Backup Control Panel for Remote Substations: Setevaya Kompaniya Develops a Simple and Effective Solution
Engineers at Setevaya Kompaniya in Tatarstan have developed a simple and reliable solution for one of the most critical grid failure scenarios, when a substation loses all power and control capabilities. An automatic backup power system restores power to essential control equipment within seconds.
A typical substation receives power from multiple high-voltage transmission lines. If all of them lose power, the substation's control equipment, including its switching devices, also shuts down. Under such circumstances, restoring power by switching consumers to backup lines requires an emergency crew to travel to the site, a process that can take up to one and a half hours.
To eliminate that risk, engineers at the 110kV Yambukhtino substation operated by the Privolzhskiye Electric Grids branch have launched pilot industrial operation of a 12kW gasoline generator integrated into the station service power panel. The generator is controlled by an Automatic Transfer Switch (ATS) system and starts within seconds after a power outage. Its fuel supply provides two hours of uninterrupted power for the control panel. During that time, dispatchers can remotely transfer consumers to backup transmission lines or neighboring substations without waiting for an emergency crew to arrive.
The new system was developed through the company's research and development programme. Rather than introducing a single piece of equipment, the project establishes a universal methodology for selecting the optimal generator-and-automation combination based on climate conditions, site remoteness, and the operational characteristics of each specific substation. For example, the automated system keeps the generator operational throughout the year without operator intervention. It automatically charges the batteries and heats the insulated equipment enclosure to prevent engine lubricants from freezing during winter.
For Setevaya Kompaniya, deploying the new system means higher equipment reliability, lower operating costs, and a reduced risk of major outages caused by failures in individual sections of the grid. For electricity consumers, it translates into more reliable power supply and a substantial reduction in incidents involving complete power loss.
Toward a Standardized Engineering Solution
Following the pilot programme at the Yambukhtino substation, the automatic backup system will be introduced at additional Setevaya Kompaniya facilities. Priority will be given to remote substations with single-line configurations, where emergency response teams cannot reach the site quickly.
If the technology proves successful, other grid operators across Russia could also adopt the approach. Meanwhile, the system itself will continue to evolve. Developers may extend its autonomous operating time and complement it with uninterruptible power supply (UPS) units to provide an immediate response during power disturbances.
From Generators to Lithium-Ion UPS Systems
The need to provide backup power for substations has long been recognised across the power industry, and different operators have addressed the challenge in different ways. Setevaya Kompaniya itself implemented a pilot project using a diesel generator at a 110kV substation as early as 2016.
In 2021, NTTs Rosseti FSK EES developed and deployed a lithium-ion battery backup power system at the 220kV Svarochnaya substation in Sverdlovsk Region. In 2023, similar equipment was installed at the 220kV Svobodnenskaya substation in Amur Region.
Compared with those solutions, Setevaya Kompaniya's development is significantly less expensive. Instead of relying on costly energy storage systems, it uses a relatively inexpensive gasoline generator that can be integrated into existing infrastructure with minimal complexity.
Restoring Control Where None Previously Existed
Setevaya Kompaniya's technical solution demonstrates that a major operational challenge can be addressed with a straightforward and cost-effective approach. It does not require construction of additional backup transmission lines or investment in expensive equipment.
The company's engineers will soon begin testing the system at other remote substations across Tatarstan. Looking ahead, the solution could become part of standard designs for the construction or modernization of new Setevaya Kompaniya power facilities.
For grid operators, the system provides the ability to control substations remotely during emergencies without waiting for an emergency crew to reach the site. More broadly, deploying this approach could strengthen the resilience of electricity distribution networks, even under Russia's demanding climatic conditions.
