I

Automatic Power Factor Improvement and Monitoring by Using PLC &

SCADA

A Project Submitted

By

Under the Supervision of

MR. DEEPAK KUMAR CHOWDHURY Chairman

Department of Electrical and Electronic Engineering

Port City International University

Department of

Electrical and Electronic Engineering

August, 2019

Port City International University

MOHAMMAD SIFUR RAHMAN

MIZANUR RAHMAN

MD. ASHRAFUL ALAM

JOY BARUA

MD. ABDUL KARIM

DIPU CHOWDHURY

ID: EEE 01005783

ID: EEE 01005829

ID: EEE 01005809

ID: EEE 01005833

ID: EEE 01005849

ID: EEE 00905587

II

Automatic Power Factor Improvement by Using PLC & SCADA

A project submitted to the Electrical and Electronic Engineering Department of the Engineering Faculty,

Port City International University in partial fulfillment of the requirements for the degree of Bachelor of

Science in Electrical and Electronic Engineering.

MOHAMMAD SIFUR RAHMAN

MIZANUR RAHMAN

MD. ASHRAFUL ALAM

JOY BARUA

MD. ABDUL KARIM

DIPU CHOWDHURY

ID: EEE 01005783

ID: EEE 01005829

ID: EEE 01005809

ID: EEE 01005833

ID: EEE 01005849

ID: EEE 00905587

Department of

Electrical and Electronic Engineering

August, 2019

Port City International University

III

DECLARATION

This is to certify that this thesis “Automatic Power Factor Improvement and Monitoring by Using

PLC & SCADA” is my original work. No part of this work has been submitted elsewhere partially or

fully for the award of any other degree or diploma. Any material reproduced in this project has been

properly acknowledged.

Students’ names & Signatures

MOHAMMAD SIFUR RAHMAN

MIZANUR RAHMAN

MD. ASHRAFUL ALAM

JOY BARUA

MD. ABDUL KARIM

DIPU CHOWDHURY

IV

APPROVAL

The Project titled “Automatic Power Factor Improvement and Monitoring by Using PLC & SCADA”

has been submitted to the following respected members of the Board of Examiners of the department of

Electrical and Electronic Engineering in partial fulfillment of the requirements for the degree of Bachelor

of Electrical and Electronic Engineering on August, 2019 by the following student and has been accepted

as satisfactory.

MOHAMMAD SIFUR RAHMAN

MIZANUR RAHMAN

MD. ASHRAFUL ALAM

JOY BARUA

MD. ABDUL KARIM

DIPU CHOWDHURY

ID: EEE 01005783

ID: EEE 01005829

ID: EEE 01005809

ID: EEE 01005833

ID: EEE 01005849

ID: EEE 00905587

Supervisor

MR. DEEPAK KUMAR CHOWDHURY Chairman

Department of EEE

Port City International University

VI

ACKNOWLEDGMENT

First and foremost, we would like to express our special thanks to our supervisor MR. DEEPAK KUMAR

CHOWDHURY, Chairman, Department of Electrical and Electronic Engineering, Port City International

University for giving our enormous support, motivation and invaluable advices regarding this project. He

has been my idol and role model in the last couple of months and we are grateful to Almighty Allah for

giving our opportunity to learn under such a great supervisor.

Secondly, we would like to express our special thanks to all the faculty members of Department of Electrical

and Electronic Engineering, Port City International University for giving our comments and invaluable

advice for further extension of this project.

We would like to thank my family and friends, without whose patience and support we would never have

reached our goal.

MOHAMMAD SIFUR RAHMAN

MIZANUR RAHMAN

MD. ASHRAFUL ALAM

JOY BARUA

MD. ABDUL KARIM

DIPU CHOWDHURY

VII

TABLE OF CONTENTS

ABSTRACT 1

CHAPTER 1: INTRODUCTION Page 2-10

1.1 Introduction 2

1.2 Objectives 4

1.3 Methodology 4-5

1.4 Choosing Monitoring Location 5

1.5 System Discussion 6-9

1.5.1 Experimental Setup 6

1.5.1.1 Input Design 6

1.5.1.2 Output Design 6-7

1.5.1.3 Power Meter Wiring 7

1.5.1.4 Terminal Block Wiring 8

1.5.1.5 PLC Wiring 8

1.5.1.6 Ladder Programming 9

1.5.1.7 Final SCADA Model 9

1.6 Results and Discussion 10

1.6 Application of the project 10

CHAPTER 2 : LITERATURE REVIEW Page 11-13

Literature Review 11-13

CHAPTER 3 :

THEORETICAL OVERVIEW

Page 14-36

3.1 List Of Electrical Components 14

3.1.1. PLC SIEMENS S7 200 (CPU 215 DC/DC/DC) 14-17

3.1.2. Power Supply 220V AC TO 24V DC 17-18

3.1.3. Software Micro win v4.0 SP9 19-20

3.1.4. WinCC Flexible (SCADA) 20-21

3.1.5. Electromechanical Relay 21-24

3.1.6. RS 485 USB-MPI PLC Programming Cable 25-26

3.1.7. Transformer 220v AC to 110v AC 26

3.1.8. PR-4116 (Universal Transmitter) 26-28

VIII

3.1.9. CT-Current Transformer 28-29

3.2.0. Weidmuller WAS1 CMA 1/5/10A ac 29-30

3.2.1. Capacitor Bank 31-32

3.2.2. Voltage Regulator 32-33

3.2.3. Load Fan 33-34

3.2.4. CT-K type sensor 34-35

CHAPTER 4: BLOCK DIAGRAM Page 36-40

4.1 Block Diagram 36-37

4.2 Flow Chart 38

4.3 Schematic diagram 39

4.2.1 Circuit Operation 40

4.2.2 Working Principle 40

4.2.3 Circuit Application 40

CHAPTER 5:

DESIGN AND IMPLEMENTATION

Page 41-42

5.1 Body design: 41

5.2 Software Description 42

5.3 Hardware 42

CHAPTER 6:

FUTURE WORK AND CONCLUSION

Page 43-27

6.1 Applications 43

6.2 Advantages 43

6.3 Benefit 44

6.4 Disadvantages 44-45

6.5 Future Enhancements 45

6.6 Conclusion 45

REFERENCES 46-47

IX

List of Figures

Figure No Figure Name

Page

Figure 1.1: Relation between active power and reactive power 2

Figure 1.2: Power Angle Triangle 3

Figure 1.3: Capacitors Connected Parallel To The Load. 5

Figure 1.4: Input design 6

Figure 1.5: Output design 7

Figure 1.6: Power meter wiring 7

Figure 1.7: Terminal block wiring 8

Figure 1.8: PLC wiring 8

Figure 1.9: Ladder programming 9

Figure 1.2.1: SCADA model 9

Figure 3.1: PLC SIEMENS S7 200 Pin Diagram 15

Figure 3.2 Power Supply 220v AC to 24v DC 18

Figure 3.3: Micro WIN V4.0 19

Figure 3.4: WinCC Flexible 21

Figure 3.5: Electromechanical Relay Pin out 22

Figure 3.5.1: Eelctromechanical Relay Coil – Magnetic Field 22

Figure 3.5.2: Electromechanical Relay Working (OFF condition) 23

Figure 3.2.3: Electromechanical Relay Working (ON condition) 23

Figure 3.6: RS 485 USB-MPI PLC Programming Cable 25

Figure 3.7: Transformer 220v AC to 110v AC 26

Figure 3.8: PR-4116 Universal Transmitter 27

Figure 3.9: Current Transformer 29

Figure 3.10: Weidmuller WAS1 CMA 29

Figure 3.11: Capacitor Bank 31

Figure 3.12: Voltage Regulator and Pin out 33

Figure 3.13: Load Fan 33

Figure 3.14: CT-K type sensor 34

Figure 4.1: Block diagram of project 37

Figure 4.2: Flowchart of working process 38

X

Figure 4.3: Circuit diagram of the prototype model 39

Figure 5.1: Front View 41

Figure 5.2: Side View 41

Figure 5.3: Full View 41

Figure 5.3: Output of the Project 41

Figure 5.4: Block diagram of experimental set 42

XI

List of Tables

Table No Table Name

Page

Table 1.1: Bluetooth module Pin Configuration 10

Table 3.1: Siemens S7-200 (CPU 215 DC/DC/DC) 16-17

Table 3.2: Power Supply 220v AC to 24v DC Configuration 18

Table 3.3: WinCC SCADA Configuration 21

Table 3.4: PR-4116 Universal Transmitter and Confrontation 28

Table 3.5: Weidmuller WAS1 CMA and Configuration 30

Table 3.6: Fan and Configuration 34

Table 4.1: Three Phase Induction Motor Configuration 36

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ABSTRACT

Power factor correction (PFC) is a process of negotiating the unwanted effects of electric loads that

create a power factor less than one. Power factor correction may be applied either by an electrical

power transmission utility to enhance the efficiency of transmission network. In this paper three

transformers of different ratings have been used which acts as inductive load each of which produce

different power factor variation. The power factor of the supply line is directly monitored by the Power

Meter which is connected in parallel to the supply line. The value of the capacitance (capacitor bank)

required for correcting the power factor variation due to each transformer and their

combination is found out separately. Capacitor bank for the respective load is triggered by using PLC,

which connects the capacitor bank parallel to the load and thereby bringing the power factor near to

unity. This paper represents the most effective automatic power factor improvement and monitoring

by using static capacitors which will be controlled by a PLC with very low cost although many existing

systems are present which are expensive and difficult to manufacture. In this study, many small rating

capacitors are connected in parallel and a reference power factor is set as standard value into the PLC.

Suitable number of static capacitors is automatically connected according to the instruction of the PLC

to improve the power factor close to unity. Some tricks such as using resistors instead of potential

transformer and using one of the most low cost PLC SIEMENS S7-200 CPU215 DC/DC/DC which

also reduce programming complexity that make it most economical system than any other controlling

system.

Keywords: PLC SIEMENS S7-200 CPU215 DC/DC/DC, current transformer, comparator, relay,

capacitor, Software Micro win v4.0 SP9, Win CC Flexible (SCADA), Supervisory Control and Data

Acquisition, Power meter, Industrial control system, Remote control unit.

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CHAPTER 1

INTRODUCTION

1.1 Introduction

Power Factor can be explained as relationship between the active power and apparent power.

For understanding power factor, look at the figure 1 in which a horse is dragging a car along a

track. As the railroad path is not even, the horse should pull the car at an angle to the track.

Now the horse pulls the car at some angle to the direction in which car is travelling. The force

needed to pull the car along the given track is working power. Total power in this case is horse

power. As a result of the angle created by the horse’s pull, (not all horse power taken into

account) is utilized to drag the car along the given path. The car cannot move in sideways

direction; thus the effort made by horse in sideways is not taken into account. The angle which

the horse force is applied is basis of power factor. It can be defined as the ratio between real

powers to apparent power. If the horse is present between the centers of the track, the angle

made by force because of side pull decreases and the real power apparent power becomes

almost equal. As a result, the ratio between real and apparent power or the power factor of

given system becomes equal to 1. As the power factor tends to 1, the reactive power tends to

0.

Real Power

Power Factor (pf) =

Apparent Power

Fig. 1.1: Relation between active power and reactive power

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The relation between the types of power used to run the given force system is generally as a right-

angled triangle as in figure 1.1. Active power is indicated at right angles to reactive power, generally

known as waste as it is out-of-phase, and work done is not taken into account. So, because of the

angle created horse needs to do more work compared to the required original work.

Fig. 1.2: Power Angle Triangle

Power Factor of a system has generally a value between 0 and 1 which is equal to the ratio of active

power to apparent power or Cos φ as shown in fig 1.2. The bigger the number is, the more powerful

the system becomes. So, a system with a Power Factor of 0.9 is much superior to one with a low

Power Factor of 0.6. An electrical system which has power factor of 1 uses 100% useful current

Without any power loss.

Electricity distribution companies own and operate the infrastructure required to connect customers

to the network. At present, the low-voltage three-phase four-wire distribution systems are facing the

poor power quality problems such as high reactive power burden, unbalanced load excessive neutral

current and voltage distortion. Industrial plants typically present a poor power factor to the incoming

utility due to proliferation of diode and thyristor rectifiers, induction motors and harmonic rich loads.

Low power factor is the predominant problem nowadays. Poor power factor has various consequences

such as increased load current, large KVA rating of the equipment, greater conductor size, larger

copper loss, poor efficiency, poor voltage regulation and reduction in equ ipment life.

Therefore it is necessary to solve the problem of poor power factor. To improve the power factor,

shunt capacitor banks have been applied in many power distribution systems and industrial circuits

for reactive power compensation. The power factor regulator is designed to optimize the control of

reactive power compensation. Reactive power compensation is achieved by measuring continuously

the reactive power of the system and then compensated by the switching of capacitor banks. At the

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end user connection points, the integrating breaker switched capacitor banks into a compact design

with the intelligent control unit offers a reliable and affordable reactive power compensation

solution for distribution systems. The benefits of doing so are:

Improvement in power factor, which either eliminates or reduces the demand charges imposed

by the utility.

Reducing the energy loss in electrical conductors by reducing the required current.

Maintaining a proper voltage level at the end user for improved productivity of industrial

processes.

Releasing of valuable system capacity.

Increasing the useful life of pieces of distribution equipment.

Improvements in planning where planning engineers can more precisely decide to place

additional capacitor banks to account for load growth.

1.2 Objectives

We have chosen this topic to modern technology system of improvement and monitoring power factor using

PLC and SCADA.

To develop an automatic Power actor system protection and control this system using PLC and

SCADA.

To increase the efficiency of an industrial plant by incorporating the automation system which

replaces the manual Protection of Power system protection unit system.

1.3 Methodology

The problem of low pf can be solved by connecting power factor correction capacitors to the industrial

electrical system. The capacitors can be of low rating for lower rated loads, and rating of capacitors

will increase for loads with high rating.

The capacitors are made as a combination according to the respective loads and then they are

connected parallel to the load as shown in figure 1.3. Capacitors give needed reactive power (KVAr)

to the given industrial power supply. By providing the reactive power, it decreases the total amount

of apparent power supplied.

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Fig. 1.3: Capacitors Connected Parallel To The Load.

1.4 Choosing Monitoring Location

Obviously, we would like to monitor conditions at virtually all locations throughout the system to

completely understand the overall power quality. However, such monitoring may be prohibitively

expensive and there are challenges in data management, analysis, and interpretation. Fortunately,

taking measurements from all possible locations is usually not necessary since measurements taken

from several strategic locations can be used to determine characteristics of the overall system. Thus,

it is very important that the monitoring locations be selected carefully based on the monitoring

objectives. Another important aspect of the monitoring location when characterizing specific power

quality problems is to locate the monitors as close as possible to the equipment affected by power

quality variations.

It is important that the monitor sees the same variations that the sensitive equipment sees. High-

frequency transients, in particular, can be significantly different if there is significant separation

between the monitor and the affected equipment.

A good compromise approach is to monitor at the substation and at selected customer service entrance

locations. The substation is important because it is the PCC for most rms voltage variations. The

voltage sag experienced at the substation during a feeder fault is experienced by all the customers on

other feeders supplied from the same substation bus. Customer equipment sensitivity and location on

a feeder together determine the service entrance locations for monitoring. For instance, it is valuable

to have a location immediately down line from each protective device on the feeder.

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1.5 System Discussion

In this section we will discuss about system process. There is some process.

1.5.1 Experimental Setup

Following are the experimental setup made for the experiment:

1.5.1.1 Input Design

The main components of the input side are the transformer (i.e. the inductive load) and the 4 pole

relay. The 4 pole relay has 14 terminals. The terminals 1,2,3,4 are normally closed and 5,6,7,8 are

normally open. Terminals 9,10,11,12 are common terminals 13 and 14 are meant for excitation of

relay.

Fig. 1.4: Input design

In the figure 1.4 the excitation coil and the switch S (toggle switch) are shown. When S is closed, the

coil gets energized by the 230 V supply. Hence the terminals of relay switch gets attracted towards

the normally open terminals. The transformer is connected across the terminals 7 and 8. So the circuit

is completed and the load gets active by 230 V supply. Here the 24 V supply is provided by the SMPS.

Whenever the load gets ON, +24 V is given to the PLC through the 5th terminal.

1.5.1.2 Output Design

The output side mainly consists of the capacitor banks and the 2 pole relay as shown in fig. 1.5. The

2 pole relay is energized by the 24 V dc supply. This supply is fed from the PLC i.e. once the

transformer load is ON, a 24 V dc supply comes across the PLC. As a result, PLC energizes the relay

coils and the corresponding capacitor bank will be switched ON. Hence the power factor is corrected

to a value nearly equal to 1.

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Fig. 1.5: Output design

1.5.1.3 Power Meter Wiring

The most important component in the hardware is the power meter. The main ports in a power meter

are the supply port, voltage port, current port and communication port as in fig. 6. A 230V supply will

be given to the supply port. Here voltage port is used to measure the voltage across the load and the

current port is used to measure the current. So the voltage port is connected parallel to the supply and

the current port is connected in Series with the supply. The communication port is connected to the

serial adapter of the PLC, so it reads the power meter.

Fig. 1.6: Power meter wiring

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1.5.1.4 Terminal Block Wiring

The first two wires are the supply wire through these wires the PLC feeds 24 V dc supply to the

hardware as shown in fig. 1.7. 2 represents three wires which connects the three transformer loads

to the PLC input port , so that the PLC gets indication about the status of input side . 3 represents

the six wires which connects the output ports of the PLC to the six capacitor banks. 4 represents

the three wires which connect the communication port of the power meter to the PLC.

Fig. 1.7: Terminal block wiring

1.5.1.5 PLC Wiring

As shown in fig. 1.8, the three transformer loads are connected to the input ports of the PLC. The

common terminal of the input side is connected to the negative terminal of SMPS. Connections from

the capacitor banks are given to the output port of the PLC. The common terminal of the output side

is connected to the positive terminal of SMPS. The communication port of the PLC is connected to

the system via the communication cable and the serial adapter is connected to the powermeter.

Through the supply ports, a 24 V dc supply is given to the PLC.

Fig. 1.8: PLC wiring

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1.5.1.6 Ladder Programming

Ladder logic is a programming language that represents a program by a graphical diagram based on

the circuit diagrams of relay-based logic hardware. It is primarily used to develop software for

Programmable Logic Controllers (PLCs) used in industrial control applications. These programmes

are then downloaded to PLC using communication cable. Ladder program is shown in fig. 1.9.

Fig. 1.9: Ladder programming

1.5.1.7 Final SCADA Model

SCADA model has been designed as per the requirements to show the different parameters like load,

switches, capacitor banks etc. It also facilitates the user to select whether he wants to select automatic

or manual triggering of capacitor banks. Even the power meter has been synchronized to show the

fluctuations in the power factor directly on the users screen as shown in fig. 1.1.1.

Fig. 1.1.1 SCADA model

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1.6 Results and Discussion This chapter provides the necessary information for Result and Discussion. In this section we will

discuss about system process. There is some process.

A project on “Industrial Power Factor Correction” has been done. The aim of the project was to

improve the power factor up to 0.9 and it was possible to improve the power factor till 0.71.

Table 1.1: Bluetooth module Pin Configuration

Load(s) “ON” Corresponding

Capacitor Banks Earlier PF Corrected PF

L1 CB1+CB2+CB3 0.277 0.557

L2 CB2+CB6 0.502 0.710

L3 CB6 0.380 0.613

L1+L2 CB1+CB3+CB5+CB6 0.345 0.598

L2+L3 CB2+CB3+CB6 0.480 0.700

L1+L3 CB1+CB2+CB5+CB6 0.300 0.601

L1+L2+L3 CB3+CB4 0.342 0.62

Table 1 shown above explains the final result of corrected power factor. There are total seven cases

which has been considered. In case 1, load 1 is switched on and earlier pf was 0.277. After triggering

of capacitor banks 1, 2 and 3, corrected pf was found to be 0.557. In second case load 2 is switched

on. After triggering the corresponding capacitors the corrected pf was found to be 0.710. In third case

the corrected pf was found to be 0.613. After this combination of loads were switched on. In case

when load 1 and 2 was switched on, earlier pf was found to be 0.345. After triggering

the required capacitor banks the corrected pf was found to be 0.598. Similarly in fifth and sixth case

corrected pf was found to be 0.700 and 0.601 respectively. In last case all three loads were taken into

account. After switching the required capacitors the corrected pf was noted as 0.626.

1.7 Applications of the project

Industry

Residential Area

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CHAPTER 2

LITERATURE REVIEW

A Programmable Logic Controller Based Power Factor Controller for a Single Phase

Induction Motor. [4]

Power factor is the value of a system that reflects how much power is being borrowed from Power

Company for the system. If power factor becomes poor than unity, then organization or industry

requires more current for supplying same amount of power.as the current increases line losses also

increases because of voltage drop=I2R.Induction motor is widely used in industries due to

their features like low cost, reliability, robustness. At no load induction motor has very low power

factor of about 0.33 as the load goes on increasing the power factor also get improved as we go towards

full load. Power factor correction serves to correct low power factor by reducing phase difference

between voltage and current phasors.

Keywords: Programmable logic controller (PLC), Current transformer, Relays, Condenser, SMPS, 1

phase induction motor

Power Factor Correction of Inductive Loads using PLC. [5]

This paper proposes an automatic power factor correction for variable inductive loads, most

dominantly induction motors (IM) utilizing the Programmable Logic Controllers (PLC). This

hardware implementation of a 3Ø Inductive load system focuses on the automatic correction of

power factor using PLC. With the help of PLC, different performance parameters current

level, real power and inductive power are obtained and logged in the PC. Using PLC program,

according to control strategy to obtain a pre specified power factor a set of capacitors sized in

a binary rate will be switched on or off with the help of switching relays and contactors. This

PLC control strategy relies on a lookup table which is prepared based on two input parameters

- peak current and power factor, at constant voltage. From these parameters, PLC will calculate

reactive power of the system and accordingly the right sequence of the capacitors are switched

on in order to compensate reactive power. Keyword: Automation, Power factor improvement,

inductive loads, capacitors and Programmable Logic Controllers PLC.

.

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Recent Trends in SCADA and Power Factor Compensation on low Voltage Power

Systems for Advanced Smart Grid. [6]

This paper presents an extending a smart grid to switched capacitor banks at the low-voltage three-

phase four-wire distribution systems. New power factor regulators using MSP430 microcontrollers

will be proposed instead of ordinary regulators to be suitable for connecting to the Supervisory Control

and Data Acquisition (SCADA) system that actually has been implemented since 2005 in the Middle

Egypt Electricity Distribution Company (MEEDCO). In MEEDCO, there are quite a lot of mounted

power factor regulators in different locations, but most of these regulators are far from each other and

also far from the control center of MEEDCO's SCADA system. This paper also discusses the suitable

technology to communicate the suggested regulators with the control center efficiently and how this

will be done in the framework of a secure smart grid.

Keywords— Data Transfer, MSP430, Smart Grid, SCADA, Security.

Analysis of Rectifier Circuits with Power Factor Correction. [7]

Power Factor, the ratio between the real power and the apparent power forms a very essential

parameter in power system. It is indicative of how effectively the real power of the system has been

utilized. With rapid development in power semiconductor devices, the usage of power electronic

systems has expanded to new and wide application range that include residential, commercial,

aerospace and many others. Power electronic interfaces have proved to be superior. However, their

non‐linear behavior puts a question mark on their high efficiency. The current drawn by the interfaces

from the line is distorted resulting in a high Total Harmonic Distortion (THD) and low Power Factor

(PF). Individually, a device with harmonic current does not pose much serious problem however when

used on a massive scale the utility power supply condition could be deteriorated. Other adverse effects

on the power system include increased magnitudes of neutral currents in three‐phase systems,

overheating in transformers and induction motors etc. Hence, there is a continuous need for power

factor improvement and reduction of line current harmonics. Development of new circuit topologies

and control strategies for Power Factor Correction (PFC) and harmonic reduction has become

essential. This project aims to develop a circuit for PFC using passive filters.

Automatic Power Factor Correction by Continuous Monitoring. [8]

The Purpose of this paper is implementing a new technology for power factor improvement of 3 phase

induction motor as well as for single phase induction motor , as improvement of power factor is

necessary for industrial as well as domestic areas & to make power factor as close as unity without

13 | P a g e

facing penalty from electrical distributers. As we know in industries most of motor which is usually

used is induction motor and induction motor having low power factor also. Home appliances which

are generally used are generally having low power factor. Hence there is need of power factor

improvement in case of household appliances as well as in industrial purpose. Induction motor is

most widely used motors in industries .As name of this motor specifies this motor having low power

factor. Hence there is need of power factor improvement. .

PLC & SCADA based Power Quality Improvisation in Induction Motor. [9]

Energy conservation has been one of the most talked about topics in the past decade or so because of

the decrease in the energy resources. Power shutdown is a major problem now-a-days and it occurs

because a lot of power is wasted in industries. Energy monitoring and controlling deals with this type

problem in a effective ways. We implement three phase induction motor monitoring and controlling

with the help of PLC and SCADA. PLC can be connected with computer using RS-232 or Ethernet

cable. PLC monitor different perimeter of IM such as over and under voltage, over current, over

speed, etc. If any contingency will arise, SCADA give alert or shutdown system automatically.

.

KEYWORDS: Power quality, Energy Audit, Monitoring and Controlling System, PLCs, SCADA

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CHAPTER 3

THEORETICAL OVERVIEW

We describe their theatrical overview of the project. For power factor improvement and monitoring

system, Using PLC, power supply Ac to DC, SCADA, MicroWind software, Capacitor Bank, Load.

This is totally automatic system output showing SCADA in computer monitor.

3.1 List of Electrical Components

In this chapter we will discuss various types of equipments. Which we used to build our project, and

these equipments are useful for various projects in our daily life.

3.1.1 PLC SIEMENS S7 200 (CPU 215 DC/DC/DC):

Brief about PLC SIEMENS S7 200 (CPU 215 DC/DC/DC)

The power factor correcting circuit is driven by S7-300 PLC which is shown in fig.4,

it consists of several modules power supply, CPU, digital inputs, Digital outputs, and

Analog to-Digital converter. The digital input module is a 24 V DC, 13- - ut ports. The analog module

is a 2-channel, 12-bit analog to-digital converter (ACD). The digital output module is a 32 port, 0.5 A

output current, 24 V DC rated load voltage. The two outputs of the interfacing circuit are given to the

PLC in the following way; the output of the phase angle measuring circuit is given to the digital input

module of the PLC whereas the output of the current peak detector is given to the input of analog to

digital converting module. The PLC then calculates the lagging reactive power of the system, and

accordingly gives signal to digital output module. The digital output module has the switching circuit

connected to it, which in turn connects the sequence of capacitors from capacitor bank which is shown

in fig.3.1.

24 on board I/O

12kbytes programmer memory

5kbytes data memory

6 x 30 kHz high speed counter

In-built real time clock

4 x 20 kHz pulse train outputs (dc powered model only)

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Figure 3.1: PLC SIEMENS S7 200 Pin Diagram

Output ratings are 28.8Vdc maximum for transistor outputs (stock no. 488-6713), 30Vdc or 240Vac

maximum for relay outputs (stock no. 488-6814).

Siemens S7-200 Base Units - 3rd Generation

The S7 brings to the user a powerful solution to a host of control applications, which is easy to adapt

and expand the system. The S7 is a family of PLCs which allows the user to tailor their selection of

components which best suits their requirements, and is the long term successor to the highly successful

S5 range. Whatever the S5 can do, the S7 can do more quickly and more easily. The 3rd generation

of S7-200 now builds on the success of the original range and exploits new CPU's in order to produce

even faster and more powerful range of PLC's. The range of CPU's available has been increased with

the introduction of the new 224XP, as has the range of digital, analogue and communications

expansion modules. For the faster type of application real time control is easily achieved by use of the

comprehensive range of built-in interrupts. Timed, Communication, High Speed Counter, High Speed

Pulse Output, and hardware interrupts are all available, and the implementation of a priority table

means that all the interrupts can work simultaneously. Communications with S7-200 is built in. Inter

PLC communications is achieved using two wire network which can be up to 1200 meters and can

have up to 126 nodes. In "Freeport" mode the PLC's RS-485 port runs in free ASC11 mode making it

possible to communicate with other devices. In line with Siemens objective to make the programming

of S7-200 as user friendly as possible MicroWin programming software has been further improved.

These improvements all help minimise program development time. This has been achieved by

including more and improving existing "wizards". These help program developers with the more

routine/complex parts of their programs, e.g. TD200 configuration, PID loop configuration, High

Speed Counter configuration, etc. Inclusion of context sensitive help also means that all the

information required is at the users fingertips.

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New CPU hardware support provides the option to turn off run mode edit to obtain more program

memory.

CPU 224XP supports onboard analogue I/O and two communication ports CPU 226 includes

additional input filters and pulse catch facility 0.22μs processing time per instruction.

Modular Expansion up to 256 total I/O (except S7-221) Powerful Instruction Set, and Real Time

performance Programming via RS-485 common port All models have EEPROM memories for user

program storage 2 or 4 x 30kHz pulse train outputs (dc powered models only ).

Specifications

Table 3.1: Siemens S7-200 (CPU 215 DC/DC/DC) Configuration

Attribute Value

For Use With SIMATIC S7-200 Series

Manufacturer Series S7-200

Number of Inputs 14

Number of Digital Inputs 14

Input Type Analogue, Digital

Number of Digital Outputs 10

Voltage Category 20.4 → 28.8 V dc

Output Type Analogue, Digital, Transistor

Number of Outputs 10

Communication Port Type RS485

Program Capacity 12 kB

Programming Interface Computer, SIMATIC PG/PC

Number of Communication Ports 1

Output Current 750 mA

Dimensions 80 x 120.5 x 62 mm

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Minimum Operating Temperature 0°C

Maximum Operating Temperature +45°C

Length 80mm

Depth 62mm

Width 120.5mm

Mounting Type Rack Mount

Battery Backup Yes

Programming Language Used AWL, FUP, Ladder Logic

Memory 8 (Data Memory) kB, 12 (Program Memory) kB

3.1.1 POWER SUPPLY 220V AC TO 24V DC:

Brief Description on Power Supply 220v AC to 24v DC

Although converting voltages is pretty easy, converting voltages *efficiently* is the real deal.

It really depends on how you intend to use the system and what type of supply (source) are you using.

If you can be sure that you’ll receive a constant supply of 240V AC, using a transformer followed by

a bridge rectifier would be the best choice in terms of efficiency and cost.

If however, you intend to source 240V from AC mains supply, you’ll have to keep in mind the huge

swings that can occur (a popular margin is 100V to 270V rms). In this case a switched mode power

supply (SMPS) is very useful. The AC voltage will have to be converted to DC, switched back to AC

at a higher frequency to be fed into the SMPS.

Application:

If your application involves consumer electronics, it is a good idea to isolate your power lines from

the load (for example, with a transformer). Mobile phone chargers involve decent circuitry that

incorporates isolating the load from the source using an auto-transformer configured in subtractive

polarity, followed by the SMPS unit.

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Fig. 3.2: Power Supply 220v AC to 24v DC

Specifications:

Table 3.2: Motion Sensor Pin Configuration

Input Voltage: 110V-220V

Output Voltage: DC24V

Output Current: 2A

Output Power: 24W

Size: 85*60*33mm(L*W*H)

Protection: Short circuit/Over load/Over voltage

Shell Material: Metal case/Aluminum base

Application: LED strip, led module, led lamp

Connection:

L, N: AC power input

AC power Ground

-V : DC power output "-"

+V : DC power output "+"

ADJ: Adjust the output voltage

Working Temperature:-10~+50°c

Storage Temperature:-20~85°c

Ambient Humidity:20%~95% Non-Condensation

Package Included:

1 X DC12V 2A 24W Power Supply

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3.1.2 Software Micro win v4.0 SP9:

Brief Description on Micro WIN V4.0 SP9

Compatibility:

The two Service Packs 9 for STEP7 Micro WIN V4.0 are compatible with all S7-200 CPUs (CPU

21x and CPU 22x).

Programs created with earlier Micro WIN versions can be opened and further processed without any

restrictions.

Projects created with the new Service Packs can be neither opened nor processed with older versions.

INSTALLATION INSTRUCTIONS for STEP7 Micro WIN V4 SP9

Download the file to your PC

Unpack the archive and the required Service Pack

Open the folder Disk1 and execute the file setup.exe

Follow the prompts that will come up during the installation to conclude the installation

process.

When the installation has been concluded successfully you will find STEP7 MicroWIN V4

SP9 in your start menu under the item Simatic.

After the installation please delete the temporary sub-directory with the installation files.

This must be done manually.

Figure 3.3: Micro WIN V4.0

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INSTALLATION INSTRUCTIONS with a simultaneous change of the operating system

On the computer with the executable predecessor version zip the file microwin.exe. You will

find it with the standard installation in drive C in the folder:

Program Files\Simatic\STEP 7-MicroWIN V4\bin

Copy the packed file to the computer with the new operating system and unpack the file.

Start the installation in line with the installation instructions of the relevant Service Pack.

Security information

In order to protect technical infrastructures, systems, machines and networks against cyber threats, it

is necessary to implement – and continuously maintain – a holistic, state-of-the-art IT security

concept. Siemens’ products and solutions constitute one element of such a concept. For more

information about cyber security.[8]

3.1.4 WinCC Flexible (SCADA):

Brief Description on WinCC Flexible (SCADA)

The PIR sensor stands for Passive Infrared sensor. It is a low cost sensor which can detect the presence

of Human beings or animals. This sensor has three output pins Vcc, Output and Ground as shown in

the pin diagram above. Since the output pin is 3.3V TTL logic it can be used with any platforms like

Arduino, Raspberry, PIC, ARM, 8051 etc.

The module can be powered from voltage 4.5V to 20V but, typically 5V is used. Once the module is

powered allow the module to calibrate itself for few minutes, 2 minutes is a well settled time. Then

observe the output on the output pin. Before we analyse the output we need to know that there are

two operating modes in this sensor such as Repeatable (H) and Non- Repeatable (L) and mode. The

Repeatable mode is the default mode.

The output of the sensor can be set by shorting any two pins on the left of the module as shown below.

You can also notice two orange colour potentiometers that can be used to set the sensitivity and time

which will be explained further below.

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Figure 3.4: WinCC Flexible

Pin Configuration

Table 3.3: WinCC SCADA and Configuration

Pin

Number Pin Name Description

1 Vcc Input voltage is +5V for typical applications. Can range from 4.5V- 12V

2 High/Low

Ouput (Dout)

Digital pulse high (3.3V) when triggered (motion detected) digital

low(0V) when idle(no motion detected

3 Ground Connected to ground of circuit

PIR Sensor Features

Wide range on input voltage varying from 4.V to 12V (+5V recommended)

Output voltage is High/Low (3.3V TTL)

Can distinguish between object movement and human movement

Has to operating modes - Repeatable(H) and Non- Repeatable(H)

Cover distance of about 120° and 7 meters

Low power consumption of 65mA

Operating temperature from -20° to +80° Celsius.

3.1.5 Electromechanical Relay:

Brief about Electromechanical Relay

The electrical and electronics circuits are usually operated over a wide range of voltage, current, and

power ratings. For every circuit or equipment or electrical network or power system protection

system is desired to avoid the breakdown or temporary or permanent damage. Such that, equipments

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or circuits used for protecting are called as protecting equipment or circuit. In case of a small

amount of voltage ratings, protection of the circuit depends on the cost of the original circuit to be

protected and cost of the protection system essential to protect the circuit. But, in case of high cost

circuits or equipments, it is desired to adopt a protection system or protection circuit and controlling

device or controlling circuit to avoid economical loss and damage.

Figure 3.5: Electromechanical Relay Pin out

The relay is an electromechanical switch used as a protecting device and also as a controlling device

for various circuits, equipments, and electrical networks in a power system. The electromechanical

relay can be defined as an electrically operated switch that completes or interrupts a circuit by

physical movement of electrical contacts into contact with each other.

Electromechanical Relay Construction

The flow of current through an electrical conductor causes a magnetic field at right angles to the

current flow direction. If this conductor is wrapped to form a coil, then the magnetic field produced

gets oriented along the length of the coil. If the current flowing through the conductor increases, then

the magnetic field strength also increases (and vice-versa).

Figure 3.5.1: Eelctromechanical Relay Coil – Magnetic Field

The magnetic field produced by passing current through coil can be used for various purposes such as

inductors, construction of transformer using two inductor coils with an iron core. But, in

electromechanical relay construction the magnetic field produced in coil is used to exert mechanical

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force on magnetic objects. This is similar to permanent magnets used to attract magnetic objects, but

here the magnetic field can be turned on or off by regulating current flow through the coil. Thus, we

can say that the electromechanical relay operation is dependent on the current flowing through the

coil.

Electromechanical Relay Working

The electromechanical relay consists of various parts such as movable armature, movable contact &

stationary contact or fixed contact, spring, electromagnet (coil), the wire wrapped as coil with its

terminals represented as ‘C’ which are connected as shown in the below figure to form

electromechanical relay.

If there is no supply given to the coil terminals, then the relay remains in the off condition as shown

in the below figure and the load connected to relay also remains turned off as no power supply is given

to load.

Figure 3.5.2: Electromechanical Relay Working (OFF condition)

If the relay coil is energized by giving supply to the coil terminals at ‘C’, then the movable contact of

the relay is attracted towards the fixed contact. Thus, the relay turns on and the supply is connected to

the load as shown in the below figure.

Figure 3.5.3: Electromechanical Relay Working (ON condition)

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There are various types of relays, the relays which are energized by electrical supply and performs a

mechanical action (on or off) to make or break a circuit are called as electromechanical relays. There

are various types of relays such as Buchholz relay, latching relay, polarized relay, mercury relay, solid

state relay, polarized relay, vacuum relay, and so on.

Applications of Electromechanical Relay

There are numerous applications for electromechanical relays. Various types of relays are used in

various applications based on different criteria such as rating of contacts, number & type of contacts,

the voltage rating of contacts, operating lifetime, coil voltage & current, package, and so on. Relays

are frequently being used in power system networks for controlling purpose, automation purpose, and

protection purpose.

The typical applications of electromechanical relays include motor control, automotive applications

such as an electrical fuel pump, industrial applications where control of high voltages and currents is

intended, controlling large power loads, and so on.

Electromechanical Relay Logic

The method of using relays and contacts to control the industrial electronic circuits is called as relay

logic. The inputs and outputs of relay logic circuits are represented by a series of lines in schematic

diagrams and hence relay logic circuits are also called as line diagrams. An electromechanical relay

logic circuit can be represented as an electrical network of lines or rungs where each line or rung have

continuity for enabling the output device.

Application of Electromehanical Relay Logic

The railways routing and signaling are controlled using relay logic and is considered as a key

application of relay logic. This safety critical application is used to reduce the accidents and to avoid

the selection of conflicting routes by using interlocking. The human elevator operator was replaced

by large relay logic circuits in elevators. The relay logic circuits are used in electro-hydraulics and

electro-pneumatics for controlling and automation purpose.

Do you want to know the basic design of relay logic? Are you interested in designing electronics

projects? Then, post your queries, comments, suggestions, ideas in the comments section below.

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3.1.6 RS 485 USB-MPI PLC Programming Cable:

Brief about MPI Data Cable

Description

Isolation 0CB20+ PLC programming adapter cable:

Support Siemens S7- 200/300/400 series PLC upload and download with optical isolation

function, shielding the electromagnetic interference,

online debugging, stable monitoring.

The Cable applies 2464 material specification 28AWB(7/0.12mm)

The wire insulating layer PVC in line with the POHS standard.

Multipurpose 0CB20 PLC programming adapter cable:

Support Siemens S7-200/300/400 series PLC upload and download

The Cable applies 2464 material specification

The wire insulating layer PVC in line with the POHS standard

Advantages of the isolation cables:

Since there is the frequency converter, modules, ect exists in the larger industrial site, it will occur the

interference and affect the data transmission fast when it is start or pause, isolation cable can avoid

this kind of issue happen and will make the debugging work smooth.

Figure 3.6: RS 485 USB-MPI PLC Programming Cable

The Multi-Point Interface – Siemens (MPI) is a proprietary interface of the programmable logic

controller SIMATIC S7 of the company Siemens. It is used for connecting the stations programming

(PC or personal computer), operator consoles, and other devices in the SIMATIC family. This

technology has inspired the development of protocol Profibus. The MPI is based on the standard EIA-

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485 (formerly RS-485) and works with a speed from 187.5 kBd to 12 MBd. The network MPI must

have resistance at the end of the line and it is generally included in the connector and activated by a

simple switch. Manufacturers using MPI technology offer a range of connections to a PC: MPI cards,

PCMCIA cards, USB adapters or Ethernet.

3.1.7 Transformer 220v AC to 110v AC:

Brief about Transformer 220v AC to 110v AC

The step-down converters are used for converting the high voltage into low voltage. The

converter with output voltage less than the input voltage is called as a step-down converter, and

the converter with output voltage greater than the input voltage is called as step-up converter.

There are step-up and step-down transformers which are used to step up or step down the

voltage levels. 230V AC is converted into 110V AC using a step-down transformer.

Figure 3.7: Transformer 220v AC to 110v AC

3.1.8 PR-4116 (Universal Transmitter):

Brief about PR-4116 (Universal Transmitter)

4116 Universal Transmitters are for linearizing electronic temperature measurement with RTD or TC

sensor. Also for the conversion of linear resistance variation to a standard analog current/voltage

signal, i.e. from solenoids and butterfly valves or linear movements with attached potentiometer.

The transmitter are programmable via detachable display front (4501), process calibration, signal and

relay simulation, password protection, error diagnostics and selection of help text in several languages.

The 4116 is designed according to strict safety requirements and is therefore suitable for application

in SIL 2 installations.

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Input for RTD, TC, Ohm, potentiometer, mA and V

Power supply and signal isolator for 2-wire transmitters

Output for current, voltage and 2 relays

Universal AC or DC supply

A green/red front LED indicates normal operation and malfunction. A yellow LED is ON for each

active output relay

4-port 2.3 kVAC galvanic isolation

FM-approved for installation in Div. 2

DIN Rail mounting

Advanced features

Programmable via detachable display front (4501), process calibration, signal and relay

simulation, password protection, error diagnostics and selection of help text in several

languages.

Application

Linearized, electronic temperature measurement with RTD or TC sensor.

Conversion of linear resistance variation to a standard analog current / voltage signal, i.e. from

solenoids and butterfly valves or linear movements with attached potentiometer.

Power supply and signal isolator for 2-wire transmitters.

Process control with 2 pairs of potential-free relay contacts and analog output.

Galvanic separation of analog signals and measurement of floating signals.

The 4116 is designed according to strict safety requirements and is therefore suitable for

application in SIL 2 installations.

Figure 3.8 PR-4116 Universal Transmitter

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Technical characteristics

When 4116 is used in combination with the 4501 display / programming front, all

operational parameters can be modified to suit any application. As the 4116 is designed

with electronic hardware switches, it is not necessary to open the device for setting of DIP-

switches.

A green / red front LED indicates normal operation and malfunction. A yellow LED is ON

for each active output relay.

Continuous check of vital stored data for safety reasons.

4-port 2.3 kVAC galvanic isolation.

Specifications

Table 3.4: PR-4116 Universal Transmitter and Confrontation

Attribute Value

Input Type Analogue

Output Type Current

Signal Conditioner Type Analogue to Current

Input Range 0 → 12 V dc, 0 → 20 mA, 4 → 20 mA, 10 MΩ, 20 Ω

Output Range 0 → 10 V dc, 0 → 20 mA

Supply Voltage 19.2 → 300 V dc, 21.6 → 253 V ac

Mounting Type DIN Rail

Sensor Compatibility Linear Resistance, Potentiometer, RTD, Thermocouple

Minimum Operating Temperature -20°C

Maximum Operating Temperature +60°C

Number of Channels 1

Operating Temperature Range -20 → +60 °C

Series 4116

3.1.9 CT-Current Transformer:

Brief about CT-Current Transformer

The current transformer is an instrument transformer used to step-down the current in the circuit to

measurable values and is thus used for measuring alternating currents. When the current in a circuit is

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too high to apply directly to a measuring instrument, a current transformer produces a reduced current

accurately proportional to the current in the circuit, which can in turn be conveniently connected to

measuring and recording instruments. A current Transformer isolates the measuring instrument from

what may be a very high voltage in the monitored circuit. Current transformers are commonly used in

metering and protective relays.

Figure 3.9 Current Transformer

Like any other transformer, a current transformer has a single turn wire of a very large cross-section

as its primary winding and the secondary winding has a large number of turns, thereby reducing the

current in the secondary to a fraction of that in the primary. Thus, it has a primary winding, a magnetic

core and a secondary winding. The alternating current in the primary produces an alternating magnetic

field in the magnetic core, which then induces an alternating current in the secondary winding circuit.

3.2.0 Weidmuller WAS1 CMA 1/5/10A ac:

Brief about Weidmuller WAS1 CMA 1/5/10A ac

Current-Measuring Transducer WAS1 CMA LP 1/5/10A ac, input switchable 0..1/5/10AAC

250VAC, output 4..20mA current loop, 6kV electrical isolation, power via output-side current loop,

22.5mm, Weidmüller.

Figure 3.10: Weidmuller WAS1 CMA

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Output current loop fed AC current monitoring components WAS/WAZ1 CMA LP. They can measure

single-phase 50/60 Hz AC currents of up to 10 A using the Root Mean Square (RMS) method on the

input side. They can also be switched between three ranges. No external power supply is used; the

supply is only via the 4...20 mA current loop on the output side. The input and output circuits are

securely isolated with 4 kV.

The monitoring components come in a 17.5-mm-wide WAVEBOX housing. These devices can be

used in many process automation applications because they are not dependent on an external power

supply. International approvals (such as ATEX Zone 2 and UL C1D2) also permit usage in explosion-

risk zones.

Technical Specifications

Table 3.5: Weidmuller WAS1 CMA and Configuration

Physical

Mount DIN Rail

Number of Pins 9

Weight 150 g

Technical

Accuracy 0.5 %

Max Operating Temperature 50 °C

Min Operating Temperature 0 °C

Number of Inputs 1

Number of Outputs 1

Operating Supply Voltage 24 V

Voltage Rating 300 V

Dimensions

Depth 92.4 mm

Length 72 mm

Width 22.5 mm

Compliance

Approvals CE, EN, cULus

Lead Free Lead Free

Radiation Hardening No

RoHS Compliant

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3.2.1 Capacitor Bank:

Brief about Capacitor Bank

Capacitor banks may also be used in direct current power supplies to increase stored energy and

improve the ripple current capacity of the power supply. The capacitor bank consists of a group of

four ac capacitors, all rated at 400V, 50 Hz i.e., the supply voltage and frequency. The value of

capaci

in parallel to one another and the load. The capacitor bank is controlled by the relay module and is

connected across the line. The operation of a relay connects the associated capacitor across the line in

parallel with the load and other capacitors.

A Capacitor Bank is a group of several capacitors of the same rating that are connected in series or

parallel with each other to store electrical energy. The resulting bank is then used to counteract or

correct a power factor lag or phase shift in an alternating current (AC) power supply. They can also

be used in a direct current (DC) power supply to increase the ripple current capacity of the power

supply or to increase the overall amount of stored energy.

What Does a Capacitor Bank Work?

Capacitor banks work on the same theory that a single capacitor does; they are designed to store

electrical energy, just at a greater capacity than a single device. An individual capacitor consists of

two conductors which are separated by a dielectric or insulating material. When current is sent through

the conductors, an electric field that is static in nature then develops in the dielectric which acts as

stored energy. The dielectric is designed to permit a predetermined amount of leakage which will

gradually dissipate the energy stored in the device which is one of the larger differences between

capacitors and batteries.

Figure 3.11: Capacitor Bank

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How is Capacitance Measured?

Capacitors are rated by the storing characteristic referred to as capacitance which is measured by the

scientific unit, farad. Each capacitor will have a fixed value that they are rated at storing which can be

used in combination with other capacitors in a capacitor bank when there is a significant demand to

absorb or correct AC power faults or to output DC power.

What are the Applications of a Capacitor Bank?

The most common use of a capacitor bank for AC power supply error correction is in industrial

environments which use a large number of transformers and electric motors. Since this equipment

uses an inductive load, they are susceptible to phase shifts and power factor lags in the power supply

which can result in a loss of system efficiency if left uncorrected. By incorporating a capacitor bank

in the system, the power lag can be corrected at the cheapest cost for the company when compared to

making significant changes to the company power grid or system that is supplying the equipment.

Other uses for capacitor banks include Marx generators, pulsed lasers, radars, fusion research, nuclear

weapons detonators, and electromagnetic railguns and coilguns

3.2.2 Voltage Regulator:

Brief about Voltage Regulator

A voltage regulator is used to regulate voltage level. When a steady, reliable voltage is needed, then

voltage regulator is the preferred device. It generates a fixed output voltage that remains constant for

any changes in an input voltage or load conditions. It acts as a buffer for protecting components from

damages. A voltage regulator is a device with a simple feed- forward design and it uses negative

feedback control loops. There are mainly two types of voltage regulators: Linear voltage regulators

and switching voltage regulators; these are used in wider applications. Linear voltage regulator is the

easiest type of voltage regulators. It is available in two types, which are compact and used in low

power, low voltage systems. Let us discuss about different types of voltage regulators.

Voltage regulator, any electrical or electronic device that maintains the voltage of a power source

within acceptable limits. The voltage regulator is needed to keep voltages within the prescribed range

that can be tolerated by the electrical equipment using that voltage. Such a device is widely used in

motor vehicles of all types to match the output voltage of the generator to the electrical load and to

the charging requirements of the battery. Voltage regulators also are used in electronic equipment in

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which excessive variations in voltage would be detrimental. In motor vehicles, voltage regulators

rapidly switch from one to another of three circuit states by means of a spring-loaded, double-pole

switch. At low speeds, some current from the generator is used to boost the generator’s magnetic field,

thereby increasing voltage output. At higher speeds, resistance is inserted into the generator-field

circuit so that its voltage and current are moderated. At still higher speeds, the circuit is switched off,

lowering the magnetic field. The regulator switching rate is usually 50 to 200 times per second.

Electronic voltage regulators utilize solid-state semiconductor devices to smooth out variations in the

flow of current. In most cases, they operate as variable resistances; that is, resistance decreases when

the electrical load is heavy and increases when the load is lighter.

Figure 3.11.2: Voltage Regulator and Pin out

Voltage regulators perform the same function in large-scale power-distribution systems as they do in

motor vehicles and other machines; they minimize variations in voltage in order to protect the

equipment using the electricity. In power-distribution systems the regulators are either in the

substations or on the feeder lines themselves. Two types of regulators are used: step regulators, in

which switches regulate the current supply, and induction regulators, in which an induction motor

supplies a secondary, continually adjusted voltage to even out current variations in the feeder line.

3.2.4 Load/Cooling Fan:

Fig. 3.13: Load Fan

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Specification: Table 3.6: Fan and Configuration

Item description: dc fan Size: 40 * 40 * Voltage: 24V Current: 0.02A~ 0.24 A The actual current: 0.15 A Power: 0.75 W Speed: 6300 RPM Air volume: 7.17 CFM Noise: 24DBA

3.2.5 CT-K type sensor:

Brief about CT-K type sensor

A Thermocouple is a sensor used to measure temperature. Thermocouples consist of two wire legs

made from different metals. The wires legs are welded together at one end, creating a junction. This

junction is where the temperature is measured. When the junction experiences a change in

temperature, a voltage is created. The voltage can then be interpreted using thermocouple reference

tables to calculate the temperature.

Fig. 3.14: CT-K type sensor

Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the most common type

of thermocouple. It’s inexpensive, accurate, reliable, and has a wide temperature range. The type K

is commonly found in nuclear applications because of its relative radiation hardness. Maximum

continuous temperature is around 1,100C.

Type K Temperature Range:

Type K Thermocouple Grade Wire Thermocouple grade wire, –454 to 2,300F (–270 to 1260C)

Extension wire, 32 to 392F (0 to 200C)

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Type K Accuracy (whichever is greater):

Standard: +/- 2.2C or +/- .75%

Special Limits of Error: +/- 1.1C or 0.4%

Type of K Thermocouple

Consideration for bare wire type K thermocouple applications

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CHAPTER 4

BLOCK DIAGRAM

4.1 Block Diagram

Here, we represent the block diagram of proposed system in figure. We measure and monitor the

parameter of inductive load to maintain the power factor monitoring and improvement with help of

PLCs and SCADA. This system contains different working element which mainly consist of inductive

load, capacitor bank and 24-volt DC supply (SMPS). As seen from figure, inductive load is the last

element whose parameter we must measure and monitor on SCADA window. Inductive load receives

AC main supply through VFD.

VFD plays important role in system as it is protecting motor from various faults like overloading,

overvoltage, over current etc. and controls the speed of motor. 24-volt DC supply (SMPS) also fed

from AC main supply. Input rag of PLC relates to capacitor bank and VFD and output rag relates to

personal computer which has SCADA window. User can show the various parameters of motor and

control from computer. Here we communicate between PLC and SCADA using RS-232

communication cable.

A Capacitor Bank is a group of several capacitors of the same rating that are connected in series or

parallel with each other to store electrical energy. Capacitor banks are used for problems such as lag

or phase shifts. These banks can also be used simply to increase the energy storage of a system. These

banks are often the most cost-efficient ways of dealing with power shift and AC power supply

problems. Here, especially we use capacitor bank for correct AC power problems and to reduce

harmonics from the system.

Inductive Load: Here we use three phase induction motor whose parameter we must measure. Table

shows the rating

of an induction motor.

Table 4.1: Three Phase Induction Motor Configuration

Type

Volts

Phase/cycle

Power(kw/HP)

Speed in R.P.M

:

:

:

:

:

T.E.F.C

415

3/50

2.2/3

1400

Current (amps)

Frame

Connection type

Insulation class

Manufacturer

IV. IMPLEMENTATION

: 4.7

: 100L

: Delta

: B class

: Benn Electrical

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In any industry, induction motor plays significant role due to its low cost and simplicity. By

implementing a monitoring and control system for the speed of motor, the induction motor can be

used in high performance variable speed applications. First and basic step is to select the rating of

induction motor and according to it control devices are selected and the circuit is designed accordingly

and finally the programming is done in the PLC according to inputs applied and the outputs required

in the operation of the induction motor. Capacitor bank is connected in parallel with

induction motor. It is required for reduce harmonics and for improve power factor of motor. Capacitor

bank also compensate reactive power of motor. The capacitor draws leading current and partly or

neutralize lagging reactive component of load current. This will improve the power factor.

Figure 4.1: Block diagram of project

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4.2 Flow Chart

Fig: 4.2 represent the flow chart diagram of the process. There is a start menu, If not start and select

Start button again. Sense temperature and start cooling fan. When Temperature >40 degree C start

the fan and <35 degree C stop the fan. But if temperature increases greater than 48 degree C send

alarm and stop the system.

Over voltage >250V send an alarm and stop the system and under the voltage <100V again send an

alarm and fully stop the system.

Over current >7A send alarm and stop the system.

Power factor =96 and A =1 start the capacitor bank-1 and Power factor =98 and A=10 capacitor

bank-2 start.

Current >5A load shading start if load shading time out stop the system.

Figure 4.2 Flowchart of working process.

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4.3 Schematic diagram

This chapter provides the necessary information for simulated circuit design and its functional

output. Hardware implementation with input sensors defines the mechanism of this chapter. To

make the project more efficient, different values are taken as a short survey and a comparison is

shown to find the defect.

Figure 4.2: Circuit diagram of the prototype model

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4.3.1 Circuit Operation

This is a circuit operation of the project. We using a 220v AC to 110v AC transformer. Power supply

send to EM 235 Module EM 235 Module Al 3*12 Bits and AQ 1*12Bits. Input voltage C+, C-.

Current Transformer connected to B+, B-. There UA is EM 235 input and Uh 230v three phase load

current. PR 4116 Universal Transformer connected to A+, A-. Universal Transformer output for TC

K type sensor, 24v DC supply, 11 and 14 pin is connected to EM 235 A+ and A- point. RS 485 USB-

MPI PLC Programming Cable connect to PC and showing output on SCADA. M and L+ pin connected to

CPU 214 PLC module M, L+, 2M, 2L+ and 1M, 1L pins are connected from 220V AC to 24V DC

supply. 24V DC supply connected also relays. 0.3 to 0.7 relays are lode relay and 1.0, 1.1 relays are

load and fan relay. 220V AC converted 24V DC using step down transformer connected to PLC 1M

and 1L+. Connected also relay there is five relays for load connecting pin 0.3, 0.4, 0.5, 0.6, 0.7 and

two for fan and load connecting pin 1.0, 1.1.

4.3.2 Working Principle

This is a full circuit diagram of the working project. There are no wire is required to send data.

The connecting wire is use for AC to DC power supply 220V AC to 24V DC. There is three step to

working process. Firstly 110v AC power supply connected to EM 235 module. The step is sense

Transformer oil Temperature, when transformer temperature is increases start the cooling fan and

temperature is normal cooling fan is shut up.

Secondly improvement of Power Factor. When current in inphase Power Factor normally 1.0 stable

but physically it is not possible. When inductive load increases power factor going decrease. For

decrease power factor improvement using capacitor bank. Capacitor bank develop power factor near

0.9. Here generally capacitor bank-1 start of the circuit. Current and Voltage angle is Power factor

and save more cost

Thirdly load distribution feeder to feeder.

4.3.3 Circuit Application

Power factor correction, Improvement, Monitoring

PLC Automation

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CHAPTER 5

DESIGN AND IMPLEMENTATION

5.1 Body design

This is the part which we used to design the Power Factor system. We also used PVC board,

Aluminum sheet to make the device with a good shape and PC.

Figure 5.1: Front View Figure 5.2: Side View

Figure 5.3: Top View

Figure no 5.4: Output of the project

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5.2 Software Description

SCADA: For SCADA window, we use wonder ware –In touch. In SCADA window, main switch is

ON motor is ON. Different parameter of motor is shown in window like phase voltage, current, speed

of motor etcetera. Waveform of motor is shown in trend. When switch is ON motor colour is GREEN,

it indicates motor is in running operation and vice versa in RED colour.

After operating the system using PLC and SCADA, we get the results as per the Fig. 3. Here, we get

the line voltage of all the three phases, frequency of the system, speed of the induction motor, output

waveforms without capacitor and with capacitor. All the results are store in the memory for further

analysis.

SCADA, it will collect the needed data from PLC and displaying them on the monitor of master

computer of control room, store appropriate data in the hard drive of computer and allow the control

of field device from the control room. As mention above, in any contingency SCADA would give

alarm or automatically cut-off the supply. Here, for interfacing between PLC and SCADA we use RS-

232 cable.

Micro win v4.0 SP9: The two Service Packs 9 for STEP7 Micro WIN V4.0 are compatible with all

S7-200 CPUs (CPU 21x and CPU 22x).

Programs created with earlier Micro WIN versions can be opened and further processed without any

restrictions.

Projects created with the new Service Packs can be neither opened nor processed with older

versions.

5.3 Hardware

Hardware comprises of single phase supply, interfacing circuit, PLC, switching circuit, capacitor bank

and single phase load as shown in fig.5.5.

Fig.5.5: Block diagram of experimental set

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CHAPTER 6

FUTURE WORK AND CONCLUSION We know every system has some advantage or disadvantage. So our project will also have very good

practical advantage and some limitations which we called it disadvantages.

6.1 Applications

Electricity industry: power factor correction and monitoring of linear loads: Power factor

correction is achieved by complementing an inductive or a capacitive circuit with a (locally connected)

reactance of opposite phase. For a typical phase lagging power factor load, such as a large induction

motor, this would consist of a capacitor bank in the form of several parallel capacitors at the power

input to the device. Instead of using a capacitor, it is possible to use an unloaded synchronous motor.

This is referred to as a synchronous condenser. It is started and connected to the electrical network.

Instead of using a capacitor, it is possible to use an unloaded synchronous motor. This is referred to

as a synchronous condenser. It is started and connected to the electrical network. It operates at full

leading power factor and puts VARs onto the network as required to support a system’s voltage or to

maintain the system power factor at a specified level. The condenser’s installation and operation are

identical to large electric motors. The reactive power drawn by the synchronous motor is a function

of its field excitation. Its principal advantage is the ease with which the amount of correction can Be

adjusted. It behaves like an electrically variable capacitor.

6.2 Advantages

Reduced Utility Bills: The power factor of a customer will become a direct or indirect factor

in the utility bill. Power bills may be reduced by introducing capacitors to the facility, which

can reduce the need for kVAr required from the utility. .

Electrical System Capacity: Capacitors in a facility produce reactive energy that motors

require to produce magnetizing current for induction motors and transformers. This reduces

the overall current needed from the power supply. This translates into reduced loads on both

transformers and feeder circuits. Reduced loads on transformers can have less maintenance,

reduced breaker trips, and higher full-load capacity. .

Improved Voltage Levels: Low voltage may be caused by a lack of reactive energy dynamic

load changes. In facilities with motors, low voltage reduces motor efficiency and can cause

overheating.

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6.3 Benefits

There are several advantages in utilizing power factor correction capacitors.

Benefits of Power Factor Correction. There are numerous benefits to be gained through power factor

correction and monitoring. These benefits range from reduced demand charges on your power system

to increased load carrying capabilities in your existing circuits and overall reduced power system

loses. These include:

Avoid power factor penalties

Reduced demand charges

Increased load carrying capabilities in existing circuits

Improved voltage

Reduced power system losses

Reduced demand charges.

Increased load carrying capabilities in existing circuits.

Improved voltage

Power system loses

Power system becomes unstable

Resonant frequency is below the line frequency

Current and voltage increase

6.4 Disadvantages

Reduction in system losses, and the losses in the cables, lines, and feeder circuits and therefore

lower cable sizes could be opted for.

Improved system voltages, thus enable maintaining rated voltage to motors, pumps and other

equipment. The voltage drop in supply conductors is a resistive loss, and wastes power heating

the conductors. Improving the power factor, especially at the motor terminals, can improve the

efficiency by reducing the line current and the line losses.

Improved voltage regulation.

Increased system capacity, by release of KVA capacity of transformers and cables for the

same KW, thus permitting additional loading without immediate expansion.

Reactive power decreases

Avoid poor voltage regulation

Overloading is avoided

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Copper loss decreases

Transmission loss decreases

Improved voltage control

Efficiency of supply system and apparatus increase

6.5 Future Enhancement

The automotive power factor correction using capacitive load banks is very efficient as it reduces the

cost by decreasing the power drawn from the supply. As it operates automatically, manpower is not

required and this Automated Power Factor Correction using capacitive load banks can be used for the

industries purpose in the future.

6.6 Conclusion

Power factor correction has got wide range of advantages in industrial sector. The most important one

is reducing the electricity tariff. Usually capacitor banks used for power factor correction are placed

in a scattered manner throughout the industry for better performance. Fixed shunt capacitors that we

have used here are the least expensive way to achieve near unity power factor by providing a static

source of leading reactive current. They can be installed either close to the highly reactive loads or at

the service entrance.

We discuss on power quality issue and factor concerning related with modern utilities. We should

know how to choose monitoring location and control scheme. We perform experiment on particular

system to monitoring and controlling for three phase induction motor. The system is successfully

implemented and tested. The software Rockwell has been successfully worked for PLC and

Wonderware-Intouch for SCADA. With the use of PLC & SCADA, the control system is more

reliable. Monitoring system gives facility of analyzing the operation of an induction motor in

online/offline mode which make the system to be safe from fault/error condition. It deals with the

most important types of failures of an induction motor such as over and under voltage, over current,

over speed etc. If any fault appears during the operation of motor then the motor stops immediately.

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