plc overview
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MARSYANGDI POWER STATION WEIR CONTROL MODERNIZATION & MODIFICATION
Keshab Shrestha, Asst. Manager, LPPO&MD
Ram Dular Yadav, Engineer, Kaligandaki ‘A’ HPS
Ramu Shrestha, Engineer, Middle Marsyangdi HPS
Tuesday, April 11, 2023 2
PRESENTATION OUTLINE
1
1. PROJECT OVERVIEW
2. SYSTEM OVERVIEW
3. SOLUTION1. INSTRUMENTATION
2. CONTROL CONCEPT
3. CONTROL SYSTEM
4. SPECIFIC FUNCTION DESCRIPTION1. INTAKE GATE CONTROL
2. SPILLWAYGATE CONTROL
3. FLUSHING GATE CONTROL
4. SLUICE GATE CONTROL
5. WATER SUPPLY AUTOMATION
6. TRASH RACK MONITORING INTAKE GATE
7. PROCESS CONTROL SYSTEM RITOP
5. PLC 5. Basic Introduction
6. History & Origin
7. PLC Characteristics
8. PLC Software List
9. PLC used in NEA powerhouse
10. PLC Components
11. PLC Operation
12. PLC Programming Languages
13. PLC Application – Riflex, Ritop
Tuesday, April 11, 2023 3
PROJECT OVERVIEW
2
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
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VIEW OF HEADWORK FROM GOOGLE EARTH
3
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Marsyangdi Dam
Radial Gates
Desilting Basin
Intake
Reservoir
Marsyangdi River
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Marsyangdi Powerhouse
Surge Tank
Powerhouse
Tailrace
Marsyangdi River
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SYSTEM OVERVIEW
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SOLUTION
WATER LEVEL MEASUREMENT
• Submersible Pressure Transmitter for Head Loss Measurement at Intake
• Radar Type Device for Level Measurement of Reservoir, Settling Basin and Tailrace
GATE POSTION MEASUREMENT
• Spillway Gates (5 Nos. with 2 Nos. Flaps)
• Flushing Gates (2 Nos. with 2 Nos. Flaps)
• Sluice Gate (1 Nos.)
TURBINE DISCHARGE MEASUREMENT
• Differential Pressure Transmitter, hydrostatic (3 Nos.)
INSTRUMENTATION-FIELD DEVICES
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SOLUTION Contd…
CONTROL CONCEPT
• Local-Priority 1 (Operation of each Gates from existing Power Packs)
• HMI-Priority 2 (Operator Station in NWCB or PH)
CONTROL SYSTEM
• RITOP at NWCB and PH for Centralized Supervision and Control of WSA
• LOCAL CONTROL• Spillway Gates• Sluice Gates• Flushing Gates
COMMUNICATION
• PLANT PROCESS BUS• SINGLE MODE FIBRE-
OPTIC ETHERNET NETWORK
Tuesday, April 11, 2023 11
PROCESS STATION
• RIFLEX M1• Power
Supply• CPU with
memory• D/A
Interfaces
SYSTEM TIME
• TIME STAMPING FOR PROCESS VARIABLES
PROCESS INTERFACE
• INTERFACE BETWEEN CONTROL SYSTEM AND PROCESSES
• GALVANICALLY ISOLATED SIGNAL CABLES
SOLUTION Contd…
SPECIFIC FUNCTION DESCRIPTION
INTAKE GATE CONTROL
1. NO CONTROL2. HEAD LOSS
AVAILABLE ON RITOP FOR MONITORING
SPILLWAY GATE CONTROL
OPERATION MODES• INSPECTION• LOCAL• REMOTE
• OFF/AUTO Y/WSA
FLUSHING GATE CONTROL
OPERATION MODES• INSPECTION• LOCAL • REMOTE
SLUICE GATE CONTROL
OPERATION MODE• INSPECTION• LOCAL • REMOTE
SPECIFIC FUNCTION DESCRIPTION
WATER SUPPLY AUTOMATION
OPERATION MODES• ON (Level Regulation)• OFF (No set point
commands to the Actuator
1.RESERVOIR LEVEL MEASUREMENT ANDDISPLAY
2. CALCULATION OF DISCHARGE3. LEVEL CONTROL FOR
RESERVOIR4. AVAILABILITY OF CONTROL
ELEMENTS
ACTUATORS 5 Spillway Gates and 2 Flaps
TRASH RACK MONITORING GATE
CONTINUOUSLY SUPERVISE HEAD LOSS OF TRASH
RACK AND INDICATE AT
RITOP
PROCESS CONTROL SYSTEM RITOP
PROCESS SUPERVISION
ALL AGGREGATES ARE
CONTROLLED
Tuesday, April 11, 2023 14
PLC Basic Introduction
Programmable Logic Controller is• Very specialized type of digital computer• Used for automation of electromechanical
processes in machines and industries.• Has multiple inputs and outputs
arrangement• Has programs to control machine operation
Tuesday, April 11, 2023 15
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.
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Complete Factory Automation
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Characteristics of PLCruggedized
permanently installed
monitor and control other devices and processess
After being programmed, they operate “automatically”.
Most don’t have built-in operator interface devices
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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
Tuesday, April 11, 2023 19
PLC and HMI/SCADA
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Programming Terminal - laptop or desktop PC.
PLC Software. PLC manufacturers have their own specific software and license key.
Communication cable for connection from Laptop to PLC.
Backup copy of the ladder program (on diskette, CDROM, hard disk, flash memory). If none, upload it from the PLC.
Documentation- (PLC manual, Software manual, drawings, ladder program printout, and Seq. of Operations manual.)
List of items required when working with PLCs:
Tuesday, April 11, 2023 21
Allen-Bradley – Rockwell Software RSLogix500 Modicon - Modsoft Omron - Syswin GE-Fanuc Series – Logic Developer PC/PLC Square D- PowerLogic Texas Instruments – Simatic Telemecanique – Modicon TSX Micro Siemens- S5 Toshiba Mitsubishi, Festo, Nais etc. Riflex, Ritop
PLC Programming Softwares:
Tuesday, April 11, 2023 22
PLC used in NEA-powerhouseGE Fanuc Series 90-30 : Kaligandaki A HPS-unit controlMiddle Marsyangdi HPS- unit control
SIEMENS – Simatic step 5 : Marsyangdi HPS unit control, Kaligandaki A HPS dam control, Middle Marsyangdi HPS Desandar flushing system
Schnieder – Middle Marsyangdi HPS- CWS
Rittmeyer - RITOP & RIFLEX : Marsyangdi HPS (Weir Control & Modernization)
DPU Distributed Processing Unit :Devighat HPS for individual system control (AVR, Governor, Unit Protection, feeder, dewatering, compressor, forebay water level)
Tuesday, April 11, 2023 23
A typical PLC has:
• A power supply- 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.
Tuesday, April 11, 2023 24
Components of a PLC SystemProgrammer
Input
InputDevices
Input Tables
Output Tables
Output Devices
Circuits
Data Memory
Fault/Diagnostics Memory
Logic Memor
y
O/I TerminalsHMI System
Circuits Output
Configuration Memory
Central Processing Unit
Bit Memory
PLC O/S
Refresh Memory
Tuesday, April 11, 2023 25
PLC Operation
PLC sweep: Automatically operated repeated cycle
receives signals from input devices
executes its application program
sends signals to the output devices
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A typical example of PLC Operation
Tuesday, April 11, 2023 27
A typical example of PLC Operation
• When Switch 4 is closed, the content of its memory location is changed to 1.
• it places a 1 in output memory locations 1 and 3.
• when Light 1 and Light 3 receive the new data from the PLC, they lit.
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It starts with Sensors…”Inputs”
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And ends with Loads…”Outputs”
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With Programs linking Inputs to Outputs
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PS CPU
GBC
ETH
PS CPU
GBC
ETH
AB
NIU
AB
NIU
AB
NIU
S/W
PC
31 30
1 2 29
SERIES 90-30 & 90-70 SINGLE LAN REDUNDANCY WITH HMI COMMUNICATION REDUNDANCY
Rack 1 Rack 2
Genius bus
DROPS
Tuesday, April 11, 2023 34SBO/ PMM/ EJ501/ Jun2011
PLC Programming Languages
•Ladder diagram (LD)
•Sequential Function Charts (SFC)
•Function Block Diagram (FBD)
•Structured Text (ST)
•Instruction List (IL)
•C-Programming
Tuesday, April 11, 2023 35
PLC Ladder Diagram Instructions
1) Relay,
2) Timer and counter,
3) Program control,
4) Arithmetic,
5) Data manipulation,
6) Data transfer, and
7) Others, such as sequencers.
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Program Instructions
• Contacts– Normally Open Contact– Normally Closed Contact– Positive transition Contact– Negative transition contact
• Outputs– Output Coil– Set Coil– Reset Coil– Master Control Relay– Skip/Jump
• Timers
– On Timer– Off Timer– Counters– Up Counter– Down Counter
• Math Functions– Addition– Subtraction– Multiplication– Division
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Program Instructions• Move Functions
– Move– Block Move– Indirect Move
• Comparison Functions– Equal– Not Equal– Greater than– Less than– Greater than or Equal to– Less than or Equal to
• Logical Operation Functions– AND– Inclusive OR– Exclusive OR– Shift Right– Shift Left– NOT
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PB1 R1PB2
R2
R1 = PB1.AND.PB2 R2 = PB2.AND.~PB4
PB3 PB4
PB1 R1
PB2
R1 = PB1 .OR. PB2
AND
OR
AND and OR LOGIC
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R1 = PB1 .OR. (PB2 .AND. PB3)
PB1 R1
PB2 PB3
COMBINED AND & OR
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RELAYSA switch whose operation is activated by an electromagnet is called a "relay"
contact
coil
input
Relay coil
R1
R1Output contact
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N.O
C
L2 L1
L1 L2
OUTPUT MODULEWIRING
MOTOR
CONTACTOR
O:4
0CONTACTOR
LADDER PROGRAM
L1 L2
FIELD WIRING
•SOLENOID•VALVES•LAMP•BUZZER
Tuesday, April 11, 2023 43
AN EXAMPLE OF RELAY LOGIC
L1
LS1 PB1 LS2 R1
R1
R1TIMER R2
PR=5
For a process control, it is desired to have the process start (by turning on a motor) five seconds after a part touched a limit switch. The process is terminated automatically when the finished part touches a second limit switch. An emergency switch will stop the process any time when it is pushed.
LS1PB1
LS2
R1
TIMER
5Motor R2
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TIMERA timer consists of an internal clock, a count value register, and an accumulator. It is
used for or some timing purpose.
Clock
Accumulator
contact
reset
output
Register
Contact
Time 5 seconds.
Clock
Reset
Output
Count 1 2 3 40 5
Tuesday, April 11, 2023 45
PLC Application
RIFLEX
PLC from Ritmeyer
MX213, ME203
Manufacturer: Bachmann, Austria
RITOPSCADA system used for operation and monitoring
Object oriented system withRIFLEXSimatic S7/RAPRittmeyer instruments products
Tuesday, April 11, 2023 46
RIFLEX® M1 System Overview
Process BusEthernet / TCP/IP IEC60870-5-104
RITOP®Process ControlSystem
Bus Extension
Fixed cable connection orleased line
Radio / GSM
FAST Bus
Fiber optic cable
TelecommunicationNetwork
Switched line
Switched line Switched line MODBUS
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Process Bus (TCP/IP)
Switched Network
fixedconnection
RIFLEX® M1 Features• VxWorks® Real-time OS• Connection via fixed lines:
- onsite cables, leased lines- optical cables (fiber optics)
• Connection via switched lines:- analog/digital phone network (ISDN)- GSM, radio network- Intranet
• Ethernet TCP/IP based• Data links/communication through:
- IEC60870-5-104 (Ethernet)- IEC60870-5-101 (RS485)- IEC60870-5-103 (protection relays)- MODBUS-RTU (Master or Slave)- Profibus-DP (Master)- DCF77 (radio controlled clock) or GPS
• Entire maintenance, diagnostics and programming via TCP/IP, e.g. via Telnet
= high flexibility
Tuesday, April 11, 2023 48
Micro Processor Modules
RMMX213.E32Processor P133MHz 32MB
RMME203.EProcessor Intel 386/33MHz, 8MB
RMNT250Power Supply 45W 24VDC to 5VDC
RMLM201Dummy Module Protection Placeholder
RMME203.ENProcessor Intel 386/33MHz, 8MBincl. power supply
RMPCC32PC-Card Memory 32MB Flash
RMBS204Bus Back Plane4 Module Slots
RMBS208Bus Back Plane8 Module Slots
RMBS211Bus Back Plane11 Module Slots
Tuesday, April 11, 2023 49
Interface and Inputs/Outputs Modules
RMDI232Digital Input Module 32 Bit, 24V / 48V
RMDO232Digital Output Module 32 Bit, 24V / 48V
RMDIO216Digital Input / Output Module, 16 I/O, 24V
RMDIO248Dig.I/O Module, 16I, 16O,16I/O, 24V
RMAO204Analog Output Module 4 Channels 0..20mAwith galv. separation
RMAI202Analog Input Module2 Channels 0..20mAwith galv. separation
RMAI204Analog Input Module4 Channels 0..20mAwith galv. separation
RMAIO288Analog In/Out Module 8 In, 8 Out
RMAO202Analog Output Module 2 Channels 0..20mAwith galv. separation
Tuesday, April 11, 2023 50
Communication & Extension Modules
RMDPM200Profibus DP Master
RMRS204.RSer. IF 1xRS232, 3xRS232/422/485
RMBES202Bus Extension Slave
RMBES202.NBus Extension Slavewith power supply
RMFM212FAST-Bus-Master 2 Fiber optic con.
RMFM211FAST-Bus-Slave 1 Fiber optic con.
RMFS212.NFAST-Bus-Slave2 Fiber optic con.with power supply
RMBEM201Bus Extension Master
Tuesday, April 11, 2023 51
RIFLEX
• Memory Card : RMPCC32, 32 MB Flash• Interface with digital/analog inputs/outputs• Communication :Protocal Modbus, RS232,
RS485, RS422– DPM200, BEM 201
• Bus Extension Option : Max 7 substationPerformance and System limit is better in
RMMX213EXX Pentium 133 MHz than RMME203X Intel 386X 133 MHz
Tuesday, April 11, 2023 52
Programming software
– Riflex programing• logiCAD
– Used for making logic– logi.cals automation solutions & services
• WinKP– Used for making communication and for software upload to
Riflex
• Excel– Used for making variables and signals
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CIMPLICITY Software Architecture
• Scaleable Client/Server Architecture
• High Level of Data Integrity
• Easily Share Data Between Nodes
• Superior Feature Set
• Easily Replicate CIMPLICITY Projects
• Fault Tolerant System Architecture
• Open Systems - Easily Integrate to
• Enterprise Systems
VIEWERSSERVER
DISPLAYSTATION
REMOTE
SERVER
Plant-Wide Network
Pager
Mobile
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THANK YOU
Tuesday, April 11, 2023 57
Automation LevelAutomation Level
Turnkey System Functions
Process Control
Level
Data Storage andManagement
OperationReporting andStatistics
Visualization
Control
Regulation
Calculation
Alarm Signalization
Data Transmission
Data Acquisition
Measuring
SignalAcquisition
Monitoring
Field Level
Tuesday, April 11, 2023 58
WSA CONTROLLER CONCEPT
10
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