SCADA Based Power Management Trainer
Our project, SCADA Based Power Management Trainer is implementation of the SCADA System for monitoring and controlling the flow of electrical power to different types of load at remote locations. The hardware connected to the trainer is represented by a Grap
2025-06-28 16:34:53 - Adil Khan
SCADA Based Power Management Trainer
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryOur project, SCADA Based Power Management Trainer is implementation of the SCADA System for monitoring and controlling the flow of electrical power to different types of load at remote locations. The hardware connected to the trainer is represented by a Graphical User Interface (GUI) on a computer screen and based on the data acquired, electrical parameters are displayed and decisions are made such as switching, load shedding, and controlling the power flow.
Since SCADA systems are being adapted by industries for automated process and manufacture, the need has arisen for engineers to be oriented with these systems as part of their professional development. We aim to provide a trainer for engineering students so that they can be taught the process of automation in their respective majors of study. Although SCADA systems have wide range applications such as automation in the process control, oil and gas, power generation and distribution, wastewater control, irrigation, transport systems, etc., our primary focus is automation in Electrical Power Distribution System.
Project ObjectivesThe project provides a platform for industries and technical institutions to provide a solution for the upcoming Industry of SCADA and its elements that are used in the industry in a safe and secure environment. SCADA based Power management trainer is a system of software and hardware elements that allows industrial organizations to perform following tasks on that trainer in order to train their co-workers and trainees.
- To automate those systems which are already part of an industrial process.
- To monitor, gather and process real-time data.
- To interact and control different devices and parameters of these devices.
- To control locally or at remote locations.
- To record events into a log file.
- To troubleshoot and diagnose different scenarios that can occur.
Project Implementation
The implementation procedure consists of the following main components.
Software:
A software package that has all required aspects of a Supervisory Control and Data Acquisition System (SCADA) was selected as many were paid software packages, An Educational license was necessary and InduSoft Web Studio was willing to provide one for the purpose of developing a trainer for our Final year project.
Graphical User Interface (GUI):
A GUI was needed for users to interact with it, so the first step was to develop the interface. An Induction motor Panel was developed with various parameters on the display window with a switch that turns the motor on and off. Similarly, Panels of an Alternator, Load Bank and a Pump were designed with the same kind of display window. Moreover, a program was developed that automatically switched certain devices off when a certain parameter’s threshold is met and warned the users about it.
Control:
The switching of the devices was achieved with the help of PLC which gave output signals when certain conditions or certain program was executed that is programmed in the PLC. Relay and contractors were used to switch devices and the signal that acted as the brain came from the PLC program.
Communication:
Communication between the PLC, RTU and the SCADA software as achieved via KepServerEX. It is an OPC client that is used to acquire data and can also control the operation of these data via Tags. Physical Communication is based on the MODBUS protocol in which RS485 is utilized as a way to communicate between the different hardware.
Benefits of the Project- The most prominent benefit of the project is that engineering students can be given firsthand experience on the SCADA system during their undergraduate studies so that they are aware of the industry standards and this contributes to their professional skillset.
- Industries can utilize this trainer to train operation trainees before their deployment on existing systems. This ensures that the existing system of the industry is not at risk of mishandling. Technical training institutes can also utilize this trainer to provide vocational training.
- The learning through trainer is not limited to specific applications, (such as Power Management System), students will also learn core components of SCADA systems and how they work. Training can be provided on the following
• GUI design for Human Machine Interface (HMI)
• Communication Protocol Setup (MODBUS, Ethernet)
• Remote Terminal Unit (RTU)
• Sensors and their interfacing
• Report generation
- The trainer is budget-friendly and avoids heavy duties on imported trainers. Small scale training centers can benefit from this trainer at cheaper costs.
- Existing trainers can be used in different applications because the base system remains the same, only the parameters to be measured and sensors required may vary. For example, for the measurement of electrical parameters, Energy Analyzer is being used. However for application in process control parameters may change such as pressure, temperature, humidity, etc., for which appropriate RTU’s will be connected and hence the same trainer will provide a different application.
Technical Details:
Software/HMI:
The trainer is controlled via a GUI that is designed via the software, InduSoft Web Studio®, it is a powerful collection of automation tools that provide all the automation building blocks to develop HMIs, SCADA systems, and embedded instrumentation solutions.
The GUI would consist of several screens that correspond to different loads that can be operated via the onscreen buttons. Moreover, Different Parameters can also be observed and power flow can be controlled when a certain threshold or a certain parameter for a program is met.
Load Types:
The trainer would comprise of different loads which are given below,
- Inductive Load (Motor) 180W,3 Phase
- 600 Watt Resistive load
- General Load (Water Pump)
Generation:
Apart from KE supply, an alternator of 1.1KVA is available in the Power Lab of Usman Institute of Technology which is utilized to power the 600W Resistive Load.
Programmable Logic Controller:
The Brain of the whole circuit is the PLC of the system, it is the control and data acquisition element of the entire system. The PLC that is selected for this trainer is Delta DVP 28SS211R. Details of this device are given below.
- 16 Digital Inputs
- 12 Digital Outputs
- Output: Relay Type
- RS232 and RS485 Communication
A module was also used with conjunction to the above given PLC for analog input.DVP04AD-S
The Module has 4 analog inputs.
Remote Terminal Unit:
For the RTU, an Energy Analyzer is used with RS485 communication capabilities. The Energy Analyzer is SINOTIMER DDS578MR.
It has the ability to measure, display and communicate the given parameters.
- Voltage
- Active Power
- Reactive Power
- Current
- Power Factor
- Frequency
- Energy Consumed KWh
Communication Protocol:
MODBUS is being utilized for the purpose of communication between the different hardware and the HMI. In the Modbus protocol, RS485 is utilized over RS232 as it has a greater advantage in device limit and effective distance. RS-485, also known as TIA-485 or EIA-485, is a standard defining the electrical characteristics of drivers and receivers for use in serial communications systems.
Final Deliverable of the Project HW/SW integrated systemCore Industry EducationOther Industries Energy Core Technology OthersOther Technologies OthersSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 74300 | |||
| Induction Motor | Equipment | 1 | 2600 | 2600 |
| Delta PLC | Equipment | 1 | 13500 | 13500 |
| Analog Module | Equipment | 1 | 11500 | 11500 |
| RTU | Equipment | 1 | 8500 | 8500 |
| Convertor 485 to USB | Equipment | 1 | 1500 | 1500 |
| Contactors | Equipment | 2 | 500 | 1000 |
| Relays | Equipment | 10 | 150 | 1500 |
| Pump | Equipment | 1 | 2000 | 2000 |
| CT/PT | Equipment | 4 | 1200 | 4800 |
| Power Cables | Equipment | 200 | 15 | 3000 |
| Communcaiton Cables | Equipment | 1200 | 3 | 3600 |
| Electronic Componets,Verro Board,Solding wire etc | Equipment | 1 | 1500 | 1500 |
| Resisitve Bulb 100W+ | Equipment | 6 | 100 | 600 |
| Electrical Panels | Equipment | 4 | 2000 | 8000 |
| Table | Equipment | 1 | 5000 | 5000 |
| Circuit Breaker | Equipment | 4 | 300 | 1200 |
| Report Printing and Binding | Miscellaneous | 1 | 2000 | 2000 |
| Shipment Charges | Miscellaneous | 1 | 2500 | 2500 |