Challenges and Triumphs: My Experience with Site Visits and Commissioning
In the world of engineering, site visits and commissioning projects offer unique challenges that push us to apply our knowledge, experience, skills, and creativity. Despite studying manuals and guidebooks to adhere to defined standards, the real test comes when we face the unpredictable scenarios at the site. It’s like solving a jigsaw puzzle, where we must make the right choices to complete the picture. In this blog post, I will share my recent project experience involving a PV, DG, and grid hybrid system with local/Remote monitoring and data logging. Join me as I take you through the highs and lows of this endeavor and how we overcame unexpected obstacles.
Our objective was to design and develop an efficient and reliable system capable of operating for a minimum of 25 years. To achieve this objective, our team devoted three months to extensive research and development. We meticulously crafted a program for the controller to effectively regulate PV power, and we designed a user-friendly HMI (Human-Machine Interface) for seamless data monitoring and logging. Throughout the project, we were fortunate to have the guidance and support of Mr. Amin Lakhani, who played a crucial role in leading and assisting us.
To ensure the productivity of the system, we conducted a thorough factory acceptance test at DUSOL Industries. This process lasted a month, during which we fine-tuned the system to meet our customers’ expectations. With the test successfully completed, we were ready for the next phase: installation and commissioning.
This project marked my first international installation and commissioning experience. We were fully prepared and equipped for the 100 kW PV system installation at two sites in the Democratic Republic of the Congo. The first site’s PV system installation and commissioning went smoothly, with all open-circuit voltages and short-circuit currents meeting the inverter specifications. Excitement grew as we approached the integration of the PV system with the DG and grid.
Before turning on the PV system, we meticulously inspected the source voltages, frequency, and current, which were all within the AC specifications. However, upon system activation, we encountered intermittent shutdowns of the inverter. Recognizing the need to address this issue, we took a day-long data log of the sources and made some crucial observations.
Analyzing the data log, we discovered fluctuations at the DG source, along with an uneven distribution of the load. One line was drawing up to 160 amps, while the other ranged from 65 to 85 amps. This imbalance caused the generator’s voltage to drop from 422V to 365V during peak loads. Additionally, fluctuations and humming were detected from the generator. Convinced of the significance of these findings, we alerted the management and suggested maintenance for the DG, load balancing, and voltage reduction to 400V.
Following the necessary maintenance and load balancing, we started the PV system. This step significantly reduced inverter shutdowns and allowed it to operate at its maximum capacity, in sync with the source connection at the bus bar. It was a triumph to witness the system functioning as intended after overcoming the unexpected hurdles.
This experience reinforced the fact that despite our thorough preparation, the site’s unique conditions can surprise us. Commissioning projects require us to think outside the box, analyze the situation, and identify the root causes of problems. It demands intellectual and physical effort, including testing with various gadgets, decision-making, and seeking support from colleagues. The joy and learning lie in understanding the situation, resolving challenges, and collaborating with others for on-site assistance.
Site visits and commissioning projects provide engineers with invaluable opportunities to test their skills, creativity, and problem-solving abilities. My recent involvement in a PV, DG, and grid hybrid system installation taught me to expect the unexpected and rely on both my own expertise and the support of my colleagues. By sharing my experiences and lessons learned, I hope to inspire fellow engineers to embrace the challenges that come with commissioning projects, finding joy and satisfaction in overcoming obstacles and delivering efficient systems to clients.