End User: 

KSEB Pallivasal Hydro Electric Power Plant.

Scope:

Supply, installation, testing, commissioning and up gradation of existing SCADA software with two numbers industrial grade workstation SCADA Server at Pallivasal Powerhouse

Background:

The Pallivasal power project was commissioned in 1940 with an installed capacity of 37.5 Megawatt and the existing system was installed during the renovation in 2002-2003.  The total number of turbines in the power plant are six and capacity per each turbine is 3 units of 5 Megawatt and 3 units of 7.5 Megawatt.

The plant comprises of six generating units and each unit is equipped with PLC in redundant configuration. There is also a common PLC in redundant configuration for the entire six units, which is mainly used for assigning the overall set value to those redundant PLCs in individual units.

The existing SCADA system is of the make Wonderware InTouch version 7.1 with 5K tags defined and scripted. The SCADA communicates with the 7 no’s of Redundant Modicon Quantum PLCs, I/O modules in the control room and 6 no’s of Modicon Momentum PLCs which are the Governor Controllers in the machine floor, Digital Excitation Control System (DECS), HMI, GPS and also along with the Control and Protection Panels including Generator Management Relay (GMR) through the Modbus + communication protocol.

The two SCADA workstations have dual screens each and are using the same single license for operation. The SCADA server is of Compaq make with the Operating System as Windows NT4, which is configured with the MB+, LAN, Graphics, and USB communication was enabled.

The existing system installed are facing several issues such as processor lagging and hanging problems which are caused mainly due to the ageing of the system and unexpected shutdown, technical incompatibility with the current software etc.

The servers cannot be repaired due to the lack of spares of existing system and the models have become out-dated. And in case of any small failure of the SCADA server system, total control of the machine through SCADA will be lost.

System Description:

Due to the limitations in turbine control and machine protection systems, the existing system is upgraded with an entirely new, highly reliable rugged automation system.

There are two SCADA servers used for controlling the machine in the power house, one as primary server and other as standby server. The proposed SCADA system is of the make Wonderware InTouch Runtime 2017 unlimited with 60K tags. The SCADA workstations are having dual screens for each work station and using separate license for their operation. The SCADA system shall perform data acquisition, monitoring, alarm displays, Report, event & alarm logging, trends & storage of data etc.

The new SCADA system also communicates with the 7 no’s of Redundant Modicon Quantum PLCs, I/O modules in the control room and 6 no’s of Modicon Momentum PLCs in the machine floor, Digital Excitation Control System(DECS), HMI,GPS and also along with the Control and Protection panels including Generator Management Relay and feeder. 

CONSYST migrated the communication paths of the Wonderware InTouch system using Prosoft and RTU/TCP converters, this replaced legacy Modbus Plus communication protocol. PLC to SCADA communication is established through a Prosoft converter and the Generator Management Relay (GMR) is communicated to the SCADA system through a RTU/ TCP converter.

The new Wonderware InTouch Runtime 2017 has many advantages 

• The SCADA System upgrades for Accuracy, Efficiency and Reliability
• InTouch 2017 does more than ever to simplify design, increase efficiency and improves operator awareness and effectiveness, all whilst improving usability. 
• UI/UX visual enhancement:  A high performance SCADA is used for visual presentation. It has many advantages, including improved operator situation awareness and process surveillance, better abnormal situation detection and reduced training time for new operators. 
• This new system interacts with the inputs and outputs more easily than before.
• The SCADA system also uses a user’s username as input for several job assistance features like the data log print screen function etc.
• The plant overview page provides all the details a user needs to read the process and allows for adjustments to the control settings. The visualization is as simple and as clean as possible. All components are aligned with a grid, and the process orientation is logically presented.
• All related parts and parameters are given in detail on the subsystem pages. Subsystem build-up is consistent with the overview page, and all screens are kept as clean as possible to retain comprehensibility.
• The redesign stimulates the use of standards. Using standard parts and applying the standard for the colouring, alarm indications etc.
• Implemented new features to simplify user experience and improve performance. A user does not need to check for the exact location of an alarm on a whole screen since the alarm bar provides the option of jumping to that position by clicking a single button.
• The user interface shows the general state of the entire plant as well as the state of individual subsystems to keep the user informed at all times. It is also possible to simulate specific parameters and check their behaviour.
• Critical parameters will be presented differently from normal process parameters.
• For ease of monitoring, most parameters are represented in bar graphs.
• Report, event & alarm logging, trends & storage of data etc. are also better than older systems.

Result

The updated system has yielded multiple improvements in the overall operation of the plant such as: 

• Better visibility to the entire plant.
• Customised reports and trends.
• Enhanced alerts and notification page.

Rectified the issues created by outdated system such as: 

• Delay in SCADA response.
• Use of proprietary protocols.
• Troubles associated with use of old servers.

Flexibility and reliability achieved by the upgraded system has made CONSYST the best choice.