An exclusive interview with Kumar M, Director at Smart Grid Analytics and the Owner at Armax Automation. He got more than 20 years of experience in the renewable energy sector, handling the effective ways to deliver the innovative and patented SaaS solutions for power plant monitoring, control, optimization, and revenue generation.

Mr. Kumar M background includes electronics and instrumentation, as well as skills in programmable logic controller (PLC), automation, and control systems design.

Mr. Kumar M is passionate about supporting the renewable power plant owners and operators to increase their production, efficiency, and profitability with the use of latest digital twin technology, smart O&M, forecasting, and power trading features.

A successful story in executing around 24GW worth of solar SCADA and power plant controllers in India, Egypt, Zambia, Vietnam, Jordan, and Oman, and also expanded the market to other countries such as Chile.

At present, he is a director at Smart Grid Analytics, a SaaS based company, with an aim to improve the monitoring, control, and increase the production of Renewable Power Plants which could be Grid tied or Micro Grid with Green technologies for Hydrogen and Ammonia.

Digital Twin patent solutions are used for ascertaining the losses and support the increase of the revenue by increasing the generation of the plant.

Let’s learn from Mr. Kumar M about the importance of digital twin technology.

Q: What inspired you to focus on digital twin technology within the energy and utility sector?

Kumar M:

Since renewable energy is the talk of the town, I would like to enhance my views on this question further. In the current market, there is a focus on always building something that can generate revenue for the organization, as it is purely business.

But, when you are already in business and have reached a certain height, you start wondering what more you can do for society. Out of this, the thought of making a digital twin for a solar power plant was born.

As I have said, we have been into renewable energy, especially solar farm automation, since its entrance into India around 2009, and we were the very first to come out with the technology to connect, concentrate, and pick up data. From then until now, our constant focus has been customer-centric. Without customers, we do not exist, and without necessity, there is no invention required.

So, hence the Digital Twin, the reason being that solar, wind, and renewables are a growing and ever-evolving market, and there are no sufficient tools or systems for end users to depend on to confidentially invest and ensure their money is safe.

Out of that concern, like how Google has changed the entire way we live by contributing to the industry with Google Maps, I have also thought of bringing out the Digital Twin for Solar Power Plant as a tool for anybody to ensure, track, and evaluate their plant’s performance against what was built on the basis of PVSyst, considering the STC conditions of 1000 W/m2 and a module temperature of 25 degrees Celsius.

The digital twin that we have built and filed for patent is basically recreating the entire solar power plant digitally and specifically for each individual customer, and it is not unlike others who use a mathematical-based regression-based analysis based on historical data, which is the source of prediction of performance and measurement.

The source of data for our digital twin would be the data sheets for the PV modules, the inverters, cables, their distances, and transformers as per site conditions, including their angle and commissioned date.

Digitizing your power plant has many advantages, including increased operational efficiency and the ability to highlight predictive maintenance techniques combined with historical data and standard performance equations that can actually forecast equipment performance.

It can also help indirectly by tracking the equipment downtime and, due to the equipment downtime, how many kWh are lost due to the same and, combined with the PPA rate, the actual loss that is incurred either due to the plant’s equipment or related to grid-side losses.

Q: How do digital twins transform the energy grid and utility infrastructure?

Kumar M:

The digital twins can transform the way we see, as when we are replicating the same, the exact response can be derived even before the plant can be set up and can be understood, what are the scenarios that might not be in favor, and can be looked at and thought upon before hand itself, so that there will be little or no loss concerning revenue and also time.

This also helps us, the user or grid management, for better innovation and competitive advantage in terms of grid management and grid balancing with respect to power plants connected to the POI, as well as pooling substations and grid substations, ensuring that they all respond to any untoward event with respect to reactive power drawl, injection, or power factor of frequency or voltage imbalances being caused by rouge elements connected to the electrical grid system.

This will also enhance better optimization, and we will be able to indicate and understand the potential and probable scenarios that might arise tomorrow even before the event occurs in real-time.

Q: Could you share insights on the solar SCADA project?

Kumar M:

To be true to myself, the Solar SCADA projects in India are only focused on business decisions and not on what we are giving back to the user or how the user is benefiting from the use of our product.

The big names in the automation and SCADA industries have designed their systems on legacy applications, and all the SCADA’s are meant for a process industry or manufacturing industry environment where you do not have big data to handle but you have to handle the process overview, monitoring, and control of your plant.

The conventional SCADA systems are not able to handle large databases, as solar and wind power plants and EMS with BESS are heavy data-intensive applications where you need to acquire data as per IEC 61724 standards, and sampling and averaging the same and also storing at regular 1-minute intervals as per Class A, B, and C standards is what was challenging.

To overcome the same, we have addressed the potential gap in the market by introducing our Infinity+ SCADA, which can actually capture the data at the local inverter control room and also store all data with respect to alarms, events, and historical data even though it is remotely disconnected for a period of at least 30 days. Upon reconnection to Master Control Room SCADA, the data will be backfilled in the database.

Also, with the growing infrastructure requirements and cyber security measures, we want to have a think client of SCADA with a big database architecture and to also ensure the same is replicated in the cloud and that no data is lost. In any renewable power plant, data is the key and also the factor that will play a major role in the sale and acquisition of the plant.

Data is the key, and data is the source for any root cause analysis, preventive and predictive maintenance, and understanding the behavior of the plant.

Q:What role does data integration play in creating an accurate and dynamic digital twin model for energy systems?

Kumar M:

Without accurate datasheets, lengths, and metrics, it is not at all possible to recreate the systems digitally. Also, not just datasheets but also knowledge of the subject and subject matter expertise of how to use the data and what to do with the data alone can ensure that it is useful in building a digital model to replicate the plant.

Once done, it also needs to be recalibrated with the actual output to see and tune its behavior, as building digitally is not only done but also verified with the actual output and calibrated to ensure the decisions and outcomes are near-renewable world scenarios.

Q: How do you address security and privacy concerns when deploying digital twins in critical infrastructure?  

Kumar M:

Deploying digital twins in critical infrastructure, especially in renewable energy projects, requires comprehensive knowledge of security and privacy.

By implementing robust cybersecurity measures, adhering to industry standards, conducting regular audits, and fostering a culture of security awareness, the infrastructure can be effectively protected against potential threats while ensuring compliance with regulatory requirements.

1. Implementing Robust Cybersecurity Measures

• Network Security: All data transmission between the digital twin and physical assets is encrypted using advanced protocols such as TLS (Transport Layer Security) or VPN (Virtual Private Networks). This helps protect data in transit from interception or tampering.
• Access Control: Strict access control mechanisms to limit who can access the digital twin data and systems. Role-based access control (RBAC) ensures that only authorized personnel have access to sensitive information and functionalities.
• Firewall and Intrusion Detection Systems (IDS): Deploy firewalls and IDS to monitor and protect the digital twin infrastructure from unauthorized access or cyberattacks. These systems help detect and prevent malicious activities in real-time.

2. Data Encryption and Protection

• Data Encryption: Encrypt sensitive data both at rest and in transit to protect against unauthorized access. This includes encrypting data stored in databases, cloud storage, and during communication between digital twin components.
• Secure Data Storage: Use secure, compliant storage solutions for storing data associated with the digital twin. This will involve leveraging cloud storage with strong encryption standards and redundancy to ensure data integrity and availability.

3. Regular Security Audits and Penetration Testing

• Security Audits: Conduct regular security audits to assess the effectiveness of existing security measures. Audits will help identify potential vulnerabilities and ensure compliance with security policies and standards.
• Penetration Testing: Using a third party to perform penetration testing at least once in a. 6 month period to simulate cyberattacks on the digital twin infrastructure. This helps in identifying and addressing vulnerabilities before they can be exploited by malicious actors.

4. Compliance with Industry Standards and Regulations

• Adhere to Regulatory Requirements: Ensure that the deployment of digital twins complies with relevant regulations and standards such as GDPR (General Data Protection Regulation), IEC 62443, ISO 27001 and other cyber security standards as per local law.
• Industry Best Practices: Following best practices for cybersecurity in critical infrastructure, such as those recommended by organizations like CERC/CEA or IEC (International Electrotechnical Commission).

5. Secure Software Development Practices

• Secure Coding Practices: Implement secure coding practices during the development of digital twin software to prevent common vulnerabilities such as SQL injection, cross-site scripting (XSS), and buffer overflows.
• Regular Software Updates and Patching: Ensure that the digital twin software is regularly updated and patched to protect against known vulnerabilities and emerging threats.

6. Data Privacy and Anonymization

• Anonymization and Pseudonymization: By making sure to implement techniques to anonymize or pseudonymize data where possible, ensuring that personal or sensitive information cannot be easily traced back to individuals or specific assets.
• Data Minimization: Collecting only the data that is absolutely necessary for the operation of the digital twin, minimizing the risk associated with data breaches.

7. Redundancy and Disaster Recovery Planning

• Redundancy: Implement redundant systems to ensure that the digital twin can continue to operate in the event of a cyberattack or system failure. This includes backup systems and failover mechanisms.
• Disaster Recovery: Develop and maintain a disaster recovery plan to quickly restore digital twin operations in the event of a security breach or infrastructure failure.

8. Real-Time Monitoring and Response

• Continuous Monitoring: Setting up continuous monitoring systems to track the performance and security of the digital twin in real-time. This allows for the immediate detection of anomalies or potential security threats.
• Incident Response Plan: Developing and maintaining an incident response plan that outlines the steps to be taken in the event of a security breach, including communication protocols, containment strategies, and recovery procedures.

9. User Training and Awareness

• Security Training: Providing regular security training for all employees, particularly those who interact with the digital twin infrastructure. Training should cover best practices for data protection, recognizing phishing attempts, and proper handling of sensitive information.
• Awareness Programs: Implementing security awareness programs to keep all stakeholders informed about the latest security threats and the importance of maintaining security protocols.

10. Collaborative Security Approach

• Collaboration with Partners: Working closely with partners, vendors, and third-party providers to ensure that all components of the digital twin ecosystem adhere to stringent security standards.
• Security Information Sharing: Participating in industry-wide information-sharing initiatives to stay informed about the latest threats and best practices for securing digital twins in critical infrastructure.

Q: What emerging trends do you foresee in digital twin technology for the energy sector in the next few years?

Kumar M:

I can envisage and foresee many key developments. That is going to change the shape of the renewable energy industry. Some are highlighted below for your ready reference:

1. Integration with Artificial Intelligence (AI) and Machine Learning (ML)

• Predictive Analytics: AI and ML will increasingly be integrated into digital twin platforms to enhance predictive capabilities. This will allow for more accurate forecasting of equipment failures, performance optimization, and energy production, leading to greater efficiency and reduced downtime in renewable energy systems.
• Automated Decision-Making: Digital twins will leverage AI to automate decision-making processes, such as adjusting energy outputs based on real-time data from weather conditions, grid demand, and energy storage levels.

2. Enhanced Real-Time Data Processing and IoT Integration

• Edge Computing: The rise of edge computing will enable digital twins to process data closer to the source (e.g., wind turbines, solar panels), reducing latency and improving the speed of decision-making. This will be crucial for managing the intermittent nature of renewable energy sources.
• IoT Expansion: The proliferation of IoT devices will provide digital twins with more granular and real-time data, improving the accuracy of simulations and models. This trend will also facilitate better monitoring and management of distributed energy resources.

3. Cybersecurity and Data Privacy Innovations

• Blockchain for Security: Blockchain technology may be used to enhance the security of digital twins by providing decentralized, tamper-proof records of all data exchanges and transactions within the system. This will be especially important for protecting critical infrastructure in the renewable energy sector.
• Advanced Encryption Techniques: As the volume of data generated by digital twins increases, so will the need for more sophisticated encryption methods to ensure data privacy and protect against cyber threats.

4. Integration with Renewable Energy Grids

• Smart Grids: Digital twins will play a critical role in the development of smart grids, allowing for real-time monitoring, simulation, and optimization of energy flows. This will help in balancing supply and demand, managing energy storage, and integrating renewable energy sources more effectively into the grid.
• Grid Decentralization: The move towards decentralized energy systems, such as microgrids and virtual power plants, will be supported by digital twins that can model and manage complex, distributed energy networks.

5. Advanced Simulation and Optimization Techniques

• Hybrid and Multi-Physics Modeling: Digital twins will incorporate hybrid models that combine multiple physical domains (e.g., thermal, electrical, mechanical) to provide a more comprehensive understanding of renewable energy systems. This will enable more accurate simulations and optimizations.
• Optimization Algorithms: The use of advanced optimization algorithms will allow digital twins to continuously improve the efficiency and performance of renewable energy assets, from solar farms to wind turbines.

6. Scalability and Cloud-Native Digital Twins

• Cloud-Native Platforms: Digital twins will increasingly be built on cloud-native architectures, enabling them to scale easily and integrate with other cloud-based services. This will facilitate the management of large, geographically dispersed renewable energy assets.
• As-a-Service Models: The adoption of digital twin technology as a service (DTaaS) will grow, allowing smaller companies and projects to leverage digital twins without the need for significant upfront investment in infrastructure.

7. Advanced Visualization and Immersive Technologies

• Augmented Reality (AR) and Virtual Reality (VR): Digital twins will be paired with AR and VR technologies to provide immersive visualization experiences. This will be particularly useful for training, maintenance, and remote monitoring of renewable energy assets.
• 3D and 4D Modeling: Enhanced 3D and 4D modeling capabilities will allow for more dynamic and interactive representations of renewable energy systems, improving decision-making and stakeholder communication.

8. Sustainability and Environmental Impact Monitoring

• Lifecycle Assessment: Digital twins will be used to monitor and optimize the entire lifecycle of renewable energy assets, from construction to decommissioning. This will help in minimizing the environmental impact and maximizing the sustainability of energy projects.
• Carbon Footprint Tracking: Digital twins will enable real-time tracking of the carbon footprint associated with renewable energy projects, providing valuable data for achieving sustainability goals and complying with regulations.

9. Collaboration and Standardization

• Interoperability Standards: The development of industry-wide standards for digital twin interoperability will facilitate greater collaboration between different stakeholders in the renewable energy sector, including manufacturers, operators, and regulators.
• Open Ecosystems: There will be a shift towards more open and collaborative ecosystems for digital twins, allowing different tools, platforms, and services to work together seamlessly.

10. Regulatory Compliance and Reporting

• Automated Reporting: Digital twins will help renewable energy companies automate compliance reporting by continuously monitoring and documenting operations in line with regulatory requirements.
• Real-Time Compliance Monitoring: As regulations evolve, digital twins will be crucial for ensuring real-time compliance, reducing the risk of penalties and improving overall governance.

Thank you for your contributions.