© June 2023| IJIRT | Volume 10 Issue 1 | ISSN: 2349-6002

Design of PLC-SCADA Based Fuel Control System for

Thermal Power Station

Dr. G. Soorya Priya1, C. Ramya Devi2, A. Amala Punitha3, S. Preethi3

1
Assistant Professor, Department of Electrical and Electronics and Engineering Loyola Institute of
Technology, Chennai, India
2,3,4
B.E, Department of Electrical and Electronics Engineering, Loyola Institute of Technology, Chennai,
India

Abstract- Over the years the demand for high quality, and outputs (I/O), in a housing integral with the
greater efficiency and automated machines has increased processor, to large rack-mounted modular devices
in this globalised world. This paper summarizes the with thousands of I/O, and which are often networked
various stages of operations involved in the conversion of
to They can be designed for many arrangements of
a manually operated fuel system in boiler towards a fully
digital and analog I/O, extended temperature ranges,
automated. The automation is further enhanced by
constant monitoring of fuel using SCADA screen which immunity to electrical noise, and resistance to
is connected to the PLC by means of communication vibration and impact. Programs to control machine
cable. In order to automate a power plant and minimize operation are typically stored in battery-backed-up
human intervention, there is a need to develop a SCADA or non-volatile memory. PLC are broadly classified
system that monitors the plant and helps reduce the into two based on the power supply as AC and DC and
errors caused by humans. In this project SCADA system based on outputs they are classified into relay type and
is used in monitoring the boiler parameter likes transistor type respectively. PLCs use built-in ports,
temperature, pressure, flow, level. Sensors are used to
such as USB, Ethernet, RS-232, RS-485, or RS-422 to
monitor the parameter and the sensed signals are
communicate with external devices (sensors,
processed by PLC and monitor with SCADA the signals
are compared with the reference parameter and the actuators) and systems (programming software,
respective valves of the parameter are adjusted with the SCADA, HMI). Communication is carried over
monitoring and logic control system. various industrial network protocols, like Modbus,
or EtherNet/IP. Many of these protocols are vendor
Keywords: Supervisory Control and Data Acquisition specific. Other PLC and SCADA systems.
(SCADA), Programmable Logic Controller (PLC),
Inputs/Outputs tags, Programming Interface, Alarms.
B. SCADA
Supervisory control and data acquisition (SCADA) is
I. INTRODUCTION
a control system architecture comprising computers,
networked data communications and graphical user
A. programmable logic controller interfaces for high-level supervision of machines and
A programmable logic controller (PLC) or processes. It also covers sensors and other devices,
programmable controller is an industrial computer that such as programmable logic controllers, which
has been ruggedized and adapted for the control of interface with process plant or machinery.
manufacturing processes, such as assembly lines, The operator interfaces which enable monitoring and
machines, robotic devices, or any activity that requires the issuing of process commands, like controller set
high reliability, ease of programming, and process point changes, are handled through the SCADA
fault diagnosis. Dick Morley is considered as the computer system. The subordinated operations, e.g.
father of PLC as he had invented the first PLC, the the real-time control logic or controller calculations,
Modicon 084, for General Motors in 1968. PLCs can are performed by networked modules connected to the
range from small modular devices with tens of inputs field sensors and actuators.

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The SCADA concept was developed to be a universal III. PROPOSED SYSTEM

means of remote-access to a variety of local control
modules, which could be from different manufacturers A. Block Diagram
and allowing access through standard automation
protocols. In practice, large SCADA systems have
grown to become very similar to distributed control
systems in function, while using multiple means of
interfacing with the plant. They can control large-scale
processes that can include multiple sites, and work
over large distances as well as small distance. It is one
of the most commonly-used types of industrial control
systems, in spite of concerns about SCADA systems
being vulnerable to cyberwarfare/cyberterrorism
attacks.
II. LITERATURE SURVEY

Kalappan, K. Balachander & Amudha, Alagarsamy.

(2017).
In this paper they have used Allen Bradley PLC for
automation of Thermal power plant which uses light
diesel oil as a fuel mechanism. In the existing system
they just used PLC to automate the pumping process
The main aim of the project is to control the flow of
alone, not for the complete cycle of burning process,
the fuel fed into the furnace and it is controlled by
this is overcomed in the proposed model where PLC
opening and closing of the solenoid values at
as a controlling devices for the Thermal power plant
appropriate time by getting the signal from the delta
where it uses Lignite as a fuel for burning process and
plc. Here we have used Delta DVP20 EX2 model plc
SCADA is used as a monitoring tool. SCADA
for the application and its more over a relay type plc
provides a graphical representation of real time data
which is most commonly used in industries. And the
which makes easier for the user to understand the
language used for the coding purpose is called as the
entire operation and also provides various advantages
ladder language and the software used is WPL soft
such as saving of data logs, sharing across different file
V2.51 and the communication cable used for the
systems.
interfacing of PC to PLC is RS232.And SCADA is
used a monitoring tool for the entire developed model.
Rajesh Kumar, Roshan Kumar 2017). The software used in SCADA is Intouch Wonderware
In this paper the Fuel handling System (FHS) has 10.0.0.1 and the communication between the PLC and
discussed about different types of fuels that are SCADA is through KEPSERVER software which acts
generally used for initial startup of the boiler and it will as a link between the PLC and SCADA.
be used until it reaches 30% of the load demand. From
the paper we can see that the according to the load The program for the PLC is attached below:
demand the percentage of the fuel used also varies say
if there is a sudden load rise then fuel is turned on up
to a certain period of time until the plant is capable of
meeting up to the load demand. Moreover it gives a
brief overview on how to handle fuel in Thermal
power stations, these concepts are utilized in the
project as well.

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Y14- tank4 indicator

Y20 – tank change indicator
The simulation results of the WPL soft v2.51

Tank switch process in simulation of WPL soft v2.51

SCADA is used as a monitoring tool for the entire

operation developed by the PLC, here we used Intouch
Wonderware 10.0.0.1 and the exact prototype of the
existing industrial model is developed in the Scada
software and the scripts are written to monitor all the
parameters. The entire developed Scada model is
shown in the below

List of switches used

X0 – start / stop switch
X11 – Emergency Switch
X1 – tank1 switch
X2 – tank2 switch
X3 – tank3 switch
X4 – tank4 switch
X12 – reset alarm
Y0 – tank1solenoid value
Y1 – tank2 solenoid value
Y2 – tank3 solenoid value The above picture shows the schematic model
Y3 – tank4 solenoid value developed in the scada software which simulates the
Y10 – tank1 indicator real time environment, as seen there are four tanks and
Y11 – tank2 indicator they are operated in a particular sequence and process
Y13 – tank3 indicator of drain and filling is indicated by the green colour in

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the values and when the valves are closed they are
indicated by the red in colour. There is a centralised
operation switch where it can be on or off.

ALARM MANAGEMENT

The above is the Alarm management window there are

two sensors places inside each tank one for the low-
level sensor and high-level sensor and it will
SYSTEM PARAMETER automatically indicate a warning in the Alarm
In the system parameter window displays all operating management tool and also provides indications for
tank parameters and it also displays the reading of each tank.
pressure, temperature and operating time of each tank Scripts used in SCADA
and also has a dedicated switch for turning on and off application script
the system via scada there are also indicators which #declaring all the tanks are full in initial condition
blinks when the particular tank is in operation. tank1=100;
tank2=100;
tank3=100;
tank4=100;
t1 = 100;
t2= 100;
t3= 100;
t4= 100;
# tank operation sequence
IF switch==1 AND tank1>0
THEN
tank1=tank1 - 0.2;
ENDIF;
IF switch==1 AND tank1<2 AND tank2>0
THEN
tank2=tank2 - 0.2;
TREND GRAPH
ENDIF;
The above is the trend graph there are two trend graphs
IF switch==1 AND tank2<2 AND tank3 >0
which displays both temperature and pressure of each
THEN
tank, the graph on the left is called as the real time
tank3=tank3 - 0.2;
trend, as the name denotes this graph is a live graph
ENDIF;
and shows only live on field values and the graph on
IF switch==1 AND tank3<2 AND tank4>0
the right side is called as the historical trend and this
THEN
graph has historical collection of temperature and
tank4=tank4 - 0.2;
pressure reading of past few days.
ENDIF;
IF tank4<2

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THEN sec2=sec2+1;
tank1=100; ENDIF;
tank2=100; IF tank4>1 AND tank3<=0
tank3=100; THEN
tank4=100; sec3=sec3+1;
ENDIF; ENDIF;
IF switch==1 IV FUTURE SCOPE
THEN
t1=t1 - 0.2; Emergency diesel generator can be added to the
ENDIF; existing model in order to prevent entire load
IF switch==1 AND t1<2 shutdown during blackout conditions. Variable speed
THEN Drives can be added to the existing model to control
t2=t2 - 0.2; the speed of the ID(induced Draft fan) and can be
ENDIF; connected to the plc and communication can be
IF switch==1 AND t2<2 established between the plc and the Drive so that
THEN according to the load the speed of the fan as well as the
t3=t3 - 0.2; flow of the fuel can be controlled (turned on/off). For
ENDIF; additional security purpose a security script can be
IF switch==1 AND t3<2 added to the SCADA so that only authorised person
THEN can access the script or manage the changes in the files
t4=t4 - 0.2; created and make changes. The traditional solenoid
ENDIF; valves can be replaced with flow control valves so that
IF tank4<2 the flow will be limited instead of entire cut off done
THEN in the solenoid valve case
t1=100;
t2=100; V.CONCLUSION
t3=100;
t4=100; In this project designed and implemented boiler
ENDIF; automation using PLA and SCADA. Temperature and
FileWriteFields( "c:\\TANK11.csv",-1, "tank1" ,4 ); pressure are all measured using various sensors. PlC is
on show used to control the operation, while SCADA is used to
temp=28; monitor the parameters. The entire setup will
while show 7 sec shutdown and automatic check values will open to
IF switch==1 AND temp<32 release the steam and pressure if the temperature and
THEN pressure go above the predetermined value. To prevent
temp= temp+1; catastrophic failure, an emergency alarm was
ELSE activated, and automatic check values were opened.
temp=28;
ENDIF; REFERENCE
IF tank1>1 AND tank2==100
THEN [1]C.G. Saracin, M. Saracin, M. Lupu,
sec=sec+1; “Programmable logic controllers used in electric
ENDIF; drives of an intelligent building,” 7th Int. Sym. on
IF tank2>1 AND tank3==100 AND tank1<=0 Advanced Topics in Electrical Engineering, pp. 1-6,
THEN 2011.
sec1=sec1+1; [2] K. Balachander, Dr. P. Vijayakumar, “Modeling,
ENDIF; Simulation and Optimization of Hybrid Renewable
IF tank3>1 AND tank4==100 AND tank2<=0 Power System for Daily Load demand of Metropolitan
THEN

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Cities in India”, American Journal of Engineering

Research.
[3] Vijay Kumar Khatri, Ahsan Javed Ghangro,
Jetandar Kumar and Syed Jaad UI Haque., ”Industrial
Data Acquisition and Control System using two PLCs’
Networked over MPI Network” (ISIEA2009)
[4] S.Kalaivani, M. Jagadeeswari, "PLC & SCADA
based effective boiler automation system for thermal
power plant, "International Journal of Advanced
Research in Computer Engineering & Technology
(IJARCET) Volume 4 Issue 4, April 2015.
[5] Gary Dunning, Introduction to PLC, 2001.
[6] Liu Le, Wang Changsong, Wang Xingbing, “The
research of the free mode communication between
Delta PLC and PC,” Mechanical Engineering &
Automation,
[7] R. Keerthika, M. Jagadeeswari, "Coal conveyer
belt fault detection and control in thermal power plant
using PLC & SCADA. International Journal of
Advanced Research in Computer Engineering &
Technology (IJARCET) Volume 4 Issue 4, April
2015.
[8] Dr. K. Balachander, Dr. A. Amudha, “PLC based
control of fuel oil pump houses in thermal power
station,” Journal of Electronics Information
Technology Science and Management, Volume 12,
Issue 1,2022.

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