South Africa’s renewable energy sector is expanding at a rapid pace, but the speed of delivery is often slowed by the familiar and avoidable challenge of fragmented secondary plant integration.
When protection systems, SCADA development, plant-level automation and grid code compliance are handled by multiple suppliers, the result is often misaligned designs, conflicting interfaces and commissioning delays that cost developers both time and money.
According to Herman Mare, general manager at ACTOM Smart Technologies, as projects become larger and more complex, the industry can no longer afford the inefficiencies created by siloed engineering. “This is the gap ACTOM Protection and Control’s Secondary Plant Integration (SPI) solution is designed to close. By consolidating all secondary systems under a single accountable partner, the SPI provides a unified, end-to-end approach that supports compliance, reduces risk and accelerates energisation,” says Mare.
Why multi-vendor secondary systems cause delays
He notes that the most common cause of delays in renewable projects is the lack of coordination between suppliers responsible for different parts of the primary and secondary systems. Each vendor designs and tests its equipment in isolation, often without full visibility of how their components will interact with others on site. Problems only surface during integrated testing, at the point when delays are most expensive.
“When mismatches arise between plant-level systems and substation controls, teams must scramble to identify the source of the issue. This leads to duplicated troubleshooting and extended periods where the site stands still. Every day lost increases accommodation costs, travel costs and contractor fees, while pushing out the project’s commercial operation date,” says Mare.
A single, integrated framework for secondary systems
ACTOM’s SPI solution eliminates these inefficiencies by bringing primary and secondary plant functions into one coordinated architecture. Instead of managing protection relays, SCADA, plant data acquisition, communication interfaces and Eskom integration separately, the SPI solution aligns them within a single engineering framework. This integrated approach ensures that:
• Protection schemes and logic are designed to work seamlessly with plant-level systems.
• SCADA and automation functions are aligned with substation requirements.
• Communication channels are configured to support both plant and grid code needs.
• All components are tested together before reaching the site.
“By engineering the entire system under one roof, the solution removes the mismatches that typically emerge when multiple vendors work independently,” says Mare.
Minimising risk through integrated design and testing
One of the strongest advantages of SPI is the ability to conduct a full, integrated factory acceptance test before equipment is dispatched. Instead of testing components in isolation, ACTOM validates the entire system, including switchgear, protection, SCADA, communication and plant interfaces, as a complete, functioning whole.
“This approach ensures that system logic is correct, communication paths are stable, plant signals map accurately into the SCADA system, and that Eskom-required data points are fully compliant,” says Mare. “Solving issues in the factory is significantly faster and more cost-effective than resolving them on site. By the time the equipment arrives at the project, the system has already been proven, reducing commissioning risk and shortening the path to energisation.”
Grid code compliance is one of the most critical and misunderstood elements of renewable project delivery, says Mare, adding that misalignment with Eskom requirements can lead to failed audits, repeat testing and costly delays in grid connection. “SPI addresses this challenge by embedding Eskom logic, communication protocols and compliance requirements into the design from day one. This proactive approach prevents last-minute redesigns and ensures a smoother approval process,” he says.
The value of a single accountable partner
For developers and engineering, procurement and construction contractors, the benefits of having one integration partner are substantial. A single point of accountability means there is no ambiguity about responsibility, enabling faster decision making, streamlined communication, reduced engineering duplication and fewer disputes during commissioning.
“With SPI, all engineering, testing and site services are delivered by one team that understands the full system. This creates a more predictable project environment and reduces the risk of unexpected delays,” says Mare.
“Renewable energy projects demand precision, coordination and compliance. Fragmented commissioned systems undermine all three. ACTOM’s SPI provides a unified, proven approach that aligns engineering, reduces risk, and accelerates delivery from design through to energisation.”
For more information contact ACTOM,
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