Utility – 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

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

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

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

King Faisal Specialist Hospital and Research Center – Data Center Power Systems

q.t — Thu, 01 Jul 2021 08:59:44 +0000

King Faisal Specialist Hospital & Research Center – Data Center Power Systems

Reliable backup infrastructure for one of the Kingdom’s most advanced medical facilities.

Project Overview
The King Faisal Specialist Hospital & Research Center (KFSH&RC) is one of the Middle East’s most respected healthcare and research institutions. For its HITA Main and DR Data Centers, IPU SA delivered a full suite of power distribution and contingency energy solutions designed to ensure uninterrupted operation and protect sensitive medical and research data.

Clients & Partners

Client: Hadania Corporation for Trading & Contracting
Location: Riyadh, Saudi Arabia
Completion: July 2021
Facility: KFSH&RC Data Centers (Main & Disaster Recovery)

Products & Solutions Provided

Power Distribution & Switchgear Solutions:

Automatic Transfer Switches (ATS)
LV Distribution Panel Boards
Isolation Transformers
RMUs and Blokset Panels

Renewable & Contingency Energy Solutions:

1000kVA Schneider APC UPS System
UPS Battery Storage & Power Conditioning
Commissioning and FAT (at OEM Facility – France)

Technical Highlights

Component	Description
UPS System	1000kVA Schneider APC with storage and bypass
Distribution	Fully compliant LV Blokset + final DBs
Testing	OEM factory testing (France) and on-site commissioning
Redundancy	Designed for zero-failure tolerance in DR environment
Compliance	Built to IEC 61439-1 & 61439-2 standards

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Data center uptime with no margin for error	Dual-feed UPS and ATS system architecture
Third-party coordination for high-value components	Full testing and FAT coordination with Schneider in France
Medical-grade compliance and documentation	Delivered detailed as-builts, test reports, and safety validation

Key Outcome

100% backup power reliability for both main and DR data centers
Optimized UPS runtime and battery performance
Zero downtime reported post-commissioning
International-grade testing and documentation delivered
System aligns with KFSH&RC’s Tier-level reliability standards

Project Media

MODA – SFMC (Ministry of Defense and Aviation) – Generator and ATS Power Systems

q.t — Mon, 01 Feb 2021 08:59:45 +0000

MODA – SFMC (Ministry of Defense and Aviation) – Generator & ATS Power Systems

Securing defense infrastructure with seamless power transfer.

Project Overview
The Ministry of Defense and Aviation (MODA) required a highly reliable backup power system for its Saudi Field Medical Centers (SFMC) near the northern borders of the Kingdom. IPU SA was contracted to supply, test, and commission a network of 36 LV diesel generators and closed transition ATS panels — ensuring zero-interruption power switching for life-critical infrastructure supporting the Ministry’s remote operations.

Clients & Partners

Client: DATA Link
Location: Northern Border Region, Saudi Arabia
Completion: February 2021
End-User: Ministry of Defense and Aviation (MODA)

Products & Solutions Provided

36 x LV Diesel Generators (sourced and integrated)
Closed Transition Automatic Transfer Switch (ATS) Panels
Generator synchronization and load sharing logic
Site-wide coordination and phased testing
Field support and training for operations staff

Technical Highlights

Component	Description
Generators	36 x LV gensets deployed across SFMC facilities
ATS Panels	Closed transition ATS for seamless source switching
Control	PLC-based switching logic for failover without blackout
Deployment	Multi-site delivery under security protocols
Redundancy	Configured for N+1 protection and contingency handling

Challenges & IPU SA Solutions

Challenge	IPU SA Solution
Mission-critical defense application requiring zero downtime	Delivered closed-transition ATS with failover verification
Harsh site logistics along the Kingdom’s northern border	Coordinated phased equipment rollout and testing
High generator count with synchronized load logic	Built scalable control and monitoring interface per region

Key Outcome

Uninterrupted power continuity across MODA field centers
Blackout-free operation during source switching
Enhanced defense-readiness through energy reliability
Compliant with MODA’s performance and safety standards
Delivered, tested, and handed over ahead of the strategic timeline

Project Media