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Photovoltaic Systems Training
Session 3 ‐ Plant Operation
http://www.leonardo-energy.org/training-pv-systems-design-construction-operation-and-maintenance
Javier Relancio & Luis RecueroGeneralia Group
September 21st 2010
PHOTOVOLTAIC SYSTEM
Design, Execution, Operation & Maintenance
PLANT OPERATION
Javier Relancio. Generalia Group. 21/09/2010www.generalia.es
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INDEX
Control & Telecommunication system
Control system components & infrastructures
Control system gathered data management
Plant security
Security systems
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INDEX
Control & Telecommunication system
Control system components & infrastructures
Control system gathered data management
Plant security
Security systems
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Monitoring:
To control, using specially designed devices,
the state & evolution of one or various
physiologic (or others) parameters to detect
possible malfunctions
Reasons for monitoring & control:
1.- To invoice the produced energy
2.- To detect incidences & malfunctions
3.- To guarantee the plant owner
Remote control:
Group of devices which allow us to modify the state of the equipments and devices of the
plant, from a remote location
a) Availability
b) Performance Ratio
c) Production (kWh./kWp)5
Control & Telecommunication Systems: Introduction
DC / ACInverter
Photovoltaic Array Electricity
Grid
EnergyMeter
6
This presentation is based in Grid Connected PV Facilities
Both the meters and the inverters have communications outputs to allow the monitoring
of their parameters
We can also use: calibrated cells, temperature sensors, etc
Transformer
The remote control and monitoring depend on the available mechanisms.
Both in grid connected and stand alone PV facilities, electronic devices with communication
ports and dataloggers are used in order to gather the information from the different
equipment more important parameters
Control & Telecommunication Systems: Introduction
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Requirements:
Reliability: redundancy. Stable communications (wire)
Robustness: gathering errors, incidences & alarms
Solutions:
To be found in the market
Already developed.
From each manufacturer or generic (Many inverter & meter
manufacturers)
Customized solutions
They are more scalable and can be updated
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Monitoring System
The monitoring system features will depend on the capability for
each plant to afford its cost
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INDEX
Control & Telecommunication system
Control system components & infrastructures
Control system gathered data management
Plant security
Security systems
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Element Parameters Incidences
Panels ‐ String current
‐ Irradiance
‐ Module malfunctioning
‐ Isolating error
Inverter ‐ Instant power
‐ Produced energy
‐ CO2 Emissions
‐ Electronic failure (low
performance)
‐ Electric failure (stop)
Meter ‐ Produced kWh
‐ Load profile
‐Meter stop
Transformer
grid
‐ Phase voltage
‐ Frequency
‐ grid out of range
PV Facility main elements
Element Parameter Alerts / Warnings
Calibrated cell ‐ Radiation ‐ Low production, when high
radiation
Meteo Station ‐Wind speed
‐ Temperature
‐ High wind speed
Current sensors ‐ Current
‐ Voltage
‐ Overvoltage
‐ System breakdown
Protections ‐ State (ON / OFF) ‐ Trigger
Other elements within a PV facility
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Sensors
Inverter
Meter
Communications
Options:
1. Design
- Wire
- Wireless
2. Logic
- Without logic:
Converter
- With logic:
Datalogger
Control Room
Server
Display
Internet
Alarms
1.Data gathering
2.Data Analysis
3.Alert generation
4.Internet communication
5.Logs
Visualization
1. Locals:
Siren
2. SMS
3. E-mail
1. BBDD
2. Web
3. Tunnel
1. VPN
2. VNC
Datalogger
RS232/485
Ethernet
RS232/485
Monitoring System. Topology
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Monitoring system: Routine
Data gathering & Analysis
Correct
Performance: average or higher than average
Incidences & parameters log
Performance: lightly lower than average
Parameter analysis
Include modifications in preventive maintenance
Actions/Modifications on the system
- In situ or by Remote control
- Report generation
- Corrective maintenance order
Performance: lower than average
Failure diagnosis Alarm
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Gateway Server
ON/OFF switches for system reclosing (i.e. in case of breakdown)
Tracker Control
Monitoring System
Security system
REMOTE PC
INTERNET
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Remote control system. Basic topology
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Gateway Server
Tracker
Monitoring
system
Security
System
PC REMOTO
INTERNET - Updates
- Modifications
- Configuration
- New meters & inverters
- Updates
- Modifications
- Configurations
- Updates
- Modifications
- Configuration
An advanced remote control system requires larger bandwidth and robustness
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Remote control system. Advanced topology
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Internal communications
Data transference between devices, dataloggers, Server & Gateway.
Topology:
Wireless: Bluetooth, wifi, GSM/GPRS/UMTS, etc..
Wired: RS232, RS485, Ethernet, Optical Fiber, etc..
Converters’ usage: Moxa, etc..
External communications
To communicate remotely
Topologies: RTB, ADSL, Satellite, GSM/GPRS/UMTS…
Redundancy & robustness
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Communications
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Telephone
Network (PSTN)
GPRS UMTS Radio Satellite
Coverage
Bandwidth
Reliability /
Robustness
Cost
(Installing)
Cost
(Operation)
Communications
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GatewayConversor Ethernet –RS232/485
Meter BUS
Meter BUS
The electrical company remote meter reading, which is already being done in some countries,
as Spain, allows the electrical company (or the grid manager):
Avoid having dedicated staff to read the meter locally for invoicing
Receiving data from the meters, that well processed, can improve the grid performance
Modem GSM
Generator
GSM Modem
Electrical company
Gateway
Server
RS232/485
Remote Meter Reading(From the electrical company)
* In the future PLC communications could be applied
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Using the same system in different facilities
A system that works perfectly for a solar facility, may not work properly in a different one
due to different devices, SW versions, communication buses, countries, etc..
Solutions compatibility
Mixing commercial solutions from different manufacturers may produce system
malfunctions due to devices response times, transference times, bandwidths, etc..
Many solutions are still under development.
Coverage failure
Isolated areas. Without Telephone Network (PSTN), ADSL, UMTS or GPRS coverage
Losing the communication channel would mean losing 90% of the system features
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Usual problems
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INDEX
Control & Telecommunication system
Control system components & infrastructures
Control system gathered data management
Plant security
Security systems
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It is the last device in the system. The one that meters the energy
injected to the grid
We have to control that we are injecting the maximum energy to the
grid
We need references:
Radiation (calibrated cell) & temperature
Others: experience, reference facilities, etc
Operation orientated monitoring
Objective:
Maximize
productivity
The most important device is the meter
Example: If the temperature is raising continuously, it could mean:
A sporadic technical failure – REPAIR
A design failure – REDESIGN
The plant could stop.
The inverter can help to prevent future malfunctions
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To detect incidences as soon as possible (Real Time)
To predict some incidences & breakdowns
To solve some incidences & breakdowns
To warn the staff in the plant
The local plant staff can NEVER be replaced by any software or remote
control
It is essential to have spare parts and equipments at the plant
High electrical risk: training and protections
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Operation Key points
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Example: Valdecarábanos Solar Plant. Spain
Operation orientated monitoring
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Devices:
Inverter, suntracker, protections, monitoring system, security system
NEVER the meters
Reasons:
1. Save costs.
2. Legal requirement:
Requirement from the Electric Company: remote control of the
isolation cells (of the transformer)
Depending on each country regulations, the PV plants over a
certain output power could be obliged to be attached to a
generation control center
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Remote control system
Used to remotely control the devices in the plant
It will usually be linked with the monitoring system
Maintenance types
Corrective: to solve an incidence
Preventive: to prevent a possible incidence, before it happens.
Elements to maintain
Inverter
Suntracker
Panels (maintenance is required to a lesser extent): cleaning up,
replacement…
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Data sending for maintenance
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According to its seriousness:
Warning: minor failures. Many warnings can be expected. Generally, not
important
Alarm: serious failures. They should be minimized. They are important, and
could imply the plant stop
According to its origin:
Internal: from the inverter
External: from the plant.
DC side: from the panels to the inverter.
AC side: from the inverter to the grid
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Inverter maintenance
Failure classification:
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Isolation failure (cable without enough protection)
External failure: from the plant.
Low DC Voltage:
External failure: AC side problem (in the modules array)
MPP Tracking failure
External failure: a wrong configuration could produce a
deviation from the MPPT
Internal failure: Programming/Firmware problem
Grid voltage or frequency out of range
External failure: from the inverter to the grid
Temperature limit
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Inverter maintenance
Usual incidences:
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Orientation/Position failure
To check if it is synchronized or not
In case of strong wind, to check if it is in
protection state or not
Motor overvoltage failure.
Reducer breakdown
Limiting movement sensor
Overpass the end charging sensors without
activating the stop signal
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Suntracking maintenance
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INDEX
Control & Telecommunication system
Control system components & infrastructures
Control system gathered data management
Plant security
Security systems
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Reasons:
Expensive elements: inverters, panels, cable, etc
Many thefts
To avoid production losses (there are insurances which cover these losses)
Isolated areas
Long unattended periods (unless local staff is employed)
Great communication problems
The perfect solution does not exist.
But the best would be the combination of:
Local staff
Remote security systems
Security in the plant: Introduction
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The possible security systems could be:
Local staff
Video surveillance system (CCTV)
Perimeter sensors
Panel sewing
String controllers
Infrared / Microwave controllers
Security in the plant: Possibilities
The security systems keep evolving as the thieves develop new techniques
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Security in the Plan: General scheme
Source: PYSEC Seguridad
Solar plant security system
Real time mobile phone access
Real time internet access
Domo video camera
ADSL / GPRS
Control room
Optical Fiber
Acoustic & Luminous waning
Video analysis. Intrusion detection
Night mode video cameras
Local authorities warning system
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INDEX
Control & Telecommunication system
Control system components & infrastructures
Control system gathered data management
Plant security
Security systems
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Advantage
Very dissuasive solution
Drawbacks
The most expensive solution (in the Long Term)
It may reduce the plant profitability
Options
Employees
Outsourcing
The optimal solution would be Local Staff & Video surveillance
Local staff (In the plant)
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IP - based
Versatility
Good quality
Good transmission
Less wiring
CCTV
Closed TV Circuit
It requires dedicated
transmission buses
Video surveillance system
Source: Condev
CCTV vs IP
Recommended: IP
System
Digital Video Recorder (Encoder/Decoder)
D1 Real Time Quality
Great storage capacity
Optional:
Alarms & relays management
Remote control
Video analyzer
Using specialized software
Expensive
Movement detection
D1 Quality
- Full D1 video is 720x480.
- Cropped D1 is 704x480.
- Half D1 video is 352x480
Video Surveillance System: elements
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Video cameraThey can be IP or analogical
Quality: Up to D1 (Real time)
Long distance(Several Km*)Optical Zoom: 60x
InfraredLong distance
Night viewing (when the risk is higher)
Range: 1.5Km (0.00001 lux).
PTZ Control Automatic or Manual orientation & zoom control (Joystick).
* According to specs, up to 15 km.
Video Surveillance System: elements
Perimeter sensor system
Best solution: optical fiber system
Passive system: immune to storms or electrical
systems
False alarms discrimination
Alarm if the fiber is cut
Alarm if a movement is detected
Options:
At the wall. More vulnerable
Buried. More expensive (trench)
Temperature range: -30º to 75º
Movement/Passage areas
Anti – Intrusion systems
Rubber tube Metallic tube
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Presence sensor
Detects:
Infrared: thermal energy variations
Microwaves: movements
Configurable:
Alarm only if double detection
Problems in foggy areas
Alarm if any detection
False alarms
Anti-intrusion system
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Panel sewing (with optical fiber)
Attached to every panel (at the backside)
Alarm if the fiber is cut
Difficult execution
Temperature range: -30º a +75º
Another option could be a conductive wire system
Depending on the wire impedance
Immune to sabotage
Anti-theft system
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String Controller
Both for monitoring and security systems
During the days
It controls the power (Current/Voltage) on the panel strings
It protects the plant with integrated fuses
During the night
It detects if the electrical cable is cut/broken
Even if there is no voltage or current
This is quite a new system
Anti-theft system
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Local alarm:
Siren, Lighting, Speakers
Dissuasive
Local staff:
SMS, E-Mail, Phone call
To control, or to warn the authorities
Warning the authorities:
Private entity or the public authorities
We have to consider the distance from the authorities to
the plant
Siren
Study the inputs
-Plant visibility
-Distance to the
security entity
-Etc.
Two options:
- Dissuasive: to
avoid being stolen
- To try to catch the
thief
Alarm management
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Other possibilities
Virtual patrols
Nowadays, a possibility that can mean an important saving in physical surveillance is the
called "virtual patrol“
The virtual patrol simulates an ordinary guard patrol, but it is done from a remote central
of the surveillance company using a system of video cameras
Security for rooftop facilities
Usually, for this type of projects, no surveillance system is installed but the ones already
used by the clients, as this facilities are normally located in urban zones.
If the facility is located in an isolated area and the roof is not very high or difficult to
access, it is recommended to apply one of the security systems described within this
presentation
It is also recommended to have the “all risk insurance” in force.
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