CATALOG ELECTRONIC LOAD CONTROLLER (ELC) - … ELC PME.pdf · CATALOG ELECTRONIC LOAD CONTROLLER (ELC) For micro hydro power plant ... project and village electrification scheme 3

CATALOGELECTRONIC LOADCONTROLLER (ELC)For micro hydro power plant

Frequency and voltage control of micro hydro generator with microcontrollertechnology to maintain the stability and sustainable electricity supply with simple andaffordable solution.

2012

PROTEL MULTI ENERGYSmall Hydro Control and Renewable Energy

Jl. Pesantren No. 92 (Global) CibabatCimahi 40513, Jawa Barat, Indonesia

Telp/fax : +62 22 6611753www.pme-bandung.com

PROTEL MULTI ENERGYCATALOG ELECTRONIC LOAD CONTROLLER (ELC)

Jl. Pesantren No.92 (Global) CibabatCimahi 40513 Jawa Barat, Indonesia.

Telp/fax :+62 22 6611753.www.pme-bandung.com

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1. DEFINITION OF ELECTRONIC LOAD CONTROLLERElectronic load controller can be defined as electronic control system used to stabilized the output ofgenerator (frequency and voltage) when the consumer/main load is change. The control is done bydiverting the unused power to the dummy load (ballast). The diversion process is done by theelectronic switch (thyristor) controlled by the ELC main board based on the change of frequency on thesystem. In principle the purpose of ELC is to make sure that power generated by the turbine is

the same with power consumed.

Working Principle of Electronic Load ControllerProtel Multi Energy Electronic load controller (ELC-PME) is designed to suit with different type ofgenerator and various application of micro hydro, such as : Synchronous generator with AVR (brushless) (1 Phase/3 Phase) Synchronous generator without AVR (brushless) (1 Phase/3 Phase) Productive use of generator (motors, and large load) Grid interconnection Suitable with most of turbine type (Crossflow, Kaplan, Propeller, Pelton, Francis, etc)

Power turbin = Pconsumer + Pballast20.000 watt = 15.000 Watt + 5.000 Watt

ELCGenerator Consumer

Ballast Load




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2. BENEFIT OF ELECTRONIC LOAD CONTROLLER (ELC)There are many benefit with the utilization of ELC on the micro hydro scheme comparing to other typeof controls, such as:• Generated Frequency and Voltage are stable(220-230 V / ±50 hz)• Avoid the damage on electrical and electronicappliances such as lamps, TVs, radio, motors,etc. Due to frequency and voltage fluctuation• Avoid the damage of generator due to runawayspeed when the consumer is off or decreased• No water hammer effect, since no need ofwater flow adjustment or closing• Fast recovery time, capable in handling sudden large load change in very quick 10 ms.• Simple, robust and easy in operation and maintenance.• ELC is much cheaper comparing to other type of controller, thus affordable for low budgetproject and village electrification scheme

3. ELC SPECIFICATIONSProtel Multi Energy (ELC-PME) is developed based on microcontroller technology which resulting insimpler and smaller electronic circuit comparing to analog system, the control is done withprogramming software which allow the flexibility in setting and parameterization. Besides, the controlcan be done with very high precision, provided with 12 MHz external clock oscillator. Once it installed,no need of parameter adjustment during commissioning, all parameter already configured and tasted atfactory before shipment according to customer requirements or national standard.Basic electrical protection such as short circuit and overload protection is included on the cubicle andcan be extended based on customer requirement. In addition, cubicle is provided with nine (9) analogpanel meter to monitor the operation of plant and data recording.




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The main board of ELC-PME ismade per phase, the purpose is tobe easier in replacement andmaintenance in case of failure,meaning that if only one mainboard damaged no need to replacethree of it, only replace the brokenone. Besides, the independencecontrol avoiding the disturbanceof one phase to the other and minimize the failure. One main board can be utilized up to four channel ofTriac output or 2 channel of Thyristor module. The control of power diversion to dummy/ballast load isdone with phase angle control method, it adjusted the phase angle triggering based on the frequencyerror from the setting. This method allows the power control from 0-100% with fine regulation up to0.33 ms triggering angle possibility. The frequency reading is done every half cycle of sine wave orevery 10 ms on positive and negative cycles. This means that frequency error on positive wave will becompensated on the negative wave of the following cycle and vice versa.To minimize the harmonic distortion of the sine wave generator output, the diversion of power is madewith two step system, this mean that only 50% of dummy load capacity is connected at the beginning,and then the next 50% will only be used if the excess power can not be catered by first step. This hasresulting in significant reduce of total harmonic distortion of the electricity output. Limited disturbanceand radio interference to electronic device have been observed at certain phase angle triggering due tothe fast switching thyristor especially on the radius of 1 meter from the equipment.ELC-PME is provided with manual or automaticmode switch/MCB. In case of damage on ELC mainboard or dummy load, the system still can runwithout control (manual) while the problem isbeing repaired. This is not an ideal option and doesnot suggested, since running the plant withoutcontrol can lead into serious consequences andvery dangerous to generator, turbine, consumerload and the whole system. This mode onlyprovided for an emergency case.




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Main Technical Specifications :

Rated voltage : 220/380 V or 230/400V Phase : 1 or 3 phase Rated frequency : 50 / 60 Hz Frequency range : 47.5-52.5 Hz / 57.5-62.5 Hz Power output : 1—250 kW Recovery time : 10 millisecond Basic protection : short circuit and overload on consumer, over frequency/voltage Generator type : Synchronous with or without AVR (brushesless and brushes) Standard metering :

Generator voltage 1P (Volt) Generator frequency 1P (Hz) Hour meter to record the operation of system (h) Ampere meter for consumer 3P (Amp) Ampere meter for ballast load 3P (Amp) Pilot lamp on each phase 3P

Dummy/ballast load : Tubular air heater industrial standard, with the size of 110-130% fromDesign power for safety reason. Expected lifetime min. 15 years. Type of supply : Complete unit including ballast load, power cable to generator andballast load and fixing accessories. Guarantee period : 1 year of components and 3 years of ELC main board upon failure.Term and condition applied.

REMARKS !If the consumers load exceeding the generated power, the frequency and voltage ofgenerator will drop. Open the turbine further or reduce the load. In this overloadsituation the ELC can not help!




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4. THE COMPONENTS OF ELC-PME

1. PILOT LAMP220 volt lamps, indicating the presence of electric power on each phase.2. AMPERE METER BALLAST (A)Showing the current flowing to the ballast load, on normal operation it’s suggested to maintain thecurrent on ballast at minimal value to prevent overheating and continuously overloading generator.3. AMPERE METER CONSUMER (A)Showing the current flowing to the consumer. Its suggested to maintain the equal current on eachphase (balanced load)4. VOLTMETER (V)Showing the voltage of generator.5. HOURMETER (h)Recording the operational hour of the plant. This is useful for maintenance schedule and monitorthe components lifetime.6. FREQUENCY METER (Hz)Showing the generated frequency of generator

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2

3

4 5 6

7 8

9

11 12

1314

15 16 17

18 19 20

10

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7. PUSH BUTTON ONConnecting the consumer load (main load), switch on the contactor8. PUSH BUTTON OFFDisconnecting the consumer load (main load), switch off the contactor9. TRANSFORMERSupply the low voltage for ELC mainboard10. HEATSINKCooling and support of Thyristor/Triac (heat distribution)11. SCR /TRIACElectronic switch (Thyristor) to control the dummy load current switching.12. FANAir circulation and heat evacuation from heatsink / cubicle13. CURRENT TRANSFORMERMeasure the current to consumer and dummy/ballast load14. MAINBOARDThe heart of control system, its sense, process and controlling the current flow to thedummy/ballast load to maintain the steady condition of power plant15. CONTACTORTo switch on/off the consumer load through push button ON/OFF or automated with relay fromELC mainboard (optional)16. MCCB / NFBProtection against short circuit and overload on consumer side17. MCBAs switch manual/automatic of ELC, protection panel meter instrument, pilot lamps andpowerhouse installation18. GENERATOR TERMINALConnection terminal to generator19. CONSUMER TERMINALConnection terminal to consumer20. NEUTRAL AND POWERHOUSEConnection for neutral and power house installation21. BALLAST TERMINALConnection to dummy/ballast load




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5. DUMMY/BALLAST LOADBallast load or dummy load is a nearly pure resistive load and its used as a complement load when theconsumer load is less then generated power from the turbine. The element made from the winding ofwire filled with ceramics with metal casing. The heater type used is tubular air heater, which make itless maintenance requirements, longer lifetime and easy in installation comparing to water heater type.Air heater type does not need forced air convection (fan/blower), only install it in place with good aircirculation for heat evacuation i.e. windows. Tubular air heater is industrial standard heaterwhich normally used on heating and dryingprocess. Normal lifetime about 15 years andshould be more in dummy/ballast loadapplication, since it’s not fully used at all time.Avoid dummy load from water splash, rain andcombustible material. It should be out of reach ofchildren and access of public. Never replacedamaged dummy element with other type ofdummy or different size of power. It mightdisturb the stability and safety of the plant.The rated total power of the ballast normallyoverrated 10-30% of design turbine power incase of bigger turbine output then design andlonger life time of element.There are two type of ballast frame, open typewithout screen and closed type with mesh wired screen to protect the element from foreign objects.The standard version of ELC comes with open type ballast frame.




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6. PROJECTS REFERENCE PICTURES

Pic.1 Components layout of 3 phase ELC forrated power 15-40 kW

Pic.2 Standard panelmeter of 3P ELC

Pic.3 Testing and setting of ELCbefore shipment

Pic.4 ELC cubicle for MHP with ratedpower of 150 kVA

Pic.5 Ballast load for150 kVA

Pic.6 Main board assembly andlayout connection

Pic.7 Stock ELC cubicles and ballast load Pic.8 Standard frameballast load

Pic.9 ELC-PME in operation

Rev_February 2012

Documents

CATALOG ELECTRONIC LOAD CONTROLLER (ELC) - … ELC PME.pdf · CATALOG ELECTRONIC LOAD CONTROLLER (ELC) For micro hydro power plant ... project and village electrification scheme 3