Disclaimer: The images featured in this blog are for illustrative purposes only, intended to give a general idea and should not be directly compared to actual equipment. Additionally, the story and characters are purely fictional and bear no connection to any real-life scenarios.

At the heart of the Evergreen Chemical Plant stood its aging substation, a silent witness to years of manual labor and unfulfilled potential. For years, the maintenance team struggled to keep operations running smoothly. Their routine was grueling: a daily marathon from one feeder to another, jotting down readings like energy usage, reactive power, power factor —two times a day, every day.

The team dreamed of a better way. They wished for a Substation Automation System (SAS) that could bring their operations into the digital age. But the dream seemed far-fetched. Their substation, with its decades-old equipment, was not IEC 61850 compliant—the global standard for substation automation. The team had heard whispers of modern SAS installations requiring expensive overhauls. “Not for us,” they often sighed. “We’re stuck with what we’ve got.”

A Game-Changing Discovery

One afternoon, during a lunch break, the youngest engineer, Ali, stumbled upon Petrozone International’s website while scrolling through his phone. The tagline caught his attention: “Modern SAS for Legacy Substations – No System Left Behind.” His heart raced as he read about Petrozone’s ability to transform even the most outdated substations using innovative solutions.

The next morning, a spark of hope lit the meeting room as Ali shared his discovery. The team’s skepticism slowly gave way to cautious excitement. By the end of the day, they had reached out to Petrozone, eager to know more.

The Petrozone Promise

Two days later, Petrozone’s expert team arrived for a site survey. They were calm, confident, and reassuring. “Your substation’s age doesn’t matter,” said Luqman, the Petrozone engineer leading the team. “We’ve done this before, and we’ll do it here. Sit back, relax, and let us handle it.”

After gathering every detail about the substation’s configuration, the Petrozone team left, promising to return with a comprehensive plan.

“Your substation’s age doesn’t matter,” said Luqman,

The Big Plan Unveiled

In less than a week, Petrozone delivered a transformative solution, armed with a detailed and innovative system architecture. Instead of recommending a costly system overhaul, the team devised a smart, cost-effective plan: leveraging a protocol converter to seamlessly integrate legacy protection relays into a modern IEC 61850 framework. This approach skillfully utilized the existing relays’ Modbus TCP/IP capability to bridge the gap between legacy and modern systems.

The solution included:
•A Streamlined Network Layout where each protection relay interfaces with a Level 1 Ethernet switch via a dedicated Ethernet link. All Level 1 switches are then uplinked to a centralized Level 2 Ethernet switch, forming a hierarchical network structure.
•The SEL-3555 RTAC gateway at the core of the design, translating Modbus TCP/IP signals into IEC 61850 protocols, ensuring smooth communication with the modern SCADA system.
•SCADA software for monitoring, control, and reporting, installed on an industrial-grade server.
•GPS Clock For precise time synchronization
•A dedicated SAS panel securely housing all critical components, including Level 2 and Level 1 switches, the protocol gateway, SCADA server, and a GPS clock

This seamless integration minimized costs while maximizing operational efficiency, enabling Petrozone’s clients to stay ahead with cutting-edge technology.

“This is brilliant—simple yet highly effective,” said Fahad, the senior maintenance engineer, while praised the design

From Vision to Reality

Petrozone’s team began by installing a custom-designed SAS panel, followed by cable laying starting from each protection relay to the SAS panel, Once the hardware was installed, the Petrozone team developed and designed a fully customized SCADA HMI (Human-Machine Interface) system. The HMI was a game-changer. It brought the following features to life:

  • Single Line Diagram (SLD): A visual representation of the entire substation, showing real-time statuses of breakers, isolators, and transformers.
  • Breaker Faceplate Diagrams: Detailed views of individual breakers, allowing control and monitoring from a single screen.
  • Real-Time Analog Values: Live data on voltage, current, frequency, and power flows, displayed with precision.
  • Alarms and Events: Instant notifications with clear categorization for urgent attention and fault analysis.
  • Historical Data and Trends: Comprehensive logging and graphical trends for informed decision-making.
  • Remote Breaker Control: The ability to open and close breakers remotely, reducing manual intervention.

At the same time, they configured the protocol gateway with a clever approach. Each Modbus signal from the relays was assigned and linked to a matching IEC 61850 address. When a Modbus signal from a protection relay went high, its IEC 61850 counterpart also went high. This simple and effective method ensured that all Modbus signals were seamlessly converted to IEC 61850.

Finally, the GPS clock and Ethernet switch were configured to meet the system requirements.

For the maintenance team, it felt like stepping into the future. The seamless functionality and intuitive interface of the SCADA system transformed how they worked. The team could now predict and prevent faults, access real-time analytics, and make decisions based on reliable data.

The Transformation

After installation the final Site acceptance Test (SAT) was started . Every relay communication was verified, every signal checked, and the communication network stress-tested. The maintenance team, who had always been wary of technology, felt a growing sense of empowerment.

Petrozone didn’t stop there. They provided hands-on training, ensuring the team could navigate the SCADA system with ease. They learned how to monitor trends, manage alarms, and even control breakers remotely.

The New Normal

When the SCADA system was finally energized, it was as if the plant itself breathed a sigh of relief. Gone were the days of manual drudgery. Now, with a few clicks, the team could:

  • View real-time data from the comfort of their chairs.
  • Analyze trends to predict potential issues.
  • Respond to alarms instantly.
  • Generate detailed reports effortlessly.

Fahad, who had spent 20 years climbing ladders and scribbling in notebooks, summed it up best: “It’s like we’ve entered a new era. This isn’t just automation; this is freedom.”

“It’s like we’ve entered a new era," said Fahad

The Petrozone Legacy

Weeks passed, and the new system became an integral part of the plant. Productivity soared, and the once-overburdened maintenance team found themselves energized, exploring new ways to optimize operations. Petrozone’s impact went beyond technology—it instilled confidence and inspired change.

The transformation at Evergreen Plant didn’t go unnoticed. Neighboring facilities, inspired by the success story, began reaching out to Petrozone, eager to modernize their own operations. Thanks to Petrozone, the impossible became possible, proving that no system is too old for transformation.

A Vision for the Future

Evergreen Plant now stands as a model of how old systems can embrace the future. Petrozone’s commitment to the motto, “No system is too old for transformation,” has sparked a wave of change in the industry.

As for Petrozone, they’re already looking ahead. Luqman shared, “This is just the beginning. Our goal is to help more plants, no matter their size or challenges, step into the digital age.”

What outdated systems are holding back your plant? Let us help you write your success story.

Ensure every part of your operation runs smoothly. Contact Petrozone today to upgrate from outdated system to  Substation Automation System ate!