Instruction Manual - Installation, Operation and Maintenance of Wind
Contents
1. END EN NEN PR Plate Ginpole i Anchor Distance Ginpole i Anchor Downhill Guy Anchor Make sure that you have sufficient room for the tower amp turbine to tilt down 1 If the site is not in level try to position the tower in such a way so that it will be lowered in upward direction 2 Check the diagonal distance between anchor points to ensure that they are correct square 3 Screw the guy anchor at 45 degrees pointing towards the tower base stake leaving the 4 inches to 8 inches above the ground as shown in fig a below LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village T Off Pune Saswad Road Pune 412306 India Vite RENEWABLE ENERGY Phone 91 020 64011044 65110453 460 GY www windsolarzone com 1 Tower base concrete Fig a We recommend a base that is roughly 600 x 600 mm amp 600 mm deep with several pieces of steel reinforcing bars placed horizontally 2 Cast the hex bolts into the concrete so as to fix the base plate in to the bots Isometric View of Base Plate 1 Bolt the base tower section to the base plate using the nuts for tower base 2 Lay the tower sections pipes on the ground connect the tower sections each other with given hardware 3 Insert the base of tower base pipe in to the base assembly REN2. INSTRUCTION MANUAL INSTALLATION OPERATION AND MAINTENANCE OF WIND SOLAR BATTERY HYBRID POWER PLANTS CUSTOMER NAME AND ADDRESS POWER PLANT CONFIGURATION LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD F ly UD Energy Systems Pvt Gat No d Vadki Village Off Pu yt i ad dada 41 2308 In dia Pho 91 460 indso RENEWABLE ENERGY WWW W d Index This manual consists of following sub manuals Site Selection Micrositing procedure Whisper 500 wind turbine installation operation and maintenance manual EM m Installation of tower for wind turbine their erection and cable laying 4 MEM from turbine to control room and periodic maintenance oolar photovoltaic structure errection and maintenance procedure Battery bank errection cabling operation and service manual Inverter LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com SECTION A PREFACE Wind Solar Hybrid Power Plant omall battery charging wind turbine generates DC power from wind for charging batteries Solar Photovoltaic system also generates DC power from solar Radiation and charge the batteries The battery stores energy for the supply of direct DC or converted AC through inve
3. 1 Clean the battery cells and keep the cells tops in clean and dry conditions once in six months 2 Top up the battery cells with battery grade water up to the required level given once in 6 9 months Please watch the cell electrolyte indicator and top up level indicator reaches its lowest level From this you will get an indication regarding the frequency of topping up 3 Clean the battery terminals with cloth wire brush soaked in water and re apply petroleum jelly once in a year In corrosive atmosphere like near the sea side the frequency may be more 4 Check all inter cell inter row and inter tier cable connectors for the tightness of connection and tighten if found loose 5 Check battery stand for any sign of sulfation or corrosion and clean with cloth and water 6 Check voltage and specific gravity of each cell once in a month and record in the battery EQUALISING CHARGE FOR CYCLING BATTERIES 1 Tubular flooded battery cell regularly cycled charged amp discharged deeply few cells fall out of step for a period of time 2 After a period some cells have high voltage and high specific gravity and some cells are not fully charged and have low specific gravity and voltage 3 The cells which have low state of charge have a sharp voltage increase on constant current charge due to which the charger is automatically switched OFF even if your battery is not fully charged 4 To avoid this equalizing cha
4. almost always used and provide a life of around 8 10 years for large battery banks if used and maintained properly LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 m www windsolarzone com VRLA BATTERY Valve regulated lead acid VRLA batteries consists of plate pasted positive and negative plates with a glasswool absorbent mat separator in between them The glasswool mat is partially soaked with electrolyte and there is no free flooded electrolyte in the battery That is why it is also known as an AGM absorbent glass mat battery These are housed in a plastic container over sealed from atmosphere but with a relief valve which allows gas to escape if high pressure is developed inside the battery Due to the design the oxygen gas evolving from the battery is recombined and re forms back into water and no water is lost from battery due to which it does not require any water replenishment VRLA is ideally suited for floating or shallow discharge operations At 80 depth of discharge the cycle life if normally not more than 500 cycles It also cannot be charged at high voltages and its life is severely affected if exposed to higher temperatures above 35 In recent times a modified version of VRLA known as tubular gel battery the AGM technology is replaced by g
5. any wind solar power plant installation the solar panels should be located in southern most part of the site and all other installations like WTG control room DG installation etc will be on the northern side of the solar panels opace between two rows of solar structures should be atleast twice of the height of the solar panel structures at the highest point of tilt This minimum space is required to avoid shadow of one row of solar structure to fall on the row behind it Similarly if there is an obstacle on the southern side of the solar structure modules the distance of the solar structure module facing the obstruction should be atleast twice the height of the obstruction Please refer Fig No A While installing solar panels on the tin asbestos roof of any building sufficient gap is to be provided between the roof and the solar panels to avoid the solar panels getting heated by the tin roof Gaps to be provided between panels for escape of hot air Whenever solar structure are installed on the ground the area under amp around the solar panels should be covered with small stone chips and sand to discourage growth of grass all around solar panels and also to discourage cattle It also saves the solar modules from accidentally catching fire if there are any dry grass around it which can burn It is best if a water tap is located in the vicinity of the SPV installation to provide water for periodic cl
6. the battery installation layout drawing provided for the particular site UPPER TIER LOWER TIER DOUBLE ROW DOUBLE TIER LAYOUT Front View a LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 91 020 e www windsolarzone com Trad n 48V 24NOS X 2CELLS BATTERY CONNECTION DIAGRAM Top View RECEIVING INSPECITON AND STORAGE OF BATTERY AT SITE Battery received in dry and in charged condition 1 Open out packing cases and check individual battery cells for any physical damage 2 Check the no of battery cells received as per packing list Challan Invoice Check name plate of each cell for its capacity 3 Electrolyte and battery grade water is normally supplied alongwith a dry uncharged battery cells The manufacturer indicates the quantity of electrolyte required per cell from which total electrolyte quantity volume can be collected Check whether adequate electrolyte has been received 4 The manufacturer indicates the fill in electrolyte specific gravity Normally this is between 1 200 to 1 230 specific gravity 27 Check specific gravity and temperature of electrolyte delivered 5 Battery grade water is required for final adjustment of specific gravity of the cells Order for amp receive adequate water equivalen
7. turbine b Use sling wire for lifting turbine Sling wire to be fitted carefully so that the weight of turbine does not come on any weak member The sling is used to lift turbine by upper assembly Suitable soft material is to be used between sling amp turbine to avoid scratches on the turbine c The freeness of the turbine rotor should be checked by rotation turbine by hand amp also the electromagnetic braking characteristic should be check as per whisper 500 manual d Lifting of turbine Turbine should be pulled up by the pulley rope as shown in figure below are should be taken that turbine does not hit any tower structure while being lifting For this the turbine is pulled away from tower by separate rope e The temporary pipe fitted to tower for lifting turbine is fitted higher than the tower top to enable smooth insertion of turbine into the tower top pipe from the top down wards LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 91 020 64011044 65110453 460 Y www windsolarzone com f Insert tower insert inside the top of pipe the 6 nos of insert bolts are used to fix the insert of the turbine to tower Please ref Whisper 500 g Blade assembly 1 Fit the blades on blade plate which is all ready fitted on rotor can of turbine Blade
8. BLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 91 020 e www windsolarzone com The knowledge of wind conditions is very important for installation of wind turbine It is always best to have measured data of the planned site for a period of at least two years But this is not always possible for small WTG installation where the cost of measurement may exceed the price of the WTG system In case of shorter measurement of period wind consultant can find out the condition by an interpolation of long term measurement of nearby weather station Based on the information about the wind condition and the exact load it is possible to choose the type and capacity of turbine which provides the highest energy production while meeting the external requirements Based on realistic forecast of the energy production it is possible to decide whether to invest in wind energy or not SITE LAYOUT CONTROL ROOM Solar array on LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com Tubular tilt up tower with quy rope support Tools Required 1 Measuring tape 2 Hammer drill machine 3 Box spanner
9. EWABLE ENERGY LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Pune 412308 India 2 91 020 64011044 65110453 460 Wy www windsolarzone com Off Pune Saswad Road A 4 Cutthe guy ropes of appropriate length 5 Insert the D shackle or eye ring in to the holder part of the tower diagram amp the anchor support on ground 6 Make sure that the guy rings D ears are facing towards the base plate amp guy rings ear of anchor are facing towards tower 7 Slide the guy wires in to the ear ring or D shackle Please see the diagram 8 Slide the wire rope into malleable clips clip on to each wire end Malleable Clip d 9 Insert the turn buckle into eye of the anchor using D shackles 10 Roll out the side guy wire to the side anchors turn buckle 11 Lifting procedure a Start lifting the tower 10 deg to 20 deg at a time Monitor the side guy wires and gin pole ropes carefully they may become either loose or tight if the site and the anchor points are not perfectly level See the fig below b Continue lifting adjusting until the tower is 45 deg to 60 deg towards the vertical See the fig below c Asthe tower approaches vertical it is important to maintain tension on back guy wire set this should be done by standing to one side of the anchor not directly under the tower All back guy wires
10. Half threaded LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India y 77 RENEWABLE ENERGY Phone 91 020 64011044 65110453 460 amp AP www windsolarzone com 5 Following are the steps to be followed for erection 1 Obtain the drawing for foundation see the fig below d 6 Hole for 1 foundation bolt 12 Long 4Nos in C 18 in iD lt L yp Detail of Base Plate ltem No amm ci NLA a Pn i a o i ai a eae m LI 4 Imm Smm IVS Bolts amp Nuts of 1 9 amp 8 Long m 4Nos View section A A of Base Plate sometric LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road RENEWABLE ENERGY Pune 412306 India Phone 91 020 64011044 65110453 460 www windsolarzone com T 1 Mark the ground location for the tower base plate guy anchors amp the lifting anchor for the gin pole The appropriate dimension amp ground layout are shown in fig Excavation amp marking on site diagram amp process to be incorporated Tower yy Uphill Guy Anchor Side Guy Side Guy Anchor Anchor NEED
11. PV module with 4 panels connected in series and 3 such series strings connected in parallel as shown in fig No A Please note that our structure is located as close to other structure as possible leaving sufficient gap for servicing While each structure should be close to the next between structures adequate space should be allowed for free movement for servicing SPV structures should be designed in such a way that all solar panels can be easily reached by human hand for regular cleaning In India all the structures with their solar panels fitted on them should be facing magnetic south Solar panels should face true south in northern hemisphere and true north in southern hemisphere For the purpose of finding the direction magnetic compass has to be used A photograph of a common magnetic compass is given LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Pune Saswad Road T Pune 412308 Indi a RENEWABLE ENERGY dada ds can Y 7 www windsolarzone com Solar Array Solar Array Each structure should be facing south but tilted at an angle from the horizontal ground level They should be tilted from the horizontal at a degree equal to the latitude of the site location All the structure should be located in such a way that no shadows of any adjoining trees or building or structures fall on any solar panel at any time of the day For
12. UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India Phone 91 020 64011044 65110453 460 www windsolarzone com BATTERY INDEX Description of Battery Bank Tubular amp VRLA Battery room and battery stand layout Receiving Inspection amp storage of battery at site Erection and interconnection of battery bank Initial charging first charge of battery commissioning of battery bank Preventative maintenance procedure LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com 1 DESCRIPTION OF BATTERY BANK TUBULAR amp VRLA A secondary electric storage cell stores electrical energy in the form chemical energy when it is charged and delivers electrical energy by commissioning chemical energy when it is discharged Lead Acid Battery A lead acid electronic storage cell consists of a set of positive plates anode containing lead dioxide and negative plates cathode containing pure spongy lead immersed in an electrolyte which is dilute sulphuric acid Non conducting but permeable separators are used in between positive and negative plates to avoid short circuit All these components are housed in a hard rubber or plastics container which is know
13. are to be fitted wing 2 nos blade strap provided please ref of Whisper 500 manual 2 The blade are to be fitted in such a way that the concave portion faces the installer amp the convex portion away from installer amp the installer is facing wind turbine blade plate Please ensure that when the blade is in a vertical position as shown in diagram below The leading edge is on the RHS of installer 1 For your information thicker edge of blade is leading amp thinner is trailing edge Fix the nose cone as described in manual of Whisper 500 LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India Y RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com SECTION G SITING FOR SOLAR PHOTOVOLTAIC ARRAY Output from SPV array can be improved to the optimum level by taking care of the following de SPV array should be as close to the control room as possible to avoid unnecessary voltage drop power loss A complete SPV array consists of multiple structures with each structure supporting some SPV panels All structures SPV output are connected in series or parallel as required should be located as close to each other as possible to avoid voltage drop For example A typical installation of 3600W SPV system consists of 4 similar structures each of 900W 12 nos of 12V 75W S
14. ck the normal battery bank voltage LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 m www windsolarzone com V INITIAL CHARGING FIRST CHARGE OF BATTERY COMMISSIONING OF BATTERY BANK This is done for battery cells received in dry and uncharged condition 1 Fill the cells with dilute sulphuric acid supply alongwith the battery 2 Allow between 12 24 hours rest period for soaking acid in the plates and for cooling down to room temperature approximately Shorter time can allowed in winter when the cooling is fast Further more than 24 hours should not be allowed 3 Start charging with constant current at the finishing rate as given fin the chart here under 4 Obtain hourly specific gravity temperature and voltage readings of all cells as per sample sheet attached 5 Continue charging till the battery is fully charged Full charge set can be ascertained by ensuring the following parameters a Cell voltages remain constant for three consecutive hourly readings b Cells specific gravity readings remain constant for three consecutive hourly readings c Free gassing is observed in all the cells d Total cumulative amphere hour charge delivered to the battery is atleast 4 5 times of the amphere hour capacity of the battery 6 Once the battery
15. eaning To avoid the shadow effect of a panel on the total array in which that panel is included a diode must be connected in reverse polarity to avoid shadowing effect LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com 19 PLAIN CONCRETE CEMENT Location of Electrical control room Battery room Control room should be located as close of the WTG wind turbine generator and the SPV solar photo voltaic as possible but not so close as to cast shadow on the SPV The control room will house the battery wind amp solar charge controllers and the inverters The dimension of the control battery room should be atleast 12ft X 12ft X 12ft ht for upto 10 KW wind solar hybrid system and 12Ft X 20ft X 12ft ht for a 20KW hybrid system he control battery room should be well ventilated for exhausting the small amount of gas emitted by the battery bank Preferably it should be open for using natural light to the extent possible No other sensitive electronic equipment should be located in the same room as the battery to avoid corrosion This includes the master controller if supplied along with wind solar diesel hybrid system The master controller should be located in room space outside the battery room but has to be v
16. el technology has hit the market It is supposed to have a cycle life as good as the flooded tubular battery but it suffers from the same problems when charged at higher voltages Another major problem of AGM Gel batteries is the extremely difficult impossible process of reviving battery if kept in discharged condition for a long time In this manual where batteries will be exclusively used for wind solar hybrid and solar power plants we have delt with tubular batteries and operational maintenance aspect only and not for any VRLA battery I BATTERY ROOM AND LAYOUT Battery Room A battery room should have sufficient space for installing the battery stands and also for movement of personnel for servicing the batteries For this purpose a proper battery installation layout drawing should be prepared first and then the battery room design should be finalized considering the battery installation layout Sufficient gap should be provided between the wall of the battery room and the adjoining row of batteries to avoid electrical earth leakage Refer sample drawings attached LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 e www windsolarzone com Four Row Battery Layout 150 _ vvicith of Cell X No of Cells 129 Double Row Double Tier Layout Width of Cel
17. ery close to the battery bank The control battery room should be easily accessible for servicing LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com Trouble shooting The solar panels don t have any mechanical parts involved in it so there is no mechanical trouble shooting involved in it Also most of the time the solar photovoltaic panels mounting structure is fixed type and no tracking system is involved in it hence troubleshooting for the solar structure is not there Troubleshooting symptoms 1 Solar panels not giving the desired power even on bright sunny days RENEWABLE ENERGY 1 Dusty panels 2 Loose connection at panel terminals 3 Loose connection at the controller terminals 4 Loose connection at the battery terminal 5 Batteries are fully charged or sulphated 6 Cut in solar cables 1 Clean the panels at least once in three days 2 Tight all the loose connections found at solar solar panels 3 Tight all the loose connections found at solar charge controller 4 Tight all the loose connections found at battery terminals 5 Let the battery discharge or consult the battery manual from the battery manufacturer LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly
18. is fully charged most of the cells will show specific gravity more than that specified for full charge battery by the manufacturer Normally it is recommended specific gravity at full charge is 1 250 However many cells will have specific gravity above 1 250 The specific gravity of all cells are to be adjusted to 1 250 by taking out some electrolyte from the cell and adding some battery grade water While continuing the initial charging to allow the electrolyte and water to mix properly While adding water fill to the topmost level allowed This will make up for the evaporation loss and electrolysis loss of water during charging 7 Fix vent plugs and electrolyte level to indicators firmly on each cell 8 Clean all the cells especially the top portion with water and cloth so that all traces of acid is removed from the external part of the cells 9 If adequate time is available it is always better to discharge battery bank at C10 rate see the battery specs chart to 10096 discharge level and charging back fully This increases the battery effective capacity 10 The battery bank is now ready for connecting to the load commissioning LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com VI PREVENTATIVE MAINTENANCE PROCEDURE
19. itive terminals and two negative terminals of each cell use two cables for series connection from one cell to the next One cable to be connected to each set of positive and negative terminals of the adjoining cell 6 Before fixing the intercell cable connectors with nuts and bolts to the terminals smear petroleum jelly on the nuts and bolts and also on the terminals before tightening the fasteners 7 If the battery bank is installed in a double row double tier configuration the top two rows in the top tier should be connected in series and two rows in the bottom should be connected in another series Then the top tier and the bottom tier should be connected in series so that the positive terminal of the battery bank is available at the starting of upper tier and negative terminal of the battery bank is at the end of lower tier In case two battery banks are to be connected in parallel for doubling the capacity the top tier and the bottom tier will be connected in parallel that is positive end of top tier will be connected to the positive end of bottom tier which is just below it and same shall be done for the negative terminal parallel Here the positive terminal of the battery will be at one end of the top tier and the negative terminal will be at the other end of the top tier Please refer attached figure 8 After connection ensure that the vent plugs and electrolyte level indicator are normally fixed in place on each cell 9 Che
20. l X No of Cells 150 2300 The floor of the battery room should be preferably acid resistant and no inflammable materials are to be used inside the battery room The room should be well ventilated either by two open windows or by using suitable exhaust fan to enable continuous change of air inside the room A sink with a water tap is to be preferably located inside the battery room to enable washing away of acid spillage if it happens accidentally No sensitive electronic equipment is to be located inside the battery room It is better to avoid harsh direct sunlight to come inside the battery room Battery Stand Battery stands are ideally made from good quality wood coated with atleast two layer of anti sulphuric paint Alternatively mild steel battery stands can also be used if suitably coated with rubber rubberized paint good quality and thickness of epoxy It is preferable to use porcelain or hard plastics insulators between the battery stand and the floor to avoid earth leakage While it is preferable for batteries up to 48V it is an absolute must for high voltage batteries like 96V 120V 240 and above RENEWABLE ENERGY Phone 91 020 www windsolarzone com LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village T Off Pune Saswad Road Pune 412308 India y The battery stand is to be assembled and installed exactly as per
21. mp present data concerning wind speed wind speed average and preferably wind speed distribution Any municipality rules requirements regarding installation height requirements e g distance from building distance from airports sensitive areas etc Ownership of the full installation area Accessibility to the site Influence of the turbine on the environment e g shadow flickering noise emission It is important to keep a distance to next residence in order to not disturb the inhabitants by noise emission and shadow flickering of the turbine Normally there have to be at least 200m between turbine and next residence The following points are important for proper siting amp good power generation Distances between the individual turbines if multiple turbines are installed distance should be atleast 7XD where D is the diameter of the rotor This ensures that the wind turbine generator at the front does not block wind flow to the wind turbine generator behind it rotor of WIND TURBINE GENERATOR causes high turbulence that reduces the energy output of the next turbine Compared with single stand alone turbine there are also higher loads on the following turbine because of the increased turbulence Therefore the minimum distance between two turbines depend on the wind conditions and may be rotor diameters D in the main wind direction and 5 diameters in other direction To allow smooth flow of air and avoid turbulent flow to the turbi
22. n as the cell box container All positive plates are connected in parallel to the outside positive terminal and all negative plates connected in parallel to a negative terminal Direct current electricity can be delivered to and taken out from the cell through this terminals A lead acid cell has an open circuit voltage of 2V When multiple cells are connected in series the voltage of all cells are added say 12 cells connected in series will provide a total of 24V and all these cells together is known as a battery bank or more commonly Battery TUBULAR BATTERY A tubular battery consists of positive plates which are made of tubes holding lead dioxide all tubes joined together The positive plate is a flat pasted plate It has a flooded electrolyte design where electrolyte in liquid from is stored in the battery cell box The water in the electrolyte needs replenishment on periodic basis between once in 9 months to a year depending on the design of the battery The tubular battery is the steadiest among all lead acid batteries for heavy cycling or deep discharge and recharge operators Under repeated 8096 depth of discharge these batteries survive at least 1200 cycles of charge and discharge The life cycle can be increased to 2500 cycles if depth of discharge is reduced to 5096 and 5000 cycles if it is reduced to 2096 of battery capacity Generally in solar photovoltaic and wind solar hybrid power plant applications these type of batteries are
23. ne rotor turbines should be placed at a distance twice or more times the height of any man made structure The turbulent wind flow created by the structure generally extends vertically to twice the height of the structure so small structure may not have any impact on tall turbines Please see diagram no A amp C LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com gt Avoid areas of steep slope The wind on steep slope tends to be turbulent and has vertical component that can affect the turbine Also the construction cost for steep slope are greatly increased pls see the diagram D On the ridgelines and hilltops set the turbines back from the edge to avoid the impact of the vertical component of the wind pls see the diagram E Preferably select site with flat terrain where there are no significant obstacles around the proposed location of wind turbine up to a distance of 8L where L 2 25D 0 25 and D is the rotor diameter of the wind turbine LUMINOUS RENEWA
24. olarzone com IV ERECTION AND IN TERCONNECITON OF BATTERY BANK 1 Install the batteries cells on the battery stand as per battery stand battery erection drawing attached n a row the cells are to be postponed in such a way that positive terminal of one cell faces the negative terminal of the next cell and so on to enable connection in series 2 Ensure that each row of cells on the stand are positioned in an absolute straight line by matching the edge of all the cells in a row in a single line A piece of string can be used for aligning all cells in a row in a straight line There should be a small gap of about 10 20 mm between each cell in a row 3 Check polarity of each cell by a center zero voltmeter or any voltmeter and ascertain that when the positive of the voltmeter is connected to the positive terminal and negative of voltmeter is connected to negative terminal of battery the deflection from needle should be the same direction for all cells in series 4 Connect all cells in a row in series connection by connecting the positive terminal of one cell to the negative terminal of the next cell Repeat this for all other cells 5 For intercell connection use cables of adequate core size cross section supplied alongwith the battery The interconnecting cables of suitable length are supplied with the battery with both ends duly provided with cable lugs for fixing to the terminals with nuts and bolts If there are two pos
25. rge is to be imparted to battery on a periodic basis say between once in 45 days to 60 days 5 The proposal involves charging the full battery but at low approximately constant current of not more than 5 of battery capacity in amps This means for a battery of 1200 Ah max equalizing charge current will be 60 amps 6 Equalizing charging at above rate is to be continued till all cells show full charge voltage of 2 65 to 2 75 48V battery shows 66V and all the cells specific gravity become equal at around 1 250 for each cell 7 Equalizing charge increased the efficiency and life of battery and should be imparted once in 45 60 days during the entire life time of battery LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 m www windsolarzone com
26. rter on demand from the user Adequate wind speed for power generation is available for 8 to 9 months a year Whereas adequate Solar Photovoltaic power supply is also available for 8 to 9 months a year and is greatly reduced during 3 to 4 months of monsoon due to cloudy weather but high wind speeds compensates for the loss of solar power Disclaimers The information in this manual is believed to be correct and reliable However Wind turbines electrical power and battery systems and wind turbine mounting systems are all capable of causing death or serious injury or fire if incorrectly installed operated or maintained and LRES assumes no responsibility whatsoever towards usage of this info by the user for installation and operation of the system It is recommended that all activities are carried out by trained and competent personnel specification 1 subject to change without notice LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com SECTION B Micrositing Of small wind turbines Choosing the right type of wind turbine WIND TURBINE GENERATOR and its exact position are very important part This process is called as micrositing During micrositing many aspects have to be considered Wind conditions past a
27. s 4 Plyer L RES recommends the tilt up tower for Whisper 500 Whisper 200 and Air x 400 because it is cost effective and easy to install Also it can be raised or lowered by a single person with portable winch for inspection maintenance repairs to wind turbine The tilt up tower kit includes all the components amp fastness required to assemble the tower Following is the list of the tower components 1 Pipe 0139 OD x 5 5THK x 6000 long 3 nos 2 Base plate 12 THK x 460 x 460 1nos 3 Foundation bolt 1 x 12 high tensile half threaded 4 Nos 4 Gin pole assembly 1no 5 Base plate bolt with Nylock nut and washer M24 x 225 high tensile half threaded 1 no 6 5 8 x2 Nylock bolt and washer 16 nos 7 Turn buckle 8nos 8 D Shackle 12nos D Shackle LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 91 020 m www windsolarzone com 9 Guy rope 150mirs approx The tower is guyed in 4 directions each at 90 degree angle to the other At every joint of the pipe flange structure one set of 4 nos guy wires are fixed refer drawing below VIEW AT X 1 Pipe 0139 OD x 5 5 thk x 6000mm long 2 Base plate 12 THK x 460 x 460 3 Nylocknut Washer bolt M24 x 225 High tensile Half threaded 4 Nylocknut Washer bolt 5 8 x 2 High tensile
28. should held allowing the winch to pull against the tension until the tower is vertical or the gin pole is on ground LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412306 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com d Check the side guy wire tension check the security of the wire rope clips e Maintain tension on lifting cables with winch use a carpenter s level on base tube to adjust the guy wire until the base tube is vertical insure that the tower is straight by sighting up the tower while the final guy adjustment are being made Guy rope LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 64011044 65110453 460 www windsolarzone com 12 Lowering the tower The procedure is just the reverse of raising although certain precautions must be taken Wind Turbine Installation a Assemble wind turbine refer Whisper 500 Manual blades not to be fitted with
29. t to 1096 of the required volume of electrolyte 6 If the battery is not installed immediately store the battery cells in cool and dry place and avoid direct sunlight The electrolyte and water should be stored away from any sensitive electrical or electronic equipment Battery received in charged condition Some manufacturers supply batteries or cells in fully charged condition 1 Inspect each battery cell for any physical damage 2 Check electrolyte level in each cell and top up electrolyte of same specific gravity if the level is found low 3 Check specific gravity of electrolyte of all cells If it matches with the value given by the manufacturer for specific gravity in fully charged condition the battery is deemed to have been received in fully charged condition In case the specific gravity is lower than recommended the battery will require a charge to increase the specific gravity to required level and fully charge the batteries 4 Check the voltages of each individual cell and it should be between 2V and 2 1V per cell If the voltage of any cell is less than 2V it is possible that there is a defect in that cell 5 If not installed immediately store the batteries cells in a cool and dry place LUMINOUS RENEWABLE ENERGY SOLUTIONS PVT LTD Formerly UD Energy Systems Pvt Ltd Gat No 1569 B Vadki Village Off Pune Saswad Road Pune 412308 India RENEWABLE ENERGY Phone 491 020 www winds
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