Automated management of electrical sources for a pharmaceutical industrial site in Romania
Intervention type
Pre-study; Study; Pre-acceptance; CommissioningCustomer
GENSERV POWERDate of completion
Location
RomaniaAbout installation
1. Installation context
In the pharmaceutical industry, electrical continuity is essential. It determines the stability of production processes and the safety of facilities. This is the context for CRE Technology's project for Novartis in Romania.
The site has two independent grid connections via transformers (Trafo 1 and Trafo 2). A 1,000 kW backup generator provides power in case of mains failure. The three power sources are interconnected via a main busbar. Motorized circuit breakers enable automatic and safe switching between power sources.
In order to secure operations and automate the management of these energy sources, GENSERV POWER has entrusted CRE Technology with the design and implementation of the power plant control system.
2. Issues encountered by the customer
As a pharmaceutical production site, the Novartis facility is subject to particularly strict electrical availability requirements. Even a brief power interruption can have critical consequences for manufacturing processes and facility safety.
The project's primary objective was to guarantee the continuity of electrical power supply under all circumstances, including simultaneous failure of both grid inputs. It also had to automate transfers between the different energy sources, eliminating any manual intervention by operators. Secure synchronization management was also essential, particularly during grid return sequences involving the genset.
Finally, the solution had to be simple and reliable to use on a daily basis, while covering all scenarios, from degraded cases to periodic generator tests.
The solution we provided
To meet these requirements, CRE Technology deployed a fully automated control architecture based on its COMPACT range of controllers. The system automatically controls source transfers according to a priority logic: Trafo 1 as the main source, Trafo 2 as the grid backup, and the genset as a last resort.
1. GENSYS COMPACT PRIME module – generator control
A GENSYS COMPACT PRIME controller has been installed to control the 1,000 kW diesel generator. It provides:
- Automatic start and stop of the generator: the controller manages the start and stop sequences, including fault detection and a switch to safe manual mode in the case of a fault.
- Voltage (AVR) and frequency (ECU) regulation : the GENSYS COMPACT PRIME ensures regulation of the alternator voltage and engine speed in order to maintain stable electrical production in accordance with the mains parameters.
- Built-in protections: monitoring of engine parameters (oil pressure, water temperature, oil temperature, fuel level) with alarms and automatic shutdowns.
- Synchronisation with the grid: the group is capable of synchronizing with Trafo 1 or Trafo 2 before any paralleling, ensuring load transfers without disruption.
2. MASTER COMPACT 1B module – Management of grid arrivals and transfers
Two MASTER COMPACT 1B were deployed to manage Trafo 1 (main supply) and Trafo 2 (secondary supply) respectively. They ensure:
- Monitoring of grid sources : measurement of voltages and currents upstream (source side) and downstream ( busbar side) for each transformer.
- Authorization and transfer logic: management of switchover sequences between sources, without grid-to-grid paralleling. Transfers are controlled by priority (Trafo 1 > Trafo 2 > Genset).
- Grid return management: when Trafo 1 returns, the controller starts the genset and first synchronizes it with Trafo 2. The load is then transferred to the generator, allowing the Trafo 2 circuit breaker to be opened. The genset then synchronizes with Trafo 1, the load is transferred to the main grid, and the generator is gradually stopped.
- Fault detection and load shedding: in the event of simultaneous loss of both grid, the system automatically switches to the genset.
- Start signal for Trafo 2: the Trafo 1 controller automatically generates a start request to the Trafo 2 controller in the event of loss of the main grid.
3. i4Gen Box Module – Local Supervision
An i4Gen Box has been integrated into the installation to provide local supervision of the entire system:
- Real-time visualization: display of the status of all sources, circuit breaker positions, electrical measurements, and active alarms.
- Operator interface: allows site teams to access an overview of the installation and monitor operating sequences without directly intervening on the controllers.
- Modbus TCP/IP communication: the HMI communicates with the controllers via the Modbus TCP/IP protocol over an Ethernet network, using shielded Category 5e or higher cables.
4. Automated operating modes
The architecture implemented covers all operating scenarios defined in the specifications, as described in the operating overviews:
- Normal operation: Trafo 1 continuously supplies power to the site. Trafo 2 and the genset remain on standby.
- Loss of Trafo 1: automatic switchover to Trafo 2 if available. In the event of simultaneous unavailability of both grid, load shedding and automatic genset starting.
- Return of Trafo 1: the generator starts up, synchronizes with Trafo 2, takes over the load, then the Trafo 2 circuit breaker opens. The generator then synchronizes with Trafo 1, which takes over the load. The generator is gradually unloaded, its circuit breaker opens, and it cools down before shutting down.
- Loss of Trafo 2 during operation: the genset starts automatically, synchronizes with the busbar and takes over the load. The Trafo 2 circuit breaker opens to isolate the faulty source.
- Key Test function: test of the actual load group, in permanent parallel with Trafo 1, without interrupting the site's power supply.
Benefits for the customer
Thanks to this automated architecture, the Novartis site benefits from secure electrical power continuity. This is essential in a pharmaceutical environment where any interruption directly impacts production processes.
Automatic transfer management ensures reliable operation without manual intervention, while guaranteeing secure synchronization during source changes.
The system also manages several operating scenarios: normal operation, loss of one incoming mains power, or a complete loss of mains power. It thus ensures the site's power supply under all circumstances.
Finally, supervision viathe i4Gen Box provides operating teams with a clear view of the status of the installation, facilitating equipment monitoring anddaily operation.
Conclusion
This project illustrates CRE Technology's ability to design robust control-command architectures for critical electrical installations. The integration of GENSYS COMPACT PRIME and MASTER COMPACT 1B controllers ensures automated power source management, with secure transfers and controlled synchronization between the grid and the genset.
The architecture guarantees reliable power continuity, while allowing for simple and secure operation by site teams. It also offers the flexibility needed to manage different operating scenarios and ensure the availability of the backup system.
CRE Technology would like to thank GENSERV POWER for their trust and the quality of their collaboration. Their expertise and commitment contributed to the success of this project.
This project is a concrete example of CRE Technology's expertise in securing and automating industrial energy infrastructures.
Related products
GENSYS COMPACT PRIME
The GENSYS COMPACT PRIME is designed for advanced management of multiple generators in power plants, while offering interoperability with other types of energy sources for more complex systems.
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MASTER COMPACT 1B
The MASTER COMPACT 1B is designed to manage a mains incomer with a single circuit breaker. It allows advanced interoperability with various energy sources, such as generators, inverters or other mains incomers.
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