instrumentation design considerations for digital energy
TRANSCRIPT
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Jonathan P. Murray Bloomy Energy Systems
Business Unit Manager
Instrumentation Design Considerations for
Digital Energy System Monitoring and Control
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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
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What We Do
Provide test, data acquisition, and control products to
battery, automotive, and grid storage companies
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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
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Goal
Choose the right reconfigurable I/O (RIO) platform to
digitally monitor and control energy systems.
sbRIO
cRIO
PXI WSN
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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
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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
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Channel Count and Distribution
Few channels
Many channels
Distribution
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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
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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
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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
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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
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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)
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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
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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
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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
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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
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Case Study: Energy Storage System
Onboard Monitoring
Platform of choice: CRIO
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Case Study: Energy Storage System
Onboard Monitoring
Soldier View
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Case Study: Energy Storage System
Onboard Monitoring
Engineering View
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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
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▫ 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
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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
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▫ 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
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Case Study: Energy Storage System
Performance Testing
Platform of choice: PXI
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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
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▫ 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
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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
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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
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Case Study: Micro Grid Monitoring
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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
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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
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▫ 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
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Case Study: Wind Turbine Control and
Monitoring
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Case Study: Wind Turbine Control and
Monitoring
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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
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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
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Case Study: Soldier-Borne Power
Monitoring
Block Diagram
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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
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Case Study: Soldier-Borne Power
Monitoring
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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