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AUTOMATION AND MONITORING
OF POWER GENERATOR USING
PLC, HMI AND SCADA
MASTER UNIT
Group Members Aqeel Haider Butt BEES/F05/0141
Muhammad Yasir Anjum BEES/F05/0144
Ayyub Muhammad Ishaq BEES/F05/0145
Project Advisor Engr. Syed Faiz Ahmed HOD, BE (Electronics)
FACULTY OF ENGINEERING SCIENCE &TECHNOLOGY Hamdard Institute of Information Technology
Hamdard University, Main Campus, Karachi, Pakistan. August 2009
ii
3
FACULTY OF ENGINEERING SCIENCE & TECHNOLOGY Hamdard Institute of Information Technology
Hamdard University, Main Campus, Karachi, Pakistan.
CERTIFICATE This is to certify that Mr.
1. Aqeel Haider Butt S/O Mahmood Sultan Butt BEES/F05/0141
2. Muhammad Yasir Anjum S/O Muhammad Boota Anjum BEES/F05/0145
3. Ayyub Muhammad Ishaq S/O Muhammad Ishaq Haider BEES/F05/0144
Have successfully completed there final year project. This project “Automation and
Monitoring of Power Generator using PLC, HMI and SCADA Master Unit” was assigned
to them to fulfill the partial requirement for the Bachelor degree of Electronics
Engineering.
(Asst. Prof. Engr. Syed Faiz) (Asst. Prof. Rashid Hussain) Advisor (HOD, BE Electronics) Chairman Final Year Project Committee (Asst. Prof. Engr. Fahad Azim) (Prof. Dr. Iqbal Ahmed Khan)
Deputy Director, HIIT Director, HIIT
4
DEDICATION
Dedicated to our beloved parents
And teachers who always pray
For us and encouraged us
At every step specially in this project,
Report as well as in every step that we
Have taken, in our life’s.
And to all the hard working students of
HIIT
With a hope that they will succeed in
Every aspect of their Academic Career
5
ABSTRACT
This project is the replacement of manual to automatic technology i.e. if the K.E.S.C
goes off then load shift from K.E.S.C to Generator through ATS (Automatic Transfer
Switch), similarly if K.E.S.C comes back then load again transfer from power generator
to K.E.S.C. Furthermore in the absence of any phase of K.E.S.C. alternate phase share
the load of that phase which is not present.
All interlocking parameters of power generator will be monitor on the dedicated machine
through SCADA Master Unit and on site also through HMI. This PLC based control
system is more economical, reliable and efficient. So the user could set the desired
point in case of any emergency.
After comparing the result of manual Switch and ATS which is PLC control based, we
proved that micro PLC based system gives more accurate and précised result.
6
ACKNOWLEDGEMENT
This project is done with great exertion by Aqeel Haider, M. Yasir Anjum and Ayyub M.
Ishaq Special thanks to our advisor Engr. Syed Faiz Ahmed for his highly motivated and
kind assistance in this project. The report is solely based on concepts and practical
approaches of PLC, HMI and SCADA. its hardware and software parts and coding are
defined in very elegant way with clear and brief description of each component along
with figures are given for absolute clarity.
A very efficient Algorithm for controlling the PLC is proposed in very easy way that
every one could easily understand the system. And also many thanks to our
co-supervisor Engr. Salman Khan for his most significant contribution and his most
valuable advice in this project on many crucial situation.
Table of Contents
Page No
CHAPTER 01: INTRODUCTION
1.1 Motivation 01
1.2 Objective 02
1.3 Major Contribution 03
1.3.1 Contribution of PLC/Modules 03
1.3.2 Contribution of HMI 03
1.3.3 Contribution of SCADA Master Unit 04
CHAPTER 02: Overview of Power Generator
2.1 What is Power Generator? 05
2.2 Diesel Generator Processes 06
2.2.1 Fuel 06
2.2.2 Rotation per Minute 06
2.2.4 Temperature 06
2.2.4 Load 07
2.2.5 Transmission of Current to the Load 07
2.3 How Diesel Generator work? 08
CHAPTER 03: AUTOMATION 3.1 What is Automation? 10
3.2 Why Automation except of Manual 10
Table of Contents
Page No
3.3 Benefits of our Project through Automation 10
3.3.1 ATS (Automatic Transfer Switch) 10
3.3.2 Fuel Tank 11
3.3.3 Phase cut in Main Utility Line 11
3.3.4 Generator Phase Measuring 11
3.3.5 Temperature 12
3.3.6 Over Speed 12
CHAPTER 04: PLC, HMI and SCADA
4.1 What is PLC? 13
4.1.1 Features 13
4.1.2 PLC Vs with other control systems 14
4.1.3 Digital and analog signals 15
4.1.4 System Scale 17
4.1.5 Programming 17 4.1.6 User interface 18 4.1.7 Communications 19
4.2 What is SCADA? 19
4.2.1 Basic Functions 19
4.2.2 SCADA as a System 20
Table of Contents
Page No
4.2.3 Where the System is utilized? 20
4.2.4 User Interface (HMI) 21
4.2.5 SCADA SW and HW Components 21
4.2.6 SCADA Protocols 21
CHAPTER 05: Automation & Monitoring of
Power Generator Using PLC,
HMI & SCADA Master Unit
5.1 Parts of Project 22
5.1.1 Automation 22
5.1.2 Monitoring 22
5.2 Safeties and Interlocking 23
5.3 Parameters of the Project 23
5.4 Standardized Layers 24
5.5 Pictorial Diagram of SCADA System 25
5.6 Block Diagram of SCADA System 26
5.7 Modules and Components 27
5.7.1 PLC Module 27
5.7.2 Sensors 27
5.8 Description of AI Module 27
5.9 ATS Switch 28
Table of Contents
Page No
CHAPTER 06: Experimental Work
And Result
6.1 Experimental Work 38
6.1.1 Operation Panel 42
6.1.1.1 Automatic 42
6.1.1.2 Manual 43
6.2 Result 43
CHAPTER 07: Conclusions and Future
Enhancement
7.1.1 Conclusions 44
7.2 Future Enhancement 45
CHAPTER 08
8.1 Appendix A
8.2 References
8.3 Personal Comments
List of Figures
Page No
Figure 2.1: A diesel generator ……………………………………………… 05 Figure 2.2: An RPM meter ……………………………………………… 06
Figure 2.3: A temperature meter ……………………………………………… 07
Figure 2.4: An ampere meter ……………………………………………… 07
Figure 2.5: Transmission of current to the load by ATS (block diagram) … 08
Figure 2.6.1: An engine overview ……………………………………… 09
Figure 2.6.2: An engine overview ……………………………………… 09
Figure 3.1: An ATS switch control panel ……………………………………...... 11
Figure 4.1: A PLC based control panel …………………………………….. 13
Figure 4.2: A view of SCADA system ……………………………………. 19
Figure 5.1: A view of control layers ……………………………………. 24
Figure 5.2: A pictorial representation of SCADA system ……………. 25
Figure 5.3: A block diagram representation of SCADA system ……. 26
Figure 5.3.1: A block connection diagram of ATS switch b ……………. 28
Figure 5.4: A block diagram of PLC and SCADA Master Unit ……. 37
CHAPTER 01
INTRODUCTION
1.1 Motivation
With the passage of time the thing and their usage is become more user
friendly. This concept motivates us to do an industrial and user friendly
project. In the same time we got information that the deputy director city
campus 2 want to automate their 200KVA diesel generator in a least budget.
We met them and show our eager to complete this project in a minimum
budget with best feasible solution. They accept our proposal and allow us to
do work on this project.
In our proposal, we gave them the complete automatic solution of:
1. ATS as the replacement of manual switch.
2. Safeties and interlocking i.e.
I. If engine temperature overshoot then emergency will automatically be called
II. If fuel level crosses its minimum or maximum limits, alarm will automatic be generated.
III. If load exceeded on any phase of K.E.S.C, system will automatically generate an alarm.
IV. If RPM cross its limits then system will generate alarm.
Note: These all features/Parameters can control as well as monitored on your Laptop/PC or on Dedicated Machine.
3. Solution of load sharing and etc.
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1.2 Objective
The Automation and Monitoring of Power Generator using PLC
(Programmable Logic Controller) and SCADA (Supervisory Control And Data
Acquisition) which is the title of our project.
Here our objective is to make our project an industrial bases control system.
A system which not only control different processes but also there processes
can be monitored. Here the process controller is PLC and to monitor different
processes of our project at site through HMI (Human Machine Interface).
.
Finally, we are implementing SCADA Master which not only monitors but also
control the processes of our project at a control room. So using such control
systems our Power Generator is safe and secure.
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1.3 Major Contribution
Basically this project is PLC based. So, in this project major role is played by
1. PLC
2. HMI
3. SCADA Master Unit
All have their own role and importance in the completion of this system.
1.3.1 Contribution of PLC/Modules
In this project PLC is the main controlling device, which has the all control of
this system. All digital I/Os which comes from the control panel are connected
to the main unit of PLC. For analog I/Os there is analog module which is
cascaded to the main unit.
Similarly for engine temperature i.e. PT100 is connected to thermocouple
module and this thermocouple module is further connected to main PLC unit.
PLC has the major contribution in this controlling of system. It is the main
processing and controlling device in all the circuitry.
1.3.2 Contribution of HMI
Here the usage of HMI is only to provide the flexibility to generator operator.
Because if any emergency call at the site and no one present in main control
room then how generator operator troubleshoot that problem or how he will
diagnose the problem. So, for easy understanding to operator and to reduce
the burden from main control room we provide an extra feature at site and
that is HMI. In case of emergency alarm generator operator can handle and
troubleshoot the problem without entering in the control room. But one thing is
important to clear that HMI user has limited access as compared to the main
control room user.
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1.3.3 Contribution of SCADA Master Unit
As SCADA stand for Sequential Control and Data Acquisition, it is installed in
main control room and has complete accessibility to all controlling parameter
of system. In control room on PC or Laptop user can monitor as well as check
complete trend of different processes i.e. trend of fuel level, RPM of engine,
load on generator and etc.
At there user has complete command and authority on each processes of
generator. There is a facility to user of 24/7 hours of monitoring and reporting
of generator i.e. from how many hours generator is running? How much fuel
consumes and how much consumption should.
In case of emergency user can easily diagnose and troubleshoot the problem.
He can change the parameter according to the situation. Due to the SCADA
master unit maintained and troubleshooting become easy.
Basically in control room it is a complete SCADA system where user has
complete control and command on the system.
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CHAPTER 02
Overview of Power Generator
2.1 What is Power Generator?
Power Generator is the process of converting mechanical energy into
electrical energy. There is several method of directly transforming other forms
of energy into electrical energy. Some of them are solar energy, wind power
energy and electromagnetic induction etc. Here our projects related with
electromagnetic induction. In electromagnetic induction an electrical
generator, alternator or dynamo transforms kinetic energy into electrical
energy. This form of transformation of energy is widely used in all commercial
centers. [04]
We are considering in our project is a Diesel Generator.
Figure 2.1: A diesel generator [02]
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2.2 Diesel Generator Processes
There are several processes of the diesel generator to be started. These
processes along with their description are as fellows.
2.2.1 Fuel
The fuel is the initial requirement of any machine to be started. Therefore
there should be an enough fuel level in the fuel tank of the diesel generator.
2.2.2 Rotation per Minute
RPM is main unit of the generator. In this we calculate the rotation of the
motor in a minute. Basically RPM is directly proportional to the frequency. If
the rpm of the motor get required speed then we delivered the load.
Figure 2.2: An RPM meter [03]
2.2.3 Temperature
In this process of diesel generator the temperature plays a significant role.
The temperature actually defines the engine temperature of the diesel
generator. So it is obvious that the engine temperature should be neither too
low nor too higher rather, it should be moderate.
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Figure 2.3: A temperature meter [03]
2.2.4 Load
The term “load” is used for reason that how much an appliance consumes
current from the power generator. Therefore the appliances load on the diesel
generator should be eighty percentage of the total power produced by the
diesel generator.
Figure 2.4: An ampere meter [03]
2.2.5 Transmission of Current to the Load
Once the machine process are achieved and fulfilled the power from the
diesel generator is delivered to the load by using change over switch.
A change over switch is a kind of manual switch for switching load between
the main utility power and the diesel generator.
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1
Figure 2.5: Transmission of current to the load by ATS (block diagram)
2.3 How Diesel Generator work? In the diesel engine, only air is introduced into the combustion chamber. The
air is then compressed with a compression ratio typically between 15 and 22
resulting into a 40 bar (about 600 psi) pressure compared to 14 bar (about 200
psi) in the gasoline engine. This high compression heats the air to 550 °C
(about 1000 °F). At about this moment (the exact moment is determined by the
fuel injection timing of the fuel system), fuel is injected directly into the
compressed air in the combustion chamber. This may be into a (typically
toroidal) void in the top of the piston or a 'pre-chamber' depending upon the
design of the engine.
The fuel injector ensures that the fuel is broken down into small droplets, and
that the fuel is distributed as evenly as possible. The more modern the engine,
the smaller, more numerous and better distributed are the droplets. The heat
of the compressed air vaporizes fuel from the surface of the droplets. The
vapor is then ignited by the heat from the compressed air in the combustion
chamber, the droplets continue to vaporize from their surfaces and burn,
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getting smaller, until all the fuel in the droplets has been burnt. The start of
vaporization causes a delay period during ignition, and the characteristic diesel
knocking sound as the vapor reaches ignition temperature and causes an
abrupt increase in pressure above the piston.
The rapid expansion of combustion gases then drives the piston downward,
supplying power to the crankshaft. A governor is used between the alternator
and the diesel engine so that when load is placed on the alternator (you plug a
power tool in to the generator for example) the engine revs pickup to spin the
shaft fast enough to produce sufficient electricity. [04]
Figure 2.6.1: An engine overview [02] Figure 2.6.2: An engine overview [02]
9 | P a g e
CHAPTER 03
AUTOMATION
3.1 What is Automation?
Automation is the use of control systems to control processes, reducing the
need for human intervention. Automation is having technology do things for
you so that you don’t have to.
3.2 Why Automation except of Manual
There are numerous advantages of automation
• The automation reduces the need for human intervention.
• Replaces the human in task that should be work done in dangerous
environment (fire, high temperature, underwater etc.)
• Economy improvement.
• It can improve the quality, increase the performance of a machine and
reduces the cost.
• Using automation we can produce more and more products and services
within a short period of the time which is not possible through the manual
one.
3.3 Benefits of our Project through Automation
There are numerous benefits of automation concerning our project. Let us
see them in each process of our project.
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3.3.1 ATS (Automatic Transfer Switch)
ATS can mean:" ... Automatic Transfer switch, in an electrical system, switches power automatically to a generator or other standby power...
Figure 3.1: An ATS switch control panel [02]
3.3.2 Fuel Tank
As we discussed before that there should be an enough fuel in the fuel tank
for the diesel generator to be started.
Therefore an individual person was supposed to monitor the fuel tank all the
times to ensure that there is enough fuel in the fuel tank.
And the main problem is the fuel stolen of the power generator. But using
automation we can see the fuel level at the screen of our PC.
3.3.3 Phase cut in Main Utility Line
Consider a 3 phase utility line provided to the load. If one of either phase is
cut an individual is supposed to shift the load from the cut phase to the
available phase.
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But through automation, if one of either phase is cut then it is adjusted
automatically in milliseconds and there is no need of person’s intervention.
3.3.4 Generator Phase Measuring
This is actually the current consumed by load the diesel Generator. Now the
Question rises how much o maximum current can be consumed by the load
that the diesel generator remains safe.
Well the answer of the above question is that it depends on the current raring
of the generator. Say a generator of 220KVA provides maximum current rate
of 1000 A
P= 220,000
V=220
I= P/V
I= 1000 A
Now suppose a load is connected to Phase 1st of generator and it consumed
300 A, and the load on the 2nd Phase consumes 300 A and 3rd Phase
consumed 350 A. So the total current consumed is 950 A.
From the above, we see that the load on the 3rd phase high enough therefore
the load should be lowered down.
Using automation tools, an alarm generates and states that here is much load
connected to the phase else it was not possible through the manual one.
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3.3.5 Temperature
This feature will give us benefit of safety of generator specially safety of
engine of generator. If temperature rises from given limit due to any reason,
the generator automatically shut down and hence it safe the generator.
3.3.6 Over Speed
By automation we are going to have detail of RPM/Speed of the generator
(i.e. 1200, 1400 or 1500 RPM). If the engine speed increase from set limit
then automatically safety calls, and it saves the load attached with phases of
generator.
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CHAPTER 04
PLC, HMI and SCADA 4.1 What is PLC?
Figure 4.1: A PLC based control panel [02]
A programmable logic controller (PLC) or programmable controller is a
digital computer used for automation of industrial processes, such as control
of machinery on factory assembly lines. Unlike general-purpose computers,
the PLC is designed for multiple inputs and output arrangements, extended
temperature ranges, immunity to electrical noise, and resistance to vibration
and impact. Programs to control machine operation are typically stored in
battery-backed or non-volatile memory. A PLC is an example of a real time
system since output results must be produced in response to input conditions
within a bounded time, otherwise unintended operation will result. [06]
4.1.1 Features
The main difference from other computers is that PLCs are armored for
severe conditions (dust, moisture, heat, cold, etc) and have the facility for
extensive input/output (I/O) arrangements. These connect the PLC to sensors
and actuators. PLCs read limit switches, analog process variables (such as
temperature and pressure), and the positions of complex positioning systems.
Some even use machine vision. On the actuator side, PLCs operate electric
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motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or
analog outputs. The input/output arrangements may be built into a simple
PLC, or the PLC may have external I/O modules attached to a computer
network that plugs into the PLC.
PLCs were invented as replacements for automated systems that would use
hundreds or thousands of relays, cam timers, and drum sequencers. Often, a
single PLC can be programmed to replace thousands of relays.
Programmable controllers were initially adopted by the automotive
manufacturing industry, where software revision replaced the re-wiring of
hard-wired control panels when production models changed.
Many of the earliest PLCs expressed all decision making logic in simple ladder
logic which appeared similar to electrical schematic diagrams. The
electricians were quite able to trace out circuit problems with schematic
diagrams using ladder logic. This program notation was chosen to reduce
training demands for the existing technicians. Other early PLCs used a form
of instruction list programming, based on a stack-based logic solver.
The functionality of the PLC has evolved over the years to include sequential
relay control, motion control, process control, distributed control systems and
networking. The data handling, storage, processing power and
communication capabilities of some modern PLCs are approximately
equivalent to desktop computers. PLC-like programming combined with
remote I/O hardware, allow a general-purpose desktop computer to overlap
some PLCs in certain applications. [06]
4.1.2 PLC Vs with other control systems
PLCs are well-adapted to a range of automation tasks. These are typically
industrial processes in manufacturing where the cost of developing and
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maintaining the automation system is high relative to the total cost of the
automation, and where changes to the system would be expected during its
operational life. PLCs contain input and output devices compatible with
industrial pilot devices and controls; little electrical design is required, and the
design problem centers on expressing the desired sequence of operations in ladder logic (or function chart) notation.
PLC applications are typically highly customized systems so the cost of a
packaged PLC is low compared to the cost of a specific custom-built
controller design. On the other hand, in the case of mass-produced goods,
customized control systems are economic due to the lower cost of the
components, which can be optimally chosen instead of a "generic" solution,
and where the non-recurring engineering charges are spread over thousands
of places. For high volume or very simple fixed automation tasks, different
techniques are used. For example, a consumer dishwasher would be
controlled by an electromechanical cam timer costing only a few dollars in
production quantities.
A microcontroller-based design would be appropriate where hundreds or
thousands of units will be produced and so the development cost (design of
power supplies and input/output hardware) can be spread over many sales,
and where the end-user would not need to alter the control. Automotive
applications are an example; millions of units are built each year, and very
few end-users alter the programming of these controllers. However, some
specialty vehicles such as transit busses economically use PLCs instead of
custom-designed controls, because the volumes are low and the
development cost would be uneconomic.
Very complex process control, such as used in the chemical industry, may
require algorithms and performance beyond the capability of even high-
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performance PLCs. Very high-speed or precision controls may also require
customized solutions; for example, aircraft flight controls.
PLCs may include logic for single-variable feedback analog control loop, a
"proportional, integral, derivative" or "PID controller". A PID loop could be
used to control the temperature of a manufacturing process, for example.
Historically PLCs were usually configured with only a few analog control
loops; where processes required hundreds or thousands of loops, a
distributed control system (DCS) would instead be used. However, as
PLCs have become more powerful, the boundary between DCS and PLC
applications has become less clear-cut.
PLCs have similar functionality as Remote Terminal Units. An RTU,
however, usually does not support control algorithms or control loops. As
hardware rapidly becomes more powerful and cheaper, RTUs, PLCs and
DCSs are increasingly beginning to overlap in responsibilities, and many
vendors sell RTUs with PLC-like features and vice versa. The industry has
standardized on the IEC 61131-3 functional block language for creating
programs to run on RTUs and PLCs, although nearly all vendors also offer
proprietary alternatives and associated development environments. [06]
4.1.3 Digital and analog signals
Digital or discrete signals behave as binary switches, yielding simply an On or
Off signal (1 or 0, True or False, respectively). Push buttons, limit switches,
and photoelectric sensors are examples of devices providing a discrete
signal. Discrete signals are sent using either voltage or current, where a
specific range is designated as On and another as Off. For example, a PLC
might use 24 V DC I/O, with values above 22 V DC representing On, values
below 2VDC representing Off, and intermediate values undefined. Initially,
PLCs had only discrete I/O.
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Analog signals are like volume controls, with a range of values between zero
and full-scale. These are typically interpreted as integer values (counts) by
the PLC, with various ranges of accuracy depending on the device and the
number of bits available to store the data. As PLCs typically use 16-bit signed
binary processors, the integer values are limited between -32,768 and
+32,767. Pressure, temperature, flow, and weight are often represented by
analog signals. Analog signals can use voltage or current with a magnitude
proportional to the value of the process signal. For example, an analog 4-20
mA or 0 - 10 V input would be converted into an integer value of 0 - 32767.
Current inputs are less sensitive to electrical noise (i.e. from welders or
electric motor starts) than voltage inputs.
Example
As an example, say a facility needs to store water in a tank. The water is
drawn from the tank by another system, as needed, and our example system
must manage the water level in the tank.
Using only digital signals, the PLC has two digital inputs from float switches
(tank empty and tank full). The PLC uses a digital output to open and close
the inlet valve into the tank.
When the water level drops enough so that the tank empty float switch is off
(down), the PLC will open the valve to let more water in. Once the water level
raises enough so that the tank full-switch is on (up), the PLC will shut the inlet
to stop the water from overflowing.
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| | | Low Level High Level Fill Valve | |------[ ]------|------[/]----------------------(OUT)---------| | | | | | | | | | | Fill Valve | | |------[ ]------| | | | | |
An analog system might use a water pressure sensor or a load cell, and an
adjustable (throttling) dripping out of the tank, the valve adjusts to slowly drip
water back into the tank.
In this system, to avoid 'flutter' adjustments that can wear out the valve, many
PLCs incorporate "hysteretic" which essentially creates a "dead band" of
activity. A technician adjusts this dead band so the valve moves only for a
significant change in rate. This will in turn minimize the motion of the valve,
and reduce its wear.
A real system might combine approaches, using float switches and simple
valves to prevent spills, and a rate sensor and rate valve to optimize refill
rates and prevent water hammer. Backup and maintenance methods can
make a real system very complicated. [06]
4.1.4 System Scale
A small PLC will have a fixed number of connections built in for inputs and
outputs. Typically, expansions are available if the base model does not have
enough I/O.
Modular PLCs have a chassis (also called a rack) into which is placed
modules with different functions. The processor and selection of I/O modules
is customized for the particular application. Several racks can be
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administered by a single processor, and may have thousands of inputs and
outputs. A special high speed serial I/O link is used so that racks can be
distributed away from the processor, reducing the wiring costs for large
plants.
PLCs used in larger I/O systems may have peer-to-peer (P2P)
communication between processors. This allows separate parts of a complex
process to have individual control while allowing the subsystems to co-
ordinate over the communication link. These communication links are also
often used for HMI (Human-Machine Interface) devices such as keypads or
PC-type workstations. Some of today's PLCs can communicate over a wide
range of media including RS-485, Coaxial, and even Ethernet for I/O control
at network speeds up to 100 Mbit/s. [06]
4.1.5 Programming
Early PLCs, up to the mid-1980s, were programmed using proprietary
programming panels or special-purpose programming terminals, which often
had dedicated function keys representing the various logical elements of PLC
programs. Programs were stored on cassette tape cartridges.
Facilities for printing and documentation were very minimal due to lack of
memory capacity. More recently, PLC programs are typically written in a
special application on a personal computer, then downloaded by a direct-
connection cable or over a network to the PLC. The very oldest PLCs used
non-volatile magnetic core memory but now the program is stored in the PLC
either in battery-backed-up RAM or some other non-volatile flash memory.
Early PLCs were designed to replace relay logic systems. These PLCs were
programmed in "ladder logic", which strongly resembles a schematic diagram
of relay logic. Modern PLCs can be programmed in a variety of ways, from
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ladder logic to more traditional programming languages such as BASIC and
C. Another method is State Logic, a Very High Level Programming Language
designed to program PLCs based on State Transition Diagrams.
Recently, the International standard IEC 61131-3 has become popular. IEC
61131-3 currently defines five programming languages for programmable
control systems: FBD (Function block diagram), LD (Ladder diagram), ST
(Structured text, similar to the Pascal programming language), IL (Instruction
list, similar to assembly language) and SFC (Sequential function chart).
These techniques emphasize logical organization of operations.
While the fundamental concepts of PLC programming are common to all
manufacturers, differences in I/O addressing, memory organization and
instruction sets mean that PLC programs are never perfectly interchangeable
between different makers. Even within the same product line of a single
manufacturer, different models may not be directly compatible. [06]
4.1.6 User interface
PLCs may need to interact with people for the purpose of configuration, alarm
reporting or everyday control. A Human-Machine Interface (HMI) is employed
for this purpose. HMI's are also referred to as MMI's (Man Machine Interface)
and GUI (Graphical User Interface).
A simple system may use buttons and lights to interact with the user. Text
displays are available as well as graphical touch screens. Most modern PLCs
can communicate over a network to some other system, such as a computer
running a SCADA (Supervisory Control And Data Acquisition) system or web
browser. [06]
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4.1.7 Communications
PLCs have built in communications ports usually 9-Pin RS232, and optionally
for RS485 and Ethernet. Modbus or DF1 is usually included as one of the
communications protocols. Others' options include various fieldbuses such as
DeviceNet or Profibus. [05]
4.2 What is SCADA?
Figure 4.2: A view of SCADA system [03]
SCADA is an acronym that stands for Supervisory Control and Data
Acquisition. SCADA refers to a system that collects data from various sensors
at a factory, plant or in other remote locations and then sends this data to a
central computer which then manages and controls the data. [06]
4.2.1 Basic Functions
Its fundamental role is gathering information. It does so by having sensors
attached to external locations. It relays these pieces of information to the
central station. It is this system that supervises and manages the information
being submitted. [05]
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4.2.2 SCADA as a System
There are many parts of a working SCADA system. A SCADA system usually
includes signal hardware (input and output), controllers, networks, user
interface (HMI), communications equipment and software. All together, the
term SCADA refers to the entire central system. The central system usually
monitors data from various sensors that are either in close proximity or off site
(sometimes miles away).
For the most part, the brains of a SCADA system are performed by the
Remote Terminal Units (sometimes referred to as the RTU). The Remote
Terminal Units consists of a programmable logic converter. The RTU are
usually set to specific requirements, however, most RTU allow human
intervention, for instance, in a factory setting, the RTU might control the
setting of a conveyer belt, and the speed can be changed or overridden at
any time by human intervention. In addition, any changes or errors are usually
automatically logged for and/or displayed. Most often, a SCADA system will
monitor and make slight changes to function optimally; SCADA systems are
considered closed loop systems and run with relatively little human
intervention.
One of key processes of SCADA is the ability to monitor an entire system in
real time. This is facilitated by data acquisitions including meter reading,
checking statuses of sensors, etc that are communicated at regular intervals
depending on the system. Besides the data being used by the RTU, it is also
displayed to a human that is able to interface with the system to override
settings or make changes when necessary.
SCADA can be seen as a system with many data elements called points.
Usually each point is a monitor or sensor. Usually points can be either hard or
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soft. A hard data point can be an actual monitor; a soft point can be seen as
an application or software calculation. Data elements from hard and soft
points are usually always recorded and logged to create a time stamp or
history. [06]
4.2.3 Where the System is utilized?
It is currently being used in factories and for monitoring traffic signals. It is
also used in the water / power management, mass transit and other similar
industries. The reason is simple. With SCADA, the data generated by the
various components will be easier to handle. Because information is kept at
the central location, it becomes an efficient choice. [06]
4.2.4 User Interface (HMI)
A SCADA system includes a user interface, usually called Human Machine
Interface (HMI). The HMI of a SCADA system is where data is processed and
presented to be viewed and monitored by a human operator. This interface
usually includes controls where the individual can interface with the SCADA
system. [06]
HMI's are an easy way to standardize the facilitation of monitoring multiple
RTU's or PLC's (programmable logic controllers). Usually RTU's or PLC's will
run a pre programmed process, but monitoring each of them individually can
be difficult, usually because they are spread out over the system. Because
RTU's and PLC's historically had no standardized method to display or
present data to an operator, the SCADA system communicates with PLC's
throughout the system network and processes information that is easily
disseminated by the HMI.
HMI's can also be linked to a database, which can use data gathered from
PLC's or RTU's to provide graphs on trends, logistic info, schematics for a
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specific sensor or machine or even make troubleshooting guides accessible.
In the last decade, practically all SCADA systems include an integrated HMI
and PLC device making it extremely easy to run and monitor a SCADA
system. [06]
4.2.5 SCADA SW and HW Components
SCADA systems are an extremely advantageous way to run and monitor
processes. They are great for small applications such as climate control or
can be effectively used in large applications such as monitoring and
controlling a nuclear power plant or mass transit system.
SCADA can come in open and non proprietary protocols. Smaller systems
are extremely affordable and can either be purchased as a complete system
or can be mixed and matched with specific components. Large systems can
also be created with off the shelf components. SCADA system software can
also be easily configured for almost any application, removing the need for
custom made or intensive software development. [06]
4.2.6 SCADA Protocols
This system can be either open or non proprietary. Most of these are large
scale and complete. This features means there's no need to add any more
components. But there are systems that can be constructed piece by piece.
This is ideal for those who want it custom built. [06]
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CHAPTER 05
Automation & Monitoring of
Power Generator Using PLC,
HMI & SCADA Master Unit
5.1 Parts of Project
To achieve all these objective parameters, this project is divided into two
sections:
1) Automation/Controlling
2) Monitoring
5.1.1 Automation
In Automation, we have covered:
i. ATS
ii. RPM
iii. Temperature
iv. Fuel Level
v. Over Load
5.1.2 Monitoring
In monitoring section we are using SCADA Master Unit and it is monitoring:
vi. Fuel Level
vii. Temperature
viii. Over Load
ix. Over Speed
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5.2 Safeties and Interlocking
It includes:
i. High/Low Fuel Level
ii. High/Low Temperature
iii. Over speed
iv. Overload
The manual Emergency button is going to replaced by the automatic one. If
any of the above alarm is operated the system will be automatically shut
down.
5.3 Parameters of the Project
The important parameters of this project are
1) To save, and report of Fuel theft…
2) To save, and report of Electricity theft…
3) To share the load in absence of any phase of K.E.S.C…
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5.4 Standardized Layers
USER LAYER
CONTROL LAYER
FIELD LAYER
Figure 5.1: A view of control layers [07]
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5.5 Pictorial Diagram of SCADA System
RPM
SCADA
Switc
Engn. Temp Fuel Tank Load share (P1, P2 & P3)
PLC-2 PLC-1
Figure 5.2: A pictorial representation of SCADA system
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5.6 Block Diagram of SCADA System
PLC Based
Control Panel
Generator
ATS K.E.S.C
SCADA
Master Unit
Load
Figure 5.3: A block diagram representation of SCADA system
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5.7 Modules and Components
5.7.1 PLC Module
i. FBS 20_MC Module
ii. FBS_4A2D (Analog)
iii. FBS_TC 6 [01]
5.7.2 Sensors
iv. Fuel Level Sensor
v. Temperature (TC) Sensor
vi. Contactors (220V, 250 A)
vii. Relays (24V, 10A)
5.8 Description of AI Module
• In this project for analog I/O 2ATC4 is used.
• It has 0 ~ 16383 bits in uni-polar.
• Max 5V in uni-polar.
• It contains 2 analog input and 4 digital outputs.
Input Register R3840, R3841
Output Register R3940, R3941, R3942, R3943 [01]
Example
How the level of fuel tank will be detected?
We divide fuel tank in four different levels 25%
1) 50%
2) 75%
3) 100%
And set analog bits with respect to their fuel level, as
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Level Voltage Number of bits
25% 1.25 V 4096
50% 2.50 V
75% 3.75 V 12289
100% 16383 5 V
8193
5.9 ATS Switch
It stands for “Automatic Transfer Switch”.
Switches electric load b/w utility power & Generator.
Manual change over switch is replaced by ATS i.e. PLC based. [04]
Block Connection Diagram of ATS
ATS K.E.S.C Generator
Load
Figure 5.3.1: A block connection diagram of ATS switch
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ATS Circuit and Load Sharing Diagram
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Ladder Programming of the System
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Ladder Programming of the System
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PLC and SCADA Control System
[Block Diagram]
FBS_2ATC4
FBS_4A2D
Monitoring
FBS_20 MC FBS_20 MC
Figure 5.4: A block diagram of PLC and SCADA Master Unit
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CHAPTER 06
Experimental Work and Result
6.1 Experimental Work
It is the main control panel, which is monitored on Laptop/PC or on any
dedicated machine:
It is telling the present status of Generator (i.e. Fuel Level, Temperature,
Speed of Generator/RPM and Load of Generator). The detail trend/graph of
Fuel Level, Temperature, RPM and Load at Generator can be viewed by
clicking on “Detail View” of each parameter. For example:
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By clicking on “Detail View” of Fuel Level, The detail graph/trend with date
and time is:
Note:
If fuel is not enough (i.e. fuel <=20% of total) then emergency will call and it
shutdown the generator. On Main Control Panel there will glow a LED with
red light which will show that Fuel is not sufficient, for example:
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By clicking on “Detail View” of Temperature, The detail graph/trend with date and time is:
Note:
If temperature over shoot (i.e. temperature >=95 degree Celsius) emergency will call and it shutdown the generator. On Main Control Panel there will glow a LED with red light which mean engine temperature over shoots, for example:
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By clicking on “Detail View” of Speed Meter, The detail graph/trend with date and time is:
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Note: If speed of generator/RPM increase (i.e. RPM >1555), safety will call and it
shutdown the generator. On Main Control Panel there will glow a LED with
red light which mean engine speed/ RPM overshoot, for example:
Similarly, the detail trend/graph can be seen for load of generator by clicking
on “Detail View” of Load Meter. If generator overloaded then safety will call
and it shutdown the generator. LED (with red light) will glow, which show that
generator is over loaded.
6.1.1 Operation Panel
In this panel there are two (02) buttons which have there own functions. In
this panel there is an option for user that whether he/she wants to run his/her
system automatic or manual.
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6.1.1.1 Automatic
By pressing Automatic button generator will run automatically, and all its
interlocking and parameters can be control and monitor through control and
monitoring system (SCADA Master Unit).
6.1.1.2 Manual
If user wants that his system work manually, then by pressing Manual button
generator will run manually, and there will be no connection of generator with
PLC and SCADA Master Unit.
6.2 Result
Checklist table
Sr. No Project Majors Status Remarks
01 ATS Yes
02 Fuel Level Yes
03 Over Load Yes
04 Over Speed Yes
05 Engine Temperature Yes
06 Load Share Yes
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CHAPTER 07
Conclusions and Future Enhancement
7.1 Conclusions
This project concludes that it is an application of SCADA System. By
enhancing this project, this system can be implemented practically in
Hamdard University or any industry.
By implemented this cost effective project in Hamdard University, many
problems can be overcome related to generator issues and benefits can be
obtained, for example
1) ATS switch will switch electric load b/w utility power & Generator.
Manual change over switch is replaced by ATS i.e. PLC based ATS
switch.
2) Fuel theft can be control because of this system. It has 24/7 hour
monitoring and reporting features.
3) Over load safety will provide solution of electricity theft, mean if more
than calculated load will apply on generator then system will generate an
alarm and after some time it (systen0 will shut down the generator i.e. if
any one will take connection from generator without informing concerned
person or authority then automatically load will increase on generator
and hence alarm will generate and after some time generator will shut
down.
4) Engine temperature safety is for safe running of generator. On
continuous running of generator temperature gradually increases, if
temperature overshoot then it is harmful for generator. This system has
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solution of overshoot engine temperature and that is if engine
temperature over shoot beyond the limit then this SCADA system will
generate an alarm of overshoot engine temperature, and after some
time generator will shut down automatically. These safety parameters
will save the maintenance cost of the generator.
5) RPM safety parameter is for detail monitoring of RPM/Speed of the
generator (i.e. 1200, 1400 or 1500 RPM). If the engine speed increase
from set limit then automatically safety calls, and it saves the load
attached with phases of generator.
Note:
All these features/Parameters will be controlled as well as monitored in Control Room on Laptop/PC or on a Dedicated Machine.
7.2 Future Enhancement
By enhancing this project, this system can be implemented practically in
Hamdard University or any where. Some enhancement should be take place
for the practical implementation of this project/system. By taking these
enhancements this system will become more efficient and problem tolerate.
1) Emergency stop button should be at site also.
2) Safe operation for neutral missing detection
3) There should over voltage safety also.
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CHAPTER 08
8.1 Appendix A
1) Data sheet of 2N 1208 2) Data sheet of BR805D 3) Data sheet of LM 324
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8.2 References
1) http://www.fatek.com
2) http://www.google.com
3) http://www.ultravista.com
4) http://www.wikipedia.com
5) http://www.pacontrol.com
6) http://www.tech-faq.com
7) http://www.electrotech.com
8) http://www.metacrawler.com
9) http://www.wonderware.com
10) http://www.electroniczone.com
11) http://www.training-classes.com
12) http://www.electronic-circuits.com
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8.3 Personal Comments
What we judge in our four (04) academic years at Hamdard University,
Hamdard University is the best place in Pakistan to learn. Atmosphere and
HU culture is very impressive. Hamdard University site (location), its culture
and its peaceful environment make it best Institute in Pakistan especially in
Karachi. We are not saying that every thing is perfect but mostly are very
good. Faculty staff is very talented and cooperative specially Engr. Saifuddin
Hirani, Engr. Fahad Azim, Engr. Syed Faiz Ahmed, Engr. Junaid Hashmani
and Engr. M. Salman Khan. There is little bit lack of management in academic
and administration. But now Mr. M. Usman Siddiqui with his team is trying to
improve administration department, While Mr. Abdul Aleem is making his
effort for Academics department. During last four years, we learned a lot from
this University. In our opinion HIIT is the best place for any engineering
discipline.
Finally our best wishes for this great Institute and University. HIIT should be
towards greater height.
(Aameen)
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Hamdard Institute of Information Technology (HIIT)
FEST Hamdard University
FACULTY OF ENGINEERING SCIENCE &TECHNOLOGY
Hamdard Institute of Information Technology Hamdard University, Main Campus, Karachi, Pakistan.
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