Windfarm SCADA Backup PLC for Offline Power Control

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Solution Overview

Problem

Windfarms face operational disruptions and security risks due to the unavailability of the supervisory control and data acquisition (SCADA) system, which can lead to power output fluctuations and potential cyberattacks.

Innovation Solution

A backup system comprising a programmable logic controller (PLC) that monitors the SCADA system's status, switches to a backup mode to maintain power output within set parameters, and employs a data diode to prevent unauthorized access, allowing remote control of wind turbines through terminal interface units (TIUs) to simulate start/stop button actions and manage faults.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the SCADA system is used to control wind turbines, then centralized monitoring and control capability is improved, but system reliability deteriorates when the SCADA system goes offline

Engineering Contradiction:

Improvecentralized monitoring and control capabilityVSAvoidsystem reliability when SCADA is offline

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Each wind turbine is equipped with a local controller that can independently execute start/stop commands and maintain operational states. This local autonomy ensures that individual turbines can continue operating reliably even when the centralized SCADA system is offline, resolving the contradiction between centralized control capability and system reliability during SCADA outages.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The control system is segmented into independent units where each wind turbine has its own controller that can function autonomously. This segmentation allows the system to maintain reliability at the individual turbine level even when the overall SCADA system fails, while still preserving centralized monitoring capabilities when available.

Inventive Principle:

Principle #1Segmentation

2Productivity

If remote control commands are sent to wind turbines during SCADA offline mode, then power output control is improved, but response time deteriorates due to communication delays

Engineering Contradiction:

Improvepower output control capabilityVSAvoidresponse time for control commands

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

Control commands are pre-configured and stored in the local turbine controllers. When SCADA is offline, these pre-configured commands can be executed immediately without waiting for communication delays, thus maintaining power output control capability while minimizing response time loss.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The centralized control logic is copied to each local turbine controller. This allows the local controllers to execute control functions independently when SCADA is offline, eliminating communication delays while maintaining the same control capabilities that would otherwise require real-time SCADA communication.

Inventive Principle:

Principle #26Copying

3Object-affected harmful factors

If the windfarm shuts down during SCADA offline mode, then system security is improved, but power generation loss increases

Engineering Contradiction:

Improvesystem security protectionVSAvoidpower generation output

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The wind turbines are designed to self-monitor their operational states and self-regulate power output within safe parameters using local controllers. This self-service capability allows the windfarm to continue generating power securely during SCADA outages without requiring shutdown, thus maintaining productivity while ensuring system security through autonomous safety monitoring.

Inventive Principle:

Principle #25Self-service

4Measurement precision

If on-site technician intervention is required during SCADA offline mode, then fault diagnosis accuracy is improved, but operational disruption increases

Engineering Contradiction:

Improvefault diagnosis accuracyVSAvoidoperational continuity

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

Local controllers continuously monitor turbine operational parameters and provide real-time feedback on system status. This automated feedback mechanism enables accurate fault diagnosis without requiring immediate technician intervention, thus maintaining operational continuity while preserving diagnostic accuracy through continuous monitoring and alerting systems.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20190249646A1Secure windfarm power production during a scada system offline mode

Publication Date: 2019.08.15 INVENTUS HOLDINGS LLC

AI summary

A system for generating power includes a supervisory control and data acquisition (SCADA) system that provides control commands to a plurality of turbine controllers to cause a windfarm to output power at a level within power parameters in a setpoint. Each turbine controller is installed at a corresponding wind turbine of a plurality of wind turbines in the windfarm. The system also includes a backup system comprising a programmable logic controller (PLC). The PLC receives turbine state information from the SCADA system that characterizes an operational state of each of the plurality of wind turbines in the windfarm and detects that the SCADA system is offline. The PLC also selectively provides start and stop commands to a plurality of terminal interface units (TIUs) to cause the windfarm to output power at a level within the power parameters identified in the setpoint in response to the detecting.