Intelligent Control System for a Diesel Generator Fleet with Total Capacity of 10 MW Based on DEIF

Implementing emergency power generator synchronization for a metallurgical facility.
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Challenge and Current Situation:

To protect against a complete power outage (blackout), the enterprise installed a powerful emergency generation system – 10 diesel generators (0.4 kV), each with a capacity of 1 MW. They were connected to a 6 kV network through three step-up transformers.

 

The initial control system had significant limitations:

  • It allowed generators to operate in parallel with each other only in “island mode” (complete disconnection from the grid).
  • Synchronization with the grid was permitted only for individual units (Fixed Power mode).
  • Transient processes were accompanied by voltage fluctuations, creating risks for sensitive technological equipment.
  • Operation required constant personnel presence and manual intervention.

Task:

To create a unified, fully automated system that would integrate all ten generators into a centralized complex with the ability for flexible and safe synchronization with the plant’s high-voltage network.

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KSIMEX Solution

Our specialists developed and implemented a centralized synchronization and control system based on advanced DEIF controllers.

Key Project Innovations

  • Load Take Over Mode: Ensures smooth (seamless) transfer of load from the main grid to generators and vice versa. No voltage spikes during switching.
  • Peak Shaving Mode: Enables generators to operate in parallel with the grid while limiting power consumption from the external network.
  • Fiber Optic Network: Since the generator site is located far from the control room, a high-speed optical communication channel was deployed.
  • Modern SCADA System: Operating personnel gained full visual control over the entire workshop power system, including event logging and convenient mode selection. Centralized control is implemented via the DEIF AGI 400 operator panel.
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Business Results

Successful tests with full simulation of a 150 kV line outage confirmed the effectiveness of the solution:

  • Zero downtime: Guaranteed seamless transition to backup power without stopping production lines.
  • Autonomy: Eliminated the need for constant on-site personnel presence near generators. The system independently makes decisions based on grid conditions.
  • Operational flexibility: The enterprise gained a tool for efficient balancing of its own energy consumption and generation.

This project proves that DEIF controllers are an ideal solution for critical infrastructure, where even a second of power loss is unacceptable.

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