4|15 The customer magazine of Phoenix Contact | December 2015 Reliable energy Phoenix Contact makes energy networks more intelligent
02 Editorial UPDATE 4|15 Stephan Frigge, Sales Manager Control & Industry Solutions On the path to Energy 2.0 Dear readers, Until some time ago, electricity only went in one direction: from top to bottom. Electricity was generated in central power stations and then was sent via the transport network and distribution network to the consumers. But this picture has changed considerably. Decentralized power generation, with a high percentage of renewable energy, is taking on ever more basic supply tasks that used to belong to large-scale power stations. This is accompanied by massive challenges for network operators and energy providers. Voltages, frequencies and reactive power have to be measured and controlled at many points in the network in near real-time, which has significantly increased the need for communications technology. The intelligent power grid of tomorrow will communicate directly between many decentralized units. We at Phoenix Contact are meeting this challenge together with our partners in the energy industry and are creating solutions for the new energy market. In the following pages we report on some of the results. To contribute in shaping the process for transforming the energy market sustainably and intelligently, we have formed industry-specific sales and engineering units. The units' technical expertise will provide you with significant added value. This is in line with our increasing trend to transform from a conventional component manufacturer to a solution and system provider. Thanks to our more than 50 sales subsidiaries and 30 additional sales partners, we are near our customers nearly anywhere in the world. And so we would like to accompany you on the path to Energy 2.0 as your partner and create innovative solutions that sustainably secure our energy supply. We won't be satisfied with any less. Editorial 02 Stephan Frigge Interview 03 Wolfgang Friedrich, Bilfinger Mauell Cover story Municipal solution for lighting 04 Efficient street lighting via TC Mobile remote control system Solutions for the future 14 Energy supply VHPready standard for virtual power stations On site Interface technology 08 System cabling on HVDC converter platform 10 12 16 Marking Power station labeling system at RWE Connection technology Protective device test with innovative plug-in test system Control technology Secured access to cogeneration plant Infrastructure solutions 18 Wireless communication in a power station's wastewater treatment plant New products 21 21 Function blocks for energy Flexible wiring of measuring transducers 21 High-current PCB terminal block 21 I/O module for the energy environment Current events 22 Phoenix Contact takes over SysMik 22 IT-secure production without downtimes 23 Award-winning tool making phoenixcontact.com
UPDATE 4|15 Interview 03 More intelligence in the distribution network Pilot project from Bilfinger Mauell and Phoenix Contact At Bilfinger Mauell GmbH, Wolfgang Friedrich is the sales manager for the distribution network automation area. The editors of UPDATE interviewed him about a Phoenix Contact pilot project, which both companies are carrying out together for a transmission network operator. The expert reports about his experience with Axioline for decentralized automation in protection and control technology. This was based on integrated communication in accordance with the IEC 61850 standard. UPDATE: Mr. Friedrich, what does the solution consist of at its core and what makes it special? Wolfgang Friedrich: Our customer, a transmission network provider, was looking for a Wolfgang Friedrich, Bilfinger Mauell Wolfgang Friedrich: We have been working on intelligent distribution networks as a new business field for a good ten years – along with the business fields of conventional energy automation solutions for transport and distribution networks. The goal is to develop solutions for the energy transition, i.e. the transition from centralized power supply to decentralized power supply. To do so, we established partnerships to develop products that support the reversal of energy flows in the best possible manner. UPDATE: How far along are the energy providers or utility companies in using new communication technologies? Wolfgang Friedrich: The customers are still using pilot systems in many cases. At times, there is still resistance to communication solutions, because these new technologies also require a change in employee training. That means, on-call services have to be changed and the classic network installers, which used to repair cables, now must also be able to handle the electronic systems. forward-looking solution to transmit messages, such as automatic tripping of the circuit breaker, to the station control system. Together with Phoenix Contact, we have developed a complete concept: The signals are detected by the new Axioline bus coupler with integrated IEC 61850 communication. To do so, the new Axioline terminals are used to record signals with an increased impulse withstand voltage of 5 kV and a voltage range of 110 to 220 V DC. UPDATE: Are you breaking new ground with the topic of bringing more intelligence to the distribution network? "The customers are still using pilot systems in many cases." UPDATE: What was special about the partnership with Phoenix Contact in this project? Wolfgang Friedrich: As a distributor, we are always looking for partners with whom we can implement certain solutions that we do not have in our portfolio. This project was an excellent addition: The Phoenix Contact electronic systems collect the signals decentrally in the lower field level. The field device data is then gathered in our remote control system and then transmitted to the control system. UPDATE: Thank you very much for talking to us.
04 Cover story UPDATE 4|15
UPDATE 4|15 Cover story 05 Keeping the Rhineland illuminated Efficient street lighting via TC Mobile remote control system Gerhard Kleiker is responsible for public lighting at RheinEnergie AG controlling the street lighting. Key components here include the TC Mobile remote control device, which enables communication with the ODP open remote control protocol. "We were looking for a fitting, already existing standard solution for communication that could be installed quickly and easily in the control cabinet to keep costs within reason," Kleiker recalls. The compact TC Mobile X300 remote control device triggers the lights in the street lighting distributor with its four digital input and four output contacts. Communication occurs from the central system by a ODP/OPC server using a mobile wireless connection via GPRS. The digital output contacts can be used to control the contactors in the street lighting distributor for night-time lighting, half night-time lighting and for a special activation of the crosswalks. The digital input contacts can be used to transmit the activation of the lighting to the central system, where it can be logged. Decentralized activation and deactivation times can be stored on the device to be able to switch on the street lighting in a time-controlled manner in the case of a communication failure. Software for operating was developed based on a web-based Phoenix Contact control system. The first field tests took place at RheinEnergie headquarters Street lighting is often switched via twilight switch by a central system using ripple control technology. A disadvantage of this technology is that there is usually no feedback to the central system. Cologne-based RheinEnergie AG is now implementing a system for controlling street lighting with bidirectional communication. The key component is the compact TC-Mobile X300 remote control system from Phoenix Contact. RheinEnergie AG is a large municipal company for energy services that is primarily regional, but also active throughout Germany in energy distribution and energy services. Gerhard Kleiker, along with 26 employees, is responsible at the company‘s department in Cologne, Germany for providing lighting to streets and public spaces in Cologne and its surrounding communities. Ripple control technology is being discontinued For a long time, there were not many options for controlling municipal street lighting. In many cases, street lighting is still time- controlled or switched via twilight switch by a central system using ripple control technology. A disadvantage of this technology is that there is usually no feedback to the central system and, as a result, operators cannot detect faults. "Because some energy providers have announced that they will stop ripple control technology in the medium term, it was clear that we have to take new approaches to controlling lighting systems and lighting cable networks," explains Kleiker. Thus, in late 2014, initial discussions with Phoenix Contact began about developing a new light management system, which was also to enable bidirectional communication. Solution with standard technology preferred The experts from RheinEnergie and Phoenix Contact began to develop an overall system for
06 Cover story UPDATE 4|15 Here, the RheinEnergie customers placed value on an easy-to-use and easy-to-expand interface. Web-based operation and monitoring software is installed on the central computer, which also allows maintenance personnel direct control cabinet-related activation via tablet or smartphone on-site during a light test. The burning time and activation times for the street lighting are recorded using logging software, which is secured against tampering. The reporting function can be used to visualize the operating data for the street lighting. The broad-scale launch took place after the pilot test in Bornheim The first field tests were carried out at the RheinEnergie company grounds in Cologne. After the successful trial, the system was introduced as a pilot installation for the first time in Bornheim, a city 20 kilometers away from Cologne. Here, the twilight switch with two different switching thresholds was placed centrally in the city. The first switching threshold is at 30 lux to activate the crosswalks, while the The software for lighting control can be operated intuitively In the street lighting distributor, each block can be activated individually thanks to TC Mobile
UPDATE 4|15 Cover story 07 Small, but communicative: the compact TC Mobile X300 remote control device Remote control using a mobile device made easy with TC Mobile TC Mobile is a cost-efficient alternative for monitoring and controlling processes. The mobile wireless module uses the mobile wireless network to monitor the analog and digital signals from remote stations easily and reliably. The relays can be controlled re- motely. The integrated calendar can be used to specify the switching times of the relays. Monitoring of systems using remote stations is optimized by having the mobile wireless module communicate continuously with an ODP server as an ODP remote workstation via the GPRS wireless service. second switch level at 15 lux is responsible for the remaining street lighting. Both switching thresholds are transferred to the central system via TC Mobile. From here, ODP is used to control (currently) ten TC Mobiles in the street lighting distributor, which activate street lighting in a distributed manner in Bornheim. After expansion is complete, up to 220 street lighting distributors can be activated. soon as a light can no longer be switched on. The lighting hours of the lights are also logged and archived in the central system. Along with detailed cost control and expense accounting, this can be used to initiate maintenance once a certain lighting duration is reached. After the pilot test phase, RheinEnergie is planning to introduce the new control technology in additional communities. The auxiliary contacts of the switch Christoph Manegold contactors are reported back to the central system via a digital contact. This can be used to eliminate faults extremely efficiently as phoenixcontact.com
08 On site UPDATE 4|15 High performance on the high seas: HVDC platform Helwin planned to transmit 690 MW Image source: Siemens Systematic project success System cabling on HVDC converter platform Offshore wind farms make an important contribution to renewable energy generation. System cabling from Phoenix Contact ensures that the control cabinets can be tested and commissioned quickly and without errors on the respective transmission platforms. In the HelWin2 grid connection project, the alternating current is transformed to 320 kV DC on the high-voltage direct current transmission (HVDC) platform. The power is transmitted over an 85-kilo meter-long sea cable and a 45-kilometer-long land cable to the Büttel converter station located east of the city of Brunsbüttel. There, the DC voltage is transformed back to AC voltage and fed into the maximum-voltage network via a neighboring substation. Because no employees are stationed on the HVDC platform, a large number of measurement and control devices are needed to collect the data and transmit them to the operations center in Lehrte, close to Hanover. A medium and low-voltage power supply is also required on the platform to run equipment such as pumps and safety devices. Technomatic, an engineering contractor based in Maxdorf, Germany, has comprehensive expertise in this segment. This earned the company six work packages from Dutch shipyard Heerema, which was responsible for the HVDC platform of the HelWin2 project. Plug-and-play connection of the control systems To set up the control cabinets in the most efficient manner possible, the Technomatic team, headed by Josef Hasselbach, decided on system cabling from Phoenix Contact. This involves components for plug-and-play connection of control systems, such as the Simatic S7-400H and ET 200M used in the HelWin2 project. The system cabling consists of a front plug matched to the respective module that is equipped with one or more insulation displacement connectors. A preassembled and tested cable is connected to the connectors. Users plug the other end of the preassembled cable into a termination board. As a result, in just a few minutes, they have a fault-free connection between the I/O module and the field level. Because Phoenix Contact offers many different types of termination boards, the signals can be connected in the field using different methods. For example, there are passive boards for 1:1 signal patching as well as active boards
UPDATE 4|15 On site 09 with relay or solid-state relay. The Phoenix Contact portfolio includes a system cabling range that makes do without halogens but is still flame-resistant in accordance with IEC 60332-3-22. Despite the lack of plasticizers, the cables feature outstanding low rigidity. In addition, they are compatible with almost all front adapters that Phoenix Contact offers for connecting a variety of automation devices. Accelerating the necessary tests In addition to the great time savings, the system cabling provides yet another benefit for Technomatic. This involves the Factory Acceptance Test (FAT) and the Site Acceptance Test (SAT): After the control cabinets have been finished, all signals have to complete the FAT at the control engineering company's facility, where all I/Os are checked for correct function. Once the test has been passed, the control cabinets are removed from the patching cabinets and sent to the client. An additional benefit of the system cabling plays out here. Due to the defined interfaces through the connectors, disconnecting the cabinets is easy. The subsequent assembly at the customer's facility is likewise problem-free, and the SAT can begin immediately. This means that the FAT is repeated with the actual voltage supply of the system. "It can be very costly and time-consuming if four terminal points per signal have to be disconnected and then reconnected for 6000 signals," says Managing Director Josef Hasselbach. "In most cases, we have no more than two months for setting up the control cabinets. As a result, the system cabling from Phoenix Contact has made an invaluable contribution to the project success of Technomatic." Daniel Utermöhle phoenixcontact.com The Varioface termination boards with insulation displacement connectors Image source: Technomatic GmbH
10 On site UPDATE 4|15 Barcode scanning – printing errors would make onsite identification considerably more difficult Efficiently marked – safely guided Power station labeling system at RWE In power stations, accurate and long-lasting labeling of all operating equipment is of particular importance, as errors have unforeseeable consequences. The rules for this are defined by the Identification System for Power Stations (KKS). For labeling, RWE Power AG uses marking solutions with LED UV printers from Phoenix Contact. The KKS assigns process technology components to the control system functions clearly and unambiguously. The encoding of the more than 250,000 pieces of operating equipment helps to manage the data centrally and efficiently. As a result, an integral part is central inventory management across the entire lifecycle of the components used. Clear and unambiguous labeling of process technology units and operating equipment is also important for occupational safety and health. Connecting the wrong piece of electrical equipment can result in severe injury and harm to the system. As part of the overhaul of the control engineering in power station blocks D and E of the Neurath power station in the Rhenish lignite mining area, a large number of master cables had to be relabeled. When looking for a suitable printing system, the specialist department decided on the Bluemark LED system from Phoenix Contact. Important criteria included low energy consumption and low-noise operation. The successor model, the Bluemark CLED, enables up to 120 labels per hour to be printed in an environmentally friendly manner. In addition to information about where the cable comes from and where it is going, an unambiguous cable labeling includes the KKS number and the cable type. In accordance with DIN EN 62491, cables must be labeled on both ends at minimum. Barcode for rapid identification One important requirement was for the new labels to fit into the already installed holders in the power station block. All process technology identification labels in the power station fleet of RWE Power AG in the Rhenish lignite mining area (Frimmersdorf, Neurath, Niederaußem and Weisweiler) have a barcode in addition to the Identification System for Power Stations code and the short text. This can be used as part of mobile maintenance for applications such as damage reports. Given the harsh ambient conditions in a power station, critical factors for long-term, long -lasting labeling include high print quality and temperature resistance.
UPDATE 4|15 On site 11 After the development work at the Neurath power station, RWE Power AG decided to also introduce the printing system at its Niederaußem and Weisweiler stations. In addition to printers and labels, other accessories are used – including label holders, medium colors and mounting components. Suppliers take part In addition to the Bluemark CLED Unicard printer, RWE also uses thermal transfer printers – for example for adhesive marks for power breaker labeling. In addition to the white power station identification labels for the process technology units and operating equipment, RWE also uses the colors violet (Ex zone), yellow (SIL) and orange (protection). Meanwhile, other RWE suppliers such as Siemens AG also rely on the products of the Blomberg-based company. "With the identification system from Phoenix Contact, we can quickly and flexibly label our switchgears in accordance with RWE specifications," explains Patrick Schmidt, Project Manager in the Power and Gas company division of Siemens AG in Essen, which has already equipped some switchgears in the Weis weiler power station with the KKS labels from Phoenix Contact. "For this we also rely on the labels standardized by RWE." Integration of RFID is being advanced At Phoenix Contact, too, more work is being done on optimizing the line of identification products. The company presented its new KKS holders at the Hannover Messe 2015 trade fair. In addition to extensive mounting options, these special label holders for the identification of power stations and systems also provide for faster mounting of labels by using latches. This makes it possible to further reduce personnel costs for assembling the labels. For areas with high mechanical strains, the labels can be additionally secured with plastic rivets. Phoenix Contact will continue advancing the integration of RFID technology into labeling of systems. The goal is to set up paperless and efficient processes for maintenance management. Karsten Natus phoenixcontact.com Labeling of cables in accordance with RDS-PP – the RDS-PP code, source, target and cable type are documented on the label
12 On site UPDATE 4|15 New options for modern switchgears: Munich Municipal Utilities (Stadtwerke München) uses Fame for testing and checking Quickly checked, easily connected Protective device test with innovative plug-in test system at Munich Municipal Utilities (Stadtwerke München) Networks everywhere are being updated, expanded and monitored with ever greater precision. In order for service, maintenance and expansion of the networks to be made simpler and more reliable, Phoenix Contact has developed the testing and checking system called Fame. Munich Municipal Utilities (Stadtwerke München, SWM), one of the largest municipal providers in Germany, is using this system to modernize its network and increase network availability. tree are reliably detected. "Then the network master relay triggers the circuit breaker, which disconnects the respective line," explains Maximilian Gruner, team leader for Secondary Technology (Power) at SWM Infrastruktur GmbH. "Since the supply reliability significantly depends on the function of the network master relays, we carry out protection checks regularly." Converter switch terminals were replaced Munich Municipal Utilities operates its own substations to provide its customers with high network availability. This includes nine plants for maximum to high voltage, 328 for high to medium voltage and 5,184 for medium to low voltage. A prerequisite for safe and reliable operation of the power grids is fast detection of faults, so that the corresponding power cables can be switched. This requires constant monitoring of measured variables. Digital network master relays handle this task. They draw their measurement readings from current and voltage transformers out of the transformer and distribution stations. Faults such as a short-circuit in the line due to a fallen Until about two years ago, Munich Municipal Utilities installed test sockets for this. During protection checks, signal and trigger contacts open in succession through switch actions on the terminal strip. Only for select lines is redundant protection of the line in the medium voltage range in place. A fault during the protection check can have far-reaching consequences in the case of non-redundant protection systems—thus, for example, the supply reliability can be jeopardized or individual parts of the system may even be destroyed. To enable all of these tasks to be carried out more easily, more clearly and above all
UPDATE 4|15 On site 13 more reliably, Phoenix Contact developed the Fame system for checking connections. An advantage is provided here by the fast contacting, which saves up to 50 percent of time during preparation of the test. "By using Fame, we can connect a complex test circuit for a protective device with the test device in a single connection process," Gruner says. "We can reliably and automatically implement all of the necessary switching operations." The sequence of the contact bridges, separations and contacts is specified by the connector—and therefore is always correct. There are many wiring variants, so that numerous serial switch sequences of the converter switch terminals can be implemented in a single connection action controlled simultaneously. Working reliably and preventing mistakes Working this way can prevent many mistakes, such as open connections or setting the short- circuit jumper for the current transformers. The protection technician can concentrate on the wiring of the test plug. "This way we further increase reliability by using prefabricated test plugs," explains Gruner. Now carrying out checks is much easier for the maintenance personnel, too. To prevent test plugs with the same polarity from being connected incorrectly, the test connector strip and test plugs can be coded with plastic profiles. Moreover, different function groups can be wired on a standardized test connector strip. Gruner says, "Thus we start, for example, by routing the main and reserve protection relay through a test connector strip with two separate test plugs, which saves us a lot of space." Configuring flexibly for even more measuring and checking options The Fame product line also includes additional accessories such as bypass connectors and color- coded single-pole connectors. The single-pole connector can be used for quickly and efficiently carrying out individual measurements or disconnecting the high-voltage switch's trigger coil from the protective device. Furthermore, Fame is designed to prevent finger contact in both the connection zone and the connection area. There is also the option of implementing neutral points in the current transformer set via jumpers directly in the test connector strip. An additional serial terminal strip with converter switch terminals is unnecessary. Fame can be used to carry out complex switch actions with a single test process Conclusion Munich Municipal Utilities achieves high flexibility as well as greater reliability and increased operating convenience by using the Fame plug-in test system. "The advantages of the system are found in the clear contact overlapping or manufacturing of test plugs for specific projects. Even a rotary switch can't provide that," says Gruner. "The good mechanical guidance when connecting and for preventing the plug from being pulled at an angle provide us with additional advantages." Three connecting times can be selected for free assignment of the contacts. These include the long contact for the Off signal and auxiliary signals, the medium contact for voltage transformers and the short contact for current transformers. A non-assigned contact acts as a dead contact. Bernd Schairer phoenixcontact.com
14 Solutions for the future UPDATE 4|15 Control over decentralized power VHPready standard for virtual power stations Decentralized power generation units can be combined into a virtual power station to better control the power grid. The communication infrastructure also plays an important role in this. The VHPready standard simplifies setup and operation of virtual power stations. All Phoenix Contact control classes support this standard. The concept of a virtual power station is not new. Various projects have already been tested successfully, but the communication and logic sequences for the individual power stations were separately defined for these. Therefore the implementation of each virtual power station was associated with a high degree of engineering effort and high costs. A standardized interface for decentralized power units is needed to keep corresponding networking activities as low as possible. Here, VHPready has set the goal of creating this type of standard for the remote control protocols IEC 60870-5-104, IEC 61850-7-420 and DNP3, which is addressed to all decentralized power generators and accumulators and flexible consumers. The individual, decentralized units are compiled to do this. Their data transfer to the virtual power station was given a unified structure. Access protection via VPN tunnel If a system operator would like to have its energy generation unit certified in accordance with the VHPready standard, communication must be access-protected via VPN tunnel (VPN = Virtual Private Network). After the system has been certified successfully, it can be connected to any virtual power station that supports the VHPready standard. An additional advantage of VHPready is a result of the integration of hot water tanks. If too much current is produced, the excess energy can be used to heat the tanks using an additional heating rod as long as it cannot be stored electrically. This saves fossil fuels. Furthermore, the virtual power station can centrally monitor the connected systems and receive a notification immediately Decentralized energy generation systems must be connected to a central control room for communication
UPDATE 4|15 Solutions for the future 15 Basis for flexible consumption models VHPready can be used to connect decentralized electricity and heat generation systems, consumers and energy accumulators to a virtual power station and control them accordingly. If these mechanisms have been established, flexible consumers such as cold storage spaces or charging stations for electric cars also benefit from a virtual power station. During the time in which too much energy is available in the network, they can draw electricity more cheaply. Therefore, electric cars get priority for charging when there is a strong wind, because then the current production of the wind turbines is the highest. This is how the electric cars relieve the load on the power supply without negatively influencing the lifecycle of their battery. The number of cost-intensive electrical accumulators can be reduced by increasing the use of flexible electrical consumers and generators. if errors occur in the decentralized units. This allows immediate responses. If the system of a power generator fails, other generators can compensate for the missing current via direct activation commands or flexible consumers can be switched off. The VHPready standard was originally developed by the Vattenfall Group and taken over in February 2014 by Industrieforum VHPready e.V., which is headed by the Fraunhofer Fokus Institute. Phoenix Contact is one of the 15 founding members. This allows the company to incorporate its many years of practical experience into the further development of VHPready. The Blomberg-based automation specialist implements the standard for decentralized energy units in its ILC 171 small-scale controller. The Inline Controller has two Ethernet interfaces for Modbus TCP and Profinet. The eight digital inputs can also be used to process S0 signals. In addition, the ILC 171 controller can be expanded using modules for Modbus RTU, M-Bus and temperature sensors and for pulse width modulation. Schedules are stored for up to four days in a ring buffer. Therefore, even if there is a connection failure, the combined heat and power station knows which power stage has been calculated previously in the control room for the next fifteen minutes. If the power balance of the virtual power station changes briefly, the schedules can be overwritten by direct commands. If a combined heat and power station supplies locally connected processes with heat, this has the highest priority and the virtual power station is notified accordingly. Based on the Powerworx function block library that has been created by Phoenix Contact, electricity, gas and heat meters as well as additional boilers and buffer storage units can be connected. These devices communicate with the control room without additional configuration. They log counter readings automatically to an SD card, which is inserted into the controller. Sebastian Prus phoenixcontact.com
16 Technology UPDATE 4|15 The combined heat and power station supplies all energy to the Phoenix Contact Lower Saxony location No access to internal networks Efficient energy management based on a combined heat and power station At the Phoenix Contact location in Bad Pyrmont, a newly installed combined heat and power station provides a cost-efficient and reliable power supply to production and administration buildings. The power station manufacturer must be able to access the system remotely to achieve a flexible utilization of the system of more than 70 percent. An industrial firewall solution is used to reliably limit data traffic. One of the Phoenix Contact production locations in Germany is in Bad Pyrmont in Lower Saxony. There, approximately 1500 employees work in the areas of development, manufacturing and marketing of electronic modules and automation technology. To date, electricity has been bought in as an important energy source, which led to a significant dependence on the purchase prices. To break away from this trend, the company has now introduced gas as a second energy source. Using an in-house combined heat and power station, the gas is converted to electricity and heat. If the combined heat and power station manufacturer is not allowed to access the system remotely, the combined heat and power station may be operated at a maximum utilization of 70 percent. The power station can operate at 100 percent capacity only if a maintenance contract that includes remote access is in place. Initial studies of the Phoenix Contact Facility Management department show that in most cases, operating the combined heat and power station at more than 70 percent capacity is useful from a business management perspective. Thus, it is in the company's own interest to grant the combined heat and power station manufacturer access to the system. However, at the same time, it must be ensured that the manufacturer cannot access the company's internal network via remote maintenance access. The manufacturer equips the combined heat and power station with a DSL router, which can be used to externally access the combined heat and power station controller via a secure Virtual Private Network (VPN) tunnel. Internally, facility management also requires data access to the system. To separate the applications from each other, a firewall has been installed between the combined heat and power station and the network for building management. This is used to meet the high security requirements of the IT department of Phoenix Contact.
UPDATE 4|15 On site 17 Simple implementation for various operating states The FL mGuard RS4000 TX/TX IT security router is used as an industrial firewall. This device provides a high level of security and performance in a compact metal housing that can be installed on the DIN rail. Thanks to the integrated Stateful Packet Inspection Firewall, the device is suitable for decentralized protection of networks, because rules can be used to filter incoming and outgoing data packages in both directions – from the external network into the protected internal network and vice versa. Logs, source addresses and ports as well as target addresses and ports can be used to limit network communication in a targeted manner to a defined measure required for production. Gerrit Boysen phoenixcontact.com High access security and performance in a compact housing on the machine or as central security components in branched networks. This makes them a flexible and scalable security solution. The new generation of fanless industrial security routers provides the user high security and performance in a compact metal housing, which can be installed on a DIN rail. The devices have an SD card slot, which, as part of a data exchange, can be used to transfer the respective configuration data easily to another device. Besides this, there are connections for the VPN enable switch and VPN status indicators. Based on a hardened, embedded Linux operating system, the FL mGuard series contains four security components adapted to each other: • A bidirectional stateful inspection firewall • A flexible NAT router • An especially secure VPN gateway • Optional protection from malware using CIFS Integrity Monitoring. The devices from the product range are designed for use in the field as an industrial VPN router, where they can be used directly The combined heat and power station in Bad Pyrmont The FL mGuard RS4000 TX/TX security router ensures a high level of access security
18 On site UPDATE 4|15 Easy to use and reliable Wireless communication in a power station's wastewater treatment plant The process wastewater from the RWE power station in Neurath in the Rhenish lignite mining region is fed back to the process to the greatest possible extent. Wireless technology and additional components from Phoenix Contact contribute to making the wastewater treatment plant of the power station work flexibly and reliably. RWE Power AG operates the Neurath power station in the south of Grevenbroich, Germany. With an electric gross output of 4400 megawatts, it is the largest lignite-fueled power station in Germany and the second largest in Europe. A wastewater treatment plant with four circular scrapers processes the wastewater on the premises of the power station to feed it back to the process. RWE Power AG modernized its wastewater treatment plant in 2014. "As part of the renewal process, the control system, which was until now a self-sufficient blackbox system, has been discontinued and integrated into the Procontrol P14 control system of ABB. This was necessary as part of the block flexibilization," reports Stefan Strasser, the responsible project manager, whose work at the Technical Services department of RWE Power encompasses multiple power stations. "Procontrol controls all auxiliary systems of the power station, which include the pilot fuel pump station and fire extinguishing system." During the conversion, one goal was in the foreground: The wastewater treatment plant, which previously had been operated exclusively on site, was also to be given a remote control mode. To do this, all wastewater treatment areas had to be displayed on monitors of the power station's control room and the process sequences had to be depicted in real time. "Because of the continuous rotary movement of the circular scrapers and the limited number The power station's integrated wastewater treatment plant with four circular scraper sedimentation tanks
UPDATE 4|15 On site 19 of slip rings, using a maintenance-prone slip ring package to transmit the feedback and control commands was out of the question," says Strasser. Therefore he and his colleagues looked for a communication solution that was robust enough to fulfill the requirements of the power station operator for high availability of all system parts. Strasser explains, "Since we already knew about the successful use of the Radioline wireless system at other RWE power station facilities, we got in touch with Phoenix Contact. During an on-site inspection, employees of the Blomberg-based company then tested the wireless coverage on our grounds so that they could evaluate the signal strength and reliability of the data transmission." Industry-specific wireless technology The Radioline system is based on the Trusted Wireless 2.0 technology, which Phoenix Contact developed specially for industrial applications. It is particularly suited for forwarding sensor and actuator information wirelessly and for exchanging small to medium amounts of data in vast systems. With a clear line of sight it is possible to bridge distances between two mobile subscribers ranging from several hundred meters to a few kilometers. The Frequency Hopping Spread Spectrum (FHSS) method provides for robust communication here. The technology uses a selection of up to 127 channels from the entire spectrum of the frequency band, which it hops between on the basis of a pseudo-random pattern. Automatic and manual coexistence mechanisms also ensure reliable parallel operation of various wireless systems. This applies to multiple solutions with Radioline that are operated at various radio frequencies, as well as to WiFi systems for which the channels in use can be specifically blocked. Though it is theoretically possible for unauthorized parties to intercept data packets, the 128-bit encryption ensures that they cannot understand it. This makes data transmission secure. In addition, an integrity check verifies the sender's authenticity and rejects altered messages. Another feature of Trusted Wireless 2.0 is its distributed network management, on account of which the data is forwarded faster. Moreover, the system provides extensive functions for diagnostics and makes it possible to build flexible network structures with automated connection management. Four directional antennas ensure an optimum signal strength, regardless of the current position of the circular scrapers
20 On site UPDATE 4|15 Modular expandability The master module of the Radioline system can be equipped with various antennas and expanded in modular fashion by adding up to 32 I/O modules. A broad temperature range from -40 °C to +70 °C allows for a wider variety of application options in the rough industrial environment. After all tests were completed with positive results, the employees of RWE Power began planning the wastewater treatment plant with support from Phoenix The master module of the Radioline system can be expanded in modular fashion by adding up to 32 I/O modules Contact. Each of the four circular scrapers was to be given its own wireless system. The central switchgear cabinet for the P14 control system is housed in the pump house of the wastewater treatment plant. In addition, many signals of different voltage levels had to be transferred in potential-free form over optocouplers. After the planning phase was completed, the project was officially put up for bid. SAG GmbH was awarded the contract. This service and system supplier from Cologne created the four control cabinets for the circular scrapers and the central switchgear cabinet for the control system in a workshop on the power station grounds. Then the control cabinets were installed in the wastewater treatment plant. Due to outdoor operation, they are equipped with a corresponding heater for protection against condensation. In the case of high-availability systems, the redundant power supply in particular plays an important role. "Aside from the power supply units of the Quint product range for converting voltages, we use an active redundancy module from the same series," Strasser reports. The integrated auto-current-balancing (ACB) technology loads the device uniformly, so that its service life is extended. "Thanks to continuous monitoring of input voltage, output current and the decoupling section, the redundancy module makes a substantial contribution to the high availability of the system and significantly reduces lifecycle costs," Strasser continues. Optimum signal strength The control cabinets on the circular scrapers continuously move in a circular path, and therefore each is equipped with an omnidirectional antenna. At the receiver on the pump house there is a total of four directional antennas. This achieves optimum signal strength, regardless of the current position of the circular scrapers. To protect the antenna system, employees of RWE Power also installed surge protection from Phoenix Contact in the control cabinets. The devices ensure the highest possible availability and, thanks to their low damping values, do not interfere with the signal transmission between the mobile subscribers. "Starting up the Radioline modules proved to be really easy," Strasser says in conclusion. "All we had to do was assign the radio modules to one another via a thumbwheel on the device. Thus a digital input is set to the same number as the corresponding digital output, and then the signals are distributed in the system correctly, without any programming. After the enabling and restoration of the power supply, the mobile subscribers automatically find each other again within a few seconds. We were thrilled by this intuitive operation as well as the support we received from Phoenix Contact." Karsten Natus phoenixcontact.com
UPDATE 4|15 New products 21 Flexibly wiring measuring transducers The UT 6-T/SP test disconnect terminal blocks up to 6 mm² have up to six universal function shafts for potential distribution or test purposes. All of the potential distribution tasks can be carried out quickly using jumpers that can be freely assembled and have from 2 to 16 positions. There are through-terminals with the same contour for a design that suits the application. Thanks to its functionality and combination options, the terminal reduces the wiring eff ort, both in the unmetered area as well as in protection for switchgears, lines, machines and devices. Libraries for power transmission and distribution Powerworx contains several preprogrammed function blocks for PC Worx for easy confi guring and startup in various application areas. This includes, for example, intelligent local area network stations or virtual power stations. All common measuring devices can be used for easily acquiring the relevant data in the low- and medium-voltage network as short-circuit messages, measured values and events, and for transmitting them to the control center. High-current PCB terminal block I/O module for energy applications The MKDSP 95 heavy-duty PCB terminal block has a current carrying capacity of 232 A and a wire connection capacity of up to 95 mm2 in the compact 20-mm spacing. To transmit the tightening torque reliably even for large wire cross-sections of up to 95 mm2, the terminal has a Torx drive. The MKDSP 95 PCB terminal block can be processed in a normal wave soldering process using a multilayer circuit board with other components. This reduces manufacturing costs considerably, because there is no need for assembly processes. The new bus coupler of the Axioline F I/O system processes the IEC 61850 confi guration fi les CID or SCD directly. The devices specifi cally meet requirements in the energy environment, which include an increased nominal voltage of 220 V DC or the impulse withstand voltage of 5 kV. The new modules feature particularly high interference immunity up to 8 kV, high durability when subjected to mechanical loads such as shocks up to 30 g, and fast signal detection. The I/O system does this without insulation plates so that the modules can be freely combined. phoenixcontact.com
22 Current events UPDATE 4|15 Phoenix Contact takes over SysMik Takeover strengthens position in building automation Since October 1, Dresden-based SysMik GmbH has been part of the Phoenix Contact group of companies. SysMik is a supplier of automation products for decentralized automation based on open industrial standards, particularly for building automation and building-related infrastructure. Since 1991, the company has sold components, control systems and engineering software developed and manufactured in-house. SysMik solutions are based on an IoT (Internet of Things) framework for smart devices and smart systems. The platform off ers a comprehensive system for web-based control systems and M2M communication and facilitates new, service- oriented business models. Before the takeover, both companies have collaborated since 2003 in the development and production of automation modules. Phoenix Contact plans to make the Dresden location, which currently has a staff of 16, into a corporate center of building automation expertise for the group. "To date, we have implemented only a handful of building infrastructure projects. By integrating SysMik into the Phoenix Contact group, we are expanding our range of solutions off ered by adding an innovative product range for building automation. In addition, we are gaining a valuable resource for developing solutions for the use of Internet technologies in building systems," says Roland Bent, Managing Director of Phoenix Contact. Gert-Ulrich Vack remains Managing Director of SysMik GmbH Dresden. The company continues to do business under the name SysMik GmbH Dresden. IT-secure production without downtimes IBM and Phoenix Contact present security solution for industrial networks At this year's SPS IPC Drives trade show, global IT player IBM presented solutions for Industry 4.0 in conjunction with a variety of partners from the automation technology fi eld, including Phoenix Contact. These are intended for quick and reliable practical implementation, particularly by small and medium-sized companies. In Hall 9, IBM and Phoenix Contact demonstrated how intelligent security mechanisms can be used as an ideal safeguard for industrial networks, from the gateway to the shop fl oor. The display featured the interaction of the QRadar SIEM (Security Information and Event Management) software solution with the mGuard security devices. Simulations included everything from minimally invasive attacks to massive attacks on critical infrastructures. Forensic analytical tools were then used to secure and evaluate the traces left by the digital break-in attempts.