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Substation control system

To ensure the substation is run efficiently, a control and monitoring systems are
needed. These systems should display the current status of all plant equipment,
including alarms and secondary system indicators. They should also provide digital
outputs to open and close switchgear, raise and lower taps on transformers, and show
analogue values for key parameters like voltage, current, megawatts, and megavars.

Substation control and monitoring systems: The eyes and ears of every power system
Aside from the standard indicators and controls, additional functions like
synchronizing, reactive and voltage control, operational and safety-related
interlocking, load control to prevent frequency collapse, etc., are also possible to
implement.

Nevertheless, the primary topics covered in this technical article are synchronization,
interlocking operations, and the substation control system.

There are typically three tiers of supervision and control, or points of human machine
interface (HMI), in a substation’s control and monitoring system. However, just the
first two tiers of control may be used, as the exact number of tiers relies on regional
norms.
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1. Bay Control: In the switchyard/switchgear buildings (bay control)

2. Station Control: At the substation control room (station control)
3. From a central network control center: Network control, remote control
center, regional control center
Typically, the decision to switch between bay or station control is made from the bay
control point, though it can also be done on an equipment-by-equipment basis. The
rules for switching control points, known as control arbitration, are up to the user.
The station control point is where you’ll make the decision as to whether the circuit is
under network control or station control.
From one facility to the next, you should expect to see a wide range of signals, alarms,
and regulated equipment.

Individual needs can dictate the grouping of alarms for network control points and
stations. At each control point, you should have the alarms and indications that are
necessary for the substation to operate safely and satisfactorily. At the station or bay
control point, you might find special facilities like synchronization.
For a visual representation of the hardware present at the HMIs, see Figure 1 below.

There is currently a marked difference between traditional human-machine interfaces

and those that are computer-based, thanks to the ever-increasing usage of digital
technology in substation equipment . The use of computer-based HMI is on the rise in
station control rooms, in addition to its prevalence at the network control level.
On the other hand, the station level does still have a few traditional HMIs. Common
and traditional HMI at bay level is direct wire control.

Ok, let’s get into the details!

Table of Contents:
1. The Good Old School HMI
2. Computer-Based Digital HMI
3. Substation Computer Performance
1. Master Station Computer
2. Subsystems Computers
3. Communications
4. Computer Loading
4. Control From the Substation
5. Control From a Network Control Center
6. Architectures of Control Systems
7. The Need For Substation Extension and Modification
8. Minimizing Undesirable Operations in the Control System
9. Interlocking Systems
10. Synchronizing and System Stability
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11. BONUS! Download Guide To Power System Protection For Relay Designers
(PDF)

1. The Good Old School HMI

On the equipment itself or in nearby local control cubicles, you’ll find the good ol’
standard HMI at bay level, which consists of control switches, indicator LEDs, and
meters. In most cases, these facilities are utilized when the controlled plant is being
serviced or as a fallback in case the station level or network control center fails.
On the station level, the primary control room is where you should find the control
panels. The human-machine interface (HMI) devices should be organized according to
circuits, and the open/close switches should only operate devices in the same
substation area as the panel itself.
Figure 1 – An example of human machine interface (HMI) locations

F
igure 1 – An example of human machine interface (HMI) locations

The substation layout should be depicted in a mimic diagram, which is often a single-
line figure. The purpose of the mimic board is to provide operational staff with an
overall perspective of the state of the switchgear. It could be assembled from separate
circuit control panels that are placed side by side.
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The main equipment layout should be the basis for the arrangement.

It’s a good advice to mount the alarm notification equipment next to the mimic
diagram or include it inside the control panel. When the alarm is turned on, the
corresponding window should flash and a sound should be heard. By pressing an
accept button, you can turn off the sound alert, stop the window from flashing, and
set the notification to react to further initiation.
To turn off alarms that have been reset, there should be a reset button.

To start the steady-state illumination of all alarm windows, you’ll need to press a lamp
test button. Separate windows, such as a red display rather than a white or amber
one, should be used for trip or protection-triggered alarms. All switches, including
controls and selectors, must be of the approved variety that meets all applicable
standards, including IEC 60337.

To operate the control switches, you’ll need to use two separate actions or use both
hands. The devices used for indication must be of the approved variety and conform
to recognized standards like IEC 60051.
Figure 2 – HMI panels of an old 132 kV substation
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Figure 2 – HMI panels of an old 132 kV substation

2. Computer-Based Digital HMI

Distributed computer systems are the backbone of computer-based human-machine

interfaces. At the network level, such systems were commonplace, but at the
substation control level, they have only been used since the 1990s. Interfacing with
machinery and relaying data to control rooms, remote terminal units (RTUs) play an
essential role.

Remote control units (RTUs) will take digital and analogue data and send out control
signals.
Depending on the level of redundancy needed, the following things may be utilized in
different quantities by the human machine interface:

1. Visual display unit (VDU)

2. Alphanumeric keyboard
3. Printer
4. Plotter
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5. Trackball
6. Joystick
7. Special function panel
8. Mouse
Large substations should have a board-style mimic display or “Visual display unit”
from a visual display device. The aforementioned components are necessary for
operator consoles to operate the substation (at the substation level) or the power
system (at the network level). All four modes—online, maintenance, training, and
programming—should be accessible via the console. Two or more consoles cannot be
“online” at the same time unless they have special software interlocks.
No less than full-graphic, multi-color visual display systems capable of continuous
operation around the clock are required. Here is the data that has to be shown:

1. Information that cannot be changed (such as a substation single-line

schematic)
2. Variable operating parameters
3. Real-time dynamic variables
Each control panel has to have an operator’s keyboard with dedicated function keys so
that commands can be typed in. You can enter data and run the computer and
substations in general using the system keyboard. On top of that, the system might
necessitate an alphanumeric keyboard.

To make managing and monitoring the plant easier, a touch screen Visual display unit
or special function panel should be considered when the substation is only manned
periodically. Plant control, Visual display unit page selection, and alarm
acknowledgment would all be handled by a limited number of dedicated push buttons
and switches on the special function panel.
All control commands to impact the operation from an HMI typically require two
stages of control: select-check-execute.

Figure 3 – LCD display of ABB’s protection relay REF 542plus HMI

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F
igure 3 – LCD display of ABB’s protection relay REF 542plus HMI

3. Substation Computer Performance

To provide the required system dependability, functional availability, and ease of

equipment maintenance, the kind and configuration of computer-based control
equipment for substation secondary system applications should be carefully
considered.

3.1 Master Station Computer

It is imperative that the HMI’s underlying computer system, the master station, has
exceptional stability and practically constant functional availability. The standard
method for meeting these demands is to implement hardware redundancy for the key
components.

When the online unit fails, the redundant components are often set to activate
automatically.
Figure 4 – Master substation computer
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Figur
e 4 – Master substation computer

3.2 Subsystems Computers

Although the reliability of computer subsystems used for distributed data collecting
should be top-notch, it is often acceptable to have the odd breakdown, as it will
typically only impact a small portion of the entire system.
Component selection should be of a high grade to provide a long mean time between
failures, however redundancy is typically not used for economic reasons.

3.3 Communications

The ability to communicate is crucial for distributed computing systems. In the

absence of physical routing for communication channels, stringent mechanical or
electrical protection is necessary. It is recommended to offer main and standby
channels over physically segregated paths in situations where the functions related to
subsystems computers are critical.
In most cases, adequate availability can be achieved using just one channel.

Figure 5 – Digital protection panel: IEC 61850 communications

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Figur
e 5 – Digital protection panel: IEC 61850 communications

3.4 Computer Loading

When a power network is functioning in a normal state, which it is for the majority of
the time, computer-based control systems often have no trouble handling all of the
activities connected with updating telemetered data and providing support for the
human machine interface (HMI). Nevertheless, when there are significant disruptions
to the network, the amount of data that is telemetered and the processing that is
connected with the HMI will both increase in the same proportion.
While it is possible to reduce these criteria to some degree in the event of catastrophic
disruptions, it is imperative that no data be lost under any circumstances.

Figure 6 – HMI screen of OHL 110 kV details page

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Figure 6 – HMI screen of OHL 110 kV details page (photo credit: dacom.ro)

4. Control From the Substation

Previously, high voltage (HV) substations typically included on-site personnel who
oversaw and managed the substation. The substation control room was responsible
for monitoring and controlling the substation’s operations through local control.

The local control comprises a data collection system and a command issuance
mechanism, known as the Human-Machine Interface (HMI). The data gathering system
provides comprehensive information regarding the status and location of circuit
breakers, disconnectors, and earthing switches, as well as line loads, transformer
temperatures and loadings, voltage levels, relay functions, and time-stamped events.

Within the substation control room, this information is presented on wall boards and
mimic diagrams (for traditional equipment) or on visual display devices (for digital
equipment). The substation control room is responsible for issuing control commands
to circuit breakers, disconnectors, tap changers, and other equipment. This allows for
complete control of the substation through the use of the Human-Machine Interface
(HMI).
In the event of a failure in control from the substation control room, an alternative
control system for circuit breakers, disconnectors, earth switches, and other
components can be activated from control cubicles situated on or near the primary
equipment.

Figure 7 – Control From the Substation

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Figure 7 – Control From the Substation (on photo: ATS’s Control System installed in
substation control room; credit: ats.com.vn)

5. Control from a Network Control Center

In the present period, all utility companies have used remote control systems, which
has resulted in a decrease in the number of manned substations. Consequently, this
has led to a reduction in the workforce and operational expenses. Currently,
substations are often unstaffed, and the control function is executed from a central
control center that also receives information from and manages multiple other
substations.

This is accomplished through the utilization of a “Supervisory Control and Data

Acquisition” system (or shorten SCADA system).
An “RTU” or remote terminal unit delivers essential information from each substation
to the area control center, allowing for a comprehensive understanding of the
monitored network. Additionally, it facilitates the transmission of directives from the
area control center to the substations.
The procurement of energy and the ideal layout of the power transmission network in
large networks with several area control centers are overseen and supervised by a
load dispatching center. This center receives information from power plants, area
control centers, and other sources.
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Local control in unmanned substations is retained for standby and maintenance

needs, albeit with a simpler architecture. However, in recently constructed
substations, the typical local control facility often consists of a display unit equipped
with a keyboard. If there is a backup control facility at a lower level, the system can be
built upon and combined with the remote control equipment. By implementing
substation automation features like automated busbar switching and automatic
activation of transformers and reactors, it becomes feasible to minimize the volume of
data sent to regional control centers, thereby alleviating the workload of control
center personnel.
In addition to its use in network control, information from the substations is crucial for
maintenance and for specialized relay personnel to monitor relay protection.
Therefore, there is a requirement for enhanced transmission of information, which
can be delegated to various centers based on their category.

Figure 8 – Electrical network control center

Figure 8 – Electrical network control center

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6. Architectures of Control Systems

During the process of selecting the architecture for the control system, it is important
to take into consideration the following factors:

Factor #1 – Dimensions and design of the substation, maximum voltage, and planned
expansion:
 Size and area
 Indoor or outdoor
 AIS or GIS (air-insulated or gas-insulated substation)
Factor #2 – Manning of substation:
 Manned
 Unmanned
Presently, the majority of substations are designed to operate without personnel. At
times, a utility company may choose to run a substation with staff present for various
reasons, including:

 Keeping up with the usual useful practice

 Technical reasons (for example, HV equipment and/or communication
lines for remote controls that don’t work well)
Factor #3 – Determination of secondary system functions to be incorporated
Factor #4 – Technology of protection and control subsystems
 Old school (traditional)
 Computer-based
Factor #5 – Projected total cost of ownership, which consists of:
 Investment,
 Training, education, and operation,
 Maintenance.
In addition to the needs for availability and dependability that the transmission
network and the energy consumer have, the characteristics that have been discussed
above should be taken into consideration in great detail. These factors serve as a
foundation for the decision-making process about the architecture of the control
system and the protection that is linked with it.

Download Guide (PDF) – Design, testing, and commissioning of an IEC 61850-based

substation automation system

7. The Need For Substation Extension and Modification

There are a variety of causes that could lead to the extension or modification of
substation secondary security systems:
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1. It is necessary to procure additional primary bays.

2. The configuration of the substation has been changed.
3. The primary equipment is being replaced.
There is an installation of additional secondary equipment, such as busbar
protection or remote control, for example.
Spare capacity should be integrated in cable trenches, ducts, and tunnels, as well as
in the central control building, during the initial design stage of a substation. This will
make it easier to extend the control system in the substation.
The typical control building is divided into two distinct functional areas, which can be
classified as follows: maintenance and operations:
1. The area that is not reliant on the size of the substation (for example,
service areas related to staff)
2. The space depending on the size of the substation (for example, the relay
room)
It is important that the component that is dependent on the size of the substation has
the capability to accept any extensions or alterations that may be foreseen with
reasonable certainty.
Good Reading – How to convert an old substation into a digital substation?

8. Minimizing Undesirable Operations in the Control System

Historically, the primary focus about undesired operations was from electromagnetic
interference. Compliance with EMC regulations is crucial for all utilities. Currently,
there are comprehensive international standards that thoroughly address this topic.
Additionally, a significant amount of knowledge and skill has been acquired in the area
of cable screening and earthing practices to minimize the likelihood of malfunctions.
Moreover, the growing utilization of fiber optic cables for inter-bay
communication has also diminished this risk.
Nevertheless, in the contemporary period, we are confronted with an additional peril,
specifically, cyberattack or the unauthorized manipulation of circuits and network
controls by malicious individuals commonly referred to as “hackers“. Occurrences of
this phenomenon have previously been witnessed on electricity networks in Ukraine in
2015 and several other countries in the last ten years.
Ensuring the protection of control systems software against intrusion by hackers is
increasingly crucial.

Good Reading – Should we be concerned about the cybersecurity of modern digital

substations?
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9. Interlocking Systems

Many utilities utilize interlocking systems to guarantee the proper sequence of

operation for disconnectors, fixed earthing switches, and circuit breakers (when
necessary). This ensures that operators do not compromise the integrity of the
transmission system by mistakenly or unintentionally operating equipment.
The prevalent situations encompassed by interlocking schemes are:

Condition #1 – Interlocking mechanisms are employed between disconnectors and

circuit breakers to prevent the interruption or connection of load currents by the
disconnectors.
Condition #2 – The interlocking mechanism between disconnectors and earth switches
guarantees that earth switches cannot be closed onto circuits that are locally
energized. Similarly, earth switches cannot be energized when closed by the closing of
a disconnector.
Condition #3 – The interlocking mechanism allows the disconnector to be engaged for
maintenance purposes only when the adjacent earth switches on both sides are
closed.
Condition #4 – In order to guarantee that the switching operations for on-load
transfers are carried out in the correct sequence at multiple busbar substations and
that there is a parallel path between the disconnectors that are attached to each bar.
During the functioning of the bus transfer, certain utilities prevent the tripping of a
bus coupler or bus section that is providing the parallel path.
Condition #5 – To guarantee that a bus coupler or bus section circuit breaker can only
be closed when the disconnectors on each side are either both closed (in an
operational condition) or both open (in a maintenance condition), the circuit breaker
must be in the operational condition.
Condition #6 – To prohibit access to portions of a substation where safety
clearances may be violated (for example, filter equipment), unless suitable safety
precautions have been implemented, such as isolating the area and earthing it.
In situations when the switching sequences solely include operated switchgear, it is
common practice to use electrical techniques to accomplish the interlocking. If
everything goes according to plan, the right interlocking status ought to be
automatically checked whenever an operation is started, regardless of whether the
operation is being started by an operator or as part of an automatic sequence.

Interlock Scheme Example

Incomer Circuit Breaker and Earth Switch Interlocking

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The incomer circuit breaker (Q-IL or Q-IR) and earth switch (E-IL or E-IR) are
mechanically interlocked to prevent both being closed at the same time. The earth
switch can only be closed once the circuit breaker is open and racked-out to the test
position. The circuit breaker can only be racked-in for closing, once the earth switch is
open.
An additional level of interlocking is required. The incomer earth switch cannot be
mechanically operated until power is removed from the incoming supply. This
prevents closing the earth switch onto a live supply.

This interlocking is achieved in one of two ways:

Way #1 – Mechanically by using key access. The incomer earth switch (E-IL or E-IR)
handle operation is only accessible by using a key, retrieved from the upstream circuit
breaker when it is open and racked-out.
Way #2 – Electrically by using a solenoid. A solenoid is energized when the upstream
circuit breaker is open and racked out, allowing access to the incomer earth switch (E-
IL or E-IR) handle operation.
Figure 9 – Interlock scheme example: Incomer circuit breaker and earth switch
interlocking

Figur
e 9 – Interlock scheme example: Incomer circuit breaker and earth switch interlocking

While it is possible that it will be necessary to bypass an interlock during an automatic

switching scheme on occasion, it is important to note that this should be the exception
rather than the rule.
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In situations when the switching sequence involves plant that is operated manually,
the interlocking could be accomplished using either electrical or mechanical
components. In an ideal scenario, the interlocking should be designed in such a way
that it instantly verifies the status of the interlocking before any operation is
performed. When it is feasible, interlocking schemes should allow for the greatest
possible operational flexibility and should not impose predetermined working
sequences, unless it is absolutely necessary to do so.
The schemes should be intrinsically fail safe, and it should be impossible to defeat
them unless one makes use of tools or a facility that is specifically designed to override
them.
In general, such override facilities ought to be lockable with a lock that is distinct from
the others. Interlocking should be effective for switching and operating sequences
when they are followed in either direction (for example, if an earthing switch needs to
be closed before an access gate can be opened, then the gate needs to be closed and
locked before the earth switch can be opened). Interlocking should also be effective
for switching sequences.

There are some locations where it might not be possible to completely interlock a
device. As an illustration of this, consider the earth switch that is located at the line
entry. In most cases, it is not feasible to interlock it with the equipment that is located
at the remote end of the line, unless the line in question is extremely short. Under
these circumstances, it would be considered standard practice to provide a warning
label that indicates that the earth switch is not fully interlocked.
Mechanical interlocking is typically accomplished through the utilization of key-
operated systems. It is recommended that the keys have a design that is not capable
of being mastered. This means that there should not be any master keys, nor should it
be feasible to produce a master key with the current design.

At the same substation location, the differs (Note: differ is the name for the difference
in a key that prevents it from being interchangeable with another) should not be
repeated by users. Typically, an identifying reference that is specific to the location is
carved on the interlocking keys by the staff. During normal operation, the key is
typically positioned in a certain location, and the key locations are typically identified
with the identifier of the associated key.
The identifier would typically comprise the system number of the switching device
where the key is typically located.

Good Reading – Learn how to interpret interlocking schemes between MV cubicles

(single line and wiring diagrams)
There is a possibility that key exchange boxes will be required for more complex
interlocking schemes. These boxes ought to be situated in areas that are convenient
for the substation to operate normally. Electromechanical key exchange boxes, which
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offer a connecting up of the electrical interlocking and the mechanical interlocking for
a circuit, may be required periodically. These boxes are used to exchange keys.
Historically, the process of electrical interlocking has been accomplished by the
utilization of hardwired contact logic. Therefore, it is easy to develop some software
logic in order to carry out the interlocking function when using computerized control
systems because the state of all of the plant is already known within the control
system.

However, when additions or alterations are required at the substation, it is possible to

run into complications. It is evident that this considerably minimizes the amount of
cabling that is required on the site, and it is highly effective when used to new site
substations.
Usually this will involve building a mimic of the entire revised substation in the factory
to test the modified interlock software before loading it onto the actual computer
system on site.

10. Synchronizing and System Stability

It is necessary to perform synchronization on transmission networks in order to

guarantee the maintenance of system stability, reduce the amount of damage
accomplished to plant, and make it easier to re-parallel a split system. When circuit
breakers are closed when the systems on either side are not in synchronism, a shock
load can be imposed on generators, and a significant amount of synchronizing power
will flow on the network.
This has the potential to cause a significant amount of disruption.
When it comes to the transmission network, the two forms of synchronizing that are
typically utilized are check synchronizing and system synchronizing (refer to Figure 10).
Check synchronizing is typically the case when the circuit breaker that is being closed
is located within a system that is solidly connected, whereas
system synchronizing takes place when the circuit breaker that is being closed is
connecting two systems that are not connected simultaneously.
Figure 10 – Example showing check synchronizing and system synchronizing (Note, the
circled ones indicate the CBs are open)
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F
igure 10 – Synchronizing relay connections and comparison of incoming and running
voltages for synchronizing

For a synchronized close to occur, the following requirements must be met:

1. Both sides of the CB have the same frequency, which is referred to as zero
slip.
2. Additionally, there is no phase angle variation between the voltages on
both sides of the CB.
3. Both sides of the CB have the same magnitude of voltage, which is
approximately equivalent to the nominal value
Referring to Figure 11, the synchronizing relay will determine whether or not these
conditions are satisfied within a predetermined range of tolerance.

Figure 11 – Synchronizing relay connections and comparison of incoming and running

voltages for synchronizing
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Figure 11 – Synchronizing relay connections and comparison of incoming and running

voltages for synchronizing

In most cases, there will not be any voltage transformers installed on the busbars.
Accordingly, a voltage selection scheme will be necessary in order to acquire the
voltage of the busbar in order to establish a “running” voltage.

Because the absence of a voltage will be interpreted as a dead bar or a dead line, it is
important to highlight that the output of the voltage transformers should be
monitored (for example, by an MCB). A voltage selection scheme, an analogue
synchronizing screen that would display the running voltage, the incoming voltage,
and a synchroscope that would indicate the instantaneous angle between the two
voltages were among the components that comprised the synchronizing system in the
past.
In order to achieve a “lamps-light” or “lamps-dark” kind of synchronization, these
instruments were occasionally supplemented with lamps.
Referencing Figure 12, which illustrates the MCB and its auxiliary contacts connected
alongside the main contacts, here’s how this system works:

Figure 12 – Schematic Diagram of VT Miniature Circuit Breaker with Auxiliary Contacts

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Figu
re 12 – Schematic Diagram of Voltage Transformer (VT) Miniature Circuit Breaker (MCB)
with Auxiliary Contacts

It is also possible to utilize a synchronizing relay in order to perform a check on the

voltages, angle, and slip of this relay, as well as the contacts of this relay that are
linked in series into the closing circuit of the circuit breaker. In order to ensure that
manual and automatic switching are in sync with one another, this synchronizing
mechanism would be essential.

Because computerized control systems “know” all of the necessary information to

determine an appropriate running voltage, there is no longer a requirement for a
separate voltage selection scheme for synchronization. This is because the computer
control system has become more advanced.
To enable manual closing of the circuit breakers, it is also possible to design
appropriate software that will allow all of the necessary inspections to be carried out
within the computer control system. Any of the following conditions will typically
result in the circuit breaker being activated to close the circuit:

 Dead bar/dead line

 Live bar/dead line
 Dead bar/live line
 Live bar/live line (with check synchronizing or system synchronizing as
appropriate)
The synchronization check function is typically incorporated into contemporary
numerical auto-reclose relays (also known as auto-reclosing) in order to facilitate
automatic closing.

The link is as follows :

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https://electrical-engineering-portal.com/substation-control-monitoring-systems

Great Reading – The art of generator synchronization techniques that every true
engineer MUST know about