VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI – 590014, KARNATAKA

An Internship Report

“HMI and PLC implementation in PQCE”

Submitted in partial fulfillment for the award of degree of

Bachelor of Engineering in
Electrical and Electronics Engineering
During the Year

2023-2024
Under the guidance of
Internal: External:
Prof. Geeta, Karthikeyan Duraisamy
Asst. Professor Project Manager
Dept of EEE, BMSECE Delta Electronics Ind Pvt Ltd,

Submitted by
NARESH KUMAR U 1BM21EE440

BMS EVENING COLLEGE OF ENGINEERING

Department Electrical and Electronics Engineering
Bull Temple Road, Basavanagudi, Bengaluru – 560 019

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 BMS COLLEGE OF ENGINEERING
Bull temple road, Bangalore–560019
(Affiliated to Visvesvaraya Technological University, Belgaum)

DEPT. OF ELECTRICAL AND ELECTRONICS ENGINEERING

CERTIFICATE:
This is to certify that Internship on topic “HMI and PLC implementation in PQCE” is a
bona-fide work carried out by NARESH KUMAR U(1BM21EE440) as a partial fulfilment
for the award of Bachelor’s Degree in Electrical and Electronics Engineering for
Internship as prescribed by Visvesvaraya Technological University, Belgaum for the
academic year 2023-2024.

Prof. GEETA Dr. A.N. NAGASHREE Dr. SAKEY SHAMU

Assistant Professor Professor & HOD Principal
Dept. of EEE, BMSCE Dept. of EEE, BMSCE BMSCE

Internal Viva Examiner Signature with date:

1.

2.
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 VISVESVARAYA TECHNOLOGICAL UNIVERSITY
BELAGAVI – 590014, KARNATAKA

BMS Evening College of Engineering Bengaluru – 560 019

Department of Electrical & Electronics Engineering

DECLARATION
We, Naresh kumar U, 1BM21EE440 students of sixth semester be, in the Department of
Electrical and Electronics Engineering, BMS Evening Collage of Engineering, Bangalore
declare that the internship entitled " HMI and PLC implementation in PQCE” has been
carried out by us and submitted in partial fulfilments of the course requirements for the award
of degree in Bachelors of Engineering in Electrical and Electronics Engineering of
Visvesvaraya technological university Belagavi during the academic year 2023-2024. The
mater embodied in this report has not been submitted to any other university or institution
for the award of any other degree.

NARESH KUMAR U
(1BM21EE440)

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4
 INTERNSHIP REPORT
(09-05-2024 TO 10-06-2024)
Delta Electronics India Private Limited

BY
NARESH KUMAR U

SUBMISSION DATE 12-06-2024

DELTA ELECTRONICS INDIA PRIVATE LIMITED
BANGALORE

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ACKNOWLEDGEMENT

I wish to extend my sincere gratitude to Delta Electronics India Private Limited for affording
me the invaluable opportunity to undertake a one-month internship.

I would like to convey my special appreciation to Mr. Janardhan D for his unwavering
guidance, enabling me to immerse myself in diverse learning experiences.

I am deeply thankful to Mr. Karthikeyan for entrusting me with novel assignments and
providing continuous support in honing my skills and acquiring new knowledge.

I extend my heartfelt gratitude to Mr. Thangaraja.P for his invaluable contributions during my
internship. Mr. Thangaraja.P expertise and guidance significantly enhanced my learning
experience, fostering my professional growth. I am truly appreciative of his support and
mentorship.

I also want to express my appreciation to Mr. Janardhan D for his consistent assistance and
mentorship that proved instrumental in navigating through my tasks.
I extend my heartfelt thanks to all those individuals who graciously contributed their expertise,
playing a pivotal role in the successful culmination of this internship.

NARESH KUMAR U
( Usn No:1BM21EE440)

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ABOUT THE COMPANY

Delta Group in India is operating since 2003 and is part of Delta, founded in 1971 with
its Global Headquarters in Taiwan. Delta Electronics India Private Limited, is a group entity
and a leading Power and Energy management company. Delta operates in three business
categories: Power Electronics, Automation and Infrastructure. It has a legacy of operating in
India with market leadership in Telecom Power Solutions, Renewable Energy
Solutions and Display Solutions. It is also a leading provider of Industrial Automation
Solutions, UPS & Datacenter Solutions, EV Charging Solutions, Rail Transportation
Solutions, Energy Storage Solutions, DC Fans & Blowers, and Components. With fourteen
regional offices, four manufacturing facilities (Rudrapur, Gurgaon, Hosur and Krishnagiri) and
two R&D centres (Gurgaon and Bengaluru), Delta has a strong presence across India with more
than 200 channel partners.

Research & Development

Innovation is the focus of Delta’s research and development and Delta India has state-
of-the art R&D centers located in Gurgaon and Bangalore. Besides working on core product
area and applications we are working on complete solutions for smart-grid applications and
automotive applications. On our core product area and applications, we are constantly
enhancing the efficiency rate of the power converters and infrastructure monitoring solutions
for Telecom sites. We offer highly customized products and R&D facilities in India working
for indigenization of UPS and display solutions products suited to India and SAARC customer
requirements and environment. Developing Custom power supply for storage and network
equipment is another core area for Delta India’s R&D activity.

Delta design process is based on Product Life Cycle Management (PLM) providing a
stringent and accelerated design cycle while ensuring product quality and reliability. Our
capability for innovative design is what sets us apart from the competition. Our R&D’s
continuous enhancement of our engineering capabilities allows us to develop products with
better value and performance.

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Table of Contents
1. Executive Summary ....................................................................................................................... 9
2. Introduction ................................................................................................................................. 11
3. Power Quality Restorer (PQR) ................................................................................................... 12
4. PLC and SCADA Systems........................................................................................................... 15
5. Project Implementation ............................................................................................................... 16
6. Programming and Configuration ............................................................................................... 19
7. Testing and Validation of PLC in PQR ...................................................................................... 21
8. Challenges and Solutions ............................................................................................................. 22
9. Benefits and Impact of PLC in PQR .......................................................................................... 24
10. Conclusion .................................................................................................................................... 25
11. Recommendations........................................................................................................................ 26
12. Appendices ................................................................................................................................... 27
13. References .................................................................................................................................... 32

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1. Executive Summary
Power quality issues are a growing concern in today's industrial landscape. The
fluctuation and distortion of electrical power can lead to costly downtime, damaged equipment,
and operational inefficiencies. To address these challenges, the implementation of a Power
Quality Restorer (PQR) supported by Programmable Logic Controller (PLC) and Supervisory
Control and Data Acquisition (SCADA) systems has become indispensable. This executive
summary provides an overview of the project's objectives, achievements, and the impact of
implementing PLC and SCADA for a Power Quality Restorer.

The primary objective of this internship project was to design, implement, and validate a
comprehensive solution for power quality restoration using state-of-the-art automation
technology. The project took place at Delta electronics India pvt ltd a leading player in the
power industry, where power quality is a critical concern due to its implications on industrial
processes.

The Importance of Power Quality and PQR

The first part of this executive summary outlines the significance of power quality and the role
of Power Quality Restorers. In an era where industries rely heavily on sensitive electronic
equipment and automated processes, even minor disturbances in power quality can result in
significant financial losses. The Power Quality Restorer, or PQR, is a technology designed to
mitigate these issues. By detecting voltage sags, swells, harmonics, and other power quality
issues, the PQR acts swiftly to compensate, ensuring that downstream systems receive stable
and reliable power.

The Role of PLC and SCADA

The second part of this executive summary discusses the essential role of Programmable Logic
Controller (PLC) and Supervisory Control and Data Acquisition (SCADA) systems in this
context. PLCs serve as the brains behind the operation, executing control logic, and responding
to real-time data. SCADA systems provide the user interface for monitoring and controlling
the PQR system. This integration of PLC and SCADA allows for seamless communication,
data analysis, and control of the PQR, making it a robust solution for power quality restoration.

Project Implementation and Achievements

We then move on to discuss the project's implementation, highlighting the system's
architecture, hardware components, and software components. The PLC programming,
SCADA configuration, and their integration are detailed. The project was meticulously tested
and validated to ensure that it met its objectives.

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Challenges and Solutions
Despite its success, the project faced several challenges, which are also outlined in this
summary. These challenges, including technical, logistical, and operational hurdles, were met
with innovative solutions, reflecting the adaptability and problem-solving abilities of the
project team. The experience gained in addressing these challenges has proven invaluable.

Benefits and Impact

Lastly, the executive summary delves into the tangible benefits and impacts of the implemented
system. The system significantly improved power quality, resulting in cost and energy savings
for the company. The reduction in power quality-related issues translated into fewer operational
disruptions and increased sustainability.

Conclusion
In conclusion, the successful implementation of PLC and SCADA for the Power
Quality Restorer at Delta electronics India Pvt ltd has proven to be a pivotal milestone in
addressing power quality issues in the industrial setting. The project's achievements
demonstrate the effectiveness of this automation technology in ensuring power quality and
operational efficiency. It underscores the vital role of PLC and SCADA systems in the power
industry. The project has not only met its objectives but also presented opportunities for further
enhancements and continuous research in this domain.

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2. Introduction
A Delta Power Quality Restorer (PQR) is a specialized device used in the field of power quality
management and electrical distribution systems. It is designed to mitigate and correct power
quality issues, ensuring the stable and reliable operation of sensitive electrical equipment.
Power quality problems can lead to equipment malfunction, downtime, and financial losses,
making devices like the Delta PQR crucial in various industrial and commercial settings.
Here's an introduction to the Delta Power Quality Restorer:
Purpose: The primary purpose of a Delta PQR is to improve power quality by addressing
various issues, including voltage sags, voltage swells, harmonics, flicker, and voltage
imbalances. It acts as an advanced power conditioning system that compensates for
disturbances in the electrical supply.

Key Features:
Voltage Correction: PQRs can quickly correct voltage variations, ensuring that sensitive
equipment receives a stable and consistent power supply.
Harmonic Filtering: They filter out unwanted harmonics and high-frequency disturbances,
which can damage or disrupt the operation of connected devices.
Dynamic Compensation: PQRs can respond in real-time to voltage disturbances, making them
particularly effective in mitigating voltage sags and swells.
Modular Design: Many Delta PQRs have a modular design, allowing for scalability and
customization to meet the specific needs of an application.

Applications:
Industrial: Delta PQRs are used in industrial environments to protect critical machinery and
manufacturing processes from power quality issues that can lead to downtime and production
losses.
Commercial: They find applications in data centers, medical facilities, and other commercial
buildings to ensure the reliable operation of sensitive electronic equipment.
Renewable Energy: PQRs are also used in renewable energy systems to maintain the quality
of power generated by sources like solar and wind farms.

Benefits:
Improved Equipment Performance: By providing a clean and stable power supply, Delta
PQRs enhance the performance and lifespan of electrical and electronic equipment.
Reduced Downtime: They help prevent equipment failures and downtime caused by power
quality issues.
Energy Efficiency: PQRs can improve energy efficiency by reducing losses in electrical
systems and optimizing the operation of connected loads.
Compliance: They help organizations meet power quality standards and regulations.

Delta Power Quality Restorer (PQR) is a critical component in managing power quality
in electrical distribution systems. It plays a vital role in ensuring the reliable and efficient
operation of electrical and electronic equipment in a wide range of industrial and commercial
applications.
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3. Power Quality Restorer (PQR)

Power Quality Restorer (PQR)

The Power Quality Restorer (PQR) is a cutting-edge technology that has revolutionized the
way industrial facilities manage power quality and electrical reliability. In an era where the
uninterrupted operation of critical equipment is essential for businesses, the PQR system,
driven by advanced technologies like the Programmable Logic Controller (PLC) and
Supervisory Control and Data Acquisition (SCADA), has emerged as a key solution. This
discussion explores the PQR, its components, functions, and the transformative impact it has
on power infrastructure and industrial operations.

Introduction to the Power Quality Restorer

Power quality refers to the consistency and reliability of the electrical power supply. In an
industrial setting, maintaining high power quality is paramount to ensure the seamless
operation of machinery, minimize equipment wear, and prevent production interruptions.
Voltage sags, swells, harmonics, and other disturbances can have detrimental effects on
equipment and processes.

The Power Quality Restorer is a technology designed to tackle these power quality issues head-
on. At its core, the PQR is a comprehensive system that continuously monitors the electrical
supply, detects power quality disturbances in real time, and takes corrective actions to restore
power quality to acceptable standards. It is essentially an intelligent and adaptive system that
safeguards critical operations against power disruptions.

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Components of the Power Quality Restorer
The PQR is a multifaceted system composed of several key components that work in synergy
to achieve its objectives:

1. Voltage Sensors: Voltage sensors are strategically placed throughout the electrical
network to monitor the quality of the power supply continuously. These sensors collect
real-time data on voltage levels and waveforms.
2. Capacitors and Inductors: Capacitors and inductors are used to regulate voltage.
When a voltage sag is detected, the PQR system can quickly switch in capacitors to
boost the voltage and compensate for the drop. Conversely, when there's a voltage
swell, inductors can be employed to absorb the excess voltage.
3. Programmable Logic Controller (PLC): The PLC serves as the brain of the PQR. It
hosts a sophisticated control program that analyzes the data from the voltage sensors
and determines the appropriate corrective actions. The PLC uses algorithms to make
decisions in real time, ensuring that the response to power quality disturbances is swift
and accurate.
4. Supervisory Control and Data Acquisition (SCADA): The SCADA system provides
a user-friendly interface for operators and engineers. It allows them to visualize the
power quality data, monitor system performance, and make real-time adjustments.
SCADA also plays a crucial role in data storage, event logging, and alarm management.
5. Communication Infrastructure: To facilitate remote monitoring and control, the PQR
system is equipped with a robust communication infrastructure. This allows operators
to access the system from a central control room, monitor its performance, and make
adjustments as needed.

Functions of the Power Quality Restorer

The primary functions of the Power Quality Restorer are centered around detecting, analyzing,
and mitigating power quality disturbances:

1. Voltage Quality Monitoring: Voltage sensors continuously monitor the quality of the
electrical supply. Any deviations from predefined standards are promptly identified.
2. Real-Time Analysis: The data collected by the voltage sensors are transmitted to the
PLC for real-time analysis. The PLC's control program uses algorithms to assess the
severity of power quality disturbances.
3. Decision-Making and Control: Based on the analysis, the PLC makes decisions
regarding the corrective actions needed. It can quickly switch in capacitors or inductors
to mitigate voltage sags and swells.
4. Harmonic Filtering: The PQR system is also equipped to detect and filter harmonics,
ensuring a clean and stable power supply.
5. Remote Access and Control: The SCADA system allows operators to access the PQR
remotely. They can monitor the system's performance, adjust control parameters, and
respond to alarms or events in real time.

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The Transformative Impact of the Power Quality Restorer
The implementation of the PQR system, with its advanced components and real-time
decision-making capabilities, has had a transformative impact on industrial operations. This
impact can be summarized in the following ways:

1. Enhanced Power Quality: The PQR system has brought about a significant
improvement in power quality. Voltage sags and swells, which were once sources of
disruptions and equipment damage, are now swiftly corrected. The system's response
to power quality disturbances ensures a stable and consistent power supply, minimizing
downtime and enhancing operational efficiency.
2. Cost Savings: The improved power quality achieved through the PQR results in cost
savings. Reduced equipment maintenance costs, energy efficiency gains, and
minimized production downtime all contribute to significant financial benefits.
3. Environmental Responsibility: The PQR's energy savings and reduced greenhouse
gas emissions align with environmental conservation efforts. Resource conservation
and compliance with environmental regulations are additional benefits that underscore
the system's environmental responsibility.
4. Operational Efficiency: The PQR enhances operational efficiency by reducing
downtime, optimizing energy consumption, and improving the overall reliability of
industrial processes. The swift response to power quality disturbances ensures the
uninterrupted operation of critical equipment.
5. Scalability and Adaptability: The modular architecture of the PQR system allows for
scalability and adaptation to evolving requirements. As the facility's operational
demands change, the system can be expanded and enhanced with minimal disruption.

the Power Quality Restorer, with its advanced components and the intelligence of the PLC and
SCADA systems, has revolutionized the management of power quality in industrial facilities.
It stands as a testament to the potential of technology to transform operational efficiency,
reduce costs, and promote environmental responsibility. The PQR system not only safeguards
the reliability of industrial processes but also contributes to a sustainable and efficient power
infrastructure.

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4. PLC and SCADA Systems

Programmable Logic Controller (PLC)

 A Programmable Logic Controller (PLC) is a fundamental component in industrial
automation and control systems. PLCs are designed to execute specific tasks based on
pre-programmed logic, making them ideal for real-time control and monitoring in
various industrial applications. The application of PLC technology in the context of our
Power Quality Restorer (PQR) project is paramount to achieving precise and reliable
control over the PQR's operations.
 PLCs are known for their robustness and reliability. In our implementation, we utilized
a state-of-the-art PLC system capable of handling the demanding requirements of
power quality restoration. The PLC unit serves as the control center for the PQR,
managing its various functions. The PLC program is responsible for monitoring
incoming power quality parameters, making real-time decisions, and adjusting the
PQR's operation to mitigate power quality issues.
 Our PLC system also allows for remote monitoring and control, which is crucial for
efficient power quality restoration. Operators can access the PLC remotely to view real-
time data, adjust control parameters, and troubleshoot issues. This capability enhances
the overall effectiveness of the PQR, ensuring a rapid response to power quality
disturbances.

Supervisory Control and Data Acquisition (SCADA)

 The SCADA system serves as the user-friendly interface for operators and engineers.
It displays real-time data related to power quality parameters, the PQR's status, and any
alarms or alerts. This information is presented in the form of graphical representations,
charts, and numerical values, allowing operators to quickly assess the system's
performance.
 One of the key features of the SCADA system is its ability to generate historical data
logs. This historical data is invaluable for analyzing the long-term performance of the
PQR and for identifying patterns in power quality issues. It aids in decision-making,
maintenance scheduling, and fine-tuning the control logic within the PLC.
 Moreover, the SCADA system is equipped with alarm and event management. When
deviations from the predefined power quality standards occur, the SCADA system
triggers alarms and sends notifications to the relevant personnel. This ensures a rapid
response to critical events, preventing potential disruptions to industrial processes.
 The integration of PLC and SCADA is seamless and critical to our system's success.
The PLC communicates with the SCADA system in real time, providing data and
receiving control commands. This integration allows operators to make dynamic
adjustments and optimize the PQR's response to power quality issues, all while having
a clear, comprehensive overview of the system's performance.

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5. Project Implementation

System Design and Architecture

 The implementation of a Power Quality Restorer (PQR) is a complex and integrated
process that requires careful system design and architecture. In our project, we adopted
a well-thought-out design that incorporated the principles of modularity, scalability,
and robustness.
 The heart of the PQR system is the core hardware, consisting of voltage sensors,
capacitors, and inductors. These components are interconnected in a precise
arrangement to regulate voltage and mitigate power quality issues. The design ensures
that the PQR can adapt to varying loads and voltage conditions while maintaining
optimal performance.
 Modularity was a key design principle. The PQR system comprises distinct modules
for sensing, control, and communication. This modular architecture simplifies
maintenance and upgrades, allowing for easy replacement of individual components
when needed. It also facilitates troubleshooting by isolating issues to specific modules.
 The architecture incorporates redundancy and fail-safe mechanisms. In the event of a
component failure, the system can automatically switch to backup components,
ensuring uninterrupted power quality restoration. The system architecture is designed
to minimize downtime and maintain reliability, critical for industrial applications.

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Hardware Components

PLC (Programmable Logic Controller)

The hardware components selected for the PQR system play a crucial role in its functionality.
Voltage sensors are used to continuously monitor incoming power quality. These sensors
provide real-time data on voltage magnitude and phase, enabling the PQR to respond quickly
to voltage sags and swells.

Capacitors and inductors are strategically placed within the system. They act as energy storage
devices and can be switched in or out to regulate voltage. This component choice is based on
the specific power quality issues faced by our industrial partner. The capacitors and inductors
are rated to handle the required voltage and current levels.

The control unit consists of a high-performance Programmable Logic Controller (PLC). It

serves as the brain of the PQR, executing complex control algorithms to manage the capacitors
and inductors. The PLC is equipped with multiple communication interfaces to interact with
the SCADA system and allow for remote control and monitoring.

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Software Components

Software components are equally vital in the implementation of the PQR system. The PLC
programming is tailored to respond to various power quality disturbances. Complex control
algorithms are implemented to analyze the incoming voltage data and determine the optimal
switching of capacitors and inductors.

The SCADA system software provides the human-machine interface for operators and
engineers. It allows for real-time monitoring and control of the PQR. The software is
configured to display critical parameters such as voltage, current, and power factor, ensuring
that the operators have complete visibility into the power quality restoration process.

The SCADA system also logs historical data, facilitating trend analysis and long-term
performance assessment. It stores information related to alarm triggers, system performance,
and operator actions, which is invaluable for troubleshooting and fine-tuning the system.

The PLC and SCADA software are integrated seamlessly, ensuring efficient data exchange and
control. This integration is essential for the dynamic management of power quality issues and
enables rapid adjustments to optimize the PQR's performance.

In conclusion, the successful implementation of the PQR system is the result of a carefully
designed architecture and well-chosen hardware and software components. The modularity,
redundancy, and adaptability of the system architecture, along with the precision of the
hardware and control algorithms, contribute to the reliable and efficient restoration of power
quality in industrial environments.

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6. Programming and Configuration

PLC Programming
The core of the Power Quality Restorer (PQR) system's functionality lies in the PLC
programming, which executes the critical control logic. The PLC program is meticulously
designed to monitor, analyze, and react to power quality disturbances in real time.

The PLC programming begins with the establishment of a communication link between the
PLC and the voltage sensors. Voltage data is continuously collected and processed. The
program is structured around a hierarchical control system that operates based on a set of
predefined algorithms. These algorithms consider the real-time data, the status of the system's
components, and the desired power quality standards.

The heart of the PLC program is its decision-making logic. When the system detects a power
quality issue such as a voltage sag, it rapidly assesses the severity and calculates the appropriate
compensating action. This may involve switching in capacitors or inductors to correct the
voltage deviation. The PLC program employs if-then-else statements, timers, counters, and
interlocks to ensure that the compensating actions are safe and effective.

Safety measures are a paramount concern in the PLC program. It includes interlocks to prevent
unsafe operations, ensuring that capacitors and inductors are only switched when it is safe to
do so. Emergency shutdown procedures are defined to handle critical situations, such as a fault
in the PQR system or a sudden, dangerous voltage fluctuation.

Moreover, remote access and control are vital aspects of the PLC program. Operators can
access the PLC remotely to monitor the system's performance and adjust control parameters.
Remote access facilitates rapid response to power quality disturbances and the ability to fine-
tune the PQR's response based on real-time observations.

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SCADA Configuration

The Supervisory Control and Data Acquisition (SCADA) system is the user-friendly interface
for operators and engineers, allowing them to visualize and supervise the entire PQR system.
The SCADA system is configured to provide real-time data visualization and control options.

The configuration of the SCADA system includes defining the graphical user interface (GUI).
The GUI is designed to display key parameters and system status in a clear and user-friendly
manner. It includes graphical representations of the PQR components, voltage waveforms, and
power quality metrics. Numerical values and trends are also displayed, providing operators
with a comprehensive view of the system's performance.

A critical aspect of SCADA configuration is the development of alarm and event management.
Alarms are set up to trigger when the system detects power quality deviations that exceed
predefined thresholds. Alarms are classified by severity, and when triggered, they appear on
the operator's interface with appropriate prioritization. Event logs are generated to record alarm
triggers, operator actions, and system responses. This data is essential for post-analysis and
troubleshooting.

The SCADA system is configured to support remote access and control. This feature allows
operators to monitor the PQR system from a central control room and make real-time
adjustments to optimize performance. Security measures are implemented to ensure that only
authorized personnel can access the SCADA system, protecting it from unauthorized access or
tampering.

The configuration of the SCADA system is tightly integrated with the PLC. It communicates
with the PLC to receive real-time data and send control commands. This integration ensures
that the operator's interface reflects the actual state of the PQR system and enables operators
to make dynamic adjustments based on the real-time information.

In conclusion, the programming of the PLC and configuration of the SCADA system are vital
components of the Power Quality Restorer's operation. The PLC program provides the
intelligence to monitor and respond to power quality disturbances, while the SCADA system
offers the means to visualize and control the entire process. The collaboration between these
systems ensures the efficient and reliable restoration of power quality.

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7. Testing and Validation of PLC in PQR

PLC as the Brain of the PQR

The Programmable Logic Controller (PLC) plays a pivotal role in the successful operation of
the Power Quality Restorer (PQR). It serves as the "brain" of the system, making real-time
decisions and executing control logic to restore power quality. Given the critical role of the
PLC, rigorous testing and validation procedures were employed to ensure its reliability,
precision, and responsiveness in mitigating power quality disturbances.

Functional Testing
The first phase of PLC testing involves functional testing. Here, the PLC's individual
components and functions are evaluated. This includes assessing the accuracy and
responsiveness of digital and analog input channels. Voltage sensors and other sensors are
tested to confirm their ability to provide accurate and real-time data to the PLC. The reliability
of digital and analog output channels is also scrutinized to ensure that the PLC can correctly
send control signals to the PQR components, such as capacitors and inductors.

Power Quality Disturbance Simulation

One of the critical aspects of PLC testing in the PQR system is the simulation of power quality
disturbances. The PLC program is subjected to scenarios where voltage sags, swells,
harmonics, and other disturbances are emulated. The goal is to verify that the PLC's control
logic effectively detects these disturbances and responds with the appropriate compensating
actions.

For example, voltage sag simulations test the PLC's ability to recognize a sudden drop in
voltage and respond by switching capacitors or inductors to restore voltage levels to within
acceptable limits. The PLC's decision-making logic, including if-then-else statements and
timers, is scrutinized to ensure it responds correctly to various degrees of voltage deviation.

The PLC program is also tested against complex scenarios involving multiple power quality
disturbances occurring simultaneously. These tests verify the PLC's ability to prioritize and
manage multiple disturbances efficiently, ensuring that the PQR system responds effectively
to complex real-world situations.

Safety and Fail-Safe Testing

Safety is a paramount concern in PLC programming. Fail-safe mechanisms are implemented
to prevent unsafe operations and protect equipment. The testing phase assesses the reliability
and effectiveness of these safety measures. Simulations of potential safety-critical scenarios,
such as equipment failures or rapidly changing power quality conditions, are conducted to
validate that the PLC program responds appropriately.

Emergency shutdown procedures are tested to ensure that the PQR system can be rapidly and
safely halted in critical situations. Testing scenarios include situations where immediate
shutdown is necessary to prevent damage to the system or potential safety hazards.
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8. Challenges and Solutions

Challenges Encountered
The implementation of a Power Quality Restorer (PQR) in an industrial environment is a
complex endeavor, and, as expected, we encountered several challenges during the course of
the project. Understanding and addressing these challenges was crucial for the successful
deployment of the PQR system.

1. Variability in Load Profiles: Industrial facilities often have fluctuating load profiles,
and the PQR system needed to adapt to these changes. The challenge was to develop
control algorithms within the PLC that could dynamically adjust the compensating
actions based on the changing load conditions. We needed the PQR to remain effective
even when the load profile shifted significantly.

2. Coordination of Component Switching: Coordinating the switching of capacitors and

inductors in response to voltage disturbances was challenging. Timing and coordination
were critical, and ensuring that capacitors and inductors were switched in the correct
sequence to prevent further power quality issues required careful design. Any
discoordination could lead to temporary voltage instability.

3. Harmonic Filtering: Addressing harmonics in the power supply was a substantial

challenge. Harmonics are complex and can vary in frequency and magnitude.
Developing algorithms to detect and filter harmonics effectively required a deep
understanding of power quality issues and advanced signal processing techniques.

4. Cybersecurity: The inclusion of remote monitoring and control capabilities brought

cybersecurity challenges. Ensuring the security of the PLC and SCADA systems
against unauthorized access or cyber threats was of utmost importance. We had to
implement strong authentication and encryption measures to protect the PQR system.

5. Component Failures: As with any complex system, component failures were a

possibility. We needed to address the challenge of detecting and responding to
component failures quickly and effectively to maintain the system's reliability and
safety.

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Solutions Implemented

Addressing the challenges that arose during the project required innovative solutions and
strategic decision-making. These solutions were essential to ensuring the PQR's efficiency and
reliability in mitigating power quality disturbances.

1. Adaptive Control Algorithms: To address load variability, we developed adaptive

control algorithms within the PLC. These algorithms continuously analyzed the load
profile and adjusted the PQR's response in real time. Load variations did not affect the
PQR's ability to stabilize voltage and improve power quality.

2. Synchronized Switching: We addressed the challenge of component switching

coordination by implementing synchronized switching sequences. This solution
ensured that capacitors and inductors were switched in a coordinated manner,
preventing sudden changes in voltage and maintaining power quality.

3. Advanced Harmonic Detection and Filtering: The challenge of harmonics was met
with advanced harmonic detection algorithms. These algorithms allowed the PQR to
identify harmonic frequencies and magnitudes accurately. Filtering techniques were
then employed to reduce harmonic distortion effectively.

4. Cybersecurity Measures: To secure the PQR system against cybersecurity threats, we

implemented robust authentication and encryption measures. This ensured that only
authorized personnel could access and control the system remotely, preventing
unauthorized access or tampering.

5. Redundancy and Fail-Safe Mechanisms: To address component failures, we

integrated redundancy and fail-safe mechanisms. Redundant components were
included, allowing the system to seamlessly switch to backup components in the event
of a failure. Additionally, emergency shutdown procedures were put in place to ensure
system safety in critical situations.

The challenges encountered during the implementation of the PQR system were met
with innovative and effective solutions. Adaptive control algorithms, synchronized switching,
advanced harmonic detection, robust cybersecurity measures, and redundancy mechanisms
were instrumental in overcoming these challenges, resulting in a reliable and efficient system
for power quality restoration. These solutions highlight the adaptability and problem-solving
capabilities essential in complex industrial automation projects.

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9. Benefits and Impact of PLC in PQR

Enhanced Power Quality Restoration

The incorporation of the Programmable Logic Controller (PLC) within the Power Quality
Restorer (PQR) has yielded significant benefits, particularly in the realm of power quality
restoration. The PLC's ability to make rapid and precise decisions has profoundly enhanced the
PQR's effectiveness in mitigating power quality issues, resulting in a notable impact on the
overall operation of the industrial facility.

The PLC's real-time decision-making capability ensures that the PQR can promptly respond to
power quality disturbances, such as voltage sags, swells, and harmonics. The ability to detect
these issues and initiate corrective actions within milliseconds has translated into a consistent
and stable power supply.

Minimized Production Downtime

One of the most substantial impacts of the PLC within the PQR is the significant reduction in
production downtime. Voltage sags and swells, which were previously major contributors to
equipment downtime and production interruptions, are now effectively mitigated. The swift
response of the PQR, driven by the PLC's logic, ensures that voltage deviations do not disrupt
industrial processes.

With reduced downtime, production output has increased, leading to higher efficiency and
revenue. The PLC's ability to adapt to fluctuating load conditions further minimizes downtime,
as the system remains effective in varying operational environments.

Optimized Energy Consumption

The PLC's control algorithms within the PQR not only focus on power quality restoration but
also address energy efficiency. The system's ability to manage reactive power and power factor
ensures that the facility operates closer to its power factor target. This optimization has led to
cost savings and energy efficiency.

The reduction in reactive power and improved power factor has minimized penalties associated
with poor power factor, resulting in lower electricity bills. The facility's energy consumption
is optimized, leading to notable cost savings.

Maintenance Cost Reduction

Prior to the implementation of the PQR with PLC control, voltage disturbances such as sags
and swells often resulted in equipment stress and damage, leading to increased maintenance
costs. The PQR's swift response, guided by the PLC's algorithms, prevents equipment wear and
tear, thus reducing maintenance expenses.

Equipment longevity has improved significantly, thanks to the PQR's effective mitigation of
voltage disturbances. This means that equipment replacement and maintenance are less
frequent, further contributing to cost reduction and operational stability. 24
10. Conclusion
The implementation of the Programmable Logic Controller (PLC) within the Power
Quality Restorer (PQR) system has ushered in a new era of power quality restoration,
operational efficiency, and environmental responsibility for our industrial facility. As we
reflect on the journey of integrating the PLC into the PQR, it becomes abundantly clear that
this technology has been a game-changer, with wide-ranging implications for the facility's
power infrastructure and operations.

The PLC's ability to serve as the central control unit for the PQR system is the linchpin of its
success. Through meticulous programming, real-time monitoring, and precise decision-
making, the PLC has elevated the PQR's performance to unprecedented levels. The system's
response to power quality disturbances, such as voltage sags, swells, and harmonics, has
become nothing short of remarkable. Voltage sags, once the source of disruptions and
equipment damage, are now addressed within milliseconds, ensuring a stable and consistent
power supply.

The most tangible impact of the PLC in the PQR is perhaps the remarkable reduction in
production downtime. Voltage disturbances, which were once the bane of industrial operations,
have been tamed. The PLC's rapid and adaptive control algorithms ensure that power quality
disturbances no longer disrupt the industrial processes. This translates to increased production
output, higher efficiency, and, ultimately, greater revenue. The PLC's ability to adapt to
changing load conditions means that the PQR remains effective, regardless of the operational
environment.

Beyond the realm of power quality restoration, the PLC's influence on energy efficiency is
equally significant. The system's capability to manage reactive power and power factor
optimization has led to cost savings and energy efficiency. The optimization of energy
consumption has reduced penalties associated with poor power factor and has resulted in lower
electricity bills. This not only contributes to cost savings but also aligns with the facility's
commitment to sustainability and environmental responsibility.

Moreover, the PLC's positive impact extends to the environment. The reduction in energy
consumption translates into a smaller carbon footprint. The facility's decreased greenhouse gas
emissions align with environmental conservation efforts. Additionally, the energy savings
achieved through the PQR contribute to the conservation of natural resources, as reduced
energy consumption minimizes the extraction and consumption of fossil fuels.

Furthermore, by meeting power quality standards and optimizing energy consumption, the
facility is better positioned to comply with environmental regulations and standards. This
ensures alignment with broader environmental goals and supports sustainable and eco-friendly
industrial practices.

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11. Recommendations

Continuous Monitoring and Optimization

One of the primary recommendations stemming from the successful implementation of the
Programmable Logic Controller (PLC) in the Power Quality Restorer (PQR) is the need for
continuous monitoring and optimization. While the PQR system, driven by the PLC, has
demonstrated remarkable efficiency in mitigating power quality disturbances and optimizing
energy consumption, it is essential to establish a robust framework for ongoing monitoring and
performance optimization. This includes:

1. Real-Time Data Analysis: Implement a comprehensive real-time data analysis system that
continuously monitors the performance of the PQR system. This should involve the analysis
of power quality data, equipment status, and the PLC's decision-making process. By
scrutinizing this data, potential issues or areas for further optimization can be promptly
identified and addressed.

2. Performance Metrics Tracking: Maintain a close watch on key performance metrics,

including voltage regulation, harmonic reduction, response time, and energy efficiency.
Regularly compare these metrics to established industry standards and benchmarks. If there are
any deviations, they should trigger further investigation and action.

3. Algorithm Fine-Tuning: The PLC's control algorithms, while robust, may benefit from
occasional fine-tuning. As the facility's load profiles and operational conditions evolve, the
algorithms should be adjusted to ensure they remain optimal for the current environment.
Periodic reviews and updates to the control logic can help adapt to changing requirements.

4. Remote Access and Control Enhancements: Explore opportunities to enhance the remote
access and control capabilities of the PQR system. This may involve the implementation of
advanced cybersecurity measures, improved user interfaces, and expanded remote monitoring
options. Continuous improvement in remote access ensures the flexibility and security of the
system.

26
12. Appendices

Figure A.1 :Delta PLC DVP40ES2

Figure A.2 : Delta HMI DVP 112 MX

27
Figure A.3 PQCE Communication Architecture Overview

Figure A.4: PLC Wiring Diagram

28
Appendix B: HMI Pages Samples

29
30
31
13. References

1. Programmable Logic Controllers 4th Edition (W Bolton).pdf

2. DELTA_IA-PLC_DVP_TP_C_EN_20231023.pdf
3. DELTA_IA-HMI-DOP-Series_C_EN_20200817_web.pdf
4. DVP-PLC Application Manual (Programming).pdf
5. https://filecenter.deltaww.com/Products/download/06/060301/Catalogue/DELTA_IA-
PLC_DVP_TP_C_EN_20231023.pdf
6. https://filecenter.deltaww.com/Products/download/06/060301/Manual/DELTA_IA-
PLC_DVP-PLC_PM_EN_20220407.pdf
7. https://deltaelectronicsindia.com/press-release/delta-electronics-india-inaugurated-state-
of-the-art-technology-in-medium-voltage-power-quality-restorer/

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