PLC-based solar-DG-grid sync with Zero Export, up to 60% fuel savings.
Industry
Textile
Location
Pakistan
Solution
PV-DG Synchronization
Primary Outcome
Reliability Improvement
Zimal Textile was running a 500 KW solar PV system alongside a 630 KVA WAPDA grid connection and two 100 KVA diesel generators, with no automatic synchronization between these sources. Switching between solar, grid and generators required manual intervention, risking unstable voltage/frequency transitions and preventing the plant from reliably prioritizing cheaper solar power over diesel.
Design, supply and commissioning of a PLC-based solar-diesel-grid synchronization controller for Zimal Textile's 500 kW solar PV plant, WAPDA grid connection, and diesel generator sets.
Automatrix Engineering deployed a PLC-based Solar-DG Synchronization Controller that automatically manages power source selection and load sharing between the solar system, WAPDA grid, and diesel generators. It prioritizes solar energy and seamlessly switches to grid or generator based on availability, and supports Zero Export mode to prevent reverse power to the grid where net metering is not available.
During grid outages, the controller enables solar and generator to operate in parallel, intelligently sharing the load to reduce diesel consumption. Smooth synchronization maintains stable voltage and frequency during source transitions to protect sensitive equipment. A built-in touchscreen HMI provides local control, while remote access allows real-time monitoring, configuration, and fault alerts from anywhere.
Up to 60% fuel savings, uninterrupted power supply through automatic source switching, reduced manual effort from full automation, and 24/7 remote monitoring and management of the whole power system.
Fuel Savings
Up to 60%
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Zimal Textile was running a 500 KW solar PV system alongside a 630 KVA WAPDA grid connection and two 100 KVA diesel generators, with no automatic synchronization between these sources. Switching between solar, grid and generators required manual intervention, risking unstable voltage/frequency transitions and preventing the plant from reliably prioritizing cheaper solar power over diesel.
During grid outages, the controller enables solar and generator to operate in parallel, intelligently sharing the load to reduce diesel consumption. Smooth synchronization maintains stable voltage and frequency during source transitions to protect sensitive equipment. A built-in touchscreen HMI provides local control, while remote access allows real-time monitoring, configuration, and fault alerts from anywhere.
More stable source coordination, Reduced manual intervention
Share your load profile, control objectives, and site constraints. We will propose architecture options, implementation scope, FAT/SAT plan, and support model.