Rajahmundry / India

The FMG and Pharma Major owned by a UK based MNC is operating two of its plants at Rajahmundry in India.

The process plant is equipped with 500KW Back pressure turbine fed by process steam and 6 Cummins generators.The plant usually runs on grid power.

In order to achieve the energy efficiency and to have the trouble free operations, the project department called for the design , supply and commissioning of PLC based system to provide automatic synchronizing + Load management + load shedding system so as to run every and each of the power generators to operate with each other and to operate with grid . Main emphasis was on to utilize the maximum power of the turbine and isolate the turbine to supply critical load during power failure.

GPCE Scope was to design, supply, erect and commission:

Turbine control system.

Plant synchronizing and grid monitoring system.

Load shedding and load management system.

Common synchronizing to synchronize and share between all connected generators and turbine with grid.

Supply and interfacing of the control system between new and old plant.

Major challenges were pointed below:

Supply, erection and commissioning to be carried out when the plant is operational with minimum outage.

Different generators and different governing systems were to be harmonized for smooth load sharing and load dispatch.

Train the operators on new system.

The system was designed and supplied with Schneider M340 based PLC and DIEF controllers

The grid monitoring and load shedding was enabled through VAMP 210 monitoring relays and VAMP 260 advanced power monitors.

The system was commissioned and operational.