KPTCL RTU Mandur Substation


  • Customer : Sanvigo Electric
  • Project commmissioned year: September 2025
  • Substation voltage: 66/11 kv
  • Project Type: KPTCL RTU
  • Protocols Used: Modbus RTU, DLMS, IEC60870-5-104
  • Automation Software and Hardware: Gateway - Igrid iGW/DCU , Remote terminal unit - iRTU/iRTUe

  • Project Description


    KPTCL, the state utility of Karnataka in southern India, operates the Mandur substation located near Hoskote.

    The Mandur substation near Hoskote is a 66/11kV facility, where the RTU panel houses the RTU along with communication, protection, and power supply equipment.

    The RTU panel connects physical equipment such as breakers, relays, and meters in a substation or plant to the central control system.

    The system has two redundant gateways, ensuring that if one fails the other functions as a standby, while a third gateway is connected to the HMI and equipped with 24 digital input cards, providing a total of 12 Ethernet ports (with each gateway having 4 ports).

    The panel is equipped with 3 D1A1 devices (each having 24 digital input cards and 8 analog input cards), 1 D1D1 device (with 48 digital output cards), and 5 R1R1 devices (each with 16 digital output cards), all of which are iRTUe devices.

    The project involves 80 relays communicating via digital output cards through iRTUe devices, 30 multifunction transducer meters communicating using Modbus, and energy meter data being read through the DLMS protocol using the iGW/DCU.

    The project included 144 digital input tags, 80 digital output tags, and 24 analog input tags to be read by the gateway, which transmits the data to the remote center using the IEC60870-5-104 protocol.

    The panel is equipped with two transducers for measuring the substation’s DC source.


    Silent features of this project


  • The Gateway RTU-1 and RTU-2 are configured in a redundant setup, and automatic switchovers between primary and secondary units are functioning seamlessly.
  • All digital and analog input signals are working correctly. Breakers can be operated remotely from the system (open/close) using their respective digital output commands.
  • Communication links are established via Ethernet cables or Fiber Optic cables, ensuring reliable data transfer.
  • The Multifunction Transducer (MFT) meters are connected in a daisy-chain configuration to form an RS-485 communication network using the Modbus protocol.
  • At any time, the status of all Digital Inputs (DI), Digital Outputs (DO), and Analog Inputs (AI) can be monitored through the software tool.
  • All DLMS meters are communicating properly, and data is being downloaded daily from the meters by the DCU.
  • All iRTUe devices are connected in a daisy-chain RS-422 network with true loop redundancy and even parity for enhanced reliability.
  • The HMI is connected to RTU-3 through Modbus communication. RTU-3 receives all DI, DO, and AI signals from RTU-1 and RTU-2, and it also transmits 24 DI signals back to RTU-1 and RTU-2.