SAENEWS · 2015-10-05 · proved to be a good decision. Numerous old RMR systems made by us have...

The 1981 model

The DLR at the Weilheim/Lichtenau

satellite station has been operating

two SAE 1000 telecontrol systems for

controlling parabolic antennas for 34

years now.

"After so long, it's really time we

thought about a replacement. Even

though the multiplexer has done its

job very reliably".

So this must be the oldest SAE sys-

tem still in use.

Have you got a museum piece still

in operation? Write to us and we will

sort out the "pension" arrangements

and a suitable successor.

The tension in the energy supply industry is unrelenting. Having

been almost untouched by regulatory intervention for many

years, the sector is now subject to new legislation appearing on

a yearly basis or even more frequently, and in some cases to the

reappraisal of regulations only just introduced. The increase in

energy costs as a result of the renewable energy legislation in

Germany has been the subject of public controversy and has

forced the German government to act. In order to hold onto

the aim of further expanding the use of renewables, the gov-

ernment decided on new marketing approaches which require

lower subsidies.

The "direct marketing requirement" is one of them. Whereas our

contacts and clients have so far primarily been the grid oper-

ators, we are now increasingly in direct conversation with the

operators of renewable energy plants. That is not always without

its problems as the plant operators, understandably, are often

not familiar with the details of the transmission technology.

Consequently, the co-ordination and even simply the communi-

cation of the technical requirements between the plant opera-

tors and direct marketers/grid operators can become extremely

involved. In such circumstances, very particular communication

and negotiation skills on the part of our staff are called upon.

Despite that new challenge, we obviously see the additional

application area for our technology as an opportunity and have

already been able to demonstrate our versatility in a number of

projects.

The issue of IT security also plays an important role in that

connection; the duty to operate a secure energy supply grid in

accordance with §11 Para 1a EnWG (German Energy Industry Act)

obviously also applies to this subsection of the grid.

Our investment in the area of station automation is beginning to

bear fruit. We have been able to celebrate a variety of significant

successes in the past year. The experience we have gained helps

us to discuss any imaginable facet of station automation with

our clients "at the same level" and so find mutually beneficial

solutions.

The implementation of the smart meter protocol drivers SML

IEC 62056-21 and DSfG in our telecontrol systems has also

proved to be a good decision. Numerous old RMR systems

made by us have now been replaced by linking existing intel-

ligent meters to new telecontrol systems. That means that the

comprehensive diagnosis functions of our setIT configuration

tool can now also be used in the RMR environment.

Our activities in the area of protective equipment are showing

pleasing progress – numerous big-name clients have success-

fully tested our equipment and a large number of projects have

already been completed to the total satisfaction of the clients.

The improved integration of the SG-50 system in our setIT con-

figuration tool has been enthusiastically welcomed and exten-

sively used.

Once again, we can look back on a very successful year and are

confident we can continue to set innovative trends in the market

in future by consistent ongoing development. We are doing

everything to ensure we continue to deserve your trust.

Joachim Schuster, Managing Partner

Cologne, July 2015

Inside SAE

10 Reference

Local network automation

Telecontrol equipment for 300 local

network stations in the EWV/Regionetz

supply area

04 Reference

Protective equipment

Three new transformer substations in

the Flugbereitschaft squadron area of the

military section of Cologne-Bonn Airport

Everything stays different ...

Customer Newsletter · Issue 15

SAENEWS06 Product innovation

setIT

The advantages of integrated diagnosis

using an intuitive configuration tool

14 Inside SAE

Innovation excellence

SAE has been recognised as one of most

innovative SMEs in Germany.

02 Solutions

Flexible solutions for direct mar-keting and balancing energy

Legal notice

Author: SAE IT-systems GmbH & Co. KG

Im Gewerbegebiet Pesch 14 · 50767 Cologne, Germany

Phone: +49 (0)221/59 808-0 · Fax: +49(0)221/59808-60

[email protected] · www.sae-it.de

Editors: Matthias Schuster and Jürgen Venhaus

Authors: Ronald Sinda, DLR · Susanne Freitag, Erdgas

Südwest GmbH · Christian Bühl, Erlanger Stadtwerke AG ·

Frank Färber, Regionetz GmbH · Andreas Dietrich, Innecken

Elektroanlagen GmbH · Thorsten Buschjost, SWN Stadtwerke

Northeim GmbH · Dennis Filipczyk, Netze Duisburg GmbH

· Herr Stumm, Stadtwerke Friedberg · Alfred Ködderitzsch,

Avacon AG · Tobias Rudack, Westfalen Weser Netz GmbH

Other authors: Joachim Schuster, Oliver Callegari, Wolfgang

Besler, Reiner Beckers, Jörg Schroeder, Stephan Kerkhoff

Layout: Vancado AG

Editorial by Joachim Schuster

Solutions in Mind

For plant operators, that means that

• for all plants already taking part in direct marketing, remote control capability must

be demonstrated by 01/04/2015 in order to be able to continue to claim the market

bonus

• new plants commissioned as of 01/08/2014 have to be remotely controllable within

the first two months of commissioning.

As defined by § 36 EEG, technical plant is remotely controllable if technical equipment

ensures that a directly marketing business is able at any time to read off the actual

feed-in rate concerned and reduce the feed-in capacity by remote control. The grid

operator's options for regulation (e.g. by means of a feed-in management facility) must

not be affected by that.

Special challenges in implementation

In contrast with feed-in management, it is not the grid operators but the plant opera-

tors who are responsible for implementation. The understandable lack of an electrical

engineering background in many cases, uncertainties about the existing infrastruc-

tures and envisaged concepts, and the limited access to the plants in some cases can

result in enormous co-ordination complexities for individual systems.

The plant requirements are very heterogeneous in practice and differ mostly on the

basis of the type of plant connected. Prompt and detailed clarification of the plant

requirements – from direct connection via terminals (I/Os), through linking to control-

lers or meters to integration of measured data from existing grid analysis systems – is

elementary to the smooth and efficient progress of the project in our experience.

To be able to create suitable quotations as quickly as possible for our existing and

prospective clients, we have developed a standardised

check-list to help prospective clients with the technical

details of their enquiry. (Due to the German formalities, it

is ony available in German language)

It is available online at:

www.sae-it.de/einsatzbereiche/

strom/direktvermarktung.html

The energy market remains dynamic – not least, or rather espe-

cially, as a result of the amendments to the German Renewable

Energy Act (EEG) 2014. The new legislation introduced a direct

marketing obligation in order to reduce the cost of the renewable

energy payments in the medium and long term. The new market-

ing model relies more on the market mechanisms of supply and

demand and should, therefore, require a lower level of "subsidy";

at the same time, it also offers the plant operators the opportuni-

ty to make higher profits.

Flexible solutions for di-rect marketing and load balancing energyElectricity · Direct marketing · Load balancing energy

Information supply concepts

There are various possibilities for supplying information to the direct marketer's control

centre:

1 The distribution system operator (DSO) forwards the relevant data from the feed-

in management system to the control centre of the direct marketer(s). That can be

extremely involved for the grid operator, depending on the number of different direct

marketers and connected generation plants. From out point of view, however, that

service could also be marketed as a standalone concept.

2 It is advisable to use a separate telecontrol system for direct marketing. That also

allows uncorrupted metering directly on the generation plant. Telecontrol boxes for

feed-in management by contrast are often positioned at the grid connection point

and offer only net readings for the downstream grid segments. Multiple generation

plants belonging to the same operator can also be connected to a single control box

provided they are not too far apart from one another. That reduces the investment

cost.

3 If a plant is to provide load balancing energy (fast reserve and secondary reserve out-

put) the requirements are more demanding than for "simple" direct marketing. Plants

Checkliste Steuerbox Direktvermarktung & Regelenergie

Checkliste SteuerboxDirektvermarktung & Regelenergie

Provided via DSO control centre

Control centreDSO

Providing the required data via DSO control centredepending on the amount of installations/direct marketers very complex

Network connection point

Medium Voltage

Low Voltage

Control centreDirect marketer

1

02 SAENEWS · Solutions in Mind

in this category are managed in separate pools, so to that extent a separate telecontrol box may be

necessary for this type of task, especially if load-balancing energy providers and direct marketers

are different entities. If use for load-balancing energy is planned at some future date, it is possible to

start with a simple control box for direct marketing and subsequently adapt it as necessary to the re-

quirements of load-balancing energy by adding the appropriate expansion modules. Nevertheless,

the concept for connection to the control centre should meet the higher requirements of load-bal-

ancing energy from the outset as retrospective modification of those structures can be very costly.

Typical tasks and recommendations for quantity structure and

design

General information

• IT security to §11 Para 1a EnWG

- Use of a user management system

- Use of security certificates

- Use of secure protocols

- Use of end-to-end VPN encryption

(IPsec specified for secondary balancing power)

- Use of firewalls

• Power supply → 230 V is generally available. With the 230V

versions of the FW-5 or FW-5-GATE, an additional power supply

can be dispensed with.

• Space requirements

- Compact Rittal switchgear cabinet with the following dimen-

sions:

380 × 380 × 210mm

Quantity structure for direct marketing

• Acquisition of standby condition

• Acquisition of maximum active power

• Acquisition of current active power

• Specification of required setting for active power

• Feedback of required setting for active power

Implementation:

• 3 digital inputs

• 1 analogue input

• 1 analogue output

Our recommendation:

• FW-5 + 2AO

Quantity structure for load-balancing energy

• Acquisition of other control-related influencing variable such as

- Fill levels

- Operating hours

- Wind speed

- Temperature

- Sunshine

- Maximum possible feed-in

- etc.

• "Run characteristic curve" requirement

A particular and new feature of this area of application is trans-

mission of the operating schedule by bitmap command (32 bit)

in case of a break in communication. The information contained

in the bitmap commands is converted into the relevant operat-

ing schedules by a PLC program inside the control box.

Our recommendation:

• FW-5 + 4AI

As well as direct connection via terminal, the protocols Modbus

RTU and Profibus DP also offer benefits.

The former can be implemented directly using an FW-5, while for

the latter we have developed the PDPS-1 module.

Multiple plants connected to one box

Third box for providing load-balancing energy

Control centreDSO


Medium Voltage

Low Voltage


Several installations coupled with only one telecontrol boxPossible savings for plant operators with several installations in arestricted area

2

Control centreDSO


Medium Voltage

Low Voltage


Control centreBalancing energy

Third telecontrol box for providing of balancing energy• Separation recommended/necessary• Further costs for plant operator

3

03 Solutions in Mind · SAENEWS

Exkurs 2AO – Expansion module for required setting specification

New FW-5 expansion module for reduced demand for specified

settings with direct marketing plants

• ±0.1% /10 K over entire range

• Isolated by channel, 2-pole

• 2 analogue outputs

• 16-bit specified settings

• Unipolar/bipolar ±20 mA, max. load

impedance 500 Ω

In June 2013, Innecken El-

ektroanlagen GmbH was

contracted by the Bau- und

Liegenschaftsbetrieb NRW in

Cologne to install three new transformer substations in the

Flugbereitschaft squadron area of the military part of Cologne/

Bonn Airport.

Innecken built the substations using SF6-insulated, metal-encapsulated and modular

GAE630 switching stations made by Ormazabal Anlagentechnik GmbH of Krefeld. They

were then fitted with the SG-50 Kombisave protective device made by SAE IT-systems.

The Series GAE630 switching stations are ideally suited to use in transformer and

switching stations and as consumer units on sites with MV network infrastructure. The

SG-50 Kombisave combination protection device takes care of the IOC, transformer,

directional earth fault and directional IOC detection.

The reason for choosing the SG-50 is its flexibility. It can be adapted to virtually any

protection requirement by selecting the corresponding software options. Whether dis-

tance protection, QV protection or other protective functions, the SG-50 combination

protection device can be set up for new protection tasks even when already installed.

In April 2014, the state property management agency also contracted Innecken to

install a new 10 kV energy supply at the Wahn barracks. The work comprised a new

transfer station connecting to the grid operator, RheinEnergie AG, a new transfer

station connecting to the barracks for five medium voltage rings and another eleven

transformer substations. The conversion work is to be carried out station by station

while the system is in operation. As well as the medium voltage grid already mentioned

with all its buildings and distribution points, the contract also covers the complete low

voltage system and the entire lighting system (1,000 lamps with 45 km of roads).

On average, Innecken has ten staff working on the project at any one time. The project

is scheduled to be completed in 2017.

Protective equipment at Cologne/Bonn AirportElectricity · Protective equipment

Kayserigaz was created in the course of

the first contract tendering process for the

gas supply to the Turkish city of Kayseri

instituted by the Energy Market Regulatory

Authority (EMRA) in 2003. Today, Kayserigaz

is responsible the transmission, distribu-

tion and marketing of gas in the region and is also one of the key

players in the Turkish energy sector.

As a subsidiary of EWE Turkey Holding, Kayserigaz has invested around 100 million dol-

lars in the past ten years to be able to supply the industrial areas and all of the streets

in Kayseri with gas. BTC Bilişim Hizmetleri A.Ş., a wholly-owned subsidiary of BTC AG in

Germany, had bid to deliver the project as a complete turnkey system using, of course,

the PRINS SCADA system made by its parent company.

Implementation in two phases

In the first phase of the project, the PRINS SCADA system was installed as a control

centre with fully redundant back-up. Four FEPs (front-end processors) establish the

connection with the distributed gas transfer stations in the field using the IEC 60870-

5-104 protocol. The FEPs also provided with redundant back-up units so that eight net-

line FW-50s are used. The 17 gas transfer stations, which signal differential pressures

and flow rates via Modbus, are each equipped with net-line FW-5 compact stations.

The first phase was completed in May 2015 and commissioned in the presence of

the Turkish Energy Minister. In the second phase of the project, another 112 transfer

stations – also equipped with the FW-5 – are to be completed. Final completion of the

project is scheduled for August 2015.

Kayserigaz SCADA Project Gas

Gas supply monitoring infrastructure in Kayseri

BTC PRINS SCADAControl centre

Switch/Firewall

FEP (front-end processors) (each redundant)

DSL/VPN Router

(First Phase) (Second Phase)

DSL GPRS+ DSL GPRS+ DSL GPRS+ DSL GPRS+

VPN encryption

DSL

17 Stations 112 Stations


The Friedberg public utilities

in Hessen have had an SAE

telecontrol and process control

system in operation since 1998 which is used primarily

to monitor and control water reservoirs, shafts, under-

ground wells and gas transfer and regulation stations.

In 2015, the Friedberg public utilities contracted us to

modernise, optimise and simultaneously extend the

ageing telecontrol system. The modernisation scheme

was simplified by the fact that SAE telecontrol compo-

nents have a certain degree of backward compatibility

and older components can often continue to be used in

new systems. That means that complete replacement of

the hardware is not required and the financial outlay is

substantially reduced.

Upgrade to series5

Water · Gas

wesernetz Bremen GmbH and

wesernetz Bremerhaven GmbH

are the grid operators for elec-

tricity, natural gas and domestic water and heat in the

state of Bremen and for the natural gas grid in Stuhr,

Weyhe and Thedinghausen. Among the core duties

of the company are the construction, management,

maintenance, servicing and expansion of the grids.

The power grid in Bremen comprises more than 9,400 km of power

lines, around 40 transformer stations and distribution stations, a 110 kV

transmission grid and a 10 kV medium voltage grid. "A respected man-

ufacturer has a new technology on the market. So we are keen to run

a pilot project to test out that technology. The value for money of the

functionality offered promises to be extremely attractive." That was the

statement made by Sören Sturm, service power team leader at weser-

netz Bremen GmbH, after the presentation of our SG-50 combination

protection unit in his specialist department. And so a test unit was first

rigorously tested at the wesernetz Bremen laboratory and even linked

up live to the control system in the process. Based on the very positive

test results, a deployment opportunity was immediately found for the

units in the 10 kV grid. Due to grid modifications, three distance relay

installations were required at the Huchting transformer station.

When installing the units in the switchgear panels, another fundamen-

tal advantage became evident: the size of the protective device is ideal

for conversions of this type. Whether installed in the door or – as in

this instance – with the support brackets on the rear panel, the modest

dimensions of the housing are easily accommodated.

New distance relay system as pilot project at wesernetz BremenElectricity · Protective equipment

A new feature is the display of the panel and its switch

conditions and measured data on a colour screen. Not

only the currents, voltages, power data and cos phi can

be read off but also the continuously measured R and X

levels of the cable. "So it is a fully featured protection and

control unit!" confirms Sören Sturm.

Project planning was in the hands of Stefan Diers and

his team using the intuitively usable Digicom configu-

ration software. They too were full of praise, especially

regarding the modularity of the software. Even in an

installed state extra protective functions can be added to

the systems. With the Digicom software tools, the system

layout could be designed just as easily as the system

automation. "The tools are easy to under-

stand, user-friendly and self-explanatory –

simply delightful!" enthuses Stefan Diers.

Colleagues Sören Sturm and Stefan Diers

deliver their verdict on the pilot project

thus:

"The SG-50 Kombisave is an easily

configurable and economical protective

device that can be used in the Bremen

medium-voltage grid and fully satisfies

the existing requirements."

ProCoS control system

FW-5000

Line K06

Line K05

Line K07

GÜKonrads-Brünnchen

WWOckstadt

TBOckstadt

WBObermörlen

Kühler Grund H. Busold Str. WB Warturm

Heizwerk GR Dornheim

WB Dornheim

LS-42Bauernheim

Line K08

GPRS GPRS GPRS

DSL GSM

GSM


Renewal of telecontrol and process control technology at Friedberg public utilities

The connection to the control system is down, the VPN tunnel via

GPRS is no longer available or the data from the protection device

is not being received correctly – good advice is at a premium.

Anyone in project business knows the problems. No matter how

carefully the project planning has been done, in real life things

sometimes look entirely different. Having to switch back and forth

between different tools, compare parameters and check individu-

al data loses a lot of time. And if it happens outside normal ser-

vice hours, a long way from manuals and external assistance, the

job soon becomes very time-consuming and costly.

You will be familiar with these difficulties, but as a setIT user you have a powerful

problem-solver at your disposal. The net-line series configuration tools not only helps

with configuration, prevents input errors and dramatically simplifies complex tasks, it

also offers a large number of integrated diagnosis options and utilities (see table). The

online help alone provides over 1,300 pages of important information. Pressing the

F1 key in the desired context in setIT calls up function descriptions, technical data and

wiring diagrams.

Easy diagnosis starts with the connection options

Right from establishing the connection between the computer and the target system,

setIT shows how simple it can be. If the computer already has access via the tele-

control network, you click on the desired station and select "Establish LAN link". setIT

makes the connection using the registered IP address of the station and checks that

the correct station answers on the basis of the project, station name and addresses. If

there is more than one possibility for connecting, you can, of course, select the desired

communication path. It also goes without saying that the service can communicate via

a secure SSL connection.

Only if the selected station responds correctly does setIT enable the subsequent in-

teractive functions. Now you have an online connection and can access all the station

data and diagnosis options. The first place to look is the connection status view for the

subordinate stations in the project hierarchy. There you can immediately spot whether

the stations are connected to one another or there are breaks in any lines. As you would

expect from a modern telecontrol system, the detection of communication faults is

naturally a standard feature which can be selectively signalled to the control centre by

system messages. In addition, you can also read statuses and messages from external

network components via SNMP and integrate them in the monitoring scheme as pro-

cess points. The condition-based maintenance functions also include features such as

warning indications on the remaining archive space or the SD card status.

How do I find the station on site?

That's all fine, but on site all the LAN ports are in use or else my laptop doesn't allow IP

changes.

The USB device interface is the preferred connection option on site. You do not have

to disconnect any network connections, change any addresses or look for free ports. A

good USB lead (A-miniB) between laptop and station and setIT version 4.008 or later

makes it very easy. Via the DHCP server, the station assigns the laptop an IP address at

which a new LAN segment is established. The new access point behaves like a LAN link.

Connection is up but communication is intermittent

The connection between the stations is established but very little or no data is coming

through. This is a common fault scenario in which the basic data appears to have been

correctly specified but faults, time-outs or missing keys prevent communication. With-

out examining the actual transmissions it is hard to progress any further. This is where

the interface analyser for serial protocols or the Ethernet log for LAN links can help

out. The are comprehensive filtering and trigger functions so that data logging can be

focussed on the essential details. For analysis of serial protocols, there is a LogViewer

that lists the data transmitted and received line by line, highlights time-outs and char-

acter errors, and also enables time measurements. The Ethernet logs are also record-

ed directly on the station; the data is provided in wireshark®-compatible format and

uploaded to the laptop directly after recording. On the laptop, you can open wireshark®,

a recognised, globally available freeware application for analysing network traffic

and equipped with extremely powerful analysis and filter functions. Even encrypted

communications can be analysed. For decrypting the packages, the current keys can

be read from the station via SAD/SPD through the online connection with the station in

setIT and imported into wireshark®.

If the analysis is too complicated to carry out on site, you can carry out further analyses

at the office; the records are already on your laptop. If that does not help, you can also

e-mail the records to the SAE service team.

Network analysis in online diagnosis

With some tasks such as time synchronisation or creating VPN tunnels, it is more

complicated. setIT offers diagnosis of the configured time server with indication of the

status and time error per time source. With exchange of VPN key in two phases, mul-

tiple packages are also transmitted over a relatively long period; the Ethernet log only

offers limited assistance. In that situation, network analysis during online diagnosis is

invaluable. With an ingenious but simple ping test from the station to any IP address,

the accessible of gateways, routers and stations can be selectively checked. If some-

thing is wrong, the routing table (route), the available sockets from the viewpoint of the

CPU (ifconfig) and also the actual package paths (traceroute) can be executed and load-

ed at operating system level. In the IPsec log (racoon) you can track the structure of the

What's the problem?The benefits of integrated diagnosisConfiguration

IPsec log online diagnosis

SAENEWS · Solutions in Mind06

phases of a VPN connection online and quickly identify inconsistencies. The SAD

and SPD protocols read the rules and currently used keys for a VPN tunnel so

that temporary decryption using tools such as wireshark® is possible. As the key

pairs are cyclically changed, there is no danger of a permanent leak.

Access via web server

The web server is actually another complete service interface which can be selectively enabled with

any kind of network connection. Whether that is done in normal or protected mode using https makes

no difference to the function. You can reliably find your way to the desired station without having to re-

member or copy an IP address; setIT opens the browser directly in one click with the IP of the selected

station. It goes without saying that access via user account is password-protected and should also be

correctly assigned according to BDEW Whitepaper; the relevant functions are then allocated according

to role assignment. To check station selection you will be able to see the station map and station name

after successfully logging in.

Extended diagnosis via web server

As well as representation of the process point statuses in plain English and scaled measured data and

metered values, on the web server you also have access to comprehensive hardware information and

all historical data in the archive. In a separate overview you can list the last change to the process data

together with time tag or view the entire records from the fault message, operational message or

interval archive. The immense volume of data can easily be reduced by selecting a defined time period

and then downloaded as a csv file to the laptop for further external analysis. If protective equipment

that provides fault recordings is connected, they can similarly be downloaded in the standardised

comtrade format.

A real joker in the pack is diagnosis of the LAN links by activating the Ethernet log independently of

setIT or the project database. Analysis of the file provided by the system requires only that wireshark®

is installed. In just a few clicks the data is on your computer.

Function setIT V5 Web server

Station status display in tree structure • •

Selection of important process points in overview • •

Plain English display of message statuses • •

Measured data as scaled value • •• Colour change when limits exceeded • -• Colour change on reading error • •

Measured data as bar chart in measuring range • •

Scaled metered values • •

Hardware information • •

Serial interface monitor• Trace • -• Start/Stop trigger • -

Data flow analysis • -

Memory monitor • -

Report monitor• Operating system report • -• Telecontrol report on activities in process • -

Time server • -

Station state• Cycle times, memory and module information • -• Remaining archive space • -

Extended logging of selected drivers • -

Network analysis• Online connection test with selective ping • -• IPsec log • -• Operating system log • •• Information on network interfaces at OS level • -• Station routing table • -• Actual routes in network • -• Display of keys used in an IPsec connection • -• from SAD security association database • -• Display of rules used in an IPsec connection • -• from SPD security policy database • -

wireshark® Ethernet trace• Filtering by socket, IP, Port, protocol • •• Decryption in VPN tunnel • •

Display of archive data• Last entry with time tag • •• Events chronologically listed with selective excerpt • •

Diagnostics in setIT and the station web server

Web server screenshots

Solutions in Mind · SAENEWS 07

More transparency in the medium voltage gridElectricity · Gas · Water · Heat

Netze Duisburg GmbH is the

local distribution grid operator

for the town of Duisburg. The

company was founded in 2007

as Stadtwerke Duisburg Netzgesellschaft mbH and employs

nearly 500 people. A wholly-owned subsidiary of Stadtwerke

Duisburg AG, it has been trading as Netze Duisburg GmbH since

14 October 2014. Among the core tasks of the distribution grid

operator are the planning, operation, expansion and maintenance

of the supply grids for electricity, gas, water and district heating.

The length of the regional grid is around 9,100 kilometres.

The Duisburg grid operator has been using SAE components in various areas for a

good five years. The decision to use the net-line FW-5 was taken partly because of its

integrated Modbus interface for connecting smart grid applications. Other reasons for

using the net-line FW-5 included its compact design, its simple, safe and wireless pro-

gramming on site via the Bluetooth® interface, and its support of all commonly used

communication protocols. Now, all new projects are implemented with the FW-5.

In the electricity sector, the units are used for feed-in management in renewable ener-

gy plants and for equipping new grid substations and converting existing ones for local

grid automation.

There are over 1,000 localised electricity generation plants in the Duisburg distribution

grid. Photo-voltaic arrays make up the majority of them and, together with a good 20

modular CHP plants and 3 mine gas plants, have an installed generation capacity of

roughly 27 megawatts. Of the photo-voltaic farms, 26 have switchgear cabinets with

FW-5 telecontrol units installed, while there are a further 13 wall cabinets with FW-5

units in the modular CHP plants. As well as for output control of the generating plants

according to EEG §9 Paras 1 and 2 (German Renewable Energy Act), the compact tel-

econtrol units are also used in the latter case for remote switching of the grid coupler

switch.

Modbus RTU

Coupling tocontrol centre

Short-circuit und earth fault indicator

Copper

GPRS

GPRS

FO

Telecontrol interconnection concepts at Netze Duisburg GmbH


Erdgas Südwest is a regional energy

supplier that employs around 130 staff.

The products include natural gas, bio-

gas and alternative energy in flexible

combinations. Innovative and ecolog-

ically sensible energy solutions that

offer convincing efficiency and attractive

economy are key focal points. At the

same time, environmental protection,

research and training are not left out.

Through the ProNatur initiative, Erdgas

Südwest supports numerous campaigns

in those areas and actively involves its

employees. Netze-Gesellschaft Südwest mbH, the company's

wholly-owned subsidiary, safely and reliably operates

the roughly 3,200 km of gas pipeline in 95 commu-

nities in North Baden, Upper Swabia, and the Swa-

bian Mountains. In so doing, it supplies 69,000 grid

customers with eco-friendly energy.

Using renewable energies efficiently

The law in Germany requires that if a power gener-

ation plant as defined by the Renewable Energy Act

(Erneuerbare-Energien-Gesetz, EEG) has a capacity

of more than 500 kW, the energy produced must be

marketed directly on the energy exchange. From 2016

that will apply to plants with a size of only 100 kW. That

presents the plant operators with major challenges

because the renewable energies have very volatile or

fluctuating availabilities in some cases. Direct mar-

keting therefore requires appropriate technologies

and specialist knowledge. That is a service that Erdgas

Südwest offers to plant operators.

Current weather data is used to precisely predict the

expected amount of electricity and market it accord-

ingly on the energy exchange. To be able to operate

economically, the forecast and the actually amount

of energy generated must be as close as possible to

each other. In addition, the energy generation plants

must be remotely controllable as defined by the EEG.

That means that the actual feed-in rate can be read off

at any time and regulated as required. This is where

Erdgas Südwest makes use of the SAE control box and

telecontrol technology. The SAE complete solution

provides all the necessary components that a system

has to provide for direct marketing, i.e.

• Powerful net-line FW-5 telecontrol technology as communication and

control unit

• 4-stage regulation (0%, 30%, 60%, 100%) of feed-in rate as per

§35, 36 via 4 command outputs and feedback function

• Actual data acquisition via a Profibus link

• Specification of active power via analogue outputs

• Compact wall-mounted casing

• Data transmission via DSL/GPRS

• IPSec encryption to BDEW White Paper

• Data transfer to BTC control system virtual power plant

• Communication protocol to IEC 60870-5-104

• Windows® configuration software setIT

• Configuration uploadable via LAN/USB memory stick/SD card

• Comprehensive diagnostic functions for fault analysis

As well as several combined heat and power plants of the appropriate

size, Erdgas Südwest has recently added the first solar farm to its direct

marketing portfolio. Other biogas, photo-voltaic and selected wind

turbine installations are to follow. In that way, the company is follow-

ing its vision of "creating a future naturally". On its way to becoming

a local energy partner, Erdgas Südwest saw renewable energies as a

potential field of activity for itself early on. "Renewable energy gener-

ation and energy consumption have to mesh together like the gears

of a clock movement for the full potential of the energy reforms to be

utilised", explains Ralf Biehl, chief executive of Erdgas Südwest. As part

of their "energy from here to you" campaign, the company offers biogas,

eco-friendly electricity and individual energy solutions. With concepts

such as autonomous energy supply and bio-hybrid energy storage,

Erdgas Südwest uses renewable energies efficiently, helps reduce

climate change and makes private households, businesses and commu-

nities more independent of the global energy market.

Direct marketing with SAE control boxElectricity · Gas · Renewable energy legislation · Direct marketing

When fitting out grid substations for local

grid automation, Netze Duisburg GmbH

relies on a combination of the FW-5 and

the Horstmann ComPass B short-circuit

and earth fault indicator. That combi-

nation enables greater transparency in

the medium voltage grid and allows fast

fault isolation in the event of a failure.

The combination has also proved itself

in practice because of the ease of im-

plementation of the Compass B quan-

tity structure in the setIT configuration

software.

In the area of gas pressure regulation

stations, the Duisburg grid operator

has install 39 FW-5 units. In this case,

the measured data in the medium and

high-pressure incoming lines and the me-

dium-pressure outgoing line, and also the

odorant concentration are monitored and

communicated. Data transmission to the

master telecontrol interface takes place

via GPRS or a wired connection.

The company also uses SAE-IT compo-

nents for magneto-inductive flow rate

measurement in its water supply oper-

ations. Distribution stations have been

fitted with FW-5 telecontrol units for 6

measurements. They analyse the water

pressure measurement points and trans-

mit the data established to the control

centre.

All telecontrol components use the IEC

60870-5-104 protocol for communica-

tion between substation and telecontrol

interface.

If there is no facility for wired communi-

cation, data is transferred via radio signals

using the GPRS network with VPN encryp-

tion implemented to protect the systems.

Smart Grid project team

The Smart Grid project team at Netze

Duisburg GmbH was established inn

2009 and is made up of young engi-

neers from all sectors of the supply

industry. The project team's brief is to

document the potential of smart grid

applications in Duisburg and to initiate

pilot projects for assessing the use of

smart grid applications.


In November 2014,

SAE IT-systems was

awarded the contract to

supply telecontrol equip-

ment for 300 local grid

stations in the supply area of EWV/Regionetz. The

aim of the project was comprehensive monitoring for

greater grid transparency. In addition, key stations are

also to be controllable in future.

The stations concerned are both compact and walk-in stations with 1-7

panels each. In both cases, the net-line FW-5 is used as the telecontrol

technology basis. For recording the current, voltage and quality data,

and detecting shorts and earth faults in cases of doubt, Horstmann

ComPass B short and earth fault indicators are linked to the FW-5 via

Modbus. Most of the local grid stations (about 200) are to be linked to

the higher-level Kisters Controlstar process control system via GPRS,

though some will also be connected via LAN (about 100 stations).

The IEC 60870-5-104 standard protocol will be used for that purpose.

For data transmission via GPRS, the SAE M2G-1 modem will be used.

Communication with the control system will be via encrypted VPN from

the telecontrol system. For the connection via its own cable system, the

company will use Westermo SHDSL modems.

Four different cabinet types have been designed in close co-operation

with EWV/Regionetz. The telecontrol systems will be supplied in wall

cabinets and are equipped with uninterruptible power supplies and

switchgear cabinet heaters. When selecting the cabinets, sufficient

space for subsequent modifications was allowed for. If a station is to be

enabled for remote controllability the battery has to be replaced by a

Local grid automation at EWV/Regionetz

Electricity · Local grid stations

larger one and additional command cards with external

circuit testing and 1 of n monitoring have to be installed.

The decision to award the contract to SAE was taken on

the basis of the thoroughly positive experiences from

previous projects and the comprehensive single-source

service package offered by SAE.

SAE IT-systems is responsible not only for all the engi-

neering work but also carries out the configuration work

using setIT and the installation and commissioning of

the stations on site. Around 10 stations a week have been

installed as planned so that the project is expected to

be completed on time by December 2015. So far SAE is

"bang on schedule" and Mr Färber of EWV/Regionetz is

very pleased with the highly skilled SAE engineers and

the outstanding co-operation.

SAE internal

Jubilees

Having now been with the company for 30

years, Heinz Zaunbrecher is part of the SAE bed-

rock, that is the company's indestructible and

dependable basis. Since joining on 01/04/1985,

he has made a substantial contribution to the

success of SAE; we offer our congratulations

and raise a glass to the next 30 years!

Also celebrating 30 years' service but still as

enthusiastic and committed as the day she

joined (01/07/1985) is Cornelia Blum-Bader, who

helps make sure our customers are supplied as

promptly as possible. Thanks for that, Cornelia,

and congratulations on your work anniversary!

In two decades in end-of-line testing and quality

control, Andreas Aengenheister has gathered an

enormous amount of experience – something

that he demonstrates every day, contributing

to the stability and safety of our systems in the

process. Congratulations to him on 20 years at

SAE (since 26/09/1994) and a big thank-you for

his contribution.

Stephanie Kramprich has now completed

20 years' of reliable service in Sales (since

17/07/1995). She juggles the everyday tasks with

patience and skill while emanating unflappable

calm at all times. Congratulations to Stephanie

not only on her 20 years at SAE but also on

recently completing a triathlon – respect!


SAE switchgear cabinet in compact installation

The Anger is a residential area of Erlan-

gen with a large number of local energy

resources, especially PV roof systems

producing up to 30 kWp. Because of the

previous lack of metering points in the low

voltage grid, there was no transparency

regarding the potential change in load

flows and the remaining grid capacities in

the area.

So the decision was taken to use the Anger as a pilot pro-

ject for comprehensive grid monitoring and control. The

new requirements specified by the Bundesnetzagentur

(German Federal Network Agency) also played a role

as they now allow output control of PV systems to take

place at the low voltage level. A substantial reduction in

the administration and maintenance times and longer

update intervals are the benefits hoped for.

Technical implementation

The aim was measurement of current, voltage, power

and quality data on the busbar and also at each low

voltage outfeed. The information is recorded with the aid

of various grid analysis systems made by Janitza (UMG

605, UMG 505 and UMG 103) and Horstmann (ComPass

B) which are linked via Modbus RTU or Modbus TCP.

For registering the actual feed-in of the PV systems, 30

intelligent meters have also been linked up using the IEC

62056-21 protocol – a practical solution particularly in

the case of limitation by the tone frequency ripple control

systems fitted, which cannot provide feedback them-

selves.

Pilot project "Intelligent Anger"Electricity · Local grid stations · Renewable energy legislation

"Of the difficulties that we encountered with the initial link-up of our Horstmann or Janitza equipment in this area, we will remember one thing: the speedy, uncomplicated and proficient assistance from the SAE hotline.

The enjoyable co-operation with Mr Ohlendorf during the commissioning of the meter connections also contributed substantially to the speedy link-up of the meters via the

FW-5 gateway. We were able to clear up minor misunderstandings straightaway over the phone."

Christian Bühl, Erlanger Stadtwerke

It has been possible to make use of the Erlangen public

utilities' own high-capacity fibre-optic cable network to

transmit those large volumes of data.

The data from grid analysis systems and meters is

transmitted in duplicate and both copies not only stored

in their entirety in separate databases but also managed

by the SAE telecontrol technology, which selects the data

and passes it on to the control system.

The selected data is visually displayed at the central con-

trol station and used for calculating the load flows. A sim-

ulation for assessing the further expansion possibilities

regarding PV concluded that with the maximum possible

development of PV systems in the Anger area, a voltage

spread of 5% would result – the local grid capacities are

already fully utilised.

Modbus RTU

Modbus TCP

Modbus TCP

Control centre NTP Server

Fibre optic network of Erlanger SW

Horstmann ComPass B

Janitza

Janitza

Janitza

Janitzadata base

Meterdata base

Telecontrol master station

Meter

Cable distribution cabinets(11 units)

Of�ce LAN of Erlanger SW

Janitza

…

…


Telecontrol link-up of the "Anger"

The key task of Westfalen Weser Netz

GmbH is to provide a safe, reliable and ef-

ficient supply of electricity, natural gas and

water to industrial, commercial, farming

and residential customers. The grid area

of the regional supplier extends across an

area of 6,400 km2 spanning two federal

states in the high-growth regions of East

Westphalia-Lippe and southern Lower

Saxony. Westfalen Weser Netz based in

Paderborn is a subsidiary of Westfalen

Weser Energie GmbH & Co. KG, which is

a public-domain company owned by 48

local communities and districts in its grid

area. With an efficiency factor of 100% in

the electricity sector and down times of

under seven minutes in 2014, the company

presents a convincing case. Achieving such outstanding results demands highly

competent staff but also requires modern technology

that is up to the challenge of the constantly increasing

number of renewable energy feed-in points.

At larger transformer stations and distribution stations,

the company has relied on SAE technology for its tele-

control systems for the last five years following many

years of positive experience with the equipment in the

natural gas and water supply sectors. It is largely a case

of making the various voltage levels at the transformer

stations and switching stations remotely controllable. The

SAE FW-50 remote terminal unit is used as the standard

unit and up to three size BGT-L module racks may be

combined in larger energy plants. The Siemens protec-

tion and control units are generally linked via fibre-optic

cable, with the SAE mcPS1 serving as media converter

in combination with the mcFO. Data communication

between protective equipment and telecontrol unit takes

place using the IEC 60870-5-103 protocol. Process points

that cannot be acquired in that way are implemented by

means of digital and analogue modules. Communica-

tion with the Siemens Spectrum Power control system

normally takes place via the company's own process

data network using the IEC 60870-5-104 transmission

protocol. That combination of components has proved its

Telecontrol technology Westfalen Weser Netz

Electricity

Avacon was contracted by Purena GmbH to renew

the telecontrol systems for monitoring the water

supply at the Rote Bleiche waterworks in Lüneburg.

Purena is one of the largest water companies in Lower Saxony and a service provider

to local authorities and industrial businesses.

The Rote Bleiche waterworks had the demanding task of securing the water supply from two remote water source

areas with 13 sources providing an average of 1,200 m³ per hour. As the water is naturally of a high quality, it only

has to have surplus iron, manganese, hydrogen sulphide and natural carbon dioxide removed. After that treatment

it is pumped into two purified water holding reservoirs with a capacity of 2,000 m³ each. They balance out the

fluctuations in demand and supply the water system for the town of Lüneburg, the Lüneburg South water procure-

ment group and the community of Ostheide plus the Steinhöhe main purified water reservoir, which has a capacity

of 12,000 m³.

During replacement of the telecontrol equipment at the water sources, water towers and waterworks, the data

transmission requirements in terms of security and redundant back-up increased. In that connection, Matthias

Menzel, Alfred Ködderitzsch and Sven Tuband from Avacon achieved a real master-stroke by adapting the systems

in telecontrol and control system terms to the stricter requirements using the Soft PLC codeIT application integrat-

ed in the setIT configuration tool entirely on their own.

At the waterworks control centre two FW-50 units were installed as redundant master stations. All water sources

are connected in parallel to both master stations via dedicated lines. That means that if a measured data from one

of the sources is not received via one channel it is received by the other unit on the other channel. The master

stations actively synchronise with each other. The water towers are linked by even more comprehensive security

mechanisms. The local telecontrol systems are mirrored for redundant back-up and connected via separate chan-

nels to the master stations. The main channel uses WT modems (FSK) and dedicated lines while the secondary

channel is a radio link via GPRS.

The redundant back-up configuration in the central master stations is designed so intelligently that if there is a

change-over from standby to active mode, the control function between the water sources and the water towers is

also actively taken over immediately by the new leading master.

A reliable water supply is guaranteed by an intelligent PLC function in codeIT and the net-line FW-50 stations as

redundant telecontrol interfaces.

Rote Bleiche WaterworksWater


SWN Stadtwerke Northeim GmbH is a wholly-owned sub-

sidiary of the Northeim public utilities company. The public

utilities company has been providing a safe and reliable

supply of electricity, natural gas, water and heat for decades.

With its long history, the local supplier has close ties with the region and its population.

As an operator of energy and water supply networks, SWN installs and maintains the

necessary cabling, pipelines and systems required in its grid area in order to be able to

reliably supply all customers with sufficient energy and water at all times.

In May 2013, SAE IT-systems was contracted by

Stadtwerke Northeim GmbH for "renewal of the telecon-

trol systems". The existing system had become outdated

and was no longer fit for present-day demands and so

was to be replaced. After completion of the tendering

process, the contract specified a combination of ProCoS

control system and SAE net-line telecontrol stations,

which the client had seen operating reliably for many

years at the Bovenden local plant. Stadtwerke Northeim

has a co-operative agreement with the Bovenden utility

company.

The engineers from Stadtwerke Northeim – Volker

Schmidt, Axel Jörn and Jens Linnemann – were trained on

the setIT configuration software and the ProCoS control

system and are now progressively installing the stations

as an internal contract. Linking up the waterworks posed

a special challenge. Idyllically located in a forest several kilometres from the control centre, it had to transmit a large

number of data items. A particular feature is that the remote workstation for the central ProCoS control system at the

waterworks is purely virtual. Which means that the PLC installed on site sends the information to the control centre,

which processes it and sends it back "in the opposite direction" for visual display at the waterworks. The high de-

mands placed on data transmission in both directions are implemented using SHDSL technology using the compa-

ny's own dedicated lines.

Not only the waterworks but also water towers, pressure booster systems, pumping stations, meter shafts, gas

transfer stations, gas pressure regulating stations, CHP modules, district heating stations and, for electricity, trans-

former substations, special clients and transformers, plus the control station are now equipped with SAE telecontrol

technology. Of the 185

net-line FW-5, FW-50

and FW-5000 telecontrol

units planned for the final

configuration, around two

thirds have already been

installed.

SAE equipment will then

be in use in all of North-

eim's supply sectors. We

will be very pleased to

work on more of these

projects in the future.

SAE in NortheimElectricity · Gas · Water · Heat

capabilities with very few faults in everyday operation

and has helped to achieve high levels of customer

satisfaction at Westfalen Weser Netz.

IT security in client's systems

As an additional challenge, around 300 energy gen-

eration plants with outputs over 1 MW are currently

being fitted out with telecontrol systems in order to

meet the requirements of the German Renewable

Energy Act (Erneuerbare Energien Gesetz, EEG). The

small SAE FW-5 telecontrol unit is being used for this

purpose and allows control centre staff to reduce

the feed-in rate of the energy generation plants. IT

security occupies a specially important position in this

project as the telecontrol systems are installed in the

client's stations. The use of additional firewalls and

VPN encryption is this indispensable. The planning

and configuration of the SAE telecontrol systems is

carried out by employees of Westfalen Weser Netz.

If unexpected problems or questions arise, help is

available from the SAE service hotline.

As part of their ongoing training as "officially certified

electrical engineers", two employees of the municipal

grid operator successfully completed their practi-

cal assignment using an SAE FW-5 telecontrol unit.

The aim of the practical assignment was to secure a

telecontrol

system and

its com-

munication

paths taking

account of

current leg-

islation, reg-

ulations and

standards. To

that end the

terminal de-

vices (router

and tele-

control unit)

were hard-

ware-pro-

tected, the

communica-

tion channels

secured by

various measures, and end-to-end encryption imple-

mented between remote terminal unit and process

data network using IPSec. The end-to-end encryption

in particular was new to Westfalen Weser Netz and is

to be used more widely in future.


Visual representation of the water supply in ProCoS

Specialists in telecontrol systems: Tobias Rudack

and Tobias Philipp of Westfalen Weser Netz provide

insight into the complex technology as part of a cur-

rent assignment.

The waterworks

Far-sightedness brings success: On 26 June, SAE IT-systems

GmbH & Co. KG was recognised as one of Germany's most in-

novative medium-sized businesses at the German SME Summit

in Essen. Top 100 mentor Ranga Yogeshwar presented the Co-

logne-based company with the Top 100 award established over

20 years ago. In the lead-up, SAE IT-systems had gone through a

two-stage scientific analysis.SAE IT-systems GmbH & Co. KG was a convincing contender in the Top 100 innovation

competition. In the past year, the Cologne-based IT provider achieved 70% of its sales

revenue from products that are less than 4 years old. "We aim to be the leading innova-

tor in our niche markets," emphasised chief executive, Joachim Schuster. Now "officially"

a top innovator, the company develops control and automation systems for the energy

supply sector and large scale industry and also provides all associated services such as

consultancy, project management, switchgear cabinet engineering, service, care and

maintenance and training. In recent years, SAE has placed added emphasis on devel-

oping another core skill – IT security.

Established in 1972, the company also scored highly in the innovation marketing

category at the Top 100 awards. Early analysis of potential future areas of activity and

possible problem scenarios for clients as well as joint development of suitable innova-

tive solutions is a fundamental aspect in the IT specialist's leading position.

Another factor in the operation's successful innovation are the innovation-conducive

processes within the company. Around half of the 70 employees are technical special-

ists. At any time, staff can enter product-related suggestions for improvements in an

internally developed database accessible to all employees. Those ideas are discussed

at regular innovation meetings and incorporated in the next generation of products if

suitable. In addition, the company organises special expert conventions several times a

year at which they discuss their latest developments and present them to customers.

Innovation excellence: SAE IT-systems Inside SAE

Inside SAE

"The quality of our ideas and the speed with which we implement them are a decisive

factor in our competitiveness," explains chief executive Joachim Schuster. That is why

we invest a lot of time and money in our innovation management. We put our faith in

the creativity of all our staff. I would like to thank them for achieving this Top 100 award."

The basis on which the Top 100 accolade is awarded is a two-stage analysis developed

by professor Nikolaus Franke and his team at the Entrepreneurship and Innovation Fac-

ulty at the University of Science in Vienna. The scientists examine the innovation man-

agement system and the success of innovation at medium-sized companies based on

over 100 criteria in five categories. The ultimate winner of the Top 100 award is decided

only by the scientific management.

In the last issue of SAE News (14), the report "Concepts for local network automa-

tion" contained the following wording:

"In addition to the high-quality units from Horstmann, couplings to other systems

available on the market have also been implemented, such as:

• Kries IKI 50

• A.Eberle EOR 3D,NRG 96, ESM NA 400, ESM ENA 7000

• Janitza UMG 103, 104, 604, 96"

That paragraph was, of course, not intended to imply that the products of the man-

ufacturers Kries, A. Eberle and Janitza are not of a high quality. We apologise for the

unfortunate choice of words.

Clarification


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