Implementation of a DEIF-based Microgrid system for a food processing plant in Ukraine.

Conditions and Challenges

The facility’s production cycle requires high power supply reliability. Initial site conditions included:

  • 10 kV External Grid: Permitted capacity of up to 3 MW.
  • On-site Generation (PV): A 1.2 MW solar power plant operating in parallel with the grid on the 0.4 kV side.
  • Backup Generation (Genset): A 1 MW diesel generator (10 kV) for emergency mode.

Problem:

The existing setup did not allow the facility to take advantage of the solar power plant while running on the diesel generator. When the external grid went down, the PV system would also shut down, leading to inefficient diesel fuel consumption during daylight hours and increasing production costs.

Objective:

To create an intelligent control system (Microgrid) that integrates all power sources (Grid, Genset, PV) and ensures their seamless parallel operation in any combination to achieve maximum cost-efficiency and reliability.
 

Implemented Solution

 

KSIMEX specialists designed and implemented a Microgrid system based on advanced controllers from DEIF (Denmark).

  • Genset Controller (AGC 150): Manages the diesel generator (DG).
  • Mains Controllers (AGC 150 Mains): Installed at two 10 kV inlets to monitor the grid and control the incoming circuit breakers.
  • PV Controller (ASC-4 Solar): The key element integrating the solar power plant into the overall grid.
 

All controllers are integrated into a single control network, allowing the system to make instantaneous decisions based on current load and solar availability.

 

System Operating Modes

 1. Island Mode (Genset + PV): In the event of a grid failure, the diesel generator starts automatically. The DEIF ASC-4 Solar controller automatically “mixes in” solar energy to meet the load requirements. This allows the genset to run at minimum required power, significantly saving fuel.

 2. Parallel Operation (Grid + Genset): During peak load periods that exceed the grid limit, the genset starts automatically and operates in parallel with the grid to cover the power deficit.

 3. Power Export (PV + Grid): The system ensures parallel operation of the PV plant with the external 10 kV grid. A Zero Export function is implemented: if PV generation exceeds the plant’s consumption, the system automatically limits the inverters to prevent power flow back into the external grid.

 4. Seamless Transition: When the external grid is restored, the system synchronizes the genset with the grid and transfers the load back without any momentary interruption (Short-term parallel operation).

 

Project Results

The implementation of the DEIF-based Microgrid system allowed the enterprise to:
  • ✅ Reduce operating expenses by maximizing the use of “green” solar energy, even in emergency modes.
  • ✅ Guarantee the continuity of production processes through intelligent management of power reserves.
  • ✅ Eliminate penalties for unauthorized power export to the grid thanks to the Zero Export function.
 

This project confirms that DEIF solutions are an effective tool for creating modern, flexible, and cost-efficient power supply systems for industrial enterprises.

OUR OTHER PROJECTS...