Optimized Energy Management for Complex Systems
Precision control for incineration and power generation Integrated automation with seamless switching
Challenge:
The customer was setting up a common effluent treatment and solid waste incineration plant. The incineration process generated significant heat, which was utilized to run a turbine for power generation. The plant's power sources included electricity board supply, three DG sets for backup during grid power failure, and a turbine generator powered by process heat. This complex system required precise control and seamless switching between power sources to optimize energy usage. The customer sought a partner with expertise in electrical panels, DG synchronization, and power management automation—a unique combination offered by Velox.
Solution:
Velox brought over two decades of expertise in power management solutions, combining electrical and automation know-how to execute this challenging project successfully:
- PCC Panel Design: A PCC panel with switchgear capable of bus communication was selected, featuring a main grid incomer rated at 6300 A and a panel fault level of 70 kA.
- Advanced Synchronization: Dedicated DG synchronizing and load management relays were implemented with peer-to-peer and main bus communication capabilities.
- Redundant PLC System: A redundant S7-300 PLC system with ET200S and special digital output cards ensured seamless freezing of the status as per requirements.
- Comprehensive SCADA Control: Siemens WinCC SCADA was deployed for plant control and data management, with a Web Navigator solution enabling remote monitoring.
Why Velox Makes Sense
For the Client:
The execution was flawless, with all logics and systems functional on the first attempt. The Velox system delivered beyond expectations, offering additional benefits such as:
- Load Sharing and Shedding: Automated load management ensured optimized energy distribution.
- Automatic Bus Transfer: Ensured uninterrupted operations during power source transitions.
- Energy Monitoring and Savings: Detailed reports enabled precise energy consumption calculations, making the customer more competitive in the market.
For the Environment:
Reusing energy from the incineration process exemplifies sustainable energy practices. This project set a benchmark in energy conservation, showcasing Velox’s commitment to environmental sustainability while delivering efficient and innovative solutions.