONTROLLER SIZING

DESCRIPTIONSSPECIFICATIONS


Within the period of 2011 - 2015 ELC PME are being in operation in more than 430 MHP site

worldwide, ranging from 1-200 kW with total installed capacity of about 7.5 MW. ELC is

spread all over the Indonesia archipelago, mostly for village electrifications. Besides our local

market, about 20% of our ELC is exported to some country such as ; Malaysia, Philippine, Thailand, Australia, Turkey, Switzerland, Iran, Francis, Pakistan, South Africa, Kenya,

Mozambique, Ethiopia, Nigeria,.

We always try to improve our product quality and services. We are dynamically improved to

follow the last technology and requirements to meet the customer need. We are very

welcome to advice and input from the customer to improve our product quality and service.

Following are some of the ELC projects we have been completed;

ELC+pelton turbine 75 kW Palu– Indonesia ELC 2x150 kW Kalimantan - Indonesia

ELC installed rural electrification projects (PNPM) in Sumatera and Sulawesi Indonesia

ELC PROJECTS REFERENCE


ELC + hydraulic actuator - Thailand ELC 90 kW with PELTON Turbine – Turkey

ELC + water heater Ballast load – Pakistan ELC on mini Geothermal Turbine – Bandung

ELC 2x100kW Mozambique & South Africa ELC 1 Phase for Sarawak projects - Malaysia

1510 brosur elc eng

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