Manufacturing of an insulator through embedded scada using power line carrier communication

1

MANUFACTURING OF AN INSULATOR THROUGH EMBEDDED SCADA USING POWER LINE CARRIER COMMUNICATION

RAHUL S. KALRA ELECTRONICS & COMMUNICATION,

VADODARA INSTITUTE OF ENGINEERING, KOTAMBI VILLAGE,

VADODARA-HALOL TOLL ROAD, GUJARAT, INDIA.

[email protected]

“Sometimes hidden wires in the infrastructure

can be used to bridge the gap between two

nodes.”

Abstract-

Different communication technologies are

being used for information transmission.

Ample amount of information revolves

through entire globe every day, creating an

essential need for a transmission medium that

is not only fast but also reasonable. One such

technology is Power Line Carrier

Communication. Industries comprise several

units/plants. An engineer would take hours to

move across different plants. To ease the

communication between two plants, this paper

comes up with an idea of sending information

over Power Line Network. As industry consist

same power line moving across various plants,

Engineer can access functioning of plant1

when he is actually in plant2 by using Power

line networking. This way the paper reveals

fact of communicating between two distant

entities by using an existing electrical network,

offering a "no new wires” solution. The paper

uses pre-existing patent filed which is with

respect to invention of Computers. This paper

also uses the most famous GUI to monitor

status of the plant comfortably from control

room itself, thus, giving born to a Custom

Scada to which the paper title refers to

Embedded Scada. This paper urges to merge

data communication over DC and AC lines to

efficiently manage the Manufacturing Plant of

an Insulator.

Keywords- Power Line Networking, Communication, SCADA, Programming. CITATIONS

Research paper on communicating

through power lines

A Power Line Communication Tutorial -

Challenges and Technologies, Phil

Sutherlin and

Walter Downey

Power line communication, John Wiley

and Sons

Dhiraj S. Bhojane, Saurabh R.

Chaudhari, Eshant G. Rajgure, Prakash

D. More / International

Journal of Engineering Research and

Applications (IJERA)

http://www.datasheetcatalog.com //

LM1893, LM2893 Carrier Current

Transceiver

http://www.agilent.com/semiconductors

http://freecircuitdiagram.com/2008/11/1

6/power-line-modem-circuit-for-home-

automationapplication/

http://www.xtentechnology.com

http://www.avagotech.com

http://www.TexasInstruments.com

http://www.ebook.com

http://www.robokits.com

http://www.sunromtechnologies.com

http://www.freescalesemiconductor.com,

Motorola.com/Semiconductor

DRM035/D

http://www.slideshare.com

http://www.wikipedia.com

http://www.microsoft.com

http://youtube.com

2

INTRODUCTION-

This research paper talks about controlling the

manufacturing plant using embedded

technologies. Until now embedded applications

were meant to perform real time task and were

not bothered about its security and monitoring.

The paper gives keen emphasis on monitoring the

manufacturing of an Insulator by controlling its

various machine parameters and thereby gives

the world a broader perspective to make an

Industrial stand in the Electronics & Electrical

Market.

An Engineer will be able to manufacture and

control the Insulator sitting at one corner in the

Control Room from where he will able to control

the entire process on-going on the Field.

Research Paper derives the concept of Power

Line Communication from an Electrical

background with which it urges to transmit

certain information over power line from Plant1

and receive it at the Plant2, thereby initiate the

manufacturing process at Plant2. In this way

paper will eliminate wires moving all around on

the field and send the data at negligible speed

which will lead to a reliable data transmission.

Hence Paper mainly focuses on two modes of

communication viz. Wired Communication (USB

to Serial Cable) which is in respect to Embedded

Scada Concept and Power Line communication

in-order to notify the kind of event taking place

to the USER no matter whether the operator is in

the vicinity, a few steps away or at a distance.

In this way the paper concatenates data

communication over DC lines and AC lines to

efficiently manage the manufacturing plant of an

Insulator. From Transmitter Side, Data travels

over DC power line and is then followed by AC

power line leading to the concept of Modulation.

Exact opposite to it occurs at receiver side giving

rise to Demodulation.

AIMS-

1. To control the Manufacturing of an

Insulator by implementing Custom

Scada.

2. To communicate two plants of an

Industry situated in different corners by

using existing Power Line Network.

OBJECTIVES-

1. To provide Visual representation of

the Manufacturing plant for the ease

of the user.

2. Data Communication over the

cheapest channel (i.e. over Power

Line)

REASONS FOR SELECTING THE SUBJECT-

One can undoubtedly go for implementing

external wired network but it will limit one’s

freedom of movement by wandering all around in

the workspace which would in turn make one feel

restricted and annoyed. Untidiness is an

additional disadvantage of implementing an

External Wired Network. “Wires… Urghh…”

One can even think of implementing a wireless

network as they can penetrate through walls but

are again limited to ranges; moreover their

implementations is not that easy and are costly as

well.

So, apart from the above stated ideas, idea that

can overcome the mentioned facts is of “Hidden

Wires.” Yes, the wires hidden into the

Infrastructure, the Power Line Cables.

Then the question arises: Is Data communication

possible over Power Line?

Yes, it is!

These Hidden wires are so much capable of

carrying data over power signals. Power Line

reaches there where RF fails to reach. Power

Lines are though not seen by naked eyes, their

contribution in the field of data communication

cannot be left unseen.

3

LITERATURE SURVEY

INSULATOR-

An electrical insulator is material whose electric

charges do not flow freely and which therefore

does not conduct an electric current under the

influence of electric field. Insulators are used to

isolate two live lines such that they do not come

into contact. Live lines are suspended from

insulator and supported by the towers or poles.

Span between the two poles or tower is

dependent on allowable sag in the line. Sag

between the towers should be such that it does

not touch the ground. Touching of which will

cause severe accidents. Sag should be such that it

is less than 10% of the total span. In all,

Insulators are substances which resist the flow of

electric current.

TYPES OF INSULATORS-

1) Pin insulators.

2) Solid post insulators.

3) Suspension insulators.

4) Hollow insulators.

5) Long rod single piece porcelain insulators.

One must be wondering how manufacturing of an

Insulator takes place, what all machines are

involved and of course how many processes are

included in it. The below figure discloses all

those facts.

Raw materials:

China Clay, Feldspar, Quartz, Alumina,

Toughened glass, Glazed porcelain

Mixer (Ball mill): Used for preparation of slurry

Conveyor:

Used to guide output from the mixer to the filter

press

Filter press:

Used to form cake by applying pressure of 250-

300 kg/cm²

Extruder (Pug mill):

Used for blank formation (Pug)

Dryer: Used to reduce moisture of the formed pug up to

0.1 % to 0.4 % where maximum temperature is

140° C for 400 hrs.

Storage Sector: It is used to store dried pugs. It is also known as

Pug Godown.

Turning Machine: A Numerically controlled machine used to cut

the pug as per the design parameters which take

reference of the values stored in its X, Y and Z

co-ordinates. Pug is now in the shape of an

Insulator.

Heater:

Minimum temperature is 50° C and Maximum

temperature is 1235 ° C. Heating continues for

several hrs.

Glazing: Insulator is dipped into the glaze. Gravels sprays

on top and bottom outer diameter.

Firing: Insulators are fired after glazing. High speed

diesel or Propane gas is used for firing. Process

continues for 24 hours where shrinkage is around

- 11 to 14 %.

Fig.1: Process of manufacturing insulators.

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POWER LINE CARRIER COMMUNICATION-

PLCC is a method of transmitting information

using power network spread over several miles of

geographical area. PLCC is a communication

technique that follows point to point protocol.

Signals that can travel over this hidden channel

are speech signals (300- 2000Hz) & data signals

(200 – 3000Hz). PLCC basically works on the

principle of superimposing an information signal

onto the carrier signal which is power signal in

this case.

For superimposing information over the carrier, it

is important to take below mentioned

considerations.

1) PLCC station (power line node)

2) Line matching unit (LMU) / CV

3) Wave trap (WT) / line trap (LT)

4) Coupling devices (cc)

Let us now design a basic network using these

considerations as real electrical devices.

Fig. 2: Basic Network Diagram.

PLCC equipment is solely responsible for

transmitting or receiving information. But this

transmission or reception is not that easy, it

involves modulation and demodulation

techniques installed for data encryption and

decryption which may refer to amplitude

modulation, frequency modulation, orthogonal

frequency division multiplexing or any other

modulation schemes. Now there comes time to

turn the table round, when it comes to

superimposing an information signal on power

lines actually.

There are different ways by which one can

connect a PLC unit with power lines or

superimpose information onto the carrier signal –

i.e. through Capacitive Coupling or by Inductive

Coupling.

In capacitive coupling, a capacitor is used to

superimpose the modulated signal on to networks

voltage waveform. Another way is inductive

coupling which employs an inductor to couple

the signal with networks waveform. No physical

connection is required to establish inductive

coupling. This makes it safer as compared to

capacitive coupling. However this method has

higher tendency to lose the signal during

coupling and therefore is not used. So we have

capacitive coupling giving a reliable result.

If we categorize capacitive coupling we have,

1) Phase to Ground Coupling

2) Phase to Phase Coupling

3) Interline/ Inter circuit Coupling

1) Phase to Ground Coupling:

Fig.3: Phase to ground coupling

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2) Phase to Phase Coupling:

Fig. 4: Phase to Phase coupling

3) Inter circuit coupling:

Fig.5: Inter Circuit Coupling

SIGNIFICANCE OF EACH DEVICE:

Wave trap:

- Wave traps are used between the

transmission line and the power stations

to avoid carrier power dislocation in the

power plant and cross talk with other

power line carrier circuits connected to

the same power station.

- It consists of number of choke coils

connected in series. It prevents carrier

current from entering the power

equipment. It offers negligible

impedance to power frequency & high

impedance to carrier frequency.

Fig.6: Wave Trap

Coupling Devices – Coupling Capacitor:

- Used for line impedance matching.

- Used as high voltage, high stability mica

capacitors with low losses

- For lower voltage class of tuning units

with impulse test voltage rating up to 40

KV, polystyrene capacitors are used.

- For higher voltage class of tuning units

with impulse test voltage rating up to 150

KV, capacitors with mineral oil

impregnated paper dielectric are used.

Line Matching Unit: - The output of PLCC is connected to the

matching unit before to the power lines

to achieve the proper impedance

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matching in between PLCC equipment

and the power line.

Fig. 7: Line Matching Unit

CVT

- It is Control Voltage transformer/

Coupling capacitor.

- This is used for blocking the high voltage

entering to the PLCC Equipment

Fig.8: Control Voltage Transformer

SOME SUBSIDIARY DEVICES WHICH WHOSE

SIGNIFICANCE CANNOT BE IGNORED

Earth Switch

- Earth Switch is used at the time of

maintenance of Line Matching Unit.

Lightening Arrestor

- Used to protect the system from the

damaging effect of lightening

- It works as an insulator between light

and the power line

Fig.9: Lightning Arrestor

Coaxial Cable

- This is used for inter connection between

PLCC & L.M.U for carrying the high

frequency signal.

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Fig. 10: Coupling Arrangement of PLCC installation

PLCC INSTALLATION:

Now as we are familiar with carrier signal and

power signal we can say that carrier signal will

have some carrier frequency current and power

signal will have some power frequency current.

As per the coupling arrangement shown, carrier

current are prevented to enter station bus by the

wave trap and power frequency current is

blocked by coupling capacitor to enter PLC

equipment. This leads to collision free data

communication over the cheapest channel which

is undoubtedly the Power Line channel.

SUMMARY

PLC is like any other communication technology

whereby a sender modulates the data to be sent,

injects it onto medium, and the receiver de-

modulates the data to read it. The major

difference is that PLC does not need extra

cabling, it re-uses existing wiring. Considering

the pervasiveness of power lines, this means with

PLC, virtually all line- powered devices can be

controlled or monitored (explained below). The

communication device used for the

communication over the power lines is a

MODEM, commonly known as Power Line

MODEM (PLM) or Power Line

equipment/unit/panel. It works as both

transmitter and receiver, i.e., it transmits and

receives data over the power lines. A power line

modem not only modulates the data to transmit it

over the power lines and but also demodulates

the data it receives from the power lines. By

using modulation techniques, binary data stream

is keyed on to a carrier signal and then coupled

on to the power lines by PLM. Coupling is

defined earlier. At the receiver end another PLM

detects the signal and extracts the corresponding

bit stream.

Explanation can be made clearer by the following

block diagram (fig.11):

The block diagram (fig.11) shows the working of

entire PLCC system. Data is processed before

transmission on power lines. First data is

modulated & filtered and then by using couplers,

it is sent over the power lines.

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Fig.11: Block Diagram of PLCC Installation

Power-line communication is based on electrical

signals, carrying information, propagating over

the power-line. A communication channel is

defined as the physical path between two

communication nodes on which the

communication signal is propagated. The quality

is estimated from how good the communication

is on a channel. The quality is mostly a parameter

of the noise level at the receiver and the

attenuation of the electrical signal at different

frequencies. The higher the noise level the harder

it is to detect the received signal. If the signal

gets attenuated on its way to the receiver it could

also make the decision harder because the signal

gets more hidden by the noise.

A Power Line Modem/Unit would consist of an

opto-coupler which would play a major role in

isolating DC signals and AC signals. It would

also contain a RC filter, Coupler as a transformer

module, an amplifier and a well programmed

power line IC dedicated to transfer information

from one point to another through supplementary

devices.

One would observe characteristics of power line

communication as progresses with reading.

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EMBEDDED 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. These processes

include industrial, infrastructure, and facility-

based processes. Industrial processes include

those of manufacturing, production, power

generation, fabrication, and refining, and may run

in continuous, batch, repetitive, or discrete

modes.

Common System Components:

A SCADA system usually consists of the

following subsystems:

o A human–machine interface or HMI is

the apparatus or device which presents

processed data to a human operator, and

through this, the human operator

monitors and controls the process.

o SCADA is used as a safety tool as in

lock-out tag-out

o A supervisory (computer) system,

gathering (acquiring) data on the process

and sending commands (control) to the

process.

o Remote terminal units (RTUs)

connecting to sensors in the process,

converting sensor signals to digital data

and sending digital data to the

supervisory system.

o Scada is a Communication infrastructure

connecting the supervisory system to the

remote terminal units in simple terms.

Fig.12: Details of Embedded SCADA

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SYSTEM CONCEPTS

- The term SCADA usually refers to

centralized systems which monitor and

control entire sites, or complexes of

systems spread out over large areas

(anything from an industrial plant to a

nation).

- Data acquisition begins at the

Controlling level and includes meter

readings and providing status reports that

are communicated to Host Computer

where SCADA is installed as required.

Data is then compiled and formatted in

such a way that a control room operator

using the HUMAN MACHINE

INTERFACE can make supervisory

decisions. Data may also be fed to a

Historian, often built on a commodity

Database Management System, to allow

trending and other analytical auditing.

HUMAN-MACHINE INTERFACE

A human–machine interface or HMI is the

apparatus which presents process data to a human

operator, and through which the human operator

controls the process.

HMI is usually linked to the SCADA system's

databases and software programs, to provide

trending, diagnostic data, and management

information such as scheduled maintenance

procedures, logistic information, detailed

schematics for a particular sensor or machine,

and expert-system troubleshooting guides.

The HMI system usually presents the information

to the operating personnel graphically, in the

form of a mimic diagram. This means that the

operator can see a schematic representation of the

plant being controlled. For example, a picture of

a pump connected to a pipe can show the

operator that the pump is running and how much

fluid it is pumping through the pipe at the

moment. The operator can then switch the pump

off. The HMI software will show the flow rate of

the fluid in the pipe decrease in real time. Mimic

diagrams may consist of line graphics and

schematic symbols to represent process elements,

or may consist of digital photographs of the

process equipment overlain with animated

symbols.

The HMI package for the SCADA system

typically includes a drawing program that the

operators or system maintenance personnel use to

change the way these points are represented in

the interface. These representations can be as

simple as an on-screen traffic light, which

represents the state of an actual traffic light in the

field, or as complex as a multi-projector display

representing the position of all of the elevators in

a skyscraper or all of the trains on a railway.

METHODOLOGY:

Block diagram:

As depicted in figure 13, the block diagram

comprises of:

1) Transmitting and Receiving Controllers

2) GUI (Computer)

3) LCD

4) Outputs and Inputs

5) PLCC Transmitter

6) PLCC Receiver

7) Power Supply

Fig.13: Methodology: Block Diagram

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Power Supply:

The power supply module provides 5V supply to

drive the two microcontrollers with the help of

5V regulator IC.

Inputs:

This block gives logic “0” to the microcontroller

to which the microcontroller responds and

performs a dedicated task. It is because

microcontroller does not understand logic ‟1‟

signal since the ports are pulled up.

Outputs:

This block comprises of 230V Lamps connected

through some drivers to indicate the functioning

of the Machines as programmed in the

microcontroller. Please note – These outputs

devices consume low power.

LCD:

This block displays the Current happenings and

the previous status of the Manufacturing plant of

an Insulator.

Transmitting Controller:

It transmits a byte of information with reference

to the given input, to the PLCC transmitter where

transmitted byte is modulated over a carrier

signal

PLCC Transmitter:

This block accepts byte of information from the

Transmitting Controller or from the GUI Scada

system and transmits it on to the power bus

thereby modulating information signal on the

carrier (power) signal.

PLCC Receiver:

This block receipts a byte of information that is

transmitted from the PLCC transmitter, decodes

it and apply error checking phenomenon, thereby

inputs it to the Receiving Controller.

Receiving Controller:

It receives a byte of information from PLCC

receiver and performs the operation as per the

received stream of bits.

SCADA (GUI):

This block is so designed to easily communicate

with the user using c# coding language.

Graphical user Interface is simply a programmed

screen to which when clicked performs some task

as guided in its backend window. This way the

screen creates an illusion of the real event that is

taking place on the field. Hence we can say this

SCADA technique creates a Virtual On-Field

environment in the control room.

FLOWCHART:

Main tools used

- Power line communication modem

- USB to serial cable

Fig. 14: Flow chart of methodology.

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SOFTWARES:

Intense study of below mentioned software will

lead an upcoming Engineer to run a successful

application like this.

Following software were used to design &

program the model, they are as follows:

- PROTEUS

- HMI-DOP SOFT

- EAGLE

- MICRO-C FOR AVR

- VIRTUAL SERIAL PORT DRIVER

SOFTWARE

- VISUAL STUDIO

Proteus:

Single application with many service modules

offering different functionality like schematic

capture, PCB layout, etc. makes it so popular

amongst all. Proteus is a wrapper that enables all

of the various other tools to communicate with

each other as it has got virtual terminal built in. It

has got different frameworks ISIS and ARES

sharing the same data base. Moreover 3D feature

makes its use more frequent and easy.

Eagle:

Eagle is a widely used design tool for PCB

designing and manufacturing.

It allows us to draw schematic with the help of its

inbuilt wide library. Moreover the circuit

designer can also make new packages according

to his product configurations easily. The

Software automatically defines the routes as

drawn in the Schematic which is nicely depicted

by the Auto-routing tool in the Board Window.

This feature saves lots of time of the Circuit

Designer. Eagle software allows us to make till

16 layers of PCB which would make the design

more compact and efficient.

Mikro c:

It is easy to create embedded programs on AVR

series through this software. It allows project

management, source code editing, debugging and

complete simulation in one powerful

environment. It is more user friendly then C-

Programming. The Mikro-C PRO for AVR is a

powerful, feature-rich development tool for AVR

microcontrollers. It is designed to provide the

programmer with the easiest possible solution to

develop application program for embedded

systems, without compromising performance or

control. It allows quickly develop and deploy

complex applications.

Visual studio:

Microsoft Visual Studio is an integrated

development environment (IDE) from Microsoft.

It is used to develop computer programs for

Microsoft Windows superfamily of operating

systems. It can produce both native code and

managed code. Visual Studio includes a code

editor supporting IntelliSense as well as code

refactoring. The integrated debugger works both

as a source-level debugger and a machine-level

debugger. Other built-in tools include a forms

designer for building GUI applications, web

designer, class designer, and database schema

designer. It accepts plug-ins that enhances the

functionality at almost every level. The term

Visual denotes a brand-name relationship with

other Microsoft programming languages such as

Visual Basic, Visual FoxPro, Visual C#, Visual

J# and Visual C++. All of these features are

packaged with a graphical IDE and support rapid

application development of Windows-based

applications.

HMI-DOP Soft:

HMI (Human Machine Interface) is a medium for

information exchange and mutual communication

between electromechanical system's and the user.

This software offer's fast and convenient drawing

for controlling of manufacturing automation

processes. DOP series Human Machine Interface

also offers fast and convenient control functions

for industrial automation machines. By using this

software, the user can quickly edit images and

graphs and set suitable environment in the form

of a mimic by using its various features.

Virtual serial port driver:

Virtual Serial Port Driver creates virtual serial

ports and connects them in pairs. Applications on

both ends of the pair will be able to exchange

data in such a way, that everything written to the

first port will appear in the second one and

backwards. All virtual serial ports work and

behave exactly like real ones, emulating all their

settings. You can create as many virtual port

pairs as you want, so there will be no serial ports

shortage and no additional hardware crowding

your desk.

TESTING

In order to carry out the entire manufacturing of

an Insulator through Embedded Scada using

Power Line Carrier Communication, paper

develops an idea of creating a SCADA design

13

using Visual Studio using C# coding language. In

this way the paper develops virtual on-field

environment in the Control Room. The

developed Scada design is as shown in the figure.

Fig.15: Scada Design using Visual Studio and C#: Login Page

Fig. 16: Scada Design using Visual Studio and C#:Virtual depiction of on field machines.

14

The custom Scada referring to Embedded Scada

welcomes the user with a Login page. This way,

only the authorized user will be able to control

the manufacturing of an Insulator. Thus, it makes

the usage of resources confidential.

Once the user name and password are accepted,

the user is allowed to monitor and control the

field.

Now the user can click anywhere on the form

design to individually control the functioning

of Manufacturing Plant. Scada design is followed

by the cable running into the power line circuitry

including microprocessors and their efficient

logics built in. On every appropriate mouse click

event, SCADA environment transmits some

information through the cable which is connected

to the power line unit. That information so

transmitted moves over the power line and

travels until it detects any power line receiver.

There demodulation of the information takes

place and deciphered data is fed to the

application circuitry which involves output

interfacing with the microcontrollers. If the data

received is same as the destination address then

state of machine would change from idle to

active or vice-versa depending upon previous

state.

Whatever information is sent from the Scada

design is modulated over the power line and

received at the power line receiver modem where

it is demodulated and the data is fed to the

microcontroller based application program as

shown in the figure. Virtual terminal shows the

data received by the receiver modem. Based on

the information received the state of the lamps is

changed. Note: Entire application is based on

Serial Communication.

In order to create virtual environment the paper

uses virtual serial terminal driver to communicate

between the software (Visual Studio & Proteus).

The paper thus reveals all the facts of power line

communication and its one of the Scada based

application which is very cheap and reliable.

Industries need not to pay any service tax or

service amount for this as it has to pay for

installing any wireless network.

On-field machines are depicted in the form of

lamps creating a virtual environment in some

software as shown in the figure 17.

Fig 17: Virtual environment of machine in Proteus software.

15

OBSERVATIONS

1. It is possible to modulate information

signal on to the power signal. Simulation

of the same is depicted in the figure 18.

The diagram shows the data

communication over AC Mains through

two virtual ports, one acting as a

Transmitter and other as a Receiver.

2. Superimposing information signal in

figure 19, it is continuous square wave

onto the carrier signal which is a

continuous sinusoidal wave.

3. This observation (Fig. 20) is based on

effect of noise (Impulse noise + tonal

noise + high frequency noise) seen on the

power line due to variations in plugging

and unplugging devices having different

wattages. This is because electrical

devices which are connected to the

power mains inject significant noise back

to the network due to presence of

inductors. The characteristic of the noise

of such devices varies widely.

4. Examining the waveform with keen

sense will let you know the difference

between the two. This observation is just

a replica of observation 3 with a clear

view of characteristic noise acting on the

medium due to uneven loads. (Fig. 21)

5. Fig 22 shows variations in the AC

Voltage waveform due to loads acting on

it. The below picture give the closer view

as seen from the oscilloscope. One can

think that how difficult it would be to

modulate the information signal on this

type of noisy environment. One has to

take into consideration various

parameters like impedance matching,

filtration, attenuation, spread spectrums,

couplers and so many other factors as

well. The speed of information signal

that has to travel from one node to

another depends solely on how harsh is

the environment through which it has to

pass through. Moreover it is also

observed that as the number of sockets

increases i.e. number of devices on the

network increases, attenuation (dB) also

increases. Therefore proper amplification

of the signal is necessary. (Fig 22)

EXPECTED INDUSTRIAL CHANGES

Industrial Manufacturing would become

more fluent.

Engineers can devote their time in

researching other important parameters

of Industry that are lacking behind.

Manufacturing Plant is more secured

through continuous monitoring from

control room.

If industry adopts for any other wireless

network it has to pay amount for the

same. Using existing cables capital of the

industry can be invested in other

progressive efforts.

KEY FACTOR

The carrier frequency range is allocated to

include the audio signal, data signals, protection

and the pilot frequency. Carrier frequency band

ranges from 125 KHz-140 KHz.

16

Fig. 18: Observation 1

Fig.19: Observation 2

Fig. 20: Observation 3

Fig. 21: Observation 4

Fig. 22: Observation 5

17

RESULTS

Results of the paper are as shown below.

A:

B:

Fig 23 (a & b): Practical Results.

18

ADVANTAGES

Making use of existing electrical cables

The data can be transfer at reliable rate

over many miles of electrical cable

Higher mechanical strength and

insulation level of high voltage power

lines result in increased reliability of

communication and lower attenuation

over long-distances

Power lines usually provide the shortest

route between the power stations.

Power lines have large cross-sectional

area resulting in very low resistance per

unit length

Largest spacing between conductors

reduces capacitance, which results in

smaller attenuation at high frequencies.

The large spacing also reduces the cross

talk to a considerable extent

Current status of the plant can be known

with the help of using Supervisory

Control and Data

Acquisition technique

Visual representation of the plant can be

characterized for the ease of the user.

Entire Plant can be controlled sitting at

one corner in the control room

Process Control

Used to manage a physical process

SCADA is used to make sure that

productivity targets are met and all

systems run smoothly.

The SCADA system in place on a

production line tracks how many units

have been produced and how many are in

various stages of completion.

Monitor and change the state of the

Industrial machines.

Error Detection and Security

LIMITATIONS

Persons using PLCC against high

voltages and currents on the lines have to

take care as it can cause frequent

accidents if handled lethargic.

Proper care should be taken to guard the

carrier equipment

Reflections are produced on lines

connected to high voltage lines. This

increases attenuation and creates

problem.

High voltage lines have transformer

connections which attenuate carrier

currents.

Sub-station equipment adversely affects

the carrier currents.

Noise introduced by power lines is very

large, proper filters can be overcome this.

This noise is generated by discharge

across insulators & various switching

processes.

Load imbalance is a frequent issue on

power line due to plugging and

unplugging the devices.

Environmental changes affect the

characteristics of power line.

It is obvious that an effective power lines

carrier system must overcome these

difficulties.

CONCLUSION

Thus the research paper concludes that if

two entities are sharing the same power

line no matter whether they are miles

apart can communicate with each other at

approximately at a negligible data rate

which can vary as per conditions.

The paper also concludes that

implementing a SCADA kind of

environment in the Industry saves ample

amount of time of an Engineer by

reducing frequent site visits. VOTE OF THANKS

I feel privileged to thank Prof. Ashok

Patel, for allowing me to work under his

expert supervision, for his help

throughout graduate studies. I highly

appreciate his continuous motivation

which kept me focused towards my goal.

I also extend my sincere thanks to H.O.D

Isha Gautam and all faculty and staff of

the Electronics & Communication

Engineering (ECE) Department.

I am particularly thankful to my family

for their emotional, moral and undying

support.

Finally I would like to thank Google and

YouTube for being so resourceful to me.

Last but not the least I feel great

gratitude towards thanking god for

giving me that potential of researching

and completing my research paper

effectively.

I also thank all my well-wishers for

making me a part of their divine prayers!