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

PRESENTATION OUTLINE
1. PROJECT OVERVIEW 2. SYSTEM OVERVIEW 3. SOLUTION
1. 2. 3. INSTRUMENTATION CONTROL CONCEPT CONTROL SYSTEM

4.
1. 2. 3. 4. 5. 6. 7.

SPECIFIC FUNCTION DESCRIPTION

INTAKE GATE CONTROL SPILLWAYGATE CONTROL FLUSHING GATE CONTROL SLUICE GATE CONTROL WATER SUPPLY AUTOMATION TRASH RACK MONITORING INTAKE GATE PROCESS CONTROL SYSTEM RITOP

5. PLC
1. 2. 3. 4. 5. 6. 7. 8. 9. Basic Introduction History & Origin PLC Characteristics PLC Software List PLC used in NEA powerhouse PLC Components PLC Operation PLC Programming Languages PLC Application Riflex, Ritop
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PROJECT OVERVIEW
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 2
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VIEW OF HEADWORK FROM GOOGLE EARTH

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Marsyangdi Dam
Radial Gates Reservoir Marsyangdi River

Desilting Basin

Intake

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Marsyangdi Powerhouse
Surge Tank

Powerhouse

Tailrace

Marsyangdi River
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SYSTEM OVERVIEW

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SOLUTION
INSTRUMENTATION-FIELD DEVICES
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.)

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SOLUTION Contd
CONTROL CONCEPT

CONTROL SYSTEM

COMMUNICATION

Local-Priority 1
(Operation of each Gates from existing Power Packs)

RITOP at NWCB and

PH for Centralized Supervision and Control of WSA

PLANT PROCESS BUS SINGLE MODE FIBREOPTIC ETHERNET NETWORK

HMI-Priority 2 (Operator Station in NWCB or PH)

LOCAL CONTROL
Spillway Gates Sluice Gates Flushing Gates

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SOLUTION Contd
PROCESS STATION RIFLEX M1 Power Supply CPU with memory D/A Interfaces
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SYSTEM TIME TIME STAMPING FOR PROCESS VARIABLES

PROCESS INTERFACE
INTERFACE BETWEEN CONTROL SYSTEM AND PROCESSES GALVANICALLY ISOLATED SIGNAL CABLES

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SPECIFIC FUNCTION DESCRIPTION

INTAKE GATE CONTROL SPILLWAY GATE CONTROL
OPERATION MODES
1. NO CONTROL 2. HEAD LOSS AVAILABLE ON RITOP FOR MONITORING

FLUSHING GATE CONTROL

OPERATION MODES
INSPECTION LOCAL REMOTE

SLUICE GATE CONTROL

OPERATION MODE
INSPECTION LOCAL REMOTE

INSPECTION LOCAL REMOTE OFF/AUTO Y/WSA

SPECIFIC FUNCTION DESCRIPTION

WATER SUPPLY AUTOMATION
OPERATION MODES ON (Level Regulation) OFF (No set point commands to the Actuator

TRASH RACK MONITORING GATE

PROCESS CONTROL SYSTEM RITOP

1.RESERVOIR LEVEL MEASUREMENT ANDDISPLAY 2. CALCULATION OF DISCHARGE 3. LEVEL CONTROL FOR RESERVOIR 4. AVAILABILITY OF CONTROL ELEMENTS

CONTINUOUSLY SUPERVISE HEAD LOSS OF TRASH RACK AND INDICATE AT RITOP

PROCESS SUPERVISION
ALL AGGREGATES ARE CONTROLLED

ACTUATORS 5 Spillway Gates and 2 Flaps

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

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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 PLC
ruggedized

permanently installed monitor and control other devices and processess After being programmed, they operate automatically.

Most dont 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

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PLC and HMI/SCADA

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List of items required when working with PLCs:

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.)
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PLC Programming Softwares:

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
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PLC used in NEA-powerhouse

GE Fanuc Series 90-30 : Kaligandaki A HPS-unit control Middle 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)
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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.

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Components of a PLC System

Programmer Central Processing Unit

Circuits
Input

Input Tables

Logic Memory Bit Memory Data Memory

Output Tables

Output Circuits

Input Devices HMI System

Fault/Diagnostics Memory Configuration Memory Refresh Memory PLC O/S

Output Devices O/I Terminals

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PLC Operation
PLC sweep: Automatically operated repeated cycle
receives signals from input devices

sends signals to the output devices

executes its application program

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A typical example of PLC Operation

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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 SensorsInputs

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And ends with LoadsOutputs

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With Programs linking Inputs to Outputs

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SERIES 90-30 & 90-70 SINGLE LAN REDUNDANCY WITH HMI COMMUNICATION REDUNDANCY
PC Rack 1 PS C P U 31 G B E C T H S/W 30 PS C G P B U C Rack 2

E T H

Genius bus 1 NIU A B 2 NIU A B DROPS 29 NIU A B

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PLC Programming Languages

Ladder diagram (LD) Sequential Function Charts (SFC) Function Block Diagram (FBD) Structured Text (ST)

Instruction List (IL) C-Programming

Sunday, March 03, Jun2011 SBO/ PMM/ EJ501/2013

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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

Timers

Normally Open Contact Normally Closed Contact Positive transition Contact Negative transition contact
Output Coil Set Coil Reset Coil Master Control Relay Skip/Jump

Outputs

On Timer Off Timer Counters Up Counter Down Counter

Addition Subtraction Multiplication Division

Math Functions

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Program Instructions
Move Functions
Move Block Move Indirect Move

Logical Operation Functions

AND Inclusive OR Exclusive OR Shift Right Shift Left NOT

Comparison Functions
Equal Not Equal Greater than Less than Greater than or Equal to Less than or Equal to

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AND and OR LOGIC

PB1 PB2 R1 R1 = PB1.AND.PB2

AND

PB3

PB4

R2 R2 = PB2.AND.~PB4

PB1

R1 R1 = PB1 .OR. PB2

OR

PB2

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COMBINED AND & OR

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

PB1

R1

PB2

PB3

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RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact

coil

input

Relay coil R1

Output contact
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R1
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CONTACTOR

L2

L1

N. O MOTOR SOLENOID VALVES LAMP BUZZER

L2 L1 FIELD WIRING

OUTPUT MODULE WIRING

L1

O:4

L2

CONTACTOR

LADDER PROGRAM
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AN EXAMPLE OF RELAY LOGIC

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.
L1 LS1 R1 TIMER R2 PB1 LS2 R1

R1

PB1 LS1

LS2

PR=5

TIMER 5

Motor R2

R1

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TIMER
A timer consists of an internal clock, a count value register, and an accumulator. It is used for or some timing purpose.
Clock

Accumulator re se t Re giste r

conta ct Contact output

Clock Reset Output Count 0 1 2 3 4 5

Time 5 seconds.
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PLC Application RIFLEX

PLC from Ritmeyer

RITOP
SCADA system used for operation and monitoring Object oriented system with

MX213, ME203 Manufacturer: Bachmann, Austria

RIFLEX
Simatic S7/RAP Rittmeyer instruments products

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RIFLEX M1 System Overview

RITOP Process Control System

Ethernet / TCP/IP IEC60870-5-104

Process Bus

Fixed cable connection or leased line

Bus Extension

FAST Bus Fiber optic cable Radio / GSM

Switched line

Telecommunication Network Switched line Switched line MODBUS

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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) fixed connection - 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

Process Bus (TCP/IP)

Switched Network

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Micro

Processor Modules

RMMX213.E32 Processor P133MHz 32MB

RMME203.E Processor Intel 386/33MHz, 8MB

RMME203.EN Processor Intel 386/33MHz, 8MB incl. power supply

RMBS204 Bus Back Plane 4 Module Slots

RMBS208 Bus Back Plane 8 Module Slots

RMBS211 Bus Back Plane 11 Module Slots

RMNT250 Power Supply 45W 24VDC to 5VDC

RMLM201 Dummy Module Protection Placeholder

RMPCC32 PC-Card Memory 32MB Flash

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Interface and Inputs/Outputs Modules

RMDI232 Digital Input Module 32 Bit, 24V / 48V

RMDO232 Digital Output Module 32 Bit, 24V / 48V

RMDIO216 Digital Input / Output Module, 16 I/O, 24V

RMDIO248 Dig.I/O Module, 16I, 16O,16I/O, 24V

RMAI202 Analog Input Module 2 Channels 0..20mA with galv. separation

RMAI204 Analog Input Module 4 Channels 0..20mA with galv. separation

RMAO202 Analog Output Module 2 Channels 0..20mA with galv. separation

RMAO204 Analog Output Module 4 Channels 0..20mA with galv. separation

RMAIO288 Analog In/Out Module 8 In, 8 Out

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Communication & Extension Modules

RMDPM200 Profibus DP Master

RMRS204.R Ser. IF 1xRS232, 3xRS232/422/485

RMBEM201 Bus Extension Master

RMBES202 RMBES202.N Bus Extension Slave Bus Extension Slave with power supply

RMFM212 FAST-Bus-Master 2 Fiber optic con.

RMFM211 FAST-Bus-Slave 1 Fiber optic con.

RMFS212.N FAST-Bus-Slave 2 Fiber optic con. with power supply

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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 substation Performance and System limit is better in RMMX213EXX Pentium 133 MHz than RMME203X Intel 386X 133 MHz
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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

VIEWERS

SERVER

Pager

REMOTE

Mobile Plant-Wide Network DISPLAY STATION SERVER

Scaleable Client/Server Architecture

Easily Replicate CIMPLICITY Projects Fault Tolerant System Architecture Open Systems - Easily Integrate to Enterprise Systems

High Level of Data Integrity

Easily Share Data Between Nodes Superior Feature Set

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Turnkey System Functions

Visualization
Reporting and Statistics Alarm Signalization Data Transmission Process Control Level Data Storage and Management Operation Control

Automation Level Automation Level

Regulation Calculation

Data Acquisition

Monitoring Field Level

Signal Acquisition Measuring

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WSA CONTROLLER CONCEPT

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