Substation Automation, Communications & SCADA/DCS Integration
IEC 61850, SCADA and DCS configuration (Siemens SICAM and PCS 7, ABB, Honeywell, Yokogawa and others), I/O tests and FAT/SAT.
Substation and industrial automation connects relays, equipment and the control system so the operator can see and command everything from the control room. ENP configures, tests and commissions both substation automation (IEC 61850 and SCADA) and industrial distributed control systems (DCS), from relay configuration to signal testing in the control room.
Substation automation architecture
| Level | Equipment | Role |
|---|---|---|
| Process level | CT/VT, breaker, disconnector, merging unit | Measurement and command of primary equipment |
| Bay level | Relays and bay controllers (IEDs) | Protection, control and measurement for each feeder |
| Station level | Gateway, HMI, local SCADA server, GPS | Data collection and link to the control centre |
| Network level | Industrial switches, optical fibre | Communication with redundancy |
IEC 61850 and protocols
| Protocol | Application |
|---|---|
| IEC 61850 MMS | Relay to server and HMI (measurements, events, commands) |
| GOOSE | Fast peer-to-peer messages between relays (interlock, trip, block) within milliseconds |
| Sampled Values | CT/VT samples over the network (digital substation) |
| IEC 60870-5-101/104 | Link to control centre and dispatch |
| DNP3 | SCADA link in distribution and industrial networks |
| Modbus RTU/TCP | Link to instruments, meters and PLCs |
ENP work here includes creating and editing SCL files (ICD / CID / SCD), dataset and report configuration, GOOSE mapping, time synchronization (SNTP/PTP), communication testing with tools such as IEDScout and Wireshark, and GOOSE testing with real injection.
Brands and software covered
| Brand | Relay / IED | Control and SCADA |
|---|---|---|
| Siemens | SIPROTEC 4 / 5 (DIGSI software) | SICAM PAS, SICAM 230, SICAM A8000, Spectrum Power |
| ABB / Hitachi Energy | Relion series (PCM600 software) | MicroSCADA Pro, System 800xA |
| Schneider Electric | Easergy, MiCOM | EcoStruxure Power SCADA, ADMS |
| General Electric (GE) | Multilin series | EnerVista, iCS |
| SEL | 700 series | SEL Real-Time Automation Controller |
Distributed control systems (DCS)
A DCS controls an industrial process (refinery, petrochemical, steel, cement, power plant) with distributed controllers, a communication network and operator stations. In many projects the electrical side (relays, breakers and motor control centres) must also be connected to the DCS so the process operator sees the electrical status from the same screen.
| Brand | DCS system |
|---|---|
| Siemens | SIMATIC PCS 7 with WinCC for operator screens |
| ABB | System 800xA |
| Honeywell | Experion PKS |
| Yokogawa | CENTUM VP |
| Emerson | DeltaV |
ENP activities in DCS
- Loop check: from sensor and transmitter to the operator screen
- I/O test: digital and analogue I/O cards, 4 to 20 mA signals and saturation tests
- Cause & effect and interlock logic testing: based on the C&E matrix
- Electrical integration: connecting relays and MCCs to the DCS with Modbus, PROFIBUS, PROFINET or IEC 61850
- Power management and load shedding: testing loss-of-source scenarios
- FAT and SAT: factory and site acceptance tests with formal minutes
- Operator screens and alarms: graphics review, alarm priority and sequence of events (SOE)
Network and security
- PRP and HSR communication redundancy for critical substations
- Time synchronization for accurate event recording
- Network segregation, firewalls and access control per IEC 62443 and IEC 62351
- Project backup, version control and recovery
Deliverables
Final configuration files, a tested signal list, FAT/SAT reports, network documentation with address plan, and operator training.
Scope of work
- IEC 61850 configuration (SCL, GOOSE, MMS) and communication testing
- Siemens relays and SCADA (SICAM PAS, SICAM 230, DIGSI)
- IEC 104, DNP3 and Modbus protocols
- DCS: loop check, I/O test and cause & effect matrix
- Electrical integration with DCS (PCS 7, 800xA, DeltaV and others)
- Power management, load shedding, FAT and SAT