Journal of Electrical Engineering

The Institution of Engineers, Bangladesh

Vol. EE xx, No. xx, June/December xxxx

PLC Based Operation and Control of Two Diesel

Generator Set
P. K. Bhowmik1, M. Dey2, and S. K. Dhar3
1

Department of Instrumentation and Communication, Eastern Refinery Limited, North Potenga, Chittagong, Bangladesh
Department of Electrical & Electronic Engineering, Chittagong University of Engineering & Technology, Chittagong, Bangladesh
3
Member IEEE, Chittagong, Bangladesh
E-mail: pkbcuet@yahoo.com1, mrinmoyeee@gmail.com2, sagor378@gmail.com3
complete set up has the following facilities [4-5].
1. Programmable Logic Controller (PLC)
2. Interface Unit
3. Power supply for PLC input & output module
4. Power supply for Lamps supply (24V DC)
5. 24V DC Relay and Cables
6. Two contact relay base
7. Push button switch
8. 24V DC Flashing lamps
9. A Personal Computer (PC)
10. Sucosoft V5.02 programming software

Abstract This paper outlines the operation and control

features of a diesel generator of Reactor Operation and
Maintenance Unit (ROMU) and discuss about the system,
structure and implementation for smooth automatic operation
by using programmable logic controller (PLC). All criteria for
safe starting, synchronization, protection against electrical and
mechanical faults of the generators are taken into consideration
in the software used for the PLC. This facility enhances the
method of learning of PLC based power systems operation and
control at undergraduate level. Over the years the demand of
higher quality, greater efficiency & automated system and
machines has increased in the globalised world. To cope with
this advancement it is anticipated that this paper will be
considered very effective effort.

Personal computer
Index TermsPLC, Diesel Generator operation and control,
Sucosoft V5.02 Moeller PLC software

Sensor
Panel

I. INTRODUCTION

N order to automate a power generation system and to

minimize human intervention, PLC based system will be a
good option that monitor the system and help to reduce the
error caused by human. The wide applications of PLC in
many areas have significantly contributed to the operation
and automatic control of electrical and electronic system [24]. The internal storage of instructions for the implementing
functions such as logic, sequencing, timing, counting and
arithmetic to control through digital or analog input/ output
modules various types of machines processes. Similar PLC
based automation Systems are also widely used to monitor
and control plants or equipment in industries such as power
plants, energy, oil and gas refining and transportation.

Input
Module

24V dc power
supply for PLC

Interfacing Unit

CPU

Output
Module

Power circuit
Breaker

Load
Panel

24V dc power
supply for lamp

Main Power Supply

Fig. 1. Block diagram of the PLC together with interfacing
components
III. PROCESS SYSTEM DESCRIPTION

A. Diesel Generator Sets

The two diesel generator set defined as Generator-A and
Generator-B of ROMU are considered to get an idea of
operation for PLC based generator operation and control
system development and experimental purpose. Here the two
synchronous generator set are driven by diesel engine. The
ratings of Generator-A is 3-phase, 650-kVA, 50-Hz, and
Generator-B is 3-phase, 250-kVA, 50-Hz. Two generators are
connected to a synchronizing panel with which main
distribution board are connected. Normally utility supply
(REB) is used in ROMU, but in case of load shading the
generators are started manually and with the help of
synchronizing panel board generators are synchronized [1].
There are specific operating procedures for such activities.

II.PLC MODULE SETUP

A PLC is a 'digital operating system' designed specially for

use in an industrial environment, which uses a programmable
memory for its internal operation of user-orientated
instructions and for implementing specific function such as
logic, sequencing, timing, counting and arithmetic. PLC
controls digital and analog inputs and outputs in the various
types of machines. In a PLC inputs and outputs are not
designed for humans, but for use in the control of machines.
Machine and operator interact solely by way of limit
switches, contact switches, or photoelectric switches [2]. The
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Author Instructions: J. Elec. Engg., Instn. Engrs., Bangladesh, 36(II), December 2009
D. Protection and Control of Generator

B. Process Block Diagram

Start

Lube oil
Measurement
Sensor

REB
line

Fuel oil
Measurement
Sensor
PLC

GenA

GenB

Water level
Measurement
Sensor

A
C
T
U
A
T
O
R

REB off

Reactor
Operating

Yes

Radiator,
bearing temp
Measurement
Sensor

No

Select Gen A

Select Gen B

T1

Generator Cranking

BUS-BAR

Voltage
Sensor

Current
Sensor

PF
Sensor

Frequency
Sensor

Reset Alarm
T2
No

Fig. 2. Block diagram of automation procedure of two diesel

generator set.

All alarm
Reset

C. Process Operation Description

Successful operation of a process system depends upon
careful installation & initial start up. Before start up there
should be a thorough check of the system, like valves, control
trip, safety device, and all mechanical and electrical systems
that should be in good condition. The operating procedure of
this diesel generator system is as follows [1]1. Generator automatic selection and starting when
utility, named here as REB is off and when
starting conditions to be fulfilled are ok as
mentioned in the operation manual.
2. If Reactor in operating condition higher capacity
Generator-A will be selected. Otherwise the lower
capacity Generator-B will be selected.
3. Then generator cranking started.
4. All the alarms of the system to be reset condition.
After resetting all alarms engine purging started.
This checking & purging requires a specific time.
5. Generator starting condition checking (temperature
level and pressure of the lube-oil and fuel oil, water
level, Radiator and bearing temperature etc) mainly
all the mechanical features. This checking takes a
specific time.
6. If mechanical fault found then shutdown the engine
and then wait for alarm reset. If all mechanical
features are ok then generator speeds up gradually.
This requires a specific time to accomplish generator
rated speed.
7. After achieving the rated speed generator auto
synchronism with the bus-bar accomplished. This
also requires a specific time.
8. Bus-bar disconnection by disconnecting the circuit
breaker while electrical fault occurs (over voltage,
over current, power factor or frequency out of
desired range) and then again wait for alarm reset.

Engine
Shut down

Yes
Engine Purging

T3
Fault
T4

Checking lube oil pr,

water level, fuel oil pr.
temp, Radiator,
Bearing temp & others

Generator Speed up
T5
Gen rated speed
achieved
No
Disconnecting
Circuit Breaker

Yes
Gen Synchronizing

Gen Loading according to

the demand

T6

T- Indicates
Timer

Yes
Electrical
fault occur
No
Return

Fig. 3. Process flow diagram for operation and control of two diesel
generator set

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Author Instructions: J. Elec. Engg., Instn. Engrs., Bangladesh, 36(II), December 2009
E. Protection and Control of Generator System
In this study the starting and protection against both
electrical and mechanical faults are automated. When
electrical fault occurs (due to over load, over voltage, over
and under frequency) and violet the generator protection
features according to ANSI the bus bar would be
disconnected from load and fault-alert would be made for the
operators. The generator protection features according to the
ANSI are: differential current(87G), over voltage(59G), under
voltage(27G), over current(51G), ground current(51N), loss
of excitation(40G), reverse power(67G) and winding temp
high. When mechanical fault occurs (due to inappropriate fuel
level, lube oil pressure, water level in the radiator and high
stack temperature) individual generator would be shut down
for individual mechanical faults and also fault alert would be
made as usual. An indicator also shows the status whether the
fault is cleared or not.
Almost all the automation procedure is completed in a
program block diagram of which is shown in Figure 2. As the
number of input and output address of the PLC module that
we used is limited so only some selected control features are
considered in developing the PLC ladder program though in
the practical case many control and protection feature taken
into consideration. The generator is connected to the bus bar
through synchronizing panel and the actuator actually starts
the generator in reality.

Fig. 4. The process variable declearation for PLC system

F. Program Development
Automation software of PLC is programmed in Sucosoft
V5.02 programming software and this software is the
simulation software of the Moeller PLC which has limited
inputs and limited outputs handling capabilities. To overcome
these problems many ghost outputs as well as timers are used
in programming for convenience and only selected parameter
both electrical and mechanical are considered in this study
though the practical modern generator system handle many
control features. The Ladder Diagram (LD) PLC
programming language used easy to understand. Ladder
Diagrams are based on graphical representations with
contacts, coils and boxes, as per the circuit diagrams.
Indicator lights are used as outputs where as push button
switches are used as inputs [3].

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Author Instructions: J. Elec. Engg., Instn. Engrs., Bangladesh, 36(II), December 2009
IV. PROGRAM EXECUTION

The ladder logic program execution by Sucosoft V5.02,

Moeller PLC software requires the following steps [3]1. Program development in pou editor
2. Topology configaration
3. Program code generation
4. Program transfer from computer to PLC
5. Test and commissioning
6. Program run
After following the above mentioned steps then the PLC
become ready to run the program. PLC executes the program
successfully after pressing the start switch. PLC always scan
its input address and give an output signal according the
instruction of the program. If the process sequences may need
changed or modification only change in the program will
sufficient for successful program execution.
V. CONCLUSION

The most important aspect of any power generation system

is the generation control. Several techniques can be
implemented to control the generator in power plant. The
method that has to be used relies on varied objectives like
superior quality, increased efficiency, high profit and other
such points depending upon the purpose. With the prime
objective of catering to these necessities and the needs of the
industrial sector, significance has been given here to
automation. This paper presented here has kept in mind, the
ceaseless changes that are relentlessly taking place in the
contemporary scenario of the industrial segment. Emphasis
has been given to the automation process that is now rapidly
taking its place in all the power plants across the globe. The
Paper has furnished itself to study the integral parts of the
entire process involved, their implementation and the
problems that may show up have also been given their due
importance.
ACKNOWLEDGMENT
The authors would like to thank Mr. Sharafat Ali, Assistant
General Manager, Department of Instrumentation &
Communication, Eastern Refinery Limited, Bangladesh and
Md. Ali Zulquarnain, Member, Planning, Bangladesh Atomic
Energy Commission (BAEC) for their valuable review and
comments.
REFERENCES
[1] Diesel Generator Operation Guideline, Reactor Operation and
Maintenance Unit (ROMU) of Bangladesh Atomic Energy
Commission.
[2] GUNTE, Equipment for Engineering Education,(04/02/2012)
http://www.usdidactic.com/html/p3562.htm
[3] Sucosoft S40 V5.02, Moeller PLC Software
[4] P. K. Bhowmik and M. Dey, Protection and Control of Steam Turbine
Generator using PLC First International Conference on Mechanical
Engineering and Renewable Energy 2011 (ICMERE2011), Chittagong,
Bangladesh, December 22-24, 2011.

Fig. 5. Ladder logic program of diesel generator operation and

control

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