The client built a new 10MW photovoltaic power station, needing to realize automated operation and remote monitoring, reduce operation and maintenance costs, and improve power generation efficiency. The main needs include: 1. Realize real-time monitoring of photovoltaic arrays, inverters, combiner boxes and other equipment; 2. Realize intelligent power prediction and output dispatching; 3. Realize automatic fault diagnosis and alarm; 4. Realize unattended operation; 5. Realize docking with grid dispatching system.

Case Detailed Content

1. Client Introduction

Jiangsu Green Energy Co., Ltd. was established in 2012, specializing in the development, construction and operation of new energy power generation projects, with main businesses including photovoltaic power stations, wind farms and energy storage projects. The company currently has multiple new energy power generation projects in Jiangsu, Anhui, Shandong and other places, with a total installed capacity of over 500MW.

2. Project Background

The client built a new 10MW photovoltaic power station in Yancheng City, Jiangsu Province. In order to improve the station’s operating efficiency, reduce operation and maintenance costs, and realize unattended operation, a complete automation solution is needed. The main needs include:

1. Realize real-time monitoring of photovoltaic arrays, inverters, combiner boxes and other equipment
2. Realize intelligent power prediction and output dispatching
3. Realize automatic fault diagnosis and alarm
4. Realize unattended operation
5. Realize docking with grid dispatching system

3. Solution Design

3.1 System Architecture

Adopt hierarchical distributed architecture design:

• Equipment layer: Including photovoltaic arrays, inverters, combiner boxes, weather stations and other equipment
• Collection layer: Collect equipment operation data through smart sensors, smart meters and other equipment
• Control layer: Use ZK-PLC500 series controllers to implement logic control and data processing
• Communication layer: Use industrial Ethernet and wireless communication technologies to realize data transmission
• Application layer: Photovoltaic power station automation platform, realizing data storage, analysis and visual display

3.2 Core Equipment

• ZK-PLC500 Series Controllers: Implement logic control and data processing
• Smart Sensors: Collect meteorological data such as temperature, humidity, wind speed, and irradiance
• Smart Meters: Collect electrical parameters such as current, voltage, and power
• Video Monitoring System: Realize video monitoring and security management of the power station
• Photovoltaic Power Station Automation Platform: Realize visual monitoring, data analysis and remote control

3.3 Main Functions

1. Real-time Monitoring: 24-hour real-time monitoring of all equipment operating status
2. Intelligent Power Prediction: Realize power prediction based on meteorological data and historical operating data
3. Output Dispatching: Optimize output dispatching according to grid requirements and actual station conditions
4. Fault Diagnosis and Alarm: Automatically diagnose equipment faults and send alarm information in time
5. Video Monitoring: Realize video monitoring and security management of the power station
6. Unattended Operation: Realize automated operation of the power station without manual attendance
7. Grid Docking: Realize seamless docking with grid dispatching system
8. Data Analysis and Reports: Generate detailed operating reports and analysis reports

4. Project Implementation Process

4.1 Demand Research and Scheme Design

The project team deeply understood the client’s needs, combined with the actual situation of the photovoltaic power station, formulated a detailed solution design, including system architecture, equipment selection, function design, etc.

4.2 Product Selection and Procurement

According to the scheme design, core equipment such as ZK-PLC500 series controllers, smart sensors, video monitoring systems were procured, and equipment acceptance and testing were conducted.

4.3 On-site Installation and Commissioning

The project team conducted on-site equipment installation and system commissioning, including:

1. Equipment installation and wiring
2. System communication network construction
3. Automation platform deployment and configuration
4. Function testing and optimization
5. Docking testing with grid dispatching system

4.4 Personnel Training and System Launch

Operational personnel training was provided to the client’s operation and maintenance staff to ensure they could skillfully use and maintain the system. After system launch, the project team conducted continuous tracking and optimization to ensure stable system operation.

5. Project Achievements

5.1 Economic Benefits

• Power generation increased by 8%: Improved power station efficiency through intelligent power prediction and output dispatching
• Operation and maintenance costs reduced by 50%: Realized unattended operation, reducing labor costs
• Fault response time shortened: From 2 hours to 15 minutes, reducing fault losses
• Return on investment: Investment payback period of about 3 years

5.2 Management Benefits

• Realized unattended operation: Improved management efficiency, reduced labor costs
• Established a complete operation database: Provided data support for subsequent optimization
• Enhanced corporate image: Demonstrated the enterprise’s technical strength and innovation capability
• Improved power station safety: Enhanced power station safety through real-time monitoring and security management

6. Technical Highlights Analysis

6.1 Artificial Intelligence Power Prediction

Adopted artificial intelligence technology, combined with meteorological data, historical operating data and real-time monitoring data, realized power prediction with accuracy reaching over 95%, providing strong support for output dispatching.

6.2 Automatic Equipment Fault Diagnosis

Through analysis of equipment operating data, realized automatic diagnosis and positioning of equipment faults, reducing operation and maintenance difficulty and improving fault handling efficiency.

6.3 Industrial IoT Technology Application

Adopted industrial IoT technology, realizing intelligent interconnection and data sharing of equipment, improving system reliability and flexibility.

6.4 Full Life Cycle Management

Realized full life cycle management of photovoltaic power stations, including design, construction, operation, maintenance and other stages, improving the overall management level of the power station.

7. Client Feedback

The client is very satisfied with this photovoltaic power station automation solution, believing that the system runs stably with complete functions, achieving the expected results. The client stated that through this project, the power station realized unattended operation, improved power generation efficiency, and reduced operation and maintenance costs, providing strong support for the enterprise’s development.

8. Experience Summary

Through the implementation of this project, we have accumulated rich experience in photovoltaic power station automation solutions:

1. Deeply understand industry characteristics: Fully understand the operating characteristics and industry needs of photovoltaic power stations
2. Focus on system reliability: Adopt high-reliability equipment and technology to ensure stable system operation
3. Attach importance to data security: Strengthen system security protection to ensure data security
4. Continuous optimization and improvement: After system launch, continuously track and optimize to improve system performance

9. Related Resources

• White Paper on Photovoltaic Power Station Automation Solutions
• Product Manual for ZK-PLC500 Series Controllers
• Operation Guide for Photovoltaic Power Station Automation Platform

Adopted ZK-PLC500 series controllers, smart sensors, video monitoring systems and photovoltaic power station automation platforms, realizing the following functions: 1. Real-time monitoring of equipment status; 2. Intelligent power prediction and output dispatching; 3. Automatic fault diagnosis and alarm; 4. Video monitoring and security management; 5. Docking with grid dispatching system; 6. Data analysis and report generation.