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TEAM DETAILS

Team Name:- INFERNO

Team members-
1-Rishabh Banerjee (Team Leader)
2-Prem Kumar
3-Mohit Gupta
4-Rahul Chugh

Faculty Advisor-
Prof.Devulapalli Bhagwan Das(Department of Electrical
Engineering)
Proposal Idea
SMART MICRO-GRID SYSTEM
It is high time for us to realize the need of developing renewable sources of energy such
as solar energy, wind energy etc. An industry requires large amount of power for
running various motors, heavy machines. Solar Power is the most feasible and reliable
source of electricity whose setup can be easily installed at any industrial plant.

Smart Micro-grids are an ideal way to integrate renewable energy sources on the
community level and allow for customer participation in the electricity enterprise.
They form the building blocks of the Perfect Power System.
Smart Grid is an electricity network that can intelligently integrate the actions of all
users connected to it: generators, distributors, suppliers and consumers. This includes an
intelligent monitoring and controlling system that keeps track of all electricity flowing in
the system.
Problem Statement- REMOTE MONITORING AND CONTROL is the prime requirement of
industries today.
Factory Automation includes all the components/machines installed at a plant to be
monitored and controlled through a remote monitoring and control system. We must be
able to access all components installed, through our PC or mobile phone.
Explanation Highlighting the Theme
Smart Manufacturing is a part of Factory Automation. Industrial networking means
to control and monitor remote machineries in a system of PLCs, servos, inverters
etc.
The main aim is to use industrial networking for information processing and
control.
The use of solar ensure a clean and green energy source. The industry has options
to run either on hydel, solar or both.
Controlling and Real Time Monitoring can be done simultaneously ensuring a
better productivity and safety of the industry.
The developed application(mobile or pc) will be smart enough to deal with all
industrial problems(power cutoff, switchover, controlling motor speed or other
machines and monitoring various other faults) ensuring a hectic free life to
workers. Hence concept of SMART will be implemented.
Internet Of Things(IOT):- The application/ system can be controlled from
anywhere with just an e-mail. Monitoring can also be done remotely.

Hence the system is not just ECO FRIENDLY but SMART too.
Innovation In Proposal
The proposed system will not just only switchover the sources(
solar, hydel, generator etc.) but will also continuously monitor
and control various machines(motors, pumps etc.) and
devices(inverters, energy meters etc.) attached to the system.
A feedback mechanism has also been developed to know that
whether a load is on solar, hydel or generator. Hence ensuring
proper working of the system.
Internet Of Things has also been included in the model. Hence
all the features of the system can be accessed remotely from
anywhere.
An extra feature of Generator as source has also been proposed
so that in even in case of solar and hydel failure the monitoring
and controlling can be done efficiently and properly.
The application will be User Friendly that even a layman can
understand and use it.
The application will be developed in such a way that it can
suggest and can take decisions on its own. Therefore making the
life of the workers easy.
SYSTEM DESIGN
PROBLEM STATEMENT
The project is a small step in the direction of establishing a Smart
Micro-Grid. The main challenges in this project are as follows,
1. PLC based Remote controlled changeover
2. Flexibility to select the source for each circuit.
3. Real Time Monitoring and Controlling.
4. Connectivity through LAN throughout the Industrial network.
5. An Application to remotely monitor and control the system.

REMOTE CONTROLLING OF SWITCHGEARS PROS AND CONS

With relation to power systems, the operation of the switchgears requires


constant monitoring of the system to decide when to switch from one circuit to
the other. This is a major drawback if the system size is vast and the number of
decisions is high. Also if the power system has multiple sources of generation such
as the conventional grid supply and its own renewable energy generation then the
role of these switchgears becomes crucial as they decide which source to supply
the power from.
Hence one simple solution to this problem is the remote monitoring and control of
the Switchgears from a centralized location.
SYSTEM DESIGN Contd.
SYSTEM DESIGN CONSTRAINTS

The foremost challenge in the project is the planning of the hardware. The main constraints
for this process are as follows,
The power circuits are high power circuits while the typical control and monitoring
circuits are low power circuits. Thus, the system hardware should be such that it
seamlessly links the high power circuit to the low power circuit.
The system would be choosing between two different sources, solar and hydel, for
powering the any circuit. Since, these two sources are not synchronised, the system
should connect the circuit to only one of the two sources. If this constraint is not met,
then due to phase difference between the two sources, a large local current will flow in
the circuit which will certainly damage the control system and cause faults in the power
system.
The system should be able to sense the status of the circuits coming out of the SPV
power station. Sensing the status essentially means to identify the source driving that
circuit.
The system should be able to communicate with the command centre. The
communication should be bi-directional, i.e., the system should be able to receive the
commands from the command centre as well as send the status of the circuits to the
command centre.
The system should be able to identify the commands issued by the operator at the
command centre and act accordingly. Thus a certain level of intelligence is desired in the
control and monitoring system.
The system is to be designed focusing on these constraints.
SYSTEM DESIGN Contd.
System Software Architecture

Computer Languages Used: - C#, Ladder logic for PLC.


Computer Software and Tools: - Visual Studio IDE 2013, Mitsubishi
PLC(GX Works 2), HMI IDE.
Visual Studio will be used to develop the application on PC and an mobile
development app, which will display all the Monitoring Data from various
devices ( Inverter, PLC, Energy Meter etc.).The user can also control
various parameters of the device using the application.
The Software architecture is built in such a fashion that Real Time
Monitoring and Controlling can be done. The software will be smart
enough to take all the required decision without any Human Interface,
assuring full automation. Application has the feature to send all the data
to the users mail. The user can also control all the devices by sending an
email to the Applications E-mail account.
The Application will be installed in a server (in our case it will be a PC).
SYSTEM DESIGN Contd.
Internal Communication Architecture

LAN is used as a medium to communicate with the devices. Modbus TCP/IP


protocol is used to communicate with Inverter, Energy Meter and PLC.
Wireless communication can also be used by using a wireless router.
SYSTEM DESIGN Contd.
FILE AND DATABASE DESIGN

My SQL/ MS ACCESS/ MS EXCEL can be used as a DBMS. The front end will
have the access to the database. The data can be retrieved and can be sent
on web on users request by the Front End. Database will contain all the data
logs such as Faults, Speed of motor, Power Consumption and all the
parameters of the devices.
SYSTEM DESIGN Contd.
Human Machine Interface (HMI)

Human Machine Interface is used a Control Display Panel, production


Information Control Terminal and as a Information Data Terminal. MELSOFT
GT Works3 will be used for Screen designing of the HMI.
SYSTEM DESIGN Contd.
HARDWARE REQUIRED

1> PLC:- As given by Mitsubishi.


2> HMI:- As given by Mitsubishi.
3> Inverter:- As given by Mitsubishi.
4> Switchgears :- For switching between the sources.
5> 3phase Induction Motor.
6> SPDT Relays :- To control the Switchgears.
7> Gateway :- Serial to LAN converter.
8> Energy Meter.
9> RS485 Converter.
10> Computer:- to act as a Server.
SYSTEM DESIGN Contd.
REALIZATION OF SOLUTION
SYSTEM EXISTING AT FACULTY OF ENGINEERING, DEI, Agra
The following system is existing at the SPV power station at the Faculty of Engineering, DEI, Agra.
First and foremost there are contactors for switching between the sources, i.e., solar supply and the hydel
supply. A pair of contactors has been used for each circuit, one connects the circuit to the solar supply and
the other connects the circuit to hydel.
The contactor pairs used in the project have a mechanical coupling which ensures that only one of the two
contactors is switched on at any instant, thus preventing accidental shorting of the two sources. Since,
contactors are high power switches; they are a part of the high power circuit.
For the decision making unit, i.e., the brain of the system, we have used a microcontroller. The
microcontroller accepts the command issued by the command centre as the input, generates the
corresponding output signal intended for triggering the contactors, takes the status feedback from the
contactors and sends the status back to the command centre. The microcontroller communicates with the
Arduino Ethernet Shield through its Serial port and interacts with the contactors via its parallel ports. Since,
a microcontroller runs on a 5V regulated DC supply, it is a low power device and thus, is the part of the low
power circuit.
For linking the high power circuit with the low power circuit, Single Pole Double Throw (SPDT) relays are in
place. These relays run on a 12V DC supply. The coil of the relay is energised by the low power circuit while
the switch output drives the high power contactor circuit. A single relay controls a single contactor.
For linking the microcontroller to the relay bank, a bank of N-channel MOSFETs has been used . The gates of
the MOSFETs have been connected to the output side of the parallel port, the drain has been connected to
the 12V DC supply via the relay coil while the source has been grounded.
For the communication channel between the control & monitoring system and the command centre, we
have utilised the existing university Local Area Network (LAN). Thus, the microcontroller is connected to the
command centre via the university LAN.
Since our microcontroller communicates with the command server through its SPI while the Ethernet
Shield communicates directly in the Ethernet format, it converts the data coming in to the microcontroller
from Ethernet format to RS-232 format and vice-versa.
CONCEPTUAL DRAWING

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