Develop your project

How can I … Design and operate a small hydropower plant with PlantStruxure?

Develop your project

Tested Validated Documented Architecture Electrical Energy

© 2012 Schneider Electric All Rights Reserved

3

Important Information

People responsible for the application, implementation and use of this document must make sure

that all necessary design considerations have been taken into account and that all laws, safety

and performance requirements, regulations, codes, and applicable standards have been obeyed

to their full extent.

Schneider Electric provides the resources specified in this document. These resources can be

used to minimize engineering efforts, but the use, integration, configuration, and validation of the

system is the user’s sole responsibility. Said user must ensure the safety of the system as a

whole, including the resources provided by Schneider Electric through procedures that the user

deems appropriate.

Notice

This document is not comprehensive for any systems using the given architecture and does not

absolve users of their duty to uphold the safety requirements for the equipment used in their

systems, or compliance with both national or international safety laws and regulations.

Readers are considered to already know how to use the products described in this document.

This document does not replace any specific product documentation.

The following special messages may appear throughout this documentation or on the equipment

to warn of potential hazards or to call attention to information that clarifies or simplifies a

procedure.

The addition of this symbol to a Danger or Warning safety label indicates that an

electrical hazard exists, which will result in personal injury if the instructions are not

followed.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death

or serious injury.

Failure to follow these instructions will result in death or serious injury.


4

WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death

or serious injury.

Failure to follow these instructions can cause death, serious injury or equipment

damage.

CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor

or moderate injury.

Failure to follow these instructions can result in injury or equipment damage.

NOTICE NOTICE is used to address practices not related to physical injury.

Failure to follow these instructions can result in equipment damage.

Note: Electrical equipment should be installed, operated, serviced, and maintained only by

qualified personnel. No responsibility is assumed by Schneider Electric for any consequences

arising out of the use of this material.

A qualified person is one who has skills and knowledge related to the construction, operation and

installation of electrical equipment, and has received safety training to recognize and avoid the

hazards involved.

Before You Begin

This automation equipment and related software is used to control a variety of industrial

processes. The type or model of automation equipment suitable for each application will vary

depending on factors such as the control function required, degree of protection required,

production methods, unusual conditions and government regulations etc. In some applications

more than one processor may be required when backup redundancy is needed.

Only the user can be aware of all the conditions and factors present during setup, operation and

maintenance of the solution. Therefore only the user can determine the automation equipment

and the related safeties and interlocks which can be properly used. When selecting automation

and control equipment and related software for a particular application, the user should refer to


5

the applicable local and national standards and regulations. The National Safety Council’s

Accident Prevention Manual also provides much useful information.

Ensure that appropriate safeties and mechanical/electrical interlocks protection have been

installed and are operational before placing the equipment into service. All mechanical/electrical

interlocks and safeties protection must be coordinated with the related automation equipment and

software programming.

Note: Coordination of safeties and mechanical/electrical interlocks protection is outside the scope

of this document.

START UP AND TEST

Following installation but before using electrical control and automation equipment for regular

operation, the system should be given a start up test by qualified personnel to verify the correct

operation of the equipment. It is important that arrangements for such a check be made and that

enough time is allowed to perform complete and satisfactory testing.

WARNING EQUIPMENT OPERATION HAZARD

• Follow all start up tests as recommended in the equipment documentation.

• Store all equipment documentation for future reference.

• Software testing must be done in both simulated and real environments.


damage.

Verify that the completed system is free from all short circuits and grounds, except those grounds

installed according to local regulations (according to the National Electrical Code in the USA, for

example). If high-potential voltage testing is necessary, follow recommendations in the equipment

documentation to prevent accidental equipment damage.

Before energizing equipment:

• Remove tools, meters, and debris from equipment

• Close the equipment enclosure door

• Remove ground from incoming power lines

• Perform all start-up tests recommended by the manufacturer


6

OPERATION AND ADJUSTMENTS

The following precautions are from NEMA Standards Publication ICS 7.1-1995 (English version

prevails):

Regardless of the care exercised in the design and manufacture of equipment or in the selection

and rating of components; there are hazards that can be encountered if such equipment is

improperly operated.

It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe

operation. Always use the manufacturer’s instructions as a guide for functional adjustments.

Personnel who have access to these adjustments should be familiar with the equipment

manufacturer’s instructions and the machinery used with the electrical equipment.

Only those operational adjustments actually required by the operator should be accessible to the

operator. Access to other controls should be restricted to prevent unauthorized changes in

operating characteristics.

WARNING UNEXPECTED EQUIPMENT OPERATION

• Only use software tools approved by Schneider Electric for use with this equipment.

• Update your application program every time you change the physical hardware

configuration.


damage.

INTENTION

This document is intended to provide a quick introduction to the described system. It is not

intended to replace any specific product documentation, nor any of your own design

documentation. On the contrary, it offers information additional to the product documentation on

installation, configuration and implementing the system.

The architecture described in this document is not a specific product in the normal commercial

sense. It describes an example of how Schneider Electric and third-party components may be

integrated to fulfill an industrial application.

A detailed functional description or the specifications for a specific user application is not part of

this document. Nevertheless, the document outlines some typical applications where the system

might be implemented.


7

The architecture described in this document has been fully tested in our laboratories using all the

specific references you will find in the component list near the end of this document. Of course,

your specific application requirements may be different and will require additional and/or different

components. In this case, you will have to adapt the information provided in this document to

your particular needs. To do so, you will need to consult the specific product documentation of

the components that you are substituting in this architecture. Pay particular attention in

conforming to any safety information, different electrical requirements and normative standards

that would apply to your adaptation.

It should be noted that there are some major components in the architecture described in this

document that cannot be substituted without completely invalidating the architecture, descriptions,

instructions, wiring diagrams and compatibility between the various software and hardware

components specified herein. You must be aware of the consequences of component

substitution in the architecture described in this document as substitutions may impair the

compatibility and interoperability of software and hardware.

CAUTION EQUIPMENT INCOMPATIBILITY OR INOPERABLE EQUIPMENT

Read and thoroughly understand all hardware and software documentation before attempting

any component substitutions.

Failure to follow these instructions can result in injury or equipment damage.


8

This document is intended to describe how to design and operate a small hydropower plant with

PlantStruxure, according to the customer requirements.

DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION

• Only qualified personnel familiar with low and medium voltage equipment are to perform

work described in this set of instructions. Workers must understand the hazards involved in

working with or near low and medium voltage circuits.

• Perform such work only after reading and understanding all of the instructions contained in

this bulletin.

• Turn off all power before working on or inside equipment.

• Use a properly rated voltage sensing device to confirm that the power is off.

• Before performing visual inspections, tests, or maintenance on the equipment, disconnect

all sources of electric power. Assume that all circuits are live until they have been

completely de-energized, tested, grounded, and tagged. Pay particular attention to the

design of the power system. Consider all sources of power, including the possibility of back

feeding.

• Handle this equipment carefully and install, operate, and maintain it correctly in order for it

to function properly. Neglecting fundamental installation and maintenance requirements

may lead to personal injury, as well as damage to electrical equipment or other property.

• Beware of potential hazards, wear personal protective equipment and take adequate safety

precautions.

• Do not make any modifications to the equipment or operate the system with the interlocks

removed. Contact your local field sales representative for additional instruction if the

equipment does not function as described in this manual.

• Carefully inspect your work area and remove any tools and objects left inside the

equipment.

• Replace all devices, doors and covers before turning on power to this equipment.

• All instructions in this manual are written with the assumption that the customer has taken

these measures before performing maintenance or testing.

Failure to follow these instructions will result in death or serious injury.


9

The TVDA Collection

Tested Validated Documented Architecture (TVDA) guides are meant to help in the

implementation of specified solutions. TVDA guides provide a tested and validated example of

the proposed architecture to help project engineers and Alliance System Integrators during the

design and implementation of a project. The TVDA helps users analyze their architectures,

confirm the feasibility of their systems and speed up system implementation.

Each TVDA provides users with:

• A reference architecture based on Schneider Electric’s PlantStruxure solution

• Documentation of the system requirements of the architecture – response times, number of

devices, features

• Design choices for the application – software and hardware architectures

• Test results to confirm the requirements are met

All explanations and applications have been developed by both Schneider Electric experts and

system integrators in our PlantStruxure labs.

TVDAs are not intended to be used as substitutes for the technical documentation related to the

individual components, but rather to complement those materials.

Development Environment

Each TVDA has been developed in one of our solution platform labs using a typical PlantStruxure

architecture.

PlantStruxure, the process automation system from Schneider Electric, is a collaborative

architecture that allows industrial and infrastructure companies to meet their automation needs

while at the same time addressing their growing energy efficiency requirements. In a single

environment, measured energy and process data can be analyzed to yield a holistically optimized

plant.


10


11

Table of Contents

1. Introduction 13

1.1. Purpose 14

1.2. Customer Challenges 15

1.3. Prerequisites 16

1.4. Project Description 17

1.5. About this document 24

2. Selection 25

2.1. Customer Requirements 25

2.2. Architecture Selection 27

3. Design 37

3.1. Application Design 37

3.2. Hardware Design 54

3.3. Software Design 63

4. Configuration 89

4.1. Automation Control System Configuration 89

4.2. Application Configuration 98

5. Implementation 109

5.1. Start/Stop Process Control 110

5.2. Turbine/Excitation Regulation 113

5.3. Auxiliary System Control Application 119

5.4. Alarm Management Application 122

5.5. Intelligent Power Meter Integration 128

5.6. IP Camera Integration 131

6. Operation 133

6.1. Cubicle Introduction 133

6.2. How to switch the control mode between local and remote 135

6.3. How to start/stop one group in the small hydropower plant 138

6.4. How to find the alarms from the local panel, or remote SCADA 141


12

7. Validation 143

7.1. SOE Application Performance 143

7.2. Remote Access Application Performance 143

8. Conclusion 145

9. Appendix 147

9.1. Glossary 147

9.2. Bill of material and software 148

1 - Introduction


13

1. Introduction

These days, with the growing shortage of the nonrenewable energy resources, hydro energy is

becoming more and more popular because of its low cost, cleanness and renewability. A

hydropower plant generates electrical energy from hydro energy. Using the gravitational force of

falling or flowing water, the generator runs along with the turbine, converting hydro energy to

electrical energy.

Depending on their capacity, hydropower plants are roughly divided into three ranges: large

hydropower plants, small hydropower plants and micro hydropower plants.

The small hydropower plant is the preferable option for those areas where they would be

uneconomic to serve from a power network or the areas which are rich in water power resources.

1 - Introduction


14

1.1. Purpose

As the small hydropower plant develops rapidly, Schneider Electric would like to propose the total

small hydropower plant solution for countries and districts, not only the automation portion.

The purpose of this TVDA guide is to select a system architecture, which is referred to the

PlantStruxure, to realize the small hydropower plant application according to the customer’s

requirements.

The document provides information on the following topics:

• How to select a system architecture for the small hydropower plant according to the

reference PlantStruxure architecture

• How to integrate the small hydropower plant application into the PlantStruxure architecture

• How to design and operate the small hydropower plant with PlantStruxure

Figure 1: Small hydropower

1 - Introduction


15

1.2. Customer Challenges

System integrators face the challenges involved in setting up a small hydropower plant, and end

users face the challenges of how to increase efficiency with the small hydropower plant.

1.2.1. System Integrators

• During the project design and implementation stages, system integrators require a clear and

typical architecture to reduce the man hours and labor costs for its engineering and

commissioning.

• System integrators rely on the application guide and functional library to make the project

more flexible and the architecture and software easier to upgrade. They also reduce the man

hours and costs incurred during the project.

1.2.2. End Users

• For the managers of the small hydropower plant, the project’s system should be as safe and

stable as possible to reduce the possibility of downtime during production. Therefore, it

reduces the man hours and costs for the maintenance, increases efficiency and shortens the

payback period.

• The operation of the application should be simple for operators to reduce the chances of

malfunctions.

1 - Introduction


16

1.3. Prerequisites

Users of this TVDA guide, such as system integrators, should have the technical knowledge and

application background for:

• Hydropower plant process

• Electric power technology

In addition, experience with the following Schneider Electric products would be beneficial.

Software:

• Unity Pro

• OFS Configuration Tool

• Vijeo Citect

• Vijeo Designer

• Network protocols – Ethernet Modbus TCP, Modbus Serial Line

Hardware:

• Programmable Automation Controller (PAC) – Modicon M340

• Human Machine Interface (HMI) – Magelis

• Synchronizer – Deif GPU-3 Hydro

• Protector – Sepam G87

• Camera – PELCO

• Variable speed drive – ATV312

• Network devices – Industrial Ethernet Switch

• Power meter – PM810MG

1 - Introduction


17

1.4. Project Description

This section introduces the demo project used in this TVDA guide according to the basic

information of the small hydropower plant.

1.4.1. Small Hydropower Plant

The small hydropower plant includes the following sections:

Figure 2: Small hydropower plant

Water resource: There are two primary ways to harness the moving water to produce energy:

storage and run-of-the-water. Most small hydropower plants rely on a dam that holds back water

and creates a large reservoir. The dam is controlled and supervised by a set of PACs. The water

in the dam is diverted to the pipeline and is delivered to the energy production section.

Energy production: This is the main section in the small hydropower plant. It can include one or

more hydro turbine generator unit(s), depending to the consumers’ requirements. Each hydro

turbine generator unit includes a main control and an auxiliary control. The main control system

Dam

Primary Level

Consumer

Remote Site

Transmission Line

Consumer

Secondary Level

Storage

Transmission Line

Run-of- the river

1 - Introduction


18

realizes and manages the energy conversion and power production in the plant. The auxiliary

control system services the main control system for regular operation.

Power transmission: Through the step-up transformers, switch stations and transmission lines,

the electrical energy is supplied into the power network and on the consumers.

The following section introduces the detailed information for the hydro turbine generator unit.

Hydro Turbine Generator Unit

In the small hydropower plant, different types of electrical equipments are installed to achieve the

power generation. They are controlled and operated by the automation devices. And this

management provides the electric power system with safety, economy and guaranteed power

quality.

• Main Control Unit

The picture shown below indicates the automation control system for the power generation, and

how the devices act in the system.

Figure 3: Main control unit

The following table describes the individual components.

1 - Introduction


19

Component Characteristics

Figure 4: Hydro turbine

The water turbine is one of the key devices for power

generation. It takes energy from moving water,

produces mechanical energy, and drives the

generator. There are three main turbine types: Pelton,

Francis and Kaplan1. The selection of the turbine for

the hydro generator unit depends on the three main

technical aspects: head, flow and power. Each type

suits specific physical conditions at each location.

Figure 5: Generator

The generator is the other key device for power

generation, transforming the mechanical power into

electric power.

There are two controllable input elements for the

generator, turbine speed and excitation current. The

turbine speed is regulated by the P-f controller, and

the excitation current is regulated by the Q-U

controller via magnetic field winding.

With these inputs, the generator outputs the energy to

the power network for users.

Figure 6: P-f controller

The P-f controller, also called turbine control, controls

the water valve which regulates the inlet water of the

hydro turbine through the actuator. The turbine control

receives the feedback data from the P-f

measurement, which measures the energy status of

the generator.

Before the paralleling phase, the controller regulates

the inlet of water into the turbine so that the

generator’s frequency is close to the network’s

frequency.

After the paralleling phase, the controller regulates the

inlet of water into the turbine to satisfy the required

active power.

The turbine controller can be designed together with

main control PAC or in a dedicated PAC.

1 - Introduction


20


Figure 7: Q-U controller

The Q-U controller, also called excitation controller,

generates the excitation current for the generator,

using the controllable excitation power source and

magnetic field winding. It receives the feedback data

from the Q/U/I measurement which measures the

energy status of the generator.

Before the paralleling phase, the controller regulates

the current so the generator’s voltage is close to

target voltage.

After the paralleling phase, the controller regulates the

current to satisfy the required reactive power.

Normally, the controller is designed by the company

responsible for the excitation system development.

Figure 8: Synchronizer

Before a generator is connected in parallel with the

power network, the voltages and frequencies must be

identical and must be synchronized so that they are in

phase. The synchronizer regulates the P-f and Q-U

controllers according to the measured energy data

from the generator. Waiting until the difference in

energy status between the generator and power

network is within the preset limit, the synchronizer

sends the signal to close the circuit breaker and

makes the generator parallel into the power network.

Figure 9: Protector

A protector is used to continuously monitor the

electrical status of the generator and to de-energize it

when a serious disturbance occurs, such as short

circuit, insulation fault and so on.

Table 1: Component of main control unit

1 - Introduction


21

• Auxiliary Control Unit

The auxiliary system in the hydro turbine generator unit mainly includes the cooling/heating

system, the bearing oil system and the hydraulic pressure system. The following table introduces

these systems individually.


Cooling system The cooling system protects the generator and the bearing oil system from

overheating.

Heating system The heating system eliminates the moisture inside the generator when the

unit is stopped.

Bearing oil system The bearing oil system maintains the lubricating film on the bearing, keeps

the bearing running smoothly and decreases mechanical loss.

Hydraulic pressure The hydraulic pressure system transfers the mechanical energy into the

pressure energy of the liquid, and controls the hydraulic actuator.

Table 2: Component of auxiliary control unit

1Turbine types: There are three main types: Pelton, Francis and Kaplan. Each type is suitable to

certain physical conditions at each site, such as head, flow and power.

Turbine Characteristics

Figure 10: Pelton

A Pelton turbine is a type of action turbine or impulse turbine which uses

only the speed of the water as kinetic energy, and is appropriate for high

heads (75 meters to >1000 meters) and small flows. With the Pelton

turbine, it is easy to have a high efficiency curve and it response well to

variations in flow.

Figure 11: Francis

A Francis turbine is a type of reaction turbine which takes advantage of

the speed and the pressure of the water as it moves through the turbine,

generating the mechanical energy.

The Francis turbine is a radial turbine which is suitable for sites with a

medium head and flow.

Figure 12: Kaplan

A Kaplan turbine is a type of reaction turbine. It is an axial turbine and is

appropriate for operation with low heads and high or low flows.

Table 3: Water turbine type

1 - Introduction


22

1.4.2. TVDA Demo Project

The diagram below presents the small hydropower plant which is used in this TVDA guide as a

demo project. It includes three stages: the dam, the primary power generating level and the

secondary power generating level.

Figure 13: Small hydropower plant process diagram

• The maximum volume of the dam is 63500m3, with the 9 meters height and 80 meters width.

• The water head for the primary level is 97 meters. There are four hydro generator units in

this level. Two of them use Pelton turbines and the other two use Francis turbines. The

annual production of these units is 35 000 MWh.

• The water head for the secondary level is 34 meters. One hydro generator unit is equipped

with a Kaplan turbine. The annual production of the unit is 2 900 MWh.

This TVDA guide takes the hydro turbine generator unit with Francis turbine in the primary level

as the example, and explains how to select, design and integrate the small hydropower plant into

a PlantStruxure architecture.

The following tables show the characteristics of the generator and turbine.

1 - Introduction


23

• Generator

Parameter Value

Type Synchronous

Apparent power Sn 26.5 MVA

Real power Pn 23.4 MW

Power factor Cos phi 0.90

Phase voltage 9 kV

Table 4: Generator parameters

• Francis Turbine

Parameter Value

Type Vertical Francis

Max output of turbine 4.8 m3/s

Maximum power 24 MW

Nominal speed 1500 r/min

Table 5: Francis turbine parameters

1 - Introduction


24

1.5. About this document

This TVDA guide includes the following phases: Selection, Design, Configuration, Implementation,

Operation & Maintenance and Validation. This document provides a full description and

implementation of the selected architectures, as well as the associated performance

measurements. The main chapters of this document are described below:

1. Introduction, which introduces the small hydropower plant and hydro turbine generator unit,

as well as the customer challenges and prerequisites.

2. Selection, which describes the selected small hydropower plant architecture and how to meet

the customer requirements.

3. Design, which designs the selected architecture with applications, hardware and application

parts.

4. Configuration, which provides the configuration steps in programming software and in the

applications.

5. Implementation, which introduces the steps to realize the applications which are released in

this version.

6. Operation, which advises how to operate the small hydropower application via the visual

interfaces on the SCADA and HMI monitoring panel.

7. Validation, which offers the performance results for the Sequence-of-Event response time,

and remote access performance.

8. Conclusion, which sums up the application according to the selected architecture, and the

comparison between the customer requirements and the architecture performance.

2 - Selection


25

2. Selection

The solution for a small hydropower plant is defined according to the proposed customer

requirements.

2.1. Customer Requirements

Below are the customer requirements of the demo hydropower project control system application.

The system comprises a control center for operating and monitoring, a network structure and

three functional units: main control unit, auxiliary control unit and dam control unit.

Figure 14: Customer requirements

2 - Selection


26

The following table introduces the customer requirements.

Segment Description

Figure 15: Control room

The remote monitor and control center displays the real-time

status of the system, and is able to control the devices and

processes remotely. It also manages the event and alarm

messages during the system runtime.

Figure 16: Network

The redundant fiber optics structure is used to connect the

control room with all the functional units, with the communication

protocol Modbus TCP.

Figure 17: Main control

unit

The main control unit is the most important functional unit for

energy generation. In this unit, a local panel is used for

controlling from the local site. One set of Local Control Unit

(LCU) controls the start/stop processes and regulates the turbine

and excitation controllers. The unit should also manage

generator protection, as well as other applications, such as

integration of the intelligent power meter, Sequence-of-Event

(SOE), remote access and the IEC61850 protocol.

Figure 18: Aux. control unit

The control functions of the auxiliary devices are executed in the

LCU in the main control unit. The functions include control of the

heating and cooling systems, control of the bearing oil system

and control of the hydraulic pressure system.

Figure 19: Dam control unit

A local panel is used for control from the local site in the dam

area. The other set of LCU controls and monitors the dam status

for the energy production. Additionally, a camera is used to

visually monitor the dam area in real time and to double check

the water status.

Table 6: Customer requirements

2 - Selection


27

2.2. Architecture Selection

The architecture of the small hydropower plant is drawn out based on the PlantStruxure reference

architecture, taking into consideration of the customers’ needs.

2.2.1. Reference architectures

The PlantStruxure reference architecture is a combination of architecture elements: the global

reference architecture which gives the system architecture framework including the overall

network architecture, the control room reference architecture and several functional unit reference

architectures.

Figure 20: Reference architecture

Considering the complexity and size of the automation system, the global architecture can be

divided into three main systems: centralized automation system, modular automation system,

highly available automation system.

Figure 21: Global reference architecture

2 - Selection


28

2.2.2. Selected architecture

Considering the complexity and the size of the application, a modular architecture is selected for

this small hydropower plant architecture. It proposes a decentralized control system with multiple

PACs.

The system includes a central control room and three functional units. Because of the long

distance between the control room and the units, optical fiber is used for connecting the switches

in different areas.

The graph below illustrates the architecture framework selected for the demo application, and the

connection between the control room and the functional units.

Figure 22: Selected architecture framework

2 - Selection


29

Control room selection

As a networked SCADA system makes it possible to monitor the entire automation system, the

optimized control room and operational rooms are used with proposes a distributed operating and

monitoring solution for the process application.

Component Description

Figure 23: Vijeo Citect

Vijeo Citect, as part of the fully integrated Schneider Electric

automation solution, is a reliable, flexible and high performance

Supervisory Control and Data Acquisition (SCADA) system. Easy-to-

use configuration tools and powerful features enable users to quickly

develop and deploy solutions for any size industrial application.

Table 7: Control room selection

Functional Unit Selection

There are three functional units: main control unit, auxiliary control unit and dam control unit.

Each set of PACs is dedicated to managing one functional unit. And the HMI interfaces are

mounted in local cubicles in the main control unit and dam control unit individually.

• Main Control Unit

The field components used in the main control unit include several field devices, such as

synchronizer, exciter, protector, electronic potentiometer, transducer and meters, as well as the

control PAC and HMI interface. This section introduces the devices individually.

Note: Schneider Electric has its own meter products for measuring the energy status such as

power, voltage and current. For the purpose of the demo application in this guide, the meters

used are from DEIF, as DEIF is one of Schneider Electric’s CAPP partners.


Figure 24: M340 and

Unity Pro

Modicon M340 is a mid-range PAC for industrial process and

infrastructure. It executes the process sequences and regulates the

turbine and excitation controller in the main control process

Unity Pro is a SoCollaborative software for programming Modicon

PACs. It increases the productivity and performance of PAC

applications.

2 - Selection


30


Figure 25: HMI interface

and Vijeo Designer

The HMI interface is an advanced panel with a touchscreen. It is

compact, simple and robust for industry, infrastructure and

automation. The panel enables local operation of the main control

devices.

Vijeo Designer is an HMI configuration software. Thanks to the

user-friendly interface, it offers functions such as multimedia

capabilities and remote access for more efficiency.

Figure 26: Synchronizer

The Generator Protection Unit (GPU-3 Hydro) device from DEIF is

selected as the synchronizer in this application. It is a compact

microprocessor-based protection unit, containing all the necessary

functions for the synchronization and protection of a hydro turbine-

driven synchronous or asynchronous generator.

Figure 27: AVR

In this guide, the AVR is used as the exciter. It is regulated by the

excitation controller which is implemented in the main control PAC.

Figure 28: Protector

Sepam G87 is one of the Sepam series 80, and provides proven

solutions for electrical distribution and generator protection.

Figure 29: AC-transducer

The selectable AC-transducer TAS-331DG from DEIF is a micro-

controller-based AC-transducer with one analogue output for

measurement of power or reactive power on an AC network.

Figure 30: Intelligent

power meter

The PM800 is an intelligent power meter with multifunction, digital

instrumentation, data acquisition and control. It can replace a

variety of meters. It is able to transmit power data to the PACs via

the communication cable.

2 - Selection


31


Figure 31: Synchronizing

meter

The Check Synchronizing Relay CSQ-3 from DEIF is a

microprocessor-based synchronizing unit. It can be used in any

kind of installation where manual or semi-automatic synchronization

is required.

Figure 32: Power meter

The Watt or var meter WQ from DEIF measures power or reactive

power, and consists of a built-in coil movement and a built-in

electronic watt or var transducer.

Figure 33: Current meter

The Ammeters with built-in switch VDQ96-sw from DEIF is applied

to measure AC current. The built-in switch makes measurement of

current in a 3-phase network possible.

Figure 34: Voltage meter

The Quadratic moving iron instrument EQ96-sw7 from DEIF

measures the AC voltages. Selection of measurement of phase-to-

phase voltage or phase-to-zero voltage in a three-phase network is

possible by means of the built-in switch.

Table 8: Main control unit selection

2 - Selection


32

• Auxiliary Control Unit

The field devices in the auxiliary control unit include variable speed drives, motor protectors and

so on. The functions of auxiliary control system are implemented in the main control PAC in the

main control unit.


Figure 35: Variable

speed drive

ATV61 is an example of a variable speed drive. It is dedicated to

pump and fan applications for the industrial and buildings markets,

with exceptional performances and advanced functionalities.

Figure 36: Motor starter

TeSys U is an example of a motor protector. It is compact, simple

and modular, and adapts to all the applications.

Table 9: Auxiliary control unit selection

2 - Selection


33

• Dam Control Unit

The components in the dam control unit include the control PAC, HMI interface and a real-time

monitor.


Figure 37: M340 & Unity

Pro

Modicon M340 is a mid-range PAC for industrial process and

infrastructure. It executes the process sequences and regulates the

turbine and excitation controller in the main control process.

The Unity Pro software is a SoCollaborative software for

programming Modicon PACs. It increases the productivity and the

performance of PAC applications.

Figure 38: HMI interface

& Vijeo Designer

The HMI interface is an advanced panel with a touchscreen. It is

compact, simple and robust for industry, infrastructure and

automation applications. The panel enables local operation of the

main control devices.

Vijeo Designer is an HMI configuration software. It has a user-

friendly interface and offers functions such as multimedia

capabilities and remote access for more efficiency.

Figure 39: Camera

Pelco is a range of real-time monitoring cameras, offering an

extensive selection of network and analog camera solutions. It

enables live visual monitoring of the water status in the dam area.

Table 10: Dam control unit selection

2 - Selection


34

2.2.3. Turbine-Generator Simulation Selection

For the purpose of simulating the whole demo application, a generator, a motor and an additional

variable speed drive are engaged. The motor imitates the motion of the hydro turbine, while the

variable speed drive controls the speed of the motor, which imitates the speed of the hydro

turbine.


Figure 40: Generator & Motor

A small capacity generator simulates the real, large

capacity generator in the project.

The motor is driven by ATV312 and simulates the

motion of the turbine.

Figure 41: Variable speed drive

The ATV312 variable speed drive controls the motor

speed rate by changing the drive speed, simulating the

different wicket gatage of the turbine. The drive is

regulated by the turbine controller which is done in the

main control PAC.

Table 11: Turbine-generator unit selection

2 - Selection


35

2.2.4. Selected System Architecture

According to the selected architecture and components for the central control room and functional

units, the solution is illustrated in the following image.

The components of the automation control system in the control room and the three functional

units are connected via the Modbus TCP protocol, while the field devices in the main control and

auxiliary control units connect the PAC via the Modbus SL protocol.

Following graph indicates the selected system architecture for small hydropower plant.

Figure 42: Hydropower TVDA architecture

2 - Selection


36

3 - Design


37

3. Design

According to the solution and components selection, this chapter introduces the application

design, hardware design and software design.

3.1. Application Design

In the small hydropower plant, the following applications are included:

Plant section Application V1 V2

Control room Operation and monitoring

Event and Alarm management

X

X

X

Main control unit

Start/stop process control

Turbine/excitation regulation

Synchronization control

Generator protection

Intelligent Power Meter integration

Sequence Of Event control

Remote access (DNP3/ IEC 60870-5-101/-104)

IEC61850 protocol integration

X

X

X

X

X

X

X

X

X

X

Auxiliary control unit

Heating system control

Cooling system control

Bearing oil system control

Hydraulic pressure system control

X

X

X

X

Dam control unit Monitoring and control

Real-time monitoring

X

X

X

Table 12: Application Design

Note: The applications marked with V1 are realized in this version of TVDA guide, while the

applications marked with V2 will be realized in the next version. The applications marked with

both V1 and V2 indicate that the application has been started in this version, but will be fully

achieved in next version.

3 - Design


38

3.1.1. Start/Stop Process Control

With the purpose of providing unit protection and a quick response time, a sequence of steps is

followed during the start, normal stop, quick stop or in the case of an emergency stop.

Start Process

During the start process, before turning on the main switch to parallel the generator into the

power grid, several steps should be carried out primarily to make sure the device conditions meet

the requirements.

1. There are three stages of starting up the unit: Idle, Unload, and Parallel. With one of these

commands and the start ready condition, the auxiliary system is used to turn off the

generator heating, cool the transformer and turn on the high pressure and the bearing oil for

the turbine and generator. If the actions are not completed within 120 seconds, an alarm

message is automatically generated and the start process is stopped and the fault stop

process is initiated.

2. Open the main inlet valve until the valve gatage is 100%. If the action is not completed within

60 seconds, an alarm message is automatically generated and the start process is stopped

and the fault stop process is initiated.

3. Turn on the turbine regulator. With the Idle command, the unit then runs in IDLE mode. If the

action is not completed within 360 seconds, an alarm message is automatically generated

and the start process is stopped and the fault stop process is initiated.

4. When the turbine speed is accelerated to more than 30% of the targeted value, the

generator bearing oil is turned off. If the action is not completed within 20 seconds, an alarm



5. When the turbine speed is accelerated to more than 95% of the targeted value, the exciter is

switched on. If the action is not completed within 60 seconds, an alarm message is

automatically generated and the start process is stopped and the fault stop process is

initiated. With the Unload command, the unit then runs in UNLOAD mode.

6. When the generator voltage is accelerated to more than 95% of the targeted value, the

synchronizer is turned on. If the action is not completed within 60 seconds, an alarm



7. When the synchronization point is reached, the synchronizer sends a signal to close the

circuit breaker. If the breaker is not closed within 10 seconds, an alarm message is

3 - Design


39

automatically generated and the start process is stopped and the fault stop process is

initiated.

8. Turn on the regulation for Cosphi and water flow. If regulation is not successful within 120

seconds, an alarm message is automatically generated and the start process is stopped and

the fault stop process is initiated.

Thus, the unit is paralleled into the power network. It is in RUNNING mode.

Note: The time it takes to complete the action can be adapted according to project and its

components.

The following diagram indicates the details of each step and action for the starting process.

3 - Design


40

Figure 43: Start sequence

3 - Design


41

Normal Stop Process

During the normal stop process, the following steps should be carried out one at a time.

1. There are three stages for stopping the unit: Unload, Idle and Full Stop. With one of these

commands and the stop ready condition, the load is decreased by the regulation of Cosphi

and water flow. If the actions are not completed within 120 seconds, an alarm message is

automatically generated, the process is stopped and the fault stop process is initiated.

2. Open the circuit breaker. With the Unload command, the unit runs in UNLOAD mode. If the

action is not completed after 10 seconds, an alarm message is automatically generated, the

process is stopped and the fault stop process is initiated.

3. Switch off the exciter and decrease the line voltage of the generator. With the Idle command,

the unit runs in IDLE mode. If the action is not completed within 20 seconds, an alarm

message is automatically generated, the process is stopped and the fault stop process is

initiated.

4. Turn off the turbine regulation and close mechanical limit. If the action is not completed

within 360 seconds, an alarm message is automatically generated, the process is stopped

and the fault stop process is initiated.

5. When the mechanical limit is 0, turn off the main valve. If the action is not completed within

60 seconds, an alarm message is automatically generated, the process is stopped and the

fault stop process is initiated.

6. When the turbine speed is decreased to less than 30% of the targeted value, turn on the

generator bearing oil. If the action is not completed within 20 seconds, an alarm message is


7. When the turbine speed is decreased to less than 20% of the targeted value, turn on the

mechanical brake. If the action is not completed within 180 seconds, an alarm message is


8. When the turbine speed is decreased to 0, turn off the mechanical brake. If the action is not

completed within 20 seconds, an alarm message is automatically generated, the process is

stopped and the fault stop process is initiated.

9. Turn off the auxiliary system for bearing oil, high pressure and transformer cooling, and turn

on the generator heating. If the action is not completed within 120 seconds, an alarm

message is automatically generated.

NOTE: The time it takes to complete the action can be adapted according to the project and its

components.

3 - Design


42

The following diagram indicates the details of each step and action for the normal stopping

process.

Figure 44: Normal stop process

3 - Design


43

Quick Stop Process

The quick stop alarm is triggered because of a mechanical defect. In this case, the process is

similar to that of a normal stop, except that the machine is stopped through the commitment of

the deflectors and the excitation of the solenoid valve safety of the turbine.

1. When a quick stop alarm is sent, close the main valve. If the action is not completed within

10 seconds, an alarm message is automatically generated.

2. Decrease the generator load by regulating the Cosphi and water flow. If the action is not

completed within 30 seconds, an alarm message is automatically generated.

3. Open the circuit breaker. If the action is not completed within 8 seconds, an alarm message

is automatically generated.

4. Cut the exciter to decrease the line voltage. If the action is not completed within 10 seconds,

an alarm message is automatically generated.

5. Turn off the turbine regulator to decrease the turbine speed. If the action is not completed

within 360 seconds, an alarm message is automatically generated.

6. When the turbine speed is less than 30% of the targeted value, turn on the generator bearing

oil. If the action is not completed within 20 seconds, an alarm message is automatically

generated.

7. When the turbine speed is less than 20% of the targeted value, turn on the mechanical brake

to decrease the speed. If the action is not completed within 180 seconds, an alarm message

is automatically generated.

8. When the turbine stops, turn off the brake. If the action is not completed within 20 seconds,

an alarm message is automatically generated.

9. Turn off the bearing oil system, the high pressure, the transformer cooling, and turn on the

generator heating. Thus, the quick stop process is finished. If the action is not completed

within 120 seconds, an alarm message is automatically generated.

NOTE: The time it takes to complete the actions can be adapted according to the project and its

components.

3 - Design


44

The following diagram indicates the details of each step and action for the quick stopping

process.

Figure 45: Quick stop process

3 - Design


45

Emergency Stop Process

In the event of an internal electrical fault, an emergency stop of the group is triggered. The unit is

decoupled immediately, followed by the cut of excitation

1. With the Emergency stop alarm, open the circuit breaker and cut the exciter. If the action is

not completed within 8 seconds, an alarm message is automatically generated..

2. Stop the turbine regulator. If the action is not completed within 470 seconds, an alarm

message is automatically generated and the main valve is closed.

3. When the turbine speed is less than 30% of the targeted value, turn on the generator bearing

oil. If the action is not completed within 10 seconds, an alarm message is automatically

generated.

4. When the turbine speed is less than 20% of the targeted value, turn on the mechanical brake.

If the action is not completed within 180 seconds, an alarm message is automatically

generated and the process is stopped.

5. When the turbine stops, turn off the mechanical brake. If the action is not completed within

20 seconds, an alarm message is automatically generated.

6. Turn off the bearing oil system, the high pressure, the transformer cooling, and turn on the

generator heating. If the action is not completed within 120 seconds, an alarm message is

automatically generated and the process is stopped.

NOTE: The time it takes to complete the action can be adapted according to the project and its

components.

3 - Design


46

The following diagram indicates the details of each step and action for the emergency stopping

process.

Figure 46: Emergency stop process

3 - Design


47

3.1.2. Turbine/Excitation Regulation

Two controllers in the main unit are simulated and realized in the PAC:

• Turbine controller

• Excitation controller

Turbine Controller

The turbine regulation system includes the turbine, turbine controller, mechanical tachometer and

frequency convertor. The following is a diagram of the turbine control system.

Figure 47: Turbine control diagram

• When first starting the turbine - before reaching 20% of the targeted turbine speed - the

speed detection is done by the mechanical measuring device which is on the bearing

connecting generator and turbine. After that, the measurement is done by the intelligent

power meters.

• The turbine controller regulates the turbine frequency during the starting phase and the

active power after paralleling into the power network.

• The frequency converter is used to measure the frequency of the generator and feed the

value back to the turbine controller.

In this small hydropower system, the turbine controller and frequency convertor are done in the

PAC of the main control unit.

3 - Design


48

The turbine controller acts differently according to the different phases of the process.

Phase Description

Before parallel

The process value is less than 95 percent of the setting value. The turbine

controller regulates the turbine wicket gatage according to the generator setting

frequency, the real frequency fed back from the power meter and the

disturbance from the water flow.

Figure 48: Turbine control before parallel

Paralleling

When the process value is more than 95 percent of the setting value, but not

equal with the setting value, the group starts in paralleling section 3.1.3

Synchronization Control for detailed information.

After parallel

During the regular running period, the process value is equal to the setting

value at all times. The turbine controller regulates the turbine wickets according

to the generator setting active power, real active power fed back from the power

meter and the disturbance from the water flow.

Figure 49: Turbine control after parallel

Table 13: Turbine controller regulation

3 - Design


49

Excitation Controller

The excitation controller regulates the excitation current during the starting phase and the

reactive power after paralleling into the power network.

Figure 50: Excitation control diagram

In this small hydropower system, the excitation controller is done in the PAC in the main control

unit.

The excitation controller regulates different factors in the different phases

Phase Description

Before parallel

The process value is less than 95 percent of the setting value. The excitation

controller regulates the excitation current according to the generator setting

voltage and the real voltage fed back from the power meter.

Figure 51: Excitation control before parallel

Paralleling

When the process value is more than 95 percent of the setting value, but not

equal with the setting value, the group starts in paralleling. The excitation

current is regulated by the synchronizer. Please refer to section 3.1.3

Synchronization Control for detailed information.

3 - Design


50

Phase Description

After Parallel

During the regular running period, the process value is equal with the setting

value at all times. The excitation controller regulates the excitation current

according to the generator setting reactive power and real reactive power fed

back from the power meter.

Figure 52: Excitation control after parallel

Table 14: Excitation controller regulation

3 - Design


51

3.1.3. Synchronization Control

Synchronization is the most important step in the start sequence for the group paralleling into the

power grid. If the circuit breaker closes while the generator is out of phase with the busbar, there

will be heavy cross-currents that will cause voltage fluctuations. In extreme cases, it can damage

the equipment.

The synchronizer is the right device to regulate the energy status in the generator to close to the

power energy status in busbar. In the paralleling phase, it adjusts the voltage difference,

frequency difference and, waiting until the phase angle is within the preset limit, it sends the

signal to close the circuit breaker and makes the generator paralleling into the power network.

After that, the synchronizer is stopped.

Figure 53: Synchronization control diagram

3 - Design


52

When the process value is more than 95 percent of the setting value, but not equal with the

setting value, the group starts in paralleling.

Phase Description

Paralleling

The synchronizer regulates the turbine wicket gatage according to the

measured network voltage frequency and the feedback frequency from the

generator.

Figure 54: Synchronization control

The synchronizer regulates the excitation current according to the measured

network voltage value and the feedback of the power meter.

Figure 55: Synchronization control

Table 15: Synchronization controller regulation

3 - Design


53

3.1.4. Generator Protection

The generator protection provides full differential protection, ensuring fast, discriminative

clearance of faults within the generator. It secures the generator by monitoring the energy status

of the generator and the power network, as well as the processing data during the power

generation.

Figure 56: Protection diagram

3 - Design


54

3.2. Hardware Design

The hardware design includes two aspects:

• Cubicle layout

• System wiring

3.2.1. Cubicle Layout

Two cubicles are set up for the selected architecture of the main control unit. One cubicle is

designed mainly for the process control and supervision, including PACs, HMI interface, Ethernet

switch and Modbus hub. The other cubicle is for field device control, including synchronizer,

exciter and protector, as well as the motor and generator unit simulating the energy production in

the demo application.

View Description

Front View

Below is the front view of the cubicles, indicating the layout of the components on

the door.

The meters are mounted on the left side of the cubicle. The HMI interface, switch,

buttons and lights are also mounted in this cubicle.

The protector Sepam G87 and synchronizer GPU-3 Hydro display panel are

mounted on the front door of the right cubicle, along with the single line of the

power distribution.

Figure 57: Layout of front view

3 - Design


55

View Description

Inside View

This is the inside view of the cubicles, indicating the mounted position for the

components.

Figure 58: Layout of inside view

Table 16: Cubicle layout

3 - Design


56

3.2.2. System Wiring Design

The system schematic diagram includes the power distribution, the signal connection between all

the elements.

No. Description

1

Power supply and energy status measurement design

Figure 59: Power supply and energy status

3 - Design


57

No. Description

2

Components relationship design, including all the main automation elements in this application.

Figure 60: Component connection

3 - Design


58

No. Description

3

The following control circuit diagram includes:

• Main breaker close/open wiring design

• Generator start/stop design

• Power contribution QF/Load design

Figure 61: Control circuit

3 - Design


59

No. Description

4

The following wiring diagram describes the connection among generator, motor, ATV312 and

AVR.

In this demo application, a motor is used to represent the hydro turbine. It is driven by a variable

speed drive ATV312, which simulates the inlet water running into the turbine by regulating the

drive speed. The input AI2 of the ATV312 is regulated by the turbine controller in the PAC to

simulate the change of turbine wicket gatage. The input AI2 and COM is connected to the

analog output module of the PAC. See Pane A in the diagram below.

The Exciter is represented by the generator AVR, which regulates the generator voltage and

reactive power by the increasing or decreasing signal from the excitation controller in the PAC.

The AVR input AVR+/AVR- is connected to the analog output module of the PAC. See Pane B

in the below diagram.

Figure 62: Simulated system connection

A

B

3 - Design


60

No. Description

5

The following diagram illustrates the wiring of the selected synchronization controller GPU-3

Hydro

Pins 1 and 2 are used for power supply; Pin 25 allows the GPU-3 Hydro to regulate the energy

status when it is ready for synchronization in remote mode; Pins 26 and 27 are used to detect

the status from the main breaker; Pins 23 and 24 are used to detect the mode between local

and remote; The Relays 14 and 17 control the main breaker to close or open; The Relays 65

and 67 regulate the turbine frequency with speed increasing or decreasing speed; The relays 69

and 71 regulate the excitation voltage with current increasing and decreasing current.

Figure 63: GPU-3 Hydro wiring

6

The following figure shows the wiring for the digital input module. The module receives the

status of the generator, switch mode, GOV and AVR regulation, generator voltage regulation,

emergency stop and circuit breaker for the main control program.

Figure 64: Digital input module wiring

3 - Design


61

No. Description

7

The following figure shows the wiring for the digital output module. The outputs include all the

commands to field devices, such as the control of the circuit breaker, main valve, generator

voltage, generator, GPU mode, excitation and power distribution. The module also outputs the

status of indicator lights mounted on the door of the cubicle which illustrate the current status.

Figure 65: Digital output module wiring

8

The following figure shows the wiring diagram of the analog input module. The data on real

power, EPN frequency and EPN voltage are obtained via this module.

Figure 66: Analog input module wiring

3 - Design


62

No. Description

9

The following figure shows the wiring diagram of the analog output module. Through this

module, the main control program regulates the speed of the ATV312 and the excitation current

of the AVR.

Figure 67: Analog output module wiring

Table 17: Wiring diagram

3 - Design


63

3.3. Software Design

This section outlines the design of the PAC program, SCADA system and HMI application.

3.3.1. PAC Application Design

The following diagram illustrates the hierarchy of the small hydropower plant in the PAC

application. It includes:

• Dam area -- Simulation

• One hydro-turbine generator unit

• Main control – Turbine and excitation regulations, start/stop processes and simulation

• Auxiliary control – Simulation of the auxiliary control

Figure 68: PAC application design

The following table introduces the symbols used in the chart above.

Symbol Description

The block with a green background color and white text color

indicates that the application is realized in this version of the TVDA

guide

3 - Design


64

Symbol Description

The block with a green-black background color and white text color

indicates that the application is started in this version of the TVDA

guide but will be achieved in next version.

The block with a gray background color and black text color

indicates that the application will be realized in next version of the

TVDA guide.

This symbol stands for the Derived Function Block (DFB). The DFB

is created to help users to improve their efficiency during

development, and realize the required application.

This symbol stands for the Function Block Diagram (FBD). It is a

graphical programming language that operates as a logic diagram.

This symbol stands for the Sequential Function Chart (SFC). It can

be used to graphically represent the operation of a sequential PAC

in a structured manner.

This symbol stands for the Structured Text language (ST). It is an

elaborate language close to computer programming languages. It is

able to structure series of instructions.

Table 18: Symbol introduction

3 - Design


65

Derived Function Block Design

There are several DFBs created for the applications, such as turbine/excitation regulation,

process steps, auxiliary control system and so on.

DFB Purpose

MC_TurAVRRegOut Regulate the turbine and excitation control

AutoSteps Step used in auxiliary sub-system

AC_PumpValveSys Monitor and control the auxiliary system

ProcessValuePercentExchange Process value format exchanges from percentage to real

ProcessValuePulseChange Manually regulates the parameter

ProcessValueAlarm Generate the alarm message in certain condition

SS_ProcessValueDelayReal Simulate the process value delay

SS_ProcessValue Simulate the regulation of process value

Table 19: DFB description

• DFB1: MC_TurAVRRegOut

Figure 69: DFB MC_TurAVRRegOut

Function:

This DFB is used to manage the turbine and AVR regulation output value during different process

steps, including before synchronization, during synchronization and after synchronization.

The following table introduces the DFB input/output pins:

Input/Output No Parameter Type Comment

Input 1 SyncRdy BOOL The generator can be synchronized to power network.

2 SyncCompleted BOOL The generator is connected to power network.

3 - Design


66


3 TurPACRefHz INT The generator speed input value (before

synchronization)

4 TurSyncCtrlRefHz INT The generator speed regulated value from

synchronization (during synchronization)

5 TurPACRefMW INT The generator active power input value (after

synchronization)

6 AVRPACRefVolt INT The generator voltage input value (before

synchronization)

7 AVRSyncCtrlRefVolt INT The generator voltage regulated value from

synchronization (during synchronization)

8 AVRPACRefMVar INT The generator reactive power input value (after

synchronization)

9 MinTurRegOut INT Minimum output value of the turbine regulation

10 MaxTurRegOut INT Maximum output value of the turbine regulation

11 MinAVRRegOut INT Minimum output value of the AVR regulation

12 MaxAVRRegOut INT Maximum output value of the AVR regulation

Output 1 TurRegOut INT The output value of the turbine regulation

2 AVRRegOut INT The output value of the AVR regulation

Table 20: DBF MC_TurAVRRegOut pins

3 - Design


67

• DFB2: AutoSteps

Figure 70: DFB AutoSteps

Function:

This DFB is used to start/stop the Aux sub-system step by step.



Input

1 Start BOOL AutoSteps in start process mode

2 Stop BOOL AutoSteps in stop process mode

3 Reset BOOL AutoSteps reset

4 StepNum INT Maximum steps in the AutoSteps

5 StepDelay TIME Step delay time between steps

Input/Output 1 StepsOut INT Current step out value

Output 1 StepsDirection BOOL Steps direction with increase or decrease

Table 21: DBF AutoSteps pins

3 - Design


68

• DFB3: AC_PumpValveSys

Figure 71: DFB AC_PumpValveSys

Function:

This DFB is used to control and monitor the auxiliary system in the small hydropower plant,

including pump and valve controlling and pressure, temperature and level monitoring. It can be

adapted in the cooling, bearing oil and hydrolic pressure system.

3 - Design


69



Input

1 Pump1CMD BOOL Start/stop primary pump command

2 Pump2CMD BOOL Start/stop standby pump command

3 ValveMCMD BOOL Open/close main valve command

4 ValveS1CMD BOOL Open/close S1 channel valve command

5 ValveS2CMD BOOL Open/close S2 channel valve command

6 PressureS1M REAL S1 channel pressure process value measurement

7 TemperatureS1M REAL S1 channel temperature process value

measurement

8 PressureS2M REAL S2 channel pressure process value measurement

9 TemperatureS2M REAL S2 channel temperature process value

measurement

10 TankLevelM REAL Tank level process value measurement

11 TankTemperatureM REAL Tank temperature value measurement

Output

1 SysRun BOOL System running

2 Pump1Run BOOL Primary pump running

3 Pump2Run BOOL Standby pump running

4 ValveMOpen BOOL Main valve open

5 ValveS1Open BOOL S1 channel valve open

6 ValveS2Open BOOL S2 channel valve open

7 PressureS1 REAL S1 channel pressure real-time value

8 TemperatureS1 REAL S1 channel temperature real-time value

9 PressureS2 REAL S2 channel pressure real-time value

10 TemperatureS2 REAL S2 channel temperature real-time value

11 TankLevel REAL Tank level real-time value

12 TankTemperature REAL Tank temperature real-time value

13 Alarm REAL System alarm status word

Table 22: DBF AC_PumpValveSys pins

3 - Design


70

• DFB4: ProcessValuePercentExchange

Figure 72: DFB ProcessValuePercentExchange

Function:

It is used to take the real format to manage the process value.



Input

1 PrcoessValuePercent REAL The percent of the process value

2 MinProcessValue REAL Minimum process value

3 MaxProcessValue REAL Maximum process value

Output 1 ProcessValue REAL Transferred the process value from percent

format to real value

Table 23: DBF ProcessValuePercentExchange pins

3 - Design


71

• DFB5: ProcessValuePulseChange

Figure 73: DFB ProcessValuePulseChange

Function:

The function block regulates the parameters manually.



Input

1 ProcessValueAddPulse BOOL The signal for increasing the offset

2 ProcessValueDecPulse BOOL The signal for decreasing the offset

3 ProcessValueChangeDelta REAL The amount value for each increasing or

decreasing step

4 ProcessValueChangeMin REAL The minimum amount value for decreasing

5 ProcessValueChangeMax REAL The maximum amount value for increasing

Input/Output 1 ProcessValueLink REAL The parameter for regulating manually

Table 24: DBF ProcessValuePulseChange pins

3 - Design


72

• DFB6: ProcessValueAlarm

Figure 74: DFB ProcessValueAlarm

Function:

The function block is used for generating the alarm messages when the value reaches the

max/min limits.



Input

1 ProcessValueArr ARRAY[0..9]

OF REAL The array links to process value

2 ProcessValueMinArr ARRAY[0..9]

OF REAL

The array of minimum limit for the low alarm

of value

3 ProcessValueMaxArr ARRAY[0..9]

OF REAL

The array of maximum limit for the high alarm

of value

4 ProcessValueMMinArr ARRAY[0..9]

OF REAL

The array of minimum limit for the low-low

alarm of value

5 ProcessValueMMaxArr ARRAY[0..9]

OF REAL

The array of maximum limit for the high-high

alarm of value

6 NumberOfProcessValue INT The number of process value in the array

Output

1 ProceeValueMinAlarmArr ARRAY[0..9]

OF BOOL The array for low alarm

2 ProceeValueMaxAlarmArr ARRAY[0..9]

OF REAL The array for high alarm

3 ProceeValueMMinAlarmArr ARRAY[0..9]

OF REAL The array for low-low alarm

4 ProceeValueMMaxAlarmArr ARRAY[0..9]

OF REAL The array for high-high alarm

Table 25: DBF ProcessValueAlarm pins

3 - Design


73

• DFB7: SS_ProcessValueDelayReal

Figure 75: DFB SS_ProcessValueDelayReal

Function:

This DFB is used to simulate the process value delayed with its representation in a real process

control system.



Input

1 ProcessValueIN REAL The process value to be delayed

2 DelayTime TIME Delay time

3 MinProcessValueOUT REAL Minimum process value

4 MaxProcessValueOUT REAL Maximum process value

5 ChangeProcessValue REAL The amount for process value changed each time

Output 1 ProcessValueOUT REAL Output the delayed process value

Table 26: DBF SS_ProcessValueDelayReal pins

3 - Design


74

• DFB8: SS_ProcessValue

Figure 76: DFB SS_ProcessValue

Function:

This DFB is used to simulate the regulation of the process value for the process control system.



Input

1 InitProcessValue REAL Initial process value

2 MinProcessValue REAL Minimum process value

3 MaxProcessValue REAL Maximum process value

4 IncreaseProcessValue BOOL Increase the process value command

5 DecreaseProcessValue BOOL Decrease the process value command

6 DeltaProcessValue REAL The amount for process value changed each time

7 Reset BOOL Reset the process value to initial value

Output 1 ProcessValue REAL Process value output

Table 27: DBF SS_ProcessValue pins

3 - Design


75

Functional Section Definition

According to the program hierarchy shown previously, different sections are defined to achieve

the required applications.

Section Description

Figure 77: IO

The I/O sections exchange the I/O data, read the parameters from

the intelligent power meter via communication and pretreat them

for the applications.

Figure 78: Sequence

The sequence sections manage the sequences for the hydro-

turbine generator unit, including the Start, Normal stop, Quick

stop and Emergency stop sequences.

Figure 79: Controller

The controller section regulates the turbine and excitation

controller for the production process.

Figure 80: Auxiliary

The two auxiliary sections simulate auxiliary system.

Figure 81: Alarm

The alarm section is used for alarm management.

Table 28: Functional section

3 - Design


76

3.3.2. SCADA Application Design

The following diagram indicates the hierarchy of the small hydropower plant in a SCADA system.

It includes:

• Overview of the whole small hydropower plant – Layout and power distribution

• Dam – Data control and IP camera supervision

• Primary Level – Electrical, mechanical and processes of one hydro-turbine generator unit

• Secondary Level – No detailed information in this application

• Alarm – Alarm and events

Figure 82: SCADA application design

3 - Design


77

The following table shows examples of the screens within the SCADA application:

Name Description

SHPP

Overview

The Overview page displays the general status of hydropower plant, regarding the

dam area and the hydro-turbine generator units. From this page, users can

access all other pages

Figure 83: SHPP Overview

3 - Design


78

Name Description

Power

distribution

The Power Distribution page displays the power distributing to power grid network

or to plant power consumption.

Figure 84: Power distribution

Dam

The Dam page monitors and controls the automation system in the dam area.

Figure 85: Dam area

3 - Design


79

Name Description

Primary

level

The Primary Level page introduces the main process of the main control unit, with

the breakdown of the process.

Figure 86: Process

Mechanical

The Mechanical page displays the brief mechanical status of the unit.

Figure 87: Mechanical

3 - Design


80

Name Description

Electrical

The Electrical page displays the electrical information of the unit with the Start and

Stop sequences.

Figure 88: Electrical

Start

Sequence

The Start Sequence page displays the start sequence actions and steps.

Figure 89: Start Sequence

3 - Design


81

Name Description

Stop

Sequence

The Normal Stop Sequence page displays the stop sequence actions and steps.

Figure 90: Stop Sequence

Quick Stop

Sequence

The Quick Stop Sequence page displays the stop sequence actions and steps.

Figure 91: Quick Stop Sequence

3 - Design


82

Name Description

Emergency

Stop

Sequence

The Emergence Stop Sequence page displays the stop sequence actions and

steps.

Figure 92: Emergency Stop Sequence

Alarm

The Alarm page records the alarm messages when errors occur.

Figure 93: Alarm

Table 29: SCADA application

3 - Design


83

3.3.3. HMI Application Design

The following diagram indicates the hierarchy of the small hydropower plant in an HMI application.

It includes:

• One hydro-turbine generator unit in Primary level – Electrical, mechanical and processes

• Alarm – Alarm and events

Figure 94: HMI application

3 - Design


84

The following table introduces the HMI application screens

Name Description

Overview

The Overview page displays the general status of the small hydropower plant.

Figure 95: SHPP Overview

TurGenUnit

The Hydro Turbine Generator Unit page introduces the main process of the main

control unit, with the breakdown of the process.

Figure 96: TurGenUnit

3 - Design


85

Name Description

Mechanical

The Mechanical page displays the brief mechanical status of the unit.

Figure 97: Mechanical

Electrical

The Electrical page displays the electrical information of the unit with the Start and

Stop sequences.

Figure 98: Electrical

3 - Design


86

Name Description

StartSeq

The Start Sequence page displayes the start sequence actions and steps.

Figure 99: Start Sequence

NorStopSeq

The Normal Stop Sequence page displays the stop sequence actions and steps.

Figure 100: Stop Sequence

3 - Design


87

Name Description

QStopSeq

The Quick Stop Sequence page displays the stop sequence actions and steps.

Figure 101: Quick Stop Sequence

EStopSeq

The Emergency Stop Sequence page displays the stop sequence actions and

steps.

Figure 102: Emergency Stop Sequence

3 - Design


88

Name Description

Alarm

The Alarm page records the alarm messages when an error occurs.

Figure 103: Alarm

Table 30: HMI application

4 - Configuration


89

4. Configuration

This section introduces the configuration of the automation control system and the field devices.

4.1. Automation Control System Configuration

The connection between the PAC and the SCADA system is via the OFS Configuration Tool for

processing all the parameters. The PAC transfers the variables to the SCADA system and HMI

application using a variable file which is exported automatically from the software UnityPro XL

when downloading the program.

4.1.1. Connection setup between SCADA and PAC

PAC Configuration

For the purpose of automatically exporting the variable file of the PAC program, it is necessary to

make some of the settings in UnityPro XL.

Step Action

1

Enable save XVM in Tools | Project Settings | General | Project autosaving on download

property in Unity Pro XL. After downloading each project, the XVM file is automatically renewed.

Figure 104: XVM file autosaving

4 - Configuration


90

Step Action

2

Select Data dictionary in Project Settings | General | PLC embedded data property.

Figure 105: PLC data dictionary

Note: The Data dictionary can be used as the option for exporting the PAC data for the SCADA

application.

3

Modify the XVM path in Tools | Options… | General | Paths property.

Figure 106: XVM saving path

Table 31: PAC configuration

4 - Configuration


91

OFS Configuration

The OFS is an OPC data access server which can be used to read and/or write data on devices,

such as general PACs.

The server must have the following information for the device:

• The network to use

• The address of the device on the network

• The symbol table file to use if the device variables are accessed using symbols

The setting steps are indicated in the following tables:

Step Action

1

Create a new device alias for the project, which is called SHPP in the OFS Configuration Tool.

Set the Device address with the PAC IP address and Symbol table file which indicates the XVM

file path. Enable Using Data Dictionary in PLC Embedded Data if using data dictionary in PAC.

Figure 107: New project setting

Table 32: OFS configuration

4 - Configuration


92

SCADA Configuration

This part mainly introduces the communication configuration in the SCADA system which enables

the connection to the PAC with the OFS tool. The configuration is done via the Express

Communication Wizard in Citect Explorer.

Step Action

1

Use the existing I/O Server IOServer1 in the Wizard.

Figure 108: IO server

2

Name the new I/O device I/ODev as per the example.

Figure 109: IODev

4 - Configuration


93

Step Action

3

Select OFSOPC in OPC Factory Server, as OPC is the default communication method in this

case.

Figure 110: I/O Device selection

4

Link the I/O device with the external tag database. Select the database type Unity SpeedLink to

OFS, and select the external tag database SHPP.

Figure 111: OFS setting

Table 33: SCADA configuration

4 - Configuration


94

4.1.2. Connection Setup between HMI and PAC

The local HMI interface acts as one part of the automation control system. It supervises and

controls the hydro-turbine generator unit from the local site.

Step Action

1

Create the new project in Vijeo Designer with the Project Name ‘SHPP’. Select the Target Type

and Model according to the device used in the application.

Figure 112: New a project

4 - Configuration


95

Step Action

2

Enter the IP Address and Subnet Mask for the device

Figure 113: IP address setting

3

To set up communications between the target device and the equipment, firstly create the new

driver in IO Manager in the Navigator window of the new project.

Figure 114: IO manager

4 - Configuration


96

Step Action

4

Select the Manufacturer, Driver and Equipment according to the application.

Figure 115: New a driver

5

Set the IP Address for the equipment, the CPU module of M340 PLCs. Enable the IEC61131

Syntax for the IEC variable address syntax, and select ‘0-based’ as the Addressing Mode.

Figure 116: Equipment configuration

4 - Configuration


97

Step Action

6

Right click on the Variables in the Navigator window and select Link Variables…. Select the

UnityPro symbol export type .XVM file.

Select the necessary variable Name from the pop-up window to add on the HMI application.

Create the added variables as Variables that combine equipment and name, which differentiates

the variables from other equipment.

Figure 117: New the variables

For adding the new variables, right-click Variables in Navigator window and select New Variable

From Equipment….

Table 34: HMI configuration

4 - Configuration


98

4.2. Application Configuration

This section introduces the configuration steps for the field devices in the main control unit and

dam control unit.

4.2.1. PAC

The PAC hardware and variable are configured via UnityPro software.

The steps in the PAC modules setup are outlined in the table below.

Step Action

1

Open UnityPro. Create a new project for the M340 PAC platform and double click on the PLC

Bus in Configuration. The Hardware catalog window will then pop up. Select the local drops

from the window, which includes Rack, Supply, Communication, Discrete, Analog, Counting and

Temperature measurement.

Figure 118: PAC module configuration

4 - Configuration


99

Step Action

2

Double click on the SerialPort of the CPU module BMX P34 2020 in Configuration in Project

Browser. In the pop-up window, select the Modbus link for the Function, MAST for the Task. Set

the port Type to Master, Transmission speed to 9600 bits/s, and setup the Data length, Stop bit

and Parity mode.

Figure 119: CPU module configuration

4 - Configuration


100

Step Action

3

Double click on the analog input/output module, and configure the channels range with voltage

or current mode.

Double click on the module BMX AMI 0810. In the pop-up window, select the used Channel and

Port, and modify the Symbol, Range and Scale for each port.

Figure 120: Analog input module setting

4

Double click on the module BMX AMO 0410. In the pop-up window, modify the Symbol, Range,

Scale and Fallback value for each used port.

Figure 121: Analog output module setting

4 - Configuration


101

Step Action

5

Double click on the module BMX ART 0414. In the pop-up window, select the types of Thermo

used in the applications. Here the Thermo K is used as the example.

Figure 122: ART thermo module setting

Table 35: PAC module setting

4 - Configuration


102

The steps in the setup of the PAC variables are outlined in the table below.

Step Action

1

Open the Data Editor window to create the new variables which will be used in the project. They

can be created with elementary variable, derived variable, elementary FB instances and derived

FB instances.

Figure 123: New variables

2

The elementary variables can also be created during the section programming. The variable

creation popup window will open when the new variable is typed in by the user.

Figure 124: New elementary variable

4 - Configuration


103

Step Action

3

The variable can be selected into the animation table. Then it is possible to monitor or

modify/force these variables during the program debug phase.

Figure 125: Animation table

Table 36: PAC variable setting

4 - Configuration


104

4.2.2. Synchronizer

The synchronizer GPU-3 Hydro is configured using DEIF utility software

The device GPU-3 Hydro is connected to the PC via the PC cable. During the first connection

with the device, a driver for the UART Bridge is automatically installed, and the PC needs to

reboot to enable the driver.

Step Action

1

Once connected to the device, click the Application settings via File | Settings to configure the

application.

Select ‘Serial or USB’ as the Communication type, and ‘COM5 – DEIF USB to UART Bridge’ as

the Communication port for connecting with the configuring PC.

Figure 126: Communication setting

2

Select the symbol “Start communication with the device (F5)” or Connection | Connect. The

factory settings then transfer to the PC from the device.

Figure 127: Device connection

4 - Configuration


105

Step Action

3

Select the user level in the pop-up window. The basic level has the least authority, while the

master level has the most authority. The default password for master level is ‘2002’.

Figure 128: User and password

4

The application is thus uploaded from the device. Select the Parameters sheet by clicking the

symbol . Use the command Read from device via Connection | Batch jobs to read

the parameters.

Figure 129: Parameters read from device

4 - Configuration


106

Step Action

5

Configure the parameter by double-clicking on the line which needs modification. Take the

protection parameter “G –P> 1” for example. It is the reverse power protection, level 1. Adjust

the Setpoint and delay Timer. Set the Fail class, and/or output of the signal. After selecting

Enable, the alarm message will be generated when the condition is met.

Figure 130: Parameter setting

6 After modification, the parameters are downloaded to the device via the symbol or

Connection | Batch jobs | Write to device.

Table 37: Synchronizer configuration

4 - Configuration


107

4.2.3. Power Meter

The parameters of the power meter are set via the screen and the buttons, as shown in the figure

below. The Modbus address is set in the Unity program.

Figure 131: Front view of power meter

• Setting via Integrated Display

1. Press until the word MAINT appears

2. Press MAINT

3. Press SETUP

1. Press until 0000 appears (this is the default password)

2. Press OK

3. Press until COM (Communication) appears

4. Press COM (Communication)

5. Press COM1 (Communication port 1)

6. Press OK

7. Press to set the ADDR to 0001

8. Press OK

9. Press to set the BAUD to 9600

10. Press OK

4 - Configuration


108

5 - Implementation


109

5. Implementation

Based on the selected architecture in Chapter 2, the design in Chapter 3 and the configuration in

Chapter 4, this chapter provides information on how to implement the application which will be

released in this version:

• Start/Stop process control application

• Turbine/Excitation regulation application

• Auxiliary system control application

• Alarms display application

• Intelligent power meter integration application

• IP camera integration application

5 - Implementation


110

5.1. Start/Stop Process Control

The control of the application includes several processes:

• Start process control application

• Stop process control application

• Quick stop process control application

• Emergency stop process control application

This section uses the start process as the example

Application Action

PAC

Application

Select the SFC program type to realize the start process control. Follow the start flow chart in

the design section to program the application.

Figure 132: PAC sequence program

5 - Implementation


111

Application Action

SCADA

Application

On the Electrical page, set the property for each process step. When the steps are finished, the

background color changes, and the OK mark appears.

Figure 133: SCADA sequence setting


On the Start Sequence page, set the property for each action and condition.


5 - Implementation


112

Application Action

HMI

Application

On the Electrical page, set the property for each process step. When the steps are finished, the

background color changes, and the OK mark appears.

Figure 136: HMI sequence setting


On the Start Sequence page, set the property for each action and condition.


Table 38: Start process implementation

5 - Implementation


113

5.2. Turbine/Excitation Regulation

This section includes two regulation applications:

• Turbine regulation application

• Excitation regulation application

5.2.1. Turbine control application

Application Action

PAC

Application

Select the FBD program type to implement the turbine control application, and follow the turbine

regulation method in the application design section to complete the programming, which

includes:

• Before paralleling. The regulation command is done by PAC calculation, and the output

process value is named MC_TurPACRefHz. The object of the task is to control the power

frequency produced by the generator so it reaches the 95% network power frequency.

Figure 139: Before parallel

• During paralleling. The regulation command is done by the GPU-3 synchronizer controller,

and the output process value is named MC_TurSyncCtrlRefHz. The object of the task is to

control the power frequency produced by generator so it reaches the allowed limited

frequency error between generator and network.

Figure 140: During parallel

5 - Implementation


114

Application Action

• After paralleling. The regulation command is done by PAC calculation. This function will be

designed in next version. In this program section, the PID function is used to regulate the

active power.

• Programming for turbine regulation output. The output process value is named as

TurRegOUT.VALUE. The object of the task is to select the turbine regulation output value

with different process phases, which include before, during and after the paralleling phase.

Figure 141: PAC output

SCADA

Application

The wicket gatage of the turbine is set on the Mechanical page. Input the Level expression in

the Fill tab; enable the Specify range for the level range; check the Level at the maximum and

minimum limits, and define the Fill direction for the object.

Figure 142: SCADA application setting

5 - Implementation


115

Application Action

HMI

Application

Enable the check box Enable Vertical Fill Animation in the Fill tab on the Mechanical page for

the wicket gatage. Set the Start Point and Value Range for the expression.

Figure 143: HMI application setting

Table 39: Turbine control implementation

5 - Implementation


116

5.2.2. Excitation control application

Application Action

PAC

Application

Select the FBD programming type to implement the excitation control application, and follow the

excitation regulation method in the application design section for programming. It includes:

• Before paralleling. The regulation command is given by the PAC programs, and the output

process variable is named as MC_AVRPACRefVolt. The task of the segment is to regulate

the power voltage produced by the generator to reach 95% of the network power voltage.

Figure 144: Before paralleling phase

• During paralleling. The regulation command is made by the GPU-3 Hydro synchronization

controller, and the output process variable is named as MC_AVRSyncCtrlRefVolt. The task

of the segment is to regulate the power voltage produced by the generator to reach the

allowed limit compared with the voltage of the power network.

Figure 145: During paralleling phase

5 - Implementation


117

Application Action

• After paralleling. The regulation command is given by the PAC programs, and this function

will be accomplished in next version of the TVDA guide. In this phase, the PID function

blocks will be used to regulate the reactive power.

• Programming for excitation regulation output. The output process variable is named

AVRRegOUT.VALUE. The task of the segment is to output the excitation regulation result

according to the different phases, including before, during and after paralleling.

Figure 146: PAC output

SCADA

Application

The value of excitation regulation is output on the Electrical page of the SCADA system.

Figure 147: SCADA application setting

5 - Implementation


118

Application Action

HMI

Application

The value of excitation regulation is output on the Electrical page of the HMI application.

Figure 148: HMI application setting

Table 40: Excitation control implementation

5 - Implementation


119

5.3. Auxiliary System Control Application

This section explains how to implement the auxiliary system control application,

Application Action

PAC

Application

Select the LD program type to implement the auxiliary system start/stop. Following is the

example application for the auxiliary system started with auto run mode.

Figure 149: LD programming

Select the FBD program type to implement the auxiliary system controlling. Following is the

example application for the cooling control system.

Figure 150: FBD programming

5 - Implementation


120

Application Action

SCADA

Application

On the Mechanical page, set the property for the On / Off symbol of the auxiliary object in the

Appearance tab.

Figure 151: Symbol setting

Set the Action in the Input tab to open an action window. Define the window title for easy

understanding.

Figure 152: Action setting

Set the Numeric expression for the parameters showing values on the Mechanical page.

Figure 153: Data display setting

5 - Implementation


121

Application Action

HMI

Application

Enable the color animation for the auxiliary object, as well as the parameter value.

Figure 154: Symbol setting

Figure 155: Data display setting

Table 41: Auxiliary application implementation

5 - Implementation


122

5.4. Alarm Management Application

The alarm messages are supervised in the Alarm list of the SCADA and HMI applications. This

section presents an example of how to set the alarms in the applications.

5.4.1. In PAC application

The original limits of the parameters must be written in the variables list before generating the

alarm messages for the application.

Step Action

1

Link the process values to the alarm variables.

Figure 156: Data pretreat

2

Set the original limits for the parameters: 15 for low-low alarm limit, 20 for low alarm limit, 30 for

high alarm limit, 35 for high-high alarm limit. Set 9 for the number of process value.

Figure 157: Variable preset

5 - Implementation


123

Step Action

3

Take the DFB ProccessValueAlarm to realize the alarm application for protecting.

Figure 158: Alarm realization

Table 42: Alarm implementation in PAC

5 - Implementation


124

5.4.2. In SCADA application

Step Action

1

Define the Alarm Servers in Servers in the software Citect Project Editor.

Figure 159: Alarm server

2

Specify the Fonts in System for alarm message for different types of messages, such as:

• AlarmOn-Unacknowledged

• AlarmOff-Unacknowledged

• AlarmOn-Acknowledged

• AlarmOff-Acknowledged

• Alarm-Disabled.

Define the Font Type, Pixel Size and Colours for the messages.

Figure 160: Fonts

5 - Implementation


125

Step Action

3

Define the Alarm Categories in Alarms. Specify the Category Number, fonts and formats for the

messages.

Figure 161: Alarm categories

4

Define the Time Stamped Analog and/or Digital Alarms with the Add button to create the

messages.

Figure 162: Digital alarm

Table 43: Alarm implementation in SCADA

5 - Implementation


126

5.4.3. In HMI application

Step Action

1

Create the alarm group for the Alarms & Events in the Navigator window.

Figure 163: New alarm group

2

Define Alarm Group Name with Alarm_Active, and select Mandatory ACK as the Alarm

Behavior.

Figure 164: Alarm group setting

3

Specify the Alarm Group for the alarm variables in the Variables list in the Navigator window.

Figure 165: Alarm setting

5 - Implementation


127

Step Action

4

Right-click on the variable and select Properties. Set the parameters in Alarm.

Figure 166: Alarm message setting

Table 44: Alarm implementation in HMI

5 - Implementation


128

5.5. Intelligent Power Meter Integration

This section explains how to implement the intelligent power meter integration application. The

application for the GPU-3 Hydro is used as the example.

Application Action

PAC

Application

Select the FBD program type to implement the intelligent power meter, and use the READ_VAR

EFB to read the parameters which are located in the intelligent power meter memory through

Modbus serial. The results will be stored in the EFB output pin which is named RECP.

Figure 167: PAC setting

5 - Implementation


129

Application Action

After getting the data from the intelligent power meter, select the ST program type to implement

the power meter parameters management. The GPU-3 Hydro power meter is used as an

example here.

Figure 168: Power meter management

SCADA

Application

Set the variables for the energy status on the SHPP_Overview and Electrical pages, including

the voltage, frequency, current, power factor, active and reactive power and so on.

Figure 169: SCADA setting

5 - Implementation


130

Application Action

HMI

Application

Set the variables for the energy status on the Overview and Electrical pages, including the

voltage, frequency, current, power factor, active and reactive power and so on.

Figure 170: HMI setting

Table 45: Power meter implementation

5 - Implementation


131

5.6. IP Camera Integration

The IP address of the camera is preset to 192.168.0.8. The user name and password are preset

to be “aocct” and “solution”.

Step Action

1

Adjust the azimuth of the camera using the four direction keys and two zooming keys. Set the

number 15 in Preset. When the button Set is clicked, the number is saved in the system, so that

the camera will automatically switch to this azimuth each time the number 15 is input.

Figure 171: Camera setting

2

Add the video component into the Dam page in SCADA application, as well as the two functions

SHPPAlarm(), and RunSelectedPreset(SelectedPreset) in the Cicode script.

Figure 172: SCADA setting

5 - Implementation


132

Step Action

3

Configure the properties of the video component. Set the Object Name with PelcoCam in the

Access tab.

Figure 173: Object name

Table 46: IP camera integration

6 – Operation


133

6. Operation

This chapter introduces the basic operation of the small hydropower plant developed in this

version, using the demo cubicles as the example.

• How to switch the control mode between local and remote

• How to start/stop one group in the small hydropower plant

• How to find the alarms from the local panel and the remote SCADA

6.1. Cubicle Introduction

The introduction of the operation is based on the demo cubicles.

Layout Description

Front View

This is the front view of the cubicles, indicating the layout of the components on the door.

The meters mounted in the left cubicle indicate the energy status, such as voltage, current,

active power, reactive power and so on. The meter CSQ measures the busbar and generator

voltages and frequencies, and compares these, as well as the phase angle relationship. The

HMI interface is the local visually controlling and supervising unit. The buttons and lights enable

local controlling and monitoring of unit status, while the switch enables the control from the local

HMI interface and buttons, or the remote SCADA system.

The protector Sepam G87 and synchronizer GPU-3 Hydro display panel mounted on the front

door of the right cubicle protect and control the process. The single line of the power distribution

mimics the status of the main breaker with closed or open.

Figure 174: Front view

6 – Operation


134

Layout Description

Inside View

This is a view inside the cubicles. The generator and motor are mounted in the bottom of the

right cubicle, simulating the energy generating process.

Figure 175: Inside view

Table 47: Cubicle introduction

6 – Operation


135

6.2. How to switch the control mode between local and remote

The local control mode enables operation from local cubicles, including the switches and the push

buttons, as well as the operation from the HMI panel. Meanwhile, the control from the SCADA

application is disabled. The remote control mode enables the operation from the SCADA

application, while control from the local cubicle, including the switches, buttons and HMI panel, is

disabled.

Step Action

1

Turn the mode switch to LOCAL position.

Figure 176: Local position of switch

6 – Operation


136

Step Action

2

The local operation from the local cubicle is enabled - both the push buttons and HMI panel -

and the control from the SCADA application is disabled.

Figure 177: Push buttons


Figure 179: SCADA application

6 – Operation


137

Step Action

3

Turn the mode switch to REMOTE position.

Figure 180: Remote position of switch

4

The remote operation from the SCADA application is enabled, and the control from the HMI

panel is disabled. In this position, the signals from the local push buttons are shielded.


Figure 182: SCADA application

Table 48: Control mode

6 – Operation


138

6.3. How to start/stop one group in the small hydropower plant

The start and stop processes can be executed either by pressing the push buttons on the cubicle,

or from the HMI panel (locally) or the SCADA application (remotely).

This section introduces the execution of start and stop processes operating locally on the HMI

panel for example.

Step Action

1

Turn the mode switch to LOCAL position.

Figure 183: Local position of switch

2

Click on the Start unit button to begin the start-up process.

Figure 184: Start unit

6 – Operation


139

Step Action

3

This screen shows the unit during the starting process.

Figure 185: Unit starting

4

When the unit is running properly, click on the Stop unit button to stop the unit.

Figure 186: Stop unit

6 – Operation


140

Step Action

5

This screen shows the unit during the stopping process.

Figure 187: Unit stopping

Table 49: Start and stop process

6 – Operation


141

6.4. How to find the alarms from the local panel, or remote SCADA

When alarm messages occur, the information is monitored both in the SCADA application and in

the HMI panel.

Application Description

SCADA

application

All the times, the three most recent alarm messages can be viewed at the bottom of the SCADA

application.

Figure 188: Latest alarm message on SCADA

All the alarm messages are displayed in the Alarm_Active and Alarm_Summary lists.

Figure 189: Alarm list on SCADA

6 – Operation


142

Application Description

HMI

Application

All the times, the two most recent alarm messages can be viewed at the bottom of the HMI

application.

Figure 190: Latest alarm messages on HMI panel

All the alarm messages are displayed in the Alarm Summary list.

Figure 191: Alarm list on HMI panel

Table 50: Alarm

7 - Validation


143

7. Validation

This chapter specifically addresses the performance of the small hydropower plant application,

which includes:

• SOE Application Performance

• Remote Access Application Performance

Next version of TVDA guide will be dedicated to the validation of these performances with the

architecture which is selected by this version.

7.1. SOE Application Performance

The SOE (Sequence of Events) application is very popular in a hydropower plant, and can be

used to find the root cause when the fault occurs. The SOE application performance is also very

important, as it needs to record the events with time stamps, with a desired precision of 1ms.

7.2. Remote Access Application Performance

This release does not cover the remote access architecture between the local PAC and a remote

control and monitoring center through the telemetry communication protocol which includes

IEC60870-101/104 or DNP3.0.

7 - Validation


144

8 - Conclusion


145

8. Conclusion

This TVDA guide starts with the introduction of the small hydropower plant process, and helps

users gain a general knowledge of the main processes and functions. Then, from Chapters 2

through 5, the guide introduces the steps involved in setting up a monitoring and control system

for small hydropower plant process, including the selection of the appropriate Schneider Electric

PlantStruxure architecture adapted to the process; the design of the application, hardware and

software; the configuration of the devices and communication used in the system; and the

implementation of the PAC and SCADA programming to realize the small hydropower plant

process. In Chapter 6, users see how to operate from local cubicles and a remote SCADA system.

Chapter 7 explains users the performance for the SOE and remote access applications will be

validated in next version.

This guide also offers one demo application for helping users to better understand the small

hydropower plant process, including PAC, SCADA and HMI applications. Meanwhile, one

dedicated cubicles and control center system is setup to realize the process. With the friendly

HMI interface, it is convenient for operators to operate from local site, with less chances of

malfunction. The SCADA application enables the users controlling and monitoring from the

remote site, providing the services like alarm and events, and trends. The solution offered for the

small hydropower plant in this guide has a higher stability and reliability, efficiently reduces the

power disturbance during paralleling and the loss of the devices, and decreases the man-hour

and cost during maintenance.

This is the first version for the small hydropower plant TVDA guide. It includes some of the

applications, as well as the start/stop process, turbine and excitation regulation, generation

protection, auxiliary control system and IP camera integration. In the next version of guide, the

applications for SOE and remote access will be added, and some processes and functions will be

updated.

All in all, referring to this guide, the applications and the platform, users are able to setup their

own monitoring and control system for a small hydropower plant process using Schneider

Electric’s PlantStruxure offers.

8 - Conclusion


146

9 - Appendix


147

9. Appendix

9.1. Glossary

This table explains the glossaries used for this document.

Term Description

HMI Human Machine Interface

Modbus SL Modbus Serial Line – an application layer messaging protocol

PAC Programmable Automation Controller

SCADA Supervisory Control and Data Acquisition

SOE Sequence Of Events

TVDA

Tested, Validated, Documented Architecture – provides technical

guidelines and recommendations for implementing technologies to

address customer needs and requirements

Table 51: Glossary

9 - Appendix


148

9.2. Bill of material and software

The following table summarizes all of the selected hardware:

Description Reference Firmware Function

PAC

M340

BMXXBP0800

BMXCPS2000

BMXP342020

BMXDDI6402K

BMXDDO6402K

BMXAMI0810

BMXAMO0410

BMXART0414

BMXNOR0200H

BMXEHC0200

---

---

2.4

---

---

1.1

2.1

1.0

1.5

1.0

Rack

Power supply

CPU

Digital input

Digital output

Analog input

Analog output

Temperature measurement

Remote terminal unit

Counter

HMI XBTGT7340 2.0 HMI local interface

Switch TCSESM083F2CU0 6.0 Ethernet switch

Synchronizer GPU-3 Hydro --- Synchronization

AVR --- --- Excitation control

Protector Sepam G87 --- Generator protection

AC-Transducer TAS-331DG --- Convert the digital pulse into analog output

Intelligent

Power meter PM810 12.200 Intelligent energy status detection

Synchronizing meter

CSQ-3 --- Synchronizing indication

Power meter WQ --- Active and reactive power detection

Current meter VDQ96-sw --- Current status detection

Voltage meter EQ96-sw7 --- Voltage status detection

Variable speed

drive

ATV61

ATV312

---

5.1

Device control in auxiliary system

Drive the motor

Camera Pelco --- Real-time monitoring

Table 52: bill of material

9 - Appendix


149

The following table summarizes all of the selected software:

Description Software version Function

Unity Pro V6.0 PAC configuration and programming

Vijeo Citect V7.20 SP2 SCADA application

Vijeo Designer V6.0.0.201 HMI application

OFS Configuration Tool V3.34 Communication between PAC and SCADA

Table 53: bill of software

9 - Appendix


150

PlantStruxure™, Altivar™, PlantStruxure™, Unity Pro, Vijeo Citect™, and Vijeo Designer™ are trademarks or

registered trademarks of Schneider Electric. Other trademarks used herein are the property of their respective

owners.

Schneider Electric Industries SAS

Head Office

35, rue Joseph Monier

92506 Rueil-Malmaison Cedex

FRANCE

www.schneider-electric.com

Due to evolution of standards and equipment, characteristics indicated in texts and images in this document are binding only after confirmation by our

departments.

Print:

Version 5.02 – 08 2012

Develop your project

Documents

Transcript of Develop your project