Development of a SCADA System for Micro Hydro Power Plants

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LABORATORY TOWARD DEVELOPMENT OF SCADA SYSTEM

By Rega Manggala

11111041

BACHELOR’S DEGREE in

MECHANICAL ENGINEERING - MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY EduTown BSD City

Tangerang 15339 Indonesia

August 2015

Revision after the Thesis Defense on 7^th August 2015

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Rega Manggala STATEMENT BY THE AUTHOR

I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

Rega Manggala

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Student Date

Revision after the Thesis Defense on 7^th August 2015

Approved by:

Ir. Arko Djajadi, M.Sc, Ph.D

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Thesis Advisor Date

Dr. Phil. Mathias Guenther, M.Sc

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Thesis Co-Advisor Date

Dr. Ir. Gembong Baskoro, M.Sc

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Dean Date

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Rega Manggala ABSTRACT

TESTING OF MICRO HYDRO POWER PLANT AT ASEAN HYCOM LABORATORY TOWARD DEVELOPMENT OF SCADA SYSTEM

By Rega Manggala

Ir. Arko Djajadi, M.Sc, Ph.D, Advisor Dr. Phil. Mathias Guenther, Co-Advisor

SWISS GERMAN UNIVERSITY

Micro hydro power plant is one of the viable solution against shortage of electricity supply especially in the remote area, it is relatively easy to operate and to maintain, and usually such micro hydro system is developed and run without or only with minimum monitoring SCADA system even at experimental laboratory in HYCOM

In this thesis online monitoring system is developed and implemented to allow real time monitoring of micro hydro performance at the facilities of ASEAN Hydropower Competence Center (HYCOM). This development is based on the experience of field / lab testing in that laboratory. To equip the lab with proper monitoring system parameter monitoring to enable quick performance evaluation of the generated electric power.

The monitoring system, will monitor / measure the water pressure, the flow rate of the water, the RPM of the turbine and the generated electric output in the lab water from pool pump through the pipe line into the turbine with varying flow rate. Varying flow rates produce varying turbine speed and also varying electric power and electric AC frequency in real operations this real time monitoring would allow quick performance evaluation and effective troubleshooting as needed.

Keywords: Water Pump; Flow Rates; Crossflow Turbine; Cross Flow Turbine; RPM;

Output Power

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Rega Manggala

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Rega Manggala DEDICATION

I dedicate this works for my family

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Rega Manggala ACKNOWLEDGEMENTS

I wish to express my sincere gratitude to my two supervisors (advisor and co –advisor) Ir. Arko Djajadi, M.Sc, Ph.D, as well as Dr. Phil. Mathias Guenther, M.Sc., who have all devoted their valuable time and effort to assist me with this project.

My appreciation is given also to the many technicians at the HYCOM who assisted me with my research on the practical side, and in particular, Messrs Iman and Niam and also Mr Gerhard Fischer for providing us with the requisite equipment.

Thanks are due also to all my colleagues at SGU especially Messrs Michael Wijanarko, Stefanus Richard Gunawan, and Yudha Tirtandanu for their help.

In addition I wish to acknowledge the encouragement I received from Mr Tubagus for his tolerance in allowing me the resources and opportunity to complete the final phase of this thesis.

This acknowledgment would not be complete without reference to both financial support I received from my family and, in the reassurances I received from the many friends I made whilst studying at the Swiss German University.

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Rega Manggala TABLE OF CONTENTS

Page

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENTS ... 7

LIST OF FIGURES ... 10

LIST OF TABLES ... 11

CHAPTER 1 - INTRODUCTION ... 12

1.1 Background ... 12

1.2 Objectives... 13

1.3 Hypothesis... 13

1.4 Thesis Limitations ... 14

1.5 Thesis Problem... 14

1.6 Methodology ... 15

1.7 Thesis Organization ... 15

CHAPTER 2 - LITERATURE REVIEW ... 16

2.1 Introduction ... 16

2.2 Micro-Hydro Power Plants (MHPP) ... 16

2.2.1 Overview of Typical MHPP ... 16

2.2.2 MHPP in the HYCOM Lab... 18

2.3 Basic SCADA Monitoring of Micro-Hydropower Plants... 20

2.3.1 PLC ... 22

2.3.2 RTU... 23

2.3.3 Microcontroller ... 23

2.4 Sensor ... 24

2.4.1 Flow Rate ... 24

2.4.2 Water pressure... 26

2.4.3 Tachometer... 27

2.4.4 Power meter ION6200 ... 27

CHAPTER 3 - RESEARCH METHODS ... 29

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Rega Manggala

3.3 Determining Required Monitoring Parameter to be Monitor and Control ... 32

3.3.1 Inverter ... 34

3.3.2 Flow Rate Measurement ... 35

3.3.3 Water Pressure Measurement... 36

3.3.4 RPM Measurement ... 36

3.3.5 Voltage and Current Measurement ... 38

3.4 Sensor and Instrument Design for MHPP SCADA ... 39

3.5 Overview of MHPP Sensor ... 40

3.5.1 Flow Rate Sensor ... 41

3.5.2 Flow Rate Instrumentation Design ... 42

3.5.3 Water Pressure Sensor ... 44

3.5.4 Water Pressure Instrumentation Design... 44

3.5.5 RPM Sensor ... 47

3.5.6 RPM Instrumentation Design... 47

3.5.7 Voltage and Current Sensor ... 49

3.5.8 Voltage and Current Instrumentation Design ... 50

3.6 Concluding Remarks ... 51

CHAPTER 4 - RESULTS AND DISCUSSIONS ... 52

4.2 Micro-Hydro Monitoring Preparation Result ... 52

4.2.1 Flow Rate Testing Result ... 53

4.2.2 RPM Testing Result ... 55

4.2.3 Water Pressure Testing Result ... 56

4.2.4 Power Calculation Result ... 56

4.3 Sensor Instrumentation Result ... 58

4.3.1 Flow Rate Sensor Instrumentation Result... 58

4.3.2 RPM Sensor Instrumentation Result ... 60

4.3.3 Water Pressure Sensor Instrumentation Result ... 62

4.3.4 Power Meter Instrumentation Result ... 64

4.4 Monitoring Result ... 66

4.5 Monitoring Benefactor ... 67

CHAPTER 5 - CONCLUSIONS AND RECCOMENDATIONS... 68

5.1 Conclusions ... 68

5.2 Recommendations ... 68

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GLOSSARY ... 69

REFERENCES ... 70

APPENDICES ... 71

APPENDIX A – DATASHEET ... 72

A1. DATASHEET OF ARDUINO UNO ... 72

A2. DATASHEET OF WATER FLOW SENSOR ... 79

A3. DATASHEET OF PRESSURE TRANSMITTER ... 81

A4. DATASHEET - ION 6200 ... 83

A5. DATASHEET OF INVERTER ... 87

APPENDIX B – PROGRAMMING ... 96

APPENDIX C – BILL OF MATERIALS ... 101

CURRICULUM VITAE ... 102