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WEIR CONTROL MODERNIZATION & MODIFICATION
Keshab Shrestha, Asst. Manager, LPPO&MD Ram Dular Yadav, Engineer, Kaligandaki ‘A’ HPS Ramu Shrestha, Engineer, Middle Marsyangdi HPS
1. PROJECT OVERVIEW 2. SYSTEM OVERVIEW 3. SOLUTION
1. 2. 3. INSTRUMENTATION CONTROL CONCEPT CONTROL SYSTEM
1. 2. 3. 4. 5. 6. 7.
SPECIFIC FUNCTION DESCRIPTION
INTAKE GATE CONTROL SPILLWAYGATE CONTROL FLUSHING GATE CONTROL SLUICE GATE CONTROL WATER SUPPLY AUTOMATION TRASH RACK MONITORING INTAKE GATE PROCESS CONTROL SYSTEM RITOP
1. 2. 3. 4. 5. 6. 7. 8. 9. Basic Introduction History & Origin PLC Characteristics PLC Software List PLC used in NEA powerhouse PLC Components PLC Operation PLC Programming Languages PLC Application – Riflex, Ritop
Sunday, March 03, 2013
ENERGY ACCESS AND EFFICIENCY IMPROVEMENT PROJECT (EAEIP) PROCUREMENT OF MARSYANGDI POWER STATION WEIR CONTROL MODERNIZATION AND MODIFICATION (CONTRACT NO. MPS-067/68-01(R) ESTIMATED COST MNRS 65.93 CONTRACT VALUE MNRS 29.80 JOINTLY FUNDED BY ADB (UNDER EAEIP), GON/NEA MAIN CONTRACTOR: RITTMEYER LTD., SWITZERLAND PROJECT DURATION: 18 MONTHS 2
Sunday, March 03, 2013 3
VIEW OF HEADWORK FROM GOOGLE EARTH
Sunday, March 03, 2013
Radial Gates Reservoir Marsyangdi River
Sunday, March 03, 2013
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2013 7 .Marsyangdi Powerhouse Surge Tank Powerhouse Tailrace Marsyangdi River Sunday. March 03.
March 03.SYSTEM OVERVIEW Sunday. 2013 8 .
March 03. Settling Basin and Tailrace GATE POSTION MEASUREMENT • Spillway Gates (5 Nos. Flaps) • Sluice Gate (1 Nos. Flaps) • Flushing Gates (2 Nos. with 2 Nos. hydrostatic (3 Nos.) Sunday. with 2 Nos.SOLUTION INSTRUMENTATION-FIELD DEVICES WATER LEVEL MEASUREMENT • Submersible Pressure Transmitter for Head Loss Measurement at Intake • Radar Type Device for Level Measurement of Reservoir.) TURBINE DISCHARGE MEASUREMENT • Differential Pressure Transmitter. 2013 9 .
March 03. 2013 10 .SOLUTION Contd… CONTROL CONCEPT CONTROL SYSTEM COMMUNICATION • Local-Priority 1 (Operation of each Gates from existing Power Packs) • RITOP at NWCB and PH for Centralized Supervision and Control of WSA • PLANT PROCESS BUS • SINGLE MODE FIBREOPTIC ETHERNET NETWORK • HMI-Priority 2 (Operator Station in NWCB or PH) • LOCAL CONTROL • Spillway Gates • Sluice Gates • Flushing Gates Sunday.
March 03. 2013 SYSTEM TIME • TIME STAMPING FOR PROCESS VARIABLES PROCESS INTERFACE • INTERFACE BETWEEN CONTROL SYSTEM AND PROCESSES • GALVANICALLY ISOLATED SIGNAL CABLES 11 .SOLUTION Contd… PROCESS STATION • RIFLEX M1 • Power Supply • CPU with memory • D/A Interfaces Sunday.
SPECIFIC FUNCTION DESCRIPTION INTAKE GATE CONTROL SPILLWAY GATE CONTROL OPERATION MODES 1. HEAD LOSS AVAILABLE ON RITOP FOR MONITORING FLUSHING GATE CONTROL OPERATION MODES • INSPECTION • LOCAL • REMOTE SLUICE GATE CONTROL OPERATION MODE • INSPECTION • LOCAL • REMOTE • INSPECTION • LOCAL • REMOTE • OFF/AUTO Y/WSA . NO CONTROL 2.
CALCULATION OF DISCHARGE 3.RESERVOIR LEVEL MEASUREMENT ANDDISPLAY 2.SPECIFIC FUNCTION DESCRIPTION WATER SUPPLY AUTOMATION OPERATION MODES • ON (Level Regulation) • OFF (No set point commands to the Actuator TRASH RACK MONITORING GATE PROCESS CONTROL SYSTEM RITOP 1. LEVEL CONTROL FOR RESERVOIR 4. AVAILABILITY OF CONTROL ELEMENTS CONTINUOUSLY SUPERVISE HEAD LOSS OF TRASH RACK AND INDICATE AT RITOP PROCESS SUPERVISION ALL AGGREGATES ARE CONTROLLED ACTUATORS 5 Spillway Gates and 2 Flaps .
PLC Basic Introduction Programmable Logic Controller is • Very specialized type of digital computer • Used for automation of electromechanical processes in machines and industries. 2013 14 . March 03. • Has multiple inputs and outputs arrangement • Has programs to control machine operation Sunday.
PLC-History and Origin • Developed to replace relays in the late 1980s • Become the most common choice for manufacturing controls • PLC was invented in response to the needs of the American automotive manufacturing industry • Costs dropped and became popular by 1980s • Now used in many industrial designs. 2013 15 . Sunday. March 03.
March 03. 2013 16 .Complete Factory Automation Sunday.
March 03. Most don’t have built-in operator interface devices Sunday. 2013 17 . they operate “automatically”.Characteristics of PLC ruggedized permanently installed monitor and control other devices and processess After being programmed.
2013 18 . March 03.PLC must be • Easy to program • Not need receiving the control system if change the program • Smaller in size • Cheaper • Cost competitive • High reliability • Simple construction • Low maintenance Sunday.
March 03. 2013 19 .PLC and HMI/SCADA Sunday.
List of items required when working with PLCs: Programming Terminal . of Operations manual. PLC manufacturers have their own specific software and license key. 2013 20 . Backup copy of the ladder program (on diskette. If none. hard disk.laptop or desktop PC.(PLC manual. Documentation. upload it from the PLC. CDROM. drawings. and Seq. March 03. flash memory). Communication cable for connection from Laptop to PLC. ladder program printout.) Sunday. Software manual. PLC Software.
PowerLogic Texas Instruments – Simatic Telemecanique – Modicon TSX Micro Siemens. Riflex. Nais etc.S5 Toshiba Mitsubishi.Modsoft Omron . 2013 . Festo.Syswin GE-Fanuc Series – Logic Developer PC/PLC Square D. March 03.PLC Programming Softwares: Allen-Bradley – Rockwell Software RSLogix500 Modicon . Ritop 21 Sunday.
forebay water level) Sunday.PLC used in NEA-powerhouse GE Fanuc Series 90-30 : Kaligandaki A HPS-unit control Middle Marsyangdi HPS. dewatering.RITOP & RIFLEX : Marsyangdi HPS (Weir Control & Modernization) DPU Distributed Processing Unit : Devighat HPS for individual system control (AVR. March 03. Unit Protection. feeder.unit control SIEMENS – Simatic step 5 : Marsyangdi HPS unit control.CWS Rittmeyer . 2013 22 . compressor. Governor. Kaligandaki A HPS dam control. Middle Marsyangdi HPS Desandar flushing system Schnieder – Middle Marsyangdi HPS.
Sunday. March 03.that converts incoming line power to the DC voltage needed to operate the PLC • A CPU (Central Processing Unit) • Input and Output devices • Screw-down terminals for connecting wires from input and output devices to the PLC. 2013 23 .A typical PLC has: • A power supply.
March 03.Components of a PLC System Programmer Central Processing Unit Circuits Input Input Tables Logic Memory Bit Memory Data Memory Output Tables Output Circuits Input Devices HMI System Fault/Diagnostics Memory Configuration Memory Refresh Memory PLC O/S Output Devices O/I Terminals Sunday. 2013 24 .
PLC Operation PLC sweep: Automatically operated repeated cycle receives signals from input devices sends signals to the output devices executes its application program Sunday. March 03. 2013 25 .
March 03.A typical example of PLC Operation Sunday. 2013 26 .
2013 27 . Sunday. the content of its memory location is changed to 1. • it places a 1 in output memory locations 1 and 3. March 03. they lit. • when Light 1 and Light 3 receive the new data from the PLC.A typical example of PLC Operation • When Switch 4 is closed.
March 03. 2013 28 .It starts with Sensors…”Inputs” Sunday.
March 03. 2013 29 .And ends with Loads…”Outputs” Sunday.
March 03. 2013 30 .With Programs linking Inputs to Outputs Sunday.
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2013 33 . March 03.SERIES 90-30 & 90-70 SINGLE LAN REDUNDANCY WITH HMI COMMUNICATION REDUNDANCY PC Rack 1 PS C P U 31 G B E C T H S/W 30 PS C G P B U C Rack 2 E T H Genius bus 1 NIU A B 2 NIU A B DROPS 29 NIU A B Sunday.
Jun2011 SBO/ PMM/ EJ501/2013 34 .PLC Programming Languages • Ladder diagram (LD) • Sequential Function Charts (SFC) • Function Block Diagram (FBD) • Structured Text (ST) • Instruction List (IL) • C-Programming Sunday. March 03.
such as sequencers. Sunday. 2) Timer and counter. 3) Program control. 4) Arithmetic. 6) Data transfer. 2013 35 . March 03.PLC Ladder Diagram Instructions 1) Relay. 5) Data manipulation. and 7) Others.
2013 36 . March 03.Program Instructions • Contacts – – – – – – – – – • Timers – – – – – – – – – Normally Open Contact Normally Closed Contact Positive transition Contact Negative transition contact Output Coil Set Coil Reset Coil Master Control Relay Skip/Jump • Outputs On Timer Off Timer Counters Up Counter Down Counter Addition Subtraction Multiplication Division • Math Functions Sunday.
Program Instructions • Move Functions – Move – Block Move – Indirect Move • Logical Operation Functions – – – – – – AND Inclusive OR Exclusive OR Shift Right Shift Left NOT • Comparison Functions – – – – – – Equal Not Equal Greater than Less than Greater than or Equal to Less than or Equal to Sunday. March 03. 2013 37 .
Sunday. 2013 38 . March 03.
~PB4 PB1 R1 R1 = PB1 .AND and OR LOGIC PB1 PB2 R1 R1 = PB1.AND. PB2 OR PB2 Sunday. March 03.OR.PB2 AND PB3 PB4 R2 R2 = PB2. 2013 39 .AND.
(PB2 . 2013 40 .AND. PB3) PB1 R1 PB2 PB3 Sunday.COMBINED AND & OR R1 = PB1 . March 03.OR.
2013 R1 41 . March 03.RELAYS A switch whose operation is activated by an electromagnet is called a "relay" contact coil input Relay coil R1 Output contact Sunday.
March 03. O MOTOR •SOLENOID •VALVES •LAMP •BUZZER C L2 L1 FIELD WIRING OUTPUT MODULE WIRING L1 O:4 L2 CONTACTOR 0 LADDER PROGRAM Sunday. 2013 42 .CONTACTOR L2 L1 N.
2013 43 . The process is terminated automatically when the finished part touches a second limit switch. March 03.AN EXAMPLE OF RELAY LOGIC For a process control. L1 LS1 R1 TIMER R2 PB1 LS2 R1 R1 PB1 LS1 LS2 PR=5 TIMER 5 Motor R2 R1 Sunday. it is desired to have the process start (by turning on a motor) five seconds after a part touched a limit switch. An emergency switch will stop the process any time when it is pushed.
Clock Accumulator re se t Re giste r conta ct Contact output Clock Reset Output Count 0 1 2 3 4 5 Time 5 seconds. It is used for or some timing purpose. a count value register. March 03.TIMER A timer consists of an internal clock. and an accumulator. Sunday. 2013 44 .
2013 45 . ME203 Manufacturer: Bachmann. March 03.PLC Application RIFLEX PLC from Ritmeyer RITOP SCADA system used for operation and monitoring Object oriented system with MX213. Austria RIFLEX Simatic S7/RAP Rittmeyer instruments products Sunday.
2013 46 . March 03.RIFLEX® M1 System Overview RITOP® Process Control System Ethernet / TCP/IP IEC60870-5-104 Process Bus Fixed cable connection or leased line Bus Extension FAST Bus Fiber optic cable Radio / GSM Switched line Telecommunication Network Switched line Switched line MODBUS Sunday.
leased lines .Intranet • Ethernet TCP/IP based • Data links/communication through: . March 03.DCF77 (radio controlled clock) or GPS • Entire maintenance.IEC60870-5-103 (protection relays) .IEC60870-5-101 (RS485) fixed connection .MODBUS-RTU (Master or Slave) .optical cables (fiber optics) • Connection via switched lines: . radio network .onsite cables.IEC60870-5-104 (Ethernet) .g. via Telnet Process Bus (TCP/IP) Switched Network Sunday.analog/digital phone network (ISDN) .Profibus-DP (Master) .GSM.RIFLEX® M1 Features • VxWorks® Real-time OS • Connection via fixed lines: . diagnostics and programming via TCP/IP. e. 2013 47 .
E Processor Intel 386/33MHz. 2013 48 .EN Processor Intel 386/33MHz. 8MB RMME203. March 03.E32 Processor P133MHz 32MB RMME203.Micro Processor Modules RMMX213. 8MB incl. power supply RMBS204 Bus Back Plane 4 Module Slots RMBS208 Bus Back Plane 8 Module Slots RMBS211 Bus Back Plane 11 Module Slots RMNT250 Power Supply 45W 24VDC to 5VDC RMLM201 Dummy Module Protection Placeholder RMPCC32 PC-Card Memory 32MB Flash Sunday.
16I. 2013 49 . March 03. separation RMAIO288 Analog In/Out Module 8 In.20mA with galv. 24V RMDIO248 Dig.. 24V / 48V RMDIO216 Digital Input / Output Module. 24V / 48V RMDO232 Digital Output Module 32 Bit.20mA with galv..Interface and Inputs/Outputs Modules RMDI232 Digital Input Module 32 Bit. 16O.20mA with galv.I/O Module. 8 Out Sunday.20mA with galv.. 16 I/O.16I/O. separation RMAO204 Analog Output Module 4 Channels 0. separation RMAI204 Analog Input Module 4 Channels 0.. 24V RMAI202 Analog Input Module 2 Channels 0. separation RMAO202 Analog Output Module 2 Channels 0.
March 03.Communication & Extension Modules RMDPM200 Profibus DP Master RMRS204. 2013 50 .R Ser.N Bus Extension Slave Bus Extension Slave with power supply RMFM212 FAST-Bus-Master 2 Fiber optic con. with power supply Sunday. RMFM211 FAST-Bus-Slave 1 Fiber optic con. IF 1xRS232. 3xRS232/422/485 RMBEM201 Bus Extension Master RMBES202 RMBES202. RMFS212.N FAST-Bus-Slave 2 Fiber optic con.
32 MB Flash • Interface with digital/analog inputs/outputs • Communication :Protocal Modbus. March 03. BEM 201 • Bus Extension Option : Max 7 substation Performance and System limit is better in RMMX213EXX Pentium 133 MHz than RMME203X Intel 386X 133 MHz Sunday.RIFLEX • Memory Card : RMPCC32. RS422 – DPM200. RS232. RS485. 2013 51 .
cals automation solutions & services • WinKP – Used for making communication and for software upload to Riflex • Excel – Used for making variables and signals Sunday.Programming software – Riflex programing • logiCAD – Used for making logic – logi. March 03. 2013 52 .
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2013 55 .CIMPLICITY Software Architecture VIEWERS SERVER Pager REMOTE Mobile Plant-Wide Network DISPLAY STATION SERVER • Scaleable Client/Server Architecture • Easily Replicate CIMPLICITY Projects • Fault Tolerant System Architecture • Open Systems . March 03.Easily Integrate to • Enterprise Systems • High Level of Data Integrity • Easily Share Data Between Nodes • Superior Feature Set Sunday.
2013 56 .Sunday. March 03.
Turnkey System Functions Visualization Reporting and Statistics Alarm Signalization Data Transmission Process Control Level Data Storage and Management Operation Control Automation Level Automation Level Regulation Calculation Data Acquisition Monitoring Field Level Signal Acquisition Measuring Sunday. March 03. 2013 57 .
March 03. 2013 58 .WSA CONTROLLER CONCEPT 10 Sunday.