Power Management System Upgrade for a Long-Steel Plant in Barbil, Odisha

Tata Mines (NINL), operated by Tata Steel, partnered with ComAp to strengthen the reliability and flexibility of its power generation and control systems at the 1 MTPA integrated long-steel plant in Barbil, Odisha, India. As the facility reached full production capacity, its existing power management setup faced growing pressure to maintain continuous operation, particularly during periods without grid supply. To ensure stable performance and support further expansion, Tata Mines required a modern, scalable solution that could address ongoing control challenges.

The plant had been experiencing ECU communication issues, unequal load sharing, frequent reverse power alarms, interrupted start and stop sequences, and difficulties managing high inrush current. These challenges were intensified by non-standard configurations, complex commissioning requirements, limited product knowledge, and insufficient on-site support. With round-the-clock production at stake, improving power management reliability became a key priority.

ComAp, working alongside panel builder Trijal Electrikals and mining operations specialists NSIPL, supplied a white-box, plug-and-play Power Management System tailored to the site’s operational needs. The system was configured for the customer’s preferred MANUAL mode, enabling operators to start engines directly via the ComAp controller, verify operating parameters, and safely close generator and outgoing breakers. As plant demand increases, additional generators can be synchronised seamlessly, ensuring stable load sharing and smooth system expansion. Each controller is equipped with a CM3 Ethernet module, preparing the installation for future remote monitoring and diagnostics.

The solution includes an InteliGen4 200 controller paired with a CM3 Ethernet communication module, providing a flexible architecture with multi-engine capability, surge current protection, customisable logic, and detailed event and alarm logging. With improved stability, reliability, and ease of use, the system supports Tata Mines in maintaining consistent production. Following the success of this deployment, twenty-nine additional controllers have already been supplied to support further expansion across the site.