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Project Report (Final)

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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
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Page 1: Project Report (Final)

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

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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

Page 4: Project Report (Final)

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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

Page 5: Project Report (Final)

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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.

Page 6: Project Report (Final)

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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.

Page 7: Project Report (Final)

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

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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

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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

Page 10: Project Report (Final)

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

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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

Page 12: Project Report (Final)

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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Page 16: Project Report (Final)

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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Page 17: Project Report (Final)

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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Page 18: Project Report (Final)

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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Page 19: Project Report (Final)

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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Page 20: Project Report (Final)

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]

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Page 21: Project Report (Final)

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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Page 22: Project Report (Final)

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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Page 23: Project Report (Final)

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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Page 25: Project Report (Final)

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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