Client Challenge
CCP Gulbai needed to combine solar generation, WAPDA grid, and a large 630 KVA diesel generator, but manual power source selection risked excess diesel consumption and reverse power issues without net metering.
ManufacturingPV-DG SynchronizationCompleted Nov 2025
PLC-Based Solar-DG Synchronization for CCP Gulbai
A PLC-based Solar-DG Synchronization Controller integrating two SunGrow inverters with a 630 KVA diesel generator, delivering up to 60% fuel savings.
Industry
Manufacturing
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: PLC-Based Solar-DG Synchronization for CCP Gulbai is an pv-dg synchronization deployment for manufacturing operations.
- Who it is for: Industrial teams that need reliable power automation, SCADA visibility, and measurable operating gains.
- Problem solved: CCP Gulbai needed to combine solar generation, WAPDA grid, and a large 630 KVA diesel generator, but manual power source selection risked excess diesel consumption and reverse power issues without net metering.
- How it works: Automatrix deployed a PLC-based Solar-DG Synchronization Controller that automatically manages power source selection and load sharing between solar, grid and generator.
- Results delivered: CCP Gulbai achieved up to 60% fuel savings, uninterrupted power through automatic switching, reduced manual effort, and 24/7 remote monitoring and management of its power system.
- How to engage: Contact Automatrix Engineering via WhatsApp, phone, or quote form for a similar architecture review.
Existing Power / Automation Environment
Existing site architecture included mixed power sources and required structured integration for stable operations.
Scope of Work
Control strategy design, panel-level integration, commissioning workflow, and operational handover.
Solution Architecture
Automatrix deployed a PLC-based Solar-DG Synchronization Controller that automatically manages power source selection and load sharing between solar, grid and generator.
Control Logic / Operational Modes
The controller prioritizes solar energy and seamlessly switches to grid or generator based on availability, enables parallel solar-generator operation during grid outages to share load and reduce diesel use, supports zero-export mode when net metering isn't available, and provides a touchscreen HMI plus remote monitoring with real-time fault alerts.
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
- • Generator Synchronization
Technologies
PLC/HMIGenerator Synchronization
Protocols / Interfaces
- • Modbus
- • PLC-HMI integration
Results and Measurable Outcomes
CCP Gulbai achieved up to 60% fuel savings, uninterrupted power through automatic switching, reduced manual effort, and 24/7 remote monitoring and management of its power system.
- Reduced manual intervention
- Improved power reliability
Visuals and Diagram Placeholders
Electrical SLD snapshots, HMI/SCADA views, panel documentation, and commissioning records.
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Project FAQ
What was the primary challenge in PLC-Based Solar-DG Synchronization for CCP Gulbai?
CCP Gulbai needed to combine solar generation, WAPDA grid, and a large 630 KVA diesel generator, but manual power source selection risked excess diesel consumption and reverse power issues without net metering.
How was the solution implemented?
The controller prioritizes solar energy and seamlessly switches to grid or generator based on availability, enables parallel solar-generator operation during grid outages to share load and reduce diesel use, supports zero-export mode when net metering isn't available, and provides a touchscreen HMI plus remote monitoring with real-time fault alerts.
What outcomes were delivered?
Reduced manual intervention, Improved power reliability
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