Overlaying DAQ Systems on Existing Control Systems for Modernizing Power Plants to Realize Industry 4.0

Abstract

In Industry 4.0, digital technologies are integrated with control systems to use enterprise applications and data analytics to improve the efficiency and productivity of industrial processes. However, power plants in Sri Lanka are yet to get such applications primarily due to lack of data acquisition capabilities, high cost of control systems supplied with data analytic applications and lack of awareness about the capabilities of such applications.Though data analytic applications can be developed locally, obtaining data from power plants cannot be done without changing the existing control systems. This paper proposes a model to overlay a Data Acquisition System (DAQ) on top of the existing plant control system without replacing it. The acquired data can be used for Industry 4.0 applications. Due to the loose coupling of the control systems, DAQ and data analytic applications, each can be updated independently preserving each system’s investment.To demonstrate the model, an implementation of DAQ in hydropower plants in Sri Lanka in the 2000s - at a time when data analytics was not considered a part of the power plant control systems and data communication was not readily available- is discussed. Many faults were detected by these DAQs. The local development saved about Rs. 30 million for the Ceylon Electricity Board (CEB). Early fault detection would have saved billions of rupees for the CEB and Sri Lanka. This development shows the ingenuity of the engineers of the CEB at a juncture where the services and the financial operation of the CEB are questioned.Due to the availability of Internet access and the advancement of cloud systems at present, data analytics and AI applications are within the reach of power plants in Sri Lanka. By implementing the proposed model to collect data from existing control systems, the Sri Lankan Power Utility (CEB) can consider implementing Industry 4.0 applications locally without spending an excessive amount of foreign currency.