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Automation System Based On SIMATIC S7 300 PLC, For A Hydro Power Plant
Automation System Based On SIMATIC S7 300 PLC, For A Hydro Power Plant
Abstract – Based on SIMATIC S7-313C programmable logic developed for this type of process. The most significant
controller (PLC) and SIMATIC TP 177B operating touch panel disadvantage of the old system was a very hard maintenance,
(HMI), this work presents an automation solution for monitoring after many years of functionality.
and controlling a micro hydro power plant (MHC). Using the So, the decision of developing and implementing a new
specified PLC and HMI, there was implemented a reliable
automation system was the best solution for the customer, in
automated system, which produces about 120 KWH of green
energy, 24 hours a day, 7 days per week. order to keep alive this plant.
The system was developed, tested and commissioned at Starting from an asynchrony generator and a Francis turbine,
ZANOAGA Drinking Water Treatment Plant and the owner is the project mission was to develop a reliable automation
APASERV VALEA JIULUI. system for monitoring and controlling the hydro power plant.
The system architecture chosen for this plant, allows
Keywords — SCADA (Supervisory Control and Data interconnection between the PLC and a central control room,
Acquisition), PLC (Programmable Logic Controller), HMI (Human using different industrial communication protocols, such as:
Machine Interface), Local Control, Remote Control, Micro Hydro PROFIBUS DP, MPI or Industrial Ethernet.
Power Plant.
If PROFIBUS DP and MPI protocols are available
I. INTRODUCTION immediately using CPU’s integrated interfaces, the Industrial
Ethernet interface can be used, by adding a new SIMATIC
In the past, people used rivers for agricultural activities and
Ethernet Processor in controller central rack.
wheat grinding. Nowadays, the power of rivers is used not
The main requirements for the new automation systems are:
only for these types of activities, but for green energy
safety in exploitation, reliability, low cost maintenance,
production although [1].
service time as short as possible, easy way of detecting and
The electrical power generated in hydro power plants is one
solving alarms, by implementing a new and modern alarm
of the most available and renewable energy sources in the
logging management system.
world [2].
Two of the most important benefits of hydropower are its
provision of clean and renewable energy [3]. II. MHC MAIN FUNCTIONS
SARFRAZ Ahmad Khan of Pakistan developed a new
The micro hydro power plant is equipped with a
technology for hydro power energy production. His idea
horizontally Francis turbine and one asynchrony generator
doesn’t require a basin to be built and the impact on the
with nominal speed rate of 1500 rpm. Two new valves were
environment is minimal. The system based on his technology
installed and commissioned on the main inlet pipe of drinking
requires less financial resources for operating and
water and bypass pipe. New electromechanical equipment was
maintenance. [4]
installed for turbine control, called AKD. Different types of
The automation systems consisting of PLC and HMI, or
sensors were installed, for pressure and temperatures
PLC and SCADA systems can be reliable and economical
monitoring. The actual values read from these sensors are used
solutions for monitoring and controlling different types of
as interlocks in PLC software application.
hydro stations [5].
The main steps on project implementation are shown in
Next chapters of this paper will describe the automation
figure1.
system, based on SIMATIC S7-300 programmable logic
One electrical cabinet was built, for integrating all the
controller and SIMATIC TP 177B operating touch panel, for
electrical circuits, necessary for controlling the following
controlling and monitoring a small hydro power plant.
equipment: inlet valve, bypass valve, lubrication pumps, AKD
The old automation system for this plant was based on third
and main switch. Although, the electrical cabinet integrate
party electronic hardware and software components,
operating mode, all the protections are active, and the the inlet valve in the same time with closing the bypass valve
algorithm is the one that controls the entire plant. and the AKD will be opened. After the generator speed is over
The functional diagram of the MHC is displayed in figure 3. the minimum set value, the AKD opening rate is over a
There were defined 4 steps for automatic AKD opening and predefined value or the inlet valve position is over a minimum
closing, because it is important for maintaining inlet pressure, value, the PLC will link the system to the electrical network
over the minimum accepted value. The operator will set the by coupling the main switch.
maximum value for the opening rate, and the PLC calculates The AKD will continue opening until the maximum
the opening rate for each step. When the preset value is allowed position is reached. This is the point, where the PLC
reached, the PLC will set the new set point. Every step, before reads the inlet pressure and acts by opening or closing the
the new set point is activated, the algorithm will check the AKD, for maintaining the pressure over the accepted
inlet pressure value and it will define the new set point, only if minimum value.
the current value of the pressure is over the minimum value.
Otherwise the PLC will start closing the AKD, until the inlet
pressure is over the minimum value. IV. IMPLEMENTATION
Auto Mode was developed using three possible states for MHC model described above was implemented using a
the system: Starting, Started and Stopping. When the operator SIMATIC S7 313C-2DP CPU with MPI and PROFIBUS
interfaces built in.
Operating interface was developed using SIMATIC using an analog input channel configured for 4-20 mA unified
WINCC Flexible platform and it is running on a SIMATIC TP signal.
177B operating touch panel. Data exchange between the PLC The inlet (admission) valve installed in this location is
and HMI is realized using PROFIBUS DP industrial protocol produced by AUMA Company. Commands circuits for it were
over RS 485 serial interface. designed using RDOL (Reversible Direct Online) scheme,
PROFIBUS network integrates although, the electronic using two contactors for direct and reverse movements.
module SENTRON PAC 3200. A MAINSPRO decoupling The following protections signals are available for AUMA
relay was used for protecting the generator. All the protections motor: thermal overload, opening torque and closing torque.
like overvoltage, low voltage and overcurrent are implemented All three signals are integrated as protective interlocks inside
inside of this relay. The PLC monitors the signals coming the PLC.
from the protection relay and if a protection became active, the The bypass valve is although produced by AUMA company
MHC will be stop. and all the electrical protections used for admission valve,
Electrical parameters read using SENTRON module, are were activated in this case too.
displayed in figure 4. Using command buttons displayed in figure 6, the operator
Process parameters, like: inlet water pressure, generator speed is able to activate the following commands: Start MHC group,
rate, bearings temperatures, temperatures of motor windings, Stop MHC group, Fast Stop the MHC group, Restart the
valves opening rates are displayed in the main screen shown in group, Auto Mode activation, Manual Mode activation.
figure 5. The operator has the possibility to monitor the status of the
Opening rates for inlet and bypass valves are monitored automatic group using the information displayed in figure 6.
using two analogs input channels which read the electrical A special screen, displayed in figure 7, was developed for
process parameters settings.
signals coming from the integrated positioners of the AUMA There were defined two different levels for the inlet pressure
valves, using 4-20 mA unified signal. as follows: Minimum Inlet Water Pressure at Starting and
Inlet water pressure value is monitored using an IFM analog Minimum Inlet Water Pressure in Running.
sensor for pressure monitoring and it is integrated in the PLC
Figure 4 – Electricals parameters monitoring Figure 6 – MHC Commands
Using first parameter, the operator defines minimum value If the pressure decreasing does not stop, AKD opening rate
of the inlet pressure necessary for MHC starting. If the current will be decreased with another preset value.
value of the pressure is lower than this parameter, the MHC If, during this sequence, the real value of the inlet water
cannot be started. decreases under the minimum value, the MHC will be
stopped.