Journal of Engineering and Technology for Industrial Applications

ITEGAM-JETIA
Manaus, v.XX n.XX, p. XX-XX. Mon./Mon., 20XX.
DOI: https://doi.org/10.5935/jetia.XXXXX.XXX
ISSN ONLINE: 2447-0228

RESEARCH ARTICLE OPEN

ACCESS

A PLC BASED CONTROL SYSTEM FOR LOAD FREQUENCY CONTROL IN AN

ISOLATED SMALL HYDRO POWER PLANT

Julio Cesar Bravo Cortés1 and José Rafael Abreu García2

1
Empresa de Automatización Integral (CEDAI) – UEB Villa Clara, Cuba.
2
Universidad Central “Marta Abreu” de Las Villas – Santa Clara, Cuba.

1
http://orcid.org/0000-0001-6346-6463 , 2http://orcid.org/0000-0002-8344-8796

Email: [email protected], [email protected]

ARTICLE INFO ABSTRACT

Article History Renewables provide 20 % of the power generation worldwide, being hydro power the
Received: Month 01th, 20XX cheapest and most sustainable way to generate power, representing almost a fifth of the
Accepted: Month 15th, 20XX generation worldwide. In Cuba, electrification in mountainous areas is through isolated
Published: Month 30th, 20XX small hydro power plants from the National Electroenergetic System. One of the most
important components in hydro power plants is the frequency controller, due to the
Keywords: changing condition of the demand of power generated by users. The use of inefficient
Load Frequency Control, regulation systems with regulation techniques made from resistive load or ballast, provides
PID, the statement of frequency regulation through the management of the water flow as a
Programable Logic Controller viable technical solution. In the current work, the frequency regulation in the small hydro
(PLC), power plant “Hanabanilla” with a PID as a controller designed in Matlab Simulink and its
Small Hydro power Plant, implementation in a control system made from a PLC M241 by Schneider Electric is
Servo drive. proposed.

Copyright ©2016 by authors and Galileo Institute of Technology and Education of the Amazon (ITEGAM). This work
is licensed under the Creative Commons Attribution International License (CC BY 4.0).

I. INTRODUCTION operation, consumers require a continuous and quality

service, being the frequency of the system one of the
The generation of electric power through hydro power quality rates. Deviation of the instant frequency value is
plants is one of the most efficient and safest ways to an inevitable fact due to the imbalance produced
generate power. The beginning of its use dates back between generation and the charges connected to the
from the first Industrial Revolution in England, being system that vary randomly depending on the
the civil engineer John Smeaton its main promoter. incorporation or desconnection of such charges. In order
Currently, it plays an essential role in the electrification to maintain the instant frequency value of the system
of rural areas located far from the big networks of within the recommended ranges, it is necessary to
power distribution, especially in developing countries. implement a frequency regulation mechanism.
Normally, small hydro power plants, whose power The problem of frequency control in small hydro power
ranges between 50 and 500 kW according to the Latin plants can be pictured as a rejection before disruption
American Energy Organization (known in Spanish as [2] and it is subject to variations of operation’s
OLADE) [1] are more profitable and cleaner for the conditions of the plant. The load-frequency control or
environment than hydro power plants which have bigger automatic control of generation (known in Spanish as
power. There are two ways of operation in the small AGC) is focused on maintaining the frequency within
hydro power plants: isolated mode and that connected to the permissible limits and controlling the interchange of
an electric network. By working in both ways of power between the different areas. In Cuba, out of the

Journal homepage: www.itegam-jetia.org

 One, Two and Three, ITEGAM-JETIA, Manaus, v.XX n.XX, p. XX-XX, Mon./Mon., 20XX.

107 small and micro hydro power plants currently this type of systems. Some of the most well-known
working, only six of them have some frequency methods are the Fuzzy Multimodel Control [8], the
regulation mechanism, and since these systems are Intelligent Hybrid Control [9], the Multiple Flow
technologically obsolete and energetically inefficient Control [10], the Integral Control based on Neural
due to the use of the load or regulation for ballast Networks [11] and the Adaptive Control [12], [13]. A
resistances, it is necessary the design of a frequency review [14] did some research on the new operation
control in isolated systems which are adapted to the strategies and control for electric distribution networks
demands of quality in the generation of electric power connected to small hydro power plants.
and which are best used on the available water resource. A scheme of Sliding Mode and model order reduction
The small hydro power plant “Hanabanilla” ranks in the has been recently implemented by Qian [15] for the
type of run-to-the-river small hydro power plant and solution of the problem concerning frequency-load
consists of a unit which generates 130 Kw of power control in small hydro power plants. In this project, how
with a Pelton turbine, and it is currently working the system in the two ways of operation works is
connected to the National Electroenergetic System explained: isolated and connected to an electrical
(known in Spanish as SEN), since it does not possess a network. The system is modelled mathematically under
frequency regulation system to work in an isolated both ways of operation, by obtaining the reduced model
mode. Since its beginnings, this small hydro power for its further analysis and, according to the order
plant worked in an isolated mode with an electronic reduction model, a sliding control algorithm is applied.
system of frequency regulation by resistive load, being Since the control algorithm is applied to the original
its purpose to feed the plant service of the Hydro power system, a sufficient condition about the stability of the
Plant “Hanabanilla” with 43MWh and the system according to the theory of small earn in control
Administrative Building of the entity. This regulation systems is demostrated.
system broke down leaving the unity inoperative until it A combination of the diffuse logic and the adaptive
was decided to syncronize it to the National control comes true in Weldcherkos’s proposal [16],
Electroenergetic System (known in Spanish as SEN). where he uses an adaptive inference system with diffuse
The proposal to design a frequency regulation system logic (Adaptative Neuro-Fuzzy Inference System -
for the small hydro power plant intends to get the unity ANFIS) and this result is compared with the responses
which generates back to work in isolated operation, as it of the system with a conventional PID control. By using
was originally conceived, working as a backup to the ANFIS, a faster transitional response is achieved (5-
plant service of the Hydro power Plant “Hanabanilla” second order), much more than using PID (60 seconds).
before eventualities such as cyclones or breakdowns in An adaptive controller with diffuse logic for small
the Hanabanilla-La Moza-Santa Clara System, so as to hydroelectric plants by Özbay and Gençoğlu is
perform a black start without having to depend on the proposed [13], by using dynamic models of linear and
SEN. non-linear turbine without taking into account the water
The main contribution of this work is the proposal of a hammer effect. It is interesting how faster settling times
frequency regulation system made from PLC in a small are achieved with the non-linear model than with the
hydro power plant where the final action element is a linear model by using this algorithm.
servomotor which is controlled by a Lexium 32 servo On the other hand, Asoh, Mbinkar, and Moutlen [17]
control. propose a PI control with diffuse logic in a linear plant
model and in another case with non-linear model. The
II. THEORETICAL REFERENCE obtained results in the simulations for the linear plant
showed settling times of 95 seconds with a conventional
Two main ways to control the frequency in small PI, while with a PI control with diffuse logic the settling
hydro power plants are known: the control of the water times were of 12 seconds, this with load variations of a
flow which gets in the turbine and the adjustment of the 3% of the total value of the plant generation power.
generator load by using resistances banks for the A controller of variable structure is introduced by
adjustment of the frequency [3], though Peña’s work [4] Kumar and Mathew [18] to show the significant
successfully combines both regulation methods so as to improvement in the transient response with different
reach an optimus adjustment of the frequency-load step-typed reference inputs for changing loads. The
control as the operation point of the plant varies. The authors explain the functioning of a plant working in
first method consists of adjusting the controller to an isolated mode and the range of power losses. They also
operation point of the plant by regulating the quantity of reduce the value of wasted power to a 50% of the power
water that flows into the turbine [5] and the second fixes delivered by the plant, due to the variation in the water
the operation to a value of constant power, normally the flow.
maximum value, by balancing the loads of the users Another of the tendencies is the use of an electronic
with a resistive loads system connected in parallel [6], load controller, developped by Kapoor, Phunchok,
[7]. Kumar and Rahi [19], which senses and regulates the
From these two main ways to operate an isolated small frequency generated by a small hydro power plant. It is
hydro power unit, a wide variety of control methods in explained in the work that an electronic load controller
the scientific litterature has been implemented in order is a solid state device, designed to regulate the output
to solve the problem with the frequency regulation in power of a small hydro power-typed generation system
 One, Two and Three, ITEGAM-JETIA, Manaus, v.XX n.XX, p. XX-XX, Mon./Mon., 20XX.

and keep to the closest possible constant load value in is made by using three different optimization methods:
the turbine to generate stable voltage and frequency. Lightning Search Algorithm (LSA), Particle Swarm
Kenzhaev [20] proposes the use of an automatic digital Optimization (PSO) y Quasi Oppositional Based
microprocessor control system, based on the analysis of Lightning Search Algorithm (QOLSA). Finally, the
the current use of digital frequency controllers as optimized PID with the QOLSA method showed better
automatic ballast load controllers for small hydro power voltage and power responses to the output of the unit
plants. At present, there are two practical circuit designs than that with the other methods.
of this type of a controller: 1. Step ballast load A PI controller has been used by Safaei [26] to reduce
connection to the generator output using a contactor- the peak of frequency deviation. The optimal gain of PI
relay switching; and 2. The use of analog power controller and integrator of dump load is obtained by
semiconductor automation (analog ballast load). The genetic algorithm (GA) to achieve minimum frequency
advantage of this solution is more accurate automatic deviation. In this method, the peak of frequency
control. One of the most promising circuit designs for deviation is reduced less than 1 Hz while in the
small hydro power plant ballast load controllers is a conventional scheme, the peak of frequency deviation is
digital frequency controller. Digital measurement is 3 Hz. In other words, the positive or negative peak of
widely used in modern circuitry, characterized by high frequency deviation has been reduced about 60%.
accuracy and is well combined with a stepwise Gupta [27] proposed in his work the use of a
automatic ballast switched by thyristor contactors. The Programmable Logic Controller (PLC) for control and
practice of using digital frequency controllers to automation of small hydro power (SHP) station, its
stabilize the rotational speed of an off-grid small hydro advantages and cost effectiveness. Programmable logic
power plant has shown that they provide adequate controllers (PLC) can be used for control & automation
power plant dynamic indicators and stable plant of SHP station. The main reason for this is cost
operation with almost all types of hydraulic turbines. effectiveness. Various functions and controls can be
While Marques and Molina [21] discuss in a detailed achieved by programming the PLC. They can be used
way the modelling and the proposal of a new control for full plant automation including governing of auto-
scheme of a three-phase electrical network connected to operation includes speed control, load control,
a small hydro power type of plant. They implement a excitation control, and level control automatic start/stop
new control scheme, which consists of a multi-level sequencing, gate control, start/stop of auxiliary systems,
hierarchical structure and it adds a maximum power and protection requirement etc. Functions other than
point tracker for a better use of the hydraulic power control like continuous monitoring, data recording,
contributed to the system. instrumentation and protections can also be performed.
Karthikeyan, Menna Eligo and Dawit [22] also propose For remote operation, communication with PLC can be
a control structure with a tuning method for a load- performed. For continuous monitoring purpose, a
frequency controller in systems of PID type of power. personal computer can be interfaced with PLC and
The proposed scheme assures stability in the system continuous data can be recorded regularly.
during dynamic state conditions. Alam and Chopra [28] paper present a project based on
Saad’s work [23] is based on the design of a PID control Proportional–Integral–Derivative (PID) for the
for an isolated small hydro power plant. The simulations implementation of load controller for three-phase
of the plant with the PID varying the operation point of synchronous generator. Electronic load controller is a
this, result in settling times between 9 and 30 seconds device which is related to power electronics method of
for a variation of the load by disturb of 2% out of the controlling, managing and monitoring frequency of a
total of the installed power. system. Mostly, in rural areas, we do not have access to
A Digital PI control algorithm is proposed by Huerta grid for power. There pico- and micro-hydropower can
[24] for the speed regulation in a synchronous Pelton- be implemented to provide power. For persistent
generator turbine system in a small hydro power plant. operation and control of a three-phase synchronous
The developped scheme is waterfall-type with a generator, an electronic load controller has been
proportional control in the internal bow and an integral- implemented rather than using speed controller
proportional control in the external bow, achieving a governor which is much more expensive. With the help
settling time response of 12 seconds before a unitary of the proposed device, load output can be controlled,
step input. and thus, frequency can be maintained constant which
Peña, Fariñas and Domínguez [4] bring forward a again reduces worst case of overloading on generator.
proposal for the adjustment of a controller by looking Therefore, with the help of the proposed scheme,
for the optimum operation point of a small hydro power protection of both generator and user’s load can be
plant through the combination of both ways to regulate maintained. The proposed system can play a vital role in
frequency: by resistive loads (ballast) and through the run-off-river type hydropower station because there is
water flow control which goes into the turbine. Settling no point of saving water. Thus, the proposed system can
times up to 5 seconds for impulsive loads of 11% are be used to minimize the overall cost of installation of
obtained and in the range between 20 to 30 seconds for the hydropower plant up to a large extent in rural areas
step type of input of 13%. where we do not have access to grid connection for
In Shashikant and Shaw’s research [25], an interesting electricity.
comparison as for the tuning of the PID type of control
 One, Two and Three, ITEGAM-JETIA, Manaus, v.XX n.XX, p. XX-XX, Mon./Mon., 20XX.

Maina [29] paper investigates the performance of a generator and the time constant
single unit small hydropower plant in both grid- 2∗2.88
connected and islanded operation. The overexcitation Tp= =0.12 s ,resulting in:
60∗0.8
and volt/hertz excitation limiters have been included in
the study to compare their responses in both modes of
operation. The plant is evaluated under different loading 1.25
G p= (2)
scenarios considering both resistive and inductive loads. 0.12 s +1
A PI tertiary control for speed reference setting in
islanded operation is introduced in the governor to As an element of final action a direct current
enable regaining of 50 Hz frequency after load changes. servomotor fulfilling with high dynamic performances
The results obtained from the simulation study show the and being capable of developing a constant nominal
importance and difference of analysing different loading torque of 33 Nm was chosen, given by the mechanical
scenarios both in grid-connected and island modes. demands of the injector needles of the turbine. It is well-
Also, the inclusion of PI control in governor aids in known that this type of drive gives stability to the
returning the frequency to its nominal value. system for being a first typical order, this in detriment
of other electro-hydraulic type of actuators that are also
III. MATERIALS AND METHODS mentioned in litterature [30], [31], but that present
non-linear features in its behavior.
The modelling of the turbine-generator system of the
The transferential function which describes the
small hydro power plant “Hanabanilla” was performed
dynamics of the direct current selected servomotor is
by having into account the technical data of the plant
given by [32]:
and taking as reference the linear model stated by
Kundur [30], where it is assumed that:
10
 The water resistance is significant. Gk = (3)
0.0139 s+1
 The water pipe is inelastic and the flow is
incompressible.
 The water flow speed varies directly with the
sluicegate’s opening and with the square root
of the net hydraulic load.
 The output of the unit’s power is directly
porportional to the product of the hydraulic
load and volumetric water flow.
For the Pelton turbine model, 100 meters was taken as
an average hydraulic load and an average water speed in
the pipe of 6.5 m/2, staying as transferential function of Figure 1: Control scheme of the small hydro power
the turbine: plant “Hanabanilla”
Source: Authors, (2022)
−4 s+1
Gt = (1) The droop constant of the system was taken into
2 s +1
account R=5%, thus, we have in the feeback 1/R=20, as
While for the 200 kW synchronic generator, from the it is stated by Kundur [30].
Due to the need of achieving a response from
the system with zero error in stable state so as
to achieve to keep the frequency in 60.00 Hz, it
was decided to firstly tune a PI type of control
before the value-step entry 30 for disturb, by
making use of the Matlab-Simulink software
and to assess its performance. The transitional
response with the comprehensive proportional
control, with Kp=0.015 and Ti=0.5s, is
considered to be quick, with settling time of
7.3 seconds; however, it was decided to tune a
PID control so as to improve the transitional
electrical data, the load-damping constant was
response.
1 1
Kp= = The tuned PID shows a response with settling times of
calculated D=0.8 to find the ∂ Pl D of the 6.6 seconds, having as the following parameters: Kp=
∂F 0.016, Ti= 0.5 s, Td= 0.1 s.
Figure 2: Variation of the frequency with controllers
type PI and PID.
Source: Authors, (2022)
 One, Two and Three, ITEGAM-JETIA, Manaus, v.XX n.XX, p. XX-XX, Mon./Mon., 20XX.

drive. Schneider Electric M421 PLC only has two Pulse

In the figure 2, the improvement of the response of the Train Output (PTO). When combined with the Lexium
PID respect to a PI type of control is showed. In red 32 servo drive, they only allow to control only one
color, the response of the PI and in blue, that of the PID. servo since it is necessary to change the direction of
The improvement of the transitional response which rotation of both motors to achieve the opening and
introduces the derivative action in the PID, makes this closing operations of the injectors. It was then decided
to be the chosen one in detriment of the PI. It is evident to control the first one with PID through the two Pulse
the inverse response of the system given by the zero in Train Outputs for a fine adjustment of the system
0.5 which introduces the transferential function of the frequency and the other servomotor was controlled with
hydraulic turbine, which brings stability problems and a a ON/OFF controller.
slow response given that two physical phenomena with A Power Logic iEM3250 network analyzer is used as
opposed dynamics are manifested in the process. an element of the frequency measurement so as to
The frequency regulation proposal in the small hydro communicate with the automaton by Modbus Serial
power plant “Hanabanilla” is based on a Control System IOScanner protocol and transfer the reading value of the
made from PLC M241 by Electric Schneider. The system frequency, as well as the other electrical
reason for his choice is given by the robustness and parameters such as active and reactive energy, power
demonstrated reliability which provide the control factor, voltages and phases currents for the setting of the
systems made from programmable logic controller alarms and plant’s shots.
(known in Spanish as PLC) and its high flexibility in the Figure 4 shows the frequency control loop according to
configuration of the software and the hardware, as well the ISA S5.1-84 norm: the Lexium 32 (FC-2) servo
as the capacity they have to execute several tasks and controller and the Schneider Electric M241 PLC (PLC-
operations in real time simultaneously. 1) constitute the controller, the servomotor of direct
current (FZ-2) is the actuator, and the Power Logic
iEM3250 network analyzer (ST-2) is the
measurement element closing the control loop.

Figure 4: Frequency control loop scheme according

to the ISA Norm.
Source: Authors, (2022)
Figure 3: Control paltform based on PLC M241.
Source: Schneider Electric Courtesy, (2018) The scheme also includes the motorized valve control
which allows the water input to the turbine, which is
operated with a frequency converter (FC-1) located in
M241 has two Pulse Train Output (PTO), which will
the control panel. This is an ON/OFF type of control
be necessary for the control of the position of the two
and is covered by the boot sequence and stop of the
CD servomotors, which will work on the needles of the
plan.
injectors of the turbine through the Lexium 32 servo
controllers (servo drive) of the own Schneider Electric
manufacturer. IV. RESULTS AND DISCUSSIONS
It is also fundamental the possibility of setting a PID The efect of varying the operation point of the plant
function within the M241 programming logic, allowing (hydraulic load) with the PID controller in the control
to put into practice the design of a controller of this sort. system of the Small Hydro power Plant “Hanabanilla”
Automaton programming was performed with the does not damage significantly the system reponse.
software created by the own SoMachine v.4.3 Figure 5 and Table 1 reflect the behavior of the system
manufacturer. Aside from tuning the PID controller, the reponse in each case.
electrical drive of the CD servomotors with the Lexium Figure 5: Variation of the plant response with the
32 module was set in the program, and all the boot
sequence, the stop and the unit operation, as well as the
alarms and plant’s shots were programmed.
The design of the control system was performed by
taking into account that the turbine has two injectors,
therefore, it is necessary to use two servomotors for its
 One, Two and Three, ITEGAM-JETIA, Manaus, v.XX n.XX, p. XX-XX, Mon./Mon., 20XX.

PID varying the hydraulic load. The design of a PID controller, through the linear
Source: Authors, (2022) model of the plant is adjusted to the technical operation
As showed in the graphic of figure 5, settling times in demands of a isolated small hydro power plant and the
the most critical cases never exceed the 10 seconds time settling times of the response before variation of the
despite the variation of the operation point of the plant hydraulic load are similar to those stated in litterature.
with the change of the hydraulic load of the unit. The choice for a direct current servomotor as an
Similar responses were obtained in the works presented actuator element in the control loop gives stability to the
by Padhan and Majhi [33], Tan [34] and Anwar and Pan system.
[35], where from the PID controllers designed by The use of the PLC M241-based control platform by
frequency method [33], [35], and from IMC inner Schneider Electric allows a flexibility both in the
controller model, settling times of 4.4 seconds and 8.4 development of the control system and in the
seconds respectively were obtained. communication of this with supervision systems that
can be added in higher levels of the automatization
Table 1: System response with PID varying the pyramid.
hydraulic load. The use of the Lexium 32 servo controller integrated to
R the PLC-bsed control platform for the frequency
Maximum regulation in a small hydro power plant constitutes a
Hidraulic Settling contribution to this work so as to give a technical
Response overshoot
load time-ts solution to the state problematic, since this type of servo
%Mp
95 m Violet 32 9.5 seg actioning are frequently used in applications of packing
100 m Yellow 16 6.6 seg and packaging lines processes in the food-processing
105 m Blue 18 6.9 seg industry where the speed control of conveyor belt and
the position control in different axes is necessary, given
110 m Red 3 7.3 seg
that the use in the control areas of the electrical power
115 m Green 5 7.5 seg
systems is not well stated in litterature.
Source: Authors, (2022)
VI. AUTHOR’S CONTRIBUTION
A PID controller for the load-frequency control Conceptualization: Ing. Julio César Bravo Cortés,
in a plant with similar features to that of the present Dr.H.C. José Rafael Abreu García.
article is tuned in the work of Saad and Chi [23]. For a Methodology: Dr.H.C. José Rafael Abreu García.
turbine with response time of 4 seconds and with a Investigation: Ing. Julio César Bravo Cortés.
droop feature of 5%, the tuned controller by Saad grants Discussion of results: Dr.H.C. José Rafael Abreu
the turbine-generator system a much slower response García.
(33.6 seconds) that those obtained in this work. The Writing – Original Draft: Ing. Julio César Bravo
simulations performed by Saad were for variations of Cortés.
the demand of 2% of the total generation capacity of the Writing – Review and Editing: Ing. Julio César Bravo
generator whereas those performed in this work were of Cortés, Dr.H.C. José Rafael Abreu García.
25%. Once the adjustment of the PID control was Supervision: Dr.H.C. José Rafael Abreu García.
obtained through the stated technical design Approval of the final text: Dr.H.C. José Rafael Abreu
requirements, all the control logic of the small hydro García.
power plant “Hanabanilla” was programmed. The boot
sequences and stop of the unit, the process and safety
VII. ACKNOWLEDGMENTS
interlocks, the alarms and the shots of the plants were
taken into account. The reading of all the electrical
parameters of the generator, sensed by the Power Logic We would like to thank the specialists and technicians
iEM3250 network analyzer, lead to the supervision and of the Small hydro power plant “Hanabanilla” for the
control of the plant’s shots and to a safe operation. support and the provision of all the technical
The functioning of the program with the the same information that has been proved useful in the writing of
simulator of the SoMachine v4.3 software was this research.
simulated, by forcing all the conditions so as to check
the correct functioning of the sequences automatically VIII. REFERENCES
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