Emergency Power for Phosphates Treatment Plant in El Jadida, Morocco

The project has been designed for one of the most important companies in the engineering and constructin sector, with headquarters in Marseille (France).

Situated 80KM south of Casablanca and 17Km from El Jadida is the Jorf Lasar industrial complex, a phosphates treatment plant which Genesal Energy has supplied with 3 specially designed gensets for emergency back-up.

The plant whose installations cover an area of 1,700 hectares began its production in 1986 and its numbers are quite impressive: the recuperation of 2 million tonnes annually of P2Oin the form of phosphorus acid.

Genesal Energy has supplied this elaborate facility in Morocco with a genset island comprising of identical generators for outdoor use (3 units at 400V/50Hz containerised with a control system) designed to work in parallel or if necessary individually. Five circuit breakers make up the switchgear.

In detail

As with every project undertaken by Genesal, the control system designed for this phosphate treatment plant was managed to the tiniest detail:

  • If the gensets are operational, they can be synchronised, either with the output switch of each genset or with the coupling point, therefore reducing the number of movements required by the switches in case of changes in the operational format.
  • If a generator is stopped, the circuit breaker is disabled to avoid damage from unwanted power inputs from external busbars
  • If the client has not indicated that a connection panel should receive an electrical feed, the incoming power cabinet circuit breaker will not be permitted to close (not even manually), in order to avoid short circuits caused by external voltage not from the actual genset island.

15,000kVA Power station with continuous operation

Project summary

Location:  Dairy Products. Manufacturing Plant.
Required power:  12,500 kVA
Installed power: 2,500 kVA x 6 = 15,000 kVA (continuous).
Special configuration: Working in parallel depending on the power requirements of the factory.

Objective

To provide a safe, permanent power supply. The public grid will cover any possible emergencies in exceptional situations when the generator plant comes to a complete halt.

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Solution

Based on the loads and the operating system of the plant, a solution was adopted using installations of 6×2,500 kVA working in parallel, with one unit always in reserve. The equipment is rotated according to the number of operating hours.

Features:

  • Can operate in parallel, delivering a total power output of 16.5 MVA.
  • Includes protection switchgear and transformers to step down voltage from 690 V to 400 V.
  • Individual control using ComAp intelligent system.
  • Touchscreen in the electrical control room.
  • Remote master control screen at the factory central monitoring point.
  • Siemens power switchboards rated at 6,300/6,300 A.
  • Secure command and control network with UPS.
  • PLC for managing load input into the installation.

PDF Case study, 15,000 kVA Power Station with continuous operation