Application of Supervisory Control and Data Acquisition ...

Title page Application of Supervisory Control and Data Acquisition System in AIT

Electrical Distribution Network (22kV 400V/230V)

by

Abu Salman Shaikat

A thesis submitted in partial fulfillment of the requirements for the

degree of Master of Engineering in

Mechatronics

Examination Committee: Assoc. Prof. Erik L.J.Bohez (Chairperson)

Dr. Manukid Parnichkun

Dr. Weerakorn Ongsakul

Nationality: Bangladesh

Previous Degree: Bachelor of Science in Electrical and

Electronic Engineering

Ahsanullah University of Science and Technology

Dhaka, Bangladesh

Scholarship Donor: AIT Fellowship

Asian Institute of Technology

School of Engineering and Technology

Thailand

May 2015

i

ACKNOWLEDGEMENTS

First and foremost, I would like to thank Assoc. Prof. Erik L.J. Bohez, my thesis supervisor, for his

valuable guidance, support and the direction without which this research would not have been

possible.

Also, I would like to extend my gratitude towards my thesis committee members-especially Dr.

Weerakorn Ongsakul and Dr. Manukid Parnichkun for their valuable feedback and advice.

Much appreciation for the hard work and commitment shown by ISE staffs and colleagues, especially

express my sincere thanks to laboratory supervisor, Mr. Hoang Hung Manh, for his guidance and

support me with all equipment and facilities in Automation lab and also with my pilot projects.

Finally, I would like to express my sincere and heartfelt appreciation and gratitude to my Family for

their endless support and continuous faith in me.

ii

ABSTRACT

Supervisory Control and Data Acquisition (SCADA) have been applied very successfully in Electrical

network as well as others. Equipment’s have been supervised to help if system detects serious faults

when it’s occurring and system will respond automatically to segregate break point.

In this thesis, SCADA will be applied to distribution station in AIT electrical distribution network. The

whole station can be connected with operating center via Ethernet.

Main function has been constructed by Programmable Logic Controller software SimaticS7-300.

Human Machine Interfaces (WinCC) is studied and applied to monitoring the whole control model.

This work is concerned with path of Ethernet and its simulation information network from peripheral

station to center. This research may also serve as a useful reference for exploring and understanding

basic of electrical network as well as automation network.

Keywords:

Electrical Distribution Network

Programmable Logic Controller (PLC)

Supervisory Control and Data Acquisition (SCADA)

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TABLE OF CONTENTS

CHAPTER TITLE PAGE

TITLE PAGE I

ACKNOWLEDGEMENTS I

ABSTRACT II

TABLE OF CONTENTS III

LIST OF FIGURES VII

LIST OF TABLES X

1 INTRODUCTION 1

1.1 Background 1

1.2 Statement of Problem 1

1.3 Objective of the Study 2

1.4 Scope and Limitation of Study 2

2 LITERATURE REVIEW 3

2.1 Overview of substation 3

2.1.1 Overview of Distribution Substation 5

2.2 Review of Literature on Control device and SCADA (Supervisory control 6

and data acquisition)

2.3 Review of Literature on Communication medium 8

2.3.1 Fieldbus 8

2.3.1.1 Introduction 8

2.3.1.2 Benefit of Fieldbus 8

2.3.1.3 Application of fieldbus 8

2.3.2 Profibus 8

2.3.3 OPC 8

2.3.4 ETHERNET 8

iv

2.3.4.1 Introduction 8

2.3.4.2 Broadcast network operation 9

2.3.4.3 Physical layer of Ethernet 9

2.3.4.4 The role of Fiber Media in Industry 9

2.3.4.5 Migrations from Serial Communication to Ethernet 9

2.3.4.6 Benefits of Ethernet 10

2.4 Energy Management Network 10

2.4.1 Function of Energy Management Network 10

2.5 Summary 11

3 METHODOLOGY 13

3.1 Flow Chart 13

3.2 Existing operation 13

3.2.1 AIT One-line Diagram 14

3.2.2 Main distribution board of Substation 11 (Existed) 14

3.3 Evaluating and analyzing the current system 20

3.3.1 Fault History 21

3.4 Data collection 21

3.4.1 Capacity of Substations and installed capacity 22

3.4.2 Location of Substations 23

3.4.3 AIT power supply system 24

4 SYSTEM CONFIGURATION 25

4.1 Hardware configuration 25

4.2 Project 26

4.2.1 Apparatus 26

4.2.2 Diagram 27

4.2.3 Schematic Diagram 29

5 HARDWARE IMPLEMENTATION 30

5.1 List of equipment’s need for real implementation of Substation 11 30

5.2 Proposed model of Substation 11 31

5.3 Proposed hardware configuration 32

v

5.3.1 Proposed hardware configuration of switching devices 32

5.3.2 Proposed hardware configuration of ISE and SOM (MDB) 34

5.3.3 Proposed hardware configuration of ISE and SOM (LC) 35

5.4 Proposed one-line diagram 36

5.5 Proposed wiring diagram 37

5.5.1 Wiring diagram (PLC & Control and protection equipment) 37

5.5.2 Wiring diagram (PLC & MDB) 38

5.5.3 Wiring diagram (PLC & LC) 38

5.5.4 Wiring Diagram (Monitoring unit) 39

6 CONTROL ALGORITM AND HMI 40

6.1 Control Algorithm 40

6.1.1 S7-300 Program structure 40

6.2 Input/ output parameters connect with PLC 41

6.2.1 Transformer protection 42

6.2.1.1 PLC program for transformer protection 42

6.2.2 Circuit breaker/ Relay protection 43

6.2.2.1 PLC for circuit breaker protection 43

6.2.3 Energy meter, Reactive power, cost estimation 44

6.2.3.1 PLC of Energy meter, Reactive power and cost estimation 45

6.2.4 Voltage estimation 45

6.2.4.1 PLC of voltage estimation 45

6.2.5 Fault location analysis 46

6.2.5.1 PLC of Fault Location Analysis 46

6.2.6 Power factor correction 47

6.2.6.1 PLC of Power factor correction 47

6.3 Create Project Using WINCC (HMI) 48

6.3.1 Function used in program 48

6.3.1.1 Tag manager 48

6.3.1.2 Graphics Designer 49

6.3.1.3 Log Tagging 49

6.3.1.4 Alarm Logging 49

6.3.1.5 Report Design 49

6.3.2 HMI programs 50

6.3.2.1 Transformer screen 50

6.3.2.2 Circuit breaker screen 50

6.3.2.3 Fault Location Analysis 51

6.3.2.4 Real power, Reactive power and cost estimation 52

vi

6.3.2.5 Power factor calculation 52

6.3.2.6 Fault record 53

6.3.3 Conditions using for Temperature fault (Hardware) 54

6.3.4 Analog voltmeter of transformer (Hardware) 55

7 RESULTS AND DISCUSSION 56

7.1 Results of different parameters 56

7.1.1 Bucholtz Alarm 56

7.1.2 Storm Mode 57

7.1.3 Tap Changer 58

7.1.4 Voltage 60

7.1.5 Current 61

7.1.6 Temperature of Transformer 63

7.1.7 Oil level of Transformer 66

7.1.8 Current Alarm of Circuit Breaker 68

7.1.9 Pressure of Circuit Breaker 71

7.1.10 Energy, Reactive power and cost estimation 72

7.1.11 Fault Location Validation 74

7.1.12 Power Factor Correction 75

8 CONCLUSION AND RECOMMENDATION 77

8.1 Summary 77

8.2 Result and Conclusion 77

8.3 Recommendation 77

REFERENCES 79

APPENDIX A 81

APPENDIX B 111

APPENDIX C 114

APPENDIX D 118

vii

LIST OF FIGURES

FIGURE TITLE PAGE

Figure 2-1 Components of a Substation [14] 3

Figure 2-2 Overview of Distribution substation [6] 5

Figure 2-3 Typical Distribution Substation [6] 5

Figure 2-4 SCADA system structure [2] 7

Figure 2-5 Topology with serial lines and Ethernet [4] 9

Figure 3-1 Overview of the study plan 13

Figure 3-2 AIT one line diagram 14

Figure 3-3 Board that provide transformer output 15

Figure 3-4 Schematic diagram of MDB in substation 11 (old) 15

Figure 3-5 Main picture of distribution board in substation 11 17

Figure 3-6 MDB-1 panel of ISE building 18

Figure 3-7 MDB-2 panel for SOM building 19

Figure 3-8 Fault history of last 1 year in AIT [AIT] 21

Figure 3-9 Location of AIT power system substations 23

Figure 3-10 AIT power supply system [AIT] 24

Figure 4-1 Hardware Connection 25

Figure 4-2 Construction of the hardware 27

Figure 4-3 Connection of Profibus OLM with mpi-interface and PC via bus connecter 28

Figure 4-4 Four input (Pushbuttons) and seven outputs (Relays and lamps) connection in PLC board 28

Figure 4-5 Distance measurement using Solidworks 2013 29

Figure 5-1 Proposed model of Substation 11 31

Figure 5-2 Proposed hardware configuration of switching devices 32

Figure 5-3 Proposed hardware configuration of main distribution board 34

Figure 5-4 Proposed hardware configuration of ISE and SOM (Load center) 35

Figure 5-5 Proposed one-line diagram 36

Figure 5-6 Wiring diagram (PLC with Switching Equipment’s) 37

Figure 5-7 Wiring diagram (PLC and MDB) 38

Figure 5-8 Wiring diagram (PLC & LC) 38

Figure 5-9 Wiring diagram (Monitoring unit) 39

Figure 6-1 S7-300 Program structure 40

Figure 6-2 Protection of transformer 43

Figure 6-3 Protection of circuit breaker 44

Figure 6-4 Energy, Reactive power and cost estimation 45

Figure 6-5 Voltage estimation 46

Figure 6-6 Fault Location Analysis 47

Figure 6-7 Power factor correction 48

Figure 6-8 Transformer and voltage interface in WINCC 50

Figure 6-9 CB interface in WINCC 51

Figure 6-10 Fault location analysis 51

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Figure 6-11 Real power, Reactive power and cost estimation 52

Figure 6-12 Power factor correction 52

Figure 6-13 Fault record 53

Figure 6-14 Temperature Faults in WINCC 54

Figure 6-15 Analog voltmeter in WINCC 55

Figure 7-1 Bucholtz Alarm Validation (Active) 56

Figure 7-2 Bucholtz Alarm Validation (Deactivate) 56

Figure 7-3 Storm mode validation (active) 57

Figure 7-4 Storm mode validation (deactivate) 57

Figure 7-5 Tap changer (0 to 1) 58

Figure 7-6 Tap Changer (1 to 2) 58



Figure 7-9 Voltage Validation (0V to 220V) 60



Figure 7-12 Current Validation (0A to 20A) 61

Figure 7-13 Current Validation (20A to 40A) 62

Figure 7-14 Current validation (40A to 0A) 62

Figure 7-15 Temperature of Transformer (0⁰C) 63

Figure 7-16 Temperature of Transformer (0⁰C to 20⁰C) 63




Figure 7-20 Temperature of Transformer (Backup) 65

Figure 7-21 Oil Level Validation (20 bar) 66

Figure 7-22 Oil Level Validation (1 bar) 66

Figure 7-23 Oil Level Validation (0.8 bar) 67

Figure 7-24 Oil Level Validation (0.4 bar) 68

Figure 7-25 Current Alarm Validation (0A) 69

Figure 7-26 Current Alarm Validation (0A to 500A) 69



Figure 7-29 Pressure Validation (7 bar) 71

Figure 7-30 Pressure Validation (7 bar to 5.8 bar) 71

Figure 7-31 Pressure Validation (5.8 bar to 3 bar) 72

Figure 7-32 Energy, Reactive power and Cost Validation (θ=0⁰) 72

Figure 7-33 Energy, Reactive power and Cost Validation (θ=89.964⁰) 73

Figure 7-34 Energy, Reactive power and Cost Validation (θ=44.9⁰) 73

Figure 7-35 Fault Location Validation (230V) 74


ix


Figure 7-38 Power Factor Correction Validation (θ=0⁰) 75



x

LIST OF TABLES

TABLE TITLE PAGE

Table 2-1 Important Literature reviews as a Tabular summary 12

Table 3-1 Existing system vs Proposed system 20

Table 3-2 AIT power system distribution and capacity of transformer among different substations 22

[AIT]

Table 4-1 List of equipment of network 26

Table 5-1 List of equipment’s need for real implementation 30

1

1 CHAPTER 1

INTRODUCTION

1.1 Background

A power supply is a device that supplies electrical power to an electrical load. Power supply is

necessary all over the world. It is one of the most valuable resources to the human society.

But, however there are many problems with power system such as controlling, protection,

communication system failure, disturbances and human operation errors. Therefore, it is

necessary for us to maintain the power system stable and reliable. In power system, computer

network and data communication play a very important role in modern world.

In power system, we can use SCADA (Supervisory Control and Data Acquisition System)

system which is referring to the mixture of data acquisition and telemetry. In power system,

we don’t use the full control system, but we focus on the supervisory level, remote

measurement, monitoring, control and protection which are used for power system reliability

and stability. This process consists of many parts. At first, we have to collect all information.

Then taking it back to central site and moving out necessary control and analysis. At last, it

should display these data in operation screens.

The SCADA system is used for control and monitor of plant or equipment. Control system

can be automatic or manual.

1.2 Statement of Problem

In power system, power distribution is one of the most important parts. Electricity should be

distributed in all over the country or state. In modern world, our main challenge is how to

supply electricity without interrupt. So it is a very important matter to distribute power in a

state without any interrupt.

In my thesis, I focus on AIT power system. So I just focus on the distribution of power in

AIT. I also concern about the power consumption.

In this thesis, we have to control power distribution and power consumption with the help of

electrical parameters. So we have to supervise control for detect and solve any fault quickly.

Then acquisition data for analysis which can avoid the previous data and then supply data for

operate the power supply. We can do it easily by SCADA system.

2

1.3 Objective of the Study

To evaluate the benefits of SCADA systems for AIT electrical network compare to the current

system.

Implement and design Human Machine Interface (HMI) for monitoring the whole system.

Implement pilot SCADA (Supervisory Control and Data Acquisition) system.

1.4 Scope and Limitation of Study

In AIT, there are 15 substations. So it is not possible to make SCADA system for all

substations in a limited time. So in this thesis, I choose substation 11 which includes SOM1,

SOM2 and ISE building in AIT. In this substation, it use 800 KVA transformer, 3 phase 22

KV in primary side and for secondary side, it use 400 V for 3 phase and for 1 phase, it use

230 V.

3

2 CHAPTER 2

LITERATURE REVIEW

This chapter explore about some works already done related with this field and different types

of methods, they used for that. At first, the operation of substation is described in brief. After

that, some review about control, SCADA system, Communication medium and energy

management system will describe.

2.1 Overview of substation

Figure 2-1 Components of a Substation [14]

4

Substation mainly consists of three parts: Generation, Transmission and Distribution.

Substation converts high to low voltage using step-down transformer or low to high voltage

using step-up transformer. Normally, we use high to low voltage for factories. After passing

many substations, voltage will go to end user such as buildings, factory, water treatment etc.

There are various components of substation which is shown on Figure 2-1. The basic

functions of these components are written below.

Generation

Power station and switchyard: Generates the power and switchyard is used for

transforming the electricity from one voltage to other.

Transmission

Bulk supply point: Use to make multiple supplies from one point to cover the

whole distribution system.

Sub Transmission substation: Supply voltage to distribution system. It uses

step-down transformer.

Zone substation: Transform primary to secondary voltage.

OH HV (Overhead High Voltage) feeder: Supply voltage to different

substations through overhead.

UG HV (Underground High Voltage) feeder: Supply voltage to different

substations through underground.

Pole transformer substation: Distribution transformer which is climbed on the

pole.

Distribution

Distribute the voltage for different users.

Distribution Transformer: Supply voltage from primary distribution unit to

secondary distribution unit or different areas.

General

Circuit breaker/ Relay: Use as protection devices

Meter/ Indicator: Use in many purposes such as displaying energy, reactive

power, cost etc.

5

2.1.1 Overview of Distribution Substation

Figure 2-2 Overview of Distribution substation [6]

Distribution substation mainly use for residential, commercial and industrial usage. It uses

input voltage which is coming from transmission, and with the help of step-down transformer,

it can produce the distribution voltages which can be used in different purposes.

Figure 2-3 Typical Distribution Substation [6]

6

From Figure 2-3, we can see that, incoming Transmission line is connected with Step-down

transformer. So it creates low voltages and it will provide to distribution buses. Distribution

bus connects with circuit breaker which is connecting to underground line to distribution

circuit. This system protects when there is abnormal condition. Lightening arrestor is located

upper than transmission line to protect the line. Control house connect with circuit breaker

and outgoing low voltage distribution line which will help the voltage to go to different areas.

2.2 Review of Literature on Control device and SCADA (Supervisory control and data

acquisition)

Substation Automation [6] is new concept which interact the existing substation with new

network infrastructure. By doing this, it can easily do the automatic tasks like equipment

control, fault record and data acquisition. Substation automation can include different types of

devices such as relay controller, measuring units, signals, PLC and automation units. It

combines telecommunication, electronic and signal processing to enable the operation. We

can do controlling, monitoring, measuring, management and protection of different devices all

together using substation automation. All primary devices are converted to intelligent

equipment’s and all secondary devices are networked. All the operation and management will

become automated.

Distribution automation system [8] is mainly a combination of distribution substation, user

and customer. For past days, when the fault is coming, then engineers should fix it manually.

At first, they need to locate fault location. It needs a lot of time to find. After coming fault

management, in every location of distribution line, it needs to energize. If the fault location

comes, the relay will trip in that area. This system was automatic and manual. Now a days,

microprocessor and PLC’s are coming which can easily detect fault location automatically

and restore it when the system will become normal again.

Energy meters are used to measure total energy. It’s connected with PLC, controlling each

source locally and measure real time data. PLC network [9] is connected with Profibus

communication. For supervision of the system, it uses SCADA system.

PLC are used as RTU in SCADA because lot of resources and low cost. Also PLC is very

reliable. It can operate in high temperature.

Previously, DCS (Distributed Control System) [10] was used in which control and data

acquisition are done by lots of microprocessor based unit. And it should be located near the

control devices. PLC (Programmable Logic Controller) are widely popular because of it can

use with many input and output. Also, PLC is user-friendly.

7

SCADA system can be used not only for monitoring, but also troubleshooting machines and

different processes. Supervisory control can mainly do two things: Energy management and

control.

Figure 2-4 SCADA system structure [2]

Figure 2-4 describes about the structure of SCADA system. At first, we need to collect data.

Then by using these data, we need to make a control algorithm which can control the overall

system. At last, controlling units can be monitored in SCADA system.

The benefits of SCADA systems are described below. [3]

Monitoring and controlling with remote network system

Analysis of faults

Maintain alarm system when there is any fault

Network overview

Attaining and moving of circuit loading

Maintenance work with the help of feeder tagging

Online database management system

Reduce costs

8

2.3 Review of Literature on Communication medium

2.3.1 Fieldbus

2.3.1.1 Introduction

A fieldbus [1] is a serial data transmission system which is used in industries. In this, all data

are digital.

2.3.1.2 Benefit of Fieldbus

1. Easy to use

2. Easy to install

3. It can use in any environments

2.3.1.3 Application of fieldbus

1. Suitable to be used in explosion protected zones

2. Give the operating power to the field devices through bus cable.

2.3.2 Profibus

Profibus [1] (Process Field Bus) is a standard for fieldbus communication in

automation technology and was first invented in 1989 by BMBF (German department

of education and research) and then largely utilizes by Siemens. It has many nodes (up to

126 nodes). It transfers 244 bytes per node per cycle. It’s the maximum capacity to transfer.

Bit rates of profibus are from 9.6 kbit/s to 12 Mbit/s. Between 2 repeaters, cable length is

between 100m to 1200m. It can connect with different types of field devices such as digital

and analog I/O, robots, drivers and transducers etc.

2.3.3 OPC

OPC is the short form of “Open Process Control”. It is industrialized software which specifies

different interface of software server which gathers all the data from PLC and field devices.

OPC server can connect the PLC, monitoring unit, and fieldbus with more than 150 vendors.

For different exchanges [11] of data and accessing different database, OPC server can be

used. OPC contains 3 major components: Access of data, alarm logging and handling and

historical data analysis.

2.3.4 ETHERNET

2.3.4.1 Introduction

Industrial Ethernet [12] is one of the most important parts in substation automation. It can use

not only in industry, but also in office environments too. Many devices can operate with a

single Ethernet. This new Ethernet Technology combined with the sampled values and

GOOSE-message and process-bus applications in tomorrow’s substations.

9

2.3.4.2 Broadcast network operation

Ethernet used broadcast network operation. In broadcast network operation, hosts are

connected to a network via single shared medium. Its main advantage is it doesn’t need to go

for destination, because all hosts are located in shared medium.

2.3.4.3 Physical layer of Ethernet

The physical layer use low level electronic way for transmission of signal. It uses the voltage

level of ±0.85 V which transmits the logic level along the medium.

2.3.4.4 The role of Fiber Media in Industry

Ethernet [4] is coming and expanding with the help of fiber media into different industrial

environments and particularly in power substations. Ethernet is extending because its

resistance power to electrical interference, avoidance of ground loops, high bandwidth & its

capacity for longer distance. Fiber media mostly installed serial lines and used with RTUs,

voice-grade circuits, modems and shifting data from PLCs (Programmable Logic Controllers),

distributed relays, RTUs (Remote Terminal Units), and IEDs (Intelligent Electronic Devices)

to the central control area.

2.3.4.5 Migrations from Serial Communication to Ethernet

In serial communication, it linked with private protocols and limited speed. However,

Ethernet can provide standards-based interoperability and performance.

Serial cable uses point-to-point cable whereas Ethernet uses shared media packetized

protocol, which allows many devices connecting in one shared fiber cable.

Figure 2-5 Topology with serial lines and Ethernet [4]

In substations, they use fiber and copper cables. Fiber cabling is mostly used in serial and

Ethernet. Ethernet need cat 5 twisted pair copper cabling with R-45 connectors. Copper

cabling isn’t popular because it is not noiseless similar to fiber. But still copper cabling is

applied in Ethernet system for the short runs where system is protected.

10

2.3.4.6 Benefits of Ethernet

Many nodes can be installed.

This protocol is very good especially with respect to error detection and remove.

High throughput under conditions of light load.

Cabling is easy type and taps are submissive. Without affecting the network, the node

can install and remove.

Low cost.

Reliability.

Redundancy.

Need short response time.

Can use in any conditions.

Power supplies suitable for substations.

2.4 Energy Management Network

2.4.1 Function of Energy Management Network [1]

The functions of energy management network mainly divided into 3 types.

Energy accounting

An efficient system is the mostly needed requirement of energy management system. In

this process, the measuring, analyzing and reporting is done in a continuous basis so that

the system will become more efficient. Actually this process is the monitoring process of

SCADA system.

Energy analysis

A system needs all data in one machine. So system needs to centralize. In standalone

systems, there are following drawbacks which is indicated below.

a) In standalone mode, we normally get readings from raw data which is not effective.

b) In this, data is not correlated in real time which can create a large error when we need

data analysis. Hence efficiency will decrease.

c) In standalone, we can’t get online data. So optimization and energy conservation is

not possible in it.

d) Sometimes, there are some human errors which can give big inaccuracies in

system.So it’s necessary to make a centralized system for better efficiency.

11

Evaluation and decision making

In this process, it includes calculation, assumption and process. We need it for make control

strategies which is based on raw data. If we can build this control strategy, then we can easily

make an efficient system.

2.5 Summary

The literature review shows a brief idea about PLC and SCADA in substation. However, all

the researchers are working with just fault location and energy management whereas, we want

to implement for all the substation devices including those. However, one researcher of PECO

company [12] do with microprocessor based SCADA for substation, but they do it with

microprocessor and they do just with wires. This research is closest with my thesis. But in this

thesis, I use PLC as a control device and profibus, Ethernet as communication medium. Also,

the researcher [17] who is used PLC and SCADA is just for energy meter, but they don’t use

for reactive power or cost measurement whereas I include all in my thesis. Furthermore, a

researcher [18] just based on the difference between PLC and DCS system which is the main

benefit that we choose PLC for my thesis.

The table 2-1 shows the brief summary of my major works and different ideas by many

researchers.

12

Table 2-1 Important Literature reviews as a Tabular summary

Author Proposed idea Pros Cons

David Dolezilek

(2008-2009)

Microprocessor

with PLC in

substation

Cost reduce

IED (Intelligent Electronic Device)

integration

Control and monitoring

Historical data

Don’t use

Ethernet

Moxa

(2011)

Distribution

Substation

Substation

Automation

Distributing voltages to many areas

Combine existing with new system in

Substation

Musse Mohamud

Ahmed

(2010)

Distribution

Automation

System

Fault detect automatically and restore

automatically

Joao M. G.

Figueiredo

2010

Energy meter Can monitor and control Energy meter

clearly

Reactive

power or cost

not included

Cristina Anita

Bejan, Mihai

Iacob and

Gheorghe-Daniel

Andreescu

2008

PLC is better

than DCS

Cost effective

User friendly

Can use many input and output

Hasan A.M. Abu

Meteir

2012

SCADA system

for substation

Brief idea about SCADA system Not

implemented

till now

Le Hong Duong

2003

Fieldbus and

Profibus

Energy

Management

System

Used for faster and cheap

communication medium

Used for monitoring, analyzing and

controlling the raw data

Prof. Dr. H.

Kirrmann

(2007)

OPC Connect with different field devices

and SCADA as a communication

server

Clemens Hoga

(2007)

Industrial

Ethernet in

substation

Substation

automation

Low cost

High reliability

Make the combination of new and old

system

Expensive

Frank Marden

(2004)

Ethernet in

Substation

Use many devices with one Ethernet

Low cost, High throughput

13

3 CHAPTER 3

METHODOLOGY

3.1 Flow Chart

Existing Operation

Evaluating and analyzing the current network

Data collection in AIT Power system

Choosing hardware and software configuration

Developing control software

Developing Graphic User Interface for control process

Simulating the operation of operation network and

develop SCADA for AIT power system

Figure 3-1 Overview of the study plan

3.2 Existing operation

In AIT, we have 15 substations and in all substations, we use 400/230 V in secondary lines

and in primary, we use 22kV lines. I concern about substation 11. All meters are analog meter

in existed substation 11. They use copper wires to all connection. No monitoring unit is

available now.

14

3.2.1 AIT One-line Diagram

Figure 3-2 AIT one line diagram

Figure 3-2 shows the total AIT one-line diagram. However, we concern with Substation 11.

For this, we just indicate Substation 11 with blue borders. It shows that, 22 kVA is coming

from transmission line. After that, power goes to seven substations. Other substation comes

from some of these primary substations. Substation 11 also comes from Substation 10.

Substation 11 has a rating of 1600 kVA and current rating of 800 A. After that, this substation

will distribute the power to SOM1, SOM2 (SOM New), ISE.

3.2.2 Main distribution board of Substation 11 (Existed)

In AIT, there are 15 substations. Among them, I choose substation 11.

In substation 11, the output of transformer is coming in 3 parts: ISE, SOM1 and SOM2. In the

picture below, it shows the board where the output is coming.

15

Figure 3-3 Board that provide transformer output

The main distribution board is looks like the figure 3-4.

Figure 3-4 Schematic diagram of MDB in substation 11 (old)

16

In MDB board, there is a voltage and current indicator. Here, 3 phase is defined as R-S-T

which actually means, there are 3 load terminals. It follows the US system. Here, they use Air

circuit breaker and capacitor bank which used mostly for power factor correction. And at last,

there are parts of ISE and SOM building which can control by on-off switch.

The figure 3-5 shows the original figure of main distribution board.

17

Figure 3-5 Main picture of distribution board in substation 11

For SOM and ISE building, it just uses MDB-1 and MDB-2 and one air circuit breaker each.

The figure is shown in Figure 3-6 and Figure 3-7.

18

Figure 3-6 MDB-1 panel of ISE building

19

Figure 3-7 MDB-2 panel for SOM building

20

3.3 Evaluating and analyzing the current system

Existing systems are all analog whereas, in proposed model, we use analog and digital input

and outputs. We can monitor the fault and also, the fault location in proposed system.

Previously, AIT just used an Energy meter. In the proposed model, we can use reactive power

and also, the cost. Moreover, we can use intelligent switchgear and all protection and control

will be done by PLC. We can use Ethernet for the communication between devices.

The table 3-1 shows the advantages, that we get if AIT implement this system.

Table 3-1 Existing system vs Proposed system

21

3.3.1 Fault History

10 August, 2013: Breaker Trip shutdown for 10 minutes.

Solution: We use generator when breaker trip will shut down.

28 March, 2015- Main circuit breaker was burned for storm and it took 5 hours to change and

recover the system again.

Solution: We can use “Stormpulse” software to detect the area of storm. It will send a

message to circuit breaker for trip. And that time, generator will work and system will recover

again, when “Stormpulse” software send another message for normal condition.

Figure 3-8 Fault history of last 1 year in AIT [AIT]

3.4 Data collection

In AIT power system, we have to collect the data from AIT. At first, we have to collect

the data about load, substation locations, installed capacity, peak power demand value, power

supply, fault history.

22

3.4.1 Capacity of Substations and installed capacity

Table 3-2 AIT power system distribution and capacity of transformer among different

substations [AIT]

AIT have 15 substations, in which, the total install capacity is 13.5 MW whereas the peak

load is only 2 MW.

23

3.4.2 Location of Substations

Figure 3-9 Location of AIT power system substations

24

3.4.3 AIT power supply system

Figure 3-10 AIT power supply system [AIT]

Figure 3-10 shows the overall power supply system of AIT. 5 substations are upgraded

already and 9 substations will propose to upgrade. It shows the overall high voltage line of 22

kV.

25

4 CHAPTER 4

SYSTEM CONFIGURATION

4.1 Hardware configuration

Figure 4-1 Hardware Connection

Ethernet

26

Fiber optic cables are used in both master and slave for replacing RS 485 interfaces. This

technique can be used in PROFIBUS-DP masters and slaves such as SIMATIC programmable

controllers. The PROFIBUS OLM is works like repeater. It uses electrical and optical

interfaces, catching the signal from any transmitted port and then distributed that to all other

ports.

Line, ring and star topologies follow the characteristics of PROFIBUS OLM. It uses signaling

contact to link with HMI and display that status on graphics. Optical fibers, which are

normally used, are made with plastic or glass. For plastic, it can enabling up to 80 kilometers

and for glass, it’s up to 15 kilometers between 2 nodes. Ethernet can also be used in here. For

5 Ethernet switch, we can get 1000 m fiber ring. Sometimes, big distances can come because

of cascading depth of OLMs. OLM can be used in all PROFIBUS applications.

The power supply of PROFIBUS must be lower than IEC 950/ VDE 0805, which is between

+18V to+32V. Normally, it’s 24V. Power supply between OLM and PLC is DC24V.

Transmission reliability is increased a lot with use of optical fiber or Ethernet instead of

twisted 2-wire cable. So it reduces the problems of circuits or higher voltages.

4.2 Project

4.2.1 Apparatus

In hardware, we use the following things which are written below:

Table 4-1 List of equipment of network

Items Product description Quantity

1 PC 1 set

2 Programmable Logic Controller S7-300 Siemens 1 set

3 Fiber optic cable Plastic FO cable for indoor application with small range

6XV1 820-6BT01

10 meter

4 Optical Link Module Standard version OLM/S3 distance up to 2850m

6GK1 502-3AA10

2 set

5 Bus connector for profibus 6ES7 972-0BA10-0XA0 2 set

6 Bus connector for profibus 6GK1 500-0E A00 2 set

7 communication processor CP5611 1 set

27

4.2.2 Diagram

The diagram of construction structure is shown below.

Figure 4-2 Construction of the hardware

8 Profibus cable 6XV1 830-0AH10 3 meter

9 Digital Input SM 321 DI 16x24 DC 1 set

10 Digital Output SM 322 DO 16x24 DC 1 set

11 Push buttons 4 set

12 Lamps 4 set

13 Relay 3 set

14 Board 1 set

15 Analog Multimeter 1 set

28

Figure 4-3 Connection of Profibus OLM with mpi-interface and PC via bus connecter

Figure 4-4 Four input (Pushbuttons) and seven outputs (Relays and lamps) connection

in PLC board

29

4.2.3 Schematic Diagram

We use Solidworks 2013 to measure the distance between among all equipment’s. The

diagram is shown below.

Figure 4-5 Distance measurement using Solidworks 2013

We use a board in which 2 edges are 18.8976 inch and 6.29921 inch. Diameter of

pushbuttons and lamps are 1.06 inch and 1.22 inches respectively. The distance between each

pushbutton to another pushbutton or each lamp to another lamp is 2.19 inch. Each pushbutton

is parallel with a lamp. For 3 relays, the 2 edges are 2.36 inch and 2.95 inch. At last, we set

analog meter beside 3 relays which have 3.74 inch and 5.71 inch edges.

30

5 CHAPTER 5

HARDWARE IMPLEMENTATION

5.1 List of equipment’s need for real implementation of Substation 11

Table 5-1 List of equipment’s need for real implementation

Model no. Company

name

Reason Cost/ piece

(Approx.)

Vamp arc protection

relay system

Schneider

Electric

Arc protection

$50

MiCOM PB41 Schneider

Electric

Auto reclose &

check synchronism

$1000

MiCOM PB21 Schneider

Electric

Circuit breaker

failure

$1000

Sepam Series 60 Schneider

Electric

Capacitor bank

protection

$4200

SEL-751 SEL

company

Feeder protection $1750

MiCOM P63x Schneider

Electric

Transformer

protection and

control

$6750

PT 740

PT G226

(5 pcs.)

Firstmile

company

Ethernet switch $850

$1500

PLC (Siemens PLC

S7-200/S7-300/S7-

400/S7-1200)

(3 pcs.)

Shenzhen

Company

Industrial control

$100-$1000

BN30G [Kasuga]

(3 pcs.)

A-recycle

Company

Emergency Stop

Switch

$1-$2

ALFNE9F911-G A-recycle

Company

Idec Illuminate

Push Button

$1-$2

AAA AD16-22DS

(3 pcs.)

A-recycle

Company

Pilot Lamp $1-$2

MP

(3 pcs.)

Thaimeter

Company

Multi Function

Panelmeter

$3000-

$5000

TBUM298076 Schneider

Electric

Ethernet cable $32

Vamp measurement

& monitoring units

Schneider

Electric

Measurement and

monitoring

$500

31

PTS 740

Digital

meter

MP

PT G226

5.2 Proposed model of Substation 11

Figure 5-1 Proposed model of Substation 11

This is the proposed hardware implementation model of Substation 11. We can use 2 types of

Ethernet switches. Firstmile company invent a Ethernet switch in which 5 Ethernet switches

can cover 1000 m area and recovery time is less than 20 ms. Substation 11 is located to

opposite of SOM. In there, we just have to modify and insert some new switches which are

needed for protection of Transformer and circuit breakers and we need to install a PLC station

at Substation 11 which can directly connect with switching devices. We can use many

Substations in one area which can make cost-effective for total system. Beside the substation,

we need to install a generator which can be used in emergency and it can control with PLC.

SOM is located near Substation 11 and it can control in same zone. We need to install the

PLC station inside of it to control the main distribution board (MDB) and digital meters. ISE

is only 300 m from SOM. So we use same Ethernet zone for that to cover the area. For ISE,

we need to do as same as SOM building. We can monitor the total system in the monitoring

unit. And in case of emergency or any fault, we can use backup monitoring unit.

PTS 740

1000m fiber ring

Recovery time<20 ms

Monitoring PC

(Backup)

Monitoring PC (Main)

Main station

monitoring server (Main)

Substation 11

Generator

PTS 740

SOM ISE

PLC

boar

d

Digital meter

MP

MDB (ISE)

Ethernet

PT 740

MDB(SOM)

300m

32

5.3 Proposed hardware configuration

5.3.1 Proposed hardware configuration of switching devices

Figure 5-2 Proposed hardware configuration of switching devices

33

Here, we use existing system with modified system. Existed system was shown in Figure 3-3.

We insert protection devices, sensor for fault location, emergency stop switch which act like a

switch as a modified system and control for tripping the whole system in emergency cases or

in case of any faults. This total system is connected with PLC station for control

automatically. Also, we can use it manually by using these switches. All the system can be

shown in monitoring unit or HMI. We can monitor the unit in the hardware such as Energy

meter, Reactive power and cost.

34

5.3.2 Proposed hardware configuration of ISE and SOM (MDB)

Figure 5-3 Proposed hardware configuration of main distribution board

Idec Illuminate push button

ALFNE9F911-G (For DB-1)


ALFNE9F911-G (For DB-2)

MDB

Pilot lamp

AAA AD16-22DS

(Green)

Pilot lamp

AAA AD16-22DS

(Yellow)

Pilot lamp

AAA AD16-22DS

(Red)

Measurement &

Monitoring

M: Vamp Measurement

& Monitoring unit

Auto

Manual

Idec Illuminate

push button

ALFNE9F911-G

Emergency stop

switch

BN30G

Idec Illuminate

push button

ALFNE9F911-G

(For LC-1)

Idec Illuminate

push button

ALFNE9F911-G

(For LC-2)

Idec Illuminate

push button

ALFNE9F911-G

(For DB-1)

Idec Illuminate

push button

ALFNE9F911-G

(For DB-1)

35

In existing system, all is there except emergency stop switch which can be used when there is

fault located at SOM1, SOM2 or ISE individually. We can insert a PLC station which can be

connected with this system. This can control the whole system automatically or manually.

5.3.3 Proposed hardware configuration of ISE and SOM (LC)

…………………….

……………………

Figure 5-4 Proposed hardware configuration of ISE and SOM (Load center)

LC

Pilot lamp

AAA AD16-22DS

(Green)

Pilot lamp

AAA AD16-22DS

(Yellow)

Pilot lamp

AAA AD16-22DS

(Red)

Measurement &

Monitoring

M: Vamp Measurement

& Monitoring unit

Auto

Manual

Idec Illuminate

push button

ALFNE9F911-G

Emergency

stop switch

BN30G

Arc Protection

M: Vamp arc

protection

relay system

(Room2)

Arc Protection

M: Vamp arc

protection

relay system

(Room1)

Arc Protection

M: Vamp arc protection

relay system

(Room N)

……………………….

36

Relay

In load center, we just modify the arc protection devices for each room and use emergency

stop switch for protect the whole system. This can be connected with same PLC station which

is installed for MDB.

5.4 Proposed one-line diagram

Transmission line (22kV)

Figure 5-5 Proposed one-line diagram

On proposed model, we just need to change the circuit breaker to relay. And we need to

remove wiring and for switching the whole system, we can insert Ethernet as a whole

communicating medium.

Relay

SOM1 ISE SOM2

Relay

Substation 11

800 A

1600 KVA

Ethernet

Relay Relay

37

5.5 Proposed wiring diagram

5.5.1 Wiring diagram (PLC & Control and protection equipment)

…..

Figure 5-6 Wiring diagram (PLC with Switching Equipment’s)

PC

PLC

board

Digital

i/p,

Digital

o/p,

Analo

g i/p,

o/p

Ethernet

PT 740

Voltage indicator

Current indicator

On/off switch

Air CB

Capacitor bank (Manual/Auto)

Emergency stop switch

BN30G

Arc Protection

M: Vamp arc protection relay system

Autoreclose and check synchronism

MiCOM PB41

Circuit breaker protection

MiCOM PB21

Feeder protection

SEL 751

Voltage & freq. protection

MiCOM C264P

Pilot lamp (6)

AAA AD16-

22DS

Idec Illuminate push button (6)

ALFNE9F911-G

Ethernet cable

TBUM298076

Measurement & Monitoring

M: Vamp Measurement & Monitoring unit

38

In the proposed model, we need to install a PLC station which is connected with switching

devices. The communicating medium is made with Ethernet switch. The wiring diagram can

be look like the Figure 5-6.

5.5.2 Wiring diagram (PLC & MDB)

…..

Figure 5-7 Wiring diagram (PLC and MDB)

We need to install a PLC station which is connected with PC via Ethernet. Wiring diagram

should be like Figure 5-7.

5.5.3 Wiring diagram (PLC & LC)

…..

Figure 5-8 Wiring diagram (PLC & LC)

PC

PLC

board

Digital

i/p,

Digital

o/p,

Analo

g i/p,

o/p

Ethernet

PT 740




ALFNE9F911-G (4)

Auto/Manual switch


BN30G

Arc Protection

M: Vamp arc protection

relay system(1..n)

Ethernet cable

TBUM298076

Pilot lamp

AAA AD16-22DS(3)

PC

PLC

board

Digital

i/p,

Digital

o/p,

Analog

i/p, o/p

Ethernet

PT 740




ALFNE9F911-G

Auto/Manual switch


BN30G

Ethernet cable

TBUM298076

Pilot lamp

AAA AD16-22DS(3)

39

We can use the same PLC station of MDB which is connected with PC via Ethernet. Wiring

diagram should be like Figure 5-8.

5.5.4 Wiring Diagram (Monitoring unit)

….

.

Figure 5-9 Wiring diagram (Monitoring unit)

We need six monitoring unit to monitor the whole control and protection. Control can be done

automatically with the help of PLC. Wiring diagram can be look like Figure 5-9.

PC

Monitoring unit (Transformer)

Monitoring unit (CB)

Monitoring unit (Fault record)

Monitoring unit (Fault location)

Monitoring unit (Energy &

Reactive power)

Ethernet

P 740

Ethernet

PTS G6226

Ethernet

P 740

PLC

Ethernet cable 35004255

Ethernet cable 35004255

Monitoring unit (pf correction)

40

6 CHAPTER 6

CONTROL ALGORITM AND HMI

6.1 Control Algorithm

For control the whole substation, we use Siemens Simatic S7-300 program. In this program,

we use “statement list” or “Ladder logic” format.

6.1.1 S7-300 Program structure

Figure 6-1 S7-300 Program structure

OB1: Organization block which is used for creating main program block.

In program, it calls 3 main variables: transformer, voltage and circuit breaker.

FC1, FC2, FC3, FC4, FC5, FC6, FC7, FC8, FC9, FC10: Function which is used for

programming and we can declare the variables here.

In program, FC5, FC6, FC9 and FC8 are creating the main program. In S7 dialog box, it

defines the symbol and data types which are used in program. These variables are temporary.

After that, it needs to makes the variables permanent. So, we use FC1, FC2, FC3, FC4, FC7

and FC10 which make the variables permanent with the help of BLD function for digital and

for analog, we use data blocks.

41

DB1, DB4, DB6: It’s mainly a variable declaration section which is used because we can use

analog data in here using REAL.

VAR_1: Variable table uses for implement the result of data in output. It can shows Boolean

data for digital and binary, HEX, decimal and floating point or character data for analog

signal.

6.2 Input/ output parameters connect with PLC

For transformer protection-

1. Bucholtz alarm

2. Storm mode

3. Tap changer

4. Different cooling system fault

5. Oil level fault

6. Tripping network

7. Power estimation

8. Backup protection

For circuit breaker protection-

1. Circuit breaker in operation

2. Manual block switch

3. Circuit breaker mode (auto or manual)

4. Current faults

5. Gas faults

6. Circuit breaker trip

For energy, reactive power and cost estimation-

1. Real power estimation

2. Reactive power estimation

3. Cost estimation

For voltage-

1. Voltage indicator

2. Total Voltage

For fault location-

1. Determining location of fault

2. Determining fault type- high or low voltage

42

For power factor correction-

1. Determining power factor

Determining value of capacitor bank activation

6.2.1 Transformer protection

AIT has 15 substations which have just a main circuit breaker for protection device. Now, we

introduce some protection device such as arc protection relay, capacitor bank protection,

overcurrent protection, auto reclose and check synchronism device, transformer protection

and control, measurement and monitoring unit in the main substation. For fault location, we

use pilot lamp to measure, in which area, fault occurs. In the main distribution board, all the

equipment’s are same as before. For each room, there is one circuit breaker for each room.

6.2.1.1 PLC program for transformer protection

When there is excessive gas, then Bucholtz gas sensor will on, which causes main

circuit breaker trip. It will recover automatically when the gas will become less.

“Stormpulse” software can generate data, which is used to know, when the storm will

come. If the data will come in system, then the sensor, storm modes will on, this

causes the whole transformer trip. It will recover again, when the storm will over.

In substation 11, only 1 tap changer will require. This can automatically show in real

HMI. It can automatically increase or decrease depends upon number of turns.

For temperature fault, we use 3 conditions. When it reaches 35⁰C-45⁰C, then alarm

signal will glow. Then when it reaches 45⁰C to 55⁰C, then it opens the fan. Here, it

shows only with a sensor. At last, when temperature reaches up to 55⁰C, then Relay is

on, which trips the total transformer for protection. It will recover automatically when

temperature will become less. We can see figure 6-4 to understand about it.

For oil level fault, we also use 2 conditions. If oil level is less than 0.9 bars, then oil

alarm sensor will glow automatically. Then, when oil level reaches less than 0.5 bars,

then the system will trip and recover again when oil level is ok again. We can see

figure 6-4 to understand about it.

For tripping, we just use one tripping network, which can trip faults.

For knowing about power, we just use voltage*current which is shown in HMI.

For backup protection, we use a generator for whole system. It will work when

tripping network will on.

43

Figure 6-2 Protection of transformer

6.2.2 Circuit breaker/ Relay protection

6.2.2.1 PLC for circuit breaker protection

First, we need to concern about circuit breaker operation. If it’s in test mode, then it

will turn off the operation of circuit breaker.

If there is some emergency, then circuit breaker can automatically turn off. Or if we

want, then we can turn off it manually.

If the current flow in circuit breaker is between 630 A- 1200 A, then Overcurrent

alarm will glow. And if the current will go up to 1200 A, then circuit breaker trip

automatically.

For circuit breaker gas pressure, if it’s between 4.5 bars- 6 bars, then low gas indicator

will on. If the pressure decreases again and become less than 4.5 bars, then gas block

sensor will go which will trip the circuit breaker.

44

We use a tripping network to determine, when the fault will occur and it makes the

circuit breaker/ relay trips automatically and recover again, when system will become

ok.

We can see figure 6-5 to understand, how the total thing will occur.

Figure 6-3 Protection of circuit breaker

6.2.3 Energy meter, Reactive power, cost estimation

For load calibration, we need energy and reactive power.

We just use 2 formulas:

Real power= voltage*current*cosθ

Reactive power= voltage*current*sinθ

For AIT, they use 4.5 baht/unit.

Total cost (without tax and other fees)= 4.5*Energy

45

6.2.3.1 PLC of Energy meter, Reactive power and cost estimation

Generate energy meter and Reactive power meter using the formula which is

shown in HMI and real substation (proposed).

Generate cost estimation meter.

We can see the figure 6-6 below.

Figure 6-4 Energy, Reactive power and cost estimation

6.2.4 Voltage estimation

6.2.4.1 PLC of voltage estimation

Use high, medium and low voltage Indicator to indicate the voltage level.

Generate high, medium and low bus bar voltage on HMI and those are the voltage of

the system.

46

We can see this on figure 6-7.

Figure 6-5 Voltage estimation

6.2.5 Fault location analysis

For fault location analysis, at 1st, we need to know the 3 phase voltage measurement in 3

buildings. In substation 11, main transmission line is connected with 3 buildings: SOM1,

SOM2 and ISE. We don’t need to give a sensor in substation line because if the sensor of ISE,

SOM1 and SOM2 senses the fault, then it indicates that, it have a problem in substation line.

These sensors measure the 3 phase voltage.

6.2.5.1 PLC of Fault Location Analysis

We use 220V-240 V as a threshold voltage. Threshold voltage use for detect, node

losses the power or not.

If sensor detect that node voltage is more than 240 V and less than 220 V, then it will

glow fault alarm. This closes the enable operation of remote fault indicator device for

communication purposes.

It will automatically turn of the main distribution board relays.

We can see the figure 6-8 below.

47

Figure 6-6 Fault Location Analysis

6.2.6 Power factor correction

For power factor protection, we use a capacitor bank which is already existed in substation 11.

First, we need to know, power factor is 1 or not. If it’s not 1, then we can start the capacitor

bank and the value, we need to follow the following formula:

Kvar= kw*tanθ

Here, energy value shows as kw, reactive power shows as a kvar and θ is phase difference

between voltage and current. So here, we just have to insert reactive power of that value,

which will show as kvar.

6.2.6.1 PLC of Power factor correction

If power factor is less than 1, then capacitor bank is activated.

Value of capacitor in capacitor bank= Kvar=Energy*tanθ

48

Here, θ is phase difference between voltage and current. Figure 6-9 shows the total PLC

diagram.

Figure 6-7 Power factor correction

6.3 Create Project Using WINCC (HMI)

HMI acts as the interface between system and operator. It generates a user friendly

environment for control and monitoring purposes. It can be done by WINCC Explorer

software.

6.3.1 Function used in program

6.3.1.1 Tag manager

We can transfer the data generated from configure with STEP 7 to the WINCC database.

WINCC uses the data in variable blocks and graphic objects. Each parameter store in one tag,

the tag selection dialog is used to display tags or icons from various data sources via a

selection window. For example, link them to picture objects of the Graphics Designer.

49

6.3.1.2 Graphics Designer

Process pictures create by Graphics Designer. The features are like below:

Suitable and easy user interface with tool & graphic palettes

Streamlined configuration with integrated object & icon libraries

Configurable dynamic behavior of picture objects with support from an assistant

(Dynamic Wizard)

Objects that have been made dynamic (can be operated), e.g. an I/O field, or possess

picture selection capabilities can be recognized in runtime by a cursor that changes to a flash

if it is positioned over such an object. We draw one picture for main diagram to show all

station’s equipment connect with each other and show general observer of station operate; we

have one picture more to show report, this case is Alarm report: show parameter of fault. Each

station’s equipment have picture to show parameter themselves. All of pictures will connect

with screen picture; this picture was reserved in WinCC like the main picture.

6.3.1.3 Log Tagging

Tag Logging processes some Data which have conducted and makes the data for archiving

and display. These data can provide any information.

Tag Logging is divided into two components: the Configuration System and the Runtime

System. Analog parameter configure in four archives that will setup for groups: transformer

and their level of voltage. Type is process value archives and mode short term archives.

Acquisition time cycle is set-up 1 minute; archives time is set-up 1 hour.

6.3.1.4 Alarm Logging

The editor of "Alarm Logging" is used for archiving and acquiring messages. It carries

functions for accepting messages from different processes, and then for preparing, displaying,

acknowledging, and archiving them.

Currents, oil level and temperature of transformer will monitor and will alarm when fault

occur. Value set upper limit with current and temp; set lower with oil level. Message class

chooses error that has their type alarm, warning, and failure.

6.3.1.5 Report Design

The Report Designer is at part of the WinCC basic package that give functions for the "output

of reports” & "creation".

The following two editors are available for creating reports:

Editor for page layout

Editor for line layout

It use the dynamic objects of the Report Designer for the data output. These dynamic objects

must be connected to the appropriate applications. Depending archives mode to store alarm

data, connect Dynamic table in Layout with short-term archives or long-term archives.

50

6.3.2 HMI programs

6.3.2.1 Transformer screen

For transformer, we use different type of alarms, tripping functions, number of tap changing,

backup system (generator) and different indicator which is shown in figure 6-10 below.

Figure 6-8 Transformer and voltage interface in WINCC

6.3.2.2 Circuit breaker screen

We use emergency block, operating status (on or off), different sensors (for faults), voltage

and current indicator, curves of current which are shown in figure 6-11 below.

51

Figure 6-9 CB interface in WINCC

6.3.2.3 Fault Location Analysis

Fault location analysis detects the faults actual location. Here, in HMI, we can see that, we

use sensors for SOM1, SOM2 and ISE. When the sensor senses, it indicates the fault and turn

of the following circuit breaker in the location.

Figure 6-10 Fault location analysis

52

6.3.2.4 Real power, Reactive power and cost estimation

In HMI, we can see the real time value of real power (Energy), reactive power and cost which

is shown in figure 6-13.

Figure 6-11 Real power, Reactive power and cost estimation

6.3.2.5 Power factor calculation

We can see the pf, θ and capacitor value which is needed to make the pf=1. It is shown in

figure 6-14.

Figure 6-12 Power factor correction

53

6.3.2.6 Fault record

It shows the all fault records and we can record the data for several years. It can help us to

find about most common problems occurring in a specific substation.

Figure 6-13 Fault record

Figure 6-13 shows that, when the blue color comes, it indicates that it acknowledges about the

faults (+/-). If the red color comes, it indicates the faulty situation (+) and when yellow color

54

glows, it indicate that, the fault is solved (-). Here, we can see the date and time, when the

fault will happen.

6.3.3 Conditions using for Temperature fault (Hardware)

For temperature fault, we use 3 conditions as mentioned earlier. In hardware, we have to vary

temperature. Here, we use memory bit for changing temperature. It increases by 5⁰C by

changing 1 memory bit. When it reaches 35⁰C-45⁰C, then alarm signal will glow. Then when

it reaches 45⁰C to 55⁰C, then it opens the fan. Here, it shows only with a sensor. At last, when

temperature reaches up to 55⁰C, then Relay is on, which trips the total transformer for

protection.

We can use automatic or manual system.

For automatic system, we use WINCC button to increase the temperature.

For manual system, we use push button which is connected with I0.0.

Figure 6-14 Temperature Faults in WINCC

55

6.3.4 Analog voltmeter of transformer (Hardware)

For analog voltmeter, we use a voltage generator, which can generate the voltage. We use this

device as input. And we can see the output from the analog voltmeter.

Figure 6-15 Analog voltmeter in WINCC

56

7 CHAPTER 7

RESULT AND DISCUSSION

This chapter shows the results of work by different curves and its theoretical analysis related

with the curves.

7.1 Results of different parameters

7.1.1 Bucholtz Alarm

When bucholtz alarm will active, this will prove the transformer to trip. Figure 7-1 shows

that, the curve goes to 1 gradually which means the bucholtz alarm is working.

Figure 7-1 Bucholtz Alarm Validation (Active)

When this alarm will stop, that means, when the trip goes to normal again, then the curve will

goes to 0 which is shown in Figure 7-2.

Figure 7-2 Bucholtz Alarm Validation (Deactivate)

57

7.1.2 Storm Mode

When the “Stormpulse” software detects the area which is affected by the storm, then the

storm mode will operate. It makes the transformer trip. Figure 7-3 shows the result, when the

storm mode will active.

Figure 7-3 Storm mode validation (active)

When system goes to normal condition again, then storm mode will deactivate and the curve

will goes to 0. Figure 7-3 shows the result of this condition.

Figure 7-4 Storm mode validation (deactivate)

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7.1.3 Tap Changer

We can see the tap changer position in the system. When the tap will change from 0 to 1, then

Figure 7-5 shows the actual curve.

Figure 7-5 Tap changer (0 to 1)

Then when the tap will increase from 1 to 2, then the result is shown in Figure 7-6.

Figure 7-6 Tap Changer (1 to 2)

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When the tap will decrease, then the output of curve is shown in Figure 7-7.


After that, when the tap goes to 0 again, then Figure 7-8 shows the actual curve.


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7.1.4 Voltage

We can see the voltage curves on Figure 7-9 which is shown that, when voltage goes to 0 to

220 V, then the curve will go to 220 V.

Figure 7-9 Voltage Validation (0V to 220V)

If the voltage changes from 220V to 230V, then Figure 7-10 shows the curves.


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After that, if the voltage will again come to 0V, then the curve will goes to 0V again, which is

shown on Figure 7-11.


7.1.5 Current

When the current goes to 0A to 20A, then Figure 7-12 shows the result.

Figure 7-12 Current Validation (0A to 20A)

If the current increases to 40A, then Figure 7-13 shows the result.

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Figure 7-13 Current Validation (20A to 40A)

After that, if the current come to 0A again, then the Figure 7-14 shows the curve.

Figure 7-14 Current validation (40A to 0A)

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7.1.6 Temperature of Transformer

When the temperature is 0⁰C, then Figure 7-15 shows the curve. We can see that, all is 0.

Figure 7-15 Temperature of Transformer (0⁰C)

After that, when the temperature will go to 20⁰C, then it proves the normal condition. So

alarm, fan or trip circuit is not working. Figure 7-16 shows the result.

Figure 7-16 Temperature of Transformer (0⁰C to 20⁰C)

After that, if the temperature goes high and goes beyond 35⁰C, then the alarm sensor will

glow and result can show in curve too. Figure 7-17 shows that, when temperature goes to

37⁰C, then alarm sensor will glow and curve shows the result.

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If the temperature goes to 48⁰C, then fan will work and alarm will go to low, which is

shown in Figure 7-18.


After that, if the temperature is more than 55⁰C, then transformer will trip which is shown in

Figure 7-19. It also shows that, fan will stop to operate.

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When the transformer will trip, then the backup system will start to operate which is shown in

Figure 7-20.

Figure 7-20 Temperature of Transformer (Backup)

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7.1.7 Oil level of Transformer

When the oil level is more than 0.9 bar, then the oil alarm or trip will not work. Figure 7-21

shows the result. It shows the alarm and trip curves are in 0.

Figure 7-21 Oil Level Validation (20 bar)

Figure 7-22 shows that, when oil level will comes to 1 bar, then alarm or trip will not operate.

Figure 7-22 Oil Level Validation (1 bar)

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After that, if the oil level comes to 0.8 bar, then alarm sensor will work which is shown in

Figure 7.23.

Figure 7-23 Oil Level Validation (0.8 bar)

When oil level goes below 0.5 bar, then trip will work which can make the backup generator

work. Figure 7-24 shows that, when oil level is 0.4 bar, then alarm sensor and tripping circuit

is worked. And the backup system starts to operate.

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Figure 7-24 Oil Level Validation (0.4 bar)

7.1.8 Current Alarm of Circuit Breaker

When current is 0A and circuit breaker is available, then the over current alarm and short

circuit current alarm will not work. But circuit breaker will work in normal operating

condition. Figure 7-25 shows the result.

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Figure 7-25 Current Alarm Validation (0A)

If the current will go to 500A, then alarm will not work. But circuit breaker will be on

operating mode. Figure 7-26 shows the result.

Figure 7-26 Current Alarm Validation (0A to 500A)

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If current goes beyond 630A, then Overcurrent alarm will operate. Figure 7-27 shows the

curve and result of overcurrent alarm when current is 700A.


At last, if the current will go beyond 1200A, then short circuit alarm will glow which makes

the circuit breaker stop. Figure 7-28 shows the result.


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7.1.9 Pressure of Circuit Breaker

When the gas pressure is more than 6 bar, then low gas alarm or trip will not work. Circuit

breaker will operate normally. Figure 7-29 shows the result when pressure is 7 bar and circuit

breaker is available.

Figure 7-29 Pressure Validation (7 bar)

If the pressure goes below than 6 bar, then low gas alarm will glow. But circuit breaker will

continue to work normally. Figure 7-30 shows the result.

Figure 7-30 Pressure Validation (7 bar to 5.8 bar)

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When pressure goes to 3 bar, then circuit breaker will stop and trip will work. Figure 7-31

shows the result.

Figure 7-31 Pressure Validation (5.8 bar to 3 bar)

7.1.10 Energy, Reactive power and cost estimation

We know, when power factor is 1, and then system will give maximum output. Figure 7-32

shows that, when θ=0⁰, then reactive power is 0. It’s because cos0⁰=1.

Figure 7-32 Energy, Reactive power and Cost Validation (θ=0⁰)

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After that, if θ=90⁰ (approximately), then cos θ=0 which makes the system inefficient.

Figure 7-33 shows this condition.

Figure 7-33 Energy, Reactive power and Cost Validation (θ=89.964⁰)

If θ=45⁰ (approximately), then cosθ=0.707, which means, power factor is 0.7. In this

condition, energy and reactive meter can be found. Figure 7-34 shows the result.

Figure 7-34 Energy, Reactive power and Cost Validation (θ=44.9⁰)

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7.1.11 Fault Location Validation

If the voltage is in normal operating voltage (220V-240V), then circuit breaker will work

normally. Figure 7-35 shows this condition.

Figure 7-35 Fault Location Validation (230V)

If the voltage goes beyond 240V then CB will trip which is shown in Figure 7-36.


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When voltage goes to below than 220V, then circuit breaker will trip which is shown in

Figure 7-37.


7.1.12 Power Factor Correction

When θ=0⁰, it means the power factor=1. That time, no need to insert the value from

capacitor bank. Figure 7-38 shows the result.

Figure 7-38 Power Factor Correction Validation (θ=0⁰)

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If θ=28⁰ (approximately), then pf=0.878. So we need to insert 1.09 kvar to make the pf=1

(approximately). Figure 7-39 shows the result.


If θ=57⁰, then pf=0.54, which means we need more kvar than before. Now, we need to insert

3.11 kvar capacitor value which is shown in Figure 7-40.


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8 CHAPTER 8

CONCLUSION AND RECOMMENDATION

8.1 Summary

The thesis work can be summarized as below:

Study about control and monitoring process of power distribution network.

Analysis of total process to know about control process.

Use S7-300 for programming the control process in PLC which uses LAD and

STL.

Develop Graphic User Interface using Simatic WINCC Explorer.

Setup pilot configuration hardware fiber optic network to connect PC with

peripheral system.

8.2 Result and Conclusion

Hardware and software was designed and develop based on Simatic S7-300 and Window

Control Center– WinCC from Siemens. After development, some experiences have been

gained as following:

In thesis, we concern about one Substation of AIT.

The developed system has covered all the function of SCADA system: control,

monitoring and data acquisition. WinCC is not only support to Siemens’s equipment

but also from other vendors. It provides the flexibility and openness for system.

Using PLCs as remote field devices in SCADA system has covered all the tasks of

RTU devices. PLC is a powerful software and hardware which support many useful

built-in function blocks which are integrated with some other function, so user can use

for their project. Furthermore it is more flexible: control tasks and communication are

easier to be designed and developed in PLCs. The system is best used at the field and

cell levels with distributed peripherals and powerful communication function of PLC.

Integration with SCADA functions based on PLCs network has brought more benefits

to the operators and managers: providing the overview of system status, remote

control abilities and data presentation by alarm, trend, on screen display.

In pilot project, we can see the PLC and SCADA system is worked properly and we

can see the sensor and relay output shown in there.

8.3 Recommendation

Graphical user interfacing through the WinCC and PLC is nearly an unexplored technology

today. It is recommended therefore:

The project can be applied in the whole of AIT power network. AIT has many

substations. Structure and design of each station has to be specified in detail.

In project, we can use thermocouple for temperature sensing. Here, we use only

memory bit for changing the temperature.

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For watching the value of temperature, we can use 7-segment system or temperature

indicator. Here, we just show it with WINCC interface as temperature indicator.

For real implementation, digital meter (Multi-Function Panel meter, Model no.-MP,

Thaimeter Company) can connect with PLC board. This PLC board can connected with

PC through Profibus OLM and Optical fiber/ Ethernet. And with the help of WINCC,

we can monitor the meter rating. For lot of digital meter connected to a building,

Ethernet can be used to integrate it in 1 PLC board.

We need a remote sensing data which can generate “Stormpulse” software. This

software can detect the storm. We can use that data to link with our PLC, which makes

a sensor to glow and control over it by using the tripping operation.

We don’t use “Energy Consumption” in my thesis.

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REFERENCES

[1] Le Hong Duong, 2003, Thesis- Application of Supervisory control and Data Acquisition

in Hanoi Electrical Network, ISE, Mechatronics, AIT

[2] Hasan A.M. Abu Meteir, 2012, Thesis- A proposed SCADA system to improve the

condition of the Electricity sector in Gaza strip, Department of Control systems engineering,

The Islamic University of Gaza

http://library.iugaza.edu.ps/thesis/105476.pdf

[3] Mohamed Najeh Lakhoua and Mohamed Kamel Jbira, 2012, Journal title-Project

Management Phases of a SCADA System for Automation of Electrical Distribution Networks

ijcsi.org/papers/IJCSI-9-2-2-157-162.pdf

[4] Frank Marden, President, Garrettcom, Inc., 2004, White paper title- Ethernet in Power

Utilities Substations- The changing role of Fiber Media

garrettcom.com/techsupport/papers/utilities.pdf

[5] David Dolezilek, Schweitzer Engineering Laboratories, Inc., Pullman, WA USA, 1998-

1999, Case study- Large Transmission and distribution substation automation project

http://amarnathreddy.webs.com/Technical/CASE%20Study%20on%20Large%20Trasmission

%20networks%20by%20SEL.pdf

[6] Moxa, IEC 61850-3_IEEE 1588 in Smart Substation, 2011

www.omniray.ch/energie-erzeugung-und-verteilung.html?.../Netzwerkloesungen mit IEC

61850-3_IEEE 1613 von Moxa.pdf

[7] Eng-Kiat Chan, Public Utilities Board, Singapore and Horst Ebenhoh, Siemens AG,

Germany, 1992, The Implementation and Evolution of a SCADA system for a Large

Distribution Network

http://202.120.43.103/downloads2/%7B63E45B2F-6DA2-42C3-BAF5-

071532601E69%7D.The%20implementation%20and%20evolution%20of%20a%20SCADA

%20system%20for%20a%20large%20distribution%20network.pdf

[8] Musse Mohamud Ahmed, Member, IEEE, 11-13 May 2010, Kuala Lumpur, Malaysia,

New Supervisory Control and Data Acquisition (SCADA) Based Fault Isolation System for

Low Voltage Distribution Systems

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[9] Joao M. G. Figueiredo CEM-IDMEC, Universidade Évora, Mechatronics Group R.

Romão Ramalho, 59; 7000-671 Évora, Portugal, 2010, PLC based Structure for Management

and Control of Distributed Energy Production Units

[10] Cristina Anita Bejan, Mihai Iacob and Gheorghe-Daniel Andreescu, IEEE, 2008,

SCADA Automation System Laboratory, Elements and Applications, “Politehnica”

University of Timisoara, Dept. of Automation and Applied Informatics, Timisoara, Romania

[11] Prof. Dr. H. Kirrmann, ABB Research Centre, Baden, Switzerland-2007 May, HK, OPC

(Open Process Control formerly OLE for Process Control)

[12] Clemens Hoga, Siemens Germany, IEEE, 2007, New Ethernet Technologies for

Substation Automation

[13] Rajib Baran Roy, 2012, paper title- Controlling of Electrical Power System Network by

using SCADA

http://www.ijser.org/researchpaper%5CControlling-of-Electrical-Power-System-Network-by-using-

SCADA.pdf

[14] Dominik Pieniazek, P.E., October 2-3, 2012, HV Substation Design: Applications and

Considerations

http://www.hv-eng.com/IEEE_CED_SubDesign_Full_Size.pdf

All data is from AIT

http://www.ijser.org/researchpaper%5CControlling-of-Electrical-Power-System-Network-by-using-SCADA.pdf

http://www.ijser.org/researchpaper%5CControlling-of-Electrical-Power-System-Network-by-using-SCADA.pdf

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APPENDIX A

Simatic S7-300 PLC Program in STL (Statement Languages) (Software)

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DB1

107

DB4

DB6

108

VAR_1

111

APPENDIX B

WINCC Tag (Software)

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APPENDIX C

Simatic S7-300 PLC Program in STL (Statement Languages) (Hardware)

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APPENDIX D

WINCC TAG (HARDWARE)

Application of Supervisory Control and Data Acquisition ...

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