Avs Automation

DG Set (Diesel Generator) Control Panel

A DG Set Control Panel is used to monitor, control, and protect a Diesel Generator (DG Set) for reliable power supply in case of a main power failure.

1. Types of DG Set Control Panels

🔹 Manual DG Control Panel

• Requires manual start/stop of the generator.

• Basic monitoring with analog or digital meters.

• Used in small applications where automation is not required.

🔹 AMF (Automatic Mains Failure) Panel

• Automatically starts the generator when mains power fails.

• Shuts down the generator when grid power is restored.

• Includes an AMF relay and automatic circuit breakers.

• Suitable for commercial buildings, hospitals, and industries.

🔹 Synchronizing Panel

• Used for multiple DG sets operating in parallel.

• Synchronizes load sharing between multiple generators.

• Essential for large industries, power plants, and data centers.

🔹 PLC-Based DG Control Panel

• Uses a Programmable Logic Controller (PLC) for intelligent control.

• Remote monitoring, automation, and integration with SCADA systems.

• Suitable for critical applications requiring advanced automation.

2. Key Components

✅ Controller Unit – AMF relay, PLC, or microprocessor-based controller.
✅ Circuit Breakers – ACB/MCCB for overload and short-circuit protection.
✅ Busbar System – Copper or aluminum busbars for power distribution.
✅ Meters & Indicators – Voltage, current, frequency, and fuel level monitoring.
✅ Battery Charger – Maintains generator battery for emergency starts.
✅ Safety Features – Overload, overvoltage, low fuel, and engine protection alarms.

3. Applications of DG Control Panels

🏭 Industries & Manufacturing Plants – Backup power for machinery and production lines.
🏥 Hospitals & Data Centers – Ensures uninterrupted power for critical equipment.
🏢 Commercial Buildings & Malls – Backup power for elevators, lighting, and security.
🏠 Residential Societies – Automatic backup power for homes and apartments.

4. Selection Criteria

• DG Set Capacity (kVA rating).

• Electrical Distribution Control Panel – Used in power distribution systems to manage electrical flow.

• Software Distribution Control Panel – A dashboard for managing software deployment.

• Network Distribution Control Panel – A system for handling data or internet distribution.

• Supply Chain/Logistics Control Panel – A tool for overseeing product distribution.

 

ATS (Automatic Transfer Switch) Control Panel

An ATS Control Panel (Automatic Transfer Switch Panel) is used to automatically switch between the main power supply (grid) and a backup generator (DG Set) during power failures. It ensures uninterrupted power for critical applications in industries, hospitals, commercial buildings, and residential complexes.

Synchronization Control Panel

A Synchronization Control Panel is used to synchronize two or more Diesel Generator (DG) sets or generators with the main power supply (grid) or among themselves. It ensures smooth load sharing, optimizes power generation, and improves system reliability.

1. Functions of a Synchronization Panel

✅ Automatic Synchronization – Matches voltage, frequency, and phase of multiple generators before connecting to a common bus.
✅ Load Sharing – Ensures equal load distribution among generators to prevent overloading.
✅ Auto Load Shedding – Disconnects or reconnects generators based on load demand.
✅ Grid Synchronization – Enables generators to work alongside the main utility supply.
✅ Protection & Safety – Includes overload, reverse power, and short-circuit protection.
✅ Auto Start/Stop – Automatically starts/stops generators based on power demand.

2. Types of Synchronization Panels

🔹 DG-DG Synchronization Panel

• Synchronizes multiple DG sets operating in parallel.

• Ensures efficient load sharing between generators.

• Used in industries with multiple backup generators.

🔹 DG-Grid Synchronization Panel

• Synchronizes DG sets with the main power grid.

• Helps industries with high power demand during peak hours.

• Used in solar power plants, large industries, and commercial setups.

🔹 PLC-Based Synchronization Panel

• Uses Programmable Logic Controller (PLC) for advanced automation.

• Allows remote monitoring and integration with SCADA/BMS systems.

• Provides real-time data on generator performance and load status.

3. Key Components of a Synchronization Panel

✅ Synchronization Relays – Matches voltage, frequency, and phase angle before connection.
✅ Automatic Voltage Regulator (AVR) – Maintains voltage stability during synchronization.
✅ Load Sharing Module – Distributes load equally among generators.
✅ Circuit Breakers (ACB/MCCB/VCB) – Provides overload and short-circuit protection.

An LT (Low Tension) Control Panel with a 4000A to 100A rating is designed to manage electrical power distribution for industrial, commercial, and residential applications.

Electrical Control Panel – Enclosure Materials 1. Sheet Metal (Mild Steel - MS) Enclosures

• Cost-effective and widely used in industrial applications.

• Strong and durable, suitable for indoor environments.

• Can be powder-coated to enhance corrosion resistance.

• Heavier compared to aluminum but offers good protection.

2. Stainless Steel (SS) Enclosures

• High corrosion resistance, ideal for harsh environments.

• Used in food processing, chemical, pharmaceutical, and marine industries.

• Available in SS 304 (standard) and SS 316 (high corrosion resistance).

• Expensive but offers long-term durability.

3. Powder-Coated Sheet Metal Enclosures

• Provides additional protection against rust and environmental exposure.

• Available in various colors for aesthetic and identification purposes.

• Cost-effective alternative to stainless steel for moderate environments.

• If coating is damaged, underlying metal may corrode over time.

4. Choosing the Right Enclosure

• Indoor Industrial Use → Powder-coated mild steel (MS).

• Outdoor/Harsh Environments → Stainless steel (SS 304 or SS 316).

• Corrosive/Hygienic Areas (Food, Pharma, Marine) → Stainless steel (SS 316).

 

AMF (Automatic Mains Failure) Control Panel

An AMF Control Panel automatically starts a Diesel Generator (DG Set) when the main power supply fails and shuts it down when power is restored. It ensures an uninterrupted power supply, making it ideal for industries, hospitals, commercial buildings, and residential complexes. The panel includes an AMF relay, MCCB/ACB, automatic voltage regulator (AVR), battery charger, and digital meters for monitoring voltage, frequency, and load. It protects against overload, short circuits, low fuel, and engine faults. AMF panels can be PLC-based for remote monitoring and automation, ensuring efficiency and reliability in power backup systems

A Capacitor Control Panel, also known as an Automatic Power Factor Correction (APFC) Panel, is designed to improve power factor by automatically switching capacitor banks based on load requirements. It is widely used in industries, commercial buildings, and power plants to reduce energy losses, avoid penalties, and enhance system efficiency.

Motor Control Panel (MCP)

A Motor Control Panel (MCP) is used to control and protect electric motors in industrial, commercial, and residential applications. It ensures efficient motor operation, overload protection, and automation for various motor-driven systems like pumps, conveyors, compressors, and fans.

Motor Control Centers are suitable for operation of motors ranging from 0.5HP to 500 HP capacity. Motor control center contains various types of starting viz. Direct on line (DOL), Star-Delta, autotransformer, Soft starter etc. Local and remote operation facility, compatible to PCC/DCS based operation. Motor Control Center is properly ventilated in case of higher size of motor starter. Component layout is made so as to facilitate ease of operation and maintenance.

Automatic Power Factor Control Panel is designed to maintain power factor of plant to unity. To maintain power factor of unity means to achieve demand in KVA on lower side. Power factor is maintained to set value using APFC relay in auto mode where as in case of failure of APFC relay push buttons are used. Auto as well as manual mode is provided for power factor control. Various types of capacitors are used depending on load conditions. Typically MPP, APP or mix dielectric types of capacitors are used. In case of non linear loads like VFD, UPS thyrister switching, suitable reactors are used along with capacitors to filter harmonics.