Journal of Electrical Engineering

The Institution of Engineers, Bangladesh

Vol. EE xx, No. xx, June/December xxxx

PLC Based Operation and Control of Two Diesel

Generator Set
P. K. Bhowmik1, M. Dey2, and S. K. Dhar3
1
Department of Instrumentation and Communication, Eastern Refinery Limited, North Potenga, Chittagong, Bangladesh
2
Department of Electrical & Electronic Engineering, Chittagong University of Engineering & Technology, Chittagong, Bangladesh
3
Member IEEE, Chittagong, Bangladesh
E-mail: pkbcuet@yahoo.com1, mrinmoyeee@gmail.com2, sagor378@gmail.com3

Abstract— This paper outlines the operation and control complete set up has the following facilities [4-5].
features of a diesel generator of Reactor Operation and 1. Programmable Logic Controller (PLC)
Maintenance Unit (ROMU) and discuss about the system, 2. Interface Unit
structure and implementation for smooth automatic operation
3. Power supply for PLC input & output module
by using programmable logic controller (PLC). All criteria for
safe starting, synchronization, protection against electrical and 4. Power supply for Lamps supply (24V DC)
mechanical faults of the generators are taken into consideration 5. 24V DC Relay and Cables
in the software used for the PLC. This facility enhances the 6. Two contact relay base
method of learning of PLC based power systems operation and 7. Push button switch
control at undergraduate level. Over the years the demand of
higher quality, greater efficiency & automated system and 8. 24V DC Flashing lamps
machines has increased in the globalised world. To cope with 9. A Personal Computer (PC)
this advancement it is anticipated that this paper will be 10. Sucosoft V5.02 programming software
considered very effective effort.
Personal computer Interfacing Unit
Index Terms—PLC, Diesel Generator operation and control,
Sucosoft V5.02 Moeller PLC software
Sensor Input Output Load
Panel Module CPU Module Panel
I. INTRODUCTION

I N order to automate a power generation system and to

minimize human intervention, PLC based system will be a
good option that monitor the system and help to reduce the
24V dc power
supply for PLC
Power circuit
Breaker
24V dc power
supply for lamp

error caused by human. The wide applications of PLC in

many areas have significantly contributed to the operation
and automatic control of electrical and electronic system [2-
4]. The internal storage of instructions for the implementing
functions such as logic, sequencing, timing, counting and
arithmetic to control through digital or analog input/ output
modules various types of machines processes. Similar PLC
based automation Systems are also widely used to monitor
and control plants or equipment in industries such as power
plants, energy, oil and gas refining and transportation.
II.PLC MODULE SETUP
A PLC is a 'digital operating system' designed specially for
use in an industrial environment, which uses a programmable
memory for its internal operation of user-orientated
instructions and for implementing specific function such as
logic, sequencing, timing, counting and arithmetic. PLC
controls digital and analog inputs and outputs in the various
types of machines. In a PLC inputs and outputs are not
designed for humans, but for use in the control of machines.
Machine and operator interact solely by way of limit
switches, contact switches, or photoelectric switches [2]. The
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Main Power Supply
Fig. 1. Block diagram of the PLC together with interfacing
components
III. PROCESS SYSTEM DESCRIPTION
A. Diesel Generator Sets
The two diesel generator set defined as Generator-A and
Generator-B of ROMU are considered to get an idea of
operation for PLC based generator operation and control
system development and experimental purpose. Here the two
synchronous generator set are driven by diesel engine. The
ratings of Generator-A is 3-phase, 650-kVA, 50-Hz, and
Generator-B is 3-phase, 250-kVA, 50-Hz. Two generators are
connected to a synchronizing panel with which main
distribution board are connected. Normally utility supply
(REB) is used in ROMU, but in case of load shading the
generators are started manually and with the help of
synchronizing panel board generators are synchronized [1].
There are specific operating procedures for such activities.
 Author Instructions: J. Elec. Engg., Instn. Engrs., Bangladesh, 36(II), December 2009

B. Process Block Diagram D. Protection and Control of Generator

Lube oil Start

REB Measurement
line
Sensor
A REB off
Fuel oil C
Measurement T
Sensor U
GenA PLC
A
Water level T
Measurement Reactor
O
GenB Sensor Operating No
R Yes
Radiator,
bearing temp Select Gen A Select Gen B
Measurement
Sensor
T1
Generator Cranking

Voltage Current PF Frequency Reset Alarm

BUS-BAR Sensor Sensor Sensor Sensor
T2
No
Fig. 2. Block diagram of automation procedure of two diesel All alarm
generator set. Reset
Engine
C. Process Operation Description Yes Shut down
Successful operation of a process system depends upon
careful installation & initial start up. Before start up there Engine Purging T3
should be a thorough check of the system, like valves, control
trip, safety device, and all mechanical and electrical systems
Fault
that should be in good condition. The operating procedure of
this diesel generator system is as follows [1]- Checking lube oil pr, T4
1. Generator automatic selection and starting when water level, fuel oil pr.
utility, named here as “REB” is off and when temp, Radiator,
starting conditions to be fulfilled are ok as Bearing temp & others
mentioned in the operation manual.
2. If Reactor in operating condition higher capacity
Generator-A will be selected. Otherwise the lower
capacity Generator-B will be selected. Generator Speed up
T5
3. Then generator cranking started.
4. All the alarms of the system to be reset condition.
After resetting all alarms engine purging started. Gen rated speed
This checking & purging requires a specific time. achieved
No
5. Generator starting condition checking (temperature Yes
level and pressure of the lube-oil and fuel oil, water Disconnecting
level, Radiator and bearing temperature etc) mainly Circuit Breaker Gen Synchronizing T6
all the mechanical features. This checking takes a
specific time.
Gen Loading according to
6. If mechanical fault found then shutdown the engine the demand T- Indicates
and then wait for alarm reset. If all mechanical Timer
features are ok then generator speeds up gradually.
Yes
This requires a specific time to accomplish generator Electrical
rated speed. fault occur
7. After achieving the rated speed generator auto
synchronism with the bus-bar accomplished. This No
also requires a specific time.
Return
8. Bus-bar disconnection by disconnecting the circuit
breaker while electrical fault occurs (over voltage, Fig. 3. Process flow diagram for operation and control of two diesel
over current, power factor or frequency out of generator set
desired range) and then again wait for alarm reset.

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 Author Instructions: J. Elec. Engg., Instn. Engrs., Bangladesh, 36(II), December 2009

E. Protection and Control of Generator System

In this study the starting and protection against both
electrical and mechanical faults are automated. When
electrical fault occurs (due to over load, over voltage, over
and under frequency) and violet the generator protection
features according to ANSI the bus bar would be
disconnected from load and fault-alert would be made for the
operators. The generator protection features according to the
ANSI are: differential current(87G), over voltage(59G), under
voltage(27G), over current(51G), ground current(51N), loss
of excitation(40G), reverse power(67G) and winding temp
high. When mechanical fault occurs (due to inappropriate fuel
level, lube oil pressure, water level in the radiator and high
stack temperature) individual generator would be shut down
for individual mechanical faults and also fault alert would be Fig. 4. The process variable declearation for PLC system
made as usual. An indicator also shows the status whether the
fault is cleared or not.
Almost all the automation procedure is completed in a
program block diagram of which is shown in Figure 2. As the
number of input and output address of the PLC module that
we used is limited so only some selected control features are
considered in developing the PLC ladder program though in
the practical case many control and protection feature taken
into consideration. The generator is connected to the bus bar
through synchronizing panel and the actuator actually starts
the generator in reality.
F. Program Development
Automation software of PLC is programmed in Sucosoft
V5.02 programming software and this software is the
simulation software of the Moeller PLC which has limited
inputs and limited outputs handling capabilities. To overcome
these problems many ghost outputs as well as timers are used
in programming for convenience and only selected parameter
both electrical and mechanical are considered in this study
though the practical modern generator system handle many
control features. The Ladder Diagram (LD) PLC
programming language used easy to understand. Ladder
Diagrams are based on graphical representations with
contacts, coils and boxes, as per the circuit diagrams.
Indicator lights are used as outputs where as push button
switches are used as inputs [3].

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 Author Instructions: J. Elec. Engg., Instn. Engrs., Bangladesh, 36(II), December 2009

IV. PROGRAM EXECUTION

The ladder logic program execution by Sucosoft V5.02,
Moeller PLC software requires the following steps [3]-
1. Program development in pou editor
2. Topology configaration
3. Program code generation
4. Program transfer from computer to PLC
5. Test and commissioning
6. Program run
After following the above mentioned steps then the PLC
become ready to run the program. PLC executes the program
successfully after pressing the start switch. PLC always scan
its input address and give an output signal according the
instruction of the program. If the process sequences may need
changed or modification only change in the program will
sufficient for successful program execution.

V. CONCLUSION
The most important aspect of any power generation system
is the generation control. Several techniques can be
implemented to control the generator in power plant. The
method that has to be used relies on varied objectives like
superior quality, increased efficiency, high profit and other
such points depending upon the purpose. With the prime
objective of catering to these necessities and the needs of the
industrial sector, significance has been given here to
automation. This paper presented here has kept in mind, the
ceaseless changes that are relentlessly taking place in the
contemporary scenario of the industrial segment. Emphasis
has been given to the automation process that is now rapidly
taking its place in all the power plants across the globe. The
Paper has furnished itself to study the integral parts of the
entire process involved, their implementation and the
problems that may show up have also been given their due
importance.

ACKNOWLEDGMENT
The authors would like to thank Mr. Sharafat Ali, Assistant
General Manager, Department of Instrumentation &
Communication, Eastern Refinery Limited, Bangladesh and
Md. Ali Zulquarnain, Member, Planning, Bangladesh Atomic
Energy Commission (BAEC) for their valuable review and
comments.

REFERENCES
[1] Diesel Generator Operation Guideline, Reactor Operation and
Maintenance Unit (ROMU) of Bangladesh Atomic Energy
Commission.
[2] GUNTE, Equipment for Engineering Education,(04/02/2012)
http://www.usdidactic.com/html/p3562.htm
[3] Sucosoft S40 V5.02, Moeller PLC Software
[4] P. K. Bhowmik and M. Dey, “Protection and Control of Steam Turbine
Generator using PLC” First International Conference on Mechanical
Fig. 5. Ladder logic program of diesel generator operation and Engineering and Renewable Energy 2011 (ICMERE2011), Chittagong,
control Bangladesh, December 22-24, 2011.

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