How Xtorm RTUs enhance and strengthen automation in the power sector

Designed to meet the most demanding applications in the electrical sector, the Xtorm RTUs are built with high immunity to electrostatic discharges and electromagnetic interference, combining ruggedness, versatility, high availability, and an extensive portfolio of advanced features, such as: power supply redundancy, CPU redundancy within a single rack, support for DNP3 and IEC 61850 (MMS and GOOSE) protocols, and compliance with ONS Submodule 2.7. 

In recent years, Brazil’s generation, transmission, and distribution sector has undergone significant technological advancements, and the Xtorm Remote Terminal Units (RTUs) have played a key role in this transformation. 

In this article, we will explore the technical specifications of these RTUs, highlight their key features, and showcase notable Altus application cases. 

Innovation and ruggedness for the automation of large-scale power plants

Designed in accordance with IEC 61850 and IEC 61131-3 international standards, the Xtorm RTUs are engineered to deliver high-performance supervision and control in power plants, substations, and other critical facilities. Their rugged hardware and modular design enable flexible expansion, ensuring scalability and high availability. Additionally, the Xtorm series offers a range of key benefits that enhance system efficiency and reliability — take a look: 

• Battery-free operation, eliminating the need for frequent maintenance and reducing environmental impact.
  
  
• Advanced diagnostics with One Touch Diag (OTD), allowing instant system status verification without requiring a supervisor. 
  
  
• Time synchronization via IRIG-B, essential for applications demanding precise event and log timing. 
  
  
• High immunity to electromagnetic interference (EMI) and electrostatic discharges (ESD), ensuring stable operation in harsh environments. 
  
  
• CPU and power supply redundancy, ensuring continuous operation even in adverse conditions. 
  
  
• High-speed bus, using 100 Mbps Ethernet for fast and secure communication between modules and external devices. 
  
  
• Seamless SCADA system compatibility and simplified integration, enabling connections with the industry’s leading communication protocols. 
  
  

Applicability in the power sector and success cases

The Xtorm Series has been widely adopted in power generation and transmission projects in Brazil and abroad, demonstrating its effectiveness in various applications. Its rugged and high-performance hardware was designed to operate in challenging environments, resisting mechanical vibrations and supporting extended operating temperatures, making the series ideal for power plants, powerhouse facilities, and installations near large electrical devices. 

Among Altus` success cases, some of the most important projects in the power sector include the Boa Esperança Hydroelectric Power Plant (HPP) and the Paulo Afonso I, II, and III Hydroelectric Power Plants (HPPs) in Brazil. 

Altus was also at the forefront of the modernization of the control and drive system for the cooling pumps of the converters at the Foz do Iguaçu substation, owned by Furnas, in Paraná, Brazil. Additionally, we participated in the construction of the Verde 4 and Verde 4A Small Hydroelectric Power Plants (SHPs), projects by Brookfield Renewable Energy, located between Ribas do Rio Pardo and Água Clara, in Mato Grosso do Sul, also in Brazil. This initiative illustrates our commitment to technological solutions that enhance the efficiency and reliability of power systems. 

The Xtorm technology also stands out as a pillar of stability and high availability in other strategic generation, transmission, and distribution (GTD) projects in South America. Among them are the Samuel, Nilo Peçanha, and Cachoeira Dourada Hydroelectric Power Plants (HPPs), as well as the Serra de Cavalinhos I and II, Retiro, and Eloy Chaves Small Hydroelectric Power Plants (SHPs). In these operations, the adoption of Altus technology has provided significant gains in reliability and reduced response time in system operation. 

Another notable international application is the use of the Xtorm series in a nuclear power plant in Argentina, reinforcing its versatility and high performance in different energy scenarios. 

A flexible and modular solution

The modular architecture of the Xtorm RTUs provide flexibility for different installation sizes and types. Compatibility with multiple communication protocols, including IEC 61850, DNP3, MODBUS TCP, and IEC 60870-5-104, enable seamless integration with both legacy systems and new infrastructures. 

The available modules include: 

• Digital and analog input/output modules, supporting 24 VDC and 125 VDC voltages, with isolation up to 2500 VDC. 
  
  
• Redundant power supply, ensuring continuous operation even under adverse conditions. 
  
  
• High-performance processors, supporting bus expansion and simultaneous control of multiple devices. 
  

• AC/DC measurement modules, for real-time monitoring of electrical variables. 

• Programmable logic control (PLC) modules, allowing customized configurations for various industrial applications. 
  
  
• Bus expansion with star, ring, and loopback topologies, ensuring high network availability. 
  
  

Enhanced connectivity with MasterTool IEC XE 3.70

The evolution of the Xtorm Series was accompanied by significant improvements in the MasterTool configuration and monitoring software. With version 3.70, MasterTool began offering full support for Xtorm RTUs, ensuring a more integrated and efficient configuration experience. This update enabled: 

• Expanded compatibility – The Xtorm Series can now be configured within the same MasterTool environment used for the Nexto Series, unifying the management of different automation devices. 
  
  
• Support for PROFINET Controller – The HX3040 CPU now supports the PROFINET Controller protocol in non-redundant mode, expanding its integration capabilities with high-speed industrial networks. 
  
  
• Implementation of OPC UA Server – The HX3040 CPU now also includes support for OPC UA Server in non-redundant mode, enabling efficient and secure communication with SCADA systems. 
  
  
• Cybersecurity enhancements – The update introduced improved data and automation infrastructure protection, reinforcing resilience against threats and unauthorized access. 

With these innovations, the Xtorm Series has solidified itself as an even more rugged and versatile solution, ensuring greater reliability and flexibility in automation operations within the energy sector. 

 Click here to review all the details of the latest MasterTool update. 

Benefits and impact on power infrastructure

The implementation of Xtorm RTUs in power systems has delivered numerous benefits: 

• Greater operational reliability, reducing downtime and enabling quick failure response. 
  
  
• Enhanced energy efficiency, optimizing automation and control processes. 

• Lower maintenance costs, thanks to durable components and hot-swappable modules. 

• Increased operational security, with CPU and power supply redundancy support. 

• Simplified diagnostics and maintenance, featuring an intuitive graphical interface and remote monitoring tools. 

• Compliance with international automation standards, ensuring interoperability with different manufacturers and systems.