International Journal of Electrical, Electronics and Telecommunication Engineering
ISSN:2051-3240, Vol.44, Special Issue.2
Hydrogen Cooling System in Thermal Power Plant
Using PLC & SCADA
Nowh Rajab Nowh Saad
Electrical Engineering Dept.
SHIATS-Deemed University, Allahabad-India
Email: watts_one2002@yahoo.com
ABSTRACT
The faster heat dissipation of generators in power plants
calls for hydrogen cooling, and water is used as coolant to
cool down the hot hydrogen which comes out from the
hydrogen cooling system (HCS) at the generating end.
Therefore, in large generating plants, the process of
cooling and the coolant become integral parts of the heat
exchangers. Hence, requirement of a reliable HCS is a
must. This paper presents development and
implementation of a supervisory-control-and data
acquisition-based process control and monitoring system
A novel method of six-stage standby redundant structured
(S3RS) HCS is proposed for the cooling of large
generators in thermal power plant(s). This proposed
system is equally reliable for steam-turbine-based
generating plants and integrated gasification combined
cycle plants. The entire process control and monitoring,
popularly known as human–machine interface of HCS, has
been developed and simulated on RS View SE, a real-time
automation platform by Rockwell Automation.
Additionally, the system reliability of the proposed S3RS
process model is implemented using MATLAB. This
process model satisfies the specifications of IEEE C37.1-
2007, IEEE 1413-2003, IEC 60034-3, IEC 61025, and IEC
61131-3.
Keywords - Frequency deviations; Fuzzy reasoning; PV
output power fluctuations; Maximum PV power; OPC
server, RS Logix 5000 Fuzzy Designer;
1. INTRODUCTION
A thermal power station is a power plant in which
the prime mover is steam driven. Water is heated, turns
into steam and spins a steam turbine which drives
an electrical generator. After it passes through the turbine,
the steam is condensed in a condenser and recycled to
where it was heated; this is known as a Rankine cycle. The
greatest variation in the design of thermal power stations is
due to the different fuel sources. Some prefer to use the
term energy center because such facilities convert forms
of heat energy into electricity.[1] Some thermal power
plants also deliver heat energy for industrial purposes,
for district heating, or for desalination of water as well as
delivering electrical power. A large part of human
CO2emissions comes from fossil fueled thermal power
plants; efforts to reduce these outputs are various and
widespread.
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Surya Prakash
Electrical Engineering Dept.
SHIATS-Deemed University, Allahabad-India
Email: sprakashgiri0571@yahoo.com
Almost all coal, nuclear, geothermal, solar thermal
electric, and waste incineration plants, as well as many
natural gas power plants are thermal. Natural gas is
frequently combusted in gas turbines as well as boilers.
The waste heat from a gas turbine can be used to raise
steam, in a combined cycle plant that improves overall
efficiency. Power plants burning coal, fuel oil, or natural
gas are often called fossil-fuel power plants.
Some biomass-fueled thermal power plants have appeared
also. Non-nuclear thermal power plants, particularly
fossil-fueled plants, which do not use co-generation are
sometimes referred to as conventional power plants.
Commercial electric utility power stations are usually
constructed on a large scale and designed for continuous
operation. Electric power plants typically use three-
phase electrical generators to produce alternating current
(AC) electric power at a frequency of 50 Hz or 60 Hz.
Large companies or institutions may have their own power
plants to supply heating or electricity to their facilities,
especially if steam is created anyway for other purposes.
Steam-driven power plants have been used in various large
ships, but are now usually used in large naval ships.
Shipboard power plants usually directly couple the turbine
to the ship's propellers through gearboxes. Power plants in
such ships also provide steam to smaller turbines driving
electric generators to supply electricity. Shipboard steam
power plants can be either fossil fuel or nuclear. Nuclear
marine propulsion is, with few exceptions, used only in
naval vessels. There have been perhaps about a
dozen turbo-electric ships in which a steam-driven turbine
drives an electric generator which powers an electric
motor for propulsion. Combined heat and power (CH&P)
plants, often called co-generation plants, produce both
electric power and heat for process heat or space heating.
Steam and hot water lose energy when piped over
substantial distance, so carrying heat energy by steam or
hot water is often only worthwhile within a local area,
such as a ship, in the nearby buildings.
1.1 History
The very first commercial central electrical generating
stations in the Pearl Street Station, New York and
the Holborn Viaduct power station, London, in 1882, also
used reciprocating steam engines. The development of
the steam turbine allowed larger and more efficient central
generating stations to be built. By 1892 it was considered
 International Journal of Electrical, Electronics and Telecommunication Engineering
as an alternative to reciprocating engines [2] Turbines
offered higher speeds, more compact machinery, and
stable speed regulation allowing for parallel synchronous
operation of generators on a common bus. Turbines
entirely replaced reciprocating engines in large central
stations after about 1905. The largest reciprocating engine-
generator sets ever built were completed in 1901 for the
Manhattan Elevated Railway. Each of seventeen units
weighed about 500 tons and was rated 6000 kilowatts; a
contemporary turbine-set of similar rating would have
weighed about 20% as much
Fig.1 Block diagram of thermal power generation
1.2 Inspiration
Today, operation of generating stations with a power
utility factor close to unity is essential with growing
demand and its economic implications. Such operations
require sophisticated automation systems to provide highly
productive, reliable, and safe systems popularly known as
supervisory control and data acquisition (SCADA).
SCADA systems are developed to monitor and estimate
the current operation states and to collect, analyze, and
diagnose fault alarms. Thus, it requires redundant
techniques for providing fault tolerance to plant processes
in run time. SCADA is the collective feature of telemetry
and remote control put together. Certainly, SCADA has
the capabilities to handle from a steam-based power plant
as a component of power systems to highly dynamic and
complex structured load distribution centers. Focused on
the importance of this, Thomas et al. proposed a scheme
for a state-of-the-art SCADA system [1]. Recently,
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Vicente et al. have established a remote laboratory for
industrial automation which comprises programmable
logic controllers (PLCs) from various manufacturers [2].
Nowadays, intelligent electronic devices (IEDs) are used
for precise control and monitoring of power plants as
substitutes of hardwired electromechanical devices.
Akerman and Kunsman proposed a technique for
configuring IEDs [3]. Kumar et al. proposed a fuzzy-based
algorithm for pre processing of the data at remote terminal
units (RTUs) [4]. Furthermore, Tanaka proposed an
integrated operation system dedicated to operating
generating plants [5]. Also, Turner et al. proposed an
algorithm for supplying power to an electrical grid [6].
However, Osburn, III, proposed a configuration tool
linking RTU with SCADA systems [7]. In addition, Sun et
al. proposed a method of distributed control in an
industrial environment [8].
In particular, for the cooling of large generators, hydrogen
is considered as an excellent cooling agent because of low
density,high specific heat, and high thermal conductivity.
Banister et al. proposed a power plant that produced steam
by the combustion of hydrogen with oxygen [9], whereas
Isokawa and Hisajima proposed a power generation
system which is further combined with a hydrogen
production plant [10]. However, an entire generating
section is ineffective without a reliable process model
of hydrogen. Thus, Miranda et al. proposed an application
of particle swarm optimization for improving reliability of
power system components [11]. Wang et al. conducted a
study to enhance reliability using standby components
[12], whereas Koide and Sandoh conducted a review over
customer and manufacturer viewpoints on parallel
redundancy [13]. Nevertheless, Michlin et al. proposed a
comparison between two systems based on component
reliability [14].
1.3 SCADA
SCADA (supervisory control and data acquisition) is a
type of industrial control system (ICS). Industrial control
systems are computer controlled systems that monitor and
control industrial processes that exist in the physical
world. SCADA systems historically distinguish
themselves from other ICS systems by being large scale
processes that can include multiple sites, and large
distances.[1] These processes include industrial,
infrastructure, and facility-based processes, as described
below:
• Industrial processes include those of manufacturing,
production, power generation, fabrication, and
refining, and may run in continuous, batch, repetitive,
or discrete modes.
• Infrastructure processes may be public or private, and
include water treatment and distribution, wastewater
collection and treatment, oil and gas
pipelines, electrical power transmission and
 International Journal of Electrical, Electronics and Telecommunication Engineering
distribution, wind farms, civil defense siren systems,
and large communication systems.
• Facility processes occur both in public facilities and
private ones, including buildings, airports, ships,
and space stations. They monitor and control heating,
ventilation, and air conditioning systems
(HVAC), access, and energy consumption.
1.4 Common system components
A SCADA system usually consists of the following
subsystems:
• A human–machine interface or HMI is the apparatus
or device which presents process data to a human
operator, and through this, the human operator
monitors and controls the process.
• SCADA is used as a safety tool as in lock-out tag-out
• A supervisory (computer) system, gathering
(acquiring) data on the process and sending
commands (control) to the process.
• Remote terminal units (RTUs) connecting to sensors
in the process, converting sensor signals to digital
data and sending digital data to the supervisory
system.
• Programmable logic controller (PLCs) used as field
devices because they are more economical, versatile,
flexible, and configurable than special-purpose RTUs.
• Communication infrastructure connecting the
supervisory system to the remote terminal units.
• Various process and analytical instrumentation
1.5 Hydrogen-cooled system
Hydrogen-cooled turbo generator is a turbo
generator with gaseous hydrogen as a coolant. Hydrogen-
cooled turbo generators are designed to provide a low-
drag atmosphere and cooling for single-shaft
and combined-cycle applications in combination
with steam turbines.[1] Because of the high thermal
conductivity and other favorable properties of hydrogen
gas this is the most common type in its field today. Based
on the air-cooled turbo generator, gaseous hydrogen went
into service as a coolant in the rotor and the stator in 1937
at Dayton, Ohio, in October by the Dayton Power allowing
an increase in specific utilization and a 99.0% efficiency
the use of gaseous hydrogen as a coolant is based on its
properties, namely low density, high specific heat, and the
highest thermal conductivity (at 0.168 W/(m·K)) of all
gases; it is 7-10 times better at cooling than air. Another
advantage of hydrogen is its easy detection by hydrogen
sensors. A hydrogen-cooled generator can be significantly
smaller, and therefore less expensive, than an air-cooled
one. For stator cooling, water can be used. Helium with a
thermal-conductivity of 0.142 W/(m·K) was considered as
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coolant as well, however its high cost hinders its adoption
despite its non-flammability.
Generally, three cooling approaches are used. For
generators up to 300 MW, air cooling can be used.
Between250-450 MW hydrogen cooling is employed. For
the highest power generators, up to 1800 MW, hydrogen
and water cooling is used; the rotor is hydrogen-cooled,
the stator windings are made of hollow copper tubes
cooled with water circulating through them. The
generators produce high voltage; the choice of voltage
depends on the tradeoff between demands to electrical
insulation and demands to handling high electric current.
For generators up to 40 MVA, the voltage is 6.3 kV; large
generators with power above 1000 MW generate voltages
up to 27 kV; voltages between 2.3-30 kV are used
depending on the size of the generator. The generated
power is left to a nearby station transformer, where it is
converted to the electric power transmission line voltage
(typically between 115 and 1200 kV).
To control the centrifugal forces at high rotational speeds,
the rotor is mounted horizontally and its diameter typically
does not exceed 1.25 meter; the required large size of the
coils is achieved by their length. The generators operate
typically at 3000 rpm for 50 Hz and 3600 rpm for 60 Hz
systems for two-pole machines, half of that for four-pole
machines. The turbo generator contains also a smaller
generator producing direct current excitation power for the
rotor coil. Older generators used dynamos and slip
rings for DC injection to the rotor, but the moving
mechanical contacts were subject to wear. Modern
generators have the excitation generator on the same shaft
as the turbine and main generator; the diodes needed are
located directly on the rotor. The excitation current on
larger generators can reach 10 kA. The amount of
excitation power ranges between 0.5-3% of the generator
output power. The rotor usually contains caps or cage
made of nonmagnetic material; its role is to provide a low
impedance path for eddy currents which occur when the
three phases of the generator are unevenly loaded. In such
cases, eddy currents are generated in the rotor, and the
resulting Joule heating could in extreme cases destroy the
generator.
2. MODELING OF HCS
In today’s scenario, any power plant has three impact
factors: accuracy, efficiency, and reliability. There is still a
huge scope of improvement in system reliability and
efficiency of power plants. Out of this, reliability issues
are emphasized. In particular, analysis of system reliability
for control and instrumentation(C&I) of HCS is involved
at plant level which becomes an essential analysis due to
inefficient component reliability. Enhanced system
reliability of a cooling process reduces the chances of
system failure. Hence, it requires less time for
maintenance and provides enhanced availability.
Reduction in maintenance duration of a process allows it
to keep in active mode for longer duration. In this way, it
 International Journal of Electrical, Electronics and Telecommunication Engineering
improves the efficiency of the overall power generation
system. Improvement in efficiency indicates lesser
emission of greenhouse gases; even 1% improvement may
contribute in reduction of emitted CO2 by 20 000 tons that
is 345 g/kWh as compared to 578 g/kWh. This idea has
inspired to extend the work in this direction. The proposed
processing unit of HCS is designed and simulated for the
capacity of 120–130- and 250–300-MW units of
generating stations. Furthermore, this section is divided
into two sections: modelling of the HCS and configuration
of SCADA.
2.1 Modelling of the HCS
Major control actions of HCS which are critical from the
C&I point of view are as follows: level and pressure
control of processing units, feed water control,
temperature control of generator section, and water
cooling tower (WCT). Additional components are on/off
valves, control valves, pressure, temperature, flow, and
level transducers. The major components of the HCS
considered for simulation are reservoirs for storage
of liquid hydrogen, cold converters (T-83B and T-83C) for
processing of hydrogen, heat exchangers, generator
section, WCT, and cooling water pump (CWP), as shown
in Fig. 1. In modern arena, SCADA requires to pursue the
following tasks for efficient, safe, and reliable operation of
HCS.
1) The differential pressure signal is preferred for
measuring the pressure of a closed chamber, such as HCS,
and is measured by ΔP = ρgh, ∵ ΔP = P2 − P1. The flow
rate of the coolant is measured by Q = a ∗ ν.
2) The amount of gas flow is always different for a
particular event through the control valves. Malfunction at
this stage causes faults in process control, and it could be
identified through HMI. The amount of hydrogen flow is
governed by f = Cϑf(x)?(ΔPv/Gf ).
3) Pressurized hydrogen gas falls into the category of a
compressible flow system. Thus, behaviour of the
hydrogen gas is quite different from that of the liquid
because of its low density, and it also varies with pressure.
The density of hydrogen gas is estimated by
ρ = MP/zRT, ∵ R = 8314 m3 · Pa/kmol · K.
4) Water is used as a coolant to cool down hot and
pressurized hydrogen flowing around the generator section
to suck up heat dissipated by the active components. It is
governed by the mass balance equation ωin = ρ1s1υ1 = ωout
= ρ2s2υ2.
5) Furthermore, the amount of heat transfer is measured by
the energy balance equation q = ωcCpc(Tc2 − Tc1) =
ωhCph(Th2 − Th1).
6) The net positive suction head (NPSH) of the CWP and
water extraction pump is governed by NPSH = {(P1 −Pv/ρ)
+ (υ2 /2gc)}.
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2.2 Configuration of SCADA
Here, PLC-based digital controllers are considered to
execute control operations. These digital controllers sense
data either as status information (binary pulses) or analog
variables through respective RTUs. These data are sensed
via pneumatic to-current (P/I) converters based on
standard 4–20-mA/24-V dc signals before feeding them
into respective RTUs for pre-processing. Furthermore,
each input–output signal is assigned a unique card and slot
number to identify its job by HMI. It is recognized as “The
Instrument Lists”. It is a must for online control,
monitoring, and prediction of the system. Descriptions of
some of the tags which are governed by HMI of the
proposed HCS are summarized in Table I. In order to
increase availability, in some manner, the maintainability
or repair time must be reduced. Out of several key
approaches as a part of design activity, one of the
important aspects is fault identification using the SCADA
system. It could be manual, automatic, and self-diagnostic.
For better security and reliability of the process model in
the proposed system, bumbles restart facility is provided.
It helps to auto switch the process from manual to auto
mode and vice versa without any delay. In this way, all
three modes of diagnosis are implemented by the SCADA
system through HMI. Consequently, “The Instrument
Lists” play a major role for the configuration of SCADA.
The scope of this paper is to simulate the process model
which is designed with enhanced system reliability as
compared to the existing systems. To accomplish this, it is
proposed to supervise the control objectives using the
SCADA system. The model inputs, outputs, and control
objectives are shown in Fig. 2.
3. SYSTEM RELIABILITY OF HCS
In this paper, the Weibull distribution is preferred over
other techniques, as it is the only distribution function
which can define all three stages of a product’s life (failure
region): infant mortality/detrimental failure region, steady-
state/constant failure region, and wear-out
period/incremental failure region. More details about
distribution techniques are available in [24]. All existing
and proposed methods are simplified using network
reduction techniques. Here, standby redundancy is
considered of type one out of two for the modeling and
evaluation of system reliability [25].
3.1 Proposed Method S3RS-HCS
The proposed method is a type of standby system where
active redundancy has been considered. However, it
requires smart and proven choice for selecting the number
of components as a redundant module. In this proposal,
matrices of hydrogen storage and processing tanks are
judiciously selected so that they contribute to improve
reliability and are cost-effective models. In both the
proposed models (A) (Section III-D1) and (B) (Section III-
D2), the number of standby component is chosen as k = 1.
It has twofold benefits: enhanced system reliability and
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cost effectiveness. Thus, improvement in system reliability of on/off valves, are executed through HMI, whereas
of the proposed method as compared to that of existing analog signals, in the case of control It represents
systems is one of the essences of this paper. The reliability improvement in system reliability of the proposed system
model of the proposed method for evaluating the overall (B) versus existing systems (R2/R3_1/R3_2).
system reliability of HCS is shown in Fig. 3.
1) Proposed Method (A)-S3RS Model: The system
reliability of the proposed method (A) is governed by
equation (3) while (1) and (2) are the intermediate steps of
the method RX =1 − {(1 − RTA) ∗ (1 − RSIVL)}=RTA_RSIVL
∵ RY =RHE1A_RHE1B, RZ =RHE2A_HE2B (1)
RS =RTB ∗ RZ =RT, Rα=RS_RT
Rβ =RHE3A_RHE3B, Rγ =RHE4A_RHE4B (2)
Fig.2 (a) represents Test I. Similarly, (b) and (c) represent
A−S3RS(t)=RX ∗ Rα ∗ Rβ ∗ Rγ} (3) Tests II and III, respectively. Proposed method (B) is
represented by RB, R2 represents system by Hargrove et
2) Proposed Method (B)-S3RS Model: Unlike all fore
al. [21], and R3_1 and R3_2 represent two different cases
mentioned systems, the proposed method (B) consists of a
of system by Blatter et al
newly proposed matrix of storage tanks {2 × 8} as
compared with an {8 × 6} matrix in typical systems. This valves, are executed by RTUs. Typically, these digital
matrix is recognized as a reservoir of the system. The outputs (DOs) are represented by status information
system reliability of the proposed method (B) is evaluated (binary pulses) while analog outputs (AOs) are represented
using equation (7). The intermediate steps are expressed by control signals (analogous values), as mentioned in
by equation (4)–(6) Table I and Fig. . In this section, filling and feeding events
of respective units are considered for simulating HCS.
RX_ =1 − {(1 − RTA) ∗ (1 − RSI)}=RTA_RSI
∵ RY =RHE1A_RHE1B, RY =RZ (4)
RS =RY ∗ RTB, RT =RZ ∗ RTC, Rα=RS_RT } (5)
RHE1A=RHE1B=RHE2A=RHE2B=RHE3A=RHE3B
=RHE4A=RHE4B,Rβ =RHE3A_RHE3B=Rγ (6)
B−S3RS(t)=RX_ ∗ Rα ∗ Rβ ∗ Rγ =_B} . (7)
The overall system reliability of _1(t), _2(t), _3−1(t),
_3−2(t), _A−S3RS(t), _B−S3RS(t)/_B, and _sT(t) is provided in
Table
4. IN THE APPENDIX FOR FURTHER
REFERENCE.
3) Algorithm and Control Strategy of S3RS-HCS: The
control strategy of the proposed method (B) or RB is
grouped into four events. These are as follows: “filling,” Fig. 3 P/I or SLD of the proposed processing unit of
“pressurization,” “feeding,” and “depressurization.” The S3RS-HCS
filling event of both cold converters is represented by
Fill_T83B and Fill_T83C, and similarly, the pressurization
event is represented by Pres_T83B and Pres_T83C.
Furthermore, the feeding event is represented by
Feed_T83B and Feed_T83C, and finally, the
depressurization event is represented by DePres_T83B and
DePres_T83C. Now, each event is divided into four
decision steps as shown in Fig. 4. To execute these
decision steps, both analog and digital (binary pulses)
signals are generated by the control centre (CC). This
ensures continuous feed of hydrogen through the two cold
converters (T-83C and T-83B) with one in active mode
and the other in standby mode. Digital signals, in the case

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 International Journal of Electrical, Electronics and Telecommunication Engineering
Fig. 4 SLD of the main display of proposed HCS for large
generators.
Fig. 5 Trend: The graphical display of C&I for the
continuous monitoring of online fault diagnosis.
Table 1COMPARISONS AMONG EXISTING AND
PROPOSED HCS MODELS
A. Process Simulation of Proposed Method (B)
This part of work is implemented by using a real-time
featured SCADA system. It satisfies the specifications
guided by IEC 61131-3 and IEEE C37.1-2007,
respectively. Thus, the proposed system is capable of
online fault diagnosis and continuous monitoring of
process mechanisms for HCS. Fig. 3 shows the P/I
diagram or single-line diagram (SLD) of the dynamic
mimic board at HMI. It represents the proposed processing
units of HCS, where simulation of both the cold converters
T-83B and T-83C is executed. T-83B has been kept in
redundant mode while T-83C is considered in active
mode, as shown in Fig. . Pressure indicator PI83B of tank
T-83B is high during the filling event (PV83B-1 is
controlled) while the level indicator LI83C of tank T-83C
is kept down (forced to 0%) during feeding mode. Table1
shows the front line display of S3RS-HCS which is
dedicated for C&I of the generating section at HMI. The
online fault diagnosis display is shown in Fig.5. The
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information available in Table 1 can also be collected from
the graphical pattern display called “Trend” shown in
Fig.5. It provides historical and current data to identify
faults at plant level. It also provides data for
troubleshooting, if some malfunction occurs. In this way,
fault diagnosis and trend monitoring could be executed
simultaneously. These data are provided to HMI by
interconnecting field sensors, RTUs, and controllers using
a balanced communication link such as Control Net.
5. CONCLUSION
In the case of automatic fault identification, the failed unit
is generally removed from the rest of the system and
facilitated to connect with a computerized test station.
However, in the case of self-diagnostic processes, the
failed component of the system switches over to the
diagnostic model, and the malfunctioning component gets
internally isolated. The proposed S3RS-HCS has been
equipped with both features. The model of the monitoring
system has been implemented using RS View SE for
online fault diagnosis, including process control and
monitoring of the system. At the same time, the proposed
method (B) has performed the best in terms of system
reliability. This SCADA based HCS is not only intelligent
to process the hydrogen gas and its uninterrupted supply to
generators but also capable of taking corrective measures
in case some fault occurs during the course of the cooling
process. Thus, it is referred to as performance supervision
of HCS
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AUTHOR PROFILE

Nowh Rajab Nowh Saad belongs to

Sebha Received his Bachelor of
Engineering degree From the Institution
of Engineer (Libya) in 2007, he obtained
his M.Tech. in (control &
instrumentation) Electrical Engg from
SHIATS allahabad [UP] india in 2012.

Surya Prakash belongs to Allahabad-

India, Received his Bachelor of
Engineering degree from The Institution
of Engineers (India) in 2003, He
obtained his M.Tech. in Electrical
Engg.(Power System) from KNIT,

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