Plant Management & Systems Integration

Power & Load Management Systems (PMS)

Real-time load coordination and automated unit control

MAS specialises in design and delivery of Power Management Systems from small power houses up to large utility installations, ensuring fully automated and optimised power generation.

Our Power Management and Load Management Solutions provide:

• Fast and accurate load sharing

Automated, instant and precise load distribution across all active units ensures immediate response to load variations and dispatching commands.
This eliminates operator dependency and prevents imbalances caused by delayed or inconsistent manual actions.

• Efficiency & Productivity Optimisation

Advanced load-sharing algorithms optimise unit operation based on real performance characteristics (the individual power curve of each unit).  This enables the power station to run closer to its nominal capacity, reduce spinning reserves, minimising fuel consumption and maximising overall plant productivity.

Load sharing is of particular importance in installations where different technologies are running in parallel (e.g 2-stroke, 4-stroke engines, turbines, etc).

• Advanced Unit Sequencing

Many small-scale installations primarily operate with 4-stroke engines, where unit sequencing plays a critical role in overall system performance: It enables the automated start, synchronisation and shutdown of generating units based on real-time operational demand.

Depending on the installation requirements, MAS sequencing logic may range from simple priority-based schemes to advanced optimisation strategies, incorporating parameters such as nominal power capacity, runtimes, maintenance intervals, fuel efficiency, etc.

With advanced unit sequencing, of main importance in remote and unmanned power plants, local power houses and backup systems, we ensure reliable and autonomous operation.

• Primary Frequency & Voltage Regulation

In isolated or small grid environments (eg. unconnected island), local power plants often provide the primary frequency and voltage regulation.

MAS Power Management Systems actively correct frequency and voltage in accordance with load variations ensuring grid stability. This automated control capability is critical, as manual operator intervention cannot achieve the required speed and precision, potentially exposing the grid to instability and operational risk.

• Fault Management & Operational Resilience

A critical capability of MAS Power Management Systems is the ability to show resilience to sudden power variations, whether originating internally (e.g. unit trip) or externally (e.g. grid short, auto-reclose events). In such cases, units tend to react asynchronous causing production upsets and a cascade tripping effect.

MAS Power management System algorithms respond instantly, significantly increasing the likelhood of recovery.  When integrated with our Load Shedding and Power Equilibrium Systems, we provide a comprehensive fault-response framework capable of containing disturbances and maintaining continuous plant operation, even under stressed conditions.

Energy Management Systems (EMS)

Optimisation of energy flows across hybrid systems

New and existing power production installations combine storage with a combination of PV, wind, and sometimes thermal units. These are mostly behind-the-meter assets that must work in parallel to provide stable power. 

MAS Energy Management Systems are designed to optimally manage:

• different resources depending on their current capacity and projected availability.
• Storage charge and discharge cycles, scheduled to ensure balanced, reliable and efficient operation.
• Solutions engineered to handle complex multi-technology installations.
• isolated grid environments, where energy planning must be precisely aligned with consumption patterns and system constraints.

MAS customed-engineered Power Plant Management System:

To address complex needs, MAS has developed a dedicated Power Plant Management System, capable of managing complex hybrid installations under a wide range of operating scenarios.

Power Equilibrium & Fault Management Systems (MAS Innovation)

Real-time balancing and disturbance response for operational continuity under critical conditions

The Power Management & Fault Management Systems are one of the proprietary MAS innovations, as a response to needed automation in managing faults occurring in small, isolated grids or in unmanned power producing locations.

MAS Power Management & Fault Management Systems deliver:

• Real-time balance between generation and demand

The system delivers real-time monitor of the power produced by the units and the power exported to the grid.  If this equilibrium is upset, the system will take instant action to contain the problem.

• Immediate corrective response to disturbances

Unlike conventional load shedding schemes which operate on predefined and often rigid logic, MAS Power Equilibrium & Fault Management Systems apply a more advanced and adaptive system, design to keep the station in operation even in critical events.  Connected to all Power production units and load feeders, these systems use a combination of frequency monitoring and step-load variations to calculate in real-time the spinning reserves and the recovery curve.

MAS Power Management & Fault Management Systems enable automated recovery from:

• unit trip in high load low spinning reserve situations
• disruptions originated from the grid (eg. short circuits )
• shedding load scheme with automatic new unit allocation/ reallocation of power generation
• total blackouts (station black start).

When integrated with MAS Power Management, Energy Management and SCADA Systems, the Power Equilibrium System forms a fully coordinated control layer capable of supporting resilient and fully unmanned plant operation.

Station Emergency Shutdown Systems (ESD)

Independent safety systems for controlled plant shutdown and coordinated plant-wide response under hazardous conditions

Emergency shutdown systems are key component of well-designed systems and often a prerequisite as per API and IEC standards. These systems operate as fully independent safety layers designed and tuned to take control when operational safety is in jeopardy.

MAS Solutions for Emergency Shutdown Systems:

• Ensure overall protection of the process including the unit level operations.
• Interconnected with multiple critical subsystems, including fire, gas detection, and other critical systems, enabling coordinated plant-wide response under hazardous conditions.
• Tailored Engineering, based on specific project requirements.

MAS delivers custom-engineered station ESD systems, where shutdown logic is tailored, defined, developed, validated and tuned to ensure:

• Activation only under true fault or hazardous conditions
• Rejection of uncorrelated events
• Reroute uncorrelated events to be handled by parallel systems (e.g. fault management). This safeguards downtime and prevents from unnecessary expenses.

Compressor Load Sharing

Automated load distribution across compressor units for stable and efficient process operation

In demanding, mission critical Process Industries, where multi compressors are involved, load sharing is of major importance. It requires specialised engineering expertise and a deep understanding of both the overall process and the compressor’ operations and dynamics.

MAS has field-proven Automated Compressor Load Sharing solutions, designed to ensure optimal performance under varying demand conditions.

MAS Compressor Load Sharing Solutions deliver:

• Operations availability and reliability, by avoiding trips causes by uneven compressor loads.
• Constant downstream processes even in demand fluctuations since load is managed automatically to meet given operational target parameters.
• Operational efficiency, units run safely, closer to their nominal values, reducing the need for additional units to maintain stability and minimising overall energy consumption
• Smother operational transitions, adding new units in production or removing existing ones, is done without disturbance in the process values, ensuring uninterrupted and stable operation.

Electrical Protection Systems

Engineered protection schemes for selective fault isolation and protection of electrical networks

Electrical protections are a crucial part not only for the safety of an installation but also for its smooth operation.

MAS delivers advanced electrical protection solutions within power production installations, closely integrated with load shedding systems or/and fault management systems to ensure the containment of any event and controlled response to abnormal events.

Like control systems, protection architectures are implemented across all electrical levels, starting from the generator, internal bus, and ultimately to the main feeders / substations.

MAS engineering ensures correct and tuned protection both in isolation and in combination with other functions.

Process Automation & Balance of Plant Integration (BoP)

Unified Control of Auxiliary Systems for Reliable and Optimised Plant Operation

The performance and reliability of any installation depend not only on its primary assets, but also on the coordinated operation of all supporting systems.

MAS integrates Balance of Plant (BoP) systems, bringing all auxiliary infrastructures into a unified and coordinated automation environment:

• Electrical infrastructure (switchgear, substations, protection systems)
• Cooling and HVAC systems
• Fuel handling and supply systems
• Water treatment and pumping systems
• Auxiliary mechanical systems
• Safety and monitoring systems

MAS  BoP Integration Engineering

System-Level Integration
MAS engineers BoP systems as part of a unified architecture:

• Integration into PLC / DCS environments
• Coordination through Plant Management Systems
• Structured connection with SCADA and digital tools

Unified Operational Logic
MAS eliminates fragmented subsystem behaviour through:

• Centralised monitoring and control
• Harmonised alarms, interlocks and system responses
• Coordinated operation across all subsystems

Electrical BoP (eBoP) Integration
MAS fully aligns electrical infrastructures, such as switchgear, transformers and motor control centres, with overall plant operation:

• Integration with Power Management Systems (PMS)
• Coordinated power distribution and load handling
• Enhanced system stability and fault response

Enabling controlled and resilient power distribution across the plant

Centralised Control & Alarm Management
MAS integrates all auxiliary systems into a centralised control environment:

• Harmonised alarm handling,
• Reduced operator workload
• Faster response to abnormal conditions.

Optimisation of Supporting Utilities
MAS transforms BoP systems into an active optimisation layer:

• Real-time monitoring of auxiliary consumption
• Better utilisation of supporting systems
• Optimisation of internal energy consumption

Supporting the overall performance, reliability and efficiency of the installation. 

Brownfield Integration Expertise
MAS delivers BoP integration of existing and often heterogeneous systems into modern architecture:

• Integration of legacy and multi-vendor systems
• Reverse engineering where documentation is limited or missing
• Minimisation of disruption during upgrades

Applications

• Power plants (thermal, hydro, hybrid, island grids)
• Oil & Gas installations (compressor stations, terminals)
• Industrial plants
• Marine vessels and offshore installations