Smart Load Management System
According to National Electric Power Regulatory Authority Pakistan, System Average Interruption Frequency Index (SAIFI) and System Average Interruption Duration Index (SAIDI) by the distribution companies, recorded for the fiscal year 2019-20 is 1426 times and 76690.71 minutes respectively. A
2025-06-28 16:29:21 - Adil Khan
Smart Load Management System
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryAccording to National Electric Power Regulatory Authority Pakistan, System Average Interruption Frequency Index (SAIFI) and System Average Interruption Duration Index (SAIDI) by the distribution companies, recorded for the fiscal year 2019-20 is 1426 times and 76690.71 minutes respectively.
Average 76690.71 minutes of outages occurred for the consumers, this interruption is very critical in some institutions, such as hospitals, servers, defense forces etc. These institutions required uninterruptible power supplies. Due to which most of the buildings and organizations are running on backup supply. But it is difficult to manage load due to the limited KVA of the backup supplies. Most of the organizations turn off their backup supplies manually, this method is suitable when it is being used in residential home. When it comes to large institutions/organizations, it may cause malfunctioning in the backup supplies. This supply may go to overload due to the heavy load switching by the personal/official. It also becomes difficult to switch on the selected load when main supply is switched off.
This project gives a portable smart switch that can be installed on main distribution box or a selected distribution box. It will control the switching of multiple input supplies and switching of loads, either fixed switching (all connected loads can be turned on during main supply and selected loads will be on during backup supply) or flexible switching (all connected loads can be turned on during main supply and selected loads can be switch on during backup supply). It will solve the problem of interruptible supply by giving continuous supply by switching between main supply and continuous supply. It will solve the overload problem of backup supply by letting consumer to switch on/off between selected loads.
Project Objectives- Automatic Switching between primary supply and secondary supply.
- To make a smart device which decides that on which supply the load should be operated (when running on two or more supplies)
- To manage devices whether its heavy or low in terms of power ratings
- To increase the quality of switching at high power load (by replacing EMRs with SSRs, which have greater lifetime than EMRs when operates on high power load).
- To provide the simple and easy way to monitor and manage the load of complete building from one place through screen.
Two supplies (i.e., primary source and secondary source) are used in this project. The main task of project is to switch the load on the supply which is on at that time and then switch the load according to the instructions provided through HMI .For this purpose the contactor FC-25 is connected after both the supplies (primary and secondary )When one of the supply is shut down the switching between primary and secondary supplies is done by contactor(A contactor is an electrical device which is used for switching an electrical circuit on or off. It is a special type of relay which is used in applications with higher current carrying capacity). The contactor is selected for this project because of the high current load of building (including AC). Now, the complete load of the building moves on the supply which is on. Moreover, it is used to turn on the supply of 24volts at its output .This supply is used to power to the PLC (programmable logic controller , is an industrial computer used to control different automation processes and used here to control all the logic operations and control the switching according to the instruction provided by the human through HMI)
After the PLC in on and starts working it takes input (at pin x0 and x1) from two Current Transformers/CT (type of transformer used to reduce or multiply alternating current). Here, CT is used to detect which supply is on, either primary or secondary. Thus, from the output of these two CTs PLC decides that how many devices should switch to the supply. Suppose the case in which the Primary supply is on in this case the complete load goes to the supply. the second case is when the primary supply is off and secondary supply is on in this case some of the load is turn to the supply and other remains off. The third case is when both supplies are on, in this case all the load turn to the primary supply. All these cases are programmed to PLC by ladder logic. Furthermore, the HMI screen is also connected to PLC, which takes instructions from the user that which load should switch on or off. Thus, the final output of PLC is the user selected load on specific supply. This output of PLC is connected to SSR / Solid state relay MGR1 D4810 (An electronic switching device that switches on or off when external voltage is applied. it works same as electromagnetic relay but has no moving part thus works longer on high current ). In this project SSRs are used to switch on or off the load according to the output of PLC. The PLC provides the 24 volts to SSR and then SSR switches the load of 220v at its output , which is the main load .Thus the switching of 1 ton ACs (in this particular case )are done in through HMI after switching between primary and secondary sources . the number of SSRs should be increase according to the number of output devices.
Benefits of the ProjectThe benefit of project is the management of the load.
- The benefit of project is the management of the load. This could results in minimization of the electric consumption and overload of backup supply.
- The project drives minimum amount of current by operating only the necessary load or the selected load according to human need. Hence, it reduces the risk of any damage or sudden breakdown of secondary supply (such as generator, ups or solar) due unnecessary load or load greater than the power supplied by the secondary supply.
- In this era of advancement and technology working on HMI make things easy and attractive for users rather than doing same task manually and this project has introduced a new way of display of the load which is much more attractive and user friendly.
- The efficiency of switching on high power load is increased due to usage of SSRs.
- Easy installation.
- Flexibility in programming and reprogramming.
- Safety of Appliances.
- It will also save time consumption which cause by switching loads manually.
The project is design to switch the loads between two supplies .here generator is use as backup source and KESC as main supply. This project run two appliances of current rating up to 10 amperes at 220v. So, the total current rating of load is 20 amperes therefore, the system can bare the load up to 25amp (for safety purpose). here we have used 2 air-conditioners, but these loads can be easily replaced by any two appliances of current rating up to 10 amp. These loads are control by HMI /screen and by using HMI the load on backup supply can be minimize . this project is designed according to requirement of 2 ACs of 1ton but in future applications the load can be increased or change according to the requirements of building by changing some parts of the project such as SSRs and contactor these are the components easily available in market with higher current ratings therefore, the project can easily installed in any building.
Final Deliverable of the Project HW/SW integrated systemCore Industry Energy Other Industries Others Core Technology Internet of Things (IoT)Other Technologies OthersSustainable Development Goals Decent Work and Economic Growth, Responsible Consumption and ProductionRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 36580 | |||
| DVP14SS211T | Equipment | 1 | 15000 | 15000 |
| SSR | Equipment | 2 | 800 | 1600 |
| 0.1 USB Connector | Equipment | 2 | 100 | 200 |
| 16mm Green light | Equipment | 2 | 120 | 240 |
| Push Button | Equipment | 3 | 110 | 330 |
| 24V Relay with base | Equipment | 2 | 500 | 1000 |
| UC-MS030-01A | Equipment | 2 | 1600 | 3200 |
| Plug | Equipment | 3 | 60 | 180 |
| Bulb (100w) | Equipment | 3 | 180 | 540 |
| Holder | Equipment | 3 | 60 | 180 |
| Jumper Wires | Equipment | 1 | 200 | 200 |
| Bridge Rectifier | Equipment | 3 | 100 | 300 |
| 8 pin connector | Equipment | 2 | 150 | 300 |
| multi core wire | Equipment | 1 | 150 | 150 |
| Ulugs | Equipment | 10 | 50 | 500 |
| Tools and Accessories | Miscellaneous | 1 | 2000 | 2000 |
| Printing and accessories | Miscellaneous | 1 | 5000 | 5000 |
| 12x12 lamp | Equipment | 3 | 220 | 660 |
| Power Supply | Equipment | 1 | 3500 | 3500 |
| 5 meter wire 9mm | Equipment | 3 | 100 | 300 |
| Contactor | Equipment | 1 | 1200 | 1200 |