Upgrade of the PLC-based production management and execution system of a power plant

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Supervisor:
Dr. Kiss Bálint
Department of Control Engineering and Information Technology

In one of the country's largest thermal power plant the production management and execution system has been updated in terms of hardware and software. I was part of this complex and time-consuming job on behalf of Gamma Digital Ltd.

The control system is based on Siemens hardware (PLC) and software (WinCC), and it can be divided into several levels. The system consists of a real-time data collecting system and the various networks providing the communication platforms between the subunits.

The control is executed by four Siemens S7 PLCs. In this thesis, the controlled processes will be presented in detail. The surveillance of the process is done by WinCC applications (server and clients) which are running on virtual machines. A Microsoft SQL database is part of the system where every data is stored. The several communication channels between the units will also be presented.

In the beginning of my thesis I briefly discuss why the PLC is the ideal choice for an industrial control system. The next part I present the hardware and software design guidelines of a Siemens-based system.

The execution system of the power plant is presented by highlighting the roles of the PLCs, after that the newly implemented functions will be demonstrated. In the main part I present the upgrade of the weighing and registration procedures in the new system.

In the end of the thesis I present the used methods of testing and commissioning, and finally I sum up the achieved results.

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