S Real-Life Design Project Approach to Teaching Renewable Energy Dr. Elena Brewer, Anthony Dalessio Erie Community College 2013 Sustainability Conference, Alfred State SUNY College of Technology, June 7, 2013
S
Real-Life Design Project Approach
to Teaching Renewable Energy
Dr. Elena Brewer, Anthony Dalessio
Erie Community College
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Existing PV Systems course
(since 2011)
S Examinations
S Homework assignments: - theoretical - practical (load analysis using kill-a-watt meter, shading analysis using Solar PathFinder, solar irradiance analysis with PV Watts calculator or solar irradiance tables, etc.
S Comprehensive Group Design Project
S Assessment
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
New Wind Power course: Some of the Topics Covered
S Wind turbine site analysis
S Wind resource analysis (Rayleigh distribution, Weibull
distribution, etc.)
S Turbine power output / energy output estimates
S Blades aerodynamics
S Mechanical and Electrical aspects
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
System Needs and
Requirements
S The EET department presently has a need for an off-grid
power system to power lights and power tools for the
college’s overhead construction and climbing facility for
Energy Utility Technology program:
- overhead climbing class runs 3 or 6 weeks every summer,
5 days a week, 8 hours per day;
- no electricity on site;
- hot temperatures.
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Superwind 350
Wind Turbine • The turbine was installed at
south campus during summer 2012 climbing school.
• The department was going to complete the stand-alone wind/PV system for data acquisition purposes and to run lights in the trailer for the climbing school.
• Budgetary issues prevented us from completing this project in 2012.
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
Installation of
Wind Turbine
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Installation of
Wind Turbine
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
ASEE ETD (Engineering Technology Division)
Mini-Grant
S In the Fall of 2012, ASEE ETD division announced the competition for mini-grants (up to $5,000) for partial funding on project which will benefit ETD or a segment of the engineering technology community.
S ETD gave as much latitude as possible to ETD members in the choice of projects. The project should benefit ETD itself or a significant portion of the engineering technology community. It may focus on a single discipline and/or be of use to a particular college or system, so long as the results will benefit the larger ETD community.
S EET department applied and won one of three mini-grant awards.
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
Budgetary Constraints
S ASEE ETD mini grant - $4,200 for equipment, $800 for
conference
S ECC matching costs:
- $2,500 Superwind 350 24V wind turbine
with wind charge regulator and dump load,
- available assortment of PV charge controllers ($400 -
$1,500)
- available 140W solar panels (if students choose to use them)
- 10 available AGM 105 Wh batteries (if students choose to use
them)
- up to $1,000 from EET department budget
- installation of the pole ($1,400) plus pole cost ($600)
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Design Competition
S Several students groups (2-3 students each) competed for the best design of the system within current specifications (energy audit, wind resource analysis, shading analysis, customer load requirements, customer system requirements, budgetary constraints, already existing equipment, NEC requirements, etc.) during Spring 2013 semester.
S Design competition provided students with real life experience designing actual renewable energy system.
S The combination of PV Systems course and Wind Power course (electives) provided students with unique background for possible design of the hybrid PV-Wind system.
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Design Competition
S Deliverable – design of the viable PV/Wind/hybrid stand alone system with battery back up: - PowerPoint presentation - Portfolio with supporting materials (wind resource and shading analysis, load specs, major system components specs, array and battery bank sizing calculations, wire sizing calculations, etc.)
S The competition judging panel consisted of PV/wind industry representatives, customers (instructor from National Grid teaching the climbing school), ECC faculty
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
Design Competition
S 4 student group designs were presented ranging from
systems utilizing only PV array to hybrid systems with wind
turbine and PV panels.
S The winning project was determined based on judging panel
scores.
S The grade for the student design project was determined
based on judging panel scores, portfolio with system
specification, presentations performance, student self-
evaluation.
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
Design
Competition:
Judging
Criteria
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
EL 264 PV/Wind System Design Competition
Project: ______________________________________________________________
Assign a rating of each relevant criteria based on a 10 point scale (10 rated the highest and 1 rated the
lowest rating)
Technical Aspects
Criteria Rating (1 to 10) Comments
Load analysis
Were minimum load
requirements met?
Were space requirements
met?
Shading analysis
Available wind energy
analysis (if applicable)
PV Array / Wind turbine
sizing
Charge controller and
battery bank sizing
Inverter sizing
BOS sizing (disconnects,
wiring)
System components
completely priced out
Was project cost kept under
budget?
Were specs for all system
components provided?
Sources for all components
How complete the proposal
is
Room for expansion
Presentation aspects:
Criteria Rating (1 to 10) Comments
Eye contact
Team work (everybody
presents)
Appropriate use of
PowerPoint
Technical content
Timing (15-20 min)
Elocution and appropriate
audio level
Design
Competition:
Presentation
Evaluation
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
EL 264 PV/Wind System Design Competition
Project: ______________________________________________________________
Assign a rating of each relevant criteria based on a 10 point scale (10 rated the highest and 1 rated the
lowest rating)
Technical Aspects
Criteria Rating (1 to 10) Comments
Load analysis
Were minimum load
requirements met?
Were space requirements
met?
Shading analysis
Available wind energy
analysis (if applicable)
PV Array / Wind turbine
sizing
Charge controller and
battery bank sizing
Inverter sizing
BOS sizing (disconnects,
wiring)
System components
completely priced out
Was project cost kept under
budget?
Were specs for all system
components provided?
Sources for all components
How complete the proposal
is
Room for expansion
Presentation aspects:
Criteria Rating (1 to 10) Comments
Eye contact
Team work (everybody
presents)
Appropriate use of
PowerPoint
Technical content
Timing (15-20 min)
Elocution and appropriate
audio level
Design
Competition:
Peer
Evaluation
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
Peer Teamwork Assessment Rubric NAME: ____________________________________
Student Outcome (f): Demonstrate the ability to work cooperatively in teams
To be completed by each team member: For each of the other members of your project team, assign a
rating of the team member on each of the 10 criteria listed in the table below. Indicate the extent to which
you agree, or disagree, with each assertion about each of your team members.
Rating scale: 5 – strongly agree
4 – agree
3 – not sure
2 – disagree
1 – disagree strongly
Criterion Team Member 1:
Team Member 2:
Roles were clearly defined and executed
1: Had a clear understanding of what was expected of them
2: Maximized the use of her/his individual skill set for the
benefit of the team
Followed a schedule for timely completion
3: Complied with mechanisms to track the progress of the
project
4: Could be expected to complete assignments in a timely
fashion
Negotiated consensus when needed
5: Showed respect for the opinions of the other team
members
6: Showed willingness to negotiate and compromise
Equitable participation by team members
7: Contributed her/his own ideas and viewpoints
8: Did their fair share of the work
Shared responsibility for success and failure
9: Actively sought and shared information from/with other
team members
10: Was flexible/adaptable to changing requirements
Design
Competition:
S Teamwork rubric
S Behavior rubric
S Organization rubric
S Time Management rubric Self
Evaluation
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
System
Requirements • Lighting inside the 40 ft.
trailer (on 20A circuit)
• Portable ice maker (on 20A
circuit)
• Small monitoring/data
logging system
• Wireless access point
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Inside the
Trailer View
Potential
Additional
Loads
• Larger PLC-based data
logging system
• Flood lights / sign lighting
• Small refrigerator
• Weather station
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Pole Yard
Aerial View
Additional
System
Requirements
• Low maintenance batteries:
either AGM or gel
• 30-40 ft. from the trailer to
the poles
• Poles are 40 ft. high
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Pole Yard side
View
Site
Characteristics
• Good wind resource (throughout the whole year)
• Low shading
• During winter – heavy snow (poor solar generation)
• Low winter temperatures: - average low -8C - record low – 29 C (poor battery performance in winter)
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Shading
Analysis • 4 groups of students did
laboratory experiment for
shading analysis at the site
of future installation using:
- Solar Pathfinder
- Solmetric SunEye
• Different possible PV array
locations were tested:
- pole mount
- ground mount (south end)
- on top of the trailer
- on the south side of the
trailer
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Wind Resource Analysis for
Superwind 350 24V turbine
S There is no detailed wind data for the site.
S Data for average wind speeds from weather station at Buffalo International airport were used to determine Rayleigh wind speed distribution and projected turbine generated energy output.
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
S
The Winning Student
Design Project Hybrid System
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
4x High efficiency light bulbs inside
conex box (LED 15W, 25,000hr lifespan)
Portable ice maker (Ice under 10 min)
Flood light – ECC sign
Outlet in conex box for charging cell
phones.
Inverter
PM-100-D PentaMetric
Proposed Load
Load Requirements
Load Watts Estimated
Daily Use
Watt hours per
day
4x Light Bulbs 60 (15 ea.) 6 hrs 360
ECC Sign 24 12 hrs 288
Ice Maker 230 2 hrs 460
Inverter 12 24 hrs 288
PM-100-D PentaMetric ½ 24 hrs 12
Cell Phone charging
outlet
10.5 2 hrs 21
Total 337 --- 1429
Critical Design Month Analysis Month Daily Power
Consumption
(Wh/day)
Insulation (-15
degree fixed) (PSH)
Critical Design
Ratio
January 588 2.17 271
February 588 2.95 199
March 588 4.25 138
April 588 4.85 121
May 588 5.57 106
June 1429 6.19 231
July 1429 5.88 243
August 588 5.38 109
September 588 4.62 127
October 588 3.31 178
November 588 2.08 283
December 588 1.82 323
120W solar panel
24V SuperWind 350 Micro turbine
Inverter
Charge Controller
8x 105Ah Batteries
Proposed Design
Proposed Design Design is simple and
low cost. It is a 120W solar panel mounted on the utility pole in conjunction with a 24V Superwind micro-turbine. Design is backed by a large battery bank which is positioned at the base of the pole.
Based on Rayleigh wind distribution curve the
turbine is expected to produce 1kWh/day.
Superwind Micro-turbine
Proposed PV panel is a 120 Watt Solarland High efficient
Multicrystalline at 28º tilt for maximum summer output.
Array
For example the 120W array during the month of June:
120W x 6.19 PSH x (de-rates)
( 0. 95 X 0.98 X 0.96 X 0.9x0.85 ) = 507.87W
Connected Load 1429 Wh With the superwind turbine average daily
output is 1KW So 1429 – 1000 = New connected load is 429Wh De – rates : battery charging/discharging – 0.90
• Array to cc – 0.96 • wiring losses – 0.98 • Elevated temp, soiling, mismatch – 0.95 • Tilt and azimuth angle, shading – 1.00 • Inverter efficiency – 0.85
Array must generate 429Wh/(0.9)*(.96)*(.98)*(.95)*(.85)= 628W
Array
Array must generate 628Wh
Array tilt to maximize
summer output
performance -15 degrees
July – PSH = 5.88
Array minimum rating :
628Wh / 5.88 PSH = 107 W
Array
1.5 Days of Storage ( Worst Case Scenario, no power generation )
24 V system Loads between June and July B out = 1429Wh x 1.5 days / 24V = 90 Ah
Loads Between August to May B out = 588Wh X 1.5/ 24V = 37 Ah
How much stored energy will be
necessary?
De – Rates 0.98 – wiring losses 0.30 – DOD 0.76(Aug-may), - Temp & discharge rate 0.875(June-July)
0.85 – Inverter inefficiency Battery Storage for June and July B rated = 90Ah / ( 0.98 x 0.30 x 0.875 x 0.85 )= 411 Ah at 24 V Battery Storage for August to May B rated = 37Ah / ( 0.98 x 0.30 x 0.76 x 0.85) = 195 Ah at 24 V
Battery Storage
B rated = 411 Ah at 24 V
Marine / RV Intimidator AGM 12 V, 105 Ah ( ECC supplied with 10 )
Need 2 in series and 4 in parallel = Total of 420 Ah
Battery Specifications
Proposed design
has 8 batteries. 4
strings of 2 batteries
in parallel to
produce 420Ah at
24V.
Battery Setup with Enclosure
I out = ( P array + P turbine / V bat ) * C.C
efficiency
I out = (120 + 350 / 24V ) * 0.96 = 18.8A
Need 20A or higher , 24V charge controller
Charge regulator SCR 24 Marine 40A , 24V ,
96% efficiency, Max Voc = at least 55 V,
Charge Controller
Required power 107 W
Module: 120 Watt Solarland High efficienct Multicystalline PV Isc = 3.86A
Imp = 3.49A
Voc = 43.2V
V mp = 34.4V
Cv = -.080 V/°C
V max = 43.2 V + (-.080 V/°C ) (-28.9°C - 25°C ) = 47.51V
V min = 34.3 V + (-.080 V/°C ) ( 37.2°C +30°C -25°C ) = 30.92V
Imp = 3.49A x 1.25 = 4.36A + turbine current 14.58A = 18.94A < 40A
Factor of 1.25 accounts for the period of higher than STC insolation
Array Configuration
Excluding June and July the load will only be 558W, the turbine produces on average 1 kW of energy a day, therefore there is an adequate amount of energy to supply the load during those months.
Comparison of daily loads (Wh) and energy
availability (Wh) for stand alone system
For the 120W array - June : 120 W x 6. 19 PSH X de-rates ( 0. 95 X 0.98
X 0.96 X 0.9x0.85 ) = 507.87W+ 1000 W from turbine = 1507.87W ,
required is 1429 Watts
Samex America PST – 2000 – 24
2000W 24 V inverter
85% peak inverter efficiency
Continuous output power of
2000 W
Surge Output power 3500 W
Inverter
DPW Solar Panel Side of the Pole Mount SPM3-C
Features: Mounts three solar panels Solar Panel can be sized at W 22 - 27
inches and L 56 - 63 inches (panel is 27 inches wide by 59 inches
long) Flexible array tilt angle Easy to install
Includes: Standard solar mounts designed to
withstand 90 MPH wind zones Stainless steel module mounting
hardware High strength stainless steel band clamps
Mounting Hardware
Batteries – Supplied by ECC
Flood Light –supplied by ECC
Inside Conex box lights - $87.52 for four
Solar panels - 120 Watt array - $ 445.20
Charge Controller – Supplied by ECC
Wind Turbine – Supplied by ECC
Battery enclosure – $796.32 for 8 batteries
Inverter - $665.15
Disconnect box –4 @ $60 for 30 A box Mount – $240
Penta metric – Supplied by ECC
Portable Ice maker - $110
*AC wire – 250 ft 14 gauge $43.84
*DC wire – 50 ft , 10 gauge $78.62
Wire Conduit – 80 ft @ $13.95 per 10 ft , Total - $111.60
Total = $2578.25
Cost
*Wiring specification calculation
sheet included in folder
ECC South Campus – Stand Alone PV System
Spec. Sheets & Pricing Options
(portfolio)
1. Operation Manual and Average Daily output of Superwind 350 turbine 2. Solar Pathfinder Site Report with PSH for utility pole location 3. Buffalo, NY Record Low and Record High temps. (ºC) 4. Gel Battery capacity ( % rated capacity) vs. Temperature 5. Angle and Azimuth De-rate factor
6. 120 W High efficiency Multicrystalline PV module spec. sheet 7. Charge Regulator SCR 24 Marine Spec. sheet 8. Marine/RV Intimidator AGM 12v, 105 AH Spec. sheet 9. Samalex America PST 2000W 24V inverter, Spec. sheet and pricing 10. GE General Disconnect Box pricing
11. Battery Enclosure, Spec. sheet and pricing 12. Solar Panel Mount, Spec. sheet and pricing 13. LED light Bulb, 15 Watt 25,000 hour lifespan pricing 14. Koldfront Ultra Compact Portable Ice Maker pricing 15. AC and DC wiring sizing calculations 16. AC wire pricing
17. DC wire pricing 18. Wiring conduit pricing
Project Discussion
S Students did not present/consider:
- additional power generation to charge batteries and run
full loads at the same time,
- calculations to determine proper cables for the battery
bank,
- specs and prices for the conduites,
- specs and prices for the blocking diode for the solar panel.
2013 Sustainability Conference, Alfred State SUNY
College of Technology, June 7, 2013
Conclusions
S Designed hybrid system met load requirements and specified system requirements
S The system (with minimum modifications) can be installed within the budget constraints
S Students received valuable experience designing real-life hybrid stand-alone system
S EET and EUT students will gain more experience during installation of the system (late June 2013)
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013
Conclusions
S The installed system will be utilized to power lights, ice maker, and other small loads during summer climbing school
S The rest of the year, the system will provide power for monitoring/ data collection system allowing us to collect data pertinent to solar and wind power production at the site. EET department has plans of offering this site as a testing site for various small turbines in the future.
S Generated data can also be used in the various courses related to renewable energy generation.
2013 Sustainability Conference, Alfred State
SUNY College of Technology, June 7, 2013