Substation Automation — HT/LT Panel Monitoring & Control

Overview

Elezon delivered a complete PLC and SCADA solution for the electrical substations of a large public sector defence facility — integrating all HT and LT substations into a single centralised supervision and control system for the first time.

The scope covered 1,350+ I/O points across multiple substations, real-time breaker supervisory control, energy monitoring with RS-485 metering and a fully redundant communication architecture.

Client challenges

Before optimization, the facility struggled with several energy-related issues:

• LT / HT panels spread across a large campus with no centralised communication network

• Manual breaker operation creating safety risk and slow fault response

• No real-time energy visibility — no data for efficiency or compliance reporting

• Integration required with new and existing switchgear from multiple manufacturers

• Defence facility uptime requirements — commissioning with zero production disruption

Objectives

The key objectives of the project were to:

• Centralise monitoring and control of all HT/LT substations under a single SCADA

• Enable remote breaker supervisory control — eliminating manual local operation

• Implement real-time energy monitoring across all incomer and feeder points

• Establish fibre optic communication network across entire facility

• Complete commissioning with zero unplanned outages to facility operations

Solution approach

Elezon designed and implemented a centralised PLC and SCADA system covering all electrical substations. A fibre optic network connected all substations to a central control room. PLC-based breaker supervisory control enabled remote open and close from the control room. SCADA displayed real-time single line diagrams, breaker status and energy dashboards. Alarm management with notification and historian for long-term data storage completed the solution.

Core elements of the solution included:

• PLC-based substation automation panel

• 1,350+ I/O points — breaker status, energy metering, alarms

• Centralised SCADA with single line diagram displays

• Fibre optic communication network across entire facility

• Remote breaker supervisory control — open and close from control room

• RS-485 energy metering at all incomer and feeder points

• Alarm management with SMS and email notification

• Historian for long-term energy and event data storage

• Full redundancy at communication and control layers

  
  

Implementation process

The project was delivered through a structured and low-disruption process:

• Design
  Campus audit. Substation inventory compiled. Communication network routing designed. I/O schedule across 1,350+ points developed.

• Manufacturing
  PLC automation panels manufactured at Elezon's Bengaluru facility. FAT conducted with full I/O simulation.

• Deployment & Integration
  Fibre optic network installed. PLC panels commissioned at each substation. SCADA integration completed with live breaker control testing.

• Training & Reporting Setup
  Energy monitoring validated. Alarm management configured. Electrical and operations teams trained on SCADA, breaker control and alarm response.

Conclusion

Elezon delivered complete centralised visibility and control across a defence facility's HT/LT substation — 1,350+ I/O points, commissioned without a single unplanned outage. Remote breaker control eliminated manual local operation, improving both safety and response time. Energy monitoring data immediately enabled identification of power factor issues with measurable cost reduction.