Case Study 

Scope:  

Designing, engineering, supplying, installing, and commissioning a standalone RTU and SCADA system for centralized monitoring and control of power distribution at 2 major power stations. The scope also encompasses integrating all RTUs, the HT panel controller, and switchyard signals with the SCADA system. 

 Background: 

Our client, being a leading Chemical Process Company, aimed to modernize substation operations by implementing a state-of-the-art Remote Terminal Unit and Supervisory Control and Data Acquisition (SCADA) system for the centralized monitoring and control of 2 substations.  

The operational management of these 2 stations relies heavily on manual intervention and localized control mechanisms. This entails personnel manually checking equipment status, adjusting controls, and responding to alarms or abnormalities as they occur. And hence there is limited real – time visibility into the operation of the plant. 

System Description: 

Our system features Schneider Electric M340 RTUs to oversee and manage the operations of two substations. The RTUs serve as the central hub, receiving field discrete inputs and outputs from all substations IEDs and equipment via control cables. Digital outputs are interfaced with the RTU output module through relay card isolation. The Analog Signals have signal Isolators for protection from external surges. The integration of energy meters, which provide the electrical data is facilitated through RS-485 (Modbus) Connection, with serial Modbus devices converted to an Ethernet platform utilizing dedicated converters (Modbus over TCP/IP). 

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

So, this RTU – SCADA control system interfaced with SCADA System serves as the primary operator interface, facilitating seamless monitoring and control functions. This integration helps the operators to monitor and report operational parameters of both the substations. 

Our Approach: 

We have deployed local RTUs 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, we’ve implemented an Ethernet switch with dual optical fiber connections, establishing a robust network topology for communication with the SCADA system. Synchronization of RTUs and the SCADA system to a GPS-based real-time clock guarantees accurate timekeeping and coordination. 

In addition, 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 enables us to expand monitoring and control capabilities across multiple locations, enhancing operational efficiency and flexibility. By integrating RTUs from various substations, operators can centrally monitor and manage diverse assets, ensuring compliance with operational practices and philosophies at each site. 

Result 

• 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 time in case of fault 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.