AUTOMATION AND MONITORING OF POWER GENERATOR USING PLC, HMI AND SCADA MASTER UNIT

Group Members
Aqeel Haider Butt Muhammad Yasir Anjum Ayyub Muhammad Ishaq BEES/F05/0141 BEES/F05/0144 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

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 2. Muhammad Yasir Anjum S/O Muhammad Boota Anjum 3. Ayyub Muhammad Ishaq S/O Muhammad Ishaq Haider BEES/F05/0141 BEES/F05/0145 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)

Advisor (HOD, BE Electronics)

(Asst. Prof. Rashid Hussain)

Chairman Final Year Project Committee

(Asst. Prof. Engr. Fahad Azim)

Deputy Director, HIIT

(Prof. Dr. Iqbal Ahmed Khan)

Director, HIIT

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 lifes. And to all the hard working students of HIIT With a hope that they will succeed in Every aspect of their Academic Career

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 prcised result.

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:
1.1 1.2 1.3 Motivation Objective Major Contribution

INTRODUCTION
01 02 03 03 03 04

1.3.1 Contribution of PLC/Modules 1.3.2 Contribution of HMI 1.3.3 Contribution of SCADA Master Unit

CHAPTER 02: Overview of Power Generator

2.1 2.2 What is Power Generator? Diesel Generator Processes 2.2.1 Fuel 2.2.2 Rotation per Minute 2.2.4 Temperature 2.2.4 Load 2.2.5 Transmission of Current to the Load 2.3 How Diesel Generator work? 05 06 06 06 06 07 07 08

CHAPTER 03:
3.1 3.2 What is Automation?

AUTOMATION
10 10

Why Automation except of Manual

Table of Contents

Page No
3.3 Benefits of our Project through Automation 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 ATS (Automatic Transfer Switch) Fuel Tank Phase cut in Main Utility Line Generator Phase Measuring Temperature Over Speed 10 10 11 11 11 12 12

CHAPTER 04:
4.1 What is PLC? 4.1.1 Features

PLC, HMI and SCADA 13 13 14 15 17 17 18 19 19 19 20

4.1.2 PLC Vs with other control systems 4.1.3 Digital and analog signals 4.1.4 System Scale 4.1.5 Programming 4.1.6 User interface 4.1.7 Communications 4.2 What is SCADA? 4.2.1 Basic Functions 4.2.2 SCADA as a System

Table of Contents

Page No
4.2.3 Where the System is utilized? 4.2.4 User Interface (HMI) 4.2.5 SCADA SW and HW Components 4.2.6 SCADA Protocols 20 21 21 21

CHAPTER 05:

Automation & Monitoring of

Power Generator Using PLC, HMI & SCADA Master Unit

5.1

Parts of Project 5.1.1 Automation 5.1.2 Monitoring

22 22 22 23 23 24 25 26 27 27 27 27 28

5.2 5.3 5.4 5.5 5.6 5.7

Safeties and Interlocking Parameters of the Project Standardized Layers Pictorial Diagram of SCADA System Block Diagram of SCADA System Modules and Components 5.7.1 PLC Module 5.7.2 Sensors

5.8 5.9

Description of AI Module ATS Switch

Table of Contents

Page No

CHAPTER 06:

Experimental Work And Result

6.1

Experimental Work 6.1.1 Operation Panel 6.1.1.1 6.1.1.2 Automatic

38 42 42

Manual

43 43

6.2

Result

CHAPTER 07:

Conclusions and Future Enhancement

7.1.1 Conclusions 7.2 Future Enhancement

44 45

CHAPTER 08
8.1 8.2 8.3 Appendix A References Personal Comments

List of Figures

Page No
Figure 2.1: A diesel generator Figure 2.2: An RPM meter 05 06 07 07 08 09 09
11

Figure 2.3: A temperature meter Figure 2.4: An ampere meter

Figure 2.5: Transmission of current to the load by ATS (block diagram) Figure 2.6.1: An engine overview Figure 2.6.2: An engine overview

Figure 3.1: An ATS switch control panel ......

Figure 4.1: A PLC based control panel .. Figure 4.2: A view of SCADA system Figure 5.1: A view of control layers . . . .

13 19 24 25 26 28 37

Figure 5.2: A pictorial representation of SCADA system

Figure 5.3: A block diagram representation of SCADA system Figure 5.3.1: A block connection diagram of ATS switch b Figure 5.4: A block diagram of PLC and SCADA Master Unit

. .

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 automatically be called overshoot then emergency will

II.

If fuel level crosses its minimum or maximum limits, alarm will automatic be generated. If load exceeded on any phase of K.E.S.C, system will automatically generate an alarm. If RPM cross its limits then system will generate alarm.

III.

IV.

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.

1|Page

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.

2|Page

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.

3|Page

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.

4|Page

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]

5|Page

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.

6|Page

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.
7|Page

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,
8|Page

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|Page

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 dont 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.

10 | P a g e

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.
11 | P a g e

But through automation, if one of either phase is cut then it is adjusted automatically in milliseconds and there is no need of persons 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.

12 | P a g e

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.

13 | P a g e

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
14 | P a g e

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 were to replace adopted thousands by the of relays.

Programmable

controllers

initially

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
15 | P a g e

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-

16 | P a g e

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.
17 | P a g e

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.

18 | P a g e

| | | 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
19 | P a g e

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 coordinate 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 directconnection 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
20 | P a g e

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]

21 | P a g e

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]

22 | P a g e

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
23 | P a g e

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
24 | P a g e

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]

25 | P a g e

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. ii. iii. iv. v. ATS RPM Temperature Fuel Level Over Load

5.1.2 Monitoring In monitoring section we are using SCADA Master Unit and it is monitoring: vi. vii. viii. ix. Fuel Level Temperature Over Load Over Speed

26 | P a g e

5.2

Safeties and Interlocking It includes: i. ii. iii. iv. High/Low Fuel Level High/Low Temperature Over speed 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

27 | P a g e

5.4

Standardized Layers

USER LAYER

CONTROL LAYER

FIELD LAYER

Figure 5.1: A view of control layers [07]

28 | P a g e

5.5

Pictorial Diagram of SCADA System

SCADA

Switc

PLC-1 Engn. Temp Fuel Tank

PLC-2 Load share (P1, P2 & P3) RPM

Figure 5.2: A pictorial representation of SCADA system

29 | P a g e

5.6

Block Diagram of SCADA System

SCADA Master Unit

PLC Based Control Panel

Generator

K.E.S.C

ATS

Load

Figure 5.3: A block diagram representation of SCADA system

30 | P a g e

5.7

Modules and Components

5.7.1 PLC Module i. ii. iii. FBS 20_MC Module FBS_4A2D (Analog) FBS_TC 6 [01]

5.7.2 Sensors iv. v. vi. vii. Fuel Level Sensor Temperature (TC) Sensor Contactors (220V, 250 A) 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 Output Register Example

R3840, R3841 R3940, R3941, R3942, R3943 [01]

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

31 | P a g e

Level

Voltage

Number of bits

25% 50% 75% 100%

1.25 V 2.50 V 3.75 V 5V

4096 8193 12289 16383

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

Generator

ATS

K.E.S.C

Load
Figure 5.3.1: A block connection diagram of ATS switch

32 | P a g e

ATS Circuit and Load Sharing Diagram

33 | P a g e

34 | P a g e

35 | P a g e

36 | P a g e

Ladder Programming of the System

37 | P a g e

Ladder Programming of the System

38 | P a g e

39 | P a g e

40 | P a g e

PLC and SCADA Control System [Block Diagram]

FBS_20 MC

FBS_20 MC

FBS_4A2D

Monitoring

FBS_2ATC4

Figure 5.4: A block diagram of PLC and SCADA Master Unit

41 | P a g e

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:

42 | P a g e

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:

43 | P a g e

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:
44 | P a g e

By clicking on Detail View of Speed Meter, The detail graph/trend with date and time is:

45 | P a g e

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.

46 | P a g e

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 01 02 03 04 05 06 Project Majors ATS Fuel Level Over Load Over Speed Engine Temperature Load Share Status Yes Yes Yes Yes Yes Yes Remarks

47 | P a g e

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
48 | P a g e

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.

49 | P a g e

CHAPTER 08
8.1 Appendix A 1) 2) 3) Data sheet of 2N 1208 Data sheet of BR805D Data sheet of LM 324

50 | P a g e

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

51 | P a g e

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)

52 | P a g e

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.