1200 kW Cummins C1675D5 containerized diesel genset with reduced noise level for Petrovax pharmaceutical manufacturer

Techexpo LLC delivered an original 1200 kW Cummins C1675D5А.G8 diesel genset for pharmaceutical manufacturer Petrovax. The diesel genset will operate under constant load conditions for a new vaccine-producing shop in Podolsk, Pokrov village.

The Cummins C1675D5А.G8 diesel genset is completed with a KTA50.GS8 engine, a Stamford PI734D1 current generator and an RSS3.3 control panel. The diesel genset is housed in a Sever-type all-welded container 10000х2800х3000 with a 2000-liter tank, muffling chambers, a structure for reducing the muffler noise level. View Techexpo production facilities >>>.

The Techexpo service department carried out a range of construction and pre-commissioning works, including routing copper cable VVGng-LS 1х150 (5 threads per 1 phase) 1800 m long and cable VVGng-LS 1х150 (2 threads per 1 phase - neutral bus) 240 m long, erecting two cable bridges, implementing grounding and foundation for the diesel genset.

To provide the diesel genset continuous operation, we laid a fuel main with incut into the existing one. 

Engineering documentation and working drawings list for production buildings powered by a containerized 1200 kW diesel genset::

• cable-support system diagram
• technical bridge
• bridge supporting structures analysis
• attachment fittings of cable trays
• cable tray pass-through through the diesel genset
• pass-through unit through walls
• fuel-supply line
• grounding

The project provides for routing cable lines from the diesel genset to a production building. Cables are laid in metal cable trays 600х50 and 100х50 with a cover. Cable trays are fixed with mounting elements. The route length from the diesel genset to the main distribution board is 43 m +10% = 47 m.

The jumper length from the 2500А automatic breaker to the common bus is 10 m. The route length from the main distribution board to the input distribution device VRU2.2 is 105 m +10% = 115 m. To route cable trays between the existing diesel genset and the production building, the project provides for installing a metal trestle. 

The trestle supports are made from a 300x8 steel pipe and a 40SH2 H-beam. All steel structures are double-coated with enamel and double-coated with primer G-021. All welding seams are performed with manual arc welding. The project provides for a pile foundation for installing trestle supports.

Under the project, we sized the sections of cables 1*150, 1*400 and carried out the connection of an automatic circuit breaker and cable lines. The automatic circuit breaker (an input switching device with an automatic circuit breaker and synchronization) consists of two existing diesel gensets, the main distribution frame with the common bus of the diesel gensets – existing; a diesel genset DGU-3 - projected – a diesel generator set TE.1200C-Т400-2RN. Input distribution device board VRU.DGU3.2500 (dimensions 2000х1800х800), two-section, one-way maintenance, with a pull-out automatic circuit breaker placed inside, rated current 2500А, projected. Intended use – to connect Input distribution device VRU2.2 into the main power supply scheme (outgoing cable protection), and provide uninterruptible power for the periods of diesel genset DGU-3 downtimes for maintenance and repair 

Cable lines:

Cable line KL-1 (58 m) – from diesel genset DGU-3 – to input buses VRU.DGU3.2500:

• cable VVGngLS 18х(1х400) 1044 m – 3P+N+РЕ in cable ladders 2х(600х50) along the trestle horizontally to the ‘main distribution frame wall’ mark, then vertically along the main distribution frame wall, then horizontally through the passage in the wall (sandwich) in cable ladders 2х(600х50) to input buses VRU.DGU3.2500.
• cable VVGngLS 5х6 47 m – diesel genset auxiliaries - in cable ladders 100х50 along the trestle horizontally to the ‘main distribution frame wall’ mark, then vertically along the main distribution frame wall, then horizontally through the passage in the wall (sandwich) in cable ladders 100х50 to the terminal point in the main distribution frame.
• cable VVGngLS 14х1,5 47 m – providing launch and signal transmission - in cable ladders 100х50 along the trestle horizontally to the ‘main distribution frame wall’ mark, then vertically along the main distribution frame wall, then horizontally through the passage in the wall (sandwich) in cable ladders 100х50 to the terminal point in the main distribution frame.

Cable line KL-2 (150 m) - from board VRU.DGU3.2500 – to input distribution device 2VRU 2.2

cable VVGngLS 36х(1х150) – 3P+N+РЕ 5400 m - in cable ladders 2х(400х50) from input distribution device board VRU.DGU3.2500 horizontally through the passage in the wall (sandwich), then vertically along the main distribution frame wall, then in cable ladders 2х(600х50) along the trestle horizontally to input distribution device 2VRU 2.2

Cable line-3 (5 m) – from diesel genset common bus – to VRU.DGU3.2500 (a jumper connecting common bus VRU.DGU3.2500 to diesel genset common bus):

cable VVGngLS 18х(1х400) – 3P+N+РЕ 90 m - allocation without using cable-support designs from board to board – top-top.

Cable line KL-4 – (30 m from diesel genset-3 control panel – to diesel genset-2 control panel – providing the parallel operation of diesel genset DGU-3 with existing diesel genset DGU-2 and DGU-1- cable KVIPng (А) 4х4х1,2 – 35 m in cable ladders 50х30.

For the technical trestle, we carried out supporting structure analysis, based on the beam analysis, the operation factor of the section is 0,7 (30% margin). The beam fixity is guaranteed by the stiffness of joints. The joint is made equal in strength, the joint location is of no importance. The trestle column is a stand made from a pipe rigidly fixed in the foundation. The beam is hinge supported on the column.

Pile analysis conclusions: the pile group is to be made from 4 piles with a diameter of 133 mm. Based on a 3D analysis concerning the actual distribution of forces along the elements, the maximum pile force is 59 kN, which is close to the maximum material load-bearing capacity of pile d108. It's recommended to use a pile d133, with a material load-bearing capacity of 100 kN. Trays are fixed to the beam from two sides through fixing elements.