SCADA-Automation – Modernisation of hybrid power plant TWL

Hybrid System Ludwigshafen

Safely steered into the future: control that creates trust

Initial Situation

Since 2018, Technische Werke Ludwigshafen (TWL) has been operating Germany's first hybrid power plant. This innovative facility combines a 9.6 MW battery storage system with a 4.5 MW gas turbine to compensate for grid fluctuations caused by renewable energy sources. The battery storage provides energy within milliseconds, while the gas turbine ensures long-term capacity. After several years in operation, the plant no longer ran optimally. There was no manufacturer support or maintenance contract in place, which made modernisation urgently necessary.

Challenge

The goal was to fully modernise the hybrid power plant and restore full operational capability. To integrate all components - battery storage and gas turbine - into one efficient system and meet the rapid response times required for primary reserve, a complex software control solution was needed. In addition, future failures had to be prevented, and a sustainable maintenance and support system established.

Our team tackled this challenge with a clear focus: maintaining operational availability throughout the work and giving the client maximum control over the facility.

Solution

SCADA-Automation modernised the hybrid power plant with a comprehensive redesign of control and operations management. Our solution delivers future-ready and reliable energy management, including:

Optimised control and operations
By replacing the existing system control, we ensured stable, efficient and future-proof operations.

Intelligent battery-inverter integration
The integration of our smartBat software enables precise, vendor-independent control of the battery-inverter combinations.

Dynamic regulation of battery systems
The existing plant controller was extended by our PrioHUB system, which optimises energy flows in real time and ensures efficient load distribution.

Enhanced visualisation and usability
A modern HMI/SCADA system replaces the previous interface and enables intuitive control and comprehensive real-time monitoring.

Maximum availability through continuous monitoring
A customised service contract with fast-response support and continuous monitoring ensures the highest level of operational security.

New operating modes for greater independence
In autumn 2024, the system will be expanded with island and black start capabilities, enabling safe operation even off-grid.

Outcome and Benefits

The modernisation of the hybrid power plant delivered the following benefits:

Enhanced control capability

The plant can now provide both primary and secondary power within minutes and efficiently perform load shifting.

Full control

The client now has unrestricted access to the power plant’s control system - fully independent of third-party providers.

Islanding and black start capability

In the event of a grid failure, the system can be started both automatically and manually, significantly enhancing supply security.

Minimal downtime

Despite the comprehensive upgrade, the commissioning phase lasted only 15 days, with the full conversion taking just three months.

Trusted partner

We continue to support our client as a reliable expert, providing monitoring and optimisation services for efficient operation.

Conclusion

This project demonstrates how targeted modernisation can increase both efficiency and reliability while also unlocking new economic potential. TWL is now well equipped to meet the growing demands of the energy market and remains a pioneer in the use of innovative energy solutions.