This document describes a project to implement automatic power factor improvement and monitoring using a programmable logic controller (PLC) and supervisory control and data acquisition (SCADA) system. A group of six students will connect capacitor banks in parallel with various loads to correct low power factors. A PLC will control the capacitor banks based on power factor measurements from a power meter. The students will design input and output modules for the PLC, develop ladder logic programming, and create a SCADA model for monitoring. The goal is to develop a low-cost automated system using PLC and SCADA to replace manual power factor correction methods. This will improve efficiency in industrial plants by maintaining a high power factor near unity.

1. I
Automatic Power Factor Improvement and Monitoring by Using PLC &
SCADA
A Project Submitted
By
Under the Supervision of
MR. DEEPAK KUMAR CHOWDHURY
Chairman
Department of Electrical and Electronic Engineering
Port City International University
Department of
Electrical and Electronic Engineering
August, 2019
Port City International University
MOHAMMAD SIFUR RAHMAN
MIZANUR RAHMAN
MD. ASHRAFUL ALAM
JOY BARUA
MD. ABDUL KARIM
DIPU CHOWDHURY
ID: EEE 01005783
ID: EEE 01005829
ID: EEE 01005809
ID: EEE 01005833
ID: EEE 01005849
ID: EEE 00905587

2. II
Automatic Power Factor Improvement by Using PLC & SCADA
A project submitted to the Electrical and Electronic Engineering Department of the Engineering Faculty,
Port City International University in partial fulfillment of the requirements for the degree of Bachelor of
Science in Electrical and Electronic Engineering.
MOHAMMAD SIFUR RAHMAN
MIZANUR RAHMAN
MD. ASHRAFUL ALAM
JOY BARUA
MD. ABDUL KARIM
DIPU CHOWDHURY
ID: EEE 01005783
ID: EEE 01005829
ID: EEE 01005809
ID: EEE 01005833
ID: EEE 01005849
ID: EEE 00905587
Department of
Electrical and Electronic Engineering
August, 2019
Port City International University

3. III
DECLARATION
This is to certify that this thesis “Automatic Power Factor Improvement and Monitoring by Using
PLC & SCADA” is my original work. No part of this work has been submitted elsewhere partially or
fully for the award of any other degree or diploma. Any material reproduced in this project has been
properly acknowledged.
Students’ names & Signatures
MOHAMMAD SIFUR RAHMAN
MIZANUR RAHMAN
MD. ASHRAFUL ALAM
JOY BARUA
MD. ABDUL KARIM
DIPU CHOWDHURY

4. IV
APPROVAL
The Project titled “Automatic Power Factor Improvement and Monitoring by Using PLC & SCADA”
has been submitted to the following respected members of the Board of Examiners of the department of
Electrical and Electronic Engineering in partial fulfillment of the requirements for the degree of Bachelor
of Electrical and Electronic Engineering on August, 2019 by the following student and has been accepted
as satisfactory.
MOHAMMAD SIFUR RAHMAN
MIZANUR RAHMAN
MD. ASHRAFUL ALAM
JOY BARUA
MD. ABDUL KARIM
DIPU CHOWDHURY
ID: EEE 01005783
ID: EEE 01005829
ID: EEE 01005809
ID: EEE 01005833
ID: EEE 01005849
ID: EEE 00905587
Supervisor
MR. DEEPAK KUMAR CHOWDHURY
Chairman
Department of EEE
Port City International University

5. VI
ACKNOWLEDGMENT
First and foremost, we would like to express our special thanks to our supervisor MR. DEEPAK KUMAR
CHOWDHURY, Chairman, Department of Electrical and Electronic Engineering, Port City International
University for giving our enormous support, motivation and invaluable advices regarding this project. He
has been my idol and role model in the last couple of months and we are grateful to Almighty Allah for
giving our opportunity to learn under such a great supervisor.
Secondly, we would like to express our special thanks to all the faculty members of Department of Electrical
and Electronic Engineering, Port City International University for giving our comments and invaluable
advice for further extension of this project.
We would like to thank my family and friends, without whose patience and support we would never have
reached our goal.
MOHAMMAD SIFUR RAHMAN
MIZANUR RAHMAN
MD. ASHRAFUL ALAM
JOY BARUA
MD. ABDUL KARIM
DIPU CHOWDHURY

6. VII
TABLE OF CONTENTS
ABSTRACT 1
CHAPTER 1: INTRODUCTION Page 2-10
1.1 Introduction 2
1.2 Objectives 4
1.3 Methodology 4-5
1.4 Choosing Monitoring Location 5
1.5 System Discussion 6-9
1.5.1 Experimental Setup 6
1.5.1.1 Input Design 6
1.5.1.2 Output Design 6-7
1.5.1.3 Power Meter Wiring 7
1.5.1.4 Terminal Block Wiring 8
1.5.1.5 PLC Wiring 8
1.5.1.6 Ladder Programming 9
1.5.1.7 Final SCADA Model 9
1.6 Results and Discussion 10
1.6 Application of the project 10
CHAPTER 2 : LITERATURE REVIEW Page 11-13
Literature Review 11-13
CHAPTER 3 : THEORETICAL OVERVIEW Page 14-36
3.1 List Of Electrical Components 14
3.1.1. PLC SIEMENS S7 200 (CPU 215 DC/DC/DC) 14-17
3.1.2. Power Supply 220V AC TO 24V DC 17-18
3.1.3. Software Micro win v4.0 SP9
19-20
3.1.4. WinCC Flexible (SCADA) 20-21
3.1.5. Electromechanical Relay 21-24
3.1.6. RS 485 USB-MPI PLC Programming Cable 25-26
3.1.7. Transformer 220v AC to 110v AC 26
3.1.8. PR-4116 (Universal Transmitter) 26-28

7. VIII
3.1.9. CT-Current Transformer 28-29
3.2.0. Weidmuller WAS1 CMA 1/5/10A ac 29-30
3.2.1. Capacitor Bank 31-32
3.2.2. Voltage Regulator 32-33
3.2.3. Load Fan 33-34
3.2.4. CT-K type sensor 34-35
CHAPTER 4: BLOCK DIAGRAM Page 36-40
4.1 Block Diagram 36-37
4.2 Flow Chart 38
4.3 Schematic diagram 39
4.2.1 Circuit Operation 40
4.2.2 Working Principle 40
4.2.3 Circuit Application 40
CHAPTER 5: DESIGN AND IMPLEMENTATION Page 41-42
5.1 Body design: 41
5.2 Software Description 42
5.3 Hardware 42
CHAPTER 6: FUTURE WORK AND CONCLUSION Page 43-27
6.1 Applications 43
6.2 Advantages 43
6.3 Benefit 44
6.4 Disadvantages 44-45
6.5 Future Enhancements 45
6.6 Conclusion 45
REFERENCES 46-47

8. IX
List of Figures
Figure No Figure Name
Page
Figure 1.1: Relation between active power and reactive power 2
Figure 1.2: Power Angle Triangle 3
Figure 1.3: Capacitors Connected Parallel To The Load. 5
Figure 1.4: Input design 6
Figure 1.5: Output design 7
Figure 1.6: Power meter wiring 7
Figure 1.7: Terminal block wiring 8
Figure 1.8: PLC wiring 8
Figure 1.9: Ladder programming 9
Figure 1.2.1: SCADA model 9
Figure 3.1: PLC SIEMENS S7 200 Pin Diagram 15
Figure 3.2 Power Supply 220v AC to 24v DC 18
Figure 3.3: Micro WIN V4.0 19
Figure 3.4: WinCC Flexible 21
Figure 3.5: Electromechanical Relay Pin out 22
Figure 3.5.1: Eelctromechanical Relay Coil – Magnetic Field 22
Figure 3.5.2: Electromechanical Relay Working (OFF condition) 23
Figure 3.2.3: Electromechanical Relay Working (ON condition) 23
Figure 3.6: RS 485 USB-MPI PLC Programming Cable 25
Figure 3.7: Transformer 220v AC to 110v AC 26
Figure 3.8: PR-4116 Universal Transmitter 27
Figure 3.9: Current Transformer 29
Figure 3.10: Weidmuller WAS1 CMA 29
Figure 3.11: Capacitor Bank 31
Figure 3.12: Voltage Regulator and Pin out 33
Figure 3.13: Load Fan 33
Figure 3.14: CT-K type sensor 34
Figure 4.1: Block diagram of project 37
Figure 4.2: Flowchart of working process 38

9. X
Figure 4.3: Circuit diagram of the prototype model 39
Figure 5.1: Front View 41
Figure 5.2: Side View 41
Figure 5.3: Full View 41
Figure 5.3: Output of the Project 41
Figure 5.4: Block diagram of experimental set 42

10. XI
List of Tables
Table No Table Name Page
Table 1.1: Bluetooth module Pin Configuration 10
Table 3.1: Siemens S7-200 (CPU 215 DC/DC/DC) 16-17
Table 3.2: Power Supply 220v AC to 24v DC Configuration 18
Table 3.3: WinCC SCADA Configuration 21
Table 3.4: PR-4116 Universal Transmitter and Confrontation 28
Table 3.5: Weidmuller WAS1 CMA and Configuration 30
Table 3.6: Fan and Configuration 34
Table 4.1: Three Phase Induction Motor Configuration 36

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ABSTRACT
Power factor correction (PFC) is a process of negotiating the unwanted effects of electric loads that
create a power factor less than one. Power factor correction may be applied either by an electrical
power transmission utility to enhance the efficiency of transmission network. In this paper three
transformers of different ratings have been used which acts as inductive load each of which produce
different power factor variation. The power factor of the supply line is directly monitored by the Power
Meter which is connected in parallel to the supply line. The value of the capacitance (capacitor bank)
required for correcting the power factor variation due to each transformer and their
combination is found out separately. Capacitor bank for the respective load is triggered by using PLC,
which connects the capacitor bank parallel to the load and thereby bringing the power factor near to
unity. This paper represents the most effective automatic power factor improvement and monitoring
by using static capacitors which will be controlled by a PLC with very low cost although many existing
systems are present which are expensive and difficult to manufacture. In this study, many small rating
capacitors are connected in parallel and a reference power factor is set as standard value into the PLC.
Suitable number of static capacitors is automatically connected according to the instruction of the PLC
to improve the power factor close to unity. Some tricks such as using resistors instead of potential
transformer and using one of the most low cost PLC SIEMENS S7-200 CPU215 DC/DC/DC which
also reduce programming complexity that make it most economical system than any other controlling
system.
Keywords: PLC SIEMENS S7-200 CPU215 DC/DC/DC, current transformer, comparator, relay,
capacitor, Software Micro win v4.0 SP9, Win CC Flexible (SCADA), Supervisory Control and Data
Acquisition, Power meter, Industrial control system, Remote control unit.

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CHAPTER 1
INTRODUCTION
1.1 Introduction
Power Factor can be explained as relationship between the active power and apparent power.
For understanding power factor, look at the figure 1 in which a horse is dragging a car along a
track. As the railroad path is not even, the horse should pull the car at an angle to the track.
Now the horse pulls the car at some angle to the direction in which car is travelling. The force
needed to pull the car along the given track is working power. Total power in this case is horse
power. As a result of the angle created by the horse’s pull, (not all horse power taken into
account) is utilized to drag the car along the given path. The car cannot move in sideways
direction; thus the effort made by horse in sideways is not taken into account. The angle which
the horse force is applied is basis of power factor. It can be defined as the ratio between real
powers to apparent power. If the horse is present between the centers of the track, the angle
made by force because of side pull decreases and the real power apparent power becomes
almost equal. As a result, the ratio between real and apparent power or the power factor of
given system becomes equal to 1. As the power factor tends to 1, the reactive power tends to
0.
Real Power
Power Factor (pf) =
Apparent Power
Fig. 1.1: Relation between active power and reactive power

13. 3 | P a g e
The relation between the types of power used to run the given force system is generally as a right-
angled triangle as in figure 1.1. Active power is indicated at right angles to reactive power, generally
known as waste as it is out-of-phase, and work done is not taken into account. So, because of the
angle created horse needs to do more work compared to the required original work.
Fig. 1.2: Power Angle Triangle
Power Factor of a system has generally a value between 0 and 1 which is equal to the ratio of active
power to apparent power or Cos φ as shown in fig 1.2. The bigger the number is, the more powerful
the system becomes. So, a system with a Power Factor of 0.9 is much superior to one with a low
Power Factor of 0.6. An electrical system which has power factor of 1 uses 100% useful current
Without any power loss.
Electricity distribution companies own and operate the infrastructure required to connect customers
to the network. At present, the low-voltage three-phase four-wire distribution systems are facing the
poor power quality problems such as high reactive power burden, unbalanced load excessive neutral
current and voltage distortion. Industrial plants typically present a poor power factor to the incoming
utility due to proliferation of diode and thyristor rectifiers, induction motors and harmonic rich loads.
Low power factor is the predominant problem nowadays. Poor power factor has various consequences
such as increased load current, large KVA rating of the equipment, greater conductor size, larger
copper loss, poor efficiency, poor voltage regulation and reduction in equipment life.
Therefore it is necessary to solve the problem of poor power factor. To improve the power factor,
shunt capacitor banks have been applied in many power distribution systems and industrial circuits
for reactive power compensation. The power factor regulator is designed to optimize the control of
reactive power compensation. Reactive power compensation is achieved by measuring continuously
the reactive power of the system and then compensated by the switching of capacitor banks. At the

14. 4 | P a g e
end user connection points, the integrating breaker switched capacitor banks into a compact design
with the intelligent control unit offers a reliable and affordable reactive power compensation
solution for distribution systems. The benefits of doing so are:
 Improvement in power factor, which either eliminates or reduces the demand charges imposed
by the utility.
 Reducing the energy loss in electrical conductors by reducing the required current.
 Maintaining a proper voltage level at the end user for improved productivity of industrial
processes.
 Releasing of valuable system capacity.
 Increasing the useful life of pieces of distribution equipment.
 Improvements in planning where planning engineers can more precisely decide to place
additional capacitor banks to account for load growth.
1.2 Objectives
We have chosen this topic to modern technology system of improvement and monitoring power factor using
PLC and SCADA.
 To develop an automatic Power actor system protection and control this system using PLC and
SCADA.
 To increase the efficiency of an industrial plant by incorporating the automation system which
replaces the manual Protection of Power system protection unit system.
1.3 Methodology
The problem of low pf can be solved by connecting power factor correction capacitors to the industrial
electrical system. The capacitors can be of low rating for lower rated loads, and rating of capacitors
will increase for loads with high rating.
The capacitors are made as a combination according to the respective loads and then they are
connected parallel to the load as shown in figure 1.3. Capacitors give needed reactive power (KVAr)
to the given industrial power supply. By providing the reactive power, it decreases the total amount
of apparent power supplied.

15. 5 | P a g e
Fig. 1.3: Capacitors Connected Parallel To The Load.
1.4 Choosing Monitoring Location
Obviously, we would like to monitor conditions at virtually all locations throughout the system to
completely understand the overall power quality. However, such monitoring may be prohibitively
expensive and there are challenges in data management, analysis, and interpretation. Fortunately,
taking measurements from all possible locations is usually not necessary since measurements taken
from several strategic locations can be used to determine characteristics of the overall system. Thus,
it is very important that the monitoring locations be selected carefully based on the monitoring
objectives. Another important aspect of the monitoring location when characterizing specific power
quality problems is to locate the monitors as close as possible to the equipment affected by power
quality variations.
It is important that the monitor sees the same variations that the sensitive equipment sees. High-
frequency transients, in particular, can be significantly different if there is significant separation
between the monitor and the affected equipment.
A good compromise approach is to monitor at the substation and at selected customer service entrance
locations. The substation is important because it is the PCC for most rms voltage variations. The
voltage sag experienced at the substation during a feeder fault is experienced by all the customers on
other feeders supplied from the same substation bus. Customer equipment sensitivity and location on
a feeder together determine the service entrance locations for monitoring. For instance, it is valuable
to have a location immediately down line from each protective device on the feeder.

16. 6 | P a g e
1.5 System Discussion
In this section we will discuss about system process. There is some process.
1.5.1 Experimental Setup
Following are the experimental setup made for the experiment:
1.5.1.1 Input Design
The main components of the input side are the transformer (i.e. the inductive load) and the 4 pole
relay. The 4 pole relay has 14 terminals. The terminals 1,2,3,4 are normally closed and 5,6,7,8 are
normally open. Terminals 9,10,11,12 are common terminals 13 and 14 are meant for excitation of
relay.
Fig. 1.4: Input design
In the figure 1.4 the excitation coil and the switch S (toggle switch) are shown. When S is closed, the
coil gets energized by the 230 V supply. Hence the terminals of relay switch gets attracted towards
the normally open terminals. The transformer is connected across the terminals 7 and 8. So the circuit
is completed and the load gets active by 230 V supply. Here the 24 V supply is provided by the SMPS.
Whenever the load gets ON, +24 V is given to the PLC through the 5th terminal.
1.5.1.2 Output Design
The output side mainly consists of the capacitor banks and the 2 pole relay as shown in fig. 1.5. The
2 pole relay is energized by the 24 V dc supply. This supply is fed from the PLC i.e. once the
transformer load is ON, a 24 V dc supply comes across the PLC. As a result, PLC energizes the relay
coils and the corresponding capacitor bank will be switched ON. Hence the power factor is corrected
to a value nearly equal to 1.

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Fig. 1.5: Output design
1.5.1.3 Power Meter Wiring
The most important component in the hardware is the power meter. The main ports in a power meter
are the supply port, voltage port, current port and communication port as in fig. 6. A 230V supply will
be given to the supply port. Here voltage port is used to measure the voltage across the load and the
current port is used to measure the current. So the voltage port is connected parallel to the supply and
the current port is connected in Series with the supply. The communication port is connected to the
serial adapter of the PLC, so it reads the power meter.
Fig. 1.6: Power meter wiring

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1.5.1.4 Terminal Block Wiring
The first two wires are the supply wire through these wires the PLC feeds 24 V dc supply to the
hardware as shown in fig. 1.7. 2 represents three wires which connects the three transformer loads
to the PLC input port , so that the PLC gets indication about the status of input side . 3 represents
the six wires which connects the output ports of the PLC to the six capacitor banks. 4 represents
the three wires which connect the communication port of the power meter to the PLC.
Fig. 1.7: Terminal block wiring
1.5.1.5 PLC Wiring
As shown in fig. 1.8, the three transformer loads are connected to the input ports of the PLC. The
common terminal of the input side is connected to the negative terminal of SMPS. Connections from
the capacitor banks are given to the output port of the PLC. The common terminal of the output side
is connected to the positive terminal of SMPS. The communication port of the PLC is connected to
the system via the communication cable and the serial adapter is connected to the powermeter.
Through the supply ports, a 24 V dc supply is given to the PLC.
Fig. 1.8: PLC wiring

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1.5.1.6 Ladder Programming
Ladder logic is a programming language that represents a program by a graphical diagram based on
the circuit diagrams of relay-based logic hardware. It is primarily used to develop software for
Programmable Logic Controllers (PLCs) used in industrial control applications. These programmes
are then downloaded to PLC using communication cable. Ladder program is shown in fig. 1.9.
Fig. 1.9: Ladder programming
1.5.1.7 Final SCADA Model
SCADA model has been designed as per the requirements to show the different parameters like load,
switches, capacitor banks etc. It also facilitates the user to select whether he wants to select automatic
or manual triggering of capacitor banks. Even the power meter has been synchronized to show the
fluctuations in the power factor directly on the users screen as shown in fig. 1.1.1.
Fig. 1.1.1 SCADA model

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1.6 Results and Discussion
This chapter provides the necessary information for Result and Discussion. In this section we will
discuss about system process. There is some process.
A project on “Industrial Power Factor Correction” has been done. The aim of the project was to
improve the power factor up to 0.9 and it was possible to improve the power factor till 0.71.
Table 1.1: Bluetooth module Pin Configuration
Load(s) “ON” Corresponding
Capacitor Banks
Earlier PF Corrected PF
L1 CB1+CB2+CB3 0.277 0.557
L2 CB2+CB6 0.502 0.710
L3 CB6 0.380 0.613
L1+L2 CB1+CB3+CB5+CB6 0.345 0.598
L2+L3 CB2+CB3+CB6 0.480 0.700
L1+L3 CB1+CB2+CB5+CB6 0.300 0.601
L1+L2+L3 CB3+CB4 0.342 0.62
Table 1 shown above explains the final result of corrected power factor. There are total seven cases
which has been considered. In case 1, load 1 is switched on and earlier pf was 0.277. After triggering
of capacitor banks 1, 2 and 3, corrected pf was found to be 0.557. In second case load 2 is switched
on. After triggering the corresponding capacitors the corrected pf was found to be 0.710. In third case
the corrected pf was found to be 0.613. After this combination of loads were switched on. In case
when load 1 and 2 was switched on, earlier pf was found to be 0.345. After triggering
the required capacitor banks the corrected pf was found to be 0.598. Similarly in fifth and sixth case
corrected pf was found to be 0.700 and 0.601 respectively. In last case all three loads were taken into
account. After switching the required capacitors the corrected pf was noted as 0.626.
1.7 Applications of the project
 Industry
 Residential Area

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CHAPTER 2
LITERATURE REVIEW
 A Programmable Logic Controller Based Power Factor Controller for a Single Phase
Induction Motor. [4]
Power factor is the value of a system that reflects how much power is being borrowed from Power
Company for the system. If power factor becomes poor than unity, then organization or industry
requires more current for supplying same amount of power.as the current increases line losses also
increases because of voltage drop=I2R.Induction motor is widely used in industries due to
their features like low cost, reliability, robustness. At no load induction motor has very low power
factor of about 0.33 as the load goes on increasing the power factor also get improved as we go towards
full load. Power factor correction serves to correct low power factor by reducing phase difference
between voltage and current phasors.
Keywords: Programmable logic controller (PLC), Current transformer, Relays, Condenser, SMPS, 1
phase induction motor
 Power Factor Correction of Inductive Loads using PLC. [5]
This paper proposes an automatic power factor correction for variable inductive loads, most
dominantly induction motors (IM) utilizing the Programmable Logic Controllers (PLC). This
hardware implementation of a 3Ø Inductive load system focuses on the automatic correction of
power factor using PLC. With the help of PLC, different performance parameters current
level, real power and inductive power are obtained and logged in the PC. Using PLC program,
according to control strategy to obtain a pre specified power factor a set of capacitors sized in
a binary rate will be switched on or off with the help of switching relays and contactors. This
PLC control strategy relies on a lookup table which is prepared based on two input parameters
- peak current and power factor, at constant voltage. From these parameters, PLC will calculate
reactive power of the system and accordingly the right sequence of the capacitors are switched
on in order to compensate reactive power. Keyword: Automation, Power factor improvement,
inductive loads, capacitors and Programmable Logic Controllers PLC.
.

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 Recent Trends in SCADA and Power Factor Compensation on low Voltage Power
Systems for Advanced Smart Grid. [6]
This paper presents an extending a smart grid to switched capacitor banks at the low-voltage three-
phase four-wire distribution systems. New power factor regulators using MSP430 microcontrollers
will be proposed instead of ordinary regulators to be suitable for connecting to the Supervisory Control
and Data Acquisition (SCADA) system that actually has been implemented since 2005 in the Middle
Egypt Electricity Distribution Company (MEEDCO). In MEEDCO, there are quite a lot of mounted
power factor regulators in different locations, but most of these regulators are far from each other and
also far from the control center of MEEDCO's SCADA system. This paper also discusses the suitable
technology to communicate the suggested regulators with the control center efficiently and how this
will be done in the framework of a secure smart grid.
Keywords— Data Transfer, MSP430, Smart Grid, SCADA, Security.
 Analysis of Rectifier Circuits with Power Factor Correction. [7]
Power Factor, the ratio between the real power and the apparent power forms a very essential
parameter in power system. It is indicative of how effectively the real power of the system has been
utilized. With rapid development in power semiconductor devices, the usage of power electronic
systems has expanded to new and wide application range that include residential, commercial,
aerospace and many others. Power electronic interfaces have proved to be superior. However, their
non‐linear behavior puts a question mark on their high efficiency. The current drawn by the interfaces
from the line is distorted resulting in a high Total Harmonic Distortion (THD) and low Power Factor
(PF). Individually, a device with harmonic current does not pose much serious problem however when
used on a massive scale the utility power supply condition could be deteriorated. Other adverse effects
on the power system include increased magnitudes of neutral currents in three‐phase systems,
overheating in transformers and induction motors etc. Hence, there is a continuous need for power
factor improvement and reduction of line current harmonics. Development of new circuit topologies
and control strategies for Power Factor Correction (PFC) and harmonic reduction has become
essential. This project aims to develop a circuit for PFC using passive filters.
 Automatic Power Factor Correction by Continuous Monitoring. [8]
The Purpose of this paper is implementing a new technology for power factor improvement of 3 phase
induction motor as well as for single phase induction motor , as improvement of power factor is
necessary for industrial as well as domestic areas & to make power factor as close as unity without

23. 13 | P a g e
facing penalty from electrical distributers. As we know in industries most of motor which is usually
used is induction motor and induction motor having low power factor also. Home appliances which
are generally used are generally having low power factor. Hence there is need of power factor
improvement in case of household appliances as well as in industrial purpose. Induction motor is
most widely used motors in industries .As name of this motor specifies this motor having low power
factor. Hence there is need of power factor improvement. .
 PLC & SCADA based Power Quality Improvisation in Induction Motor. [9]
Energy conservation has been one of the most talked about topics in the past decade or so because of
the decrease in the energy resources. Power shutdown is a major problem now-a-days and it occurs
because a lot of power is wasted in industries. Energy monitoring and controlling deals with this type
problem in a effective ways. We implement three phase induction motor monitoring and controlling
with the help of PLC and SCADA. PLC can be connected with computer using RS-232 or Ethernet
cable. PLC monitor different perimeter of IM such as over and under voltage, over current, over
speed, etc. If any contingency will arise, SCADA give alert or shutdown system automatically.
.
KEYWORDS: Power quality, Energy Audit, Monitoring and Controlling System, PLCs, SCADA

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CHAPTER 3
THEORETICAL OVERVIEW
We describe their theatrical overview of the project. For power factor improvement and monitoring
system, Using PLC, power supply Ac to DC, SCADA, MicroWind software, Capacitor Bank, Load.
This is totally automatic system output showing SCADA in computer monitor.
3.1 List of Electrical Components
In this chapter we will discuss various types of equipments. Which we used to build our project, and
these equipments are useful for various projects in our daily life.
3.1.1 PLC SIEMENS S7 200 (CPU 215 DC/DC/DC):
Brief about PLC SIEMENS S7 200 (CPU 215 DC/DC/DC)
The power factor correcting circuit is driven by S7-300 PLC which is shown in fig.4,
it consists of several modules power supply, CPU, digital inputs, Digital outputs, and
Analog to-Digital converter. The digital input module is a 24 V DC, 13- - ut ports. The analog module
is a 2-channel, 12-bit analog to-digital converter (ACD). The digital output module is a 32 port, 0.5 A
output current, 24 V DC rated load voltage. The two outputs of the interfacing circuit are given to the
PLC in the following way; the output of the phase angle measuring circuit is given to the digital input
module of the PLC whereas the output of the current peak detector is given to the input of analog to
digital converting module. The PLC then calculates the lagging reactive power of the system, and
accordingly gives signal to digital output module. The digital output module has the switching circuit
connected to it, which in turn connects the sequence of capacitors from capacitor bank which is shown
in fig.3.1.
24 on board I/O
12kbytes programmer memory
5kbytes data memory
6 x 30 kHz high speed counter
In-built real time clock
4 x 20 kHz pulse train outputs (dc powered model only)

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Figure 3.1: PLC SIEMENS S7 200 Pin Diagram
Output ratings are 28.8Vdc maximum for transistor outputs (stock no. 488-6713), 30Vdc or 240Vac
maximum for relay outputs (stock no. 488-6814).
Siemens S7-200 Base Units - 3rd Generation
The S7 brings to the user a powerful solution to a host of control applications, which is easy to adapt
and expand the system. The S7 is a family of PLCs which allows the user to tailor their selection of
components which best suits their requirements, and is the long term successor to the highly successful
S5 range. Whatever the S5 can do, the S7 can do more quickly and more easily. The 3rd generation
of S7-200 now builds on the success of the original range and exploits new CPU's in order to produce
even faster and more powerful range of PLC's. The range of CPU's available has been increased with
the introduction of the new 224XP, as has the range of digital, analogue and communications
expansion modules. For the faster type of application real time control is easily achieved by use of the
comprehensive range of built-in interrupts. Timed, Communication, High Speed Counter, High Speed
Pulse Output, and hardware interrupts are all available, and the implementation of a priority table
means that all the interrupts can work simultaneously. Communications with S7-200 is built in. Inter
PLC communications is achieved using two wire network which can be up to 1200 meters and can
have up to 126 nodes. In "Freeport" mode the PLC's RS-485 port runs in free ASC11 mode making it
possible to communicate with other devices. In line with Siemens objective to make the programming
of S7-200 as user friendly as possible MicroWin programming software has been further improved.
These improvements all help minimise program development time. This has been achieved by
including more and improving existing "wizards". These help program developers with the more
routine/complex parts of their programs, e.g. TD200 configuration, PID loop configuration, High
Speed Counter configuration, etc. Inclusion of context sensitive help also means that all the
information required is at the users fingertips.

26. 16 | P a g e
New CPU hardware support provides the option to turn off run mode edit to obtain more program
memory.
CPU 224XP supports onboard analogue I/O and two communication ports CPU 226 includes
additional input filters and pulse catch facility 0.22μs processing time per instruction.
Modular Expansion up to 256 total I/O (except S7-221) Powerful Instruction Set, and Real Time
performance Programming via RS-485 common port All models have EEPROM memories for user
program storage 2 or 4 x 30kHz pulse train outputs (dc powered models only ).
Specifications
Table 3.1: Siemens S7-200 (CPU 215 DC/DC/DC) Configuration
Attribute Value
For Use With SIMATIC S7-200 Series
Manufacturer Series S7-200
Number of Inputs 14
Number of Digital Inputs 14
Input Type Analogue, Digital
Number of Digital Outputs 10
Voltage Category 20.4 → 28.8 V dc
Output Type Analogue, Digital, Transistor
Number of Outputs 10
Communication Port Type RS485
Program Capacity 12 kB
Programming Interface Computer, SIMATIC PG/PC
Number of Communication Ports 1
Output Current 750 mA
Dimensions 80 x 120.5 x 62 mm

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Minimum Operating Temperature 0°C
Maximum Operating Temperature +45°C
Length 80mm
Depth 62mm
Width 120.5mm
Mounting Type Rack Mount
Battery Backup Yes
Programming Language Used AWL, FUP, Ladder Logic
Memory 8 (Data Memory) kB, 12 (Program Memory) kB
3.1.1 POWER SUPPLY 220V AC TO 24V DC:
Brief Description on Power Supply 220v AC to 24v DC
Although converting voltages is pretty easy, converting voltages *efficiently* is the real deal.
It really depends on how you intend to use the system and what type of supply (source) are you using.
If you can be sure that you’ll receive a constant supply of 240V AC, using a transformer followed by
a bridge rectifier would be the best choice in terms of efficiency and cost.
If however, you intend to source 240V from AC mains supply, you’ll have to keep in mind the huge
swings that can occur (a popular margin is 100V to 270V rms). In this case a switched mode power
supply (SMPS) is very useful. The AC voltage will have to be converted to DC, switched back to AC
at a higher frequency to be fed into the SMPS.
Application:
If your application involves consumer electronics, it is a good idea to isolate your power lines from
the load (for example, with a transformer). Mobile phone chargers involve decent circuitry that
incorporates isolating the load from the source using an auto-transformer configured in subtractive
polarity, followed by the SMPS unit.

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Fig. 3.2: Power Supply 220v AC to 24v DC
Specifications:
Table 3.2: Motion Sensor Pin Configuration
Input Voltage: 110V-220V
Output Voltage: DC24V
Output Current: 2A
Output Power: 24W
Size: 85*60*33mm(L*W*H)
Protection: Short circuit/Over load/Over voltage
Shell Material: Metal case/Aluminum base
Application: LED strip, led module, led lamp
Connection:
L, N: AC power input
AC power Ground
-V : DC power output "-"
+V : DC power output "+"
ADJ: Adjust the output voltage
Working Temperature:-10~+50°c
Storage Temperature:-20~85°c
Ambient Humidity:20%~95% Non-Condensation
Package Included:
1 X DC12V 2A 24W Power Supply

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3.1.2 Software Micro win v4.0 SP9:
Brief Description on Micro WIN V4.0 SP9
Compatibility:
The two Service Packs 9 for STEP7 Micro WIN V4.0 are compatible with all S7-200 CPUs (CPU
21x and CPU 22x).
Programs created with earlier Micro WIN versions can be opened and further processed without any
restrictions.
Projects created with the new Service Packs can be neither opened nor processed with older versions.
INSTALLATION INSTRUCTIONS for STEP7 Micro WIN V4 SP9
 Download the file to your PC
 Unpack the archive and the required Service Pack
 Open the folder Disk1 and execute the file setup.exe
 Follow the prompts that will come up during the installation to conclude the installation
process.
 When the installation has been concluded successfully you will find STEP7 MicroWIN V4
SP9 in your start menu under the item Simatic.
 After the installation please delete the temporary sub-directory with the installation files.
This must be done manually.
Figure 3.3: Micro WIN V4.0

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INSTALLATION INSTRUCTIONS with a simultaneous change of the operating system
 On the computer with the executable predecessor version zip the file microwin.exe. You will
find it with the standard installation in drive C in the folder:
Program FilesSimaticSTEP 7-MicroWIN V4bin
 Copy the packed file to the computer with the new operating system and unpack the file.
 Start the installation in line with the installation instructions of the relevant Service Pack.
Security information
In order to protect technical infrastructures, systems, machines and networks against cyber threats, it
is necessary to implement – and continuously maintain – a holistic, state-of-the-art IT security
concept. Siemens’ products and solutions constitute one element of such a concept. For more
information about cyber security.[8]
3.1.4 WinCC Flexible (SCADA):
Brief Description on WinCC Flexible (SCADA)
The PIR sensor stands for Passive Infrared sensor. It is a low cost sensor which can detect the presence
of Human beings or animals. This sensor has three output pins Vcc, Output and Ground as shown in
the pin diagram above. Since the output pin is 3.3V TTL logic it can be used with any platforms like
Arduino, Raspberry, PIC, ARM, 8051 etc.
The module can be powered from voltage 4.5V to 20V but, typically 5V is used. Once the module is
powered allow the module to calibrate itself for few minutes, 2 minutes is a well settled time. Then
observe the output on the output pin. Before we analyse the output we need to know that there are
two operating modes in this sensor such as Repeatable (H) and Non- Repeatable (L) and mode. The
Repeatable mode is the default mode.
The output of the sensor can be set by shorting any two pins on the left of the module as shown below.
You can also notice two orange colour potentiometers that can be used to set the sensitivity and time
which will be explained further below.

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Figure 3.4: WinCC Flexible
Pin Configuration
Table 3.3: WinCC SCADA and Configuration
Pin
Number
Pin Name Description
1 Vcc Input voltage is +5V for typical applications. Can range from 4.5V- 12V
2
High/Low
Ouput (Dout)
Digital pulse high (3.3V) when triggered (motion detected) digital
low(0V) when idle(no motion detected
3 Ground Connected to ground of circuit
PIR Sensor Features
 Wide range on input voltage varying from 4.V to 12V (+5V recommended)
 Output voltage is High/Low (3.3V TTL)
 Can distinguish between object movement and human movement
 Has to operating modes - Repeatable(H) and Non- Repeatable(H)
 Cover distance of about 120° and 7 meters
 Low power consumption of 65mA
 Operating temperature from -20° to +80° Celsius.
3.1.5 Electromechanical Relay:
Brief about Electromechanical Relay
The electrical and electronics circuits are usually operated over a wide range of voltage, current, and
power ratings. For every circuit or equipment or electrical network or power system protection
system is desired to avoid the breakdown or temporary or permanent damage. Such that, equipments

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or circuits used for protecting are called as protecting equipment or circuit. In case of a small
amount of voltage ratings, protection of the circuit depends on the cost of the original circuit to be
protected and cost of the protection system essential to protect the circuit. But, in case of high cost
circuits or equipments, it is desired to adopt a protection system or protection circuit and controlling
device or controlling circuit to avoid economical loss and damage.
Figure 3.5: Electromechanical Relay Pin out
The relay is an electromechanical switch used as a protecting device and also as a controlling device
for various circuits, equipments, and electrical networks in a power system. The electromechanical
relay can be defined as an electrically operated switch that completes or interrupts a circuit by
physical movement of electrical contacts into contact with each other.
Electromechanical Relay Construction
The flow of current through an electrical conductor causes a magnetic field at right angles to the
current flow direction. If this conductor is wrapped to form a coil, then the magnetic field produced
gets oriented along the length of the coil. If the current flowing through the conductor increases, then
the magnetic field strength also increases (and vice-versa).
Figure 3.5.1: Eelctromechanical Relay Coil – Magnetic Field
The magnetic field produced by passing current through coil can be used for various purposes such as
inductors, construction of transformer using two inductor coils with an iron core. But, in
electromechanical relay construction the magnetic field produced in coil is used to exert mechanical

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force on magnetic objects. This is similar to permanent magnets used to attract magnetic objects, but
here the magnetic field can be turned on or off by regulating current flow through the coil. Thus, we
can say that the electromechanical relay operation is dependent on the current flowing through the
coil.
Electromechanical Relay Working
The electromechanical relay consists of various parts such as movable armature, movable contact &
stationary contact or fixed contact, spring, electromagnet (coil), the wire wrapped as coil with its
terminals represented as ‘C’ which are connected as shown in the below figure to form
electromechanical relay.
If there is no supply given to the coil terminals, then the relay remains in the off condition as shown
in the below figure and the load connected to relay also remains turned off as no power supply is given
to load.
Figure 3.5.2: Electromechanical Relay Working (OFF condition)
If the relay coil is energized by giving supply to the coil terminals at ‘C’, then the movable contact of
the relay is attracted towards the fixed contact. Thus, the relay turns on and the supply is connected to
the load as shown in the below figure.
Figure 3.5.3: Electromechanical Relay Working (ON condition)

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There are various types of relays, the relays which are energized by electrical supply and performs a
mechanical action (on or off) to make or break a circuit are called as electromechanical relays. There
are various types of relays such as Buchholz relay, latching relay, polarized relay, mercury relay, solid
state relay, polarized relay, vacuum relay, and so on.
Applications of Electromechanical Relay
There are numerous applications for electromechanical relays. Various types of relays are used in
various applications based on different criteria such as rating of contacts, number & type of contacts,
the voltage rating of contacts, operating lifetime, coil voltage & current, package, and so on. Relays
are frequently being used in power system networks for controlling purpose, automation purpose, and
protection purpose.
The typical applications of electromechanical relays include motor control, automotive applications
such as an electrical fuel pump, industrial applications where control of high voltages and currents is
intended, controlling large power loads, and so on.
Electromechanical Relay Logic
The method of using relays and contacts to control the industrial electronic circuits is called as relay
logic. The inputs and outputs of relay logic circuits are represented by a series of lines in schematic
diagrams and hence relay logic circuits are also called as line diagrams. An electromechanical relay
logic circuit can be represented as an electrical network of lines or rungs where each line or rung have
continuity for enabling the output device.
Application of Electromehanical Relay Logic
The railways routing and signaling are controlled using relay logic and is considered as a key
application of relay logic. This safety critical application is used to reduce the accidents and to avoid
the selection of conflicting routes by using interlocking. The human elevator operator was replaced
by large relay logic circuits in elevators. The relay logic circuits are used in electro-hydraulics and
electro-pneumatics for controlling and automation purpose.
Do you want to know the basic design of relay logic? Are you interested in designing electronics
projects? Then, post your queries, comments, suggestions, ideas in the comments section below.

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3.1.6 RS 485 USB-MPI PLC Programming Cable:
Brief about MPI Data Cable
Description
Isolation 0CB20+ PLC programming adapter cable:
 Support Siemens S7- 200/300/400 series PLC upload and download with optical isolation
function, shielding the electromagnetic interference,
online debugging, stable monitoring.
 The Cable applies 2464 material specification 28AWB(7/0.12mm)
 The wire insulating layer PVC in line with the POHS standard.
Multipurpose 0CB20 PLC programming adapter cable:
 Support Siemens S7-200/300/400 series PLC upload and download
 The Cable applies 2464 material specification
 The wire insulating layer PVC in line with the POHS standard
Advantages of the isolation cables:
Since there is the frequency converter, modules, ect exists in the larger industrial site, it will occur the
interference and affect the data transmission fast when it is start or pause, isolation cable can avoid
this kind of issue happen and will make the debugging work smooth.
Figure 3.6: RS 485 USB-MPI PLC Programming Cable
The Multi-Point Interface – Siemens (MPI) is a proprietary interface of the programmable logic
controller SIMATIC S7 of the company Siemens. It is used for connecting the stations programming
(PC or personal computer), operator consoles, and other devices in the SIMATIC family. This
technology has inspired the development of protocol Profibus. The MPI is based on the standard EIA-

36. 26 | P a g e
485 (formerly RS-485) and works with a speed from 187.5 kBd to 12 MBd. The network MPI must
have resistance at the end of the line and it is generally included in the connector and activated by a
simple switch. Manufacturers using MPI technology offer a range of connections to a PC: MPI cards,
PCMCIA cards, USB adapters or Ethernet.
3.1.7 Transformer 220v AC to 110v AC:
Brief about Transformer 220v AC to 110v AC
The step-down converters are used for converting the high voltage into low voltage. The
converter with output voltage less than the input voltage is called as a step-down converter, and
the converter with output voltage greater than the input voltage is called as step-up converter.
There are step-up and step-down transformers which are used to step up or step down the
voltage levels. 230V AC is converted into 110V AC using a step-down transformer.
Figure 3.7: Transformer 220v AC to 110v AC
3.1.8 PR-4116 (Universal Transmitter):
Brief about PR-4116 (Universal Transmitter)
4116 Universal Transmitters are for linearizing electronic temperature measurement with RTD or TC
sensor. Also for the conversion of linear resistance variation to a standard analog current/voltage
signal, i.e. from solenoids and butterfly valves or linear movements with attached potentiometer.
The transmitter are programmable via detachable display front (4501), process calibration, signal and
relay simulation, password protection, error diagnostics and selection of help text in several languages.
The 4116 is designed according to strict safety requirements and is therefore suitable for application
in SIL 2 installations.

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Input for RTD, TC, Ohm, potentiometer, mA and V
Power supply and signal isolator for 2-wire transmitters
Output for current, voltage and 2 relays
Universal AC or DC supply
A green/red front LED indicates normal operation and malfunction. A yellow LED is ON for each
active output relay
4-port 2.3 kVAC galvanic isolation
FM-approved for installation in Div. 2
DIN Rail mounting
Advanced features
 Programmable via detachable display front (4501), process calibration, signal and relay
simulation, password protection, error diagnostics and selection of help text in several
languages.
Application
 Linearized, electronic temperature measurement with RTD or TC sensor.
 Conversion of linear resistance variation to a standard analog current / voltage signal, i.e. from
solenoids and butterfly valves or linear movements with attached potentiometer.
 Power supply and signal isolator for 2-wire transmitters.
 Process control with 2 pairs of potential-free relay contacts and analog output.
 Galvanic separation of analog signals and measurement of floating signals.
 The 4116 is designed according to strict safety requirements and is therefore suitable for
application in SIL 2 installations.
Figure 3.8 PR-4116 Universal Transmitter

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Technical characteristics
 When 4116 is used in combination with the 4501 display / programming front, all
operational parameters can be modified to suit any application. As the 4116 is designed
with electronic hardware switches, it is not necessary to open the device for setting of DIP-
switches.
 A green / red front LED indicates normal operation and malfunction. A yellow LED is ON
for each active output relay.
 Continuous check of vital stored data for safety reasons.
 4-port 2.3 kVAC galvanic isolation.
Specifications
Table 3.4: PR-4116 Universal Transmitter and Confrontation
Attribute Value
Input Type Analogue
Output Type Current
Signal Conditioner Type Analogue to Current
Input Range 0 → 12 V dc, 0 → 20 mA, 4 → 20 mA, 10 MΩ, 20 Ω
Output Range 0 → 10 V dc, 0 → 20 mA
Supply Voltage 19.2 → 300 V dc, 21.6 → 253 V ac
Mounting Type DIN Rail
Sensor Compatibility Linear Resistance, Potentiometer, RTD, Thermocouple
Minimum Operating Temperature -20°C
Maximum Operating Temperature +60°C
Number of Channels 1
Operating Temperature Range -20 → +60 °C
Series 4116
3.1.9 CT-Current Transformer:
Brief about CT-Current Transformer
The current transformer is an instrument transformer used to step-down the current in the circuit to
measurable values and is thus used for measuring alternating currents. When the current in a circuit is

39. 29 | P a g e
too high to apply directly to a measuring instrument, a current transformer produces a reduced current
accurately proportional to the current in the circuit, which can in turn be conveniently connected to
measuring and recording instruments. A current Transformer isolates the measuring instrument from
what may be a very high voltage in the monitored circuit. Current transformers are commonly used in
metering and protective relays.
Figure 3.9 Current Transformer
Like any other transformer, a current transformer has a single turn wire of a very large cross-section
as its primary winding and the secondary winding has a large number of turns, thereby reducing the
current in the secondary to a fraction of that in the primary. Thus, it has a primary winding, a magnetic
core and a secondary winding. The alternating current in the primary produces an alternating magnetic
field in the magnetic core, which then induces an alternating current in the secondary winding circuit.
3.2.0 Weidmuller WAS1 CMA 1/5/10A ac:
Brief about Weidmuller WAS1 CMA 1/5/10A ac
Current-Measuring Transducer WAS1 CMA LP 1/5/10A ac, input switchable 0..1/5/10AAC
250VAC, output 4..20mA current loop, 6kV electrical isolation, power via output-side current loop,
22.5mm, Weidmüller.
Figure 3.10: Weidmuller WAS1 CMA

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Output current loop fed AC current monitoring components WAS/WAZ1 CMA LP. They can measure
single-phase 50/60 Hz AC currents of up to 10 A using the Root Mean Square (RMS) method on the
input side. They can also be switched between three ranges. No external power supply is used; the
supply is only via the 4...20 mA current loop on the output side. The input and output circuits are
securely isolated with 4 kV.
The monitoring components come in a 17.5-mm-wide WAVEBOX housing. These devices can be
used in many process automation applications because they are not dependent on an external power
supply. International approvals (such as ATEX Zone 2 and UL C1D2) also permit usage in explosion-
risk zones.
Technical Specifications
Table 3.5: Weidmuller WAS1 CMA and Configuration
Physical
Mount DIN Rail
Number of Pins 9
Weight 150 g
Technical
Accuracy 0.5 %
Max Operating Temperature 50 °C
Min Operating Temperature 0 °C
Number of Inputs 1
Number of Outputs 1
Operating Supply Voltage 24 V
Voltage Rating 300 V
Dimensions
Depth 92.4 mm
Length 72 mm
Width 22.5 mm
Compliance
Approvals CE, EN, cULus
Lead Free Lead Free
Radiation Hardening No
RoHS Compliant

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3.2.1 Capacitor Bank:
Brief about Capacitor Bank
Capacitor banks may also be used in direct current power supplies to increase stored energy and
improve the ripple current capacity of the power supply. The capacitor bank consists of a group of
four ac capacitors, all rated at 400V, 50 Hz i.e., the supply voltage and frequency. The value of
capaci
in parallel to one another and the load. The capacitor bank is controlled by the relay module and is
connected across the line. The operation of a relay connects the associated capacitor across the line in
parallel with the load and other capacitors.
A Capacitor Bank is a group of several capacitors of the same rating that are connected in series or
parallel with each other to store electrical energy. The resulting bank is then used to counteract or
correct a power factor lag or phase shift in an alternating current (AC) power supply. They can also
be used in a direct current (DC) power supply to increase the ripple current capacity of the power
supply or to increase the overall amount of stored energy.
What Does a Capacitor Bank Work?
Capacitor banks work on the same theory that a single capacitor does; they are designed to store
electrical energy, just at a greater capacity than a single device. An individual capacitor consists of
two conductors which are separated by a dielectric or insulating material. When current is sent through
the conductors, an electric field that is static in nature then develops in the dielectric which acts as
stored energy. The dielectric is designed to permit a predetermined amount of leakage which will
gradually dissipate the energy stored in the device which is one of the larger differences between
capacitors and batteries.
Figure 3.11: Capacitor Bank

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How is Capacitance Measured?
Capacitors are rated by the storing characteristic referred to as capacitance which is measured by the
scientific unit, farad. Each capacitor will have a fixed value that they are rated at storing which can be
used in combination with other capacitors in a capacitor bank when there is a significant demand to
absorb or correct AC power faults or to output DC power.
What are the Applications of a Capacitor Bank?
The most common use of a capacitor bank for AC power supply error correction is in industrial
environments which use a large number of transformers and electric motors. Since this equipment
uses an inductive load, they are susceptible to phase shifts and power factor lags in the power supply
which can result in a loss of system efficiency if left uncorrected. By incorporating a capacitor bank
in the system, the power lag can be corrected at the cheapest cost for the company when compared to
making significant changes to the company power grid or system that is supplying the equipment.
Other uses for capacitor banks include Marx generators, pulsed lasers, radars, fusion research, nuclear
weapons detonators, and electromagnetic railguns and coilguns
3.2.2 Voltage Regulator:
Brief about Voltage Regulator
A voltage regulator is used to regulate voltage level. When a steady, reliable voltage is needed, then
voltage regulator is the preferred device. It generates a fixed output voltage that remains constant for
any changes in an input voltage or load conditions. It acts as a buffer for protecting components from
damages. A voltage regulator is a device with a simple feed- forward design and it uses negative
feedback control loops. There are mainly two types of voltage regulators: Linear voltage regulators
and switching voltage regulators; these are used in wider applications. Linear voltage regulator is the
easiest type of voltage regulators. It is available in two types, which are compact and used in low
power, low voltage systems. Let us discuss about different types of voltage regulators.
Voltage regulator, any electrical or electronic device that maintains the voltage of a power source
within acceptable limits. The voltage regulator is needed to keep voltages within the prescribed range
that can be tolerated by the electrical equipment using that voltage. Such a device is widely used in
motor vehicles of all types to match the output voltage of the generator to the electrical load and to
the charging requirements of the battery. Voltage regulators also are used in electronic equipment in

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which excessive variations in voltage would be detrimental. In motor vehicles, voltage regulators
rapidly switch from one to another of three circuit states by means of a spring-loaded, double-pole
switch. At low speeds, some current from the generator is used to boost the generator’s magnetic field,
thereby increasing voltage output. At higher speeds, resistance is inserted into the generator-field
circuit so that its voltage and current are moderated. At still higher speeds, the circuit is switched off,
lowering the magnetic field. The regulator switching rate is usually 50 to 200 times per second.
Electronic voltage regulators utilize solid-state semiconductor devices to smooth out variations in the
flow of current. In most cases, they operate as variable resistances; that is, resistance decreases when
the electrical load is heavy and increases when the load is lighter.
Figure 3.11.2: Voltage Regulator and Pin out
Voltage regulators perform the same function in large-scale power-distribution systems as they do in
motor vehicles and other machines; they minimize variations in voltage in order to protect the
equipment using the electricity. In power-distribution systems the regulators are either in the
substations or on the feeder lines themselves. Two types of regulators are used: step regulators, in
which switches regulate the current supply, and induction regulators, in which an induction motor
supplies a secondary, continually adjusted voltage to even out current variations in the feeder line.
3.2.4 Load/Cooling Fan:
Fig. 3.13: Load Fan

44. 34 | P a g e
Specification:
Table 3.6: Fan and Configuration
Item description: dc fan
Size: 40 * 40 *
Voltage: 24V
Current: 0.02A~ 0.24 A
The actual current: 0.15 A
Power: 0.75 W
Speed: 6300 RPM
Air volume: 7.17 CFM
Noise: 24DBA
3.2.5 CT-K type sensor:
Brief about CT-K type sensor
A Thermocouple is a sensor used to measure temperature. Thermocouples consist of two wire legs
made from different metals. The wires legs are welded together at one end, creating a junction. This
junction is where the temperature is measured. When the junction experiences a change in
temperature, a voltage is created. The voltage can then be interpreted using thermocouple reference
tables to calculate the temperature.
Fig. 3.14: CT-K type sensor
Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the most common type
of thermocouple. It’s inexpensive, accurate, reliable, and has a wide temperature range. The type K
is commonly found in nuclear applications because of its relative radiation hardness. Maximum
continuous temperature is around 1,100C.
Type K Temperature Range:
Type K Thermocouple Grade Wire Thermocouple grade wire, –454 to 2,300F (–270 to 1260C)
Extension wire, 32 to 392F (0 to 200C)

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Type K Accuracy (whichever is greater):
Standard: +/- 2.2C or +/- .75%
Special Limits of Error: +/- 1.1C or 0.4%
Type of K Thermocouple
Consideration for bare wire type K thermocouple applications

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CHAPTER 4
BLOCK DIAGRAM
4.1 Block Diagram
Here, we represent the block diagram of proposed system in figure. We measure and monitor the
parameter of inductive load to maintain the power factor monitoring and improvement with help of
PLCs and SCADA. This system contains different working element which mainly consist of inductive
load, capacitor bank and 24-volt DC supply (SMPS). As seen from figure, inductive load is the last
element whose parameter we must measure and monitor on SCADA window. Inductive load receives
AC main supply through VFD.
VFD plays important role in system as it is protecting motor from various faults like overloading,
overvoltage, over current etc. and controls the speed of motor. 24-volt DC supply (SMPS) also fed
from AC main supply. Input rag of PLC relates to capacitor bank and VFD and output rag relates to
personal computer which has SCADA window. User can show the various parameters of motor and
control from computer. Here we communicate between PLC and SCADA using RS-232
communication cable.
A Capacitor Bank is a group of several capacitors of the same rating that are connected in series or
parallel with each other to store electrical energy. Capacitor banks are used for problems such as lag
or phase shifts. These banks can also be used simply to increase the energy storage of a system. These
banks are often the most cost-efficient ways of dealing with power shift and AC power supply
problems. Here, especially we use capacitor bank for correct AC power problems and to reduce
harmonics from the system.
Inductive Load: Here we use three phase induction motor whose parameter we must measure. Table
shows the rating
of an induction motor.
Table 4.1: Three Phase Induction Motor Configuration
Type
Volts
Phase/cycle
Power(kw/HP)
Speed in R.P.M
:
:
:
:
:
T.E.F.C
415
3/50
2.2/3
1400
Current (amps)
Frame
Connection type
Insulation class
Manufacturer
IV. IMPLEMENTATION
: 4.7
: 100L
: Delta
: B class
: Benn Electrical

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In any industry, induction motor plays significant role due to its low cost and simplicity. By
implementing a monitoring and control system for the speed of motor, the induction motor can be
used in high performance variable speed applications. First and basic step is to select the rating of
induction motor and according to it control devices are selected and the circuit is designed accordingly
and finally the programming is done in the PLC according to inputs applied and the outputs required
in the operation of the induction motor. Capacitor bank is connected in parallel with
induction motor. It is required for reduce harmonics and for improve power factor of motor. Capacitor
bank also compensate reactive power of motor. The capacitor draws leading current and partly or
neutralize lagging reactive component of load current. This will improve the power factor.
Figure 4.1: Block diagram of project

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4.2 Flow Chart
Fig: 4.2 represent the flow chart diagram of the process. There is a start menu, If not start and select
Start button again. Sense temperature and start cooling fan. When Temperature >40 degree C start
the fan and <35 degree C stop the fan. But if temperature increases greater than 48 degree C send
alarm and stop the system.
Over voltage >250V send an alarm and stop the system and under the voltage <100V again send an
alarm and fully stop the system.
Over current >7A send alarm and stop the system.
Power factor =96 and A =1 start the capacitor bank-1 and Power factor =98 and A=10 capacitor
bank-2 start.
Current >5A load shading start if load shading time out stop the system.
Figure 4.2 Flowchart of working process.

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4.3 Schematic diagram
This chapter provides the necessary information for simulated circuit design and its functional
output. Hardware implementation with input sensors defines the mechanism of this chapter. To
make the project more efficient, different values are taken as a short survey and a comparison is
shown to find the defect.
Figure 4.2: Circuit diagram of the prototype model

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4.3.1 Circuit Operation
This is a circuit operation of the project. We using a 220v AC to 110v AC transformer. Power supply
send to EM 235 Module EM 235 Module Al 3*12 Bits and AQ 1*12Bits. Input voltage C+, C-.
Current Transformer connected to B+, B-. There UA is EM 235 input and Uh 230v three phase load
current. PR 4116 Universal Transformer connected to A+, A-. Universal Transformer output for TC
K type sensor, 24v DC supply, 11 and 14 pin is connected to EM 235 A+ and A- point. RS 485 USB-
MPI PLC Programming Cable connect to PC and showing output on SCADA. M and L+ pin connected to
CPU 214 PLC module M, L+, 2M, 2L+ and 1M, 1L pins are connected from 220V AC to 24V DC
supply. 24V DC supply connected also relays. 0.3 to 0.7 relays are lode relay and 1.0, 1.1 relays are
load and fan relay. 220V AC converted 24V DC using step down transformer connected to PLC 1M
and 1L+. Connected also relay there is five relays for load connecting pin 0.3, 0.4, 0.5, 0.6, 0.7 and
two for fan and load connecting pin 1.0, 1.1.
4.3.2 Working Principle
This is a full circuit diagram of the working project. There are no wire is required to send data.
The connecting wire is use for AC to DC power supply 220V AC to 24V DC. There is three step to
working process. Firstly 110v AC power supply connected to EM 235 module. The step is sense
Transformer oil Temperature, when transformer temperature is increases start the cooling fan and
temperature is normal cooling fan is shut up.
Secondly improvement of Power Factor. When current in inphase Power Factor normally 1.0 stable
but physically it is not possible. When inductive load increases power factor going decrease. For
decrease power factor improvement using capacitor bank. Capacitor bank develop power factor near
0.9. Here generally capacitor bank-1 start of the circuit. Current and Voltage angle is Power factor
and save more cost
Thirdly load distribution feeder to feeder.
4.3.3 Circuit Application
 Power factor correction, Improvement, Monitoring
 PLC Automation

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CHAPTER 5
DESIGN AND IMPLEMENTATION
5.1 Body design
This is the part which we used to design the Power Factor system. We also used PVC board,
Aluminum sheet to make the device with a good shape and PC.
Figure 5.1: Front View Figure 5.2: Side View
Figure 5.3: Top View
Figure no 5.4: Output of the project

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5.2 Software Description
SCADA: For SCADA window, we use wonder ware –In touch. In SCADA window, main switch is
ON motor is ON. Different parameter of motor is shown in window like phase voltage, current, speed
of motor etcetera. Waveform of motor is shown in trend. When switch is ON motor colour is GREEN,
it indicates motor is in running operation and vice versa in RED colour.
After operating the system using PLC and SCADA, we get the results as per the Fig. 3. Here, we get
the line voltage of all the three phases, frequency of the system, speed of the induction motor, output
waveforms without capacitor and with capacitor. All the results are store in the memory for further
analysis.
SCADA, it will collect the needed data from PLC and displaying them on the monitor of master
computer of control room, store appropriate data in the hard drive of computer and allow the control
of field device from the control room. As mention above, in any contingency SCADA would give
alarm or automatically cut-off the supply. Here, for interfacing between PLC and SCADA we use RS-
232 cable.
Micro win v4.0 SP9: The two Service Packs 9 for STEP7 Micro WIN V4.0 are compatible with all
S7-200 CPUs (CPU 21x and CPU 22x).
Programs created with earlier Micro WIN versions can be opened and further processed without any
restrictions.
Projects created with the new Service Packs can be neither opened nor processed with older
versions.
5.3 Hardware
Hardware comprises of single phase supply, interfacing circuit, PLC, switching circuit, capacitor bank
and single phase load as shown in fig.5.5.
Fig.5.5: Block diagram of experimental set

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CHAPTER 6
FUTURE WORK AND CONCLUSION
We know every system has some advantage or disadvantage. So our project will also have very good
practical advantage and some limitations which we called it disadvantages.
6.1 Applications
Electricity industry: power factor correction and monitoring of linear loads: Power factor
correction is achieved by complementing an inductive or a capacitive circuit with a (locally connected)
reactance of opposite phase. For a typical phase lagging power factor load, such as a large induction
motor, this would consist of a capacitor bank in the form of several parallel capacitors at the power
input to the device. Instead of using a capacitor, it is possible to use an unloaded synchronous motor.
This is referred to as a synchronous condenser. It is started and connected to the electrical network.
Instead of using a capacitor, it is possible to use an unloaded synchronous motor. This is referred to
as a synchronous condenser. It is started and connected to the electrical network. It operates at full
leading power factor and puts VARs onto the network as required to support a system’s voltage or to
maintain the system power factor at a specified level. The condenser’s installation and operation are
identical to large electric motors. The reactive power drawn by the synchronous motor is a function
of its field excitation. Its principal advantage is the ease with which the amount of correction can Be
adjusted. It behaves like an electrically variable capacitor.
6.2 Advantages
 Reduced Utility Bills: The power factor of a customer will become a direct or indirect factor
in the utility bill. Power bills may be reduced by introducing capacitors to the facility, which
can reduce the need for kVAr required from the utility. .
 Electrical System Capacity: Capacitors in a facility produce reactive energy that motors
require to produce magnetizing current for induction motors and transformers. This reduces
the overall current needed from the power supply. This translates into reduced loads on both
transformers and feeder circuits. Reduced loads on transformers can have less maintenance,
reduced breaker trips, and higher full-load capacity. .
 Improved Voltage Levels: Low voltage may be caused by a lack of reactive energy dynamic
load changes. In facilities with motors, low voltage reduces motor efficiency and can cause
overheating.

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6.3 Benefits
There are several advantages in utilizing power factor correction capacitors.
Benefits of Power Factor Correction. There are numerous benefits to be gained through power factor
correction and monitoring. These benefits range from reduced demand charges on your power system
to increased load carrying capabilities in your existing circuits and overall reduced power system
loses. These include:
 Avoid power factor penalties
 Reduced demand charges
 Increased load carrying capabilities in existing circuits
 Improved voltage
 Reduced power system losses
 Reduced demand charges.
 Increased load carrying capabilities in existing circuits.
 Improved voltage
 Power system loses
 Power system becomes unstable
 Resonant frequency is below the line frequency
 Current and voltage increase
6.4 Disadvantages
Reduction in system losses, and the losses in the cables, lines, and feeder circuits and therefore
lower cable sizes could be opted for.
 Improved system voltages, thus enable maintaining rated voltage to motors, pumps and other
equipment. The voltage drop in supply conductors is a resistive loss, and wastes power heating
the conductors. Improving the power factor, especially at the motor terminals, can improve the
efficiency by reducing the line current and the line losses.
 Improved voltage regulation.
 Increased system capacity, by release of KVA capacity of transformers and cables for the
same KW, thus permitting additional loading without immediate expansion.
 Reactive power decreases
 Avoid poor voltage regulation
 Overloading is avoided

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 Copper loss decreases
 Transmission loss decreases
 Improved voltage control
 Efficiency of supply system and apparatus increase
6.5 Future Enhancement
The automotive power factor correction using capacitive load banks is very efficient as it reduces the
cost by decreasing the power drawn from the supply. As it operates automatically, manpower is not
required and this Automated Power Factor Correction using capacitive load banks can be used for the
industries purpose in the future.
6.6 Conclusion
Power factor correction has got wide range of advantages in industrial sector. The most important one
is reducing the electricity tariff. Usually capacitor banks used for power factor correction are placed
in a scattered manner throughout the industry for better performance. Fixed shunt capacitors that we
have used here are the least expensive way to achieve near unity power factor by providing a static
source of leading reactive current. They can be installed either close to the highly reactive loads or at
the service entrance.
We discuss on power quality issue and factor concerning related with modern utilities. We should
know how to choose monitoring location and control scheme. We perform experiment on particular
system to monitoring and controlling for three phase induction motor. The system is successfully
implemented and tested. The software Rockwell has been successfully worked for PLC and
Wonderware-Intouch for SCADA. With the use of PLC & SCADA, the control system is more
reliable. Monitoring system gives facility of analyzing the operation of an induction motor in
online/offline mode which make the system to be safe from fault/error condition. It deals with the
most important types of failures of an induction motor such as over and under voltage, over current,
over speed etc. If any fault appears during the operation of motor then the motor stops immediately.

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