PLC BASED POWER AUTOMATION SYSTEM.

Faisal Masood
Asst. Manager- Sales.

Sofcon Systems India Pvt. Ltd.

C-87, Sector 88, NOIDA. Uttar Pradesh. E-mail: faisal.masood@sofcononline.com, sales@sofcononline.com

Sofcon Mission & Core Competency

Mission: Full line scalable solution provider Core Competency :
World class Industrial Controls, Information,

Instrumentation and Electrical solution provider. (Sofcon Systems India Pvt. Ltd)
Training :
Automation Training: A leading national hands on

training providers. (Sofcon India Pvt. Ltd)

Business Locations
SOFCON SYSTEMS INDIA PVT. LTD.
DELHI. NOIDA. LUCKNOW. AHMEDABAD. BARODA. BHOPAL. JAIPUR.

SOFCON AFRICA LTD.

NAIROBI, KENYA.

Established in 1995 Employees- 300

Solutions/ Offerings
Solution Areas
Power, Control & Information Systems Coordinated Drive & Motion Control Systems Turnkey Control & Instrumentation Solution Manufacturing Executions Systems (MES) Management Information Systems SCADA Solutions for all PLC/ PAC

Networking Consulting & Implementation

Multi-vendor integration Radio Telemetry Solutions RFID Solutions

Solutions/ Offerings

Project Definition & Consulting:

User Requirements Detailed Specifications & Functional Design

Validation & Benchmarking Services

Project Execution:
Project Management Detailed Engineering Hardware/ Software Detailed Panel Engineering and Manufacturing Application Software development Factory Acceptance test

Installation, Commissioning and Start-up

Sofcon Domain Expertise

Metals & Cement Process Industry
Specialty & Fine Chemicals, CPP Food & Beverage

Infrastructure, Power
Water & Waste Water Material Handling Power & Energy Management Systems - DG/TG

Automotive

Typical Applications
Cement & Metals

Energy Management

Energy Management, Load Management, DG Control, DG Synchronization/ TG Synchronization, with State Electricity De-sulphurisation Plant

Boiler and BOP

Boiler/ Burner Automation Ash Handling Plants Water treatment plants Flue Gas control

Clinkerisation Raw Mill, Coal Mill, Cement Mill, Material Handling, Silo Extraction, Clinker/Gypsum/Slag Transport Cement Mill/Silo, Packing and loading plant Sinter Machine, Blast Furnace, Skip Control, Material Handling, Coke Ovens, Walking Beam, Furnace, Pickling Vertical Boring, Carbon Plant, Green Anode, Ageing Furnace, Extrusion Press, Slab and billet casting reporting and Networking, Pot Air Slide System, Hyper Dense Phase System, Carbon Plant, Pitch Fume Treatment Stripping Machine Vibro Compactor, Rodding Room Conveying Melting / Holding Furnace Melting Furnace

Typical Applications

Hydrogen Plant, Nitrogen Plant, Paint Plant, EG & MA Recovery System, Level Monitoring, Polyester Chip Conveying, Electrical Interlocking

Chemical

CIP Evaporator, Casein, Lactose Prod. Material Handling, Flour Mill, Bottling Plant, Sugar Mill, Vegetable Oil extraction

Food

CAB Overhead Conv. CAB Assembly Line, CAB Trim Line, Engine Assembly Line, Engine Testing Line

Automotive

HVAC Wrapping Machine Sterilization Chamber

Pharmacy

POWER AUTOMATION SYSTEM

NEED OF THE HOUR.

In todays power deficient industrial environment most industries choose to be self-reliant. Captive power plants / DG sets are installed across all industries. The common unforeseen problems customers face. How to synchronize among the DGs. How to ensure optimum load sharing between the DGs. How to protect the system from electrical / mechanical damage How to schedule loads - critical /non-critical to avoid power breakdown.

KEY BENEFITS
Monitoring and control of all electrical parameters without any transducers. User configurable for unparalleled flexibility in applications. Integrated synchronizer, load sharer manager & power monitor. Inbuilt temperature scanners (bearing, winding etc). No need of conventional relays. All protection relays built in . Auxiliary drive control DG load management for fuel saving Unmanned plant operation with fault diagnosis Synchronization with grid to avoid heavy starting current of big drives on alternator Power factor correction to enhance DG capacity

FEATURES OF PLC SYSTEM

The system will directly accept CT & PT signals for Electrical parameter monitoring and control Depending upon the load requirement starting and stopping of DG sets. Automatic synchronizing of DG sets in Auto mode. Active and Reactive power sharing of each DG set. Automatic selection of next DG as master after stopping /tripping of master DG to close NGR circuit breaker. Monitoring of electrical parameter per DG, Voltage , Frequency, Reactive load, active load, Energy produced , voltage error (%), Frequency error and phase angle error etc. Load shedding system (Fast acting, Under frequency, Gradual overload ) Grid maximum demand controller Provision to test the DG after repairs through PLC Isochronous/ Droop mode Synchronization.

FEATURES OF PLC SYSTEM Cont

Status and Control of outgoing breakers. Back up protection electrical / mechanical by time delayed tripping of DG sets. Reverse power, Reverse KVAR , under voltage , Over voltage, Under/ over frequency, over current, low lube oil pressure, high cooling water pump, over speed etc. Isochronous/ Droop mode Synchronization. Incorporated Data acquisition system for recording & display of all important & critical parameters of the engine, alternator & system as such in total operation of the system will also be through operator interface with graphics (SCADA) screen. B checks alarm after each DG complete 300 hours of running for proper maintenance. Tripping of less priority loads in the plant in case of under frequency of bus both in isolation as well as synchronized mode.

PLC SYSTEM OVERVIEW

Automatically synchronizes a cogeneration or stand-by power
system

Regulates power output to maximize the utilization of available generated power

High performance, cost effective solution for the retrofit of

existing / new power generation control equipment

Increases system speed, accuracy & overall performance while

reducing the integration time, cost, space & hardware

Why Power EMS?

Critical Loads Limited In-plant Generation Insufficient reliability of Public Grid
Several Generators Contracted Power Importation

Different Electrical Operational Configurations possible

Complex Distribution Networks Local only Control facilities

} } } }

Load Shedding

Power Control

Mode Control

SCADA

Why SOFCON For EMS?

Great experience of the electrical process 2 decades of experience in Power EMS . Specialized software, well documented, tested, proven technology Fast Response Time for Load Shedding, Mode Control, Power

Control, Re-acceleration
High Resolution and Accuracy of

Sequence of Event recording

Seamlessly Customizable as per the requirement. Single responsibility: One supplier for Power EMS integrated with

protection, governor, excitation, tap-changer, Motor Control Centre, Variable Speed Drive, etc.

Functionality Power EMS

Load Shedding. Load Sharing. Active and Reactive Power Control. Supervision, Control and Data Acquisition (SCADA)

Mode Control.
Re-Acceleration / Re-Starting.

Synchronization.
Critical Load Management.

Load Shedding: The types

Fast Load Shedding on Loss of Power Resources Load Shedding on Frequency Drop Slow Load Shedding on Overload Slow Load Shedding for Peak Shaving Manual Load Shedding

Power EMS Load Shedding: Keywords

Fast Exact

Flexible
Co-ordinated Deterministic Security and Reliability

Accurate Event Logging

Operator Guidance Independent Back-up System

Active and Reactive Power Control

Active Power Sharing:
Efficient Power Generation Power Exchange optimization (Power Demand Control) Avoid component overloading Spinning reserve optimization Standby optimization
P

Reactive Power Sharing:

Achieve stable operation Power Factor optimization

Q-Lead

Q-Lag

Mode Control
for Generators
for Turbines for Transformers for Switchboards

Supervision, Control and Data Acquisition

Load Shedding Active and Reactive Power Control Mode Control Supervision, Control and Data Acquisition

Functionality Power EMS

Clearly Structured Presentation Controls - Select Before Execute Status Indications Consistency Analysis Time Tagged Events (1 ms resolution) Alarm handling, Reports, Trends Supervision and Self Diagnostics Single Window concept

Integration with supervisory systems

Plant Information Systems - MIS Regional Dispatch Centres Power Generation Co-ordination Centres Energy Trading Utility Management Systems Process DCS

Integration with subordinated systems

Satellite Time Receiver (GPS) Alarm annunciators SF-6 Density Monitoring Units Motor Control Centres Battery Chargers Meteorological Stations Diesel Generators Generator- and turbine controller Protection and Control Units

Integrated Protection & Control Units

Measuring of U,I,E, calculation of P & Q Monitoring & Control Interlockings Alarm annunciation

Event Time Tagging Disturbance Recording

Local storage of trip-events Serial communication to Power EMS

Functionality Power EMS

Triggered by Load Shedding or Under voltage

Individual motors
Priority per motor Max. allowed time delay per motor

Network configuration check Network restoration

Display Synchronisation

AB

Display Synchronisation

Functionality Power EMS

Load Shedding Active and Reactive Power Control Mode Control Supervision, Control and Data Acquisition (SCADA) Re-Starting Synchronisation Circuitbreaker Control Transformer Control Motor Control Generator Control

Network Configuration Determination

POWER AUTOMATION SYSTEM at INDIA GLYCOLS LTD. KASHIPUR.

The system comprised of :-

Grid Supply. 4 Turbines (1x4MW), (1x2MW), (1x12MW), (1x9.5MW). 4 Wartsila Diesel Generators (2x3MW), (2x4MW).

Few recent Projects.

KOTA THERMAL POWER PLANT-A KOTA THERMAL POWER PLANT-B BIRLA CELLULOSIC IGL SIMBHAOLI SUGAR MILLS LTD. AWADH SUGAR MILLS CHILWARIA SUGARS LTD. SAMTEL COLOR LTD. CHILWARIA SUGARS LTD. VARDHMAN ACRYLIC. SAHARA AMBY VALLEY.
TOYOTA KIRLOSKAR.

JAIPRAKASH HYDRO-BAGLIHAR YKK

DLF, CALCUTTA

SUBROS DENSO
STEEL EXCHANGE

HERO HONDA. HMT PINJORE.

LG HOTLINE.

POWER GRID CORP. OF INDIA. SGS THOMSON.

SIEL HONDA.

SANGHI POLYESTERS. SAMTEL COLOR. LUXAR SUGAR.

SSJV. SSJV, KULLU.

TECUMSEH INDIA & Many More

Cost of Ownership is about thinking ahead and knowing what is hidden under the iceberg
Purchase price

Running costs

Customer benefits

& Have a great Business Ahead

Faisal Masood
Asst. Manager- Sales.

Sofcon Systems India Pvt. Ltd.

C-87, Sector 88, NOIDA. Uttar Pradesh. E-mail: faisal.masood@sofcononline.com, sales@sofcononline.com