Hybrid Substation Modernization: IEC 61850, DNP Integration with Modular Enclosure

Wunderlich-Malec Engineering (WM) delivered a complete turnkey substation solution that leverages advanced technology and proven engineering efficiency. Our expert team managed the full scope of design, engineering, fabrication, and programming to energize a complete replacement substation. The project utilized state-of-the-art IEC 61850 technology that integrates seamlessly with existing communication systems through a comprehensive Digital Network Protocol (DNP), resulting in a modern and reliable hybrid substation architecture.

Our engineers specialize in executing complex utility and substation projects within tight outage windows while helping clients reduce overall project costs. WM provides fully integrated turnkey solutions that feature our high-quality Modular Integrated Control Enclosures (MICE). Each enclosure is fully programmed, factory tested, and commissioned on site to ensure smooth integration with existing utility infrastructure and long-term operational reliability.

Background & Customer Needs/Requirements

A major eastern utility needed to expand its reliable power needs with a replacement two-line, three breaker and capacitor bank substation. The utility required:

• New IEC 61850 (DNP) equipment for protection and control relays.
• Integrated into first of its kind “Hybrid” modular control enclosure including physical control handles and switches for local control.
• Communication with existing Orion RTU and HMI used for area SCADA communications.
• Delivered and commissioned within a tight turnover window.
• A project budget significantly less than a substation “stick-build” solution.

WM ’s Approach & Solutions

1. Design & Fabrication of Modular Integrated Control Enclosure (MICE):
   WM designed and constructed the modular control enclosure at WM’s manufacturing facility in Winslow Maine. The control house included:
   • A single Orion RTU, a single HMI unit, Hirschman network switches, with a new SEL-2488 GPS clock and over 15 protection relays.
   • The Orion RTU device was used for data collection and control for the local area SCADA system.
   • The HMI was used for indication and alarming only; no controls were passed through the HMI.
   • All Local control is performed from the control handles and switches physically located within the protection cabinets.
2. Programing & Factory Acceptance Testing (FAT) of MICE:
   WM completed programming and FAT at our Maine manufacturing facility concurrently with the site substation construction saving onsite costs and schedule. The programing and FAT process provided:
   • In collaboration with the client design, programming and commissioning for the SCADA RTU/Data Concentrator and HMI.
   • Relay Testing of all elements for protection and automation logic. Numerous settings and protection logic issues were uncovered during the FAT. This saved countless weeks onsite.
   • Also, having complete control over the RTU and HMI allowed for quick and easy corrections to the issues found during the FAT.
   • Circuit breaker simulators and Doble F6150 test sets, simulated substation operating conditions, faults, and interlocks.
   • WM Testing and Commissioning Engineers performed operations using relay faceplates to prove all RTU and HMI logic.
3. On-Site Coordination and Testing:
   WM provided on-site engineers in tandem with the MICE FAT to deliver the following services:
   • SCADA acceptance test was completed with the end devices (Breakers, switches etc.) and testing was with area dispatch.
   • WM provided all National Electrical Testing Association (NETA) Acceptance Testing for the new devices installed onsite including testing of Breaker CT’s, CCVT’s, SSVT’s, and Grounding Systems.
   • WM supported or provided auxiliary substation equipment and system testing, commissioning and documentation.
4. Transmission Line “Cut Over” to New Substation:
   As each transmission line was cut over to the new station, WM provided Lead Commissioning Engineering services which included:
   • Provide final signoff on all equipment to be placed into service.
   • Supervision of satellite synchronized End-to-End testing of pilot communications systems for all comm aided tripping schemes between the substation and remote end.
   • Energization, Phasing and Loading Sequence Plans which provide utility operations with detailed energization sequence, primary/secondary phasing and loading plans for placing the station into service for the first time.

Why Choose Wunderlich-Malec Engineering?

Wunderlich – Malec has industry leading professional engineers and manufacturing capabilities that listen to the customers and deliver project solutions that achieve their expectations and requirements.

Contact us today to learn how WM can provide you with process and facility solutions with our diverse team of design engineering of Subject Matter Experts.

Principal Project Leader: Ryan Bolduc, PE.
Email: ryan.bolduc@wmeng.com