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A Power Plant Controller (PPC) is used to control and regulate the networked inverters, devices and equipment at a solar PV plant in order to meet specified setpoints and change grid parameters at the Point of Interconnect (POI). Site operators can communicate these setpoints and parameters to the PPC either directly, or more commonly through a SCADA system.
A PPC allows operators to control plant behavior in terms of grid stability, compliance, production levels and revenue. Though the specific requirements may vary, most PPCs can regulate voltage, frequency, reactive power, active power, power factor and ramp control.
There are also maintenance applications. Operators can use the PPC to perform remote starts/stops or other troubleshooting actions on trackers, inverters, breakers and other field and substation equipment.
We are often asked by solar PV plant owners and operators about the difference between PLC versus PC-based controllers. Let's look at the benefits and limitations of each, and how they tie in with typical site requirements.
Is a PPC a requirement by the IA, PPA or other?
Utility scale plants have Interconnect Agreements (IAs) and Power Purchase Agreements (PPAs) that require the ability to curtail or to control to a specified power factor. These functions require a PPC. While there is no standardized capacity threshold, most sites above 10 megawatts require a PPC.
However, we are now seeing even very small sites require a PPC due to ISO or utility requirements for voltage or generation. This may be a smaller or pared-down version of a PPC.
Can a PPC be used to control a BMS (Battery Management System) for projects having an energy storage component?
Yes, and it's becoming more common. At Nor-Cal, we're seeing many more requests from EPCs for our PPC to interface with their onsite BMS systems. The purpose is to set up charging and discharging at given time frames or given site requirements. There are some exciting developments in this area as we coordinate with BMS manufacturers and vendors.
What is the difference between a PLC-based PPC and a PC-based PPC?
A Programmable Logic Controller (PLC) is a dedicated piece of hardware that controls devices or processes based on pre-programmed, closed-loop logic. A PC or software-based PPC is a software that is installed on a server or PC and runs off of an Operating System (OS) like Windows or Linux.
What are some examples of each type of PPC?
At Nor-Cal Controls, we predominantly use GE RX3i controllers and Allen-Bradley ControlLogix PLCs for our systems. These are slot-based hardware PLCs that can communicate with field or substation devices and equipment via several network protocols. They can be hardwired or soft wired as needed.
We don't typically take onprojects with software-based controllers, however, some other SCADA providers do. They have proprietary software that is used for coding on their own Linux or Windows based systems.
It is also possible to create a kind of PID controller or pseudo PPC using certain HMI software. We use an HMI software called Ignition. Though it can't act as a full PPC, it does have some logical features that allow basic controls. So, in a sense, some HMI software can act similarly to a software-based PPC.
Are there any benefits to using one over the other?
Our reasoning in using hardware-based PLCs for our projects is that if a server or PC is compromised and goes down, a PC-based controller will no longer be intact, functional or operational. This may result in non-compliance issues with the PPA or IA. A hardware-based PLC can keep operating even if a server goes down due to its pre-programmed automatic function.
Windows machines often require updates, caches and simple reboots, which may take the Windows-based software PPC down. Barring some sort of network or power outage, a hardware PLC will always be online and controlling, even if you're doing updates or there's something else going on within your system.
With the specialized hardware and software that is required for hardware-based PLCs, their only downside is that they do come at a higher initial cost than PC-based controllers.
Are there any limitations to either? (hardware, software, support, functionality, etc.)?
Conventional hardware PLCs often have a more rapid response time than those that are software based. They are able to react to the external plant and the grid within milliseconds. Software-based PPCs will be limited to the specifications of the PC itself, apart from the specifications of the software and hardware. Physical, dedicated PLCs are so fast and robust because they have fewer functional responsibilities, whereas software-based PPCs have many.
This can also be viewed from the flip side. A physical PLC is great at its one job, but there are not many features you can add outside of that like you can with software-based PPCs. They're very rugged and robust, but they are less flexible in the way of modifiability or the ability to modify from a larger scale.
What project related factors dictate which type of PPC should be utilized (i.e. should a PC-based PPC only be used for smaller power plants, having less devices and points to monitor and control?)?
This involves due diligence on the part of the SCADA provider in reviewing the specifications, IA and PPA requirements. Owners may also require a dedicated control.
In our many years of project experience, we've found that the more data points and devices there are to control, the more strongly we recommend a hardware-based PPC. Reaction time of the controller is also a factor.
Smaller power plants may be able to use a PC-based controller if needed because they don't have to meet as strict of standards as the larger scale grid utility projects.
Are there any support considerations?
In our experience, support for either the PC or hardware-based PLCs really depends on the company or vendor you're going through. Either type of PLC can have outstanding or poor support; it's a case by case basis.
Learn More About PPCs
Now that you've learned about the types of PPCs, take the next step in discovering how they do their job. Our article on Power Plant Controllers: Typical Requirements for PV Sites covers the controls PPCs use to regulate active and reactive power in order to meet power requirements and support a stable grid. It also covers how PPCs tie in with the CAISO Automated Dispatch System (ADS).
If you have any questions about how Nor-Cal can help with your PLC programming, SCADA commissioning or any other aspect of your solar PV plant controls, please schedule a call today.
What added value can our product offer? How can we create an appealing design? And which channels should we use to reach our target groups?
These are a few of the questions that startups tend to ask themselves during the product development process. But production planning is just as important. Before you get into the details of marketing and distribution, you should carefully consider your product manufacturing processes. In this article, we&#;ll explain why production planning is so vital &#; especially for startups &#; and how you can put it into practice.
Startups: Focus on Product Development
Product development is one of the biggest challenges for startups. Today, there are plenty more startups turning to alternative production concepts such as the Minimum Viable Product (MVP). It&#;s a great way for your company to get a head start, but unfortunately, the MVP is not always enough. That&#;s why smart production planning might just be your ideal solution.
What is Production Planning and Control?
Production planning encompasses the entire production process.&#;It&#;s the&#;theoretical foundation on which actual production methods are built. It&#;s usually combined with production control and referred to as Production Planning and Control (PPC). This covers the operative, temporal, quantitative and spatial planning of all processes necessary for product manufacturing.
What does PPC include?
Comprehensive production planning, for most&#;industrial companies, includes:
Production Planning and Scheduling
:
W
hich products to manufacture
,
the lead
time
,
and&#;
quantity
.
If you are looking for more details, kindly visit PPC Plant.
Material Requirements Planning:
Integrated control system calculating the materials and component
s
required to manufacture the product in the desired quantity and quality.
Production Process Planning:
The manufacture of the products is divided into various subtasks. The focus is on the production of
individual components, assemblies, and the actual assembly of the products.
To get started, it&#;s enough if you understand that production planning ensures that all production processes run smoothly. If you&#;re interested in learning more, then you&#;ll find details in our free whitepaper: &#;Start-Up: Challenges & Opportunities&#;.
Production Planning and Control for Startups
Think carefully about what your production plan looks like if you manufacture physical products. Established medium-sized companies or large industrial groups have&#;the advantage of experience, the capital, and manpower to boost production. In most cases, all the necessary machines and systems&#;are available, meaning that manufacturing new products is no longer a major challenge.
Obviously, things are a little different for startups. The budget and resources are limited. However, this situation comes with advantages. You&#;re not stuck with rigid structures and can customize your production planning &#; from the outset &#; in a way that suits you and your start-up. In other words, while the established competition is losing efficiency with partly outdated methods and inflated workflows, you benefit from lean processes that have a positive impact in the long term.
Production Planning and Control Systems
Steps
Regardless of the industry you work in or the physical product you want to manufacture, your goal is to seek an efficient production that wastes as little time and resources&#;as possible. For this to succeed, you should plan this step by step:
- Product analysis:
Manufacturing a prototype or a Minimal Viable Product (MVP
) and testing it should be your priority. Get customer feedback and
discover potential production process issues as well as your
customers&#;
requirements for this product.
- Involve experience partners:
Seek out
supplier
s wi
th
experience in designing different production processes. T
hey might be able to share some with you
.&#;
- Work out the costs: Cl
ear cost planning is essential to production planning.
Get
an accurate
overview of the costs of materials,
workforce,
and the ongoing
production expenses
for the machinery and equipment.
Finally, make sure you compare the supplier prices.
- Production type:
T
here are two major types of production: mass and series production.
Obviously, variants exist
.&#; But the best type of production for you depends on your product and your options. Garment
production tends to come with low unit costs.
On the other
hand,
acq
uiring
suitable machines that can handle this is comparatively expensive.
- Validation testing: Is your
production planning in place and prototype or MVP developed?
If so, it&#;s time for some validation testing. Produce a batch
that isn&#;t intended for sales but
is meant to
highlight any final
errors in your production process
.
These steps are subject to change but give you an idea how a production planning&#;design should look like. However, another aspect to consider is the use of software solutions.
Product Development and Production Planning Networking
Product development often involves marketing and sales right from the start, whether you&#;re an established company or a start-up. However, production teams tend to be forgotten and are clearly as important. They can share their knowledge and expertise on the technologies to use, the production concept, and planning at an early stage.
Ideally, you want to mix the production and development teams with marketing and sales. Together, they can evaluate customers&#; feedback and carry out competitor analyses. The advantage is that it brings knowledge and experience from various team members while ensuring nothing is left out.
In Our Experience&#;
With the right software, production planning is easier, faster, and offers more transparency. PLM platforms provide an array of solutions for anyone involved in the production planning. Benefit from SIMULIA for virtual product tests, or DELMIA for Product Data Management (PDM) and Production and Assembly Planning.
The result is an efficient production plan and a quick market launch tailored to the requirements of the target groups. However, proper production planning can be simple and complex at the same time, and a strong partner such as TECHNIA can advise you during the initial stages of your production development. So, when can we help?
For more Hydrogen Peroxide Production Plantinformation, please contact us. We will provide professional answers.