PLC Based automatic load management system using

intelligent monitoring and control system for industrial and

commercial Sectors

By
Munir Husnain
4859
Muhammad Asif
4887
H Nawas Khalid
5790
Rana Dilfaraz
5079

Final Year Project Report

Riphah College of Engineering & Technology

Riphah International University, Faisalabad
 Fall 2020

Riphah International University, Faisalabad

PLC Based automatic load management system using

intelligent monitoring and control system for industrial
and commercial sector

A Thesis Presented to

Riphah International University, Faisalabad

In partial fulfillment
Of the requirement for the degree of

B.S. Electrical Engineering Technology

By
MUNIR HUSNAIN
4859

MUHAMMAD ASIF
4887

HAFIZ NAWAS KHALID

5790

RANA DILFARAZ
5079
 Fall, 2020

Declaration
We, hereby declare that this project neither as a whole nor as a part there of has
been copied out from any source. It is further declared that we have developed
This project and the accompanied report entirely on the basis of our personal
efforts made under the sincere guidance of our supervisor. No portion of the work
presented in this report has been submitted in the support of any other degree or
qualification of this or any other University or Institute of learning, if found we
shall stand responsible.

Signature:…………………..

Munir Husnain

Signature:…………………..

Muhammad Asif

Signature:…………………..

Hafiz Nawas Khalid

Signature:………………….

Rana Dilfaraz
 Riphah International University, Faisalabad

Fall 2020

Department of Electrical Engineering

Riphah International University, Pakistan

  
The Project PLC Based Automatic Load Management System using Intelligent Monitoring
and Control System for Industrial and Commercial Sector Presented by:

Munir Husnain 4859

Muhammad Asif 4887

Hafiz Nawas khalid 5790

Rana Dilfaraz 5079

under the supervision of their project advisor and approved by the project examination
committee, has been accepted by the Riphah International University, Pakistan, in partial
fulfillment of the requirements for the four year degree of B.S. Electrical Engineering
Technology.

(Engr Irsa abid)

Lecturer

(Dr. Muhammad Irfan Abid)

HOD
Department of Electrical Engineering
 Dedication

We would like to dedicate this project to our parents, whose unconditional love and support has
brought us where we are today.
 Acknowledgement

Apart from team efforts, accomplishment of any project rests principally on the encouragement,
inspiration, motivation and advices of several others. We take this opportunity to convey our
thanks to the individuals and organizations who have been instrumental in the successful
completion of this project..We acknowledge our heartfelt thanks to our respected teacher Engr.
Irsa Abid, who has been an inspiring and motivating force in completion of our project.

We also extend our warms thanks to Head of Department Dr Irfan Abid and to all faculty
members of Electrical Engineering department who guide us throughout this project.
 Abstract

In the industries worldwide, the plants need to be shed in order to meet with the supply and often
this results in a “not up to the standard” batch of the good. This happens because of care not
being taken in shedding the loads, at times switching off essential loads or mistiming the
shedding. Shedding is inevitable because if the loads are not shed then all will turn off eventually
due to lack of supply. To overcome this problem non-essential loads are often shed following a
certain scheme developed after thorough understanding of the product in production. The idea
behind the project is to build an automatic load shedding system with the help of a PLC, which
actually comes in action in the event of generator tripping and sheds off non-essential loads ( as
defined by the plant engineers) thereby restoring the balance between the consumption and
generation.
 TABLE OF CONTENTS
1 Introduction………………………………………………………………..........12
1.1 Project Background……………………………………………………………12
1.2 Problem Statement…………………………………………………………….14
1.3 Objectives……………………………………………………………………...15
1.4 Motivation…………………………………………………………………......15
1.5 Scope of the Project…………………………………………………………....15
2 Literature Review………………………………………………………………..16
2.1 Introduction……………………………………………………………...…….16
2.2 Literature Survey Regarding To Topologies…………………………...………16
3 Programmable logic Control……………………………………………………..20
3.1 Basic Principal of Operation………………………………………………...…20
3.2 PLC Overview……………………………………………………….................21
3.3 Hardware Components of PLC…………………………………………………21
3.4 Delta DVP 14SS………………………………………………………………..22
3.5 Applications of PLC……………………………………………………………24
3.6 Requirement and Advantages of PLC………………………………………….25
3.7 PLC Port………………………………………………………………………..26
4 Methodology……………………………………………………………………..27
4.1 Project Division…………………………………………………………………27
4.2 HMI…………………………………………………………………………….27
4.3 Load Management…………………………………………………………..….27
4.4 Functional Block Diagram……………………………………………………...28
4.5 Communication Port……………………………………………………………28
4.6 Memory…………………………………………………………………………29
4.7 Pin and Package………………………………………………………………...29
4.8 Contacts……………………………………………………………………… 29
4.9 Dc to Ac Inverter…………………………………………………………….…30
4.10 Magnetic Contactor……………………………………………………...…31
4.11 Relay……………………………………………………………………..…32
 4.12 Relay Design……………………………………………………………….32
5 Conclusion and Results…………………………………………………………..34
5.1 Software base Result…………………………………………………………...34
5.2 Single source ladder Logic…………………………………………………..…35
5.3 Two sources ladder Logic…………………………………………………...…35
5.4 Three sources ladder Logic……………………………………………….……36
5.5 Hardware base Result…………………………………………………….……37
5.6 Conclusion…………………………………………………………………..…37
5.7 References…………………………………………………………………...…38
 LIST OF FIGURES
Figure 1.1 PLC block diagram…………………………………………………………….13

Figure 1.2 Example of ladder logic………………………………………………………..13

Figure 1.3 Load Management at Normal and Ideal load…………………………………14

Figure 3.1 Architecture of PLC…………………………………………………………...20

Figure 3.2 DVP -14SS……………………………………………………………… ………….21

Figure 3.3 Overview of PLC……………………………………………………….. …………...22

Figure 3.4 Pin out diagram of PLC DVP 14SS……………………………….…………………24

Figure 3.5 Applications of PLC DVP 14SS……………………………………………….…….25

Figure 4.1 Simple diagram of DC to AC Inverter……………………………………….30

Figure 4.2 MC Operational Circuit………………………………………………………..31

Figure 4.3 Magnetic Contactor……………………………………………………………32

Figure 4.4 Relay Design…………………………………………………………………..33

Figure 5.1…………………………………………………………………………………34

Figure 5.2…………………………………………………………………………………35

Figure 5.3…………………………………………………………………………………35

Figure 5.4…………………………………………………………………………………36

Figure 5.5…………………………………………………………………………………37
 LIST OF TABLES
Table 3.1 Requirements and Advantages of PLC……………………………………………..

LIST OF ABBREVIATIONS

PLC Programmable Logic Control

HMI Human Machine Interface

MC Magnetic Contactor

LD Ladder diagram

WAPDA Water And Power Development Authority

SOLAR Sequential Oligogenic Linkage Analysis Routine

LED Light emitting Diode

LCD Liquid Crystal display

Ton Timer on

Toff Timer off

WPL Win Pro ladder

KWH Kilo Watt hour

KV Kilo Volt

DC Direct Current

AC Alternating Current

SEMS Smart Energy Management System

MW Mega Watt
Chapter 1

Introduction
Industries are usually run on multiple power sources. It can be a combination of generators and
local utility supplies. Running down multiple sources may result in the downfall of one or more
sources and this may result in a greater load to other running sources. To avoid these overloading
loads the trapping should be carried out as soon as possible.

However it is important to be careful in deciding which loads to carry and which processes are
absolutely indispensable to the current process.

1.1 Project Background:

Now-a-days industries life the energy management system is becoming more complicated due to
expansion in every unit mainly steel, cement and paper processing unit expansion and updating
of machine. The purpose of energy management is to manage and maintain optimum energy
production and consumption in any sectors. Energy saving is important and effective at all levels
of human organizations – in the total world, as a nation, as companies or individuals. Energy
Conservation decreases the energy costs and improving the profitability. Thailand began the
Energy Conservation efforts in the 1st oil crisis (1973). Then the Energy Conservation
Promotion Act was put into force in 1992. In this relation many things have been done including
announcement of the National Energy Conservation Strategic Plan (2002-2011) and Five Years
Energy Conservation Plan (2002-2006).The nation-wide Energy Conservation efforts will
contribute to lessening dependence on imported energy such as crude oils. Private companies are
also sensitive to energy costs, which directly affects their profitability and even their viability in
many cases. Especially factories in the industrial sectors are of much concern, because reduced
costs by Energy Conservation mean the more competitive product prices in the world market. In
existing method, an autotransformer maintaining the frequency is the toughest job, due to this
power source failure makes the whole process often get shutdown. In auto-transformer main
drawbacks are seasonal failure.So at the time of expansion even the power resource also need to
be altered.The main aim is to reduce the completion of auto transformer often fails due to direct
type system.so they often get an individual supply for it or often run through generators. In
proposed method, the auto transformer is to replaced through a new idea of load based auto
switching methods. In this load based auto switching method each power source will be supply
to an individual station according to it power consumption. The whole plant will be divided as
the station according to the process plan. In this method a separate station will be created and
accordingly power will be managed. [1]

Figure 1.1 Block diagram of PLC[1]

A Programmable Logic Controller is a specialized computer used to control machines and

processes. Initially designed to replace relay logic boards ie., Sequence device actuation and
Coordinate activities. Accepts input from a series of switches. Sends output to devices or relays.
It uses a programmable memory to store instructions and execute specific functions that include
on/off control, timing, counting, sequencing, arithmetic and data handling. Basically PLC is an
assembly of solid-state elements designed to make logical and sequential decisions and provide
outputs.

Figure 1.2 Example of Ladder logic

 PLCs are used for the control and operation of manufacturing process equipment and
machinery. PLC has eliminated much of the hardwiring associated with conventional relay
control circuits.

1.2 PROBLEM STATEMENT:

It makes fast and reliable power system because we will use PLC logic operation also they will
provides better economical experience. When the load changes they manage their needs and
work efficiently. In proposed method, the autotransformer is replacement by load based auto
switching method to improve the energy efficiency of the system. The shutdown of the entire
system is prevented and energy is conserved.Load-shedding is a process by which the electrical
authority handles the dearth of the electrical power being consumed by the society. Shedding is
done to minimize the load being consumed by the society through several substations which are
connected to the main power station. When the frequency of the power generator falls down, it
fails to generate the required power. Load management, also known as demand-side management
(DSM), is the process of balancing the supply of electricity on the network with the electrical
load by adjusting or controlling the load rather than the power station output. This can be
achieved by direct intervention of the utility in real time, by the use of frequency sensitive relays
triggering the circuit breakers (ripple control), by time clocks, or by using special tariffs to
influence consumer behavior.

Figure 1.3 Load Management At Normal and Ideal load [2]

1.3 OBJECTIVES:
The main purpose of this project is to create an automatic shading system that keeps track of
available electricity and meets the ongoing loads and then runs through its algorithms to decide
which loads to carry. And thus prevent the plant from being out of operation.
A human machine interface HMI is also being developed for the system which helps engineers at
the plant monitor and prioritizes the process.
1.4 MOTIVATION:
The system is designed in such a way that all industries operating on multiple power sources can
use it to manage the flow of trapping events to their plant so the plant can be kept as normal.
1.5 SCOPE OF THE PROJECT:
Due to the ongoing energy crisis in Pakistan and worldwide industries are often at the mercy of
local utility supplies or power distribution authorities. This is due to the fact that there is a small
drop in demand between electricity and supply. Therefore most industries prefer to work on local
utility supply as well as generators.
Meeting the supply requires a tripping load at the plant and often does not result in a standard
batch of goodwill. This is because caution should not be taken with the load off due to the
required load or abusive.
Shading is important because if the load is not removed then the supply will eventually be closed
due to no supply. The unnecessary burden to overcome this problem is often shed after a specific
scheme developed after thorough understanding of the product in production.
Efforts are being made internationally to implement such a model even to residential consumers
and this is the path leading to the smart grid. Many independent organizations including Siemens
are working on it.
The project could be further expanded to include features like Blackstart which allow the plant to
function normally when fully closed. Trending may also include helping it avoid such a trump in
the future.
Chapter 2

Literature Review

2.1 Introduction:

The SEMS has been in the power sector for more than a decade. The key to making such a
system work is to observe manage and improve the flow and use of power. Generally SEMS has
a difficult use in power system network production transmission and distribution systems.
Demand Side Management DSM There is two common demand side management DSM
techniques that provide specialized energy with the utilization of energy management systems.
SEMS is a significant extension of current for residential and industrial users. Demand response,
demand side management maximization and change of demand that is measured to offer
solutions to system operators increase the barrier to more robust and intellectual SEMS. The time
smart grid is used to designate an electric power so that both digital technology and long
transmission networks can be integrated to improve energy use and modernize energy production
and distribution. Action can be taken it.

2.2 Literature Survey Regarding to Topologies:

Hyung-Chul Jo et al (2013) has developed a neat heating and air conditioning forecast
technique for HEMS to consider consumer handiness and individuality of thermal appliances in a
smart home situation. The prototype software base on the projected technique for HEMS is as
well implementing. In this proposed system describe a condensed HVAC representation that
considers consumer expediency and a technique for solve the preparation problem of the HEMS
with the summary HVAC reproduction. The HEMS base on the proposed technique container be
used to resolve the least-cost schedule of the accessible energy resources even as minimize
problem to the purchaser in a smart home surroundings.[3]
Jinsoo Han et al (2014) has deals through a power line communication (PLC) obedient through
Home Plug is adopt to observe each PV unit. The PLC modems are deploying on every PV
component and supervise it. The Renewable Energy Gateway (REG) aggregate and provisions
the monitor data starting the PLC modems and the inverter. The construction of a PV system
organization base on an ordinary PLC knowledge that is fully obedient with the Home Plug
Green PHY (HPGP) is projected. The PLC modems supervise every PV module. The proposed
structural design is predictable to give to attractive the PV system organization and maintain the
presentation of the PV system. The PLC modems and the REG, obedient with the Home Plug,
can be without difficulty associated to home network base on the Home Plug.[4]

Jinsoo Han et al (2014) has proposed a smart Home Energy Management System (HEMS)
structural design that considers together energy consumption and production concurrently.
ZigBee base energy dimension module is used to manage the energy consumption of home
appliance and illumination. A Power Line Communication (PLC) based Renewable Energy
Gateway (REG) is use to check the energy age group of renewable energies. Smart HEMS
constructions that consider both power consumption and invention based on ZigBee and PLC
base REG correspondingly. This PLC monitor technology can supervise each planetary panel for
protection. The home server cans estimation the energy production based on a conditions predict.
Using the obtain energy in sequence; the home server can manage the home energy use program
to reduce the power price.[5]

Every PV unit in Jansuhan et al (2014) deals with Power Line Communication PLC compliant
trough home plugs for viewing. PLC modem and inverter. Building a common PLC knowledge
based PV system organization that is fully compliant with the home plug in green PHY. PLC
modems monitor each PV module. The proposed structure design can be predicted to make the
PV system organization attractive and to maintain the PV system offering.
H.S.V.S. Kumar Nana et al (2016) has proposed two load management strategies for
effectively utilizing plug in V2G in electric vehicles PEVs in monitoring grid connected micro
grid. The proposed scheme V2G combination strategy is implemented with PLC developed in
the Scada development framework and practically for micro grid case study management. The
proposed costing system for charging PEV is lower than both the grid connected and micro grid
process island method. This proposed approach is implemented with a multi-agent system built
into the Scada development framework.[6]

Neeraj Kumar et al (2016) introduced an energetic system in the smart grid cyber physics
system through an PLC based theory. Mobile cloud networking is a growing tool in which
mobile policy is linked to the access point from the cloud server. The game is preparing to
integrate smart strategy and service providers in which overall players and service providers are
looking to exploit their revenue through appreciation of accessible resources. In a cloud
environment, the management algorithm is executed which is measured because of the cyber
aircraft. The proposed resolution can be used to address the frequency and voltage fluctuations
on the grid.[7]

Kee Meng et al (2017) suggested that delivery system load management. Managing several
groups of gross air conditioners. The purpose of this prediction method is to present the
challenge of integrating a compound group of virtual power storage space schemes VPSSS to
deal with complex loads. The circulation management system aims to distribute the reduction of
dynamic controls needed in aggregators during the limited announcement to switch
configurations with collectors in the near future and has met a balanced position among complex
collectors. can go. From a distributed management point of view it may involve the necessary
energy restriction of co motives.[8]
Mario Collotta et al (2017) proposes to introduce the Artificial Nerve Network ANN system for
the maintenance of the Bluetom Low Energy Home Energy Management HEM management
base called Blue. Called hemes. Infrastructure technology aims to reduce emissions of
greenhouse gases and in more than a few contexts of environmental security access to basic
counting infrastructure development transportation buildings power generation and transmission.
Is to realize massive savings. A smart grid is considered as a grouping of internal electrical
networks and supersedes the communication system. Take a deep look into the ANN style in this
proposed system to find the best demo recipient. This system provides comprehensive simulated
diagnostics fully utilized through Network Simulator version 2 NS-2 for energy consumption
demand profit customer delayed HMM solution delays and package. Performs terms of delivery
relationship. Delay and root for wireless networks.[9]
Seun Chen et al (2017) provides the Human-centric Smart Home Energy Management System
SHEM with the intention of Butler aircraft. Based on this structure our SHE system provides
smart military expertise to satisfy customer supply which aims not only to maintain the cost of
electric power nor to minimize maximum load, In addition to this there is also a servant
predicting customer pressure and monitoring. Smart grid strategies have been integrated deep
into the smart home system. Consumer strategy will be more powerful and complex for the user.
In this proposed system combining human driven behavior home centered smart homes assess
the users weight and usage preference and maximize energy projects in the smart home. The
SHE system can be comprehensive for responding to a variety of response signals and results in
costly sustainability for programming and every level of utility based on a public based
framework.[10]

The structure of our load management system is presented using multiple power sources. These
supplies include the power of the Solar Power Water and Power Development Authority and
generator power supply. The load is associated with the solar power supply during normal
daytime, at night this load is connected to the WAPDA power supply. In case of failure of
WAPDA power supply the generator will be turned on by receiving signals from the controller
PLC and the load connected to this generator. It controls all three power supply trough
programmable logic controllers PLC. The ladder logic builds on PLC hardware to control its
input and output pins or devices.
Chapter 3
Programmable Logic Control

3.1 Basic Principal of Operation:

The operation of the PLC system is simple and straightforward. The Process or CPU completes
three processes: (1) scans, or reads, from the input devices (2) executes or “solves” the program
logic, and (3) updates, or writes, to the output devices.The basic elements of a PLC include input
modules or points, a central processing unit .The basic elements of a PLC include input modules
or points, a central processing unit (CPU), output modules or points, and a programming device.
The type of input modules or points used by a PLC depends upon the types of input devices used
Some input modules or points respond to digital inputs, also called discrete inputs, which are
either on or off. Other modules or inputs respond to analog signals. These analog
signalsrepresent machine or process conditions as a range of voltage or current values. The
primary function of a PLC’s input circuitry is to convert the signals provided by these various
switches and sensors into logic signals that can be used by the CPU. The CPU evaluates the
status of inputs, outputs, and other variables as it executes a stored program. The CPU then sends
signals to update the status of outputs. Output modules convert control signals from the CPU into
digital or analog values that can be used to control various output devices. The programming
device is used to enter or change the PLC’s program or to monitor or change stored values. Once
entered, the program and associated variables are stored in the CPU. In addition to these basic
elements, a PLC system may also incorporate an operator interface device to simplify monitoring
of the machine or process.[11]
 Figure 3.1 Architecture of PLC
3.2 PLC-System Overview:

Programmable Logic Controllers or PLC is the hub of many manufacturing processes. These
microprocessor based units are used in processes as simple as boxing machines or bagging
equipment to controlling and tracking sophisticated manufacturing processes. They are in
virtually all new manufacturing, processing and packing equipment in one form or another.
Because of their popularity in industry, it becomes increasingly more important to learn skills
related to these devices.
 Figure 3.2 Overview of PLC[12]

3.3 Hardware of PLC:

 Power Supply - This can be built into the PLC or be an external unit. Common voltage
levels required by the PLC (with and without the power supply) are24Vdc, 120Vac,
220V AC.
 CPU (Central Processing Unit) - This is a computer where ladder logic is stored and
processed.
 I/O (Input/Output) - A number of input/output terminals must be provided so that the
PLC can monitor the process and initiate actions.
 Input - In smaller PLCs the inputs are normally built in and are specified when
purchasing the PLC. For larger PLCs the inputs are purchased as modules, or cards, with
8 or 16 inputs of the same type on each card.
 PLC Operation: All PLCs have four basic stages of operations that are repeated many
times per second. Initially when turned on the first time it will check its own hardware
and software for faults. If there are no problems it will copy all the input and copy their
values into memory, this is called the input scan. Using only the memory copy of the
inputs the ladder logic program will be solved once, this is called the logic scan. While
solving the ladder logic the output values are only changed in temporary memory. When
the ladder scan is done the outputs will updated using the temporary values in memory,
this is called the output scan. The PLC now restarts the process by starting a self-check
for faults. This process typically repeats 10 to 100 times per second.
 Self-Test - Checks to see if all cards error free, reset watch-dog timer, etc. (A watchdog
timer will cause an error, and shut down the PLC if not reset within a short period of
time - this would indicate that the ladder logic is not being scanned normally).
 Input Scan - Reads input values from the chips in the input cards, and copies their
values to memory. This makes the PLC operation faster, and avoids cases where an input
changes from the start to the end of the program (e.g., an emergency stop). There are
special PLC functions that read the inputs directly, and avoid the input tables.
  Logic Solve/Scan - Based on the input table in memory, the program is executed 1step at
a time, and outputs are updated. This is the focus of the later sections.
 Output Scan - The output tables is copied from memory to the output chips. These chips
then drive the output devices.
 Central processor unit (CPU): The central processor unit (CPU) is a microprocessor
system that contains the system memory and is the PLC’s decision making unit. The
CPU monitors inputs, outputs, and other variables and makes decisions based on
instructions held in its program memory.

3.4 Delta PLC DVP-14SS :

The DVP-SS2 Series is Delta Electronics' second generation of slimline industrial PLCs. The
DVP-14SS211R features high speed counters, a flexible serial port, real-time monitoring and an
expansion bus that allows matching modules to be mounted on the right side of the PLC without
external wiring.The DVP-14SS211R supports PID loops with automatic tuning for process
control applications. The transistor outputs allow high speed pulse generation for servo or
stepper motor motion control applications.
Figure 3.3DVP -14SS
 Figure 3.4 diagram of DVP14SS Pinout

3.5 PLC DVP 14SS Applications:

 SCADA (Supervisory Control And Data Acquisition)

 Energy saving VFD
 Cement plants
 Automation and control industry
 Load management system
 Industries
 Figure 3.5 Some basic Applications of PLC

3.6 Requirement and Advantages OF DVP 14SS PLC

Requirement of PLC Advantages of PLC

Increase Productivity & Fine Quality Control Ability to interface/communicate with
computers
Reduce Human Interface & High Speed of Field Programming possible
Operation
Energy Saving & Power Factor Improvement Simple Programming
Most Economical, Smallest feature, Rugged, Smaller Size
Flexibility, Easy to use
Real Time Monitoring Reliable Components make these likely to
operate for years before failure
Historical data for Network Analysis High Reliability
Adequate response to customer query Computational abilities allow more
sophisticated control
Improve Information Availability Flexible and reapplied to control other systems
quickly and easily
 Better Visibility Cost effective for controlling complex systems
Real Time Event Monitoring Economical in Long Term
Table 3.1 Requirements and Advantages of PLC

3.7 PLC Ports

Comes with a small number of built-in ports for output and output. Generally, an extension is
available if the ports are insufficient for the process model. Modular PLCs have an extended
chassis, also known as a rack that is used to connect extension modules to the PLC to perform
different functions. The choice of processor and I / O module is related to particular application.
Multiple racks can be managed by a single processor, and can handle thousands of results and
outputs. A faster serial I / O link is used to distribute the rack away from the PLC, while
reducing the wiring costs for large plants. User Interface PLCs are often required to
communicate with humans (engineers on a plant) for alarm reporting, daily control and
configuration. The Human Machine Interface (HMI) is used for this purpose. Can be interpreted
as a type of HMI user interface (GUI). For a simple system, buttons and lights can be used to
interact with the user. However, text display is also available along with a graphical touch
screen. More sophisticated systems use programming and monitoring software installed on a
computer, which is connected to a PLC through a communication interface.

Chapter 4
METHODOLOGY
4.1 Project Division:
The project can be divided into five major sections. The first is to better understand the process
involved in the preparation and preparation of load shedding schemes as per the requirement of
the industry. Task After the completion of the first task, the next step is to develop a fail-safe
algorithm to handle the industry load according to the available electricity. To help understand
management and visual representation, considerable efforts were made to develop a graphical
user interface using once. Then comes a prototype hardware to demonstrate the PLC shading
algorithm with switches and panel lights.

4.2 HMI
The basic concept of the foreign key is also used in the database system to create a fixed table of
all loads and another table with fixed table keys to provide the option of a priority list of
changes. Human Machine Interface a human machine interface of PLC code. A PLC code is
written with each of the logical characters and numbers in the light. For someone they designed
the code themselves, this ideas may make some sense, but to a stranger, they are just useless and
a difficult task to understand. For this reason, an HMI has been developed that uses graphical
symbols and images to better understand the process. Siemens has WinCC to develop HMI
software. This software is automatically integrated with Step 7 and PLC Sim. In this project, four
different HMI screens have been developed. (i) Face Plate: This main screen has a priority list as
well as buttons to navigate to other screens. The buttons to change priority lists are also placed
on the same screen
Automation is used to reduce the stability of mobile networks with various control devices such
as machinery, factories, furnaces, heating equipment, management processes, and humans, ships,
aircraft and other applications. Uses. Automation usually works in a variety of ways, such as
pneumatic, electrical, mechanical, hydraulic, and electronic as well as computers. Complex
systems, such as modern factories, aircraft, and aircraft are commonly used to combine all these
techniques. Load management is the method of balancing the power on the grid to adjust the load
besides generating electricity.

4.3Load management:
Planning can be started by developing a better model to present the distribution network features,
which is the capability, topology, other lines of load characteristics and load behavior. The
analysis consists of scenarios that predict the expected load shedding instructions, weather
forecasts, expected time to fix offline goods and other factors. For seasoned product
manufacturers, these factors may be useful. Measuring the average rate, the power plant can be
facilitated by the use of load management to achieve a high capacity factor. The capacity factor
is a measure of the power plant output compared to the maximum output of this power plant. The
load factor is defined as the ratio of the peak load to the average. The high load factor is
beneficial because the plant is only less efficient at low load factors. If the load factor is affected
during unplanned interruptions, fuel shortages, maintenance shutdowns, or demand reductions
(i.e, consumption patterns vary by day), the generation should be synchronized, and as grid
energy Storage is too expensive. Small utilities that buy electricity instead of their own
generation can also benefit from the installation of load management systems. There will be a
significant reduction in the payment of costs for the peak use to the supplier. It is reported, a load
management system is compensated for itself in one season.
Programs that control the operation of a machine are stored in unstable memory. The PLC is an
example of a system that is expected to respond in a specific period depending on the input
conditions, as it will be more useless later on. Prior to the birth of the PLC, the control,
configuration, and safety mutual logic was primarily the construction of relays, timers,
sequencers, and dedicated closed loop controllers. Since this can mean that the process of
updating hundreds or even thousands of these components or changing the annual model can
lead to widespread changes in management, as personnel are required to change their operating
characteristics to the system. Needs to be tested again. Soon, general purpose computers were
deployed under the control of industrial processes.

4.4 Functional Block Diagram:

4.5Communication Port:

PLCs come with integrated communication ports, typically 9-pin RS-232, or EIA-485, but
optionally Ethernet. Modbus is also generally available as one of its communication protocols.
Other options include Device Net or Proof bus. Most advanced controllers can be networked
with another system, such as running on a SCADA system via a to connect with this system.
PLCs employing large I / O systems can have peer-to-peer (P2P) connections between
processors. It allows individual parts of a complex process to be controlled one by one, allowing
the system to synchronize over the communication ports. These communication ports are often
used for HMI devices such as PC-type workstations.

4.6Memory:

There are two sources of memory. One type is 368 bytes of RAM and the other is 256 bytes
EEPROM. Important features include power saving sleep mode, up to 14 source interruptions,
and the ability to have a single 5V in-circuit serial programming (ICSP). The sink / source
current, which indicates I / O port-driven power, is higher with 25mA. The operating power is
less than 2 mA. Peripheral features include: (a) three bar blocks: 8 bit timer / timer for counter 0
0 16- bit timer / timer for counter 1; and timer 2: 8 bit timer / 8 bit duration register, pre-scalar
and Post scalar counters. (b) Compare two captures, get 16, 16 bit, and PWM generation with 10
bit resolution to get PWM module. (c) 10 bit multi-channel (maximum 8) ADC module. (D) SPI
(Master Mode) and I2C2 (E) Universal Synchronous Asynchronous Receiver Transmitter (USRT
/ SCI) 9 bit address with synchronous serial port (SSP) With the search of (f) Parallel slave port
(PSP) is 8 bits wide. (G) I / O ports.

4.7PIN and Package:

There are three types of packaging available: PLCC, DIP, and QFP. One of the most commonly
used is the DIP, due to its excellent fit on a proto board or breadboard. Refer to figure F1 for
detailed pin configuration and functionality. The 7-segment is a light-emitting diode or LED
display, a solid-state optical PN junction diode that emits light energy in the form of "photons"
when it moves through a voltage. Gives way to its path, and this process, in electronics, is known
as electro-luminescence. The 7-segment display has many benefits from LED lamps and
traditional bulbs, the keys of which are readily available with their longevity, small size,
affordable and varied colors, and they are easy to interface with many other electronic
components.

Normally open" (NO) is an open contact with "normal" and a terminal called "normally closed"
(NC) is a closed contact when the relay is not normally energized. Similarly, when the relay
contact is triggered, the NC is opened and NO is closed to the public. In other side, apply electric
current to the contacts they will change their condition. Relays are commonly used to switch
small currents in control circuits and are generally not control by electrical equipment’s except
small motors and solenoids that draw low currents. However, the relays can "control" the high
voltage and the current through the friction of the stream by placing it on the relay coil, which in
turn transforms the high voltage through the contacts.

4.8 Contacts:
The part of the switch that creates the circuit (stops) or breaks (opens). Contact life of a relay
The useful life of a relay depends on its connections. Once the contacts are finished, the relay
contacts or the entire relay will have to be replaced. Mechanical life is the number of operations
(holes and closures) a contact can perform without electrically conducting operations. A relay
mechanical life is relatively long, offering over one million operations, 000 thousand jobs. A
relay power life is the number of operations (holes and closures) that the contacts can perform
electronically at a current rating. The electrical life of a relay contact ranges from 100,000 to
500,000 cycles. Opto-Coupler We can provide electrical isolation between an input source and
an output load called an opto-couple using a very common and expensive electronic component.
An opto-coupler, also known as a photo-coupler or opto-isolator, is an electronic component that
combines two separate electrical circuits through a light-sensitive optical interface.

4.9DC to AC Inverter:

This DC to AC converter is called an inverter. It's fairly easy to convert AC current to DC – all
you need to do is feed the current through a diode, which only passes current in one direction.
Converting from DC to AC is more complicated, because you need some kind of oscillator that
reverses the current direction at the frequency you need. There's a way to do this mechanically,
but most inverters rely on resistors, capacitors, transistors and other circuit devices.An inverter
needs one more thing: a way to alter the voltage of the current source for use by the device that
will be using the power. In other words, it needs a transformer. For example, if you're
powering your 120 V refrigerator with a 12 V battery, the inverter needs a step-up transformer
that increases the voltage by 10 times. Since it only works with AC current, the transformer
goes in the circuit after the components that alter the current from DC to AC.A device that can
change DC to AC current must be able to switch off the current going in one direction and send
it the other way, then reverse the process at regular intervals. A way to do this would be to
place a rotating wheel between a pair of terminals and arrange the contacts so the wheel
alternated the battery connections with every spin. The current would to flow one direction
when the wheel was at its starting point and in the opposite direction when the wheel had
rotated 180 degrees.

Such a crude setup would produce an all-or-nothing current in each direction, and if you
graphed the movement of an electron in the circuit, you would get what's known as a square
wave. This wouldn't be a good power inverter for the home. The current might be able to
perform simple tasks, such as making a heating element glow, but it wouldn't work for
sensitive electronic equipment. Moreover, you'd need an accurate way to control the rotaon of
the wheel to make the resulting AC power useful.
 4.1 Figure Simple diagram of DC to AC Inverter

4.10Magnetic Contactor:

When a relay is used to switch a large amount of electrical power through its contacts, it is
designated by a special name: contactor. Contactors typically have multiple contacts, and those
contacts are usually (but not always) normally-open, so that power to the load is shut off when
the coil is deenergized. Perhaps the most common industrial use for contactors is the control of
electric motors. The top three contacts switch the respective phases of the incoming 3-phase AC
power, typically at least 480 Volts for motors 1 horsepower or greater.

Figure 4.2 MC Operational Circuit[13]

The lowest contact is an ”auxiliary” contact which has a current rating much lower than that of
the large motor power contacts, but is actuated by the same armature as the power contacts. The
auxiliary contact is often used in a relay logic circuit, or for some other part of the motor control
scheme, typically switching 120 Volt AC power instead of the motor voltage. One contactor may
have several auxiliary contacts, either normally-open or normally-closed, if required. The three
“opposed-question-mark” shaped devices in series with each phase going to the motor are called
overload heaters. Each “heater” element is a low-resistance strip of metal intended to heat
upasthe motor draws current. If the temperature of any of these heater elements reaches
acriticalpoint (equivalent to a moderate overloading of the motor), a normally closed
switchcontact (not shown in the diagram) will spring open. This normally-closed contact is
usually connected in series with the relay coil, so that when it opens the relay will automatically
de-energize, thereby shutting off power to the motor. We will see more of this overload
protection wiring in the next chapter. Overload heaters are intended to provide overcurrent.

4.3 Magnetic Contactor

4.11Relay:
A relay is an electromagnetic switch that is used to turn on and turn off a circuit by a low power
signal, or where several circuits must be controlled by one signal. We know that most of the high
end industrial application devices have relays for their effective working. Relays are simple
switches which are operated both electrically and mechanically. Relays consist of an
electromagnet and also a set of contacts. The switching mechanism is carried out with the help of
the electromagnet. There are also other operating principles for its working. But they differ
according to their applications. Most of the devices have the application of relays. The main
operation of a relay comes in places where only a low-power signal can be used to control a
circuit. It is also used in places where only one signal can be used to control a lot of circuits. The
application of relays started during the invention of telephones. They played an important role in
switching calls in telephone exchanges. They were also used in long distance telegraphy. They
were used to switch the signal coming from one source to another destination. After the
invention of computers they were also used to perform Boolean and other logical operations. The
high end applications of relays require high power to be driven by electric motors and so on.
Such relays are called contactors.
4.12Relay Design:

There are only four main parts in a relay. They are

 Electromagnet
 Movable Armature
 Switch point contacts
 Spring

Figure 4.4 Relay Design[14]

The diagram shows an inner section diagram of a relay. An iron core is surrounded by a control
coil. As shown, the power source is given to the electromagnet through a control switch and
through contacts to the load. When current starts flowing through the control coil, the
electromagnet starts energizing and thus intensifies the magnetic field. Thus the upper contact
arm starts to be attracted to the lower fixed arm and thus closes the contacts causing a short
circuit for the power to the load. On the other hand, if the relay was already de-energized when
the contacts were closed, then the contact move oppositely and make an open circuit.
As soon as the coil current is off, the movable armature will be returned by a force back to its
initial position. This force will be almost equal to half the strength of the magnetic force. This
force is mainly provided by two factors. They are the spring and also gravity.

Relays are mainly made for two basic operations. One is low voltage application and the other is
high voltage. For low voltage applications, more preference will be given to reduce the noise of
the whole circuit. For high voltage applications, they are mainly designed to reduce a
phenomenon called arcing.
Chapter 5

Conclusion and Results

5.1 Software base Result:

Figure 5.1
5.2 Single Source Result:

Figure 5.2

5.3 Two Sources Result:

Figure 5.3
5.4 Three Sources Results:

Figure 5.5
5.5 Hardware Base Result:

5.6 Conclusion:
This is viable in many industries using multiple sources of power. The system will ensure that
the entire plant does not shut down when the generator trips. This can help avoid many pitfalls
such as raw materials, machines and the most valuable time. Since action is required in this event
to be expedited, an automated system is best suited rather than self-inflicted humanitarian
personnel. The trendy feature can be helpful in avoiding these events in the future, and the alarm
logging feature is useful because it tells you which generator is gone and what the load is in
response. It can then be given to the engineers for renovation. Also, flexibility in the priority list
can lead to different preferences at different times. This is needed because manufacturing often
depends on the seasons and other such factors. The display panel is really helpful to understand
the current operation
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