Analysis Of Power Consumption By Using Programmable Logic Controller (PLC).
FAKULTI KEJURUTERAAN ELEKTRIK
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ANALYSIS OF POWER CONSUMPTION BY USING PROGRAMMABLE LOGIC CONTROLLER (PLC)
Nurain Binti Othman
Bachelor of Electrical Engineering (Power Industries)
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“I hereby declare that I have read through this report entitle “Analysis of Power Consumption by using Programmable Logic Controller” and found that it has comply the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering (Industrial Power)”
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ANALYSIS OF POWER CONSUMPTION BY USING PROGRAMMABLE LOGIC CONTROLLER (PLC)
NURAIN BINTI OTHMAN
A report submitted in partial fulfill requirement of the requirements for the degree of Bachelor of Electrical Engineering (Industrial Power)
Faculty of Electrical Engineering
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
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I declare that this report entitle “Analysis of Power Consumption by using Programmable Logic Controller (PLC)” is the result of my own research except as cited in the references. The report has not been accepted for any degree and is not concurrently submitted in candidature of any other degree.
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ACKNOWLEDGEMENT
First of all, I really would like to thank to Allah S.W.T for His approval and blessing that made all this happened and come true.
Firstly, a special and most honored gratitude to my project supervisor En Mohd Shahril Bin Ahmad Khiar for his guidance, teachings and support throughout this project. I am truly honored and humble to have him as my supervisor because of his knowledge and expertise in very vast and wide. His effort and willingness to sacrifice his golden time to guide me in all aspect of final year project in order to complete the task within the specified time frame. I am beyond doubt enjoyed the challenge of discussing in various aspects and topics regarding my project with him which later helped me improve my final project and knowledge about it.
Besides that, a special thanks to my acquaintances and my family for helping me with their precious suggestions and supports throughout the completion of this project. Your kindness will be embedded in my heart forever.
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ABSTRACT
The rapid growth of electricity consumption increased in accordance with the development of the country to reach its status as the industrial countries. The development of supervisory system that control and monitor play an important role to balance energy production and to evaluate the consumption needs from the consumer. Nowadays, the usage of power for individual house may increase if there is less aware on power wasting. By turning on electrical appliances that may not be beneficial enough for the owner, it will increase the power usage that obviously will double up the cost of utility billing. The aim of this project is to control and monitor in load utilization by using Programmable Logic Controller (PLC) via Human-machine Interface (HMI). Hence, PLC is used as the centralized component of sending and receiving data to the system via HMI and analyse power consumption based on customer usage with a several cases. The eight cases of load utilization and its power consume will be investigated. This program will be run by designing ladder programming software and user interface program while its controller will be developed using PLC. The development of this monitoring and controlling system is simulated through the implementation of eight cases mentioned previously. As a result, the outputs of power obtained from HMI display are identical with theoretical value and this project can be applied in domestic house for controlling and monitoring the power usage.
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ABSTRAK
Pertumbuhan pesat penggunaan elektrik meningkat selaras dengan pembangunan negara untuk mencapai status sebagai negara perindustrian. Pembangunan sistem penyeliaan yang mengawal dan memantau memainkan peranan yang penting untuk mengimbangi pengeluaran tenaga dan menilai penggunaan keperluan dari pengguna. Pada masa kini, penggunaan kuasa untuk rumah individu boleh meningkat jika terdapat kurang kesedaran tentang pembaziran kuasa. Dengan menghidupkan peralatan elektrik yang mungkin tidak cukup memberi manfaat kepada pemilik, ia akan meningkatkan penggunaan kuasa yang jelas akan menggandakan kos bil utiliti. Tujuan projek ini adalah untuk mengawal dan memantau dalam penggunaan beban dengan menggunakan Programmable Logic Controller (PLC) melalui Muka Manusia-mesin (HMI). Oleh itu, PLC digunakan sebagai komponen berpusat bagi menghantar dan menerima data kepada sistem melalui HMI dan menganalisis penggunaan kuasa berdasarkan penggunaan pelanggan dengan mengambil kira beberapa kes. Beberapa penggunaan beban dan menggunakan kuasa yang akan disiasat. Program ini akan dikendalikan untuk mereka bentuk tangga perisian pengaturcaraan dan pengguna program antara muka manakala pengawal yang akan dibangunkan dengan menggunakan PLC. Hasilnya, pengeluaran kuasa yang diperolehi dari paparan HMI adalah sama dengan nilai teori dan projek ini boleh digunakan di dalam rumah domestik bagi mengawal dan memantau penggunaan kuasa. Pemantauan pembangunan dan strategi mengawal adalah simulasi berdasarkan pelaksanaan penggunaan beban kes.
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TABLE OF CONTENTS
CHAPTER TITLE PAGE
ACKNOWLEDGEMENT i
ABSTRACT ii TABLE OF CONTENTS iv
LIST OF TABLES vi LIST OF FIGURES vii LIST OF ABBREVIATION ix
LIST OF APPENDICES x 1 INTRODUCTION 1.1 Project Background 1
1.2 Motivation 2
1.3 Problem Statement 3
1.4 Objectives 3
1.5 Project Scope 4
1.6 Thesis Outline 5
2 LITERATURE REVIEW 2.1 Introduction 6 2.2 Control and Monitor System 6
2.3 Supervisory Control and Data Acquisition (SCADA) System 7 2.4 Applications of SCADA system 7 2.4.1 Power Substation System 8
2.4.2 Remote Control and Monitoring System 9
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CHAPTER TITLE PAGE
2.5 Serial Communication 10
2.5.1 RS-232 and RS-485 11
2.5.2 Human-Machine Interface 12
2.6 Programmable Logic Controller (PLC) 13
3 METHODOLOGY 3.1 Introduction 14 3.2 Description of Design and Development Project 17 3.2.1 Drawing Plan 18 3.3 Software Development 3.3.1 CX-Programmer Tool 3.3.2 CX-Protocol Tool 3.3.3 NB-Series Programmable Terminal(PTs) 20 20 28 32 3.4 Hardware Development 38
3.5 Analysis Power Consumption 40
4 RESULTS AND DISCUSSIONS 4.1 Introduction 42
4.2 Theoretical Result of Load Calculation 42
4.3 Experimental Verification Result 44
4.4 Discussion on Comparison between Experimental and
Theoretical Result
47
5 CONCLUSION AND FUTURE WORKS
5.1 Conclusion 50
5.2 Recommendations 51
REFERENCES 52
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LIST OF TABLES
TABLE TITLE PAGE
3.1 Address and Data Type of the whole project ladder diagram 27
3.2 Frame ID with its name 33
3.3 Hardware Development with its description for whole project 38
3.4 Implementation of eight several cases 41
4.1 Theoretical result in power (watt) value 43
4.2 Experimental result in power (watt) value 46
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LIST OF FIGURES
FIGURE TITLE PAGE
2.1 Example of SCADA system in power substation 8
2.2 Hardware configuration system 11
2.3 A poor and good HMI graphic 12
2.4 Programmable Logic Controller General Scheme 13
3.1 Flow chart of whole project methodology 15
3.2 Main equipment in this project that related to each other 18
3.3 Plan drawing for this project 20
3.4 Main Screen of CX- Programmer software programming 22
3.5 Whole Ladder diagram Project 23
3.6 Main screen of CX-Protocol tools 29
3.7 Send message command data and its check code 30
3.8 Receive message command data and its check code 31
3.9 NB-Designer tools 32
3.10 Main screen displays of the system 33
3.11 Manual Screen 1 displays 34
3.12 Manual Screen 2 displays 35
3.13 Automatic screen displays 35
3.14 Power analyzer displays 36
3.15 Graph Result Displays 37
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4.1 Experimental result in HMI displays and PLC programming for Case 1
45
4.2 Load utilization result for Case 1 46
G1 Experimental result in HMI displays and PLC programming
for Case 2
63
G2 Load utilization result for Case 2 63
G3 Experimental result in HMI displays and PLC programming
for Case 3
64
G4 Load utilization result for Case 3 64
G5 Experimental result in HMI displays and PLC programming
for Case 4
65
G6 Load utilization result for Case 4 65
G7 Experimental result in HMI displays and PLC programming
for Case 5
66
G8 Load utilization result for Case 5 66
G9 Experimental result in HMI displays and PLC programming
for Case 6
67
G10 Load utilization result for Case 6 67
G11 Experimental result in HMI displays and PLC programming
for Case 7
68
G12 Load utilization result for Case 7 68
G13 Experimental result in HMI displays and PLC programming
for Case 8
69
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LIST OF ABBREVIATIONS
PLC Programmable Logic Controller
HMI Human-Machine Interface
SCADA Supervisory Control and Data Acquisition
NB-Series PT NB-Series Programmable Terminal
RTU Remote Thermal Unit
IP Internet Protocol
SMS Short Message System
GSM Global System for Mobile
LAN Local Area Network
AC Alternating Current
DC Direct Current
W Watt
P Power
V Voltage
I Current
kWh Kilowatt-hour
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LIST OF APPENDICES
APPENDIX TITLE PAGE
A System connection between PLC and Load 55
B System connection between PLC and Power Analyzer 57
C System configuration of NB-series Programmable
Terminal(PTs) with PLC
58
D Specification of Programmable Logic Controller 59
E Serial Communication and Variable Data Mapping
Protocol
60
F Datasheet of Power Analyzer 62
G Data that Captured for All Cases for this Project in
PLC,HMI Displays and Load Utilization
63
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CHAPTER 1
INTRODUCTION
1.1Project Background
The world now is facing situation where the demand of power and electricity is very high and continuously progressing from time to time. Electricity is needed to run everyday life and to make world a better place to stay and live. The growth of electric utilities in size and number of interconnecting has increased recently. The development of advancement in software and microprocessor technology provide great controller that is very useful for human daily life. There are many studies in literature review about control and monitoring application is widely used nowadays. Great investment is made to achieve more comfortable conditions with optimal control of system to obtain maximum benefits. Today, the improvements in the system communications have simulated the implementation of distributed systems. These distributed systems are then usually managed by a centralized supervisory platform, commonly known as Supervisory Control and Data Acquisition (SCADA) system.
Besides, Human-Machine Interface (HMI) is part of the machine that involves in study, planning and design of the interaction between users and other devices. Example of HMI which user can see and touch is membrane switches, rubber keypads and touch screen. In HMI interface design it consists of three stages which is interaction specification, interface software specification and prototyping.
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controlling and monitoring system using Programmable Logic Controller (PLC). To make it even easier, the system should have HMIwhich is touch screen program to control, monitor and display all the parameters involve.
1.2Motivation
The purpose of this project is to design an advanced controlling and monitoring system of power consumption to satisfy and ease consumer’s daily routine that involve power usage. It is based on basic operation of electricity loads including lighting and fan that the controlling and monitoring process of their power consumption in different place can be achieved by one command through visual user interface. For example, lights at room are still on even though there are no people inside the room. The power wasted is highly not recommended since the peak demand may increase and literally cause the cost of power usage increasing too. Thus, this project provided time saving in which user can interact through visual user interface to control and monitor all places in the house at one point. Furthermore, the measurement of power consumption is carried out to determine the difference and relationship between types of load used in a house via eight cases.
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Demand in loads is increasing each day. Furthermore, it increasing rapidly in certain condition and the generation part cannot cope with the particular occurrence scenario that may lead to power demand exceeding the power generate in generation plants. This scenario also happens due to over-usage of power by the loads. As it is acknowledged, nowadays electrical network in domestic house is utilizing switches for on and off any particular electrical equipment. Loads like fans and lightings are installed in several places in the house and the switches might be installed everywhere nearer to the loads. Therefore, this project offers the usage of controlling and monitoring all the loads just in one single center. The center means consumer may be able to access every load in the house just in one place without putting an effort to reach for switches of the loads. Besides, this project offers consumer the power consume per loads so that the consumer may know actual power rating of loads utilized and increasing their awareness towards shutting down loads that are unused and consume higher power rating.
1.4Objectives
There are four main objectives that need to be completed in order to make this project successful. They are:
1) To study about controlling and monitoring system and its applications.
2) To design and develop a power consumption monitoring system using
Programmable Logic Controller (PLC) via Human-Machine Interface
3) To design and develop a control load using Programmable Logic Controller (PLC)
via Human-Machine Interface
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This project is focused on development and implementation on controlling and monitoring system for consumer in one of a domestic house. The aim is to control loads and monitor power consumption using PLC type OMRON CJ2M-CPU11 via HMI type OMRON NB-Series Programmable Terminal (PT) with real load utilization that consists of lighting and fan in a house. Initially, all the equipments that involve are OMRON CJ2M-CPU11 PLC-Type, OMRON NB-Series PT and Power Analyzer. All of these equipments will be connected via the utilization of serial communication standard (232 and RS-485). As for acknowledgement, OMRON NB-Series PT is the device that acts as HMI for this project. They are CX-Programmer (for PLC), CX-Protocol (for Power Analyzer) and NB-Designer (for HMI). There are number of loads involved. They are seven unit fluorescent lamps with five using magnetic ballasts and another two lamp using electronic ballasts. As additional loads, two wall fans are also involves. All of these respective loads are installed on a wooden board for the analogy of loads distribution in domestic house. There load are labeled and there are also software involve as well. Then, analysis will demonstrate in comparison of power consumption between experimental result and theoretical result based on the implementation of load utilization. The implementation of all load utilization is observed based on eight cases that control and monitor by consumer.
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Chapter 1 briefly summarizes the project background and problem statements as well as elaborates the problem statement, objectives, motivation, and scope of the project and thesis outlines.
Chapter 2 describes about literature review. The contents include about the development of controlling and monitoring system, SCADA system, HMI and power consumption theory.
Chapter 3 is about the research methodology of the project. It discusses in detailed the project development to complete the project. The utilization of software and hardware combination is implemented throughout the project. Besides, the eight cases for load are manually controlled and monitored. All steps from beginning until the end of this project are concluded.
Chapter 4 illustrates result and describes the purpose of eight cases. This chapter will conclude that most profitable method to reduce in terms of reduction of energy consumption and bill payment. The payback period on each method will be discussed on this chapter.
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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This chapter discuss about the brainstorming related with this project. The sources are from part journals and book related with monitoring and controlling system, Supervisory Control and Data Acquisition (SCADA) system and its application, serial communication and SCADA software via Human-Machine Interface (HMI).
2.2 Monitoring and Controlling System
Monitoring and control can be defined as the centralized to control of a system such as devices or network through automated system or managed by control unit either with or without display information. Nowadays, market profile is the main cause described according given to which varies among sector in industrial automation, power grid and critical infrastructure in control and monitoring system [1]. Thus, with the flows to global issue in exploration of monitoring and control system may be affected by the impacts from charging the base for drivers such as in development of services, energy efficiency, cost of oil and gas, safety, security, and others. One of example monitoring and control system that used nowadays is SCADA system.
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SCADA can be defined as a type of and industrial control system by using computer networking. The computer will be functioning as controlling and monitoring in physical world. The main purpose of SCADA is combined real-time data, monitoring and controlling equipment process in critical facilities such as oil and gas production, transmission and distribution, industrial control, electrical power distribution process monitoring, display information in a graphical user interface and others types of application that related to SCADA system [2]. A SCADA network is necessary provided connection between servers which in a particular inside a control centre and control device which located at fields sometimes are remote location. SCADA system essential of several equipments such as HMI, Remote Thermal Unit (RTU), Programmable Logic Controller (PLC), substation controller server, power equipment and others system [3]. Furthermore, SCADA system also plays an important role by providing utilities with valuable information at the same time in a reliable and safe manner.
2.4 Application of SCADA System
Application of SCADA system consists of one or more devices which is RTU and PLC. A communication system is used to transfer data between field interface device and control unit of the component in SCADA central host. Other than that, a collection of standard and custom software which is called HMI used to provide the SCADA central host and operator terminal application and support the communication system and monitor and control located field data interface devices [4]. Besides, SCADA system is applied in power substation system, remote control and monitoring system and auto-controlled automation system. All of these applications are described in the next sub chapter under application of SCADA system.
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One of example of SCADA system is in power substation is shown in Figure 2.1. Today, electrical substation required manual switching or adjustment of equipment and manual collection of data for load, energy consumption and abnormal events. According to Figure 2.1, one of room control centre will control all the room according to the connection in Ethernet, serial and others. The system use HMI (Modbus TCP) as monitoring and PLC are use as the device for control the system [5].
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Nowadays, human daily life becomes more good cause by the exploration of current development in software and microprocessor technology. Furthermore, the internet respected as powerful medium for future technology. Furthermore, the internet represented as a future technology. Distributed internet access is the fundamental assumption from one side to another set of applications that come with a solution which is save time, cost and others. The use of Personal Computers (PC), subscriber station and wireless connectivity content disperse widely lead to the popular use of high-tech devices applications. An industrial system is an example of a multi-user system that can be monitor and control by remote. The process are design based on different equipment and methods to operate system efficiently and economic. However, new applications require further development to improve the quality of performance, standards, internet protocol (IP) addressing, accessing and security [6]. The networking allows the combination of communication which involves the management and operation of smart devices and system [7]. All the information in controlling system and its status information, it can be sent along power line or other structure including wireless or others [8]. The implementation wiring can be form by communication infrastructure.
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1.5Project Scope
This project is focused on development and implementation on controlling and monitoring system for consumer in one of a domestic house. The aim is to control loads and monitor power consumption using PLC type OMRON CJ2M-CPU11 via HMI type OMRON NB-Series Programmable Terminal (PT) with real load utilization that consists of lighting and fan in a house. Initially, all the equipments that involve are OMRON CJ2M-CPU11 PLC-Type, OMRON NB-Series PT and Power Analyzer. All of these equipments will be connected via the utilization of serial communication standard (232 and RS-485). As for acknowledgement, OMRON NB-Series PT is the device that acts as HMI for this project. They are CX-Programmer (for PLC), CX-Protocol (for Power Analyzer) and NB-Designer (for HMI). There are number of loads involved. They are seven unit fluorescent lamps with five using magnetic ballasts and another two lamp using electronic ballasts. As additional loads, two wall fans are also involves. All of these respective loads are installed on a wooden board for the analogy of loads distribution in domestic house. There load are labeled and there are also software involve as well. Then, analysis will demonstrate in comparison of power consumption between experimental result and theoretical result based on the implementation of load utilization. The implementation of all load utilization is observed based on eight cases that control and monitor by consumer.
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Chapter 1 briefly summarizes the project background and problem statements as well as elaborates the problem statement, objectives, motivation, and scope of the project and thesis outlines.
Chapter 2 describes about literature review. The contents include about the development of controlling and monitoring system, SCADA system, HMI and power consumption theory.
Chapter 3 is about the research methodology of the project. It discusses in detailed the project development to complete the project. The utilization of software and hardware combination is implemented throughout the project. Besides, the eight cases for load are manually controlled and monitored. All steps from beginning until the end of this project are concluded.
Chapter 4 illustrates result and describes the purpose of eight cases. This chapter will conclude that most profitable method to reduce in terms of reduction of energy consumption and bill payment. The payback period on each method will be discussed on this chapter.
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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This chapter discuss about the brainstorming related with this project. The sources are from part journals and book related with monitoring and controlling system, Supervisory Control and Data Acquisition (SCADA) system and its application, serial communication and SCADA software via Human-Machine Interface (HMI).
2.2 Monitoring and Controlling System
Monitoring and control can be defined as the centralized to control of a system such as devices or network through automated system or managed by control unit either with or without display information. Nowadays, market profile is the main cause described according given to which varies among sector in industrial automation, power grid and critical infrastructure in control and monitoring system [1]. Thus, with the flows to global issue in exploration of monitoring and control system may be affected by the impacts from charging the base for drivers such as in development of services, energy efficiency, cost of oil and gas, safety, security, and others. One of example monitoring and control system that used nowadays is SCADA system.
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SCADA can be defined as a type of and industrial control system by using computer networking. The computer will be functioning as controlling and monitoring in physical world. The main purpose of SCADA is combined real-time data, monitoring and controlling equipment process in critical facilities such as oil and gas production, transmission and distribution, industrial control, electrical power distribution process monitoring, display information in a graphical user interface and others types of application that related to SCADA system [2]. A SCADA network is necessary provided connection between servers which in a particular inside a control centre and control device which located at fields sometimes are remote location. SCADA system essential of several equipments such as HMI, Remote Thermal Unit (RTU), Programmable Logic Controller (PLC), substation controller server, power equipment and others system [3]. Furthermore, SCADA system also plays an important role by providing utilities with valuable information at the same time in a reliable and safe manner.
2.4 Application of SCADA System
Application of SCADA system consists of one or more devices which is RTU and PLC. A communication system is used to transfer data between field interface device and control unit of the component in SCADA central host. Other than that, a collection of standard and custom software which is called HMI used to provide the SCADA central host and operator terminal application and support the communication system and monitor and control located field data interface devices [4]. Besides, SCADA system is applied in power substation system, remote control and monitoring system and auto-controlled automation system. All of these applications are described in the next sub chapter under application of SCADA system.
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2.4.1 The Application of SCADA in Power Substation System
One of example of SCADA system is in power substation is shown in Figure 2.1. Today, electrical substation required manual switching or adjustment of equipment and manual collection of data for load, energy consumption and abnormal events. According to Figure 2.1, one of room control centre will control all the room according to the connection in Ethernet, serial and others. The system use HMI (Modbus TCP) as monitoring and PLC are use as the device for control the system [5].
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Nowadays, human daily life becomes more good cause by the exploration of current development in software and microprocessor technology. Furthermore, the internet respected as powerful medium for future technology. Furthermore, the internet represented as a future technology. Distributed internet access is the fundamental assumption from one side to another set of applications that come with a solution which is save time, cost and others. The use of Personal Computers (PC), subscriber station and wireless connectivity content disperse widely lead to the popular use of high-tech devices applications. An industrial system is an example of a multi-user system that can be monitor and control by remote. The process are design based on different equipment and methods to operate system efficiently and economic. However, new applications require further development to improve the quality of performance, standards, internet protocol (IP) addressing, accessing and security [6]. The networking allows the combination of communication which involves the management and operation of smart devices and system [7]. All the information in controlling system and its status information, it can be sent along power line or other structure including wireless or others [8]. The implementation wiring can be form by communication infrastructure.