International Journal of Pure and Applied Mathematics
Volume 119 No. 14 2018, 631-636
ISSN: 1314-3395 (on-line version)
url: http://www.ijpam.eu
Special Issue
250MVA GENERATOR TRANSFORMER COOLING SYSTEM CONTROL USING PLC
S.Sankar1, R.Raghul2,,C.Selvakumar3, A.Sasidhar4, S.Jaisiva5
1,2,3,4
UG Student, Depatment of EEE, IFET College of Engineering, Villupuram
5
Senior Assistant Professor, Department of EEE, IFET College of Engineering, Villupuram
ABSTRACT
To meet out the future load demand, electrical industry
needs to be cost efficient . Existing transformer represent
as an assert thus monitoring will be prime factor for
effective use of these transformer. Online monitoring
system implies the operator to optimize the load which
has risk over the functionality of transformer.In power
system transformer plays a vital role in the conventional
ac system. Thus some transformers are critical due to
more power handling capacity. Power transformer is a
one such transformer whose capacity is more than
1MVA.such a transformer has to be given more
importance. In order to improve the performance,
cooling system and protection scheme has to be
employed. This system impact good performances along
with cost efficiency.
Keywords. Efficient, monitoring, power transformer,
protection scheme, cooling system.
INTRODUCTION:
To decrease the Down-time of existing system without
disturbing safety and electrical interlocking
arrangements, and to up-dates system control
Programmable Logic Controller (PLC) will be the best
choice at our hand. The Internal and external cooling
techniques may be provided in an effective manner with
lot more added facilities- by introducing PLC into
action. Almost, 90% of Industries are swiftly switching
over to this latest technology. More than 90% of
physical wiring will be avoided. It is a proven
technology for any level of process complications.
Our project deals how PLC may be introduced to
monitor a G.T to start cooling fans (Forced Air Cooling)
and to start oil pumps (Forced Oil Cooling) with other
included own protections of transformer and associated
switch-yard power transfer elements. To compare how
superior the PLC is we take traditional relays logic based
control for the same activity- along with principle of
working and how the circuit is formed using Electro-
Mechanical Relays and timers, to provide time delays in
process. Today’s PLC renders us superior control and
communication facilities too. It is a Real-Time
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technology, supports distributed I/Os (Inputs/Outputs)
separated even in kilometers.
GENERATOR TRANSFORMER:
Generator Transformer shortly called G.T is a Power
Transformer with a capacity of 250 MVA. It plays a
important role in any of the Power Stations to step-up
the generating voltage to grid offered level of either 230
KV or 400 KV. The term Power Transformer is used for
capacity more than one MVA.
P = VI CosΦ
Where,
P = Power in watts.
V = Voltage in Volts.
I = Current in Amps.
The above equation can be written as,
V=P/I
COOLING OF GT:
Since the Generator Transformer is Power Transformer
whose capacity is 250MVA with output of 230KV,
monitoring the temperature of Oil and Winding will be a
crucial one. The cooling system of the G.T is mainly
subdivided into three categories. They are as follows,
1. ONAN (Oil Natural Air Natural)
2. ONAF (Oil Natural Air Forced)
3. OFAF (Oil Forced Air Forced)
Being a good thermal conductor, transformer oil absorbs
generated heat and hence oil temperature increases. By
embedding Resistance Temperature Detectors and
Thermocouples in windings and transformer oil at
appropriate points, temperature rise of windings and
transformer oil can be easily monitored. Similarly,
Mercury Bulb Switches are also used to get temperature
feedback from inner parts of the transformer. Oil
Temperature and Winding Temperature are the two
parameters being received from power transformers in
general and by constantly observing these parameters,
International Journal of Pure and Applied Mathematics
we can easily define latest condition of any power
transformer in the manner that whether the latter is in
working in healthy zone or crossing its operating limit.
Normally these mercury switches are set to activate for
rise in Oil temperature from ambient to 55˚c, 65˚c, 75˚c,
90˚c and 120˚c. For 55˚c feedback from mercury switch,
the hard-wired logic wired in the way to start series-1 of
3 phase fans. For 65˚c feedback hard-wired logic will be
triggered to start the series -2 set of fans, while the
series-1 fans were in service already. Likewise for 75˚c
feedback from switch, the circuit should start oil pumps
(1&3) to transfer oil from transformer at a faster rate.
Fig No: 1-Simplified Cooling Control
COOLING SYSTEM CONTROL CIRCUIT:
Each and every pump is protected through OLR-Over
Load Relay. The setting will be decided by the capacity
of the pump drive. The setting would be approximately
made at 1.25 times of rated current IR.
Fig No: 2-GT Cooling control
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WHY DO WE GO FOR PLC?
In all type of Industries, Electrical process and
Instrumentation process are the predominant processes
based on which all other functions are being carried out.
Systems by which these processes are monitored
effectively are called control Technologies. The
following are the most widely used control technologies:
 Electro-Mechanical Relay Logic (hard-wired
logic)
 Electronics based Logic (including Digital
Logics)
 Micro-Processor Logic (µP based control)
 Micro-Controller Logic (Embedded system)
 Programmable Logic Controller with option for
SCADA
Of these available control technologies, almost 80% of
Industries have switched over to PLC from existing
control technology. What is SCADA? SCADA is used
to monitor and control plant or equipment. The control
may be automatic or initiated by the Operator. Data
acquisition is accomplished firstly by the RTUs (It may
also called PLC). This is usually at faster rate. The
central host will scan RTUs (usually at slow rate) in
sequence. Large Industrial units invariably use SCADA
technology when it is required to control the system
process in addition to parallel knowing process variables
and system parameters on-line. So, using SCADA may
be costly thing when it is sufficient to control the same
system with PLC. Hence, PLC technology is economical
as well as reliable one for most of the industrial process.
That is why, PLC is rolling ahead of all other Control
Technologies.
INTRODUCTION TO PLC:
PLC is an abbreviation for programmable logic control.
This describes equipment that controls a process. This
process occurs according to the instructions of a program
in the memory of the equipment. A programmable logic
controller (PLC) is used for automation of
electromechanical processes, such as control of
machinery on factory assembly lines, amusement rides,
or lighting fixtures. PLCs are used in many
applications.The input and output arrangements,
extended temperature range, resistance to vibration and
immunity to electrical noise. Programs to control
machine operation are typically stored in battery-backed
or non-volatile memory.
International Journal of Pure and Applied Mathematics
TYPES AND PROGRMMING TECHNIQUES:
PLCs has been classified into Nano PLC, Micro PLC
and Industrial Networked Modular PLC. The Nano PLC
and Micro PLC may be programmed using LAD
(Ladder logic) and the Industrial Networked Modular
PLC may be programmed using STL (Structured List or
Statement List), LAD (Ladder Logic), FBD (Functional
Block Diagram) or through IL (Instruction List). The
Nano PLC and Micro PLC are single module pack which
contains the CPU, Input Module, Program Memory and
Output Module.
BLOCK DIAGRAM OF PLC
Fig No: 3. Block Diagram of PLC
The above block diagram explains clearly how Micro
PLC is introduced for a small process and distance
between the control room and field (process) is
minimum.
STRUCTURE OF PLC:
The basic structure of PLC is shown in fig. It clearly
shows the available elements of PLC, including serial
port, input, output modules, timers, counters, CPU. The
all connected elements are supervised, controlled by the
intelligent CPU, which is one of a Micro- Processor. In
the next pages we will see the important hardware of
PLC and its internal structure with clear description
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Fig No: 4. Structure of PLC
PLC OPERATION
The speed of any PLC purely depends upon the scan
time of the system. The cost increases as the Scan-Time
of the system reduces and number of inputs , outputs
increases. But it is evident that if we increase the scan-
time of the system, we can control and monitor our
process happenings in REAL-TIME. Hence it is the best
suitable control technology for electrical process in Real-
Time applications.
A PLC works by continually scanning a program. We
can think of this scan cycle as consisting of 3 important
steps. There are typically more than 3 but we can focus
on the important parts and not worry about the others.
Typically the others are checking the system and
updating the current . The speed of any PLC purely
depends upon the scan time of the system. The cost
increases as the Scan-Time of the system reduces and
number of inputs , outputs increases. But it is evident
that if we increase the scan-time of the system, we can
control and monitor our process happenings in REAL-
TIME. Hence it is the best suitable control technology
for electrical process in Real-Time applications.
International Journal of Pure and Applied Mathematics Special Issue

   
PROGRAMMING FOR GT COOLING USING
LADDER

Fig No: 5-PLC Operation

INTERFACING PLC WITH GT:

If at all G.T process is introduced with latest PLC

technology the configuration would be like the above.
Process area and Control room area will be connected
through a single two core cable. The major advantages
are,

 Reduction in bunch of control cable between

process and Control Room.
 The control logic easily replaced with user-
friendly software ( Ladder/STL).

CONTROL DESK- UCB

MASTER
G.T
15 KV B
C 250 MVA
NIU SIREN 89 A U
P FLD 9507 A
D D 89 C
U BKR S
I O
GBC B
STN G
MEM SM-1 SM-2 A
DC U
S
FLASHING 52 G
SUPPLY 89 B
3 PH 230 B
HMI 15 / 230 KV SYN KV
CONVR
CKT GRID
LAN

AC

AIR
TANK
DELUGE
DISCHARGE LINE VALVE

MP
PASS-A
PASS-B

55 C SERIES-1 PROCESS AREA

F

65 C F-1
75 C
F-
2

P-1

P-2

SLAVE
F C N A D D
AC

FLOW P I
I I O
MONITOR U U
MP

SM-1 SM-2 SM-3

Fig No: 6-Interfacing PLC with GT

Fig No: 7-Ladder logic for fan control

  

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International Journal of Pure and Applied Mathematics
Fig No:8-Ladder Logic for oil pump
ADVANTAGES OF PLC OVER OTHER
AVAILABLE TECHNOLOGIES:
 The process inputs are connected directly to the
PLC input module. Hence it doesn’t require any
additional interfacing agent like the other
available technologies.
 The executed results of our process activities are
also taken directly from PLC, through its output
module.
 No limitation for the auxiliary contacts like the
hard-wired logic. We can use number of NO-NC
switches for a programmed coil or register (solid
memory)
 It does not require physical Timers, Counters. All
these will be availed as software. It just need the
delay time.
CONCLUSION
Since the Generator Transformer is Power Transformer,
monitoring the temperature of Oil and Winding will be a
crucial and most required one. By introducing PLC into
action the process becomes more flexible, reliable and
PC friendly. HMI activities may also be availed to have
better visualization of our process and control also. The
control technology is simply converted to software here
makes even complicated process to simple one. Trouble
shooting experience becomes easier now compared to
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existing technology.. PLC is user friendly Hardware
whose operation mainly depends on our own-written
Software in its memory. More than 90% of physical
wiring can be avoided. It is a proven technology for any
level of process complications.
REFERENCES:
[1] Electric Power Transformer Engineering, Third
Edition (The Electric Power Engineering
Handbook) by James H. Harlow Hardcover.
[2] Blakley, J. J., Irvine, D. A., “Teaching
programmable logic controllers using multimedia-
based courseware”, International Journal of
Electrical Engineering Education, Vol. 37, pp. 305
– 315, Oct 2000.
[3] Johnson, C. D., Process Control Instrumentation
Technology, Prentice Hall, 2006, pages 112-160.
[4] Boys, Walt (18 August 2009). "Back to Basics:
SCADA". Automation TV: Control Global -
Control Design.
[5] Boyer, Stuart A. (2010). SCADA Supervisory
Control and Data Acquisition. USA: ISA –
International Society of Automation. p. 179. ISBN
978-1-936007-09-7
[6] Basic SCADA Animations Introduction to
Industrial Control Networks". IEEE
Communications Surveys and Tutorials. 2012.
[7] Application of programmable logic controllers to
substation control and protection, IEEE
Transactions on Power Delivery 1994; 9:1.
[8] Indera ARIFIANTO, Bambang CAHYONO,
“Power transformer cooling system optimization,”
Proceedings of the 9th International Conference
on Properties and Applications of Dielectric
Materials July 19-23, 009, H2arbin, China.
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