Track: Industry 4.0 and Industry Solutions
Abstract
Power management system is a term coined to illustrate the three sub components – power/energy management system, relay monitoring system and breaker management system. The objectives of the above are achieved thorough Supervisory Control and Data Acquisition system which uses a proprietary processor, its peripherals, OT & IT networking components, proprietary software to acquire the data and powerful dashboards & mimics to gain insights as well as control the power network remotely without compromising on cybersecurity.
300+ energy meters are installed at load points (motor control center (MCC), point of common coupling with grid etc.) and critical assets (generators, transformers, motors & breakers). These meters have communication capability and interfaces with the redundant CPU over the open source MODBUS protocol. These meters also measure the power quality parameters – voltage & current harmonics (up to 15th harmonic) other than the voltage, current, frequency, power, energy & power factor (p.f.) parameters and calculates the total harmonic distortion (THD). These data are then archived by the SCADA software every 500 milliseconds which provides insights regarding the power quality (voltage profile, harmonics, voltage & current unbalance) for subsequent actions (capacitor bank charging, tap changing, installing harmonic filters, load balancing etc.)
85+ communicable numerical relays installed at critical feeders and assets are connected to the processor and interfaces over MODBUS protocol. The fault data from the relays are archived and is available for the analysis. In case of series of tripping all the fault data is available from the system centrally. The data is analyzed by the system experts and the protection systems are tuned occasionally to prevent repetitive future failures.
225+ high voltage (H.V.), medium voltage (M.V.) & low voltage (L.V.) breakers can be controlled remotely. The tripping & closing coils of the breakers are hardwired with I/O peripherals which are installed in the remote input/output (RIO) stations (38 in locations distributed across the entire plant). The RIO stations interfaces with the central redundant CPU and communicates with the same over the proprietary PROFIBUS protocol. The breaker management system aids in network re-arrangement & restoration, fast load shedding (in case of generating unit outages), safe remote breaker operations and controlling idle loads.
The plant dashboards can be accessed through the 8 local human machine interfaces (HMI) installed for the shift-in –charges/operators and monitored and controlled through the two table top servers with HMIs by a dedicated team under the supervision of system expert. Important events are sent over a message to experts and field supervisors using an M2M (mobile to mobile) module for subsequent actions. The plant dashboards can also be viewed outside the plant premises over internet by connecting to the servers through the web browsers without compromising on cybersecurity (the servers SSL certified) providing the envisioned mobility and flexibility to the system.