Modernising the Tees, Powering our Future

The Background

Redcar Power Station, located on the former SSI Steelworks site along the River Tees, remains a key part of the region’s industrial redevelopment.

Reasonable operation requires continuous visibility of high-voltage assets across a wide network of remote substations.

Real-time data transfer from these locations to the ventral control team is essential to maintain grid stability, site safety and operational reliability.

Engineering Challenge

The existing SERCK telemetry system had become obsolete, with no remaining vendor support. Aging Remote Terminal Units (RTUs) created a risk of losing visibility of critical switchgear events.

The site required a modern solution that could:

  • Provide real-time fault and alarm visibility.
  • Avoid costly civil works and new cabling across the site.
  • Deliver a reliable, future-proof monitoring platform.

The Solution

JBA Engineering completed a detailed review of site drawings, I/O records, and existing infrastructure to develop a modern substation architecture using reliable Siemens hardware.

 

  1. High-Availability Substation Hardware Modernisation: Legacy telementry equipment was replaced with Siemens S7-1200 and ET200SP modular systems. A standardised design enabled efficient installation, simplified maintenance, and reduced future operational risks.
  2. Resilient 4G LTE Communications: As the Teesworks site became part of a wider redevelopment area, traditional cable routing was restricted due to ongoing and future infrastructure changes. Installing new communication routes would have created significant disruption and cost. JBA implemented a secure wireless communications solution using Siemens CP 1243-7 LTE modules, connecting remote substations through 4G networks and providing a flexible solution for future 5G migration. Built-in buffering stores up to 64,000 timestamped events, protecting critical data during temporary communication interruptions.
  3. Redundant SCADA Visualisation: A dual-redundant Siemens SCADA system was installed to manage remote RTYs and provide secure, reliable monitoring of the power network.

Outcome

JBA Engineering transformed the legacy telementry system into a secure, reliable digital monitoring platform.

Virtual testing and Factory Acceptance Testing allowed the system to be validated before installation, reducing commissioning risks and project timescales.

The completed solution provides:

  • Reliable power monitoring with zero data loss
  • Improvised system resilience through modern hardware
  • Long-term operational support and maintenance.

The project demonstrates JBA Engineering’s ability to deliver high-availability control and communication solutions for critical infrastructure.

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Have an engineering challenge to discuss? Get in touch with our team to see how JBA can support your project. 
You can call us on (+44) 01740 665730 or email enquiries@jbaengineering.com