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A modern integrated approach to plant safety, reliability, and production

BY ROY E. COSS, JR., JAMES E. BOWEN, HARRISON T. COMBS, DONALD G. DUNN, MARTYN A. HILDRETH, & ALAN PILCHER

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HAT IS A smart industrial substation? Does it

Utility companies embraced the full power of digital microprocessors. With supervisory control and data acquisition (SCADA), utility substation protection, control, and system response was more reliable. Some SCADA benefits are as follows. 1) Notification is prompt remote operators are notified immediately of
EYEWIRE

enhance plant safety? Does it improve process reliability? Does it increase profits? How do I design a smart industrial substation? Do I already have most of the devices and components for retrofitting existing equipment? Background During the 1980s and 1990s, plant process control hardware evolved for pressure, flow, and temperature measurement sensing and control. Industrially hardened microprocessor control and communications technologies became standard. The industrial substation maintained a constant design, although microprocessor protection and metering was accepted for local devices.

any substation change. 2) Cost is reducedelect-

ricians do not go to remote substations. 3) Safety is improvedswitching operations do not require a person in the substation. 4) Data was accessed remotely on demand. The smart industrial substation is a best fit integration of traditional and modern substation devices with local/remote humanmachine interfaces (HMIs), pagers,

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and cell phones. These are tools the process and utility industries have adopted for monitoring, control, and shutdown tasks. The smart industrial substation shifts electrical technician functions from time-consuming tasks in front of substation equipment to time-saving tasks away from the substation. When fully implemented, the smart industrial substation automates substation activities and refines process and electrical control actions. For the smart industrial substation method to be considered by operating companies, it must be cost effective, intuitive, and have increased operator safety. This article justifies these requirements, proposes three system configurations, and reviews basic equipment types. Why Consider a Smart Industrial Substation? Smart industrial substations provide the following enhancements to existing plant operations. 1) the capability of intelligent electronic devices (IEDs) to inform technicians of alarms, trips, and critical substation actions 2) real-time monitoring and instant data access to switchgear, motor control center (MCC), or substation ancillaries 3) a user-friendly, graphical HMI interface for prompt and more thorough understanding of the substation configuration and health 4) substation control operations via a local or remote HMI, such as closing/tripping circuit breakers outside the arc-flash zone 5) online testing and trending for early impending failure detection to reduce unscheduled plant shutdowns 6) online documentation retrieval of the most recent document revisions from the substation 7) online instructional documents for equipment procedural review before performing an equipment task.
Annunciation

electrical supervisors via an alphanumeric pager or a detailed cell-phone voice message indicating the substation number and failure type. This significantly improves the notification method because a DCS console operator is not required to dispatch a process unit operator to go to the substation. It also improves communication to electricians before shift change or end-of-shift departure.
Online/Offline Testing and Trending

Online testing is a recent technology advancement. As this technology evolves, methods will be developed to achieve the modern goal of five to eight year maintenance intervals. Although this is an ambitious goal, operations must recognize that online circuit breakers may not trip if breaker exercising is not performed according to manufacturers instructions. Table 4 shows several available online testing modules. Industry acceptance and standardization will reduce the

TABLE 1. REAL-TIME MONITORING EXAMPLES. Switchgear heater ampacity Transformer heater ampacity Bus duct temperature Bus duct ampacity Bus duct ampacity Switchgear temperature Switchgear ampacity Thermostat temperature Switchgear critical temperature differences
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TABLE 2. TRADITIONAL ALARM EXAMPLES. Transformer fault Loss of control power Fire alarm Ground fault on high-resistance ground system

The smart industrial substation concept enables realtime monitoring of switchgear, MCC, and substation ancillary quantities and annunciation of traditional and new alarms. With more informative data and alarm notification for critical systems, faster operator response can be provided. Tables 13 indicate examples of real-time monitoring and alarm parameters. Traditionally, alarm notification was a substation common trouble alarm to a process main control room HMI or an electrician viewing equipment indicating lights and local annunciator status during substation rounds. Based on one authors experience, substation alarm response time was dependent on the distributed control system (DCS) console operator. Based on alarm priority of a substation common trouble alarm, operator dispatch to the substation may result in a response time of hours, not minutes. With modern right sizing, plant operators may not recognize an electrical condition requiring immediate attention. Occasionally, two or three trips to the substation are required before the appropriate person is notified. These types of prolonged response times can be improved by modern alarm technologies. Alarms can instantly notify

TABLE 3. NEW ALARM EXAMPLES. HVAC failure Switchgear heater failure Nitrogen purge pressure low Multi-function relay failure Circuit breaker trip coil failure Standby generator failure Standby power automatic transfer switch failure Battery system failure HMI failure UPS failure

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TABLE 4. PROPOSED ONLINE TESTING MODULES. Breaker timing Trip/close coil Transformer gas analysis Battery system Switchgear heaters Automated megger systems Switchgear partial discharge Switchgear acoustic emission Thermography (infrared)

TABLE 5. ONLINE DOCUMENTATION. System one lines Equipment drawings Breaker data Instruction manuals Device cut sheets. Proper permit guidance Required PPE Short video tutorials, such as, breaker racking operation video, including electric racking fitting and operation, when supplied

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cost of this technology and operational losses from unscheduled shutdowns. When online and offline testing is coupled with HMI database trending capabilities, an automatically generated trend report could notify when equipment repair should be scheduled, thereby avoiding an unscheduled shutdown and resulting loss of plant revenue. Reviewing trending events is also helpful in scheduling maintenance, rather than repairing unannounced failures. Typically, trends should not require complex analysis; an equipment trend may be as simple as a trend line with annual occurrences and previous maintenance dates. Another advantage of database trending is the capability of manual data entry. One beneficial example is archiving equipment infrared scans for future review and trending. With an online archive, the infrared scan and report, typically submitted for management review, can be immediately retrieved. Similarly, after offline testing is performed, manual data entry could be performed at the local substation. This provides a more accurate and less time-consuming archival method, rather than filling in hardcopy forms for database entry at a later time by a nontechnical person.
Documentation

to traditional drawings, manufacturers data, standard references, and instructional materials. Table 5 provides examples of online documentation. This documentation method significantly improves efficiency and reduces cost because pertinent data is accessible from a local HMI rather than going to a central plant library. Also, the most recent drawing revisions are available, instead of working from outdated substation stick file prints. Neither the company nor the electrical technician can accept the liability of not being prepared and informed of technical matters. Proposed Communications Configurations (Tiers) If industries are to obtain the full benefit of microprocessor devices, online communications must be implemented. Significant cost is incurred by procuring microprocessor devices, not from connecting to communicate. This applies to both new and existing installations. For a small incremental cost, both new and existing facilities can have an enhanced electrical system. Each electrical system must be evaluated to determine which communication configuration best fits the communicating devices and operational philosophy. Three communication tiers are envisioned. Tier 1 (Figure 1) provides fundamental communication within the substation to a local HMI, has minimal flexibility, and is the least costly. Tier 2 (Figure 2) increases communica-

The smart industrial substation HMI documentation provides archival capabilities previously available only at the plant library. Now, substations can have ready access

SMART SUB HMI

Touchpanel

LAN/Serial Communications

SMART SUB HMI

IED IED IED (a) PLC

IED IED IED

IED IED IED (b) PLC

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(a) Tier 1A communication system example. (b) Tier 1B communication system example.

tions capabilities outside the substation to a remote HMI, Intelligent Electronic Devices has increased flexibility, and is more costly. Tier 3 (Figure 3) is the most complex and flexible, with DCS integration Relays and Meters and automation. The digital protective relay and digital metering device Tier 1All communications remain within the substa- have been replacing the electromechanical relay and the tion building (Figure 1). All IEDs communicate, making analog meter for the past ten years. While the use of local substation data readily and conveniently available at microprocessor-based electronic protection and metering the substation HMI (touchpanel, laptop, or industrial devices are now widely accepted, one overlooked area is hardened PC). Monitoring, control, trending, and docu- the communication capabilities. mentation can also be performed by the HMI. Tier 1 moves substation monitoring and control from SCADA the front of each switchgear or MCC cubicle to a local HMI, where status lights, breaker posiElectrical LAN tion, and other pertinent data is graphically portrayed. Tier 2Communication is expanded to an HMI in the main Other Other control room (Figure 2), making Systems Systems local substation data readily available to operating personnel at the Switch process unit command center. Overall electrical conditions are efficiently reviewed from a central location, rather than making substation rounds. SMART SUB LAN/Serial Communications HMI Again, graphical HMI screens provide system overall health and system specifics. Tier 2 configurations are inplant and do IED IED not impose security concerns because they are not integrated IED PLC IED with other systems. Tier 3Communication is IED IED again expanded and integrates a 2 standalone HMI system with the Tier 2 communications system example. DCS or other HOST devices (Figure 3). Tier 3 should be the goal of every plant facility, because it DCS is safer, more efficient, and more economical than traditional hardDCS LAN wired methods. Motor starting and stopping is performed SCADA Electrical through the main control room Bridge Electrical Distributed DCS (or HMI) data highway to LAN I/O intelligent MCC contactors and circuit breakers. Expensive and Other Other space consuming substation interSystems Systems posing relay cabinets, MCC to marshalling cabinet wiring, and Switch multiconductor wiring to the DCS are eliminated. The cost jusSMART tification for the modern approach LAN/Serial Communications SUB HMI is the improvement in process efficiency and the reduction in IED IED operator time. One author experiIED IED PLC enced a savings of approximately 25% when connecting smart IED IED 3 MCCs to the DCS via a commuTier 3 communications system example. nications highway.

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The majority of electronic devices have the ability to communicate; this is either a standard or optional feature. In industrial applications, communications typically occurred over shielded, twisted-pair, copper wires. Traditionally, RS232/RS485 serial communications is used, with TCP/IP Ethernet communication for newer devices. Simple status indications for various circuit breakers protected by the individual relays could be displayed at a central location. Voltage, currents, power and power factor readings, etc., could be extracted and displayed on demand from the individual devices. Instead of hardwiring status indications to an annunciator, the data could be routed through the communications channel electronically, providing cost savings.
Nonrelay and Meter IEDs

With modern PLC communications, data could be obtained from other IEDs and placed in PLC memory locations for access by plant-wide data gathering systems, such as a plant DCS. Substation HMI With the evolution of microprocessor IEDs, more functions and features are included, adding to the device complexity. This can make IEDs both confusing and mysterious to plant operations. To circumvent the misunderstanding between plant operations and IEDs, a simple graphical HMI is proposedthe touchpanel. Touchpanel technology has been used for many years. Most touchpanel manufacturers have graphic capabilities that allow displays to show electrical single-line diagrams or switchgear doors, complete with controls and metering devices. Current, voltage, and other electrical system parameters may be displayed by linking screen objects to specific device input/output (I/O) points, thereby showing contact status or metering information. Besides displaying specific system parameters obtained from individual devices, the touchpanel can perform control actions, such as circuit breaker close or trip commands. Touchpanels have been used for years in this type of application. To prevent inadvertent operation of certain controls, most touchpanel software provides multiple level password protection at the screen or object level. Manual override can be implemented for maintenance or failure modes. Some touchpanel manufacturers, through the use of multiple drivers (communication protocols), allow simultaneous communication to multiple control systems. In other words, one port could communicate with a PLC and another port could communicate with a multidrop daisy chain string of protective relays. An industrial touchscreen computer expands the touchpanel HMI concept. It allows a third-party HMI to operate on a PC Windows-based platform, packaged as a touchpanel, thereby adding operating system and application software flexibility. The touchpanel HMI approach provides safety enhancements by automating normal manual operations, such as racking in and out of medium voltage breakers or breaker close/trip operations. Performing these operations from the touchpanel eliminates the need to have someone physically standing in front of the equipment, or connecting remote racking devices for switching. All control functions could be initiated from a localized touchpanel a safe distance from energized equipment. Implementing simple, intuitive graphical interfaces for both operators and technicians promotes safer conditions and more efficient operations, and HMI possibilities are limited only by the imagination. Protocol Converter With individual IEDs, PLCs, and HMIs available at the substation, the next step is to establish communications between the local devices. Both hardware methods and common languages are necessary for a functioning integrated system.

Some of the more common devices that can cause concern at the industrial substation level are battery chargers, UPS systems, HVAC systems, fire alarm systems, and transfer schemes. In most cases, these devices alarm a fault condition locally, but, unless a substation visit is performed, the fault may go undetected for extended periods of time. By ignoring some of these faults, more catastrophic failures may occur. Most, if not all, of these devices have the ability to communicate useful data to a central location for display. An abnormal condition could be automatically corrected, or a call out to maintenance personnel pagers or cell phones could be initiated for manual correction.
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Programmable Logic Controllers

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The programmable logic controller (PLC) has been in existence since the 1960s. Initially, they were developed for the automotive industry to replace hard-wired relay control logic that required modification every model year. Modern PLCs are much more than a control relay replacement. Through the years, analog data gathering, proportional integral derivative (PID) control, sequencing, multi-axis control, high-level math calculations, and multichannel communication capabilities have been added. This brings the PLC into the realm of the industrial computer. Size has been reduced from large clumsy boxes to modern shoeboxsized models. For many years, manufacturing and process industries have used PLCs for the unique combination of industrial ruggedness and flexible computing capability. Because of reliability and industrial hardness, the PLC is used in many applications at the industrial substation level. It is common for PLCs to be used in turbine control schemes, secondary selective residual bus transfer schemes, load shedding and motor re-acceleration schemes. Modern PLCs are small, versatile, and well adapted to industrial applications. In conjunction with providing their primary functions, PLCs are capable of troubleshooting potential problems. If a logic change is required, the ease of making program changes simplifies the engineers task. Gone are the days of having to trace back through control circuits and rerout wiring to make the logic change. Using a laptop computer, the engineer can make a few keystrokes to implement changes in the control scheme and then test the logic prior to putting the PLC back online.

Overview

With many different industrial communications systems available today, there are many communication formats or protocols. A protocol is a set of rules, which governs how data is sent from one point to another. In data communications, there are numerous widely accepted protocols for sending and receiving data. They may have open or closed proprietary communication protocols, however, even open protocol systems, are not always truly open. Today, conditions exist where two or more IEDs with the same protocol cannot communicate with one another. This prevents the integrator from incorporating these devices into one common system. It is the authors viewpoint that until the electronics and computer industries agree on a communications standard, there appears to be three options. 1) Utilize one manufacture with a common integrated communications architecture. This excludes integrating other manufacturers devices. 2) Use a protocol converter to allow connection of different protocols to a master system. 3) Use several different protocol converters, each having a specific protocol. The primary purpose of a protocol converter is to act as a translator. Protocols, such as DeviceNET, Profibus, Modbus RTU, and Ethernet/IP must be translated. Devicenet and Profibus are fieldbus types. Fieldbus includes many different industrial network protocols; most have been developed and supported by specific PLC manufacturers.
Modern Protocol Examples

able solutions are ones that allow the flexibility to configure the communications medium (i.e., serial Ethernet or fiber-optic solutions). Prewritten or developed communications drivers allow the flexibility of multiplexing several dissimilar devices into one common system. Data can then be stored within an internal database, making it available for interrogation by other master systems. Figures 13 show system examples using a protocol converter. Substation SCADA SCADA is commonplace within the process industry today; its value and use are well proven and documented. Why hasnt SCADA been better utilized within the electrical industry? Previously, a team of technicians walked the plant once or twice a day, observing electrical equipment status indications and obtaining meter readings. The gathered data was submitted to the plant electrical engineer, who used the data and previous experiences to diagnose a potential system problem. If it were possible to reliably inform a plant electrical engineer of the entire electrical system status from his office, the engineer could promptly dispatch technicians to prevent potential downtime and loss of production. This can be achieved by an electrical SCADA system with complete plant one-line diagram and status of each circuit breaker and electrical parameters, such as, current, voltage, and power consumption. Early warning alarms and shutdown trips can also be included. If SCADA screens (HMIs) are presented in a user-friendly and reliable way, the engineer will embrace it without reservation. The HMI should depict an easily recognizable and navigable image such as an aerial view of the plant or an electrical one-line diagram. The provided graphic is dependant on the complexity of the electrical system. Hot spots or hot keys should be incorporated within the image to permit the user to page down through the system and gain further detail and diagnostic information. A historical time-and-date-stamped alarm page should be made available to permit the analysis of cascaded alarms. A reporting tool should be incorporated to allow the user to produce graphical images of the historical data available within the system. This permits predictive maintenance scheduling, again increasing the efficiency of the process. The SCADA approach can achieve a staffing reduction, but, more importantly, personnel are removed from the switchgear area, and the electrical engineer is quickly provided with real-time data and diagnostic capability. The electrical technician does not have to wait for the process operator to inform him of equipment failures. When the equipment is monitored frequently, the electrical technician can be alerted in advance of an impending pump failure.

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Protocol conversion has been available for many years. The basic premise of communicating to two or more system devices remains the same. However, when the devices communicate differently, a translation must occur for each device to understand the other device. The basic communications protocol consists of a binary string of eight, 16, or 32 characters (bits). Depending on the protocol structure, the binary string contains data, which enables the receiving device to understand the transmitting device. Figure 4 shows an example of the commonly used serial protocol, Modbus RTU. A Modbus RTU message consists of four parts: 1) address location 2) function code that indicates to the server the action to perform 3) a data field that may contain additional function code data 4) error checking. Ethernet/Industrial Protocol (Ethernet/IP) is a modern communication system suitable for use in industrial environments. Ethernet/IP allows industrial devices to exchange time-critical application information. These include simple I/O devices, such as sensors/actuators, and complex control devices, such as PLCs, and process controllers.
Hardware

Microprocessor hardware systems are available to integrate different protocols into one integrated system. Some manufactures utilize either an industrially hardened PC or a dedicated single-board microprocessor. The most adapt-

Address

Function Code

Data

Error Check

4
Modbus RTU serial protocol example.

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Providing useful information to operators allows them to perform their function with greater efficiency. This is the significance of the intelligent system, but what happens when the engineer is away from the office? Operator Notification In addition to HMI or DCS alarms, modern communication advances enable plant personnel to be immediately informed of equipment status changes and trips. Todays HMI packages, through modem connections, can provide text messages to pagers or voice/text notification to cell phones. This communication method directly informs electrical personnel of system changes. Therefore, operator intervention is not always required and results in improved plant awareness and responsiveness. Distributed Control System Selecting the most effective interface method between a DCS and a substation monitoring system depends on the data type and quantity viewed. Most DCS systems are configured as a process network and a local control network. Typically, the process network contains the plant I/O. The local control network is primarily used to control the process network. In addition to the operator workstations, the local network has other modules, such as a history module, a PLC gateway module, a computer link module, etc. These module types enable the DCS to provide different functionality for varies applications. Typically, the DCS has three basic interface methods. 1) a serial interface card fits into one of the process manager I/O slots 2) a PLC gateway requires module(s) to link to the local control network 3) a computer link requires module(s) to link to the local control network. Each method has advantages and disadvantages based on the type and data quantity required to transfer. In addition, both strictly reading data from the substation network and writing data to the network impacts the interface type. The serial interface requires less configuration time and is primarily intended as input for efficiently importing large data quantities. Additionally, the typical serial interface has firmware for running diagnostic routines that monitor and report communications time-outs or errors between the module and the interfaced slave device. Most serial interfaces use Modbus RTU protocol with extensions for real numbers and string support. Typically, communications to a field device is by EIA RS-232D or EIA RS485 standards. The RS-232D communication distance limit is 15 m (50 ft), whereas RS-422/485 protocol is supported to 1.2 km (4,000 ft). The PLC gateway and computer link are not limited in the quantity of data or the data direction moving across network modules. However, limits are based on the type of overall system architecture employed at the substation level. A PLC gateway, as the name implies, is best utilized for a PLC interface. The computer link module interfaces with any device or network regardless of the configuration or communication protocol. These two methods are primarily intended as input or

output vehicles that can efficiently import or export large quantities of data. These two interface types require a greater amount of time to configure the interface and individual data points. When determining the DCS interface method, the following criteria should be considered: 1) Has the substation monitoring system configuration been thoroughly reviewed? 2) Will one server be used for all substations or one server per substation? 3) How is the data structured in the implemented system? 4) Is the data sequential per node or each individual device? 5) What is the communication protocol? 6) What is the distance to each server? 7) What type of data (status bits, integers) is moving across the networks? 8) Will data be imported and exported? Modern Ethernet Network Hardware and Software Basics Previous discussions provide the essentials for a rudimentary communications system. When implementing a Tier 2 or 3 system, a modern approach, such as an Ethernet configuration, should be utilized. Ethernet is the backbone of modern IT digital communications. The industrial sector has been slow to follow the IT lead, however, industry is moving towards using Ethernet and industrial Ethernet as the overall plant communications backbone. Likewise, fiber Ethernet solutions are becoming an even more viable industrial communications link, as the price of fiber and fiber terminations decrease. Fiber Ethernet solutions provide longer distances, greater bandwidth, future expansion capabilities, and electromagnetic interferrence (EMI) protection. Many PLC and IED manufactures are selecting Ethernet/TCP communications as the standard communications protocol. When only serial communications connections are available, serial device servers and protocol converters are readily available. Serial device servers have RS-232 or RS485 ports, a CPU with embedded operating system, and software to encapsulate serial data into TCP packets. The TCP packets are sent via an Ethernet connection. Many serial device types and configurations are available, making it possible to connect many serial communicating devices to an Ethernet network with minimal effort.
Hub, Switch, and Router

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The Open System Interconnection (OSI) Reference Model (7-Layer) is a generic model for all network types and is the basis for TCP/IP. Examples of the first three layers are introduced with commonly used network devices, i.e., hub, switch and router. Layer 1: Physical Layer (Figure 5)A hub (repeater) receives data packets on one port and forwards the data to all ports. As more IEDs are connected to a hub, or string of hubs, each IED competes for the same amount of bandwidth, therefore, when a hub is used in an Ethernet network, data collisions occur frequently.

Layer 2: Data Link Layer (Figure 6)A switch is more complex than a hub with built-in intelligence and memory to remember the physical medium access control (MAC) address of nodes on the network. A switch directs data packets from a receiving port to a destination port by comparing the MAC address in the data packet header with the MAC address in the switchs learned database. By increasing the network bandwidth, this data control method significantly reduces packet collisions. Switches are ideal to control and monitor Ethernet network applications. The ability to learn and update the address database is convenient for reorganizing automation equipment during commissioning or troubleshooting. Layer 3: Network Layer (Figure 7)A router is used to divide different networks or subnets. Routers maintain knowledge of the IP network by using detailed user defined routing tables. Typically, the two sides of a router will be on different networks. If a laptop computer is connected on one side of a router it will not be able to communicate on the other side unless it is assigned a new IP address. This makes Level 3 routing unfriendly to maintenance personal who might need to move from one part of a plant to another.
Network Topologies

topologies are ring and star. Ring topology (Figure 8) is used when long distances are required between switches and it is cost prohibitive to make a home run for each switch. All traffic must travel on the ring, thus limiting the installation bandwidth. Star network topology (Figure 9) directly connects each IED to a centralized location, improving bandwidth over ring topology. Star topology is ideal for data acquisition and control systems when long distances are not required. A major asset of star topology is a single point failure only affects the failed device, not the entire network. Implementing ring or star networks in a redundant configuration increases the networks fault tolerance for critical applications.
Software

Network topologies vary depending on plant philosophy, configuration, and application. Two typical network

Host software varies because many hardware vendors have developed unique, device-specific software interfaces. However, many vendor and third-party HMI packages use object linking and embedding (OLE) for process control (OPC). From the collaboration of Microsoft Corporation and significant hardware and automation suppliers, OPC is the industry standard. The OPC standard interface makes possible interoperability between automation and control applications, field systems and devices, and business and office

Learned MAC Address

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1 1 2 3 4

Data In

Data Out

Data Out

Data Out

Data In Switch example.

Data Out

5
Hub example. HMI Ring IP Address Table Ring Manager 4

Switch Data In Data Out IED

Switch

Switch

IED

IED

7
Router example. Ring topology example.

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HMI

Star

IED

Switch

IED

PLC IED

PLC

9
Star topology example.

a) The ability to readily and easily access real-time data, historical data, trending data, on-line testing, drawings and documentation enables plant personnel to perform more effectively and efficiently. b) Provides immediate alarm warnings to authorized users via cells phones, pagers, and the plant intranet. c) Provides stable operation time and reduces time of repair. d) The system is password protected with unique password levels, i.e., engineer, operator, maintenance, etc. e) The system is quickly and easily upgradeable from local only (Tier 1) to a SCADA interface (Tier 2) or DCS interface (Tier 3). Conclusion From the above discussions, it is intuitive that this is the time to interconnect existing and new communicating devices. It can be justified from safety, operations and maintenance viewpoints. IEDs, HMIs, touchpanels, PLCs, SCADA, DCS, communications devices, and protocols are evolving daily, hence, application engineers must remain informed of modern advances in these areas. Although the details presented above will change, fundamental concepts will not change. With a straightforward, common-sense approach, it is time to advance the industrial substation into the world of smart interactive communications. For More Information
[1] Modbus-IDA Web page [Online]. Available: http://www.modbus.org [2] OPC Foundation home page [Online]. Available: http://www.opcfoundation.org [3] DNP home page {Online]. Available: http://www.dnp.org [4] Charles Spurgeon's Ethernet Web Site [Online]. Available: http://www.ethermanage.com [5] InterOperability Laboratory home page [Online]. Available: http:// www.iol.unh.edu [6] Lantronix home page [Online]. Available: http://www.lantronix.com/ learning/tutorials/index.html [7] OPC Technology [Online]. Available: http://www.ethernet.industrialnetworking.com/opc/intro.asp [8] Differences between industrial ethernet fiber optic backbone, ring, and star topologies [Online]. Available: http://www.n-tron.com/pdf/Ring_vs_Star.pdf [9] Alliance for Telecommunications Industry Solutions (ATIS) Telecom Glossary [Online]. Available: http://www.atis.org/tg2k/ [10] Daryls TCP/IP Primer {Online]. Available: http://www.tcpipprimer. com [11] PLCopen home page [Online]. Available: http://www.plcopen.org [12] TCP/IP Tutorial [Online]. Available: http://www.itp-journals.com/ c04100.htm

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applications. OPC standards eliminate writing custom drivers for data exchange with field devices; thus, multivendor systems seamlessly share real-time and historical data. With a client-server relationship, OPC server data obtained from IEDs, PLCs, and remote I/O can be shared with clients (HMI, SCADA or DCS systems). Alarms and event notifications are provided on demand, including process alarms, operator actions, informational messages, and tracking messages. The new OPC Data Exchange (DX) standard will provide interoperable data exchange and server-to-server (OPC-to-OPC) communications across Ethernet networks. The OPC DX standard extends the existing OPC data access specification during run-time, independent of the real-time application protocol being used. OPC is the technology of choice in the central control room and is proposed as the technology of choice for the smart industrial substation. Summary 1) The smart industrial substation enhances plant electrical personnel safety by physically removing the operator from the arc flash zone (NFPA70E, Part II). 2) Facilities with existing IEDs can be economically and effectively connected to a fully communicating system. This provides operating, maintenance and diagnostics capabilities to local and remote locations. Implementation is inexpensive because the significant cost was incurred when the IEDs were procured, installed, commissioned, and made operational. 3) New grass roots sites designed with IEDs, HMIs, etc., offer a substantial cost reduction by eliminating the need for hardwiring, interposing relays, and DCS I/O. 4) By using existing, industrially hardened devices, the smart industrial substation concept provides the following inherent electrical system enhancements.

Roy E. Coss, Jr. (rcosse@powl.com), James E. Bowen, Harrison T. Combs, and Alan Pilcher are with Powell Electrical Manufacturing Company in Houson, Texas. Donald G. Dunn is with Equistar Channelview in Channelview, Texas. Martyn A. Hildreth is with Areva T&D Inc. in Houston, Texas. Coss, Bowen, and Dunn are Senior Members of the IEEE. This article first appeared in its original form at the 2003 IEEE/IAS Petroleum and Chemical Industry Technical Committee Conference.

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