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A practical implementation of modern Distributed

Control Systems in Electric Power Substations


Dănuț Adrian Poștovei Constantin Bulac
Faculty of Power Engineering Faculty of Power Engineering
University Politehnica of Bucharest University Politehnica of Bucharest
Bucharest, Romania Bucharest, Romania
postovei@yahoo.com cbulac@yahoo.com

Ion Triștiu Balduino Camachi


Faculty of Power Engineering Faculty of Automatic Control and Computer Science
University Politehnica of Bucharest University Politehnica of Bucharest
Bucharest, Romania Bucharest, Romania
ion_tristiu@yahoo.com estison@hotmail.com

Abstract—This paper presents a practical implementation In many cases, the implementation of a DCS system
of a modern DCS in energy sector, applicable for electric faces the challenges of integration of other subsystems and
power transmission and distributions substations. electronic devices designed to perform a very specific task in
When dealing with aging infrastructure the reward from the monitored and controlled process. The big challenges
investing in modern automation solution can be substantial, come from the limitations or restriction imposed by the
with benefits such increasing productivity, cost savings, safety different manufacturer proprietary communication protocols,
operations, scalable solution and a better integration in the costly solution to upgrade the older devices to the actual
modern IT facilities.
available technology or customer’s budget restrictions.
The modern DCS systems evolved into a flexible and
Nowadays, a lot of electric power transmission and
scalable automation solutions, which make them mandatory in
the actual competitive energy business environment.
distribution substations are managed by DCS systems,
Comparing to PLCs and traditional DCS, the modern DCS implemented intensively especially over the past 15 years.
systems are designed to provide automation solution in a safe, Unfortunately, since the DCS systems were not implemented
reliable and cost-effectively manner. simultaneously, the utilities operators are facing the issues of
The main goal of this article is to present and suggest an operating with different technologies, many of them being
optimal DCS design and functional solutions taking into already obsolete and need upgrade even if their life cycle is
consideration customer requirements, international and not over. In addition to that, implementation of different
customer applicable norms, budget constraint, hardware and technology over the time from various supplier make the
software limitations, integration of existing equipment, utility operators depended of the suppliers’ know-how.
cybersecurity and low impact of the monitored and controlled At this point in time, technology has evolved rapidly and
process for extension and future growth. a DCS upgrade is more costly than the replacement by a new
The principles presented in this paper can be found one. In order to reduce or avoid the design integration risk,
implemented in Romania mainly in the electric power the DCS manufacturers prefer to supply a complete new
transmission substations, owned by Romanian Transmission DCS, including in one package both the field control level
and System Operator CNTEE Transelectrica SA. and plant supervisory equipment.
A practical example is represented by a recent upgrade of
Keywords—DCS, SCADA, HMI, RTU, BCU, protection three electric power transmission substations, respectively
relays, IEC61850, Cyber Security, power transmission,
Raureni 220/110 kV, Arefu 220/110/20 kV and Hasdat
substation, network redundancy.
220/110, owned by Transelectrica SA.
I. INTRODUCTION Going back in 2018, the initial supplier was Areva T&D
France. In 2018 the owner decided to upgrade all the above-
The innovations of Information and Communication mentioned substations, but this time the contract was
Technology (ICT) applied for DCS and SCADA systems awarded to Siemens AG Germany. In this context, Siemens
overcome the geographical barriers and made the remote decided to replace the entire DCS system instead of
monitoring and control an easy task [1]. upgrading the existing AREVA ones, thus reducing the
A Distributed Control System (DCS) main purpose design integration risk, avoid the very high engineering cost
represents an uninterrupted the monitoring and control of the and prevent further delays in project implementation. Even if
field devices. A successful DCS implementation depends on the driven factor for Siemens of getting this project was the
having a detailed, complete, and accurate picture of the delivery of their own products, in the short term could be a
process facility to provide all technical means for accurate saving cost to keep the existing DCS and just upgrade it, but
monitoring and process control, reliable protection system for the entire project life cycle the previous experiences
and optimal dataflow to the Control Center. shown the opposite.
In a practical DCS implementation, especially when A modern DCS is deployed with the capabilities of easy
existing automation systems or devices are mandatory to integration with other automation systems, scalability and
remain in operation being integrated in the new system, the flexibility for future extensions, cybersecurity attack
design becomes the most important part of the project which protection, and high availability through the redundant and
can make or break it. Based on authors’ previous field modular architectures which make it a very reliable and
experience, all the gaps remained after the design stages of completely free from the failure of any single component.
the project, will certainly emerge in the implementation Moreover, a modern DCS has the capability to process
phase, at higher cost and longer implementation time. thousands of inputs/outputs from a very large number of

978-1-7281-6843-2/20/$31.00 ©2020 IEEE

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controllers distributed through the plant but monitored and The modern DCS concept improves system reliability
operated centralized from a central Human Machine and decreases installation costs by placing the control
Interface. All those characteristics are DCS core components functions near the field process but keeping centralized
and bring it as a cost-efficient automation solution, proposing remote monitoring and supervision features. Taking into
a friendly and efficient operating environment and keeping consideration the other characteristics such flexibility and
the operations personnel clearly informed and easy to control scalability, the modern DCS can handle various automation
the process. processes from a small to a very large one. In the case of
The use of common automation technologies enables substation retrofitting an optimal solution is represented by
seamless integration of the modern DCS with plant-floor and an implementation of a multi-level DCS architecture.
business systems, creating more opportunity for plant-wide
optimization [2]. Furthermore, using common technologies B. DCS hardware components
lowers the lifecycle cost of a modern DCS implementation. 1) System server
For a modern DCS to be highly reliable and economical The system server is usually an industrial computer, on
in terms of engineering, implementation and maintenance which the operating system is installed and running the DCS
costs, the major requirement in the design phase is to use the software application and represents the main component of
newest common automation technologies available by all the the system. Usually, distributed control systems related to
suppliers, for an easy integration between automation energy production, transport and distribution, are designed in
systems, compatibility with modern IT facilities and a better a redundant network architecture, which involves the use of
interface with business and plant management staff. two system servers, one running online and the other in hot-
As the competition in the automation field in growing standby.
more intense, the modern DCS systems must be designed to Through the software platform running on this computer,
perform high with less energy resources in order to keep up the main system servers’ features are acquisition, supervision
with the increasing cost pressures. and control functions.
The main operational functions of the system server are:
II. DCS SYSTEMS SURVEY - Data acquisition from the field controllers and IEDs,
A. The Distributed Control System definition processing it, decision making and exchange this data with
all the system IEDs;
A distributed control system (DCS) means a monitoring - Retries failed equipment and switch the data acquisition
and control system for an industrial process, in which the to the backup IED in case of exceeding retries but continues
monitoring and control elements are distributed throughout monitoring the failed equipment and communication links in
the plant [3]. Although the hardware part of the DCS, due to an attempt to put the failed device back into operation;
specific characteristics of each controller, is perceived as a -Control and supervision of the process, based on screens
multitude of autonomous entities, the software platform that with graphic animation, dialogs and command boxes;
manages them makes the whole process to be perceived as a - Managing all the DCS records (Data Historian);
single and coherent system. - Alarms and events management;
Practically, the DCS software platform is designed to - System user rights management;
centralize all the network elements that are distributed - Print the alarm and event lists;
throughout the entire plant, allowing central control, - Data exchange with all IEDs in the network.
monitoring and reporting of each individual component and 2) Gateway / Substation communication server
process. The above-mentioned characteristics along with The Gateway or substation communications server is an
redundancy capability make the DCS a high availability and industrial computer or in some cases an RTU without
reliability system, able to control complex facilities and acquisition I/O boards, running a software application
technological processes such thermal, nuclear, hydro, oil identical to the system server or just a software module from
refinery and electric power substations as well. that application. The main role of it is to get all the necessary
A Distributed Control System (DCS) with a typical data from the devices connected to the network and
architecture presented in Figure 1, consist mainly in three transmitted to the SCADA (Supervisory Control and Data
basic components, respectively Supervisory Computers to Acquisition) systems, respectively to National Control
collect and centralized the process data and provide the Center (NCC). It has the capability to setup a firewall with
HMI, field controllers with the associated field sensors and SCADA front end to provide a secure connection for data
control elements and a Communications Network. transmission and reception, according to Cybersecurity
requirements.
The data transfer from the communication server to NCC
is bidirectional and, in many situations involves protocol
conversion. The most common protocol conversions
performed by the communications server are: IEC 61850 to
IEC 870-5-101, IEC 61850 to IEC 60870-5-104, IEC 60870-
5-104 to IEC 60870-5-101, Modbus- IEC 60870-5-101, and
Modbus- IEC 60870-5-104.
3) HMI-Human Machine Interface
The HMI (Human Machine Interface) represents a
combination of hardware and software consisting of one or
more industrial computers running Windows or Linux
operating systems and HMI software application. There are
DCS systems with Web interface features, where the HMI
Fig. 1. Distributed Control System architecture (adapted from [2])

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application interface is simply called using a common web database configuration, programming, validation, testing
browser, such as Internet Explorer or Google Chrome. and commissioning, thus providing a common interface for
Apart from the process control, there are human all engineering activities.
interfaces which are not designed for substation operators In Romanian electric power transmission and
like Engineering Workstations (EWS), having the role of distribution sectors, the main DCS systems are known by
software database configuration like adding new signals in the name of the associated software platforms, namely
the alarm and event, and updating the BCU and protection Siemens SIMATIC PCS7, ABB Micro SCADA, Areva
relays setting files. On demand, could be supplied an PACIS, Efacec CLP500, General Electric DS Agile.
additional computer connected to the network, with the The key elements of using a unique DCS software
scope of extracting various reports for remote monitoring platform are:
- Centralized database for recording all process
or/and limited control of the substation.
information (Data Historian);
4) IED-Intelligent Electronic Device
- A single software interface for all hardware products,
The generation, transmission and distribution of power configuration of IEDs, like mimics and protection relays
needs 24/7 monitoring and control to maintain the grid settings, configuration of the HMI operator interface and
reliable and uninterrupted power supply. In this respect, the parametrization for the interface with other DSC/SCADA
flexibility in integration and interoperability of IEDs over systems.
RTUs lead to a migration from the classic RTUs to IEDs in - Easy interface for SCADA / HMI configuration and
all new DCS implementations. programming;
IEDs (Intelligent Electronic Device) are microprocessor- - Programming environment IEC 61131-3;
based equipment with continuous self-supervision, used in - Advanced 2D editor;
the electric power system for monitoring, controlling and - Realization of a unified project for the entire controlled
protection functions. There are many types of IEDs used in installation;
a substation network, such as BCU (Bay Control Units) to - Simulation environment;
monitor and control of disconnectors and circuit breakers, - Utilities for online testing of configurations;
protection relays to detect faults, switch off and isolate - Analysis of data records;
selectively the protected equipment from the power grid, - User defined libraries and templates.
AVR (Automatic Voltage Regulator), metering units (MU), The main advantages of using a unique platform are:
power transformer monitoring (Qualitrol), ATS (Automatic - High productivity;
Switch Transfer), etc. - Reduced learning curve;
In a distributed architecture these devices are located - Avoidance and detection of errors during project
close to the controlled field equipment and sensors, with the configuration;
main purpose of reducing the length of the copper cables - Optimization of the execution time of the software
and communication serial links. IEDs can manage both programming part of the project;
analog and digital inputs / outputs via analog and digital I/O -A single software environment for all engineering
boards. The number of inputs/outputs or AC/DC analog activities.
cards in a controller are scalable, obviously with respect to
the maximum allowed values and conditioned by the III. METHODS AND IMPLEMENTATION
physical or thermal capacity of the controller. All
A. General Requrements
information collected from the field elements are
transmitted to the central system server or exchanged with To illustrate a practical implementation of a modern DCS
other IEDs in the network. IEDs have a bidirectional system, this paper analyzes an example of installing a new
dataflow, meaning that they are able to send data and DCS system for Alba 220/110/20 kV substation. Practically,
receive controls from HMI interface, through the central a new DCS was installed for the 220/110 kV voltage level
system server. (later referred as HV-DCS), and the existing 20kV
5) Time server-Global Positioning Systems (GPS) substation inherited an older DCS (later referred as MV-
Presently, the synchronization for all network devices are DCS). According to the scope of supply, the existing MV-
realized through a GPS clock. As the time stamp is a very DCS had to be integrated in the new HV-DCS, taking into
important issue, the new DCS systems managing this aspect consideration a critical customer requirement, respectively
with two GPS to avoid any single failure. The GPS system to keep both systems working in parallel, with HV-DCS
does not exchange any data with satellites, but just receiving able to monitor and control the entire existing MV-DCS and
signals with information about the time. The most common in reverse, the MV-DCS to be upgraded at a minimum cost
GPS server used in substations is Meinberg Lantime M300, to get the capability of monitoring and control a specific part
with an accuracy of around 50 nanoseconds [4].
of the HV-DCS, respectively the two 110 kV transformer
6) Peripheral devices bays.
Even for a small DCS implementation, a minimum one,
and in some cases two printers are required, to print the B. Implemented DCS Architecture
alarms and SoE (Sequence of events) list and on demand to Depending on factors like customer requirements and
get HMI screen shots or specific reports. External storage normative, the substation communication infrastructure,
devices such HDD and CD/DVD are also used to archive budget and integration of the existing or new third party
the events logs or on demand reports. equipment, there are several architectures for the
C. DCS software components implementation of a DCS which each supplier should take
into consideration in the tendering and later in the design
All companies that supply distributed control systems and implementation phases.
usually use a single software platform for HMI design,

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In the presented study case, there are three voltage levels, functions, monitoring, control and metering functions. The
respectively 220kV, 110kV and 20kV, where the final DCS IEC61850 standard provides four types of communication
architecture should respect the high availability, scalability services that allow data exchange between devices
and reliability requirements. Those aspects can only be connected to the same network, such as:
achieved through a flexible architecture and redundant - Client – Server based on TCP/IP MMS (Manufacturing
communication network to prevent failures in the and to be Messaging Specification), connection oriented protocol.
able to remove or reinsert the network devices without DCS/SCADA systems use MMS Client/Server
disrupting the functionality of the system. communication to perform the monitoring and control
Taking into consideration the complexity of the functions. Applications from DCS system servers to IEDs,
implementation for the analyzed study case and the network like protection relay or BCU using the Client/Server services
devices features, a mixed solution with three network are not time critical. The acceptable latency of Client/Server
redundancy protocols was chosen, as presented in Figure 2, communication is in the range of 100-200ms, with the
and detailed here below: maximum delivery time of 800 ms and a maximum recovery
1. Dual Homing (Dual Link) is a network redundancy time of 400 ms. TCP/IP mechanisms also care for repeating
protocol with recovery time established since 2004, having lost frames and the right ordering in the receive buffers.
two active links, one is sending and the other one is in hot - GOOSE (Generic Object Oriented Substation Event)
stand-by, sending link changes if one link is down. The protocol, directly on Layer 2, multicast, repetition
switch over time is <5 milliseconds. This type of redundancy mechanism, for the fast transmission of data over the
is applicable for all industrial computers, such System network. Even if the GOOSE messages have no destination
servers, Gateways, EWS, HMI and RTU in case of 20kV address, by design they are restricted to stay within a LAN
network. and do pass not pass through routers to other LAN [6].
In practice, this type of network it is easy to handle, there Applications between IEDs like interlocking signals and
are no setting required but some field experience is needed. trip messages use the GOOSE service based on a
This solution also comes with some limitations such connectionless one to many – the multicast service. Goose
supervision of only directly linked connections and broken service has a maximum delivery time of 8 ms and a
connections in the upper or lower network will be not maximum recovery time of 4 milliseconds. IEC 61850
detected by the device. standard distinguishes between two types of reporting:
2. RSTP (Rapid Spanning Tree Protocol), it is also a buffered reporting and unbuffered reports. in the first case
network redundancy protocol with recovery time, and as it is the reports are buffered by the server in case a connection to
defined by IEEE 802.1D-2004 standard is used to prevent the the client is interrupted and in the second case the Server just
problem of loops in the communications network by forming "throws" the report to the communications network without
a logical tree network that includes all the switches in the knowing if the message get to the required Clients, and if the
network, ensuring that certain network connections are put in communication is down the message will be lost [7].
a standby state, so that there is no traffic data through that - Sampled Values (SV) protocol, directly on Layer 2,
connection, thus breaking any physical loop in the network. multicast, data stream, for the fast transmission of analogue
This is applicable for high HV-DCS network, where all the values over the network. SV has a maximum delivery time of
switches are interconnected. 2 ms and a zero recovery time (bump less redundancy).
RSTP is a networking solution for computers or devices - Basic services like NTP, SNMP, HTML are not time
which do not support parallel redundant protocol. Even if is a critical. Those services have a maximum delivery time of
budget saving network, it is reliable and support up to 500 ms and a maximum recovery time of 300 ms.
250.000 units in a ring configuration. It is used mainly in the The GOOSE and SV protocols are used for critical high-
networks where the recovery time is not critical, being in the speed functions such as station interlocking, protection
range from 1 to 2 seconds [5]. tripping and blocking schemes and other station-related
3. PRP (Parallel Redundancy Protocol) is a seamless protection devices and control functions [8].Protection
network redundancy protocol, and as it is defined by IEC devices are required to safeguard the expensive power
62439-3.4 standard consist of two active links, both sending equipment and transmission lines against overloads and
and parallel configuration. PRP networks provide the highest damages [9].
level of redundancy, with the limit of around 2000 devices, In the analyzed study case presented in Figure 2, the
and no there are not special settings for network switches as common language between IEDs, system servers and
in RSTP case. Gateways and RTU is represented by IEC61850 protocol
Devices with only one Ethernet interface (printers, [10].
laptops, GPS) can be connected just to one of the PRP 2) IEC 60870–5–104
LAN(Local Area Network). In PRP architecture the switches It is a Master-Slave protocol, released in 2000 which
must handle Jumbo-Ethernet frames and the linkage of the provides a communication profile for monitoring and control
two networks could leads to breakdown of the between two automation systems.
communication. The IEC 60870–5–104 specification combines the
PRP is applicable for all the IEDs connected in both application layer of IEC 60870-5-101[11] and the transport
Ethernet networks in shown in Figure 2. functions provided by a TCP/IP (Transmission Control
C. Communiction protocols Protocol/Internet Protocol) [12].
In the architecture presented in Figure 2, IEC 60870–5–
1) IEC 61850 Protocol 104 protocol is used to exchange data between Gateway and
Since its first release in 2003, IEC61850 was widely NCC, where the NCC is the Master/Controlling station and
adopted by all the DCS manufacturers and nowadays all the HV-DCS is the Slave/Controlled station.
architectures rely on this standard. It is a protocol based on Being a multilevel architecture, the HV-DCS Gateway
Ethernet networking and designed to perform protection acts as a Master and MV-DCS RTU as a Slave. It is observe

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that the Gateway play both role, Master and Slave. In Figure and reliability. Even if Ethernet operate at different speeds
2, HV-DCS under IEC 60870–5–104 is either a controlling and use different types of media, all the versions are
station or a controlled station. compatible with each other being able to communicate in
3) Modbus Protocol the same network through interconnection devices such as
It is a Master-Slave protocol, released in 1979 and is still a bridges, hubs, and switches. In the study case, the IEDs
standard communication protocol for connecting industrial communication boards can go up to 100 Mbps, known as
electronic devices. Fast Ethernet and the industrial computers and switches
In Figure 2 Modbus protocol is used for the have Ethernet interfaces which ca go up to 1,000 Mbps,
communication with auxiliary services equipment and ATS known as Gigabit Ethernet. Ethernet cooper cable type
(Automatic Transfer Switch) device. There are two types of are Eurocable CAT7 SFTP (Shielded Foil Twisted Pair)
implementations, one is Modbus RTU with RS232 physical protected externally by a polyurethane sheath and the 4-pair
interface which connect one RS232 device to one BCU port, grouping of foiled wires are shielded by flexible braided
in a peer-to-peer communication link, and the second screening. The optical fiber used inside the perimeter of
implementation is Modbus RTU with RS485 physical substation is multimode, as the maximum distance does not
interface which connect the substation AC/DC monitoring exceed 2000m. Multimode fiber type is 62.5/125, which
and control devices, in a multi-drop communication link. The means a core size of 62.5 micrometers (μm) and a cladding
first implementation required a full-duplex communication in diameter of 125 μm. The communication outside of the
a range of 5 meters and the second one was necessary due to substation used for tele protection functions is realized by a
long distance from the BCU to the field devices (around 500 single mode optical fiber with a smaller diameter core that
m) and the need of connecting multiple devices on the same allows only one mode of light to propagate, respectively a
link. core size of 9 micrometers (μm) and a cladding diameter of
4) Ethernet protocol. 125 μm. A smaller optical fiber core facilitates a lower
It is defined by IEEE 802.3. standard and is still the most attenuation and creating the ability for the signal to reach a
popular set of protocols for the Physical and Data Link longer distance.
layers. Ethernet protocol is preferred in electric power
substations for its data transfer quality, high speed, security

Fig. 2. Multilevel DCS architecture

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RSTP, meaning that there will not be failures due to a single
IV. EXPERIMENTAL RESULTS point of failure within each of dual redundant LANs.
The results of the study are formulated on the basis of a The implementation of an old system without a very
comparison between the implementation of a single DCS documented and a proper design brings some risks such:
system over the whole process and the integration of an - Risk of missing production goals because an outage
existing system in the new one, even having the possibility of must be extended.
operating in parallel the two systems. - Risk of emergency/abnormal operations if process
In addition to IEC 61850, IEC 60870-5-104 protocol is control is partially lost;
mandatory in the HV-DCS architecture for the - Risk of a safety incident.
communication link with NCC (National Control Center) GOOSE messages are self-monitored continuously, while
and for the communication with MV_DCS as well. this cannot be achieved by using electrical wires. More than
The use of mixed architecture achieves a short bump in that, the speed of GOOSE message control can be faster than
case of RSTP and a bump less rerouting for segment failures a wired connection. To ensure the interoperability with the
in case of PRP network links. The IEC 61850 protocol modern DCS, the integration of the old systems required
defines the restrictions and limits of these messages, but costly protocol converters, meaning additional
does not define a specific implementation solution so that communication delay in the network. Distributed IEDs in the
these messages are delivered in the required parameters, switchyard closed to the field sensors and the use of GOOSE
assuming that the communication network guarantees all the messaging, replace a big amount of copper wiring with more
requirements of these messages. By using two different convenient messages on data networks.
LANs is losing the advantage of exchanging GOOSE Further optimization in term of wired connections,
messages between all IEDs between the two networks. communication failure and delay caused by network load
As the Ethernet LAN can carry mixed traffic such binary will be to take into consideration the WLAN (Wireless Area
status, metering, IED settings, GOOSE messages, in order to Network) network in substations by using WAPs (Wireless
not overload the network, all the HV bays are installed in Access Point) instead of Ethernet switches. With the actual
the switchyard, closed to the monitored and controlled field progress of 5G technologies there is the ground to build DCS
equipment. This is done by extending the station bus into network architectures with Wi-Fi topology very soon.
the switchyard near the source, to convert voltages, currents,
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highlighted.
The first aspect related to a DCS implementation is
to use the common automation technologies available for all
the vendors for an easy and compatibility with modern IT
facilities and a better interface with business and plant
management staff.
The DCS high availability is achieved with a star or two
separates Ethernet LANs in a mixt architecture PRP and

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