Background
A major European energy distribution company operating over 200 primary substations, 4,000 secondary substations, 15,000 km of transmission lines, and 400+ power generation facilities initiated a large-scale modernization of its communication infrastructure. With more than 600,000 end customers the organization embarked on a strategic digital transformation to ensure resilience, cyber security, and long-term scalability. The project is part of a broader investment dedicated to increasing infrastructure resilience.
Project Implementation
The implementation of this large-scale connectivity overhaul addressed multiple critical challenges, all centered around the need for reliability, scalability, and security. For those exact reasons, the Advantech ICR-2431 cellular router was selected.
To ensure security for critical infrastructure, all communication between routers and central systems is fully encrypted using IPsec with IKEv2. Each SIM card uses a private APN, isolating it from the public Internet, and centralized certificate management via SCEP guarantees ongoing control and authentication of connected devices.
For network redundancy, the architecture includes dual, geographically independent VPN termination points using CheckPoint firewalls. Each router establishes two IPsec tunnels to both centers, ensuring uninterrupted service even if one path fails. At the field level, standard sites are equipped with dual-SIM routers, automatically switching between mobile operators in the event of network outages. High-priority sites go a step further with pair of the LTE routers, offering simultaneous connections over two mobile networks in hot-standby mode. Additionally, these critical locations integrate satellite connectivity as a third, independent transmission medium, achieving triple-path redundancy (2× LTE + 1× Satellite).
Legacy communication protocols also posed a challenge. Many remote devices still operate over IEC 60870-5-101 via RS232 serial ports, whereas modern SCADA systems rely on IEC 60870-5-104 over IP. To bridge this gap, Advantech provided bidirectional IEC 101/104 protocol conversion directly within the routers, along with a custom Router App for seamless integration.
Given the massive number of sites—more than 1,000 to be migrated and 4,000+ new ones to be deployed—manual configuration was not feasible. Advantech addressed this with its WebAccess/DMP management and provisioning platform, enabling Zero Touch Deployment, remote diagnostics, and site-specific configuration. The platform also features a REST API, allowing direct integration with the customer’s internal systems for streamlined rollout and monitoring.
Throughout the project, Advantech worked closely with its local partner — both a system integrator and distributor — to manage logistics, FAT testing, hardware customization, and ongoing 24/7 technical support. Together, they ensured the new infrastructure was fully integrated into the customer’s existing IP network with minimal disruption.
Conclusion
The modernization of this energy provider’s communication infrastructure demonstrates how legacy utility networks can be successfully transformed into secure, scalable, and resilient digital platforms. With thousands of substations and assets now connected via industrial-grade LTE routers, and equipped with centralized remote management and real-time diagnostics, the customer has not only met but exceeded stringent reliability and security requirements.
Advantech’s flexible hardware portfolio, combined with deep integration expertise and robust support through local partners, enabled a smooth transition from outdated serial communication to high-availability IP networks — all while maintaining ongoing operations. The result is a future-ready foundation for smart grid management, improved energy distribution efficiency, and long-term operational stability in an increasingly interconnected energy landscape.
