Applications Archives - Page 23 of 23

Emergency Energy for the Chilca Combined Cycle Power Plant

16 November 2016/in Applications, Power Plants Peru/by Gestor

Combined Cycle Plant in Chilca (Peru)

Emergency diésel power generator to be installed in a Combined Cycle Plant in Chilca, Lima province, Peru. The plant has a General Electric gas turbine and a Siemens steam turbine , capable of generating a net 110 MWe.

Requirements

Space limitations.
Internal division between 3 rooms: generator room, control room and tank room. The control room must be climate-controlled.
6 hours of independent operation at 100% load.
Corrosive atmosphere with high content of suspended dust.
Maximum noise level 85 dBA at a distance of 1 metre.
Fire detection and extinguishing system.

Unit design

Based on a study of the loads to be supplied, the selected power unit had a rating of 680/750 kVA, 60 Hz, 480 V. To meet the requested specifications, GENESAL ENERGY chose the following solutions:

To overcome the space limitations, the unit was assembled in a 30’HC container designed especially for the project.
The unit as required was divided in to 3 rooms:
- Generator room: Containing the power generator along with the batteries.
- Control room: The control panel and generator power panel are installed in this room. The wiring connections are located at the bottom of the generator.
- Tank room: A custom-made, approved, 1500 litre double-walled parallel piped-shaped tank was installed, guaranteeing 6 hours of independent operation at full load.
Because the atmosphere where the generator would be operating is highly corrosive (marine atmosphere), it was painted in accordance with ISO 12944, following a C5M diagram, which consists of type SA 2 ½ shot blasting in accordance with ISO 8501, one initial 80 µm coat of zinc-rich paint, two 100 µm coats of epoxy paint and a final, 100 µm coat of polyurethane paint (RAL 7032), giving a total dry film thickness of 380 µm.
The atmosphere where the generator is located has a high content of suspended dust. Therefore, powered grilles were installed on the generator’s air intake and outlet. The slats open when the generator is operating and close automatically when the generator shuts down.
To meet the noise requirements, the generator was attenuated with acoustic panels consisting of rock wool and perforated plates, and was equipped with noise reducing filters on the air intake and outlet. The exhaust soundproofing was installed inside the container to avoid complications during the on-site installation.
The fire extinguishing system includes a detection component consisting of a smoke detector system in all 3 rooms aswell as an extinguishing system that uses water mist in the engine room and tank room, and CO2 in the control room.
The control panel was designed to meet the specific requirements of the project engineering team.
Redundant programmable automaton.
Fibre optic communication with the redundant DCS by modbus TCP/IP.
4” touchscreen.
Protection relay meeting the following ANSI-based electrical protection requirements: 50, 51, 51N, 59N, 59, 27, 81m, 81M, 46, 49, 25, 78, 32, 40.
Protection relay meeting the following ANSI-based electrical protection requirements: 87G, 24.
Synchronizer between generator and networks.

Combined Cycle Plant GEN750TC

Super-compact GEN33D Power Generator

19 October 2016/in Applications, Power Plants Spain/by Gestor

A series of questions have been raised at engineering level:
We have been informed of the need to provide power for high-tech auxiliary electronic equipment located in a special vehicle. The equipment has to be able to operate during long daily periods under adverse conditions (high temperatures), with a load of practically 100%.

Its position in the vehicle must ensure that maintenance can only be carried out from one side, as the outer housing is armoured, and only one of the protective covers can be removed. The air outlet must be located on the top, and the air inlet on the bottom, due to the design of the vehicle.

The ultra-compact layout of the cabin and size/power of the motor means that we have to consider a design in parallel to the monoblock, with a power transmission using a toothed belt. The bottom support for the power generator must also be as low as possible to avoid exceeding the necessary height, which means that the crankcase must be at a distance of only 10 mm from the ground, and the bottom support must have an opening so that it can be fitted in place. A series of anti-vibration mountings have been installed to prevent shearing, which are capable of withstanding the movements and acceleration caused by the vehicle during its normal operation.

Finally it has been decided to use a refrigeration system using an oil-cooled motor instead of a more conventional water-cooled motor. These oil-cooled motors can reach much higher operating temperatures, under the same environmental conditions. In a conventional water-cooled motor, the maximum temperature that can be reached by the coolant is normally 100ºC, while in the case of an oil-cooled motor, this temperature can reach 135ºC, which means that the equipment can operate at environmental temperatures of 50ºC without any loss of performance. Also, there are two funnels for channelling the inlet air (cold air from the bottom part) and outlet air (hot air from the upper part), so that the air circulates correctly and cools the equipment properly.

The electrical installation is supplied separately and in different modules, so that it can be integrated into the vehicle’s control panels that allow it to be controlled from the interior, even if the equipment is installed in an external compartment.

Specifications

The power generator has to be installed in a small compartment measuring only 1105 x 950 x 750 mm (length x width x height).
We have to adapt the installation to the existing air inlets and cooling air outlets in the vehicle.
The power generator has to have a power of at least 30 kVA.
Integration with the vehicle’s electrical system.
High cooling capacity and ability to work with overloads at high temperatures.
Capable of withstanding the typical motion of a vehicle of this kind over rugged terrain.

Project summary

Application: auxiliary power generator for special vehicles.
Power: 30 kVA DC, 33 kVA emergency supply.
Special configuration: super-compact power generator.

Super-compact GEN33D Power Generator

Extra Soundproof Genset

7 September 2016/in Applications, Contingency Gensets, Soundproof generator sets Spain/by Gestor

In the engineering side we had to consider various needs.

On the one hand, and due to the unusual location of the genset inside a building in the middle of Madrid, it was necessary to ensure a genset design solution which met with the local regulations pertaining to legally permitted acoustic levels. Genesal’s engineering department proposed the manufacture of a specially built genset to comply with Madrid’s legally permitted acoustic levels. This involved several key design aspects such as extra thick walls on the genset enclosure, silencers integrated in to the air intake and exhaust systems, as well as sound proofing the base frame. This led to the development of a one piece completely enclosed mono block. Additionally Genesal went a step further and researching the need for added silent block anti-vibration parts to the standard number used in manufacture, to eliminate residual vibrations that may increase the noise output.

This was not the only consideration. Genesal’s engineers correctly assumed that the complexity of the location required a unique fuel transfer and control system for the loads to be handled by the genset. This required a fuel tank to be situated in the basement of the building, and a controlled transfer method to be installed. A special alternator was added to guarantee very high stability at different frequencies regardless of the genset load levels, with an added electronic engine speed control unit (ECU) to ensure continuous stability.

Features

Extra Soundproofed Genset
Power: 80 kVA COP, 100 kVA PRP & 110 kVA STANDBY
Project: Data Processing Centre, Abanca.
Location: Paseo de Recoletos – Madrid

Specifications

Diésel genset with 65dB(A) sound measurement at 1M distance.
Integrated silencers on the air intake and the exhaust.
Double thickness sound absorbing rock wool as standard issue for the entire enclosure including the base.
Electronic Engine Control Unit installed, which guarantees a more stable performance.
Alternator provides voltage stability of ±0,5%.
Card for Modbus set up.
Sub base fuel tank for a 20 hour plus autonomy at COP rating.
Integrated fuel level sensors for automatic fuel transfer management.
Extra addition of silent blocks to add to those mounted between the bench frame and the engine-alternator mono block, in order to eliminate any residual vibrations once installed in the building interior.

GEN80FC – EXTRA SOUNDPROOFED GENSET

15,000kVA Power station with continuous operation

23 June 2016/in Applications, Industry Angola/by Gestor

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.

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

Emergency power solution for the Álvaro Cunqueiro Hospital

3 August 2015/in Applications, Hospitals Spain/by Gestor

Localization

Situated in the city of Vigo, north-west of Spain, the new hospital Álvaro Cunqueiro covers an area of 280,000 m², has beds for 1,465 patients and will provide healthcare servides to a population of 600,000 people.