Industrial Networking and Computing Solutions

Substation Automation Case Studies Confirmed Expertise

300+ Substation LAN Projects Key Reference Sites: 750 kV, 500 kV, 220 kV, 110 kV in China, 400 kV in Poland, 110 kV in Germany, 400 kV in Algeria, 154 kV in Korea, and more.

Trusted Partnership

Satisfied Customers: China’s State Grid, China Southern Power, Korea Southern Power, Efacec, Elkomtech

Using IEEE 1588 v2 to Achieve the Synchronization of Sampled Values on the Substation Process Bus Customer Benefit

Moxa’s PowerTrans IEC 61850 industrial Ethernet switches with IEEE 1588v2 support deliver nanosecond-precise synchronized sample values on the process bus. By supporting the latest technology, PowerTrans switches enhanced a major Chinese power utility’s efficiency and uptime while minimizing technological obsolescence.

At a Glance Region: Suzhou, Jiangsu, China Substation Voltage: 500 kV Customer Needs: IEEE 1588 v2 technology to obtain precise synchronized sample measurement values on the process bus.

Key Benefits • Precise IEEE 1588 v2 timing accuracy improves monitoring and troubleshooting capabilities. • IEEE 1588 eliminates dedicated time synchs, which reduces the cost of wiring to sensors • Using the latest IEEE 1588 v2 technology prevents technological obsolescence.

Project Introduction Jiangsu province’s rapid economic growth over the past few decades has made it one of the most energy-demanding provinces in China. With a 500 kV grid as its backbone, Jiangsu uses one of the largest electricity grids in China. 220 kV transmission plants cover all the urban and rural areas across the province. Key selection criteria in Jiangsu Provincial Electric Power Co.’s procurement process for electrical networking devices are advanced technology, high reliability, and excellent service. In the Suzhou 500 kV substation, electronic current/voltage transformers (CT/VTs) and merging units convert analog signals to the IEC 61850-9-2 digital format. To deliver highly accurate synchronization of the sampled measurement values (SMV) on the process bus, Jiangsu devised a novel design based on the IEEE 1588 merging unit synchronization standard. In this project, Moxa provided IEC 61850 compliant Ethernet switches with IEEE 1588 v2 nanosecond-precise time synchronization solutions on the IEC61850 process bus.

System Requirements • Nanosecond-level time synchronization of SMV streams • Zero-packet-loss Ethernet switches for mission-critical GOOSE transmissions • Next generation IEDs/protection relays with support for IEEE 1588 Ordinary Clock functionality

System Description Highly accurate sampled measurement values (SMVs) are a crucial component of accurate system reliability analysis in the process bus environment. Without a well-synchronized SMV process bus stream, the system will be unable to achieve differential protection, synchrophasor measurements, or digital fault recording. Moxa’s IEC 61850 industrial Ethernet switches were used in this project to form a doubly redundant fiber network backbone with dual-tree topology for extra reliability. The electronic CTs/VTs and Merging Units are installed in pairs. On the process bus, the Moxa Ethernet switches used IEEE 1588 v2 transparent clock functionality for nanosecond-level accuracy synchronization of SMV streams while also eliminating the extra cabling requirements of 1PPS or IRIG-B to propagate highly accurate timing signals. In addition, rugged Moxa Ethernet switches provide zero packet loss for GOOSE transmissions. The IEEE 1588 v2 standard will only become more important for electric utilities in the future. By deploying the technology now, Jiangsu puts their network ahead of the curve and prevents costly system obsolescence. In the meantime, the technology pays dividends today by increasing the electric utility’s efficiency and uptime through improved monitoring and troubleshooting.

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Using IEEE 1588 v2 to Achieve the Synchronization of Sampled Values on the Substation Process Bus

Product

Moxa’s Advantage Only one IEC 61850 compliant Ethernet switch with support for IEEE 1588 v2 technology is needed to synchronize the SMVs and transmit mission-critical GOOSE messages with zero packet loss.

PT-7728-PTP series IEC 61850-3 24+4G-port modular managed Ethernet switches (Up to 14-port IEEE 1588 v2 support)

PT-7728 series IEC 61850-3 24+4G-port modular managed Ethernet switches • Hardware IEEE 1588 PTP for precise time synchronization of networks (PT-7728-PTP series) • Isolated redundant power inputs with universal 24/48 VDC or 110/220 VDC/VAC power supply range • Zero package loss under harsh EMI stress • -40 to 85°C operating temperature range (fanless)

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IEC 61850 Substations Modernizations Customer Benefit

Moxa products construct a highly reliable communications backbone to reap the benefits available from IEC 61850, while also providing rear cabling with front display for easier installation and maintenance.

At a Glance Region: Algeria Company: Efacec/Sonelgaz Substation Voltage: 400 kV

Project Introduction Efacec, the largest electricity solution corporation in Portugal, is a multinational corporation that employs around 4000 people and processes over 1000 million Euros in orders annually. Efacec has a presence in over 50 countries and exports half of its production. Sonelgaz, the electricity generation, transmission, and distribution company owned by the government of Algeria, looked to Efacec to supply automation systems for four new substations. Sonelgaz had two transmission substations and two distribution substations that all needed to establish communications between the central units, the bay control units, and the digital protection relays while meeting the IEC 61850 standard. Efacec chose Moxa’s PowerTrans PT7728 series IEC 61850-3 compliant Ethernet switches to provide the necessary communications backbone and IP connectivity for the substation automation systems.

Customer Needs: Construct a highly reliable and rugged communication backbone for IEC 61850 modernization.

System Requirements

Key Benefits

• A redundant ring topology that prevents failure and ensures fast recovery times to provide power to end users without interruptions or outages

• High network availability • Expandable network bandwidth • Easier maintenance

• IEC 61850-3 certified products that operate reliably under harsh power substation conditions

• A redundant uplink ring backbone • Connection to the SCADA monitoring and control system as well as the central monitoring units for easy maintenance and control

System Description To obtain the benefits of IEC 61850, the underlying communications backbone must operate reliably in harsh substation environments. This is why IEC 61850 also specifies environmental criteria for EMI immunity. Efacec chose Moxa’s products to construct a rugged substation backbone because Moxa’s PowerTrans products are designed for substation environments and have passed IEC 61850-3 and IEEE1613 certification testing conducted by KEMA, a well respected independent consulting and testing laboratory for certification services in the energy and utility markets. Moxa’s PT-7728 IEC 61850-3 compliant Ethernet switches are deployed in a 400kV transmission substation automation system to connect with protection relays and other intelligent electronic devices (IED), together forming a Gigabit ring topology protected by the RSTP protocol to guarantee recovery in the event of network failure. The PT-7728 comes equipped with four Gigabit ports that provide the power needed for a redundant Gigabit Ring backbone, and leaves a spare Gigabit port for uplink to the core switches. Additionally, several PT-7728 Ethernet switches are connected to the SCADA monitoring local server and the substation redundant central units, to give system operators an efficient way to monitor operations at the field sites. Also, the modular rack mount design with rear cabling and front display is easy to install and maintain. By having a highly reliable and future-proof communications network designed specifically for substation environments, Sonelgaz is able to reap the benefits of IEC 61850 and achieve the project goals associated with the substation modernization program.

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IEC 61850 Substations Modernizations

Product

Moxa’s Advantage • The PowerTrans PT-7728 series supports the demands of power substation automation systems as described in the IEC-61850 directive • Non-stop operation is the key criterion for mission-critical applications. The PowerTrans supports dual, isolated, redundant power supplies with 88 to 300VDC power inputs • Modular rack mount capability, rear cabling access, and an easily readable product front display were all crucial for this project.

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PT-7728 series IEC 61850-3 24+4G-port modular managed Ethernet switches • IEC 61850-3, GOOSE, and IEEE 1613 Class 2 compliant (KEMA tested) • Fast ring recovery time (< 20 ms) • Isolated redundant power inputs with universal 24/48 VDC or 110/220 VDC/VAC power supply range • -40 to 85°C operating temperature range (fanless)

Substation Automation for a Large German Power Company Customer Benefit

Moxa´s product offers an easy and straight forward firmware, and it is upgradable to Turbo Chain technology in the future for improved resilience.

At a Glance Region: Germany Company: A large German energy provider

Project Introduction Power and other utilities are essential to the modern economic infrastructure, so their systems must have rock-solid reliability and be easy to maintain. A German energy provider was looking for a reliable network backbone to connect several large and small substations with the control center. As one of the largest power providers in Germany serving around 530,000 customers, they needed a solution that could help prevent failures by using intelligent monitoring and control. In the event of failure, the system should provide workarounds and immediate recovery options. The company sought a cost-effective solution that was easy to install and maintain.

Substation Voltage: 110 kV Customer Needs: Add a star network on top of the existing substation backbone in order to create a direct connection to each substation in case of a blackout.

System Requirements

Key Benefits

• IEC 61850-3 certified products that operate reliably under the harsh conditions in substations • A future-proof solution that can be upgraded to improve resilience through redundancy to be able to provide power to the end user without interruptions or outages • Connection to the control center for easy failure detection, control and maintenance

• Cost-effectively create a more resilient, and future-proof network • Lower installation cost

System Description The power provider deployed 48 of Moxa’s IEC 618603 PowerTrans switches. The Ethernet switch connects the substations with the control center in a star topology. This is a very resilient solution. If one or more substations fail, the control center still has a direct connection to all the other substations and can rely on them as a short-term replacement power supply. Another advantage of the star topology configuration is that it can be upgraded to Moxa Turbo Chain at any time in the future, enhancing the network’s reliability with added network redundancy. Moreover, the Moxa PT-7728 could, in just one product, fulfill each of the customer’s three different configuration requirements: 1) A number of 24-Port modular managed Ethernet switches 2) A number of 48-Port modular managed Ethernet switches 3) Three central Ethernet switches for the control room

With the Moxa PT-7728, the power provider could use one product to meet all three requirements. This all-in-one solution streamlines maintenance and reduces the costs and labor required to stock backup equipment. In addition, the PT series uses an easy and straightforward firmware that facilitates programming and installation. To increase the reliability of the system even further, the customer acquired a 24/7 service contract with a Moxa partner. This ensures that the products are maintained by experts and always deliver 100 % operational reliability.

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Substation Automation for a Large German Power Company

Present System Diagram

Tomorrow’s System Diagram Non-redundant stars can be reconfigured to redundant Turbo Chains

Optical Fiber

Product

Moxa’s Advantage • KEMA tested, IEC 61860-3 certified products that operate reliably in harsh substation environments • By using just one Ethernet switch to cover three different requirements, costs were saved on additional equipment ordered within the scope of the service contract • Moxa’s firmware is easy-to-use and the network is upgradeable to Turbo Chain in the future for improved redundancy

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PT-7728 Series IEC 61850-3 24+4G-port modular managed Ethernet switches • IEC 61850-3, GOOSE, and IEEE 1613 Class 2 compliant (KEMA tested) • Fast ring recovery time (< 20 ms) • Isolated redundant power inputs with universal 24/48 VDC or 110/220 VDC/VAC power supply range • -40 to 85°C operating temperature range (fanless)

Flexible Turbo Chain Technology for Guangzhou City’s Smart Power Distribution Networks Customer CustomerBenefit Satisfaction

The city of Guangzhou saved on wiring costs and created a reliable remote monitoring system by leveraging Moxa’s Turbo Chain Ethernet redundancy technology. Moxa’s Layer 3 Ethernet switches divided a large power distribution network into more efficient subnets for improved traffic flow and network efficiency.

At a Glance Region: Guangdong, China Substation Voltage: 110 kV Customer Needs: Build an efficient remote monitoring and control system to optimize the efficiency and reliability of power distribution networks.

Key Benefits • Reduce costs by simplifying wiring installation • High network availability thanks to Moxa’s Turbo Chain media redundancy • More efficient remote monitoring using Open Shortest Path First (OSPF)

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Project Introduction The Chinese province of Guangdong is already a major industrial area and energy consumer, and its energy needs are still growing rapidly. To meet this rising demand, Guangdong needed a highly efficient and reliable energy distribution system. Distribution systems deliver electric power from the transmission system to consumers. Consequently, a typical power distribution system is a complex network with many power utility connections. The capital of Guangdong, Guangzhou, is the third largest city in China and a key transportation hub that would be central to any power distribution modernization. To achieve effective and reliable electricity distribution management, Guangzhou deployed Moxa’s PowerTrans IEC 61850-3 Ethernet switches to deliver redundant remote monitoring for power distribution networks.

System Requirements • High network availability to ensure proper electricity transmission over different districts • A cost-effective network architecture to simplify network connections over a far-ranging power distribution network • Reliable performance under extreme temperatures • Layer 3 switching capability for large scale networks

System Description Guangzhou’s power distribution system is a complex web of power utility network connections spread over several districts, with correspondingly complex wiring requirements. It was time for Guanzhou to look for new technologies that would enable highvalue, efficient, and reliable operations to address the critical factors found in large-scale power distribution automation projects. Moxa’s breakthrough Turbo Chain redundancy technology dramatically simplifies the creation of multiple redundant connections over a widely dispersed power distribution network. With Turbo Chain, PowerTrans Ethernet switches can be daisy-chained together from one Ring Main Unit (RMU) to another, with each “chain” connected to the distribution substations. If a chain segment fails, the blocked path will rapidly activate within milliseconds to ensure high network availability. Moxa’s breakthrough Turbo Chain flexible redundancy technology frees system builders from the costly limitations of conventional ring architecture. Compared with conventional ring topology, Turbo Chain eliminates the need for kilometers of extra cable and additional Ethernet ports to form ring coupling paths. In addition, the PowerTrans PT-7828 Layer 3 Ethernet switches also support Open Shortest Path First (OSPF), which uses “link state” instead of “hop count” to determine the network route and optimize the network performance.

Flexible Turbo Chain Technology for Guangzhou City’s Smart Power Distribution Networks

Product

Moxa’s Advantage • Using Moxa Turbo Chain saves a significant amount on development cost, time, effort, cabling, and Ethernet ports over an extensive power distribution network. • Beyond the limitations of conventional redundant ring technology, Moxa’s Turbo Chain addresses the challenging environment found in complex power distribution network connections and enables high network availability with its selfhealing capability. • Moxa’s PT-7828 Layer 3 Ethernet switches support Open Shortest Path First (OSPF) to improve traffic flow and network efficiency.

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PT-7828 Series Layer 3 IEC 61850-3 24+4G-port modular managed Ethernet switches

PT-7710 Series Layer 2 IEC 61850-3 8+2G-port modular managed Ethernet switches • Layer 3 switching functionality to divide a large network into hierarchical subnets (PT-7828 series) • Turbo Ring, Turbo Chain, and IEEE 802.1D-2004 RSTP/STP • Zero packet loss under harsh EMI stress • -40 to 85°C operating temperature range (fanless)

Moxa’s IEC 61850-3 Switches Networks KOSPO’s Youngwol Substation Customer Benefit

KEMA testing verified that Moxa’s IEC 61850 Ethernet switches perform with zero GOOSE message loss in horizontal IED to IED communications. In addition, Moxa’s high port density design saves costs by reducing the device count.

At a Glance Region:YoungWol, Korea Company: Korea Southern Power Co., Ltd. (KOSPO)

Project Introduction Korea Southern Power Co., Ltd. (KOSPO), a subsidiary of Korea Electric Power Corporation (KEPCO), is engaged in generating power, developing power resources, and related subsidiary businesses. The company distributes all of its power output to KEPCO through KPX (Korea Power Exchange). KOSPO operates six thermal power plants across Korea. KOSPO’s 154 kV substation in YoungWol was built based on the IEC 61850 standard. In order to harness the emerging opportunities of smart grid technologies, KOSPO decided to deploy a future-proof networking infrastructure that can support more applications in the future. High port density is another top priority, because there are over 100 IEDs used in the substation automation system.

Substation Voltage: 154 kV

System Requirements

Customer Needs: IEC 61850-3-compliant Ethernet switches with high port density to connect a large amount of IEDs in a cost-effective manner while also providing zero-packet-loss performance under harsh environmental stress.

• IEC 61850 industrial networking devices • Future-proof networking infrastructure to support more applications • High port density networking devices to connect over 100 IEDs

Key Benefits • High network availability via rugged IEC 61850 Ethernet switches tested by KEMA • Reduce costs by minimizing device count • Future-proof Ethernet network is flexible enough to add any potential new applications

System Description Over a hundred VAMP IEDs are installed in this IEC 61850compliant substation automation system. To reap the benefits of the IEC standard, KOSPO selected the Moxa PT-7728 industrial modular Ethernet switches to form the rugged communications backbone. Moxa’s PT-7728 switches passed independent testing from KEMA, the well-respected independent consulting and testing laboratory. KEMA testing verified that the switches are fully capable of all the features described in the IEC standard, such as horizontal communication with zero GOOSE message loss. The Moxa PT-7728 switches also sported an impressive array of 18 fast Ethernet ports with optical fiber connections. This large number of ports helped accommodate the large number of IEDs that KOSPO needed to support. In addition, when configured in a dual homing topology, the PT-7728 supports Moxa’s Turbo Ring self-healing topology for media redundancy and fast network recovery in under 20 ms, even in networks of up to 250 switches.

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Moxa’s IEC 61850-3 Switches Networks KOSPO’s Youngwol Substation

Product

Moxa’s Advantage • KEMA tested, IEC 61860-3 certified products that operate reliably in harsh substation environments. • High port density design creates a cost-effective solution thanks to reduced device count. • Moxa’s Turbo Ring secures a fast and reliable redundant ring communication network with recovery time under 20 milliseconds.

PT-7728 series IEC 61850-3 24+4Gport modular managed Ethernet switches • Zero package loss under harsh EMI stress (KEMA tested) • Isolated redundant power inputs with universal 24/48 VDC or 110/220 VDC/VAC power supply range • -40 to 85°C operating temperature range (fanless)

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Substation Automation for a Steel Factory in China Customer Benefit

Moxa´s product offers a reliable platform for substation automation as the ideal front-end controlling units for data acquisition and protocol conversion.

Project Introduction

At a Glance

This stainless steel factory has deployed a power substation system that contains several subsystems. Each subsystem uses smart meters, and needs to optimize resources, centralize management, and enhance efficiency. In addition, all distributed smart meters at the field site need to be centrally monitored and managed by a system called the “CCMS3000 central management system”, located at the control center. Each 35KV/10KV substation communicates with the back-end server via Intranet, and manages the centralized management and monitoring of the 35KV/10KV. The entire system aims to optimize the power network management and maintenance cost, enhance power distribution quality and management, and deliver real-time discovery, analysis, recording, and handling of problems.

Region: China Substation Voltage: 35/10 kV Customer Needs: Establish a substation network that needs powerful computers as the front-end controlling units for data acquisition and protocol conversion.

Key Benefits

Powerful and reliable front-end controlling units for a stable platform that can perform data acquisition and protocol conversion.

One of the largest steel factories in China needed proper communication control units for data processing and protocol conversion with the devices at remote field sites. These computers would replace the IPCs and can easily create a distributed system at the front-end site with a centralized management platform at the backend control center.

The CCMS300 central management system is expected to bring reliability to real-time monitoring of the operation status of all devices at the substations. It needs to perform several tasks, such as analyzing historical workload, power consumption, and system balance, as well as enhance system or device operation efficiency.

System Requirements • Centralized and stable management platform for the distributed system • Front-end data processing for the field site devices • Protocol conversion among Modbus, DLT645, and TCP/IP IEC 104 • Redundant network architecture for continuous system operation • Easy integration with other communication system • Long MTBF to enhance system reliability

System Description

This substation system includes the following subsystems Factory 1:

Factory 2:

Cold-rolled Factory:

Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, 2 optical transceivers, and communication units. Station C: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units.

Main Station: A communication cabinet includes a telecommunication control unit (DA-662), and various communication units. This DA-662 is responsible for collecting and controlling all data from stations G, K, and the water station from Factory 1.

Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the cold-rolled factory and the cold-rolled water station. The communication between the DA-662 and the back-end server is based on the TCP/IP IEC 106 protocol

Station D: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The telecommunication control unit (DA-662) is responsible for collecting and controlling all data from stations A, B, C, D, E, and the water station from Factory 1.

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Hot-rolled Factory: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the hot-rolled factory and the hot-rolled water station.

Substation Automation for a Steel Factory in China

Product

Moxa’s Advantage • Fanless, cableless, no hard drive, and low power consumption design offers a highly reliable solution for substation automation • Ready-to-run RISC-based platform provides greater flexibility, multi-level open data transmission, and stability for easy integration with third-party devices • Multiple Ethernet ports for network redundancy and continuous operation. • Moxa’s embedded computers use software to provide ready and effective protocol conversion that facilitates data communication between legacy devices using a variety of protocols.

DA-662-LX RISC-based 19-inch rack-mounted data acquisition embedded computers • Intel XScale IXP-425 533 MHz processor • 128 MB RAM on-board, 32 MB flash disk • 2 KV optical protection for serial ports

NPort 5430 4-port RS-422/485 serial device servers • Easy IP address configuration with LCD panel • 10/100M auto-sensing Ethernet

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Embedded Computers as Front-end Controllers for SCADA in Substation Customer Benefit

Moxa´s product offers the powerful embedded computers as ideal front-end controllers for data acquisition, data computing and protocol conversion.

At a Glance

Project Introduction A company in Taiwan needed powerful front-end controllers to deal with front-end SCADA tasks, such as data computing, data acquisition, and graphics control. These controllers need to deliver reliable and stable substation operations in order to reduce the front-end workload. Each substation requires four to five computers to perform these tasks.

Region: Taiwan

System Requirements

Company: A major power substation solution provider

• x86-based computers as the front-end controller • Fanless and robust design • Reliable and powerful controller for data acquisition, data computing, and graphics control

Substation Voltage: 35/10 kV Customer Needs: The customer needs computers at the front-end field site for data acquisition and graphics control.

System Description Based on the x86-architecture, the DA-710 computers can perform various industrial tasks such as data acquisition and data computing. Their powerful performance reduces the front-end workload and they can easily manage the front-end substation devices. Moxa’s DA-710 computers are particularly well-suited for the distributed architecture of the substation since they can be used with the SCADA system and come with various serial ports, and digital input/output channels. In addition, the four Ethernet ports can be used to establish network redundancy and provide continuous system operation.

Moxa’s Advantage • x86-based computer with powerful performance • Capable of performing many tasks to reduce front-end workload • A variety of interfaces for different device connections • Fanless and robust design

Products

DA-710-XPE x86-based 19-inch rack-mounted embedded computers

• Intel Celeron M 2.0 GHz processor with 533 MHz FSB • 1 X 200-pin DDR2 SODIMM socket, supporting DDR2 533 up to 2 GB • 4 PCI slots for expansion modules • Quad 10/100/1000 Mbps Ethernet for network redundancy w w w. m o x a . c o m

Utility-grade Design for Substation Environments Substations are extremely demanding environments, so the Ethernet networks that operate there must be rugged enough to deliver high communications reliability, availability, and uptime. To meet the strict requirements of substation operations, Moxa has introduced industry-specific IEC 61850-3 and IEEE 1613 compliant Ethernet switches and industrial embedded computers that have been successfully deployed in over 300 substation networking and computing applications around the world.

Substation-specific Ethernet Switches and Embedded Computers • IEC 61850-3/IEEE 1613 compliance (KEMA tested) • Zero-packet-loss Ethernet switches • -40 to 85°C operating temp. (no fans) • 20 ms network redundancy • Cyber security

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