Asset Tracking & Monitoring
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Supply, installation, testing, commissioning, and upgradation of the existing SCADA software with two industrial-grade workstation SCADA servers at Renala Khurd Powerhouse.
Renala Khurd Hydropower Plant (RKHPP), also known as Ganga Ram Powerhouse and Zaheer-ud-Din Babar Powerhouse, is a small, low-head, run-of-the-river hydroelectric generation station with a 1.1 MW (1,500 hp) capacity. Located at Renala Khurd, Okara District, North-East of Punjab province of Pakistan, on the flows of the Lower Bari Doab Canal, this plant was established to meet the electricity needs of the Mitchells Fruit Farms and Food Processing.
The plant comprises five turbine units, each rated for 22 kW (30 hp). Each unit is equipped with a redundant Programmable Logic Controller (PLC) configuration, and there is a common redundant PLC for all six units, primarily used for assigning overall set values.
The existing SCADA system is Wonderware InTouch version 7.1 with 5K tags defined and scripted. This SCADA communicates with five redundant Mitsubishi Electric MELSEC iQ-R Series PLCs, I/O modules in the control room, and five Mitsubishi Electric MELSEC iQ-R Series PLCs serving as Governor Controllers on the machine floor. It also integrates with the Digital Excitation Control System (DECS), Human-Machine Interface (HMI), GPS, and Control and Protection Panels, including the Generator Management Relay (GMR), via the Modbus+ communication protocol.
The two SCADA workstations feature dual screens and operate using a single license. The SCADA server, a Compaq model running Windows NT4, is configured with MB+, LAN, Graphics, and USB communication.
Due to processor lagging, hanging issues caused by the aging system, and technical incompatibility with current software, the existing servers cannot be repaired due to the lack of spare parts and have become outdated. Any failure of the SCADA server system would result in a total loss of machine control through SCADA.
To overcome limitations in turbine control and machine protection systems, the existing SCADA system was upgraded with a new, highly reliable, rugged automation system.
Two SCADA servers are used for controlling the powerhouse machines: one as the primary server and the other as the standby server. The new SCADA system is Wonderware InTouch Runtime 2017 Unlimited with 60K tags. The SCADA workstations have dual screens and use separate licenses for their operation. The SCADA system performs data acquisition, monitoring, alarm displays, reporting, event & alarm logging, trends, and data storage.
The upgraded SCADA system communicates with the five redundant Mitsubishi Electric MELSEC iQ-R Series PLCs, I/O modules in the control room, five Mitsubishi Electric MELSEC iQ-R Series PLCs on the machine floor, Digital Excitation Control System (DECS), HMI, GPS, and the Control and Protection panels, including the Generator Management Relay (GMR) and feeder.
FAIZAL migrated the communication paths of the Wonderware InTouch system using Prosoft and RTU/TCP converters, replacing the legacy Modbus Plus communication protocol. PLC to SCADA communication is established through a Prosoft converter, and the GMR is communicated to the SCADA system through an RTU/TCP converter.
Advantages of Wonderware InTouch Runtime 2017:
The updated SCADA system has significantly improved the overall operation of the plant, providing:
The upgrade rectified issues such as:
The flexibility and reliability achieved by the upgraded system have made FAIZAL the best choice for this modernization project.
Contact us to learn about the best implementation strategies tailored for your control system.
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