Power & Control Solutions Projects

The existing generator infrastructure and control philosophy was old, un-serviceable and unreliable. Conventional “Flip-Flop” change-over logic dictated a minimum of two outages on every mains failure while generator load-testing involved the rental and installation of specialist equipment.

The client requested a new, high end solution which would give him the ability to reverse synchronise to the mains after an outage, forward synchronise to a healthy mains for on load generator testing and integration of the entire system into the BMS for real time monitoring from the facilities team.

Using the ComAp range of Control products PCS Ltd provided the entire Control System Solution installed and commissioned without disruption to the building over 2 weekends

System Benefits

• Forward and Reverse Synchronising to the Utility for No-break Transfer making maintenance and load testing easier and cheaper
• Single outage on Mains failure with Reverse Synchronising and Soft Load Transfer
• Possibility to sell generation capability back to Utility

PCS were employed as a specialist contractor for the installation & commissioning of the complete generator control system for this project.

Throughout the contract from design to delivery PCS performance exceeded our highest expectations and had a significant input in the satisfactory delivery of this project.

The project was delivered on time and to a very high standard at all stages, the site remained operational at all times, with exception of the planned shutdowns which were handed back to the client before the agreed deadlines.

During the shutdowns, we encountered numerous inherited issues in which PCS played a major part in assisting with the identification & rectification of problems with the existing site systems within the allocated timescales.

PCS staff are very experienced, knowledgeable & committed to the project in hand in which we feel they delivered within this contract.

Utility companies are under increasing pressure to minimise the amount of Customer Minutes Lost while at the same time carrying out important maintenance on distribution equipment. Conventional synchronising techniques and logic did not provide the utility with a safe, simple and reliable solution.

The client required a safe, reliable and simple solution that would allow him to keep his customers powered while he was maintaining the network equipment

PCS Ltd designed a solution using ComAp IGNT Combi Software which allowed the utility to do exactly that. Taking his existing mobile generation fleet and upgrading the generator controls we were able to provide a solution which not only provided the functionality and safety he required but also gave him a simple user interface that Network Operators found easy to understand and use.
The control system and user interface allows the Utilities to safely transfer the network load to the generator, before isolating and maintaining the network equipment. After the maintenance is complete the load is softly transferred back to the utility with no disruption to the customer. The generator can now be moved to the next location and the process repeated.  With no restriction on the size of the generator and HV applications in pipeline it is an exciting project to be involved in.
The system is extensively used in the UK and Ireland.

System Benefits

• Allows key maintenance to be carried out during normal working hours with no disruption to supply
• No requirement for specialist generator contractor
• Scalable to all sizes of generators
• Flexible enough to adapt to new applications and environments
• Safe enough to meet exacting utility standards

ESB Networks were endeavouring to develop a user friendly LV synchronising system to suit out particular network requirements.

In PCS we found a Supplier that had an in-depth knowledge of synchronising systems and software, who connected well with our Operational Staff & who got to fully understand our operational and safety requirements. PCS, working with front line ESB Networks Operations Staff, developed & implemented a Top Class User Friendly LV Synchronising System that has now become the standard approach used in ESB.

This system enabled ESB Networks progress with extensive Network Asset Replacement Work with little or no electricity outages for ESB Customers. PCS are technically top class. They are very approachable, real good problem solvers and good listeners.

They played a significant part in supporting ESB Networks to significantly improve its own operator technical competence in relation to using generators & limiting customer electricity interruptions.

The client required an increase of power due to the serious failure of a multi megawatt embedded generator at Stornoway Power Station. Arnish was chosen as a suitable location for the main reason of space required availability to site equipment plus existing infrastructure easily utilised to suit application. 

PCS Ltd supplied, installed & commissioned a turnkey solution comprising 2 x 1650KVA 40’ containerised diesel generators. These were refitted with our specially developed control system using ComAp IGNT Combi Software and an 11KV 6.3MVA 30’ containerised package substation fitted with SF6 VCB switchgear complete with overcurrent & earth fault protection relays.

System Benefits

• More cost effective solution than having major repair carried out on aged slow speed diesel
• Fast turnaround time
• Easily operated & maintained modern equipment
• Package can be “unplugged” & deployed to other location if required
• Standardised generator control system compatible with existing SSE recently upgraded mobile generation fleet

The client was powering a labour camp in Dubai using five standalone generators.
The existing controls meant the generators had no possibility to run in parallel. The camp distribution was split into sections with each section having a dedicated generator. This had two real disadvantages in that a generator failure meant a power outage in that section and five machines running in island offered no opportunity to optimise the running KW against the actual required load

PCS Ltd designed, manufactured and installed replacement panels for all sets.  Utilising our previous experience on this style of set we were able to supply a solution that was almost entirely plug and play but for the motorising of the generator output circuit breakers.
 
The solution meant that rather than run continually on 5 sets the camp was often powered by only one.
Gen-set failures now caused minimum disruption with the installed software automatically starting the next highest priority set to take the place of the off-line machine.

System benefits

• Huge fuel saving based on fewer sets running
• Servicing costs reduced due to fewer running sets
• Servicing of sets does not require power outage on camp
• Minimal power disruption on camps

Oil & Gas production companies now have a dedicated Emergency  Response station offshore on a previously used production platform that was earmarked for closure, basing helicopter & medical services closer to the front line production services to minimise response times & assist in the evacuation/relocation of personnel should the need occur. 

The client required a replacement distribution switchboard & generator control system that would allow for selective shutdown of non essential services in the event of network failures.

Key elements of this turnkey package were:

• Front end design & documentation provided
• Fast turnaround time
• Restrictions on space availability offshore
• 80ka for 1 second switchboard fault level
• Equipment containerised for transportation & platform installation
• Commissioning & factory acceptance testing carried out for client, oil company & Lloyds register personnel
• Continuous on shore support for off shore installation, commissioning & operation

System Benefits

• Allows generators to run on load demand for maximum fuel efficiency whilst guaranteeing sufficient supply availability
• Minimised offshore installation & commissioning time
• Easily integrated controls into existing generator control panels