DESIGN OF THE GATE OPENING CONTROL SYSTEM

FOR SRINAGARIN HYDRO POWER PLANT

Mr.Natheephong Setheetheerayos
Electricity Generating Authority of Thailand
53 Moo 2 Charan Sanitwong Road, Bang Kruai, Nonthaburi 11130, Thailand, Natheephong.s@egat.co.th

ABSTRACT

Gate opening control system (GOC) of hydro power plant is very necessary for operation control in pumping
mode. It is responsible for calculation of the difference between upper and lower elevation reservoir to control
the opened position of wicket gate for the most efficient operation. Recently, Srinagarin hydro power plant has
confronted the problems in operation and maintenance. The main causes are system degeneration including
GOC and obsoleted spare parts due to discontinuous production, which affect the reliability and availability of
the power plant. Therefore, EGAT by Electrical Maintenance Division (EMD) has decided to develop the new
GOC in order to replace the deteriorated existing system. The new GOC has been already installed, tested and
operated for unit 4 and 5 of Srinagarin hydro power plant in February 2016 and April 2016 respectively. It can
replace the previous system and still has great performance so far. The detail of the new GOC is shown in this
paper.

KEYWORDS: Gate opening control system, GOC

1. INTRODUCTION

1.1 Background
Pumped-storage plant is a type of hydro power plant using electric power from main grid for load
balancing. The method is to store energy in the form of gravitational potential energy of water which is pumped
from a lower elevation reservoir to a higher elevation. Low-cost off-peak electric power is used to run the
pumps. During periods of high electrical demand, the stored water is released through turbines to produce
electric power as shown in Figure 1.

Figure 1 Pumped-storage plant

Therefore, all of pumped-storage plant have the Gate opening control system (GOC) in order to
control the wicket gate position of water turbine during the plant is operated in pumping mode. GOC is
responsible for calculation of the difference between upper and lower elevation reservoir to control the opened
position of wicket gate for the most efficient operation as shown in Figure 2.
 GOC

Upper Water Level

Optimum Wicket Gate
Lower Water Level Position Set Point
Calculator

Wicket Gate Position

Controller
Wicket Gate

GOC Command Output

Figure 2 Gate opening control system for pumped-storage plant

Unit No.4 and No.5 of Srinagarin hydro power plant are the pumped-storage plant with capacity of
205 MW per unit. They have been operated for more than 20 years. Now each GOC confronts the problems both
in operation and maintenance. It was found that the GOC was deteriorated and lacked of spare parts according to
the site survey. They affect the reliability and availability of the power plant. Besides, the performance of
Programming Tool, which used to inspect and update the control logic, is getting worse.
Therefore, EGAT by Electrical Maintenance Division (EMD) together with Srinagarin hydro power
plant has developed the GOC in order to replace the existing one, which has already been deteriorated. This
GOC is called “EGAT – Gate Opening Control System (EGAT-GOC)”.
All operation functions of EGAT-GOC have to be as same as the existing one so that they can
compatibly replace each other. Additionally, Human Machine Interface (HMI) has been added to this project for
users to control, inspect, edit program and analyze problems occurred in operation.

1.2 Objective
The gate opening control system of pumped-storage plant, named EGAT-GOC, can be designed and
developed by EGAT in order to replace the existing system, which has been deteriorated and lacked of spare
parts.

1.3 Scope of work

- Dismantle the existing system.
- Logic design, logic implementation, installation, test and system commissioning for unit 4 and 5 by
February 2016 and April 2016 respectively.

2. MAIN CONTENTS

2.1 Conceptual design

Two design concepts of this project are the EGAT-GOC shall provide the simple and easy operations
for operators, and it shall also be easily implemented, configured analyzed by users.
After studying current technology of the control system and designing as the concepts that mentioned
above, following items will be included in the project;
Human Machine Interface (HMI): it is used for monitoring and receiving command by users.
It makes operators got more information for operation. Computer and touch screen panel will
be installed at control room and local control cabinet respectively.
Programming Tool: it is used for editing the control logic and adjusting the control parameters
by users.
Programmable Logic Controller (PLC): it connects to the Input/Output interface terminals.
PLC was chosen because of inland spare part availability and friendly usage.
Ethernet Communication: it is used for connection between HMI and PLC with high speed
rate.
 The system configuration of EGAT-GOC is shown in Figure 3, including HMI, programming tool,
PLC and communication.

HMI#1 - Computer Programming Tool

Ethernet

HMI#2 – Touch Screen Panel

PLC

Figure 3 System configuration of EGAT-GOC

2.2 Project plan

The project of unit 4 started in July 2015 and finished in February 2016, duration 7 months.
Studying existing system (both 2 units) 0.5 month
Preparing TOR and equipment/tools (both 2 units) 4 months
Designation and engineering (both 2 units) 1 month
Existing system dismantling, EGAT-GOC installation (each unit) 1 month
Test and commissioning (each unit) 0.5 month
The project of unit 5 finished in April 2016 because it was installed and tested after unit 4 had finished.

2.3 Working process

2.3.1 Control logic implementation
There are three main parts for EGAT-GOC;
1. Water level feedback signal decoder: According to the signal which is sent from water level
sensor to controller unit is not standard analog signal such as 4-20 mA, 1-5 Vdc and 0-10 Vdc,
but it is binary code. So, the function of water level feedback signal decoder has to be created
in the controller. The binary code from sensor can be decoded and converted to the value of
actual water level in m.MSL (Meter – Mean Sea Level) by this function as shown in Figure 4.
EGAT-GOC
Water Level Feedback Signal
Upper Water Level Sensor Decoding Function

Float

Reservoir

Lower Water Level Sensor

Float

Tailrace

Figure 4 The function of water level feedback signal decoder

2. Optimum wicket gate set point generation: During pumped-storage plant is running, the
wicket gate has to open in optimum position for the most efficiency of the pump. Meanwhile,
the optimum position is varied according to the difference between higher and lower elevation
reservoir. Thus, the function of optimum wicket gate set point generation is necessary for the
EGAT-GOC. It is responsible for calculating the water level differential then generating the
optimum wicket gate set point for the wicket gate controller unit continuously. This makes the
plant operate with the most efficiency all the time. The function is shown as Figure 5.
Previous GOC EGAT-GOC

Optimum Wicket Optimum

Gate Position Wicket
Set Point Gate
Position
Set Point
Upper Water
Level Feedback

Upper Water
Level Feedback
Lower Water
Level Feedback
Lower Water
Level Feedback

(a) The comparison of optimum wicket gate set point generation

(b) Relation of wicket gate opening to net water level (by manufacturer)

Figure 5 The function of optimum wicket gate set point generation

3. Wicket gate position controller: It is used for controlling the wicket gate position according
to set point, which is sent from the “optimum wicket gate set point generation” function. The
actual wicket gate position is controlled to track the optimum set point by this function as
shown in Figure 6.
 Optimum Wicket Gate Position
Wicket Gate Raise Command
+ Pulse Width
Position Controller
Modulation Wicket Gate Position
Set Point - Lower Command

Actual Wicket Gate

Position Feedback

(a) Simplified block diagram of the wicket gate position controller

(b) The example of control logic

Figure 6 The wicket gate position controller

The simplified control block diagram of EGAT-GOC is shown as Figure 7.

EGAT-GOC

Upper Water Level

Water Level
Lower Water Level Feedback Signal
Decoder
Net Water Level

Optimum Wicket Gate

Position Set Point
Generation
Wicket Gate
W.G. Set Point
EGAT-GOC
Command Output Wicket Gate Position
Controller

Figure 7 The simplified control block diagram of EGAT-GOC

2.3.4 HMI graphic design

There is no graphic user interface in the existing system, so operators can control the plant in pumping
mode only by the switches that located in control room. Besides, analog values can be monitored only via meter.
For the new system, EGAT-GOC, HMI is included so that operators can operate and monitor the plant in
pumping mode via computer and touch screen panel, which are located in control room and local control cabinet
respectively. The graphic display is divided into three main parts;
 1. Pumping mode control and status: Operators can control and operate via this part, which
there are buttons and lamp indicator in the screen.
2. Analog value monitoring: The value of active power, upper water level, lower water level
and net water level are shown in the screen.
3. Optimum set point calculation: It is to show the calculated optimum wicket gate set point for
pumping mode at that time.
HMI graphic is shown in Figure 8.

2 3

Figure 8 HMI control graphic

2.3.5 EGAT-GOC installation

EGAT-GOC has been installed instead of the existing one as shown in Figure 9. HMI is located in
control room and local control cabinet for operation and monitoring. The PLC is installed in the local control
cabinet. Both parts are interfaced via Ethernet.

PLC HMI#1

HMI#2
Wicket Gate

Figure 9 EGAT – Gate Opening Control System (EGAT-GOC)

2.3.6 EGAT-GOC testing

After installation, EGAT-GOC had been tested in three steps as following;
1. Loop Test: The cables were checked for the good connections between PLC and field
instruments. Four types of signal to be checked consist of digital input, digital output, analog
input and analog output.
2. Dry Function Test: All control functions had been tested during the pumped-storage plant
being in shutdown condition.
3. Actual Test: All control functions had been tested to confirm the hardware and the control
function by commissioning team and operators.
3. RESULTS

After testing and commissioning, EGAT-GOC was then completely operated for pumping mode
operation and replaced the existing system at unit 4 and unit 5 of Srinagarin hydro power plant in February 2016
and April 2016 respectively. EGAT-GOC has been monitored every month to ensure that it can control the
wicket gate position in pumping mode with reliability and stability. The benefits of EGAT-GOC are shown
below:
1) The existing system can be completely replaced by the new system.
2) The new GOC control system is still stable and reliable.
3) EGAT can reduce the dependence of technology from OEM.
4) EGAT can save/reduce purchase cost at least 340,000 USD per unit.
5) Operators can easily and effectively monitor and control the unit via HMI.
6) Spare parts are available in the country.
7) EGAT-GOC can be applied for every other pumped-storage plant as well.
8) EGAT staff can develop and maintain the control system by themselves.

4. CONCLUSION

EGAT-GOC, designed and developed by EGAT, can be completely and fully replaced the deteriorated
existing system. It use Programmable Logic Controller (PLC) as the main processing unit. Computer and touch
screen panel are used as Human Machine Interface (HMI), which facilitate the plant operation for controlling
and monitoring the power plant. User can inspect and modify control function in PLC by programming tool. The
benefit of EGAT-GOC is the improvement cost is reduced more than 340,000 USD per unit. In the near future,
EGAT-GOC will be installed and implemented at unit 1 and 2 of Lamtakong hydro power plant with capacity of
250 MW per unit, which will lead EGAT to save the power plant improvement cost as well.
REFERENCES

[1] William P. Creager, Joel D. Justin, Hydroelectric Handbook, America, 1958

[2] J. Guthrie Brown, Hydro-Electric Engineering Practice, England, 1964

[3] Wikipedia. Pumped-Storage Hydroelectricity, July 2016

[4] Mitsubishi Heavy Industries. Operation and Maintenance Manual for Pump Turbine

[5] GE Intelligent Platforms. PACSystem* Rx3i System Manual, August 2011