Instrumentation Design Considerations for Digital Energy ...
Transcript of Instrumentation Design Considerations for Digital Energy ...
Jonathan P. Murray Bloomy Energy Systems
Business Unit Manager
Instrumentation Design Considerations for
Digital Energy System Monitoring and Control
Who We Are
▫ Vertical business unit of Bloomy Controls Inc.▫ Founded in 1992
▫ Windsor, CT; Marlborough, MA; Fair Lawn, NJ
▫ NI Platinum Alliance Partner since program began
▫ NI Certifications
▫ 16 Certified LabVIEW Architects
▫ 4 Certified TestStand Developers & Architects
▫ 17 Certified Professional Instructors
▫ Dedicated System Engineers for Energy Applications
What We Do
Provide test, data acquisition, and control products to
battery, automotive, and grid storage companies
Why We Do it
Major power disturbances in North America
We need updated Energy Systems…
How we can help:
Energy Storage Systems
Smart Grid technologies
Renewable Energy
Goal
Choose the right reconfigurable I/O (RIO) platform to
digitally monitor and control energy systems.
sbRIO
cRIO
PXI WSN
Design Considerations
▫ Channel count
▫ Channel distribution
▫ Sampling rates
▫ Resolution
▫ Accuracy & Precision
▫ Synchronization
▫ Isolation
The following design considerations need to be addressed
when determining the correct platform
Agenda
▫ Review Design Considerations
▫ Applications and Considerations
▫ Portable Renewable Energy Storage System
▫ Energy Storage System Performance Testing
▫ Micro Grid Monitoring System
▫ Wind Turbine Control and Monitoring
▫ Lessons Learned
▫ Questions
Channel Count and Distribution
Few channels
Many channels
Distribution
Sampling Rate
Samples acquired per unit time (usually seconds)
sampling too slowly:
- aliasing
- missed data
- introduction of nonexistent components
Nyquist Theorem
(2x highest frequency)
8x or better to acquire wave shape
Resolution
Number of discrete digital levels used to represent a
continuous analog signal
Example:
0 to 300V analog signal
8-bit ADC = 1.17V / digital level
24-bit ADC = 0.005V / digital level
Higher resolution:
- detect smaller amplitude changes
- reduce quantization error
Voltage
Time
Resolution
Reported digital level
Actual analog level
Quantization
error
Accuracy & Precision
Accuracy: How close the measurement is to the actual (true) value
Precision: How repeatable is the measurement
High Precision
Low Accuracy
High Accuracy
Low Precision
High Accuracy
High Precision
Use calibration techniques to achieve higher accuracy
Synchronization
Timing required to coordinate events to operate a system in
unison
Distribution Synchronization Methods:
- GPS
- IEEE 1588 (precision time protocol)
- IRIG-B
System and Channel Synchronization:
- Common clock
- Ensure data acquisition channels have
dedicated ADCs (simultaneous sampling)
Critical for power analytics
Isolation
Passing a signal from source to measurement device without a
physical connection
Common Methods:
- Analog Optocouplers (PCB level)
- Digital Isolation (PCB level)
- Isolation transformers (system level)
- Voltage / Current transducers (system level)
- Fiber optics (system level)
Case Study: Energy Storage System
Onboard Monitoring
▫ Portable Renewable Energy Storage System ▫ 4kW energy storage
▫ AC/DC bidirectional converter
▫ Inputs
▫ AC input
▫ DC input
▫ Renewable: Solar Panels
▫ Outputs
▫ 120 and 240 AC
▫ 28V DC
▫ NATO compatible
CACI proprietary
trailer design
Case Study: Energy Storage System
Onboard Monitoring
▫ Deploy an embedded monitoring system to display vital
ESS information to soldiers.
▫ Incoming, available, and outgoing power
▫ Create an engineering view to monitor all critical steps in
power conversion and storage
▫ AC and DC voltages and currents
▫ BMS, master controller communications
▫ Temperature
▫ Light
Case Study: Energy Storage System
Onboard Monitoring
▫ Design Considerations:
▫ Driving factor:
▫ Channel distribution: embedded (size constraints)
▫ Other considerations:
▫ Channel count: 20 voltage, 30 currents, 12 TC, RS232, CAN
▫ Sampling rates: 2Hz to 1 sample/15minutes configurable
▫ Resolution: course, 16bit was sufficient
▫ Accuracy: 1%
▫ Synchronization: not required, RMS power only
▫ Isolation and conditioning: PT, CT transducers
Case Study: Energy Storage System
Onboard Monitoring
▫ RMS power measurements: ▫ Apparent power (VA) only
▫ RMS transducers
▫ Simultaneous measurements not required
Synchronized acquisition loops for each NI cRIO
9205 produces negligible phase shift between
voltage and current channels
▫ Phasor power measurements: ▫ Wave shape acquisition
▫ instantaneous transducers
▫ Simultaneous measurements required
Case Study: Energy Storage System
Onboard Monitoring
Platform of choice: CRIO
Case Study: Energy Storage System
Onboard Monitoring
Soldier View
Case Study: Energy Storage System
Onboard Monitoring
Engineering View
Case Study: Energy Storage System
Performance Testing
▫ Test 25kW to 2MW energy storage systems
▫ Evaluate performance for application-specific operations
▫ 200+ mixed signal acquisition channels
▫ Generate industry reports
▫ AC Input ▫ AC Voltage and current
▫ AC Power ▫ Real power
▫ Reactive power
▫ Power factor
▫ Battery Storage ▫ DC voltage and current
▫ DC power
▫ Sample cell voltage and current
▫ Inverter ▫ AC voltage and currents
▫ DC voltage and currents
▫ Frequency
▫ System ▫ demand power kW
▫ Energy kWh
▫ Efficiency (DC/AC)
▫ Temperatures & Airflow ▫ Ambient (Inside and Outside)
▫ Battery
▫ Inverter
Case Study: Energy Storage System
Performance Testing
Measurements Tests
▫ Interconnect tests
▫ Startup / Shutdown / E-Stop
▫ Equipment failure
▫ Abnormal Grid Events
▫ Performance testing
▫ Power Rating
▫ Energy Rating
▫ Round trip efficiency
▫ Short / Long term test
▫ Application testing
▫ Frequency Regulation
▫ Peak Shaving
▫ Wind Farm Smoothing
Power quality measurements: NEN-EN-IEC 61000-4-30
Monitoring electric power quality: IEEE Std 1159-2009
Distributed power resources: IEEE Std 1547.1-2005
Case Study: Energy Storage System
Performance Testing
▫ Design Considerations:
▫ Driving factor:
▫ Channel count: over 200 channels
▫ Accuracy: 0.5%
▫ Sampling rates: 20kHz (total harmonic distortion)
▫ Synchronization: required for power quality analysis
▫ Isolation: 1200V, 2000A measurements
▫ Other considerations:
▫ Channel distribution: local to the trailer
▫ Resolution: hardware determined
▫ Total Harmonic Distortion (THD) ▫ Ratio of the sum of the power of harmonic components
to the fundamental frequency ▫ Fundamental frequency (f)
▫ Harmonics would be 2f, 3f, 4f…
▫ Usually cased by non-linearity of custom loads
▫ Harmonics can have the following effects: ▫ Distorted voltage and current waveforms
▫ Overheating of transformers & rotating equipment
▫ Neutral overloading (Triplen harmonics)
▫ Breakers and fuses tripping
▫ Wasted energy/high electric bills - kW & kWh
▫ Increased maintenance of equipment and machinery
Case Study: Energy Storage System
Performance Testing
Why sampling rate
is important:
31st harmonic @ 60Hz
31f = 1860 Hz
Required sampling rates:
(minimal) 2x = 3720Hz
(better result) 8x = 14880Hz
Case Study: Energy Storage System
Performance Testing
Platform of choice: PXI
Case Study: Micro Grid Monitoring
▫ Smart and Green Energy for Base Camps (SAGE)
▫ Reduce the quantity of fuel needed for electrical power
generation
▫ Focused components
▫ Alternative Energy Sources
▫ Smart Micro-Grid Technologies
▫ Storage and Power Generation
▫ Energy Efficient Shelters
All information is public knowledge provided on USALIA initiatives
Images courtesy of USALIA
▫ Develop and deliver a monitoring system to capture all
major base camp signals:
▫ Weather
▫ Temperature
▫ Gas flow
▫ Water flow
▫ Power
▫ Continuous monitoring for days to months
▫ Base camp components span 1000ft2
▫ Aggregate data for future analysis (DIAdem)
Case Study: Micro Grid Monitoring
Case Study: Micro Grid Monitoring
▫ Design Considerations:
▫ Driving factor:
▫ Channel distribution: 1000ft2
▫ Other considerations:
▫ Channel count: 60
▫ Sampling rates: minimum 1 samples / 5 sec.
▫ Resolution: hardware driven
▫ Accuracy: hardware driven
▫ Synchronization: windows clock
▫ Isolation and conditioning: transducers
Case Study: Micro Grid Monitoring
▫ Platform of choice: WSN
▫ Pro’s:
▫ Wireless connectivity
▫ Onboard programming
▫ Wireless updates
▫ Battery operated
▫ Con’s:
▫ External sensors still need power
▫ Limited channel types
▫ No direct write to data base
Weather stations
Flow
Temp
Power Meters
Case Study: Micro Grid Monitoring
Case Study: Wind Turbine Control and
Monitoring
▫ 6kW and 100kW turbine R&D
▫ Monitors and record turbine and
environmental signals
▫ Control turbine position to
optimize energy and power
generation
Case Study: Wind Turbine Control and
Monitoring
cRIO
Tower base
Turbine
Turbine
Control
cRIO
Nacelle Transformer Hut
Hub
Metrology Tower
cRIO
Metrology
cRIO
Transformer
• Rotor speed/position
• Turbine Yaw position
• Stator flaps control
• Braking system control
• Wind speed/direction
• Turbine strain
• Power
• Wind speed and direction
• Temperature
• Pressure
• Humidity
• Tower strain
• Power
• System interface
▫ Design Considerations: ▫ Driving factors:
▫ Channel distribution:
▫ Cover a large area
▫ Embedded in turbine
▫ Sampling rate: 10kHz+ control loops
▫ Synchronization: simultaneous inputs for control loops and power measurements
▫ Interface: must run headless, remote update and monitoring
▫ Other considerations:
▫ Channel count: 100+
▫ Resolution: hardware determined
▫ Accuracy: hardware determined
▫ Isolation and conditioning: PT, CT, anemometers, external sensors
Case Study: Wind Turbine Control and
Monitoring
Platform of choice: cRIO
Case Study: Wind Turbine Control and
Monitoring
Case Study: Wind Turbine Control and
Monitoring
Case Study: Soldier-Borne Power
Monitoring
Develop a power monitoring system to acquire, record and display the average and peak power draw of soldier borne electronics and electrical devices.
▫ Wearable and portable
▫ Low power, light weight
▫ No tethering wires to devices
▫ Integrated sensors measuring current and voltage
▫ Wirelessly route data from soldier
▫ Continuous and transient data (100kS/s/ch)
▫ Open and modular architecture
Case Study: Soldier-Borne Power
Monitoring
▫ Design Considerations: ▫ Driving factors:
▫ Channel distribution: (onboard soldier)
▫ Light weight, low power
▫ Channel count: 40 (32 wired, 8 wireless)
▫ Sampling rate: 100kS/s/ch
▫ Resolution: 16bit
▫ Emissions and Interference testing
▫ Other considerations:
▫ Accuracy: hardware determined
▫ Isolation and conditioning: custom voltage, and current sensors
▫ Synchronization: RT time stamp
System could not be
larger than an MRE
Case Study: Soldier-Borne Power
Monitoring
Block Diagram
Case Study: Soldier-Borne Power
Monitoring
• 32 16-bit analog input channels
• 100 kS/s/channel Sampling Rate
• Xilinx FPGA
• 3.2 MHz Clocking Rate
• 8 High-Speed DIO Lines
• sbRIO 50-pin header plug
Platform of choice: sbRIO Custom Hardware
Wireless Sensors
Case Study: Soldier-Borne Power
Monitoring
Lessons Learned
▫ Perform end-to-end calibration to assist with overall accuracy
▫ Choose the right power transducer – RMS vs Instantaneous
▫ Isolation – essential contributor in high power systems
▫ Don’t assume the operator is going to use the system as intended (especially with High Voltage)
▫ Plan with the end goal in mind: ▫ R&D: select a platform where you can expand channel type and count
▫ Product: select a platform which can easily go to an embedded solution if high quantities are going to be produced