Business critical power & energy solutions

By Mohammed Qaraqi

Delivering reliable power to manufacturing sites at the edge of the electricity grid can be a major challenge. Mohammed Qaraqi from ComAp Systems explains the types of systems available and the process involved in installing independent power systems.

“High quality power systems rely heavily on the latest technology”

Saudi Arabia is considered one of the most developed industrial countries in the region with a number of key manufacturing centres offering companies with guaranteed continuous and reliable power. However, as the demand for additional manufacturing capacity grows the pressure is on some companies to locate their business outside these areas resulting in the need for an alternative source of power - whether in the form of small private power stations or standby power systems.

Al Rowad National Plastic Company is a good example. In 2008, the company built a new 20,000m2 plant at Dammam producing biaxially orientated polyproplene (BOPP), with a production capacity of 30,000 tons per year. The location of the plant meant it was unable to reliably access electricity via the grid network this year, a particular issue as the process of converting raw materials and resins into plastic films and covers placed a huge electrical power demand on the facility. The production lines feature hundreds of electrical motors with variable speed controllers all managed by a complex PLC system and it is estimated that for every hour production lost the company would suffer significant financial losses.

As part of the independent solution, ComAp systems developed and installed a power management system that combines five paralleling systems designed to automatically synchronize the mains with PRIME (standby in the future) Mitsubishi diesel generators delivering a capacity of 1.6MW/380V/60Hz each (Total 28.8MW).

High quality power systems rely heavily on the latest technology. In this application the generator controllers used were ComAp InteliSysNT’s, which incorporate J1939 CAN communication. This technology enables the system to create a seamless link with a wide choice of additional peripherals such as colour displays like InteliVision 8 and the SCADA software for intuitive monitoring and trouble free systems supervision.

The system also features five Main Distribution Boards (MDB’s), 6000A bus system, type tested Form 4b construction with an impressive 100kA/1 sec short value made possible by the Merlin Gerin air circuit breakers and Schneider high quality components are used throughout. Each of MDB panels incorporates three main incomers and two bus couplers – all of which are fully controlled by ComAp controllers (InteliMainsNT), specifically designed to connect groups of generators to the mains (in the future).

The project specification also required harmonic active filters (square D type) each with 300A capacities designed to guarantee a total harmonic distortion below 5%. Power factor correction was achieved through six capacitor banks with different capacities (600kVAr, 900kVAr and 1000kVAr).
 
The standby control system is centrally supervised using a flexible web based SCADA system called (p)Control (supplied by Swiss company 42technology) that uses the LAN communication to link the generator controllers and Main Distribution Panels to a computer that displays a complete visualization of the plant and power system with touch screen control.

Any infrastructure project or manufacturing plant developed at the edges or away from the grid need reliable power as an absolute minimum; but new fully integrated control systems bring much more including easier installation, greater compatibility, increased automation and continuous monitoring capabilities with remote communication.

These benefit rich custom-designed packages are equally attractive to engineers, power distribution companies and infrastructure developers as they are to manufacturing sites like those operated by Al Rowad National Plastic Company.

Mohammed studied at the Riga Civil Aviation University in 1994 towards a degree in Aircraft Electric and Navigation Systems before leaving with a Masters Degree in Radio Electronics. His career began working as a maintenance engineer years in Jordon before moving to Riyadh in Saudi Arabia to join ComAp Systems in a capacity of Managing Director.