Project Scope

The project encompassed designing, engineering, supplying, installing, and commissioning a standalone RTU and SCADA system for centralized monitoring and control of power distribution at two major power stations. This also included integrating all RTUs, the HT panel controller, and switchyard signals with the SCADA system.

Project Background

Our client, a leading process company, aimed to modernize substation operations by implementing a state-of-the-art Remote Terminal Unit (RTU) and Supervisory Control and Data Acquisition (SCADA) system for centralized monitoring and control of two substations.

The operational management of these stations heavily relied on manual intervention and localized control mechanisms, requiring personnel to manually check equipment status, adjust controls, and respond to alarms or abnormalities. This resulted in limited real-time visibility into the plant’s operations.

System Overview

The system features Mitsubishi Electric control system to oversee and manage the operations of the two substations. The RTUs act as the central hub, receiving field discrete inputs and outputs from all substation IEDs and equipment via control cables. Digital outputs interface with the RTU output module through relay card isolation. Analog signals are protected from external surges using signal isolators. Energy meters providing electrical data are integrated through RS-485 (Modbus) connection, with serial Modbus devices converted to an Ethernet platform using dedicated converters (Modbus over TCP/IP).

An Ethernet switch equipped with dual optical fiber connection ports establishes ring connectivity to the SCADA system. Both local RTUs and SCADA are synchronized to the real-time clock through GPS.

This RTU-SCADA control system, interfaced with the SCADA system, serves as the primary operator interface, enabling seamless monitoring and control functions. This integration allows operators to monitor and report operational parameters of both substations.

Implementation Approach

Local RTUs were deployed at both substations to remotely monitor and control various field devices. These RTUs feature advanced open system architecture with network capability, allowing seamless integration with other plant systems via Ethernet. All interlocks, I/O system panels, and sequence controls are managed within the RTU system.

To ensure reliable data transmission, an Ethernet switch with dual optical fiber connections was implemented, establishing a robust network topology for communication with the SCADA system. Synchronizing RTUs and the SCADA system to a GPS-based real-time clock guarantees accurate timekeeping and coordination.

Additionally, LAN to RJ45 switches connect Power Control Centers to the RTU system, facilitating communication with the SCADA system for centralized monitoring and control of substation power distribution processes.

This scalable approach enhances operational efficiency and flexibility, enabling the expansion of monitoring and control capabilities across multiple locations. By integrating RTUs from various substations, operators can centrally monitor and manage diverse assets, ensuring compliance with operational practices and philosophies at each site.

Project Outcomes

The integration of RTU and SCADA systems enables centralized monitoring and control of the substations, reducing reliance on manual interventions and local control mechanisms. This leads to streamlined operations, faster response times in case of faults or alarms, and improved efficiency in managing the electrical system. The integration of energy meters facilitated comprehensive reporting on operational parameters, enabling operators to make informed decisions based on real-time data insights.