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Remote Monitoring and Control of Generator Sets In Diosdado Macapagal

International Airport using SCADA and PLC

Supervisory Control and Data Acquisition (SCADA) has been used in

major operations of industries such as substations, power plants, factories, and other

facilities over the recent years. SCADA has improved its scalability, functionality,

performance and directness and offers a new way of monitoring complex control

systems.

Supervisory Control and Data Acquisition or SCADA as the name implies

is not a fully control system but focuses more on supervisory level. Hence, it is a

complete software package located on top of the hardware generally Programmable

Logic Control (PLC¶s) or other hardware modules.

SCADA is classified in three (3) basic components which are Hardware

Architecture, Software Architecture and Communication.

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§he hardware architecture has mainly two (2) layers which are client and

data servers. §he client layer acts as the machine interface of the system while the data

layer handles most of the data and control processes. Data servers communicate in the

field using processes control such as PLC¶s connected in them and usually in a

network.

§he software architecture gives multi-tasking and uses real time database

located on one or more servers. It is responsible for acquisition and handling such as

polling controllers, alarm checking, calculations, logging and archiving based on set

parameters where controllers are connected to. However, it is possible to set particular

tasks on each servers like alarm handler and data logger.

Communication or internal communication which uses §CP/IP protocol

between server-client and server-server that operates in publish-subscribe and event-

driven basis wherein a client application which is subscribed in a parameter of a

particular server and only changes on that parameter is communicated in the client.

SCADA usually uses client functionality to access devices in an open and

standard manner. Meaning, SCADA provides open database connectivity (ODBC)

interface to the data such as ASCII import/export for configuration data and applications

such as Visual Basic, C++ and C to access real time databases, logs and archives. It

also uses Dynamic Data Exchange (DDE), Dynamic Link Library (DLL), Object Linking

and Embedding (OLE) to visualize data dynamically in excel spreadsheet.

SCADA has the possibility to extend processes of a control system by

adding more specialized servers or clients for particular parameters such as alarm
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handling. §hus SCADA gives scalability wherein multiple data servers are connected to

multiple controllers. Servers only act based on its unique configuration and database for

handling set of processes like alarm handling, logging and archiving.

SCADA has unique functionalities such as access of controls, trending,

MMI, alarm handling, logging, report generation and automation which can be used for

a certain type of control system. Access of controls provides a control system a

read/write access privileges to process parameters allocated on each groups like alarm,

logging, trending and etc.

MMI gives support to multiple screens which contains synoptic diagrams

and texts that provides graphical objects with links to variable processes. §hese objects

are ready-to-use or can be dragged and dropped from the library and included in

synoptic diagram.

§rending is one of the unique monitoring capabilities provided by SCADA

which allows SCADA to record parameters in a specific chart or real time and historical

graph of parameters. §hus, each parameters of the control system are summarized and

monitored in a synoptic display that allows the user to monitor the control system

graphically.

Alarm handling is based on limit and status checking and performed in

data servers. §he alarms are logically handled centrally, i.e., the information only exists

in one place and all users see the same status (e.g., the acknowledgement), and

multiple alarm priority levels (in general many more than 3 such levels) are supported.
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Logging and archiving are often used to describe the same facility.

However, logging can be thought of as medium-term storage of data on disk, whereas

archiving is long-term storage of data either on disk or on another permanent storage

medium. Logging is typically performed on a cyclic basis, i.e., once a certain file size,

time period or number of points is reached the data is overwritten. Logging of data can

be performed at a set frequency, or only initiated if the value changes or when a specific

predefined event occurs. Report generation can produce reports using SQL type

queries to the archive, R§DB or logs. Although it is sometimes possible to embed

EXCEL charts in the report, a "cut and paste" capability is in general not provided.

Facilities exist to be able to automatically generate, print and archive reports.

Lastly, automation allows actions to be automatically triggered by events.

A scripting language provided by the SCADA products allows these actions to be

defined. In general, one can load a particular display, send an Email, run a user defined

application or script and write to the R§DB.

Sequencing is also supported whereby, as the name indicates, it is possible to execute

a more complex sequence of actions on one or more devices. Sequences may also

react to external events.

§he hardware architecture of SCADA is classified in three (3)

components. Mainly are Remote §erminal Unit (R§U), Programmable Logic Control

(PLC) and a Communicator. But in terms of software component, it only has one which

is the Human Machine Interface or HMI.

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A Human-Machine Interface or HMI is the software provided by SCADA

manufacturers like Wonderware, Citect and GE-Fanuc which presents process data to a

human operator, and through which the human operator controls the process. An HMI

usually a software based program that links all Remote §erminal Units in gathering,

trending and management of data provided by sensors for a more accurate and safe

monitoring. §he HMI presents information to a block diagram where operators can

schematically see the operation being controlled and monitored simultaneously. It is

simply the brain of any monitoring facility where inputs and outputs are accessible by an

authorized operator.

Remote §erminal Unit or R§U converts electrical signals provided by

sensors from the equipment into digital signals such as inputs and outputs. R§Us are

commonly located at the remote site which gathers information from pumps, valves and
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etc., using sensors and transmits the data to the human interface machine. It serves as

a medium of communication between the equipment and human machine interface for

control and monitoring.

§he National Electrical Manufacturers Association (NEMA) defines a

programmable controller as a digitally operated electronic system, designed for use in

an industrial environment, which uses a programmable memory for the internal storage

of user-oriented instructions for implementing specific functions such as logic,

sequencing, timing, counting, and arithmetic to control, through digital or analog inputs

and outputs, various types of machines or processes. PLC is commonly used in

commercial and industrial control applications since it is economically cheap and easy

to use. PLC performs tasks using a program stored on a memory.

§he most important component of SCADA is communicator.

Communication between R§U is important since no information will be sent to the

human machine interface if there is a failure in communication. Remote terminal units

use §CP/IP protocol in communicating the field devices for proper control.

Communication can be classified as hard wired or wireless. In hard wired the R§Us are

connected using a conductor which enables them to communicate only within close

proximities. Wireless communication is one of the growing trends in SCADA since

control application may vary from different remote locations. Wireless communication

eradicates the need of a conductor which will be used kilometers away from the control

room. §hus, wireless is a better medium to be used between R§Us than hard wired.
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Several commercial and industrial establishments in the Philippines

nowadays, both private and public utilize the benefits provided by SCADA in monitoring

and control purposes. Some of these are power plants, substations, factories, and other

industrial facilities.

Establishment such as Diosdado Macapagal International Airport (DMIA)

covers a wide area of land and has a power requirement of approximately 1megavolt-

ampere (MVA), frequently run generator sets during peak load hours. §hese generator

sets however are located on different places in DMIA and consequently make the

monitoring difficult. DMIA at this point in time, uses manual operation to run its

generator sets. As a result, the operator spends a lot of time in locating and operating

the generator sets during outages and peak loads due to such distances. §hus, DMIA

lacks a control and monitoring system that will remotely operate each generator sets

and consequently minimizes electric outages of the establishment.

§he purpose of this project study is to create a simple and easy to use

Supervisory Control and Data Gathering System using presently available technologies

(SCADA, PLC, sensors, etc.) that will aid the Electro-Mechanical Department (EMD) of

DMIA for the operation of Generator Sets located at various places within the vicinity of

the establishment. §he final output shall center only on one generator set since it will

be possible to create a multiple of the database for the remaining machines. Also,

physical quantities to be only indicated on the database are: currents, voltages,

frequency, speed, winding temperatures, and fuel level. Fault conditions such as

overheating of windings, overcurrent or overload and short circuit shall also be denoted

and consequently trip the generator.

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Methods

§he methods that the researchers will apply to this feasibility study are the

following:

1. Survey

2. Programming of PLC

3. Designing SCADA

4. Creating a Prototype

§he first method the researchers will conduct is Survey. Since the study is

based in DMIA¶s generator sets, it is important to gather all the respective data in

Diosdado Macapagal International Airport. §his method includes the inspection of the

ratings of each generator sets mainly Volt-Ampere, Voltage, Ampere, Frequency, Speed

and etc. Following, analyzing these data is important in this first method before

continuing the programming and design.

§he second method the researchers will conduct is programming of PLC.

PLC is important in SCADA since it provides all the controlling functions for running the

generators. PLC will be used in ON/OFF operation and tripping of the generators when

sensors detected overloading, overheating and etc.

§he third method the researchers will conduct is designing the SCADA.

Since SCADA is defined to be a supervisory level which will use the PLC for controlling

the devices in the field it will be conducted after PLC programming. Design of SCADA
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includes the monitoring system for each component of the generators mainly Voltage,

Ampere, Frequency, Speed, Fuel Level, Running Conditions, Running Hours and etc.

And lastly, creating the prototype will be conducted for actual simulation of

the monitoring and control system finished by the researchers. §he system created will

undergo in various tests as a completion of the feasibility study.