The 33rd China International Exhibition on Electric Power Equipment and Technology
Shanghai International Energy Storage Technology Application Expo / Hydrogen Energy Expo
Industrial automation in the power sector refers to the application of programmable logic controllers (PLCs), distributed control systems (DCS), SCADA platforms, robotics, and digital communication networks to automate the operation of power generation, transmission, distribution, and industrial electricity consumers. In power plants, automation systems control boiler combustion, turbine speed, generator excitation, and auxiliary systems. In substations, automation systems manage switching sequences, protection coordination, and remote control. In industrial facilities, automation systems optimise energy consumption, manage power quality, and integrate on-site generation and storage. The convergence of operational technology (OT) and information technology (IT) — the OT/IT convergence — is transforming industrial automation, enabling real-time data analytics, cloud connectivity, and AI-driven optimisation while introducing new cybersecurity challenges.
5 Key Questions About Industrial Automation
PLCs (Programmable Logic Controllers) are ruggedised computers designed for real-time control of discrete processes — switching, sequencing, and interlocking — with scan times in milliseconds. DCS (Distributed Control Systems) are designed for continuous process control across large facilities, with distributed I/O modules, redundant controllers, and integrated operator interfaces. SCADA (Supervisory Control and Data Acquisition) systems provide supervisory monitoring and control over geographically dispersed assets — such as a power distribution network — collecting data from RTUs or PLCs at remote sites and presenting it to operators at a central control room. In practice, modern systems often combine elements of all three architectures.
Substation automation applies IEC 61850-based communication to integrate protection relays, bay controllers, and station-level SCADA into a unified system. Automated switching sequences execute complex multi-step operations (bus transfers, feeder switching) with a single operator command, reducing the risk of human error. Automatic voltage control (AVC) systems continuously adjust transformer tap positions and capacitor bank switching to maintain voltage within limits. Automated fault isolation and restoration (FIAR) systems detect and isolate faults and restore supply to healthy sections within seconds, without operator intervention.
Inspection robots are increasingly deployed in substations and along transmission lines to automate routine visual inspections, thermal imaging, and partial discharge detection. Substation inspection robots navigate autonomously, capture high-resolution images and thermal data, and report anomalies to maintenance teams — reducing the need for personnel to enter high-voltage areas and enabling more frequent inspection cycles. Drone-based inspection systems are used for transmission line and tower inspection, covering hundreds of kilometres per day with AI-powered image analysis to detect conductor damage, insulator contamination, and vegetation encroachment.
The convergence of operational technology (OT) — the control systems that operate physical equipment — with information technology (IT) — enterprise networks, cloud platforms, and data analytics — is enabling new capabilities including real-time performance optimisation, predictive maintenance, and remote operation. However, OT/IT convergence also exposes previously isolated control systems to cybersecurity threats from enterprise networks and the internet. Utilities and industrial operators must implement network segmentation, industrial firewalls, and OT-specific security monitoring to manage these risks while capturing the benefits of connectivity.
Key trends include: edge computing bringing analytics and AI inference closer to field devices, reducing latency and bandwidth requirements; digital twins creating virtual replicas of physical assets for simulation and optimisation; 5G wireless enabling high-bandwidth, low-latency communication for mobile robots and distributed sensors; AI-driven predictive maintenance using machine learning to analyse sensor data and predict equipment failures; and software-defined automation replacing dedicated hardware with virtualised control functions running on standard servers.
Key Takeaways
Industrial automation is the foundation of efficient, safe, and reliable power system operation, from generation control to substation automation and industrial energy management. The OT/IT convergence is creating new opportunities for AI-driven optimisation and remote operation while requiring careful attention to cybersecurity. EP Shanghai showcases the latest advances in PLCs, DCS, SCADA, robotics, and digital automation platforms for the power and energy sector.
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