Challenges

• To find new, proven, scalable software and robust hardware to replace the old, manual, and inefficient Load Control System and to monitor power demands. The SLCC system is also connected to the central system located in Kolkata (logistics and infrastructure office).
• The old RTUs for the field must be replaced, and a redundant communication network must be configured to provide high-level communication between software and hardware on the sites, substations, and control room. A dedicated fiber-optic network should be launched to effectively use the new remote terminal units and connect them to the central electrical data server.
• Deploying a central monitoring system using Scada architecture and management in one place was a crucial challenge. Electricity monitoring of the overall Plant at a single location is economically essential for the steel industry.
• The new system should monitor and control the distribution and sub-distribution of energy at the electrical stations, as well as energy generation and import.
• Providing alarm management, data storage, and history of changes should improve the plant electrical system's reliability and make the system controllable and manageable, thanks to a complex, integrated Scada system.

Selected applications

They selected ETAP Real-Time solution with Scada/PDMS. ETAP company provided all necessary hardware and software, provided operators and supervisors training and transfer of data between offices, focusing on system redundancy and quality.

iSLD solution was used for creating single line diagrams, and network topology.

Main Customer Benefits

• The steel plant's electrical digital twin model was developed and validated based on data directly collected from the stations, 44 substations, switchboards, and all concerned asset information. Using iSLD, the Bokaro Steel Plant Electrical Network obtained a virtual electrical model.
• ETAP provided the newest technology to ensure communication, such as an eSCADA solution, fiber, a redundant network, multi-function transducers, remote terminal units, and IT equipment. Approximately 27000 tags were integrated into the Scada system to describe the actual system. 
• A one-window solution for a complete electrical system for hardware and software based on the ETAP modeling possibilities with access by HMI is crucial if we think about efficiency and information availability. The electrical system was delivered with unmatched system visibility. Easy access to the system and data for operators working in the station improved the quality of operations.
• The ETAP team built the Operator Training Simulator bridge between the model and the real system to provide the required training for Operators and Supervisors using direct data from the electrical network. This bridge is used for transferring data to the central location in Kolkata.
• Alarm and event management with an HMI viewer and an automated report viewer dramatically increased the level of maintenance. Optimizing the load management system using load flow analysis was crucial for the customer. Manual interventions and operator errors decreased. Users can also obtain automatic reports about events, alarms, and energy by email.
• Real-time monitoring and the system analysis tool, with failure predictions, trends, contingency analysis, playback solutions, and maximum demand monitoring, give the client certainty in operations.
• The maximum demand monitoring HMI informs the situation in real time on the clear dashboards, including power factors, actual demands, grid frequency, and all needed parameters, with alarm handling. The tabular dashboards were also delivered to provide information about events and their history.

Opinions

They have no electrical network model. Since 2019, the ETAP has built the electrical network model for them, and we run the local analysis on the plant network report viewer. We have now provided them with an automated report.
By Sushil Ojha, Assistant General Manager at ETAP India

So, in this ETAP project, including the substations, RTU, and remote iOS, we integrate all 44 substations with the Control Center, the training, the drawings, and the materials we already provided and hand over to the client for the supervisor's training.
By Sushil Ojha, Assistant General Manager at ETAP India