Utility Substation Monitoring with Powerline Communications Technology

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1 Utility Monitoring with Powerline Communications Technology A Breakthrough in Security, Performance, Efficiency, and Cost-Effective Operation

2 Networking Challenges Many sensor technologies are available to monitor the myriad of equipment located within a substation. The challenge lies in transferring the data collected by the sensor from the transformer cost-effectively and efficiently back to the control house, or regional control center without compromising security, speed or reliability. Many factors can affect how the substation components are linked. The wide range of temperatures encountered in substation operations requires very robust communications equipment that can withstand harsh environments. Existing conduits, if any, are usually filled to capacity with existing wiring, ruling out adding any more. Running hard wire cables out to the transformers to read monitoring equipment is difficult to accomplish due to underground high voltage wiring. With a substation s field consisting of gravel and concrete, trenching is also extremely expensive and time-consuming. Where a suitable right-of-way between the control house and remote sensors exists, the fiber plus the required SCADA and media converters are cost-prohibitive. The magnetic and electrical fields, along with the high voltage equipment, can interfere with wireless signals, resulting in unknown signal strength and reliability Lack of security is also a concern. Utility substations represent a critical environment, requiring highly precise, real-time monitoring to ensure that catastrophic failures are avoided. Advances in powerline communications () technology provide an important new option, enabling a cost-effective, reliable and above all, real time remote monitoring platform to ensure that substation equipment is kept at the optimum performance levels. Monitoring The Critical Requirement Utility substations operate a range of potentially volatile equipment, which needs constant proactive monitoring to ensure that potential problems are identified and handled at the earliest stage. Critical fault gases can build up in transformers, leading to increased temperatures and the potential for dangerous fires or even explosions. Proactively measuring and recording temperature trends can avoid possible problems. In addition, some internal transformer faults generate gases at an early stage and a portion of these gases dissolve and remain in the transformer oil. Gaseous byproducts can also form as the insulating materials of the transformer break down from excessive thermal or electrical stress. By regularly sampling the transformer oil and measuring the dissolved gases (dissolved gas analysis or DGA), many transformer failures can be prevented. The Downside of Manual Data Collection Manually collecting the data from the remote sensors that monitor the transformer at the control house is time-consuming, cumbersome, and expensive. An engineer has to be assigned to make a physical visit to the substation site, manually recording data that is being captured on a continual basis. It is a reactive process you are always looking at past rather than real-time data, usually on a monthly basis. The problem may have already occurred, long before the engineer has returned to record the data. Engineers arriving at a site and discovering a fault condition may need to make additional trips in order to obtain the materials needed for repair. The Advantages of Real-Time Data Monitoring There is without doubt a critical need to be able to automate substation data monitoring, in order to save manpower and proactively avoid any potentially damaging component failures. The benefits are wide-ranging. With real time monitoring of voltage levels at transformers, power disturbances and outages can be avoided. Equipment failures, lighting strikes, accidents and natural catastrophes that often result in long power service interruptions, can be more quickly resolved if identified immediately, in real time. Monitoring provides the ability to perform continuous commissioning at the substation level.

3 Series 5 For Demanding Industrial Networking Series 5 is a completely a new breed, high-grade powerline communications () system, specifically hardened to meet demanding industry standards and industrial applications, such as the harsh utility substation environment. The system uses patented technology to transform a substation s existing internal electrical infrastructure into an network backbone. It transforms low-voltage AC and DC wiring into an intelligent networking platform designed specifically for substations, power plants, and utility sites where traditional connectivity is not economically, environmentally or technically feasible. With Series 5, data can be transmitted in real-time to effectively monitor the conditions of the transformer and other equipment via an Ethernet or serial interface. s innovative, patented powerline communications technology has proven to be an ideal solution to deliver simple, costeffective and secure networking in the substation environment. Series 5 provides a scalable, robust communication network between a substation and a control house. It enables online monitoring, providing a simple method to connect the sensors with the control house, providing utilities with a robust tool for continuous commissioning. The system overcomes the limitations of other networking options, delivering a simple, reliable and secure wired solution, without the security issues of WiFi. By using the existing electrical infrastructure, it eliminates the need for trenching, conduit wiring, or other direct wiring between the field components and the control house, resulting in significant cost savings and enabling rapid deployment. Running hard wires would require roughly 100 man-hours per transformer, plus materials and equipment. The versatility of using powerline communications equipment could potentially avoid tens of thousands of dollars to install dedicated copper or fiber communication lines in existing substations, especially if more than two Intelligent Electronic Devices (IEDs) need to be connected.

4 An Effective Networking Solution Series 5 Features and Benefits The result of extensive market research and development, Series 5 delivers a range of significant performance advances, specifically designed to address the exacting networking demands of the utility market. High Bandwidth 200 Mbps chip; supports speed of 65Mbps TCP and 90Mbps UDP. Series 5 is an effective networking solution for many utility applications, such as: Adding communications to devices and applications in existing substations, power plants and manufacturing facilities. Adding site access control and surveillance. Optional support for both DC and AC applications Meets the environmental standards, rigorous performance and reliability requirements for both AC and DC operating environments for utility substations and the utility marketplace. Built-in Ethernet interface and additional serial ports are available for both RS232 and RS485 interfaces Support for DNP, Mod Bus and other protocols. Enables a wide range of different devices to be networked, such as non-ethernet-enabled monitoring and metering devices. Withstands extended temperature ranges Enables monitoring and control in difficult, outdoor industrial environments, such as temperatures in the range of -40 to 70 C [-40 to 158 F] and operating on substation wiring up to 240 volts. Reducing communication costs in new construction. Enhanced Quality of Service (QoS) Assigns up to 8 different priority levels for applications such as high-speed data, voice over (Vo) and video surveillance. Providing temporary or trial-use installations of equipment requiring communication capability. Supporting multiple applications, including protection, monitoring, control and data acquisition, with flexibility in the location of communication interfaces. Series 5 helps utilities comply with mandatory federal regulations aimed at protecting the electric power grid from cyber security incidents. Real time remote monitoring and management Enables virtually any sensor system to interface with the control house control servers. Secure transmission Incorporates hardware-based 128-bit AES encryption that meets stringent commercial requirements and provides industrial users with a highly secure remote management solution; data supports encryption and and complies with NERC C standards. Robust Network performance is not impacted by difficult network traffic conditions or changing network conditions, such as full load of half load transformers. Designed to meet evolving North American Electric Reliability Corporation (NERC) Critical Infrastructure Protection (C) standards. Secure, reliable networking and monitoring eliminates data eavesdropping and unauthorized control commands.

5 Reliable The communication network operates continuously over an extended period of time, even in the presence of network element failure or network congestion; no interference with any other devices on the wire or in the area. Quick installation Completed within hours or days, without construction or disruption; built-in network management requires no drivers or additional software. Versatile Flexible regarding location of communication interfaces; supports connectivity to any Ethernet devices and applications data, voice and video. Future-proof Designed to anticipate evolving technologies and applications for electric utilities to accommodate potential modifications of the communication network. Cost effective Using existing electrical wiring eliminates the need for new wiring or trenching. Series 5 is a completely a new breed, high-grade system, specifically designed to fulfill demanding industrial applications, such as the harsh utility substation environment. Investment protection Components are recoverable for re-deployment at other locations.

6 Series 5 Installation Series 5 consists of a Gateway, Couplers and ibridges. Typically, the Gateway will be located within the control house, along with the station s master controller and any servers or recording devices. The Gateway injects into AC, DC, or both control busses via Couplers, which serve as the physical demarcation between the Gateway and the electrical wiring. With Series 5, data can be transmitted in real-time to effectively monitor the conditions of the transformer and other equipment. ibridges are deployed at the substation field locations, such as at the transformers or switches, and are connected to the sensors which monitor various aspects of the substation components. Information from the monitoring sensors is sent, via Ethernet, RS-232/485, DNP3, or ModBus, to the ibridge units, which in turn modulate the data into, which traverses the AC or DC control busses back to the control house. This topology eliminates the need for trenching, conduit wiring, or other direct wiring between the field components and the control house, and adds greatly to the savings potential of the utility. For large or unique challenges in substation environments, extenders provide additional reach and scalability for networks that require more than one Gateway. As Series 5 Industrial products are rated for environmental extremes of -40 to 70 C, they can be installed either within the waterproof cabinets of the field components, or within waterproof casings attached to those components. Thermal conditioning of the cabinets or casings is not required. Installation of the iwire System within a substation is both flexible and rapidly realized. The product components are available in both AC and DC-powered versions, which allows connection to the substations AC and DC control busses. Utility s AC or DC Bus, Master Utility s AC or DC Bus, Serial Master Data Server / Terminal Server / MUX, etc. Applications and Interface Gateway ibridge with Serial Interface SERIAL Data Server / Terminal Server / MUX, etc. Applications and Interface Gateway Ethernet LAN Ethernet LAN extender Coupler Control House extender Coupler Control House AC or DC Control Bus Series 5 Data Server / Terminal Server / MUX, etc. DNP3 100base-T RS-232 RS-485 Modbus Monitor Controller Field Transformer Switch

7 Series 5 Components Coupler (MVC-200 and DPC-200) The Coupler is wired to the AC or DC low-voltage bus and connected to the Gateway with a coaxial cable. The Coupler takes the power line carrier signal from the Gateway or extender and injects the signal into the AC or DC electrical wiring. The Coupler is also available with an integrated disconnect switch (coupler breaker). Gateway (AG5) The Gateway is a remotely manageable network interface that converts Ethernet connections to a power line carrier signal and transmits the signal to the Coupler. The Gateway allows management and configuration of Series 5 via a web browser or Telnet command line interface. ibridge (AB5) The ibridge is wired to the AC or DC supply at each point requiring a communications interface. The ibridge recovers the power line carrier signal and converts it back into an Ethernet or serial connection for the devices or applications. It contains a test function to determine the power line carrier signal strength. The system provides enhanced Quality of Service (QoS) and can handle up to 8 different communication channels, such as high-speed data, Voice over (Vo), video-on-demand and surveillance, with rate-limited bandwidth management per user. exender (AX5) The extender provides additional power line carrier signal reach and scalability for networks that cannot be covered by a single Gateway.

8 Headquarters Seneca Meadows Parkway Germantown, Maryland U.S.A. Phone: Toll-Free in the US: Fax: TSE-SMO 3/08 The logo,, and Series 5 are trademarks and service marks of, Inc. 2008, Inc. All rights reserved.