Hardware-in-the-Loop Emulator Test-Setup for a Dual-Rotor Contra-Rotating Pump-Turbine

Abstract

Recently, contra-rotating reversible pump-turbines (CR RPTs) have been proposed to increase the efficiency of low-head pumped hydropower storage applications, which are promising to provide energy storage for non-mountainous regions. To study the control architectures for these systems, a dual-rotor hardware-in-the-loop (HIL) emulator test-setup is developed. The HIL test-setup employs two induction machines controlled by separate regenerative variable frequency drives to emulate the torques on the two runners. A quasi-steady-state RPT model is developed based on 380 steady-state computational fluid dynamics (CFD) simulations and compared to three transient CFD simulations to analyse the dynamics. Furthermore, the runner torques are adapted to account for the lower friction and higher inertia of the HIL test-setup compared to the prototype CR RPT, ensuring accurate emulation. Finally, it is shown how precise calibration of the drive torque response averts torque errors related to the machine model estimator used in direct torque control. The developed emulator setup offers a cost-effective and controlled environment to optimise and validate control architectures for the novel CR RPT, providing a higher fidelity than theoretical simulation by including the physical effects of the drivetrain, electrical machines and converters that are not entirely captured in mathematical models.