2023Finished
ABB PLC troubleshooting
Troubleshooting and recovery of the electrical SCADA at PT Bio Farma in Bandung. The system runs on ABB AC500 PLCs and watches power distribution across the site's buildings, substations, power house and generators.
- Year
- 2023
- Location
- Bandung, Jawa Barat
- Status
- Finished
- Work types
- PLC
- Updated
Existing system
An electrical distribution automation and SCADA system supervises the power network of PT Bio Farma (Persero) in Bandung. Several ABB AC500 PLC masters (PM573 CPU, CM597 communication module) collect data from a large number of power meters and electrical equipment over industrial Ethernet, Modbus gateways and RS-485 networks. A central SCADA server and operator workstation show the result.
Scope of work
PLC troubleshooting. Status of the CPU and communication modules, links between the PLC masters and communication devices, Ethernet and serial communication, ports, cables and interfaces, and a direct engineering-laptop connection for diagnostics.
Communication diagnostics. The full chain from SCADA server through industrial Ethernet, PLC master and Modbus gateway to the power meters. Checks covered lost communication, invalid data, unreachable field equipment and mismatches between field devices and SCADA.
Power meter network. Modbus over RS-485 multidrop, with meters from several manufacturers on each master.
SCADA verification. Incoming utility, generators, MV switchgear, breakers, ATS, LVMDP, transformers and distribution panels, shown on mimic and single-line diagrams.
Electrical parameters. Voltage, current, active, reactive and apparent power, power factor, frequency and energy.
Switching status. ON, OFF, TRIP, LOCAL, REMOTE and MAINTENANCE indications.
Generator monitoring. Operating status, running hours, voltages, current, frequency, power, energy and maintenance information, including Woodward EasyGen 3000 controllers.
Maintenance page. Equipment that has reached, or is near, its service schedule.
Architecture review. Distributed PLC masters and network segments feeding one central SCADA, including managed switches, gateways and the Ethernet and Modbus topology.
Energy reporting. Power trends, peak active power, energy consumption and monthly energy reports.
Coverage
The monitoring spans the numbered buildings across the site, the power house, two substations, vaccine production areas, quality control and animal facilities, water treatment, the boiler house, utilities, packaging, the warehouse and administration. A single master links the meters of several production and QC areas, utilities and switchgear panels over one network.
A similar need?
Tell us about your facility.
Name the equipment you run and what has to change. We reply with the questions we would ask on site.