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Enhancing MSETCL’s Power Management with Advanced Substation Automation

Enhancing MSETCL’s Power Management with Advanced Substation Automation

  • Industry: Power

Background

Maharashtra State Electricity Transmission Company Limited (MSETCL) aimed to enhance its power distribution network, improve operational efficiency, reduce downtime, and ensure reliable power supply across the region.

Customer Vision

To establish a Central Management Center for centralized monitoring and control, automating substations to enhance efficiency, reliability, and operational effectiveness within the power distribution network.

The Challenge

Automate and centralize the monitoring and control of multiple substations, improving operational efficiency, reducing downtime, and ensuring a reliable power supply.

Our Approach and Solution

Understand

We engaged with MSETCL to fully comprehend their needs and vision, focusing on the necessity for automation to improve operational efficiency and system reliability.

Build

We developed a comprehensive solution, deploying:
  • Ethernet Switches: IEC-61850-3 compliant, KEMA certified switches for reliable data transmission.
  • RAS PCs and Workstation PCs: High processing power, fanless computers with wide operating temperature ranges.
  • Gateway PCs: QUAD core processing units with PRP/HSR support, IRIG-B hardware, and RAID configuration options.
  • Terminal Servers: 16-port RS232/485/422 to Ethernet converters for connecting non-IEC-61850 devices.
  • Modbus Gateways: Converters from Modbus RTU to Modbus TCP/IP for seamless communication.

Deliver

Our team successfully implemented the project, ensuring all substations were interconnected and monitored in real-time from the Central Management Center. This setup provided robust data transmission, enhanced monitoring, and seamless integration of all substation assets.

Value Delivered

  • Increased Operational Efficiency: Automated monitoring and control reduced manual intervention, minimized downtime, and optimized energy usage.
  • Enhanced Monitoring and Control: Real-time data transmission enabled comprehensive monitoring, improving system responsiveness and reliability.
  • Improved System Reliability and Resilience: The robust network infrastructure minimized the risk of outages and ensured continuity of power supply.
  • Data-Driven Decision Making: Real-time data facilitated proactive maintenance and optimization strategies, leading to cost savings.
  • Enhanced Customer Satisfaction: The reliable and efficient power distribution network resulted in higher customer satisfaction.
By leveraging our expertise in power management and automation, we delivered a robust solution that transformed MSETCL’s power distribution network, ensuring enhanced efficiency and reliability.
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Kailash-Vaibhav, Parksite, Vikhroli (West), Mumbai 400079, INDIA
  • CIN No.: U32109MH1985PLC036338
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MGate MB3180/MGate MB3280/MGate MB3480

1, 2, or 4 port Modbus serial (RTU) to Modbus TCP gateway

Product Features

  • Supports Auto-Device Routing for easy configuration
  • Supports route by TCP port or IP address for flexible deployment
  • Convert between Modbus TCP and Modbus RTU/ASCII
  • 1 Ethernet port and 1, 2, or 4 RS-232/422/485 ports
  • 16 simultaneous TCP masters with up to 32 simultaneous requests per master
  • Easy hardware setup and configuration
 

Product Description

These devices are Modbus RTU to Modbus TCP gateway converter for 1, 2, & 4 Serial ports. Up to 16 simultaneous Modbus TCP masters are supported, with up to 31 RTU/ASCII slaves per serial port. For RTU/ASCII masters, up to 32 TCP slaves are supported. Standard Modbus network integration, Moxa protocol converter gateway The three standard MGate™ Modbus RTU to Modbus TCP gateway converters (MB3180, MB3280, and MB3480) are designed for easy integration of Modbus RTU to Modbus TCP gateway.. With these models, Modbus serial slave devices can be seamlessly incorporated into an existing Modbus TCP network, and Modbus TCP slaves can be made accessible to serial masters. The MB3180, MB3280, and MB3480 offer features that make network integration easy, customizable, and compatible with almost any Modbus network. High density, cost effective gateway The MGate™ MB3000 Series Modbus RTU to Modbus TCP gateway converters can effectively connect a high density of Modbus nodes to the same network. The MB3280 can manage up to 62 serial slave nodes, and the MB3480 can manage up to 124 serial slave nodes. Each RS-232/422/485 serial port can be configured individually for Modbus RTU or Modbus ASCII operation and for different baudrates, allowing both types of networks to be integrated with Modbus TCP through one Modbus gateway. Auto-Device Routing for Easy Configuration (Patent Pending) Moxa’s Auto-Device Routing function helps eliminate many of the problems and inconveniences encountered by engineers who need to configure large numbers of Modbus devices. A single mouse click is all that’s required to set up a slave ID routing table and configure Modbus gateways to automatically detect Modbus requests from a supervisory control and data acquisition (SCADA) system. By removing the need to manually create the slave ID routing table, the Auto-Device Routing function saves engineers significant time and cost.

Datasheet
Technology Page

MGate MB3660 Series

8 and 16-port redundant Modbus gateways

Product Features

  • Supports Auto-Device Routing for easy configuration
  • Supports route by TCP port or IP address for flexible deployment
  • Innovative Command Learning eliminates the need to key-in
  • SCADA Modbus commands (acts as an agent gateway)
  • High performance through active and parallel polling of serial devices
  • Supports serial (Master) to serial (Slave) communications
  • 2 Ethernet ports with the same IP or dual IP addresses
  • SD card for configuration backup Modbus Auto-Device Routing
  • Access by up to 256 TCP master/client devices, or connect to 128 TCP slave/server devices
  • Dual VDC or VAC power inputs with wide power input range
  • 3-pin fault relay circuit for event alarms
  • 2 kV isolation protection (for “-I” models)

Product Description

The MGate MB3660 (MB3660-8 and MB3660-16) are Modbus RTU to Modbus TCP Gateway, redundant Modbus gateways that convert between the Modbus TCP and Modbus RTU/ASCII protocols. They can be accessed by up to 256 TCP master/client devices, or connect to 128 TCP slave/server devices. The MGate MB3660 series Modbus RTU to Modbus TCP Gateway has isolation models which provides 2 kV isolation protection suitable for power substation applications. The MGate MB3660 gateways are designed to easily integrate Modbus TCP and RTU/ASCII networks. The MGate MB3660 series gateways offer features that make network integration easy, customizable, and compatible with almost any Modbus network. For large-scale Modbus deployments, MGate MB3660 gateways can effectively connect a large number of Modbus nodes to the same network. The MB3660 series can physically manage up to 248 serial slave nodes for 8-port models or 496 serial slave nodes for 16-port models (the Modbus standard only defines Modbus IDs from 1 to 247). Each RS-232/422/485 serial port can be configured individually for Modbus RTU or Modbus ASCII operation and for different baudrates, allowing both types of networks to be integrated with Modbus TCP through one Modbus gateway.

Datasheet
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IKS-G6524A Series

24G-port Layer 2 full Gigabit managed Ethernet switches

Product Features

  • Supports MXstudio for easy, visualized industrial network management
  • V-ON™ ensures millisecond-level multicast data and video network recovery
  • 24 Gigabit Ethernet ports
  • Up to 24 optical fiber connections (SFP slots)
  • Fanless, -40 to 75°C operating temperature range (T models)
  • Turbo Ring and Turbo Chain (recovery time < 50 ms @ 250 switches), RSTP/STP, and MSTP for network redundancy
  • Isolated redundant power inputs with universal 110/220 VAC power supply range

Product Description

Process automation and transportation automation applications combine data, voice, and video, and consequently require high performance and high reliability industrial grade rackmount switches. The IKS-G6524A series full Gigabit backbone switches are equipped with 24 Gigabit Ethernet ports, and support Layer 3 routing functionality to facilitate the deployment of applications across networks, making them ideal for large scale industrial networks. The IKS-G6524A’s full Gigabit capability increases bandwidth to provide high performance and the ability to quickly transfer large amounts of video, voice, and data across a network. The switches support the Turbo Ring, Turbo Chain, and RSTP/STP redundancy protocols, and are fanless and come with an isolated redundant power supply to increase system reliability and the availability of your network backbone.

Datasheet

IKS-6726A/IKS-6728A Series

24+2G/24+4G-port modular managed Ethernet switches

Product Features

  • Modular design lets you choose from a variety of media combinations
  • -40 to 75°C operating temperature range
  • Supports MXstudio for easy, visualized industrial network management
  • V-ON™ ensures millisecond-level multicast data and video network recovery
  • 2/4 Gigabit plus 24 Fast Ethernet ports for copper and fiber
  • Turbo Ring and Turbo Chain (recovery time < 20 ms @ 250 switches), RSTP/STP, and MSTP for network redundancy
  • Isolated redundant power inputs with universal 24/48 VDC or 110/220 VAC power supply

Product Description

The IKS-6726A/6728A series of industrial rackmount switches are designed to meet the rigorous demands of mission critical applications for industry and business, such as traffic control systems and maritime applications. The IKS-6726A/6728A’s Gigabit and fast Ethernet backbone, redundant ring, and 24/48 VDC or 110/220 VAC ual isolated redundant power supplies increase the reliability of your communications and save on cabling and wiring costs. The modular design of the IKS-6726A/6728A also makes network planning easy, and allows greater flexibility by letting you install up to 4 Gigabit ports and 24 fast Ethernet ports.

Datasheet

RKS-G4028 Series

 

Product Features

  • Meets a wide range of demands from Fast Ethernet to full Gigabit industrial networks (up to 28 Gigabit ports)Modular interfaces for flexible connector type combinations
  • Support for IEEE 802.3bt PoE for up to 90 W output per port
  • High EMC immunity compliant with IEC 61850-3 and IEEE 1613
  • Hardware-based IEEE 1588 PTP for high-precision time synchronization
  • Turbo Ring and Turbo Chain (recovery time < 20 ms @ 250 switches) , and STP/RSTP/MSTP for network redundancy
  • -40 to 75°C operating temperature range
  • Supports MXstudio for easy, visualized industrial network management
  • Developed according to the IEC 62443-4-1 and compliant with the IEC 62443-4-2 industrial cybersecurity standards

Product Description

The RKS-G4028 Series is designed to meet the rigorous demands of mission-critical applications for industry and business, such as power substation automation systems (IEC 61850-3, IEEE 1613), railway applications (EN 50121-4), and factory automation systems. The RKS-G4028 Series’ Gigabit and Fast Ethernet backbone, redundant ring, and 24 VDC, 48 VDC, or 110/220 VDC/VAC dual isolated redundant power supplies increase the reliability of your communications and save on wiring costs.

The modular design of the RKS-G4028 Series also makes network planning easy, and allows greater flexibility by letting you install up to 28 Gigabit ports with various connector types.

EDS-608/EDS-611/EDS-616/EDS-619 Series

8, 8+3G, 16, 16+3G-port compact modular managed Ethernet switches

Product Features

  • Up to 19 optical fiber connections in a compact switch (EDS-619)
  • Modular design with 4-port copper/fiber combinations
  • Hot swap media modules for continuous operation
  • Turbo Ring and Turbo Chain (recovery time < 20 ms @ 250 switches), RSTP/STP, and MSTP for network redundancy
  • TACACS+, SNMPv3, IEEE 802.1X, HTTPS, and SSH to enhance network security
  • Easy network management by web browser, CLI, Telnet/serial console, Windows utility, and ABC-01
  • Supports MXstudio for easy, visualized industrial network management

Product Description

The versatile modular design of the compact EDS-600 series Ethernet switch allows users to combine fiber and copper modules to create switch solutions suitable for any automation network. The EDS-600’s modular design lets you install up to 3 Gigabit Ethernet ports and 16 Fast Ethernet ports, and the advanced Turbo Ring and Turbo Chain (recovery time < 20 ms) technology, RSTP/STP, and MSTP helps increase the reliability and availability of your industrial Ethernet network. Models with an extended operating temperature range of -40 to 75°C are also available. The EDS-600 series supports several reliable and intelligent functions, including IEEE 1588 PTPv2, EtherNet/ IP, Modbus/TCP, LLDP, DHCP Option 82, SNMP Inform, QoS, IGMP snooping, VLAN, TACACS+, IEEE 802.1X, HTTPS, SSH, SNMPv3, and more, making the Ethernet switches suitable for any harsh industrial environment.

Datasheet

EDS-510E Series

7+3G-port Gigabit managed Ethernet switches

Product Features

  • V-ON™ ensures millisecond-level multicast data and video network recovery
  • 3 Gigabit Ethernet ports for redundant ring or uplink solutions
  • Turbo Ring and Turbo Chain (recovery time < 20 ms @ 250 switches), RSTP/ STP, and MSTP for network redundancy
  • RADIUS, TACACS+, SNMPv3, IEEE 802.1x, HTTPS, SSH, and MAC address sticky to enhance network security
  • Security features based on IEC-62443
  • EtherNet/IP, PROFINET, and Modbus/TCP protocols supported for device management and monitoring
  • Supports MXstudio for easy, visualized industrial network management

Product Description

The EDS-510E is a Industrial grade managed ethernet switch. The Gigabit managed Ethernet switch is designed to meet rigorous mission critical applications, such as factory automation, ITS and process control. The 3 Gigabit Ethernet ports allows great flexibility to build up a Gigabit redundant Turbo Ring and a Gigabit uplink. The switch adopts USB interfaces for switch configuration, system file backup, and firmware upgrade, making it easier to manage.

Datasheet

EDS-G508E/EDS-G512E/EDS-G516E Series

8G/12G/16G-port full Gigabit managed Ethernet switches

Product Features

  • V-ON™ ensures millisecond-level multicast data and video network recovery
  • Up to 12 10/100/1000BaseT(X) ports and 4 100/1000BaseSFP ports (EDS-G516E)
  • Turbo Ring and Turbo Chain (recovery time < 50 ms @ 250 switches), RSTP/STP, and MSTP for network redundancy
  • RADIUS, TACACS+, MAB Authentication, SNMPv3, IEEE 802.1x, MAC ACL, HTTPS, SSH, and MAC-address sticky to enhance network security
  • Security features based on IEC-62443
  • EtherNet/IP, PROFINET, and Modbus/TCP protocols supported for device management and monitoring
  • Supports MXstudio for easy, visualized industrial network management

Product Description

The EDS-G500E series is a Industrial grade managed ethernet switch& is  equipped with 8/12/16 Gigabit Ethernet ports and up to 4 fiber optic ports, making it ideal for upgrading an existing network to Gigabit speed or building a new full Gigabit backbone. Gigabit transmission increases bandwidth for higher performance and transfers large amounts of triple-play services across a network quickly. Redundant Ethernet Turbo Ring, Turbo Chain, RSTP/STP, and MSTP increase system reliability and the availability of your network backbone. The EDS-G500E series is designed especially for communication demanding applications, such as video and process monitoring, ITS, and DCS systems, all of which can benefit from a scalable backbone construction.

Datasheet

MDS-G4028

28G-port Layer 2 full Gigabit modular managed Ethernet switch

Product Features

  • Multiple interface type 4-port modules for greater versatility
  • Easy replacement of defect ports to minimize downtime and MTTR
  • Passive backplane to minimize the risk of malfunction
  • Ultra-compact size for easy installation
  • Rugged die-casting design for use in harsh environments
  • HTML5 for a better user experience

Product Description

The MDS-G4028 Series modular managed ethernet switch supports up to 28 Gigabit ports, including 4 embedded ports, 6 interface module expansion slots, and 2 power module slots to ensure sufficient flexibility for a variety of applications. The highly compact MDS-G4000 Series is designed to meet evolving network requirements, ensuring effortless installation and maintenance, and features a hot-swappable module design that enables you to easily change or add modules without shutting down the switch or interrupting network operations. The multiple Ethernet modules (RJ45, SFP, and PoE+) and power units (24/48 VDC, 110/220 VAC/VDC) provide even greater flexibility as well as suitability for different operating conditions, delivering an adaptive full Gigabit platform that provides the versatility and bandwidth necessary to serve as an Ethernet aggregation/edge switch. Featuring a compact design that fits in confined spaces, multiple mounting methods, and convenient tool-free module installation, the MDS-G4000 Series switches enable versatile and effortless deployment without the need for highly skilled engineers. With multiple industry certifications and a highly durable housing, the MDS-G4000 Series can reliably operate in tough and hazardous environments such as power substations, mining sites, ITS, and oil and gas applications. Support for dual power modules provides redundancy for high reliability and availability while LV and HV power module options offer additional flexibility to accommodate the power requirements of different applications. In addition, the MDS-G4000 Series modular managed ethernet switches features an HTML5–based, user-friendly web interface providing a responsive, smooth user experience across different platforms and browsers. Check MDS-G4012 (12 port modular switch) clicking here & MDS-G4020 (20 ports modular switch) on clicking here

Datasheet
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EDS-G4014 SERIES

8G+6 2.5GbE-port full Gigabit managed Ethernet switches

Product Features

  • Developed according to the IEC 62443-4-1 and compliant with the IEC 62443-4-2 industrial cybersecurity standards
  • Turbo Ring and Turbo Chain (recovery time < 50 ms @ 250 switches), and RSTP/STP for network redundancy
  • Wide range of power input options for flexible deployment
  • Compact and flexible housing design to fit into confined spaces
  • Supports MXstudio for easy, visualized industrial network management
  • Increased bandwidth capabilities with fiber SFP slots supporting up to 2.5 Gbps

Product Description

The EDS-G4014 Series is equipped with eight Gigabit Ethernet ports and six 2.5 Gbps fiber-optic ports, making it ideal for upgrading an existing network to Gigabit speed or building a new full Gigabit backbone. Gigabit transmission speed increases bandwidth for higher performance and can transfer large amounts of triple-play services across a network quickly. Redundant Ethernet technologies such as Turbo Ring, Turbo Chain, and RSTP/STP increase the reliability of your system and improve the availability of your network backbone. The EDS-G4014 Series is designed specifically for demanding applications such as video and process monitoring, ITS, and DCS systems, all of which can benefit from a scalable backbone. The EDS-G4014 Series is compliant with the IEC 62443-4-2 and IEC 62443-4-1 Industrial Cybersecurity certifications, which cover both product security and secure development life-cycle requirements, helping our customers meet the compliance requirements of secure industrial network design.

Technology Page

NPort 5150AI-M12/NPort 5250AI-M12/NPort 5450AI-M12 Series

Railway 1, 2, and 4-port RS-232/422/485 serial device servers

Product Features

  • Speedy 3-step web-based configuration
  • COM port grouping and UDP multicast applications
  • Real COM/TTY drivers for Windows and Linux
  • Standard TCP/IP interface and versatile TCP and UDP operation modes
  • Complies with all EN 50155 mandatory test items*
  • M12 connector and IP40 metal housing
  • 2 kV isolation for serial signals
 

Product Description

The NPort 5000AI-M12 is a Serial to Ethernet Module, designed to make serial devices network-ready in an instant, and provides direct access to serial devices from anywhere on the network. Moreover, the NPort 5000AI-M12 is compliant with EN 50121-4 and mandatory sections of EN 50155, covering operating temperature, power input voltage, surge, ESD, and vibration, making them suitable for rolling stock and wayside applications where high levels of vibration exist in the operating environment.

NPort 5100A Series

1-port RS-232/422/485 serial device servers

Product Features

  • Surge protection for serial, Ethernet, and power lines
  • COM port grouping and UDP multicast applications
  • Standard TCP/IP interface and versatile TCP and UDP operation modes
  • Speedy 3-step web-based configuration
  • Screw connectors for secure installation
  • Real COM/TTY drivers for Windows and Linux
  • Connect up to 8 TCP hosts
  • Only 1 W power consumption
 

Product Description

The NPort® 5100A device servers are worlds most popular Serial to Ethernet Gateways, designed to make serial devices network-ready in an instant and give your PC software direct access to serial devices from anywhere on the network. The NPort® 5100A device servers are ultra-lean, ruggedized, and user-friendly, making simple and reliable serial-to-Ethernet solutions possible. A Greener Serial-to-Ethernet Solution

The MiiNe is a small but powerful Arm-based serial-to-Ethernet SoC with RAM and Flash embedded. With the MiiNe inside, the NPort® 5110A Series’ power consumption is less than 1 W. The NPort® 5100A Series saves at least 50% on power consumption compared to existing solutions on the market, helping engineers meet the tough environmental compliance challenges found in today’s industrial environments.

Datasheet
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NPort 5110/NPort 5130/NPort 5150 Series

1-port RS-232 / 422 / 485 serial device server.

Product Features

  • Easy-to-use Windows utility for configuring multiple device servers
  • Small size for easy installation
  • SNMP MIB-II for network management
  • Real COM/TTY drivers for Windows and Linux
  • Standard TCP/IP interface and versatile operation modes
  • Configure by Telnet, web browser, or Windows utility
  • Adjustable pull high/low resistor for RS-485 ports
 

Product Description

NPort 5100 series device servers (serial to ethernet converters) are designed to make serial devices network-ready in an instant. The small size of the servers makes them ideal for connecting serial devices such as card readers and payment terminals where connections are RS-232 & devices like PLC’s, Energy meters where Serial ports are RS-422 or RS-485, to an IP-based Ethernet LAN. Use the NPort 5100 series device servers to give your PC software direct access to serial devices from anywhere on the network. Using serial to ethernet converters to connect legacy serial devices to Ethernet is now common, and users expect device servers to be cost-effective and to provide a broad selection of useful functions. With its full support of Microsoft and Linux operating systems, the NPort 5110  provides the best choice for serial (RS-232)-to-Ethernet converters. For RS-485 port or a combo – RS-232 / 422 / 485 ports, please use our Nport 5130 or Nport 5150 models!

Datasheet
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NPort 5210/NPort 5230/NPort 5232 Series

2-port RS-232/422/485 serial device servers

Product Description

The NPort 5200 serial to ethernet device servers are designed to make your industrial serial devices Internet-ready in no time. The compact size of NPort 5200 serial device servers makes them the ideal choice for connecting your RS-232 (NPort 5210/5230/5210-T/5230-T) or RS-422/485 (NPort 5230/5232/5232I/5230-T/5232-T/5232I-T) serial devices—such as PLCs, meters, and sensors—to an IP-based Ethernet LAN, making it possible for your software to access serial devices from anywhere over a local LAN or the Internet. The NPort 5200 Series has a number of useful features, including standard TCP/IP protocols and choice of operation modes, Real COM/TTY drivers for existing software, and remote control of serial devices with TCP/IP or traditional COM/TTY Port.

Datasheet
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NPort 6150 Series

1-port RS-232/422/485 secure terminal servers

Product Features

  • Secure operation modes for Real COM, TCP Server, TCP Client, Pair Connection, Terminal, and Reverse Terminal
  • Nonstandard baudrates supported with high precision
  • Automatic RS-485 data direction control with Moxa’s patented ADDC®
  • Enhanced remote configuration with HTTPS and SSH
  • Port buffers for storing serial data when the Ethernet is offline
  • Supports IPv6
  • Generic serial commands supported in Command-by-Command mode
  • Security features based on IEC 62443

Product Description

The NPort® 6150 1-port device servers use the SSL and SSH protocols to transmit encrypted serial data over Ethernet. The NPort® 6150’s 3-in-1 serial port supports RS-232, RS-422, and RS-485, with the interface selected from an easy-to-access configuration menu.

Datasheet
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