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Complex Automation System of a Low Power Hydroplant

2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26. Complex Automation System of a Low Power Hydroplant. D. Mircescu 1 , A. Astilean 2 , O. Ghiran 3 1. S.C. HIDROSERV Cluj S.A.

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Complex Automation System of a Low Power Hydroplant

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  1. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Complex Automation System of a Low Power Hydroplant D. Mircescu1 , A. Astilean2, O. Ghiran3 1. S.C. HIDROSERV Cluj S.A. 2. Technical University of Cluj-Napoca, Department of Automation 3. IPA - R&D Institute for Automation, Center for Technology Transfer Speaker: dipl. eng. Ovidiu Ghiran

  2. Introduction 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Based on the new latest generation programmable automata possibilities, this work presents the main aspects of implementing them, to achieve a complex automation system of a small power hydro plant (SAC-HmP). The system is designed for complex automation of a microhydropower plant equipped with EOS type generating units (helicoidally turbine, horizontal shaft with S circuit) or FO (horizontal Francis turbine) and asynchrony generators with a nominal speed rate of 1500 rpm. This work presents the SAC-HmP model and the results of the system implemented at C.H.E.M.P. Budac 1 and C.H.E.M.P. Bolovanu (Bistriţa hydrographic basin). Complex Automation System of a Low Power Hydroplant 2/21

  3. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Main Objective The design and the implementation of an automatic control and monitoring system for SAC-HmP hydropower plants based on the last generation InLine PLCs type, which allows the speed and the scalability necessary for managing the automatic processes in a hydropower plant. The main requirements for SAC-HmP are: low cost, reliability and safety in increasing exploitation, local and remote automatic control, ease of use-which allows monitoring and installation exploitation with minimum human intervention. The equipment has to permit self-diagnosis and automatic elimination of specific minor faults achieving continuous electric production for the maximum period possible. Complex Automation System of a Low Power Hydroplant

  4. System Designing and Functions 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 SAC-HmP implements the main functions necessary for micro hydroelectric power plant control: automatic process management, generator speed rate measurement, automatic net connection, over speed rate protection, temperature control and protection at high temperatures, directing unit opening control, valve opening control, lubrication and cooling control. In addition, due to the fact that SAC-HmP is mostly used in isolated locations, without operating personnel, the system implements burglary signaling and video surveillance. Complex Automation System of a Low Power Hydroplant 4/21

  5. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 System solutions - SAC-HmP block diagram Complex Automation System of a Low Power Hydroplant

  6. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Functional flow chart of SAC-HmP Complex Automation System of a Low Power Hydroplant 6/21

  7. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Implementation - Location CHEMP Budac Pi = 756 KW Hbrut= 98,5 m Qi = 1,05 mc/s Ep = 1640 MWh/an Tb = 2x FO 90/570 Ge = 2x GA 100/42-6 Complex Automation System of a Low Power Hydroplant 7/21

  8. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Implementation – Initial State Complex Automation System of a Low Power Hydroplant 8/21

  9. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Implementation – Final State Complex Automation System of a Low Power Hydroplant 9/21

  10. The installation was achieved on a Phoenix Contact ILC150ETH modern programmable automatum and a OT4M operating panel. All functions described were implemented. At the PLC level the following electrical protections are implemented: minimum voltage protection, high voltage protection, asymmetry, phase succession, reverse power; all protections are at the voltage bar level and at the generator level. The programmable automatum permits both serial Modbus RTU communication with the group switch and the bar measurement plant and also Ehernet-OPC Server communication with the operating panel and WebServer. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 PLC & Operating Panel Complex Automation System of a Low Power Hydroplant 10/21

  11. The Masterpact NW16 type group switch is equipped with Micrologic 5.0P integrated digital protection. For the bar level electric quantities a PM710 electric parameter measurement plant was used. This intelligent equipment allows communication on an RS485 industrial network using a Modbus RTU protocol or data transmission. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Group Switch Complex Automation System of a Low Power Hydroplant 11/21

  12. Revolution measurement is achieved by an optic fork laser translator and a mechanical ensemble that allows the measurement of generator revolution in the shape of a fixed form rectangular signal with variable frequency. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Speed Sensor Complex Automation System of a Low Power Hydroplant 12/21

  13. Opening the master device is measured redundantly with an analog displacement translator with unified output signal and 3 proximity sensors for race ends. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Analog & Digital AD Sensor Complex Automation System of a Low Power Hydroplant 13/21

  14. Pressure is measured using industrial manometers with unified output signal. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Pressure Transducers Complex Automation System of a Low Power Hydroplant 14/21

  15. The admission valve position is given by a slope sensor mounted on its arm, and cooling water and lubrication oil control is done by mounting on their flow translator circuits on the calorithmetic principle 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Water & Oil flow Sensors Complex Automation System of a Low Power Hydroplant 15/21

  16. The operating panel permits the simple exploitation of the installation by the installation and maintenance operating staff offering real-time data on the production process. The data displayed by the operating panel is updated with a period of 250ms. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Local - User Interface Complex Automation System of a Low Power Hydroplant 16/21

  17. In case of passing malfunctions (e.g. voltage holes), alarms are stored in the operating panel archives without requiring confirmation by the operating shift staff; after the malfunction disappear the PLC restart the whole process starting from the initial phase. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Alarms Interface The displayed alarms have time and date stamp; the operating panel allows their storage for an indefinite amount of time. Complex Automation System of a Low Power Hydroplant 17/21

  18. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Remote Control - Interface The application runs at the programmable automatum level, the generated web page can be seen on any web browser that supports Java, or possibility of data transfers by OpcServer. With regard to the remote control a passive control was decided upon, in the sense that at the associated web server level the superior hierarchic level is permitted to monitor the installation; to visualize the alarms, the alarms’ history, the translator state and the diagnostic error codes. However, no command or parameter tuning are permitted at the web server level. To ensure data security an IP address filter can be implemented which restricts the IPs that can be viewed on the page. Switching from one screen to another can be protected by a username and a password. Complex Automation System of a Low Power Hydroplant 18/21

  19. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Web - Interface Complex Automation System of a Low Power Hydroplant 19/21

  20. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Conclusions • SAC-HmP can represent a worthwhile solution for the technological renewal of hydroelectric plants, built before 1989, in Romania , with unitary power of under 4MW. • The main benefits of the proposed system are: • Reduced cost; • Functional reliability and safety through using programmable automata; • Exploitation speed (the execution time of a cycle being under 15ms) • Simple interconnecting with intelligent communication devices; • Possibility of simple connecting with high-level teleconducting through OpcServer and WebServer • Flexible and easily configurable architecture. • The system presented in the course of this work is already implemented and functional at two low power hydroplants: C.H.E.M.P. Budac 1 and C.H.E.M.P Bolovanu as of August 2011. During the time elapsed since implementing them no malfunction or necessary intervention occurred, the automatised hydroagregates reaching production levels of 12MW/day which denotes a 20% increase in total produced energy. Complex Automation System of a Low Power Hydroplant

  21. 2012 IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR 2012) - THETA 18 - Cluj-Napoca, May, 24-26 Thank You ! Complex Automation System of a Low Power Hydroplant

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