plc overview

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


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


VIEW OF HEADWORK FROM GOOGLE EARTH

3


Marsyangdi Dam

Radial Gates

Desilting Basin

Intake

Reservoir

Marsyangdi River


Marsyangdi Powerhouse

Surge Tank

Powerhouse

Tailrace

Marsyangdi River


SYSTEM OVERVIEW


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


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


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


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


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.


Complete Factory Automation


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


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


PLC and HMI/SCADA


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:


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:


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)


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.


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


PLC Operation

PLC sweep: Automatically operated repeated cycle

receives signals from input devices

executes its application program

sends signals to the output devices


A typical example of PLC Operation


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.


It starts with Sensors…”Inputs”


And ends with Loads…”Outputs”


With Programs linking Inputs to Outputs


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


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.


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


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


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


R1 = PB1 .OR. (PB2 .AND. PB3)

PB1 R1

PB2 PB3

COMBINED AND & OR


RELAYSA switch whose operation is activated by an electromagnet is called a "relay"

contact

coil

input

Relay coil

R1

R1Output contact


N.O

C

L2 L1

L1 L2

OUTPUT MODULEWIRING

MOTOR

CONTACTOR

O:4

0CONTACTOR

LADDER PROGRAM

L1 L2

FIELD WIRING

•SOLENOID•VALVES•LAMP•BUZZER


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


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


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


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


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


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




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


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


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


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


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


THANK YOU


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


WSA CONTROLLER CONCEPT

10

plc overview

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