Analysis Of Power Consumption By Using Programmable Logic Controller (PLC)

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FAKULTI KEJURUTERAAN ELEKTRIK

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

LAPORAN PROJEK

SARJANA MUDA

ANALYSIS OF POWER CONSUMPTION BY USING PROGRAMMABLE LOGIC CONTROLLER (PLC)

Nurain Binti Othman

Bachelor of Electrical Engineering (Power Industries)

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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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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.

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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

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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

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LIST OF FIGURES

FIGURE TITLE PAGE

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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

for Case 4

65

for Case 5

66

for Case 6

67

for Case 7

68

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

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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.

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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

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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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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

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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

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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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