Transformer Automation using PLC and SCADA System at Substation
Much attention has been given to the use of PLCs (Programmable Logic Controllers) in substation and distribution automation applications in recent years. Innovative engineers and technicians have been actively seeking new applications for PLCs in substations and SCADA (Supervisory Control And Data A
2025-06-28 16:29:52 - Adil Khan
Transformer Automation using PLC and SCADA System at Substation
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryMuch attention has been given to the use of PLCs (Programmable Logic Controllers) in substation and distribution automation applications in recent years. Innovative engineers and technicians have been actively seeking new applications for PLCs in substations and SCADA (Supervisory Control And Data Acquisition) systems. The manufacturers of PLCs have responded by developing new products that meet the unique requirements of substation
automation and SCADA applications. PLCs are very cost competitive with traditional RTUs and have many benefits in substation automation applications. PLCs have an important place in substation automation and their use in substation applications will grow. As the use of PLCs in substation automation applications increases, and the demand for
substation and distribution automation increases, utility engineers are seeking ways to implement applications. With deregulation, utilities are decreasing engineering staff levels.
The importance of the electrical energy is increasing day by day all over the world in every aspect such as commercial, household, industrial etc. We require electricity in our day to day routine. The main components of the power systems are generating stations, transmission lines and distribution systems. Therefore we should have the knowledge of load flows. But we cannot acquire this without careful planning, controlling and monitoring. System should be operated in a way such that the losses are low. If there is fault occurred in the system, then it has to be cleared as early as possible as it can affect the whole system. Also sometimes the overloading can happen on the feeders in the peak hours. So we have to manage the load on the other feeders. If the clearance of the fault and the load management is done manually, then it will be time consuming and also the losses due to such things are much more in industrial sectors. Therefore to avoid this, automation of the transformer in substation is done. This can be done with the help of Programmable Logic Controller (PLC) and the various controlling processes and monitoring of parameters in substation is done by Supervisory Control And Data Acquisition (SCADA).
Project Implementation MethodFirst of all, we give 220v AC voltage to our power supply and connected both transformers parallel with the 220v AC supply. Then after the power supply, 220v AC is converted into 12v DC. And give that 12v DC to our PLC to run the apparatus. We use a circuit in the PLC input supply point where we use one diode and capacitors for the protection of our PLC components. This circuit protects our PLC components if the voltages increase or decrease from PLC inputs voltages which is about 36v DC max and 5v DC minimum. And use transformers which convert 220v AC to 12v AC RMS. Then we use a full-bridge rectifier which converts our 12v AC to 12v DC. After that, we use a capacitor to make our voltages smooth. One resister after the capacitor is used to discharge the capacitor. Then, use voltage regulators, which regulate our 12v DC into 12v DC for our load, 5v DC to operate the current sensor and temperature sensor, and give 5v DC to our PLC to operate effectively. For SCADA system, we use network module for data control and acquisition.
Benefits of the ProjectThe large installed base of PLCs offers the advantages of reduced costs, readily available and low cost spare parts and trained personnel to work on PLCs. The large installed base also allows the manufactures more opportunity to improve design and offer new products for more varied applications.
PLCs have extensive support throughout the US and most of the world. PLC manufactures have extensive of field offices, distributors and authorized control system integrators. In many, if not all, applications PLCs offer lower cost solutions than traditional RTUs for SCADA systems. They offer lower cost solutions than traditional electromechanical control relay
systems for automated substation applications. With the lower cost solutions PLC based systems offer in substation and distribution automation applications along with the other benefits, it is no surprise that there is so much interest in the application of PLCs in substation.
Substations are a critical component for maintaining electrical
supply and load control in low voltage, medium voltage and high voltage electrical distribution networks. In order to ensure the proper functioning of substations and related equipment such as line-mounted switches and capacitors,
most utilities use SCADA (supervisory control and data
acquisition) systems to automate monitoring and control.
New sites typically implement a SCADA system to monitor and control substations and related equipment. However, older facilities can also benefit by adding a SCADA system or by upgrading an existing SCADA system to take advantage of newer technologies. Not only will a new or upgraded SCADA system provide better monitoring and control, it can also extend the life of substations and related equipment by providing current data for troubleshooting small problems before they escalate. Furthermore, the ample historical data
provided by SCADA systems can improve preventive maintenance scheduling and cut associated.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 56590 | |||
| PLC pcb | Equipment | 1 | 30000 | 30000 |
| Transformers | Equipment | 2 | 1000 | 2000 |
| network module | Equipment | 1 | 800 | 800 |
| programming module for PLC | Miscellaneous | 1 | 500 | 500 |
| at mega328 | Equipment | 3 | 400 | 1200 |
| optocoupler PC817 | Equipment | 12 | 100 | 1200 |
| omron relays | Equipment | 8 | 250 | 2000 |
| ICs | Equipment | 3 | 30 | 90 |
| HMI | Equipment | 1 | 12000 | 12000 |
| wiring ducts | Miscellaneous | 2 | 300 | 600 |
| wooden board | Miscellaneous | 1 | 1200 | 1200 |
| power supply | Equipment | 1 | 1500 | 1500 |
| current sensor | Equipment | 4 | 250 | 1000 |
| lm35 temperature sensor | Equipment | 6 | 200 | 1200 |
| full bridge rectifier | Equipment | 4 | 150 | 600 |
| plc sheet | Miscellaneous | 1 | 700 | 700 |