Implementation of a Sensor Solution for Substation Digitalization

Addressing the challenges and needs in the field of power transmission and transformation

ShinozakiMaintenance and management of power transmission and substation equipment are critical for a stable supply of electricity. Currently, power company workers patrol each substation and perform maintenance work. Recent issues associated with this are an aging workforce and a shortage of human resources. Making the work more efficient and saving labor have been recognized as needs. The present solution is designed to meet those needs. By implementing our solution, it becomes possible to remotely monitor substations in real time without the need for workers to patrol substations located here and there, allowing for efficient checks on their condition with fewer personnel.

NumajiriOf course, it also reduces the risk of power outages due to equipment failure. If equipment failures can be predicted, countermeasures can be taken before failures occur and power outages can be minimized. Power outages affect not only power companies but also power consumers. In this respect as well, the sensor solution is expected to be beneficial.

ShinozakiIn recent years, in the electric power sector, digitalization that utilizes new digital technologies such as big data, IoT, and AI has also been attracting great interest. What is done in digitalization at substations is wide-ranging. Our solution utilizes IoT to save labor in checking and maintaining equipment conditions.

A solution refined through repeated on-site surveys and reviews

ShinozakiIn this solution development, I was in charge of developing the SIU and selecting the sensors. What I was particularly determined to do was to select commercially available sensors for the most part. Developing a purpose-designed product tends to be expensive. In contrast, procuring commercially available items enables cost reduction. Moreover, an advantage of doing so is that being readily available, they are easy to replace. I also made sure that the sensors would be maintenance-free by choosing a type that would not fail over a long period of time. The sensors mounted are intended to eliminate the need for patrols. Visiting the site to maintain sensors would be putting the cart before the horse. In developing the SIU, two types of communication methods, wireless and wired, were adopted to choose from according to the location, the surrounding environment, and needs of each substation. The wireless method uses LoRa wireless technology, which enables long-distance communication. This choice is intended for easier implementation of the solution in cases where a large site raises concerns about wireless coverage. Furthermore, the wired method complies with an international standard for increased versatility.

NumajiriI took care of studying higher-level components, such as the communication protocol and the maintenance data analysis system, which are above the sensors and SIUs. In the present project, the customer desired to use an existing data server, so we determined the specifications for data transmission based on the customer's requests and developed a new system interface. The present solution can tune the system configuration accommodating customer requests. Conversely, we can provide an entire set, including the data server, and are willing to make flexible proposals tailored to some specific facility environment.

ShinozakiEach customer may have a different need for a data server, so when we receive a request, we will have consultations on specifications in advance. After we made the proposal, we had meetings with TEPCO PG once a month or so. In addition, we visited the site many times to conduct repeated investigations and discussions. As we determined what kind of configuration to develop and what kind of sensors to use in cooperation with the customer, we had difficulties in reaching agreement on the sensing items required by the customer. The implementation of the solution was required to coincide with substation shutdown. Accordingly, date and time restrictions were imposed on on-site work. In the present project, the delivery was made in February, during the winter, so if the equipment were down for a long time, it would have an impact on winter electricity demand. To work in the allowed time and deliver the solution by the scheduled date, the entire team worked together to complete everything, from procuring materials to installing a maintenance data analysis system outside the substation.

NumajiriWhen developing the maintenance data analysis system, it was difficult to establish specifications tailored to the customer. Working out the solution was probably also difficult due to the need to adjust the specifications to another verification conducted by the customer. It was a tough task to make successful arrangements, but it was worth the effort. We developed the maintenance data analysis system together with an overseas partner company. In that process, establishing communication was indeed difficult. We proceeded by organizing and checking the information as appropriate to ensure that our intentions and requests were clearly understood even through an interpreter.

ShinozakiWhen it comes to difficulties, I remember that the customer had a plan to install another product in the same equipment after the delivery of our solution. Arrangements were made through consultation with the customer on the locations of our system and the system to be installed later so as not to affect each other. When the actual equipment is not available anywhere but at the site, work done in the company is naturally limited to a desk study. I remember that there was a lot of trial and error during the on-site investigation and installation work.

For expanded application to general industries as well as to electric power companies

ShinozakiWe have accumulated data since the delivery of the solution to the site. Currently, we are in the phase where we should analyze the data and, based on the analysis results, discuss with the customer the next step to take. Rather than just delivering a product, we will evaluate the sensing information obtained and propose ways to utilize that information. Data collected during demonstration and verification may contain unexpected information in the form of numerical values. I would like to analyze each of those numerical values to know the equipment conditions corresponding to those numbers, accumulate the findings, and use them as a clue to detect equipment abnormalities and failures in the future. Based on the current experience, I would like to expand the solution to other power companies in the future. Also, in the general industry sector, large factories have electric power equipment installed, so I would like to make proposals to such customers, as well as to electric power companies.

NumajiriThis project was the first time I was involved in working out specifications for communications. I'm glad that we were able to decide on them properly and that we were able to successfully complete delivery, demonstration, and verification. Also, this was my first time interacting with an overseas partner company. I would like to use this experience for future development work or other projects.

ShinozakiThis project, or a proposal-based project, was also my first experience. We provided a proposal to the customer, which was accepted, completed the solution to its final form, and conducted its demonstration and verification. These make me feel that I have achieved substantial results. In creating something from scratch, I think the real thrill and fun of being an engineer is being able to think and create it yourself, so I will continue to work on development while proactively absorbing new information and technology.