2016 Paris Session

B5-109
http://www.cigre.org

Optimization techniques reducing periodic maintenance and retrofit outage

times with digital substation technology

Thomas Werner, Stefan Meier

Switzerland
ABB

SUMMARY

Digital substations based on the communication standard IEC 61850 with process interface
units (PIUs) such as Standalone Merging Units and Breaker IEDs, installed near the primary
equipment in the switchyard, open up new opportunities towards optimized maintenance
techniques by incorporating supervision and alarming information from this equipment into
maintenance schedules. This also becomes a more and more important factor as access to
equipment installed in the switchyard is restrained during outage periods of the high voltage
side in order to allow for safe access for personnel. The paper further discusses deployment
aspects for process-close equipment in order to allow for efficient upgrades of the equipment
during its lifetime with main focus on standardizing relevant building blocks and interfaces.

KEYWORDS

Digital Substation, Merging Unit, Process Interface, IEC 61850, Periodic Maintenance,
Condition Based Maintenance, Physical Deployment, Lifecycle Costs

thomas.werner@ch.abb.com 1
INTRODUCTION

Digital substation and process bus – terminology

Substation automation systems are typically divided into three control areas – the station
level, the bay level, and the process level. The bay and process level are today largely realized
by so-called Intelligent Electronic Devices (IEDs). With the emergence of the process bus
based on IEC 61850 standard, process-level IEDs will execute parts of the functionality from
classic protection and control IEDs on the bay level in terms of acquiring information from
the primary process, and providing an actuating interface for primary switchgear.

Different driving factors apply for a wider adoption for IEC 61850 process bus – safety, the
integration of new sensor technologies with a digital interface, reduction of installation and
lifecycle costs by means of a higher degree of standardization, and a higher degree of
supervision. Beside these benefits, deployment considerations of where process bus
equipment is deployed physically in a substation or feeder have an influence on various
design aspects for merging units and switchgear IEDs.

Two device categories form the basis of process-level devices - merging units, which provide
the digitization of primary analogue values, and breaker IEDs interfacing primary apparatus
for with a sensing and actuating interface:

Merging units provide on their outputs digital message streams with samples according to
IEC 61850-9-2 [1]. Today, the output is typically referred to as a subset of IEC 61850-9-2, the
so-called 9-2 "light edition" [2]. During 2016, it is expected that relevant parts IEC 61869 will
be released, which then incorporates the existing profiles of the light edition in addition to
new, native profiles. Merging units need an accurate time synchronization as samples from
different sources may be used in the same application.

Merging units come in two flavours – so-called “Standalone Merging Units”, which take
standardized signals from conventional instrument transformers, and sensor technology with
integrated merging unit functionality. For the latter, as the input measurement circuitry is
depending on and is specific to principles used to acquire the primary quantities, the
electronics and its interface providing the information are interlinked. In other words, the
interface to the primary side is proprietary. Hence, the merging unit is considered as an
integral part of the sensor electronics.

The second device category – Breaker IEDs – provides interfacing primary apparatus such as
circuit breakers, disconnectors, or transformers by means of providing a sensing (digital
inputs) and actuating (digital outputs) interface. Here, the telegrams are exchanged by means
of IEC 61850-8-1 services (GOOSE), which provide event-based notification mechanisms. In
addition to the main functionality of interfacing and operating the primary apparatus, also
supervision functionality can be provided by those devices as supported with the IEC 61850
model.

Physical deployment of process close equipment

Process-close equipment interfaces the primary process, and typically is installed close to the
equipment in the switchyard. In order to interface a wide range of primary equipment,
merging units and breaker IEDs need to address a set of properties in their designs, such as

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the type of station, voltage level, or different feeder types and the physical dimension of
feeders.

In an air-insulated substation, distances to bridge from secondary equipment installed close to

the primary equipment and the station house are much longer compared to indoor GIS
stations. On the other side, equipment must work under harsh environmental conditions if
installed in the field.

Process level equipment needs to adapt to various busbar configurations, such as single
busbar, double busbar, 1 ½ breaker schemes, as well as different feeder types, such as line or
transformer feeder, or bus couplers. In all cases the number of signals which need to be
digitized differ from each other. A transformer feeder has more current measurement points
than voltage measurements, thus providing a need of merging units to provide measurement
channels for either voltages or current; however not always for both at the same time.

The feeder dimensions also have an influencing factor on the trade-off between the “last mile”
of copper wire from one or several marshalling kiosks with process bus equipment to the
primary equipment. One kiosk per feeder concentrates all secondary equipment in one place
(Figure 1, left); simplifying access to the kiosk as it can be placed close to a pathway as well
as connecting the kiosk to the optical communication network; on the other side increasing
the length of copper wire used to interface the primary equipment. Two (or several for
transmission type stations) kiosks per feeder reduce the length of copper cabling as the
process bus equipment sits closer to the primary (Figure 1, right). On the other hand, aspects
like physical access; DC power distribution as well as integrating all kiosks in the
communication network need to be closely weighted against.

Figure 1: Process bus equipment locations in the switchyard

Maintenance policies

With the introduction of microprocessor based protection and control relays (IEDs) it became
possible to adopt new forms of maintenance, because the modern devices can supervise
themselves and also parts of their surroundings. This self-supervision of IEDs enabled the
utilities to apply different maintenance policies than the historic approach of periodic time
based maintenance.

North American Electric Reliability Council, NERC, describes in [3] time based maintenance
programs (TBM) and condition based maintenance programs (CBM). In TBM the
maintenance tasks are executed according to a defined schedule. To verify the devices under

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test, they typically need to be removed from service for the duration of the test. In CBM, users
use supervision and monitoring data as well as event logs and records from captured
disturbances to develop a maintenance program. Further definitions are given in the technical
brochure [4]:

Preventive maintenance describes planned maintenance activities to verify that the

equipment is working as intended. The maintenance activities can be planned using
techniques like “Reliability Centred Maintenance (CBM)”, “Condition based maintenance”,
or “Time based or periodic maintenance”.

Corrective maintenance is event driven and done after detection of a failure by system
supervision functions or after a malfunction of a device.

Updating maintenance is typically done along with preventive or corrective maintenance,

during which for example the IED software is updated without enhancing the functions. If
during maintenance activities functions are changed or added or also cyber security
improvements are applied, the maintenance aspect changes from updating to upgrading
maintenance.

OPTIMIZE MAINTENANCE BY USE OF SUPERVISION INFORMATION FROM

PROCESS-CLOSE EQUIPMENT

Protective relays, as well as equipment installed in the switchyard interfacing primary

apparatus, are essential components in a substation which must be inspected at regular
intervals. Also NERC-CIP mandates that the "ability to perform" must be proven at regular
intervals.

Time-based maintenance schemes (TBM) are typical for secondary systems. At regular
intervals, the secondary system (in the sense of Main 1 and Main 2) is taken out of service
and functionality of the relays and other equipment is checked, such as the functioning of
digital inputs and outputs. Specifically, analog input measurement channels of protection
relays are undertaken secondary injection tests in order to verify the accuracy of the channels.
With the emergence of communication standards, such as IEC 61850, and the inclusion of
aspects such as primary and secondary system supervision, it is possible to aggregate much
more "live data" of the equipment and use it for enlisting equipment in maintenance schedules
on the station level. By this, maintenance schemes can be switched from TBM to so-called
condition-based maintenance schemes (CBM).

Further driving the adoption of using supervision data from the equipment for maintenance
planning is the fact that process-close equipment is typically installed close to the primary
apparatus in the switchyard, hence access to the equipment for maintenance or replacement
must be coordinated with activities of de-energizing affected bays. This will put much more
emphasis on the fact that maintenance windows of the primary equipment is used to also
inspect affected secondary equipment. Therefore, exactly knowing which equipment or
components of the secondary system to inspect is becoming important.

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Main artefacts of a digital substation – system view

Figure 2 shows a typical secondary system, divided into the three levels of process level, bay
level, and system level with the relevant equipment.

Figure 2: Installation levels and communication layers of a digital substation

The process level, depicted in Figure 2 by means of outdoor panels where equipment such as
merging units and breaker IEDs are installed, is linked to the bay and station level through
communication architectures such as HSR or PRP [6]. Typical information provided to and
from the bay level are measurements from analog equipment such as current and voltage
transformers, as well as status and supervision information from the primary equipment.
Commands, such as opening or closing primary switchgear, are communicated from the bay
level to the process level. Supervision information, such as device or communication network
"healthiness", is typically provided to SCADA systems on the station level.

There are several possibilities for providing alarming and supervision which can be used on
the station level for including this into maintenance schedules actually based on equipment
healthiness rather than fixed time schedules. Preferably, as the process close equipment
typically resides in the switchyard, alarmings on degradation of equipment can be taken into
account for the next maintenance window of the primary apparatus. Paper [7] also describes
examples of information which can be used from process-close equipment for deriving
alarmings used in maintenance schemes.

On the one side, supervision and alarming information which stems from the device
equipment itself can be used in maintenance schedules, such as the supervision of
measurement channels, or the supervision of the tripping coil of output relays. Next to
information which is continuously monitored, pattern comparison to an initial "fingerprint",
such as the light level of optical transceivers, can be included for supervision.

IEC 61860 on the other side opens up new possibilities for supervision schemes which can be
derived from continuously available data streams, such as IEC 61850 sampled values or
GOOSE messaging, and, if several measurement points exists, the same primary information

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can be compared on the secondary side against each other, and alarmings initiated on the bay
level which typically subscribes to such information.

Supervision and alarming from process-close equipment

Table 1 lists a set of properties from process-close equipment which can be integrated for
alarming and supervision.

Table 1: Supervision and alarming information from process equipment

Equipment Property Description Type

Merging Unit § SV streams Supervision of IEC 61850 SV streams
and statistical values related to network
traffic
§ Measurement Measurement channels can be Run-to-fail
channels supervised whether the sampling works Degrade
correctly, e.g. validating for clipped quality of
values. information
Measurement channels can be
supervised if dual A/D are applied, e.g.
by validating the measured values
against each other
§ Closed loop An overlay signal can be continuously
analog input chain injected into the analog input chain and
be used for recalibrating the channels
and therefore remove the requirement to
test analog input channels on a timely
basis. This is not applied today
Breaker IED § Relay outputs Relay coils of the breaker IED can be Run-to-fail
supervised
§ Inputs Different means exist for supervising Run-to-fail
digital inputs, e.g. one physical input
can be applied to two input chains and
differentiating results create an alarm
§ GOOSE Supervision of IEC 61850 GOOSE
messages and statistical values related to
network traffic
Communication § "Signal level" of A “fingerprint” can be done during Alarming
optical channel commissioning on all optical
communication channels, baselining the
signal levels of the optical transceivers.
Those baseline values can be used
during continuous operations in order to
create an alarm if signal levels of
communication channels degrade below
baseline values or specified thresholds
(e.g. dust)
Power supply § Power supply Signals from auxiliary equipment, such Run-to-fail
Kiosk failure as power supplies and temperatures of Alarming
outdoor kiosks can be constantly
supervised

The provided self-supervision functions of process equipment on one hand provide detailed
alarming and health information to the station automation system to enable fast and precise
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remedial actions and on the other hand inform the receiving protection and control devices
about potentially invalid data, allowing the affected system parts to go automatically and
immediately into a save state to ensure that for example no protection trips are initiated.
Same as with conventional systems, the redundant protection (and/or control) schemes are
required to ensure adequate protection of the substation, during failures.

"Monitoring" due to new communication schemes and data redundancy

New possibilities emerge if information available on the process or station bus is intelligently
combined by subscribing devices. Examples are listed in Table 2

Table 2: Supervision information from evaluating process data

Equipment Equipment Description Type

Bay § IED Subscription to data from process from Alarming
other measurement equipment.
Comparison of values
Station § SCADA Aggregation of alarms from process Alarming
and/or bay level

With digital substation technology wider distribution of process data to and from the process,
like measurements or protection trips, is more easily possible than in conventional systems.
Therefore it becomes feasible to for example provide redundant information to a protection
device for local evaluation or to send protection trips through different routes. Some of these
advanced evaluations will require new algorithms to be developed in bay level devices, while
other evaluations are already possible today with advanced user configurable protection and
control IEDs.

REPLACEMENT, REFURBISHMENT AND RETROFIT

At the end of equipment lifetimes, utilities have to decide whether to extend the life of the
system by upgrades or refurbishing individual components by replacing complete systems
during retrofit projects. Paper [5] clarifies the terminology used for replacement,
refurbishment and retrofit of substation secondary systems:

Replacement is the process of replacing the majority of the existing infrastructure with the
intention of improving the remaining lifetime and the functionality. Example: replacement of
a complete protection cubicle retaining the interfaces to the primary system, i.e. CT’s, VT’s.

Refurbishment is the process of major maintenance or minor repair to the existing

infrastructure with the intention of improving the remaining lifetime at a minimum cost.
Example: Replacement of a number of protective relays within one or more bay while
retaining the existing cubicles.

Retrofit refers to the addition of new technology or features to older systems with the
intention of improving the functional level at a minimum cost. Example: replacing old
electromechanical relays by new digital relays (existing cubicles are fitted with new digital
relays) often using the same housing.

Given the different life cycles of primary and secondary equipment, most substations are
likely to see one or two retrofits of the protection, control and automation system during their

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service life. Retrofits that are planned today may well be replacements of the existing systems
with digital substation technology.

Replacing a conventional secondary system with its new digital variant, using PIUs and
optical process communication, enables to keep installation times low and power outages as
short as possible. This is because the entire system from PIU to SCADA communication can
be tested off-site and only relatively short time is required for installation and commissioning.

Optimizing the upgrade of traditional secondary systems is a desirable; however the new
digital system also shall be superior regarding periodic maintenance and upgradeability at the
end of its lifetime.

BEST PRACTICES FOR UPGRADES TO DIGITAL SUBSTATIONS

When upgrading conventional secondary systems with digital variants different aspects have
to be considered.

Standardization of interfaces towards the primary process

Having clearly defined interfaces is the corner stone for efficient retrofits and to ensure that
the new system will be easy and safe to maintain and efficiently to be replaced at the end of
its lifecycle. Defined terminals shall be used to interface to the primary apparatus using
normal copper cables.

Compliance to international standards

Applying solutions that are compliant to international standards enables building

interoperable solutions that are future proof can be maintained over the complete lifecycle of
the secondary systems and also efficiently replaced at the end of its lifetime. The relevant
standards in this regard are in particular IEC 61850, IEC 61850-9-2LE, the UCAIug’s
implementation guideline, as well as the relevant parts of IEC 61869, once they are released.

Allocation of functions

While in conventional systems, the allocation of functions to products is relatively clear, the
allocation of functions to bay level devices like protection and control IEDs and to process
level devices like merging units or breaker IEDs needs to be re-assessed. The introduction of
an additional level of intelligent devices with digital substation solution may tempt one or the
other to put protection and control functions down to the process level. There are however
several reasons why it is recommended to limit the functionality of the process level devices
to the core tasks of process interface units, such as:

§ Enabling interoperable systems, potentially with devices from different vendors on

bay and process level
§ Simplifying system maintenance and testing
§ Simplifying replacement of devices on one of the levels during the life cycle of the
substation.

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Standardization of data model and communication interfaces towards bay and station
level

Alongside with the allocation of functions to devices, comes the IEC 61850 modelling of
information that shall be exchanged. Locating the appropriate logical nodes in process level
devices enables dataflow engineering in an understandable way, which facilitates maintenance
and future modifications or extensions.

As an example, logic node groups T, X, Y, which are “located” in the process devices, must
seamlessly interact with the C and P logical nodes in the bay level IEDs in a safe and
interoperable way.

Modular, scalable outdoor cubicles for interfacing the primary process

When it comes to the physical installation of process interface units, it makes sense to
standardize the outdoor cubicles that house the interface, in a modular way. This enables
utilities to re-use designs across different substations and feeder types, which not only
simplifies engineering and cubicle manufacturing, but also enables fast installation and
commissioning with minimum feeder outage times. Standardizing further supports safe and
efficient maintenance as well as future retrofits at the end of the lifecycle of the secondary
systems.

Figure 3: Example of an outdoor cubicle with process interface units

Modularizing the process interface units and cubicles not only enables the design of
standardized and scalable solutions for different feeder types, it also allows to distribute the
process interfaces across the switchyard and place them strategically to optimize installation
and minimize conventional cabling to the primary equipment. Figure 4 shows an example of
allocation of a standardized process interface cubicle in a 1 ½ breaker substation. The outdoor
kiosk houses process interface modules that interface to circuit breakers (CB), disconnector
and earthing switches (DS, ES), current (CT) and voltage (VT) transformers. The outdoor
cubicle is placed to optimize copper cabling to the primary objects.

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Figure 4: Example of allocation of cubicles to switchyard

COMPARISON OF MAINTENANCE METHODS

The adoption of Digital Substation can be separated into benefits applicable during
installation time (one-off) both for system integrators and utilities, as well as benefits which
occur over the life time of the equipment.

For the installation phase, a set of benefits are listed below:

§ Personnel safety is increased as signals can be digitized right (or close) by their source
in the field. Maintenance activities in secondary panels can be carried out with
reduced risks of electrical hazards, e.g. by open CT circuits.
§ The usage of NCIT technology, mainly for new installations, provides benefits in
terms of measurement accuracy (linearity), safety, and environmental advantages,
such as less footprint requirements or the absence of liquids and insulation gases.
§ For new installations, the requirements on current and voltage transformers can be
reduced, such as the burden as merging units terminate the cabling in close physical
proximity to the sensor. Also, less secondary cores are required compared to today, as
signals are distributed digitally over the process bus.
§ As mentioned above, the time needed to perform a retrofit activity can be reduced as
electronics panels are fabricated and pre-tested offsite. This allows to perform retrofit
activities in a more parallelized fashion, as well as reducing verification efforts onsite
so that the overall outage time is reduced.
§ Engineering time for projects is typically decreased, as the possibility to apply pre-
engineered “building blocks” with a higher degree of standardization than today based

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 on IEC 61850 can be used in projects. Functional enhancements can be done later in
project stages as the need for additional wiring is replaced by communication means
based on IEC 61850. At the same time, aspects such as the design of a (robust)
communication network, the design of a data model which is flexible enough to allow
for functional extensions, as well as applying time synchronization across the station
with possibilities to gracefully degrade functionality are key aspects which need to be
considered.

Lifecycle costs, focusing on secondary equipment, must be valued from the following
perspectives:

§ New equipment, such as merging units, breaker IEDs and network switches is
introduced with Digital Substation, while in the medium-term existing protection and
control eqipment will see simpler architectures as data sensing and actuating is moved
to process-level equipment. The latter has a life cycle similar to that of today’s
secondary equipment. In order to lower overall lifecycle costs, a certain degree of
standardization is required (equipment type, kiosk design) for equipment repair and
exchange.
§ The required capabilities, as well as required tools for performing maintenance
activities will also shift with the introduction of Digital Substations. Here, the
advantages of equipment self-supervision will provide valuable information, as failing
or degrading equipment can be detected easily. When it comes to routine testing, the
combination of self-supervision of equipment, together with the verification of the
communication chain based on testing features with IEC 61850 Edition 2 allow to
perform many activities with software-based testing tools instead of performing
physical testing activities. On the other side, this in turn shifts the knowledge required
towards software, communication networks, and software-based testing.

Table 3 and

Table 4 provide a summary of the advantages when introducing digital substation technology
for both installation and operational phase, and also list topics which must be considered for a
successful introducing of process bus.

Table 3: Considerations for introduction of process bus during installation phase

Activity Advantage Needs consideration

System design § Less cable engineering and § Design of communication network
verification (performance, bandwidth)
§ Functional enhancements based on § Concept for graceful degradation
IEC 61850 data model
Project delivery § Equipment installed and pre-tested in § Standardized designs (interfaces)
kiosks in order to benefit from production
§ Reduction of outage time due to scales.
parallel installations (kiosk delivery, § Secondary equipment in
fiber optic cable laying) switchyard requires additional
replacement cycle.

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Table 4: Considerations for introduction of process bus during operational phase

Activity Advantage Needs consideration

Maintenance § Self-supervision provides
activities in degradation and alarming
secondary panels information, also on the
communication network
§ Maintenance activities can be
executed faster and in secondary
panels without risk for personal
safety
Device § Higher degree of standardization can
replacement possibly reduce number of required
device variants and this spare parts
Device testing § Supervision allows to shift from
TBM to CBM schedules with a
higher focus on software- or tools-
based testing methods, utilizing IEC
61850
Sensors § Less maintenance activities due to
absence of liquids and gases,
electronics provides self-supervision
on health status
§ Collection and processing of
alarming information.
§ Effective use of information in
CBM systems
§ Focus on “typicals” which allow
for standardization of designs and
equipment across bays and stations
§ Required knowledge and training
with new technologies; adaptation
of processes
§ Dependency to device
manufacturer due to use of
proprietary measurement
principles
§ Higher replacement efforts when
integrated into primary equipment

CONCLUSIONS

With the emergence of process bus applications, maintenance activities and how those
activities are performed must be reviewed.

Process-close equipment provides supervision and alarming information on the “healthiness”

of the equipment itself. The efforts required for regular time based maintenance can be
optimized and routine-testing activities can be minimized due to executing less unnecessary
maintenance activities. On the equipment side, this is supported by the fact that if
functionality fails, it is exactly known what has to repaired due to supervision or alarming
functionality, rather than locating the source of the error in the field.

By knowing what to repair, the replacement activity is also simplified. Upgrades on the other
side can be executed faster due to the usage of standardized interfaces, both physical (terminal
arrangement, device grouping to kiosks), and modelling-wise which data is exchange across
device levels.

The shift towards CBM-based maintenance activities allows to reduce overall effort spent
compared to traditional maintenance schemes. On the other side, the change in technologies
also requires a careful assessment on adjustments to existing maintenance processes.

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BIBLIOGRAPHY

[1] IEC International Standard “Communication networks and systems in substations – part
9: Sampled values over ISO/IEC 802-3”, IEC 61850-9-2:2011
[2] “Implementation Guideline for Digital Interface to Instrument Transformers using IEC
61850-9-2”, UCA International Users Group, 2004
[3] System Protection and Controls Task Force of the NERC Planning Committee.
“Protection System Maintenance. A Technical Reference”. NERC, 2007
[4] Cigré working group B5-06. “Maintenance Strategies for Digital Substation Automation
Systems”. Cigré, 2011
[5] Cigré working group B5-08. “Refurbishment Strategies based on Life Cycle Cost and
Technical Constraints”. Cigré, 2011
[6] IEC International Standard “Industrial communication networks – High availability
automation networks – Part 3: Parallel Redundancy Protocol and High-availability
Seamless Redundancy”, IEC 62439-3:2012
[7] “Using IEC 61850 Process Bus to meet NERCI PRC-005-2 Condition Based
Maintenance Requirements”, R. Hunt, T. Ernst, PACWorld Americas 2014

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