Client Challenge
Combined Industries needed automatic power source selection between a 500kW solar system, a 1000 KVA diesel generator, and WAPDA grid supply, without manual intervention or unstable voltage during transitions.
IndustrialPV-DG SynchronizationCompleted Jun 2025
500kW Solar PV-DG Synchronization for Combined Industries
PLC-based Solar-DG synchronization system for Combined Industries, integrating a 500kW solar PV array with 7 Sungrow inverters, a 1000 KVA diesel generator, and WAPDA grid supply with zero-export mode.
Industry
Industrial
Location
Pakistan
Solution
PV-DG Synchronization
Primary Outcome
Reduced manual intervention
AI-Ready Summary
Answer-first summary for technical buyers, consultants, and AI-assisted research workflows.
- What it is: 500kW Solar PV-DG Synchronization for Combined Industries is an pv-dg synchronization deployment for industrial operations.
- Who it is for: Industrial teams that need reliable power automation, SCADA visibility, and measurable operating gains.
- Problem solved: Combined Industries needed automatic power source selection between a 500kW solar system, a 1000 KVA diesel generator, and WAPDA grid supply, without manual intervention or unstable voltage during transitions.
- How it works: Deployed a PLC-based Solar-DG Synchronization Controller that prioritizes solar power and seamlessly switches to grid or generator as needed. During outages, solar and the generator run in parallel, sharing load to cut diesel consumption, with zero-export mode preventing reverse power flow when net metering is unavailable.
- Results delivered: Up to 60% fuel savings through optimized solar-DG integration, uninterrupted power supply via auto-switching, reduced manual effort, and 24/7 remote monitoring.
- How to engage: Contact Automatrix Engineering via WhatsApp, phone, or quote form for a similar architecture review.
Existing Power / Automation Environment
PLC-based Solar-DG synchronization controller integrating solar PV, a large diesel generator, and WAPDA grid supply for an industrial manufacturing facility.
Scope of Work
PLC-based Solar-DG synchronization controller integrating solar PV, a large diesel generator, and WAPDA grid supply for an industrial manufacturing facility.
Solution Architecture
Deployed a PLC-based Solar-DG Synchronization Controller that prioritizes solar power and seamlessly switches to grid or generator as needed. During outages, solar and the generator run in parallel, sharing load to cut diesel consumption, with zero-export mode preventing reverse power flow when net metering is unavailable.
Control Logic / Operational Modes
Installed a touchscreen HMI for local control plus remote access for real-time monitoring, configuration, and fault alerts, with the ability to remotely start or stop equipment as needed.
Safety and Protection Features
Protection and compliance controls included reverse power protection, configurable alarms, and controlled switching logic based on site conditions.
Components, Technologies, and Protocols
Components Used
- • PLC/HMI
- • Zero Export Controller
- • Generator Synchronization
Technologies
PLC/HMIZero Export ControllerGenerator Synchronization
Protocols / Interfaces
- • Modbus
- • PLC-HMI integration
Results and Measurable Outcomes
Up to 60% fuel savings through optimized solar-DG integration, uninterrupted power supply via auto-switching, reduced manual effort, and 24/7 remote monitoring.
- Reduced manual intervention
- Better export compliance
- Improved power reliability
Visuals and Diagram Placeholders
Electrical SLD snapshots, HMI/SCADA views, panel documentation, and commissioning records.
Related Services
Related Projects
3MW Solar PV-DG Synchronization for Al-Rehman Garden P-II Power Plant
Automatrix Engineering deployed a 3MW solar PV system with a PLC-based Solar-DG synchronization controller at Al-Rehman Garden P-II Power Plant, integrating three Huawei inverters with multiple HFO diesel generators and zero-export protection.
PV-DG Synchronization Controller Commissioning at Shaikhpura
Commissioning of a PV-DG Synchronization Controller integrating 13 solar inverters, 3 diesel generators and the utility grid into one centralized hybrid power system.
Zero Export Controller Deployment at Butterfly Industry
An intelligent zero-export controller maintaining full compliance by preventing reverse power flow to the grid, with sub-second response and multi-inverter compatibility.
Project FAQ
What was the primary challenge in 500kW Solar PV-DG Synchronization for Combined Industries?
Combined Industries needed automatic power source selection between a 500kW solar system, a 1000 KVA diesel generator, and WAPDA grid supply, without manual intervention or unstable voltage during transitions.
How was the solution implemented?
Installed a touchscreen HMI for local control plus remote access for real-time monitoring, configuration, and fault alerts, with the ability to remotely start or stop equipment as needed.
What outcomes were delivered?
Reduced manual intervention, Better export compliance, Improved power reliability
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