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Implementation of a Low-Cost Smart Grid Device to Prevent Brownouts in Village Micro-Hydro Systems

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Implementation of a Low-­‐Cost Smart Grid Device to Prevent Brownouts in Village Micro-­‐Hydro Systems by Thomas Quetchenbach A Project Presented to The Faculty of Humboldt State University In Partial Fulfillment Of the Requirements for the Degree Master of Science In Environmental Systems: Environmental Resources Engineering Option August, 2011 Abstract Implementation of a Low-­‐Cost Smart Grid Device to Prevent Brownouts in Village Micro-­‐ Hydro Systems Thomas Quetchenbach Brownouts are a common problem in micro-­‐hydro mini-­‐grid systems due to the limited supply of power and the difficulty of restricting usage. The GridShare is a device designed to alleviate brownouts by limiting peak power and encouraging load-­‐shifting to off-­‐peak times. The device is installed at each household’s electrical service entrance and measures voltage and current consumption. Indicator lights inform the customer whether a brownout is occurring; if the customer attempts to use large appliances, such as rice cookers, during a brownout, the GridShare disconnects power to the house until appliance is turned off. The objective of this master’s degree project was to advance the design of the GridShare device from a prototype to a production design ready for small-­‐ scale manufacturing and to manufacture, assemble, and test enough GridShare devices to perform an installation in the village of Rukubji, Bhutan. Based on our testing and a field visit by the GridShare team in June 2010, several changes were made to the circuit design, and several prototype devices were built. To enable the production of 120 GridShare devices, a printed circuit board was designed, allowing automated fabrication and assembly. A comprehensive testing protocol was developed to evaluate the device’s ability to withstand the electrical and environmental conditions at the installation site, including exposure to low voltage and frequency and low and high ambient temperatures. The final version of the GridShare passed all tests; 120 devices were manufactured, shipped to Bhutan, and installed in Rukubji in June 2011. Further work will be needed to assess effectiveness and user satisfaction. ii Acknowledgments Funding for the GridShare project was provided by a grant from the United States Environmental Protection Agency’s People, Prosperity, and the Planet (P3) program. My participation in the project was made possible by a fellowship from the National Science Foundation (Award #1011464) through the Division of Graduate Education. In addition, sponsorships from Sunstone Circuits, Screaming Circuits, and Industrial Electric in Arcata helped make the GridShare a reality. The Schatz Energy Research Center provided financial and administrative support as well as laboratory space and machine shop services. The GridShare project would not have been possible without the help of so many people that it is impossible to name them all. Special credit goes to my supervisory committee, which consisted of Dr. Eileen Cashman, who provided invaluable assistance in writing this report and navigating uncharted waters of administrative paperwork; Dr. Peter Lehman, who also served as a faculty mentor to the GridShare team and was instrumental in keeping the project on track; and Dr. Charles Chamberlin, whose high standards for technical writing helped prepare me for this project. In addition, special thanks are due to Dr. Arne Jacobson for getting me involved with this project and for taking time from his busy schedule while on sabbatical to continue to provide the group with valuable advice. I extend special gratitude to James Apple for laying the groundwork for my project; to Meg Harper for her organizational skills, motivation, and encouragement; to Kyle Palmer for his technical expertise; and to Nathan Chase and James Robinson for their enthusiasm and dedication. Thanks are due to Kirstin Hervin for her excellent work on the educational materials and help with assembly, as well as to the many people who helped with assembly and testing, including but not limited to Kristen Radecsky, Zachary Stanko, Mark Rocheleau, and Rowan Beckensten. I would also like to thank Allison Oakland, Carolyn Ortenberger, and Alina Taalman for their efficient handling of finances, purchasing, and administrative paperwork, as well as the rest of the staff of the Schatz Energy Research Center for their support, encouragement, and advice. The project would not have happened without our in-­‐ country contact, Chhimi Dorji, who was essential in our communications with Bhutanese corporations and the Bhutanese government and in arranging our travel, or without the support of the Bhutan Power Corporation and the Bhutan Department of Energy. Rick Mayberry provided the group with valuable technical oversight and advice. Last-­‐minute packing assistance from Jessica, Chris, and the rest of the team at Post Haste in Arcata was also greatly appreciated. I would also like to extend special thanks to everyone who assisted us with our installation efforts in Bhutan, including Chhejay Wangdi and his staff at BPC Electricity Services Division Wangdue Phodrang office, who did excellent work and helped us finish the installations ahead of schedule, and to Phub Gyeltshen and the people of Rukubji for their incredible hospitality. Finally, I would like to thank Shilo for her assistance with proofreading and for her constant support and encouragement and for her willingness to not only put up with me during this process but to get married to me at the end of it. iii Table of Contents Chapter 1. Introduction and Background ...................................................................................................... 1 1.1. Introduction .................................................................................................................................................. 1 1.2. Project Site ..................................................................................................................................................... 1 1.3. Micro-­‐Hydro overview ............................................................................................................................. 2 1.4. Mini-­‐grids ....................................................................................................................................................... 3 1.5. Mini-­‐Grids and Brownouts ..................................................................................................................... 4 1.6. Micro-­‐Hydro in Bhutan ............................................................................................................................ 5 1.7. Rukubji Micro-­‐Hydro System ................................................................................................................ 6 1.8. The Brownout Problem in Rukubji ..................................................................................................... 9 1.9. Cooking and Appliance Usage ............................................................................................................. 10 1.10. House wiring in Rukubji ..................................................................................................................... 10 1.11. Project History and People ................................................................................................................ 11 Chapter 2. GridShare Circuit Design .............................................................................................................. 12 2.1. First Prototypes ......................................................................................................................................... 12 2.2. GridShare Installation Options ........................................................................................................... 13 2.3. Design criteria ............................................................................................................................................ 14 2.4. Changes Identified by GridShare Team ........................................................................................... 15 2.5. Voltage regulator selection ................................................................................................................... 16 2.6. Transformer upgrade ............................................................................................................................. 16 2.7. Relay upgrade ............................................................................................................................................ 17 2.8. Current transformer change ................................................................................................................ 17 2.9. Frequency measurement ...................................................................................................................... 17 2.10. Circuit protection ................................................................................................................................... 18 2.11. Software changes ................................................................................................................................... 19 2.12. PCB design and construction ............................................................................................................ 24 2.13. Prototypes ................................................................................................................................................. 26 2.14. Enclosure
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