Export Requirements for Packaging Machines - Moeller

INFo
The Company: www.easywayautomation.com
Products: HMI-PLC XVS400
XV100 7" wide screen
XV100 3.5" HMI-PLCs
Quicklink ID: ES2315 [www.moeller.net]
The new concept of the Ziegler hydroelectric power station in
Todtnau uses Eaton XV HMI-PLCs with a Profibus interface. The
weir, the trash rack and the machine house are designed as
island solutions with a remote peripheral connection via Profibus.
The controllers (PLC and visualization) are interconnected via
Ethernet FO. Closed-loop and open-loop control data is exchanged
on the PLC level. Thanks to the Ethernet network the relevant
information each PLC is made available to all three visualizations.
This means that all the relevant measured values and status
information is directly available, and even important operations
or parameterization tasks can be completed from all locations.
This considerably simplifies both the control and the operation of
the system – even via the Internet by means of a remote client if
required. Webcams were also installed at all essential locations,
and these can be accessed via the Internet or via the visualization
in the machine house. Fault messages reach the operator by
different routes: Firstly via an automatic telephone dialler, and
secondly via SMS and/or email, which are sent directly from the
PLC.
Converting the weir
The weir itself consists of inlet gates as well as a lateral spillway
for controlling floods. The weir has two tasks: to protect the
channel from flooding during high water and to provide a minimum
water level to the original river bed at low water, thus metering the
water supply to the channel.
The weir system control was retrofitted with a XV100 3.5
inch touch display PLC and Profibus. The PLC programming is
implemented with XSoft CoDeSys in accordance with IEC 61131;
the Galileo software is used throughout the entire installation for
visualization. The PLC is connected to the turbine and trash rack
control via Ethernet. As previously mentioned, all relevant operating
steps and parameter settings for turbines and the trash rack
installation can be carried out from this controller – based on the
latest measured values of the whole installation. Measured values
such as the water level are shown graphically and can be called
up as historical data. The same graphic includes other information
such as the operating cycles of the weir gates in order to make
retrospective assessments and any optimizations if necessary.
Converting the trash rack installation
The trash rack cleaner is designed as a chain machine and
is activated automatically if the difference in levels before or
after raking is too large. As the trash rack grill has an inherent
flow resistance depending on the flow volume, this is adjusted
dynamically according to the intake capacity of the two turbines.
The start difference could not be dynamically adjusted before the
controllers were networked.
An XV100 7-inch wide screen HMI-PLC with Profibus controls
the trash rack installation. The larger display was used here since
this location is the first to be viewed by the operator. All critical
installation parameters are then visible at a glance.
Easyway Automation is a company
based in Todtnau in the Black
Forest, which provides existing
hardware with new control
technology and implements the
conversion and expansion of
existing machines. As well as
providing support in sub areas,
the company also implements
Converting the
turbine control
Two turbines and
generators are
installed, one is
a Francis turbine
(generator with 100kW
output), and the other
is an Ossberger turbine
with two chambers
(generator with 250kW
output). Depending
on the situation, the
visualization can be
used to select which
of the two can be
run as the base load
generator, depending
on the season, the
possible degree
of pollution or the
currently available
water volume.
The innovative control
system with the
XVS400 showed
new installations. The company
focuses on customized solutions
and tailored functions. It also
provides extensive support as well
as long-term customer care.
its strengths particularly for the turbine controls, with many
improvements implemented. These include greater operating
comfort as well as the long-term increased efficiency of the
installation. As the channel also has an inherent flow resistance,
provided there is sufficient water available an artificial gradient
can be created in order to guide the water into the turbines for
more efficient power generation. This requires the recording
of all measured data and status information, and could also be
implemented in the new concept. The turbines are also run in the
ideal efficiency range for an optimized yield. Today it is possible
to prevent any contamination that can cause a subsequent loss in
output: The output of the Francis turbine is constantly controlled
and the turbine is automatically purged.
CoNCLuSIoN
Renewable energy:
Two turbines with connected 100 kW and
250 kW generators convert hydro power into
electricity.
Christian Stadler, owner of Easyway Automation, summed up
as follows: “The hydroelectric power station at Todtnau was
equipped with a system that meets the latest state-of-the-art
in automation technology. Onsite inspections by the customer
are no longer necessary since he can monitor the installation
at any time via the Internet, thus giving him worldwide
access if necessary. Today the installation responds
automatically with alternative routines to predefined faults
in order to maintain constant electricity generation. Yieldoptimized
operation has now been ensured thanks to the
seamless and perfectly matched communication variants of
all three plant sections. The joint efforts of the operator and
our company were particularly fruitful so that many new
features were made possible.”
SolutionS 23 21