Substation Automation System

Overview

Power System Automation (PSA) integrates protection, control, monitoring, and communication for efficient power systems. Petrozone delivers end-to-end PSA solutions, ensuring reliability, efficiency, and compliance with standards like IEC 61850. Our tailored systems meet the unique needs of industries and utilities, offering scalability and future readiness.

System Architecture Design

Petrozone system architecture design process involves:

• Conducting detailed assessments of existing infrastructure and requirements
• Developing a comprehensive system architecture design
• Creating detailed layouts for PSA panels and network communication
• Submitting a Functional Design Specification (FDS) document with a detailed description of the system architecture

Petrozone’s architecture includes Process Level (CTs, PTs, IEDs for data control), Bay Level (BCUs and relays for protection), and Station Level (HMI, gateways, SCADA for Control and operations).

HMI Development

HMI systems are crucial for efficient operation and monitoring of the power system

 Features of Petrozone HMI Solutions: 

• Graphical Representations of the power system topology for real-time visualization.
• Real-Time Data Monitoring and historical trend analysis.
• Comprehensive Alarm and Event Management for timely alerts and resolution.
• Access Control with user privilege configurations and password protections.
• Customizable Daily and Monthly Reports for energy tracking and operational analysis.

Gateways and RTU Configurations

Gateways and RTUs) are pivotal to effective system control and data acquisition. Petrozone configures and integrates these components to ensure seamless functionality.

Configuration tasks include:

• Setting up Ethernet switches, servers, and modems for reliable communication.
• Configuring protocol conversion gateways to bridge legacy systems with IEC61850 system.
• Establishing redundancy configurations to enhance system uptime and reliability.
• Configuring GPS Clocks for precise time synchronization across devices.
• Programming event-driven RTUs with accurate signal mapping for real-time performance.

IEC 61850 Implementation

IEC 61850 is essential for modern substation automation, enabling efficient and standardized communication. Implementation includes:

• Communication Architecture: Designing systems based on IEC 61850 protocols.
• IED Configuration: Creating and setting up CID files for each device.
• GOOSE Messaging: Enabling high-speed peer-to-peer communication.
• Sampled Values (SV): Digitizing analog measurements for precision.
• Cybersecurity: Applying IEC 62351-compliant security measures.
• Control System Integration: Connecting the automation system to higher-level control centers.

Factory Acceptance Testing (FAT)

FAT is a critical step in ensuring the PSA system meets all requirements before deployment. Key aspects include:

• Developing comprehensive test plans and procedures
• Simulating various operating scenarios and fault conditions
• Verifying communication protocols and interoperability between devices
• Testing HMI functionality and user interfaces
• Validating protection and control logic

By following this approach, we aim to deliver scalable, reliable, and future-proof PSA systems tailored to meet the specific needs of industries and utilities

Overview

At Petrozone, we specialize in SAS system site commissioning, covering installation, configuration, testing, energization, and handover of PSA systems. Our structured process ensures reliability, efficiency, and compliance with international standards like IEC 61850.

Pre-Commissioning Phase

• Site Readiness Assessment: We verify that substation infrastructure, power connections, communication networks, and equipment installations meet all required specifications.
• Documentation Review: Our experts examine system designs, schematics, and technical documents, ensuring a comprehensive commissioning checklist is in place.
• Safety Preparations: We implement robust safety measures, including Lock Out/Tag Out (LOTO) procedures, and coordinate with on-site teams to create a safe working environment.

Hardware Installation and Verification

• Equipment Installation: Petrozone ensures proper installation of all Intelligent Electronic Devices (IEDs), communication equipment, and control devices, with precise mounting, labeling, and connectivity.
• Wiring and Circuit Checks: We perform detailed AC and DC wiring verifications, ensuring all connections align with schematics and operate at the required voltage levels.
• Communication Infrastructure Setup: We install and configure communication networks, including Ethernet switches and fiber optic cables, validating device connectivity and redundancy mechanisms.

Software Configuration and Testing

• IED Configuration: Our team loads and verifies settings for all protection relays and control devices, implementing Configured IED Description (CID) files for seamless integration.
• Human Machine Interface (HMI) Setup: We configure the HMI with tailored graphics, controls, and real-time data points, ensuring operators have clear visibility and control of the substation.
• SCADA Integration: Petrozone configures communication protocols and performs point-to-point testing to validate accurate data exchange between the SAS and control centers.

Functional Testing

• Protection System Testing: We test all protection schemes, including overcurrent and differential protection, ensuring correct breaker operations and switchgear responses.
• Control System Verification: Petrozone verifies automation sequences, interlocking schemes, and remote operation of circuit breakers and switches.
• Communication Testing: End-to-end testing of GOOSE messaging, Sampled Values (SV), and redundancy protocols ensures robust and fail-safe communication.

System Integration and Performance Testing

• Integrated System Testing: Our experts conduct full system tests to ensure seamless interaction between all SAS components, simulating operational scenarios to verify responses.
• Load Testing: We simulate operational loads to evaluate system performance under normal and peak conditions, identifying and addressing any performance bottlenecks.
• Cybersecurity Verification: Petrozone implements advanced cybersecurity measures, including access controls, encryption, and penetration testing, to protect your system from vulnerabilities.

Final Commissioning and Handover

• Site Acceptance Testing (SAT): We conduct rigorous SAT to confirm the system meets all design specifications, documenting and resolving any discrepancies.
• Operator Training: Comprehensive training ensures your team is well-equipped to operate, monitor, and troubleshoot the SAS effectively.
• Documentation and Handover: Petrozone provides detailed as-built drawings, test reports, and system documentation as part of a structured handover process.
• Post-Commissioning Support: Ongoing support and maintenance protocols are established to address minor issues and ensure long-term reliability.

Overview

At Petrozone, we excel in modernizing legacy substations while retaining and optimizing existing Intelligent Electronic Devices (IEDs). Our tailored approach integrates advanced automation features without the need for costly, large-scale equipment replacements.

Below is an overview of the process:

 Assessment and Planning

• Site Survey: Evaluate existing IEDs, protocols, and control systems; identify performance bottlenecks.

• Gap Analysis: Compare the substation’s current capabilities with desired automation goals; pinpoint areas for improvement.

• Migration Strategy: Plan phased upgrades to minimize downtime; integrate gateways to bridge legacy systems with modern technologies.

Design and Engineering

• System Architecture: Develop a gateway-centric design compatible with existing IEDs, ensuring reliability through redundancy and failover mechanisms.
• Network Upgrade: Implement high-speed Ethernet and optimize traffic with VLAN configurations.
• SCADA & HMI: Design and integrate a modern SCADA system with existing IEDs, featuring intuitive HMI layouts for enhanced control and operations.

Implementation

• Gateway Deployment: Install and configure protocol gateways (e.g., Modbus to IEC 61850) with data concentration and time synchronization.
• Software Updates: Optimize IED configurations and integrate new control logic as needed.
• SCADA & HMI: Deploy SCADA servers/workstations; configure alarms, data archiving, and data points.
• Cybersecurity: Implement firewalls, encryption, and access controls; enable secure remote access.

Testing and Commissioning

• Factory Acceptance Testing (FAT): Simulate substation environments to verify gateway and SCADA functionality; test interoperability of legacy and new components.
• Site Acceptance Testing (SAT): Validate communication between legacy IEDs and gateways; ensure SCADA reliability in a live setup.
• Integration Validation: Confirm seamless operation between legacy and modern systems; test failover and redundancy for resilience.

Training and Handover

• Operator Training: Conduct hands-on training for SCADA and HMI systems; provide SOPs for efficient operation.
• Documentation: Deliver as-built documentation with updated system diagrams and detailed network schematics for maintenance