Download - The Chorus Line - questab.com Chorus Line Presentation...Doc. number 61:00-1 Rev. 5 September 2006 1 The Chorus Line Reliable Wind Power Control The Chorus Line, managed by its ChorusDIRECTOR

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Doc. number 61:00-1 Rev. 5 September 2006 1

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The Chorus Line Reliable Wind Power Control

The Chorus Line, managed by its ChorusDIRECTOR application software, puts your wind turbines in perfect tune.

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2 Doc. number: 61:00-1 Rev. 5 September 2006 ____________________________________________________________ ______ __

Quest – Introduction

Quest AB – Your Partner Since the start in 1983, Quest has built up a wealth of practical experience in the field of wind power control. This ever-growing experience is used to the benefit of the wind power industry, thus making Quest an ideal partner for development of control technology. Strategy for Success In order to be successful we follow certain key strategies:

Close partnership with windmill manufacturers

Use of industrial standard products

Open software

Modular system

Cost-effective development

Per Stjerneman, Managing Director

Co-development with the Manufacturers The Chorus system is developed in close association with our partners, the windmill manufacturers. Our partners’ demands have formed a controller well suited for modern wind turbines. Use of Industrial Standard Products Our customers’ requirements that the system should employ standard products, resulted in our choice to use standardised industrial bus systems (including Ethernet and CAN), wireless local communication (Bluetooth) and cost-effective man-machine interface (PDA’s). Open Software Functionality Quest has drawn on many years of experience when designing the control software. This know-how is now available to our partners through the open software.

This means that our partners have access to the wind turbine functionality and to various toolboxes included. Hence, our customers have the freedom to create their own specific software solutions and keep them confidential. Modular System It is essential that the development time for partner projects is kept as short as possible. In order to achieve this, the control system’s hardware and software have been made highly modular. This makes future development or modifications fast, efficient and secure. Cost-Effective Quest has been working in the field of control systems for many years. This accumulated know-how is a key ingredient when developing cost effective solutions for the wind power industry.

Quest – Your development partner!

Göteborg, September 2006

Per Stjerneman

Quest Energy Control AB SE-421 66 V.Frölunda, Sweden Tel: +46 31 510010 E-mail: [email protected] Web: www.questab.com

mailto:[email protected]

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Product Family & Central Controller

The Chorus Line – Quest’s Product Family Our family of control system products is called “The Chorus Line”.

The family includes the following hardware:

ChorusCPU Central controller ChorusTRAFO Voltage transformer ChorusIGNIT Thyristor driver … and the associated software:

ChorusOS Operating system ChorusDIRECTOR Application software

The Chorus Line is designed in such a compact way that these core products, together with a few complementary standard products, form the entire control system that your wind turbines need. ChorusCPU Highlights

High accuracy in measurements

Proven high reliability

I/O via standard industrial bus systems

Easy and quick configuration

Cost effective product

Communication The Chorus system features three high speed buses: The Ethernet and two CAN buses. The first CAN-bus is normally used to communicate with the distributed standard industrial I/O modules around the wind turbine, while the second one can be used to communicate with e.g. inverters, a vibration monitoring system or the generator. Additionally, there are two RS-232 ports and two RS-485 ports for e.g. user interface. Software Download The product software may easily be updated via a download procedure. Security Loop In order to achieve a high security in a wind power plant consisting of several different intelligent systems, Chorus includes a specific security feature monitoring an external loop (with e.g. stop buttons). It also offers two security outputs that can block external equipment in case of an emergency. Moreover, it is self supervising.

Configuration

Inputs/Outputs On-

board Max.

extension

Digital IN 24 512

Digital OUT 16 512

Analog IN 9 64

PWM OUT 6 64

Communication Number Speed

Ethernet T-base 1 10/100 Mbit/s

RS-232 2 115.2 kbit/s

RS-485 2 115.2 kbit/s

CAN-bus 2 500 kbit/s

General Data

Description Data Remarks

Power requirements 24V DC, 3A 18 – 32V

Processor type 50 MIPS RISC Motorola MPC 555

Flash memory 8 MB

EEPROM 8 KB

RAM 2 MB

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Hardware Modules

Chorus Voltage Transformer The voltage and current measurements are used to calculate energy production, blind power and to synchronise the connection to the grid.

Quest’s strategy is to separate all grid voltage devices from the controller and to use a standard properly scaled voltage input signal. Chorus uses external voltage trafos for the nominal grid voltage 690/400/230V and to obtain 110V signals from high voltage equipment.

ChorusTRAFO

Description Data

Name ChorusTRAFO

Type Single phase type

Max Voltage 690V

Accuracy 0.3 %

Output 0 – 10V

Industrial Standard Modules When expanding the standard Chorus configuration, it is easy to plug in standardised industrial I/O modules from different vendors which all connect to the CAN-bus. The amount of cabling is greatly reduced by distributing the I/O units around the mill.

A bus terminal and some I/O modules

Thyristor Driver Module Thyristors are controlled by the external driver module named ChorusIGNIT. It is typically installed close to the thyristors and communicates with the ChorusCPU module through a bus cable.

ChorusIGNIT

Description Data

Name ChorusIGNIT

Thyristor outputs 6

Output voltage, max 690V

Output current, max 1A

Over-current protection Yes

Digital inputs 6

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User Interface

Handheld User Interface + Bluetooth Chorus employs standardised hardware products also for the user interface, for example a small handheld PDA. This terminal connects to the control system via Bluetooth wireless communication The customer benefits are obvious:

Service personnel keep and manage their individual terminal.

The personnel may for example sit in a car outside the mill monitoring the operation or updating parameters.

When working in e.g. the nacelle he may operate the plant remotely. Hence, there is no need for a second person assisting at the central control system downstairs.

The total investment cost is reduced since there is only need for a couple of handheld terminals in an entire wind park consisting of several hundred machines.

Fixed Graphical Terminal The Chorus user interface may also include a fixed graphic terminal with touch screen used for demonstrations or when needed in the wind turbine.

Central Monitoring System Since the protocol and the software are open the manufacturer can incorporate the mills in the end-customer’s central monitoring system.

User interface through a handheld PDA

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Software

ChorusOS – The Real-Time Operating System This is the software platform on which the application is based. It’s a true real time system designed for the very fast processes involved in electrical energy systems. The OS provides a large number of dedicated resources for application programmers. ChorusDIRECTOR – Application Software

Open source code

Object oriented and written in C++

Facilitates communication within wind farms

Ability to communicate and use standardised industrial bus systems

Easy and quick expansion Open Source Code for Applications Occasionally, the extensive set of parameters in the application is not sufficient to fine-tune the operation. Therefore all major applications of the wind turbine are fully open to our partners. This means that the partner himself can add, change or remove functions in the system. Using predefined functions from the toolbox it is easy to make additions and adaptations. Thus, the partner has full control of the system and its future development (and it will remain confidential).

Programming in perfect control Programming Model The software is divided into objects according to their functionality. Data exchange between objects is mainly performed via a database. Debugging In case of a programmer’s mistake, extensive tools are available to track the direct source of the problem.

Key Services and Utilities

Tools for adding and manipulating database records

Classes for handling field bus I/O devices from a range of manufacturers

Tools to define I/O, irrespective of whether on the CPU unit or on a field bus I/O module

Tasks may be cyclically initiated with 1, 10, 100 or 1000 ms interval

Measurement of true RMS for six voltages and three currents, with down to 10 ms averages

Handling of communication ports

Handling of cyclic values (like wind directions)

Filters for analogue and digital measurements

Timers

Data logging

Graphical interface toolbox Handling of System Faults A special utility is devoted to the handling of any faults that may occur in the controlled process. The utility defines faults with reactions, delays, reset authorisation and location, as well as whether resets should be done. The utility may also obtain status for each fault and for each reaction or set of reactions.

As an example: If a message “HydraulicFault” is signalled, all objects can easily retrieve that information. The object handling the hydraulic pump can stop the pump and, moreover, the yawing stops if the yaw brake is hydraulic, etc.

Disconnect condition

Thyristors off

Set T_DelayThyr

Grid Fault

Disconnect bypass

Disconnect thyristors

Grid Fault

Disconnect bypass

Disconnect thyristors

Not connected

NOT_CONN

g Thyristor ramp

THYR_RAMP_g

g Bypass and

thyristors on

BYPTHYR_g

Angle == full ignition

Bypass on

Set T_delay

Disconnect condition ||

UpConnection

Thyristors off

Set T_DelayThyr

g Thyristor

regulation

THYR_REG_g

Grid fault ||

((Disconnect condition ||

UpConnection) &&

T_delay)

Thyristors off

Set T_DelayThyr

!(Braked || DownConnection) &&

(Average power > limit)

(Average power < limit &&

Mom. power < limit) ||

UpConnection ||

Disconnect condition

Bypass off

Set T_delay

Choice contactor on, small

generator

CHOICE_g

!Braked &&

Generator speed > GSChoiceOnLimit &&

Generator speed < GSChoiceMaxLimit &&

Not UpConnection &&

Not DownConnection

GSChoice on

Generator speed < GSChoiceOff limit ||

(UpConnection && T_Delay) ||

(Braked && T_DelayThyr)

GSChoice off

Set T_delayCont

Choice contactor on,

main generator

CHOICE_G

Generator speed < GMChoiceOff limit ||

((Braked || DownConnectio) && T_DelayThyr)

GMChoice off

Set T_DelayCont

(Generator speed > GChoiceOnLimit &&

T_Delay) &&

!Braked

GMChoice on

Grid fault ||

(Disconnect condition &&

T_delay)

Thyristors off

Set T_DelayThyr

Angle == full ignition

Bypass on

G Bypass and

thyristors on

BYPTHYR_G

G Thyristor

regulation

THYR_REG_G

!(Braked || DownConnection) &&

(Average power > limit ||

Mom. power > limit ||

UpConnection)

(Average power < bypass limit &&

Mom. power < bypass limit) ||

DownConnection ||

Disconnect condition ||

Braked

Bypass off

Set T_delayCont

G Thyristor ramp

THYR_RAMP_G

Main generator connect condition

Connect thyristors Std ignition

Small generator connect condition

Connect thyristors Std ignition

Example of state machine diagram

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Software Example

In order to make company specific algorithms or adjustments the wind turbine manufacturer may access the application parts of the Chorus source code, compile and link his own software and, thus, add new functionality.

The source code for a simple functional object may look like this : Header file: //****************************************************************************

//*

//* File name: GenHeater.h

//*

//* Short description: Handles generator heater output

//*

//* Source code files: GenHeater.cpp

//*

//****************************************************************************

// $History: GenHeater.h $

//

//***************** Version 1 *****************

//User: Hrm Date: 05-04-11 Time: 14:52

//Created in $/ChorusCPU/Software/Source

//

#ifndef GENHEATER_H

#define GENHEATER_H

//----------------------------------------------------------------------------

// Include files

//----------------------------------------------------------------------------

#include "../GlobalDefs.h"

#include "../shell/SysBase/SystemObject.h"

//----------------------------------------------------------------------------

// DEFINES

//----------------------------------------------------------------------------

//----------------------------------------------------------------------------

// TYPES

//----------------------------------------------------------------------------

//----------------------------------------------------------------------------

// CLASSES

//----------------------------------------------------------------------------

class CGenHeater: public CSystemObject

{

public:

CGenHeater(); // Constructor

int TimerCall(int LoopId); // Called in fixed intervals by OS

protected:

private:

THandle HOutGenHeat, HGenStatus; // Database handles

};

extern CGenHeater GenHeater;

#endif GENHEATER_H

//----------------------------------------------------------------------------

// EOF

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Software Example

Source file: //****************************************************************************

//*

//* File name: GenHeater.cpp

//*

//* Short description: Handles generator heater output

//*

//****************************************************************************

// $History: GenHeater.h $

//

//***************** Version 1 *****************

//User: Hrm Date: 05-04-11 Time: 14:52

//Created in $/ChorusCPU/Software/Source

//

//----------------------------------------------------------------------------

// Include files

//----------------------------------------------------------------------------

#include "GenHeater.h"

#include "../Shell/System/LoopMan.h"

#include "../Shell/Tables/FaultTable.h"

#include "../shell/Dashbrd/DB.h"

#include "InvExec.h"

//-----------------------------------------------------------------------------

// Name.......: CGenHeater

// Class......: CGenHeater

// Description: Constructor

//

// In.........: None

// Out........: None

// Return.....: None

//-----------------------------------------------------------------------------

CGenHeater::CGenHeater()

{

// get database handles:

HOutGenHeat = DB.GetHandle("OutGenHeat");

HGenStatus = DB.GetHandle("GenStatus ");

// put into timer loop:

LoopMan.AddIoDevice(this, LOOP100); // order a call each 100 ms

}

//-----------------------------------------------------------------------------

// Name.......: TimerCall

// Class......: CGenHeater

// Description: Constructor

//

// In.........: int LoopId; Time loop id

// Out........: None

// Return.....: int loopId

//-----------------------------------------------------------------------------

int CGenHeater::TimerCall(int LoopId)

{

if ((FaultTable.GlobalFlags() & faultGRID) || (DB.GetAsInt(HGenStatus) != 0))

{

// If grid problems or generator connected, turn off

DB.Set(HOutGenHeat, false); // clear output

}

else

{

DB.Set(HOutGenHeat, true); // set output

}

return(LoopId);

}

Comment: An instance of the class is defined in a common set-up file, the module is added to the make file and, thus, the object is activated.

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Simulation of a Wind Turbine

Development in Matlab Quest has the capacity to simulate the wind turbine using a mathematical model. This is usually conducted in close cooperation with the manufacturer.

The benefits are:

Faster development, less time needed in prototyping and deployment due to the ease of verification and testing

Refinement of control algorithms

Easy and quick test of new ideas

The output from Matlab simulations may easily be modified and tested again. There is no need to wait for the right wind conditions!

Fine-tuning a customised algorithm

Refinement of Control Algorithms In the model, new regulator models can be freely tested under all relevant wind and operating conditions. Robustness of the control system in relation to plant differences can be verified.

The Matlab Model The rotor torque and speed is calculated from wind input and the turbine’s aerodynamic and mechanical data. The model simulates a drive train with a stiff, heavy turbine, a soft axis, and a perfect gearbox. The generator speed, power and torque are calculated to model an asynchronous, squirrel cage generator. In order to adjust the model for variable speed, only the generator model needs to be changed.

A regulator is written in C++ and integrated in the model. Effects of sampling interval, noise on input data, delays in output, etc, can easily be studied.

Turbine:Stiff, heavy

disk

Main shaft:Limited stiffness and

damping

Gearbox:Ideal transition of speed and

torque

Generator:Speed -> torque

and electrical

power

Wind:Step function

Controller:Uses power, speed and wind

data to control pitch angles

Examples On the next page two examples of simulations are shown. The comparison to manufacturer data is made to verify the model. In the first diagram there is a difference at high power that is fully explained by the difference in slip (zero slip makes the model, like most wind mills, unstable).

The second diagram illustrates a simple regulator test showing the step response of the system. In addition wind may be modelled as bandwidth limited white noise or true wind traces. Pitch control Pitching equipment may also be simulated in Matlab.

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Matlab Examples

Data for a pitch regulated wind turbine has been fed into the model. The wind is modelled as a step function, with a limited derivative.

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Your Solution?

Blade 1 positioning system

DeviceNet

ChorusCPU

DeviceNet B

250 kBit/s

DeviceNet A

500 kBit/s

0-1 A AC

Hydraulics

-Pump

-Pressure

...

RS232

Base panel

with some I/O

Security loop

Remote/park

communication line

Nacelle panel

Power Cabinet



4 sliprings

or

BlueTooth

link

4 sliprings

Gear Box

-Turbine speed

-Temperatures

...

Generator

-Speed

-Temperatures

...

Vibration sensor

Inverter

ChorusTRAFO

Current

transformers

0-10 V AC

Opto or radio

links

RS485

Notes

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Your Solution?

All nacelle IO:

-Digital inputs

-Pumps and valves

-Wind speed and direction,

analog or digital

-Turbine and generator speed

-Temperatures

...

Vibration sensorStandard industrial I/O modulesYaw inverters

Power cabinet

Nacelle panel

Control cabinetBase panel

ChorusCPU

ChorusTRAFO

ChorusIGNIT

Current trf

Contactors

etc

Copper, optofibre or radio

Security loop

RS232

DeviceNet

Security loop

DeviceNet

RS422

Technical specifications are subject to change without notice.