Project – Industrial Power Units for Industry, LLC | Saudi Arabia

Ma’aden Power Plant – MV Protection Relay Design and Commissioning

q.t — Tue, 01 Apr 2025 08:59:18 +0000

Ma’aden Power Plant – MV Protection Relay Design & Commissioning

Industrial-grade protection for Saudi Arabia’s leading mining utility.

Project Overview
Ma’aden (Saudi Arabian Mining Company) is the Kingdom’s premier mining and minerals enterprise, operating complex power infrastructure at industrial scale. For its MV power generation and distribution systems, IPU SA delivered end-to-end electrical protection services — from design and relay setting to on-site testing and commissioning. The system ensures safe and reliable operation of generators, bus couplers, and feeders throughout Ma’aden’s energy network.

Clients & Partners

Client: Ma’aden
Location: Saudi Arabia
Completion: April 2025
Technology Partner: Arcteq

Products & Solutions Provided

Design and engineering of protection relay schemes
Supply of Arcteq MV protection relays
Setting configuration for overcurrent, earth fault, and feeder protection
Field wiring verification and logic testing
On-site Testing & Commissioning (T&C) of generator and feeder panels
Documentation and operator handover

Technical Highlights

Component	Description
Relay Brand	Arcteq (Finland) – MV generator and bus coupler protection
System Coverage	MV generators, bus-couplers, main and outgoing feeders
Settings	Time-current coordination and relay discrimination study
Verification	On-site testing and fault simulation during commissioning
Compliance	Designed to Ma’aden internal electrical safety standards

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Complex MV protection across interconnected assets	Relay coordination study and strategic zone setting
Need for high-speed fault clearing	Implemented optimized curve settings and backup zones
Tight timeline for commissioning window	Parallel design, testing, and field execution to compress schedule

Key Outcome

Full relay coverage for Ma’aden MV network
Improved fault isolation and system safety
Optimized generator and feeder protection logic
Reduced maintenance risks and improved compliance
On-time delivery with complete documentation and relay map

Project Media

Central Utility Complex and Tunnels – Makkah Haram

q.t — Wed, 01 Jan 2025 08:59:21 +0000

Central Utility Complex & Tunnels – Makkah Haram

Redundant MV Control Systems for Critical Pilgrimage Infrastructure

Project Overview
The Pedestrian Tunnel Haram Project was developed to support millions of pilgrims by creating a safe, efficient, and fully powered underground passageway within the sacred Haram complex in Mecca. IPU SA was contracted to engineer and commission a comprehensive MV power control system to maintain uninterrupted energy across tunnel facilities, ensuring operational reliability during peak pilgrimage seasons.

Clients & Partners

Client: Abunayyan Trading Co.
Location: Mecca, Kingdom of Saudi Arabia
Completion: Q1 2025
Technology Partners: Schneider Electric, ComAp, GE

Products & Solutions Provided

MV Synchronization Control Systems
Supervisory Control & Data Acquisition (SCADA)
Programmable Logic Controllers – Schneider Hot-Standby PLC System
GE886 Protection Relays
Dual-Substation Generator Integration
Redundant Master Control Logic
Source Transfer System (STS) for voltage continuity

Technical Highlights

Component	Description
Generators	6 x MV generators (3 per substation)
Control System	Fully redundant SCADA + Master PLCs
Synchronization	Redundant sync logic with HMI interface
Protection	GE886 relays with isolation and fault protection
System Integration	Schneider MV switchgear + full ECU control

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Need for 100% power uptime during Hajj	Dual synchronized substations with real-time failover
Real-time load balancing across substations	Load sharing with automated sequencing logic
Safe and centralized control of remote assets	SCADA-driven monitoring with secure access layers

Key Outcome

Zero unplanned downtime across tunnel energy systems
Seamless backup generator coordination and switching
Fully redundant control and protection logic installed
Integrated HMI for local diagnostics and test modes
IEC-compliant commissioning and documentation delivered

Project Media

King Salman Park – TSE and HVAC Control Systems

q.t — Thu, 01 Aug 2024 08:59:57 +0000

King Salman Park – TSE & HVAC Control Systems

Powering environmental infrastructure in the world’s largest urban park.

Project Overview
King Salman Park is one of Riyadh’s flagship Vision 2030 projects — set to become the world’s largest urban park. As part of two separate packages within the development, IPU SA was contracted to supply intelligent Motor Control Centers (MCCs) and custom HVAC control panels for both Treated Sewage Effluent (TSE) Package 3 and Buildings A & B of the park’s Phase I development.

Clients & Partners

Clients: WETICO, Energy Concept
Location: Riyadh, Saudi Arabia
Completion: Q4 2024
Technology Partners: Siemens, Schneider Electric

Products & Solutions Provided

TSE Package 3:

Motor Control Centers (MCCs)
Siemens PLCs with HMI
Skid-mounted containerized control units

Buildings A & B:

AHU & Fan Control Panels
Schneider VFDs
DOL starters with remote monitoring
Building-integrated HVAC automation

Technical Highlights

Component	Description
TSE System	30,000 m³/day capacity with packaged MCC units
PLC	Siemens PLC with HMI for TSE process visualization
HVAC Panels	Supplied and commissioned for air handling units in two major park buildings
Drives	Schneider VFDs for fan and pump efficiency
Installation	Containerized MCCs and building-mounted panel layouts

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Rapid deployment required for phased park infrastructure	Pre-fabricated, containerized MCCs
Multi-vendor coordination across large site	Modular panel systems and flexible integration logic
High HVAC load diversity across buildings	Customized control panels with VFDs and expansion options

Key Outcome

Seamless control of TSE infrastructure and HVAC distribution
Improved energy efficiency and operational responsiveness
Scalable control logic for future expansions
Fully commissioned on-time with operator interface support
Environmentally aligned with Vision 2030 sustainability goals

Project Media

NEOM Construction Village – MV Synchronization and Solar Control System

q.t — Mon, 01 Jan 2024 08:59:10 +0000

NEOM Construction Village – MV Synchronization & Solar Control System

Hybrid power for Saudi Arabia’s largest workforce infrastructure.

Project Overview
As part of the early-phase development of NEOM, the 5K and 10K Construction Villages serve as the first operational hubs for housing and supporting the labor force that will build the city of the future. IPU SA was selected to engineer, supply, and commission an integrated MV Synchronization Control System and Solar Control System that collectively manage 14 MV generators, 3 bus couplers, and nearly 3 MVA of solar power across both sites.

Clients & Partners

Client: NESMA
Location: NEOM, Saudi Arabia
Completion: January 2024
Technology Partner: ComAp

Products & Solutions Provided

Automation & Control:

MV Synchronization Control Panels
ComAp InteliNeo 6000 Controllers
Generator and bus coupler load management
Real-time SCADA integration

Renewable Energy Integration:

Solar Control Panel Systems
Hybrid logic for generator + solar load optimization
PV monitoring, isolation, and failover systems

Technical Highlights

Component	Description
Generators	14 MV gensets coordinated with 3 bus couplers
Solar System	Nearly 3 MVA of PV power integrated into hybrid controller
Controllers	ComAp InteliNeo with SCADA-based logic
Hybrid Logic	Load-sharing between solar and diesel to reduce fuel costs
Monitoring	Web-based and local SCADA visualization with alarm management

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Coordination between renewable and diesel systems	Delivered intelligent hybrid logic with PV prioritization
Massive generator network requiring redundancy	Deployed a fully redundant sync system with backup controllers
Fast-paced timeline for NEOM operational readiness	Parallel design + build execution with phased commissioning

Key Outcome

Seamless hybrid power control across 2 construction villages
Fuel savings through optimized PV integration
Real-time visibility and diagnostics across generator fleet
Aligned with NEOM’s sustainability and digitalization standards
Delivered ahead of milestone deadlines

Project Media

Al Rajhi Bank – ATS, MDB, and DC System Integration

q.t — Sun, 01 Oct 2023 08:59:47 +0000

Al Rajhi Bank – ATS, MDB, and DC System Integration

Secure power infrastructure for one of the world’s largest Islamic banks.

Project Overview
Al Rajhi Bank, a major force in Saudi Arabia’s financial sector, required a robust and uninterrupted power distribution system to support its growing operational footprint. IPU SA was contracted to supply, install, and test an integrated power system consisting of Automatic Transfer Switches (ATS), Main Distribution Boards (MDBs), and a DC system — designed to support continuous banking operations and IT infrastructure.

Clients & Partners

Client: Global Infrastructure Modules
Location: Riyadh, Saudi Arabia
Completion: October 2023
End-User: Al Rajhi Bank

Products & Solutions Provided

ATS Panels for automatic source switching
LV Main Distribution Boards (MDBs)
DC Backup Power System for sensitive IT equipment
Protection and metering integration
Installation, testing, and handover documentation

Technical Highlights

Component	Description
ATS Panels	Automatic source selection between utility and generator
MDBs	LV boards with segregated loads and surge protection
DC System	Supports uninterrupted power for data and security layers
Wiring	Professionally labeled and routed for fast maintenance
Monitoring	Optional remote diagnostics integrated via Modbus

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
High sensitivity to downtime in banking operations	Redundant source switching and controlled ATS delay logic
Compliance with banking security & electrical audit standards	Delivered IEC 61439-certified equipment with full documentation
Limited space for board layout	Custom compact MDB design with bottom-entry cabling

Key Outcome

Reliable dual-source power with automated failover
Full support for security and financial data operations
Compact, organized power room layout
Reduced maintenance time through labeled design and digital wiring maps
Delivered within timeline and aligned with Al Rajhi’s audit standards

Project Media

NEOM Hospital – MV Synchronization Control System

q.t — Wed, 01 Mar 2023 08:59:47 +0000

NEOM Hospital – MV Synchronization Control System

Smart energy control for the Kingdom’s most futuristic healthcare facility.

Project Overview
The NEOM Hospital represents a bold step in the future of healthcare in Saudi Arabia — integrating cutting-edge technology, sustainability, and patient-centered design. As part of this next-generation medical infrastructure, IPU SAdelivered a customized MV Synchronization Control System to manage power from 14 generators and 3 bus couplers, ensuring reliable and redundant electricity for the hospital’s operations.

Clients & Partners

Client: Double Vision
Location: NEOM, Saudi Arabia
Completion: March 2023
Technology Partner: ComAp

Products & Solutions Provided

MV Synchronization Control Panels
Standalone SCADA System for remote monitoring
ComAp InteliGen & InteliNeo 6000 controllers
Generator control, bus coupler logic, and protection relays
Load sharing, sequencing, and auto-transfer systems

Technical Highlights

Component	Description
Generators	14 MV generators coordinated with 3 bus couplers
Controllers	ComAp InteliNeo 6000 with load sharing logic
SCADA	Standalone interface for full system diagnostics
Design	Fully redundant with failover protection
Integration	Configured to meet NEOM’s future-readiness and quality benchmarks

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Large number of distributed MV generators	Designed and tested central control logic with high-speed synchronization
Strict reliability and performance criteria	Integrated top-tier ComAp controllers with intelligent sequencing
Social and technological commitment expectations	Delivered a future-proof solution fully aligned with NEOM’s sustainability and resilience goals

Key Outcome

Seamless synchronization of complex MV power system
Redundant control across all generators and bus couplers
Compliant with NEOM’s high-availability and ESG requirements
Optimized SCADA for maintenance and energy tracking
Delivered on time with fully documented commissioning

Project Media

Sindalah Island – Fuel Control and SCADA System

q.t — Wed, 01 Feb 2023 08:59:35 +0000

Sindalah Island – Fuel Control & SCADA System

Smart fuel management for a self-sustained luxury island destination.

Project Overview
Sindalah Island, one of the flagship destinations of NEOM, is a high-profile luxury development located on the Red Sea. Operating entirely on off-grid generation, it requires an exceptionally reliable fuel management and power control system. IPU SA was selected to engineer and commission a fully redundant PLC-based fuel control system integrated with a custom SCADA platform to monitor, report, and manage power distribution across the island’s critical infrastructure.

Clients & Partners

Client: Integrated Engineering Contracting Co.
Location: Sindalah Island, Tabuk Province, Saudi Arabia
Completion: February 2023
End-User: NEOM

Products & Solutions Provided

Schneider Electric Programmable Logic Controllers (PLCs)
SCADA System for centralized monitoring and alerts
Fuel distribution and level management logic
Generator fuel supply control and failover programming
Field device integration and I/O mapping for remote diagnostics
Redundant architecture for critical applications

Technical Highlights

Component	Description
Fuel System	Full island power generation dependent on diesel supply
Control Architecture	Redundant PLC with watchdog and override protection
SCADA	Customized user interface for real-time fuel status, alarms, and event history
Integration	Field sensors, valves, and pumps connected via digital and analog I/O
Reporting	SCADA logging, fault alerts, and preventive maintenance tracking

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Zero tolerance for fuel-related power interruption	Dual-controller redundancy with system watchdog
Harsh environmental exposure	IP-rated enclosures and marine-grade connectors
Real-time visibility across multiple field components	Custom SCADA with multi-tiered alert logic and HMI interface

Key Outcome

Fully automated fuel control supporting uninterrupted power
Remote visibility and alert system to prevent manual monitoring
Reduced operator risk and improved maintenance scheduling
Island-wide power stability supporting high-end hospitality infrastructure
Delivered on schedule with FAT and SAT completed

Project Media

Maraya, Ashar Valley – MV Synchronization and Reactor System

q.t — Thu, 01 Dec 2022 08:59:14 +0000

Maraya, Ashar Valley – MV Synchronization & Reactor Control System

Powering the world’s largest mirrored structure with smart control and stability.

Project Overview
Maraya, located in AlUla’s Ashar Valley, is a globally recognized architectural marvel and the largest mirrored building in the world. As a high-profile venue for concerts, events, and cultural gatherings, uninterrupted power and electrical stability are mission-critical. IPU SA was contracted to engineer and commission a custom MV Synchronization Control System that also manages shunt reactor logic to mitigate high capacitive reactance caused by the site’s extensive cabling.

Clients & Partners

Client: NESMA & Partners
Location: AlUla, Saudi Arabia
Completion: December 2022
Technology Partners: Schneider Electric, ComAp

Products & Solutions Provided

MV Synchronization Control Panels
MV Generator Control Integration
Reactive Power Compensation Logic
ComAp-based control for shunt reactors
Load balancing and power quality stabilization
Local and remote HMI for real-time operations

Technical Highlights

Component	Description
Network Complexity	High-reactance due to long cable runs
Reactor Control	Intelligent management of shut reactors via PLC/SCADA logic
Power Coordination	Synchronization of MV generators for load distribution
Stability	Protection logic to prevent system failure under harmonic stress
Operator Interface	Real-time diagnostics via SCADA and touchscreen HMI

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Excessive capacitive reactance from large cable network	Installed and programmed shunt reactor control for compensation
Risk of generator capacitor failure under reactive loads	Dynamic logic to adjust for live harmonic and load shifts
High sensitivity to downtime during events	Redundant control and protection layers for guaranteed uptime

Key Outcome

Optimized generator performance through reactive power control
Enhanced system stability despite complex cabling layout
Zero performance degradation under full load conditions
Delivered system meets Maraya’s world-class infrastructure standards
Reduced operational risk for public events and exhibitions

King Khaled International Airport – Harmonic Filtering System

q.t — Tue, 01 Nov 2022 08:59:24 +0000

King Khalid International Airport – Harmonic Filtering System

Power quality optimized for mission-critical airport operations.

Project Overview
At King Khalid International Airport (KKIA) in Riyadh, IPU SA was contracted to deliver a harmonic filtering solution to address significant electrical distortion issues caused by nonlinear loads. The airport was experiencing high third harmonic currents and overheating in the neutral conductors — posing a risk to critical systems. IPU SA deployed a Schneider Electric Active Harmonic Filter (AHF), fully tested and commissioned to meet IEEE 519 compliance standards.

Clients & Partners

Client: MERAS International Investment
Location: Riyadh, Saudi Arabia
Completion: 2024
Technology Partner: Schneider Electric

Products & Solutions Provided

Active Harmonic Filter (AHF) – Schneider Electric
On-site power quality analysis
Load monitoring and harmonic profile reporting
Installation, configuration, and commissioning of AHF
Compliance audit with IEEE 519 standard

Technical Highlights

Component	Description
Filter Type	Active Harmonic Filter (Schneider Electric)
Target Harmonic	3rd Harmonic – Neutral line distortion
Analysis	In-house PQ audit, THD analysis, waveform diagnostics
Regulatory Standard	IEEE 519-compliant post-installation
Thermal Risk	Resolved overheating of neutral conductor

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Excessive third harmonic current in critical circuits	Conducted detailed PQ analysis to determine source
Neutral overheating due to harmonic overload	Specified AHF with tailored filtering profile
Regulatory risk & safety exposure	Reduced TDD to acceptable levels under IEEE 519

Key Outcome

Third harmonic distortion eliminated from targeted circuits
Neutral overheating resolved without rewiring
Increased system reliability for sensitive equipment
Regulatory compliance and safety risks mitigated
Delivered with minimal operational disruption

Project Media

Saudi Customs Office – Power Factor Correction System

q.t — Tue, 01 Mar 2022 08:59:47 +0000

Saudi Customs Office – Power Factor Correction System

Improving energy efficiency in critical government infrastructure.

Project Overview
The Saudi Customs Office required a targeted electrical upgrade to improve power efficiency and eliminate reactive energy losses across its facility. IPU SA was selected to design, supply, test, and commission an Automatic Power Factor Correction (APFC) system using Schneider Electric components. The installation not only stabilized the facility’s power quality but also ensured compliance with utility efficiency standards and reduced penalty risk for low power factor.

Clients & Partners

Client: RAM International
Location: Saudi Arabia
Completion: March 2022
Technology Partner: Schneider Electric

Products & Solutions Provided

Schneider Electric Automatic Power Factor Corrector (APFC)
Real-time power factor monitoring and regulation
Capacitor banks with intelligent switching logic
Overcurrent and harmonic protection components
Installation, testing, and commissioning of complete PFC system

Technical Highlights

Component	Description
Power Factor Correction	Automatic, multi-step regulation with capacitor bank modules
Controller	Smart reactive energy controller with auto adjustment
Design	Sized per facility load study and reactive compensation need
Installation	Seamless integration into existing LV distribution system
Protection	Overload and harmonic-safe configuration for panel safety

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Low power factor triggering potential utility penalties	Installed APFC with dynamic step regulation
Risk of overheating from reactive power overload	Designed with current-limiting protection logic
Minimal shutdown time for implementation	Executed rapid retrofit and activation during low-load window

Key Outcome

Achieved power factor improvement to >0.98
Reduced utility penalty exposure and energy waste
Enhanced panel safety through reactive load balancing
Delivered within government operational standards
Schneider-certified system commissioned with full documentation