Tool of Flow Management

The tool provides the status monitoring function of all nodes connected to the SCADA network. The
healthiness monitoring of the nodes is paramount in detecting or early warn of failure or potential
failures within a system node in order for early decision making or diagnostic to avoid costly
catastrophic failure to safegurd equipment and human safety and avoid forced system outages.

Among other functionality of the tool include:

I. It provides the monitoring function of the node system process information

II. It provides the monitoring function of process information of the IMC application
III. It provides reloading and process ON/OFF functions in IMC database
IV. It provides abnormal warning and self-diagnosis report functions of the nodes
V. It provides the one key generated diagnosis function for the IMC platform

Configuration of Process List

In the “Process Configuration” the system generates a default process-list of the IMC application
according to the type of selected node in the node configuration window. The process-list
configuration of all nodes in the system can be configured here, hence generating the
corresponding configuration files in the DB directory.

A process can be added to any particular node as well by completing the following parameters:

I. Start or no - Process to be started or not

II. Program Name field with the process name to be added
III. Start Parameter field - for star ting the added process
IV. Interval field - for completing the starting of the added process
V. Starting number of the added process as needed.

On completion of the above parameters, the process need to be saved and then the data base
synchronized to all other nodes.

Monitoring of Process and System Abnormity

When there is an abnormity in the process or in the utilization of system resources, or when the system or
process is operated manually, a warning message is generated by the process-management module in the
brief-report window of IMC software, and the self-diagnosis list will be logged in and a self-diagnosis report
of the standard format will be generated for futher action by the maintenance team.

Operate the IMC or Operating System on Server-Side through Command

Flow management supports the command prompt option for operations of command-line manner.

Through the command prompt, the following operations can be executed or achieved on a particular node:

I. Restarting the local computer

II. Shutting down the local computer
III. Starting the IMC process
IV. Stopping the IMC process, etc.
Information Monitoring

Entering the main monitoring interface of progress management, the users can monitor system
resources and information as well as node status information at various nodes of the system, and
manage various nodes through IP address of the active network.

Some of the status information displayed for each node include

I. Node CPU usage

II. Percentage memory usage of each node
III. Available space on the hard disk drive on each Node
IV. Overall state of the node

The overall state of the node is categorized into 6 states. All these states have different color description
as shown below in fig …….. Depending on the color, a fault can easily be noticed or identified.

Node Normal

Node Process
failure
Node not working/Off

Node Key Process not started

Node Resource utilization

failure
Node Process failure and Node Resource utilization failure

A detailed status information of the Node can easily be retrieved by placing the mouse cursor on the
status bar of a Node.
The Local Control Local Control Units (LCU)

The configuration of Karuma SCADA system. The Software package is used to Monitor and carryout
Data Acquisition with aid of a Historian and Alarm Management. The SCADA communicate to locally
distributed PLCs or LCU for a particular individual process for supervision and monitoring.
In case host computer becomes fault or communication is interrupted, the control is carried out in the
LCU

Hardware Configuration

All LCU configuration is of a redundant dual CPU, redundant dual networks. The mode of communication
is by the optical fiber network, the data can be transferred to the central control room in real time to
remotely monitor all the through put of each LCU such as the auxiliary switches and auxiliary equipment
status, automatic alarm generation. At the LCU, the operation real-time data can be displayed at the
local touch screen. All operational commands can be achieved either by the central control room or at
the LCU touch panel

There are 6 LCU at Karuma HPP. These include:

1. Public LCU – for operating and monitoring all auxiliary equipment and switches common the
plant within the power house. Such as the dewatering systems, compressed air system, intake
and tailrace water levels, switching the station auxiliary power, etc.
2. Unit LCU – monitor and control the generator and turbine, all the unit auxiliaries and start and
stop the unit. There are 6 unit LCUs. Each local control unit provides communication with the
unit auxiliaries such as the governor PLC and the Excitation system.
3. 400KV GIS LCU - is used for the operation of various circuit breakers, isolating switches and
grounding switches of the 400kV GIS system
4. Switchyard LCU - is used control and monitor the operation of various circuit breakers, isolating
switches and grounding switches of the 132 kV
5. Dam LCU - is used to contolr and monitor operate the switches and incoming circuit breakers.
The control of Dam equipment such as the spill way gates, ecological flow gates and the under
and Over sluice gates. Mode of communication the these equipment is through Ethernet form
the equipment local control panel to the Dam LCU, then to the SCADA system

PLC Hardware components

Runs on the GE PLC PACSystem 3Xi, 1GHz, with Redundancy. with RIO (NIU)

1 Power supply Module

1 Communication device RMX

2 Ethernet Module ET
 The main PLC rack contains 6 slots. Slot 0 is for the power suppy module, slot 1 and 2 is for the CPU, slot
3 and 4 is for the Ethernet modules, slot 5 is a pare module and slot 6 is for a communication module.
The communication module is used for communication with the redundant Main PLC and ensuring that
both PLCs have the same system parameters and information. On this device, there is an option for
manually changing between the primary and secondary PLCs smoothly without system disturbance.

In the Hardware configuration widow, the CPU highlighted in bold represents the one in service as
shown in the figure below.

PLC in service

PLC on standby/redundancy

Fig……. showing hardware configuration of the main controller/PLC

Fig ….. Showing the NIU in a control Panel

 Power Supply module Ethernet modules

CPU module Spare module Slot

Communication module

Fig…….showing the PACSystem 3Xi in the control panel

The NIU

These facilitate the RIO of the main PLC. There are 10 NIUs for the Unit LCU. Each NIU has a dedicated
CPU for communicating with the main PLC CPU. The communication is through Ethernet. Each NIU has
16 slots with slot 0 being for the power supply unit, slot 1 and two for the CPU and slot 3 to 16 being
used for different I/Os such as the temperature monitoring module, Analog I/O modules, digital I/O
modules, etc. Slot 13 and 16 are spare modules for the SOE NIU

Fig……Hardware configuration of the SOE NIU in Proficy Machine Edition Fig……Hardware configuration of the NIU
 PLC Software

The LCU PLC runs on the GE Proficy Machine Edition software. All the control logic is performed and
executed with in the application. I/O configuration and communication is configured within the
software.

SCADA unit 1 start sequence

window

Unit 1 LCU PLC start sequence logic

Fig….. Showing display windows at the SCADA screen and the actual PLC logic in the LCU PLC for Unit 1 Start sequence step for governor
Troubleshooting and Debugging

In Proficy, troubleshooting and debugging can be achieved. The online and real time status of all I/O
modules and inputs can be displayed with each single I/O point from or to the field device. In this view
variables can be forced on or off, analog input measurements can be manipulated within the software
to the desired state without the actual field device.

I/O Forcing tab Selected I/O status Selected I/O point

I/O variable monitoring table

Fig……. NIU I/O showing the variable table