When running power source fails, standby source supplies power to connected auxiliaries. The system, which transfers bus from running source to standby source and vice-versa is called Bus Transfer System (BTS). Control and Solution can provide complete solution in this area.
Power interruption to some operations can cause large economic losses. Uninterrupted power supply is necessary for the industries like :
Semiconductor chip manufacturing
Process Industries (Water treatment, Petrochemical)
Manufacturing (Plastic, Film, Printing)
Data Centers etc.
An Automatic Bus Transfer System (ABTS) is ideal to meet the requirement of uninterrupted power supply for industrial and commercial facilities with critical processes (mentioned above).
It is a standard requirement of every industry to have one stand by power supply unit like, DG set, in case of the failure of the existing supply. If the existing power supply is tripped, one has to change over to another stand by unit by changing the grid. It is very much essential to transfer the grid safely and without any power interruption. The standards for the safe transfer of the grid supply are laid down in ANSI standard CS 0.41-77 (specifically covers the poly-phase induction motor). As per the standard, resultant of the present and new power shall not exceed 1.33 Volt/ Hz for 60 Hz source. As we work with 50Hz supply, to achieve uninterrupted power supply, the grid changeover is required to be done within 20 mili second (period of one cycle). Therefore, it is required to measure and compare phase angles of both the supplies at very high speed. The ANSI standards suggest that phase angle difference must be within 20 degrees for power grid change over for safe transfer.
The existing method uses the conventional relay-based system, wherein the international standards (mentioned above) are not followed. Due to lack of facility to compare the phase angle of two sources (required to have uninterrupted grid changeover), we cannot achieve the uninterrupted Bus Transfer with this method. Hence, is not recommended for the industry having critical processes. Another disadvantage of relay based system is we cannot have better operator interface like Man Machine Interface (MMI) at remote places, which is today’s requirement.
Control and Solution (I) Pvt Ltd (CSIL) has developed a system to transfer the bus as per ANSI standard. The developed bus transfer system transfers bus within 50 to 60 ms (this time depend on on/off timing of circuit breaker and may be reduced, if breaker on/ off time is less). But this transfer is the safest transfer and will not cause any damage of connected auxiliaries due to phase difference in the existing and stand by power supplies. If we have circuit breaker, which have on/off time less than 20 ms, we can achieve bus transfer without any interruption in power supply. Hence, continuity of power is remains with safe and reliable transfer.
Thermax Ltd. Pune
Thermax is a global solution provider in energy and environment engineering. It offers products and services in heating, cooling, waste heat recovery, captive power, water treatment and recycling, waste management and performance chemicals.
The Challenge :
The requirement of customer was to communicate, control & monitor the data of two S7 - 200 series Siemens PLC’s which was controlling the whole process of Vaccum Absorption Machine.
CSIL installed Indusoft Web Studio software to perform this task. Those two PLC’s of Siemens, series S7-200 were connected to each other by standard S7200 PPI cable. To identify those PLC’s different device/station ID’s were given.
As Indusoft having support to OPC driver. CSIL used OPC driver named S7200 OPC server established the communication between Indusoft & PLC’s. All the Set points, Alarm limits, Reports of both the PLC’s can be monitored & controlled by using Indusoft Web Studio.
For the above mentioned project application was used for Maduarai Power Plant & IPCL, Dahej.
GAIL (INDIA) LTD.
GAIL (INDIA) LTD. had a requirement for modern monitoring and control system for their Gas Detection Plant in Guna, Madhya Pradesh. CSIL successfully automated the plant. The main component of the system was Supervisory control and data acquisition system.
GAIL required a system to acquire data and control the same from the field instruments like gas detectors. The prime requirement in this project was to provide them with redundancy along with cost effective and round the clock reliable system.
CSIL satisfactorily fulfilled the client’s requirement by installing INDUSOFT SCADA.
The system consisted of one main server i.e. engineering PC with engineering and runtime key and two other stations – one software PC and the other one is the network PC having runtime key. The Network PC is connected to 5 other web clients over LAN for remote viewing. The 2 web servers along with the engineering PC are further connected to two phases each phase consisting of CIU (Computer Interface Unit) and FIU (Field Interface Unit). The first phase consists of 90 gas detectors and the second phase consists of 60 gas detectors. The gas detectors are connected to the FIU, which is connected to the PC’s through CIU over Modbus link The redundancy requirement is provided using LAN Teaming Protocol i.e. whenever one of the web server goes down the other takes over because of Teaming Protocol. Any changes made in the application on the engineering PC are updated in both the web servers with the help of inbuilt execution environment. The communication between the detectors and the PC’s is established over MODBUS TCP/IP.
Lubrizol Pvt. Ltd., Turbhe (Thane):
Lubrizol Pvt. Ltd. located in Turbhe, Thane is a fluid technology company concentrating on high performance chemicals, systems and services for industry and transportation. The company had a requirement of modern monitoring and control system for their installed tanks. The company has eleven branches all over the world. CSIL fulfilled the client requirement and successfully automated the plant. The main components of the system are PC-based supervisory control and data acquisition system.
Lubrizol Pvt. Ltd. required automatic monitor and control of their installed tanks status and ERP connectivity in order to improve their plant efficiency. Our goal was to find a cost effective solution with round the clock reliability and regulatory compliance.
CSIL installed INDUSOFT SCADA to overcome the above challenge, using ADAM2 inbuilt driver to pull the data from ADAM 4000 family DI /DO modules connected to the tanks and OPC driver to push the data into SAAB TANK the third party software in order to monitor the tank status and for tank data manipulations and vice-versa. The calculated data was pulled into INDUSOFT SCADA through OPC driver in order to keep record of the system parameters like fluid volume, density to improve the system performance and for auditing purpose. For reporting the calculated data was pushed into ERP using ODBC feature of INDUSOFT SCADA.
INDUSOFT provides safe, cost-effective and reliable control over plant processes. An INDUSOFT solution ensures continuous monitoring and control of plant operations.
LUPIN PHARMA LTD., Tarapur (Boisar) :
LUPIN PHARMA LTD. located in Tarapur, Boisar is a company dealing with manufacture and supply of pharmaceutical products. The company had a requirement for automatic monitoring system for their EOU plant and MICRO LAB. CSIL has satisfactorily fulfilled the client requirement by installing INDUSOFT SCADA for automated monitoring of the plant along with compliance to US FDA 21 CFR part 11 regulations.
LUPIN Limited required automatic monitoring for their EOU plant and MICRO LAB in order to avoid man made errors and to improve the system performance. The main challenge was to meet the clauses specified by the US Food and Drug Administration and provide round the clock reliability along with cost effectiveness and regulatory compliance.
CSIL installed INDUSOFT SCADA v5.1 in order to provide 21 CFR compliance. The features provided in order to provide compliance are as stated below:
Block and unblocking of user,
User creation in engineering and runtime environment,
User account lockup after specified no. of attempts,
Automatic logoff to guest mode,
Tamper proof Electronic records.
The system included PC based SCADA system which was connected to 3 Scanner devices and 24 PID controllers. The data was pulled from the plants into SCADA through scanners and PID controllers using Modbus RTU inbuilt driver. Tamper proof Electronic reports are generated through INDUSOFT SCADA to provide cross check and auditing for improving system performance.
Indian Aluminum Company Limited (INDAL), Navi Mumbai:
Indian Aluminium Company, Limited (INDAL), an Aditya Birla Group Company, has been a forerunner of the aluminium industry in India. Established in 1938, Indal operates across the value chain from bauxite mining to alumina refining, smelting and rolling.
The Challenge :
Indusoft is installed in recycle as well as New Remelt process. In Indal Ltd. Navi Mumbai the requirement was to monitor & control the data of two Allen Bradely PLC of different series with Data Acquisition System.
The Solution given :
CSIL installed Indusoft Web Studio software to communicate those two different series PLC’s of Allen Bradely, one of them was Micrologix 1200 & other was SLC 500 family. Those two PLC’s connected to each other by Allen Bradely’s Standard data cable. By using RSlogix, the PLC programming software, the different device ID’s were given to those PLC. e.g Micrologix 1200 device ID was one & SLC 500 ID was 2.
To establish the communication between those PLC’s CSIL used the Indusoft’s built in driver for Allen Bradely PLC’s named ABKE with DF1 protocol. By using this driver now Indal Ltd. people can simultaneously monitor & control the data of both those PLC. e.g. they can change the Set Points, they can change Alarm Limits from Indusoft Web Studio.
Nelco Ltd. Navi Mumbai:
Nelco manufactures supervisory control and data-acquisition systems for energy management, load dispatch, and distribution and sub-station automation. It is also into V-SAT based communication networks for the Tata Group. It provides turnkey solutions based on SC & AC drives, and automation for the metal industry.
The company specializes in real-time software activities, and caters to diverse market segments, such as the steel and metal industry, energy management, railways, and the oil and gas sectors. It has recently made forays into the defense sector.
The Challenge :
The requirement of client was to monitor the data of Energy Meters as well as of CMRI (Common Meter Reading Instrument) & create the energy audit reports for the same. The same application used for 33 different locations.
CSIL gave them the solution by using Indusoft Web Studio. The energy meters used were having communication facility with Modbus protocol. Those meters were connected to each other by multi dropping method.
As Indusoft having built in Modbus protocol to communicate with those meters, RS 485 to RS 232 converter used to establish the communication.
All the meters connected to each other had a individual device/station ID for Identifying purpose. e.g. 1,2,3 etc.
After establishing the communication between the meters & Indusoft, the energy audit reports were created with help of ODBC connectivity & Visual Basic programming software (VB).
By using ODBC functionality Indusoft can send or retrieve the data from the Databases like SQL, Oracle, Ms-Access. In this application the Indusoft used ODBC connectivity with Ms-Access. The data from Indusoft stored in Ms-Access, same database used by VB program for the calculations which were part of the Energy Audit reports.
Energy Management and Substation Automation:
CSIL offers Energy Management Solutions providing metering from different vendors.
We provide solutions for energy measurements & analysis of total energy consumption in each area of plant.
CSIL also provides solutions for State Electricity boards for Automatic Data Logging systems (ADLS) or Automatic meter reading (AMR) and Substation Automation.