3 MW Cummins power supply package for Rosgeologia JSC drill units with 6,3/0,4 kW transformers

In 2021, Techexpo LLC produced an energy complex on the basis of a Cummins diesel generator set with a total capacity of 3 MW to provide a Rosgeologia JSC drill unit on the Kanadinskaya well (Evenkiya, Taimyr) with electric power supply.

The energy complex is made in four containers (own-produced Techexpo) with overall dimensions of 12500х2450х3000 mm on skids and designed for the electric power supply of a drill unit in the 6.3 kW line. The energy complex consists of three Cummins gensets (two 1200 kW and one 640 kW), 6,3/0,4 kW transformers, a control module and supporting facilities (sites, ladder, railings, trays, inter-module communication cable products, high-voltage cables KGE-HL 3Х95-6kW, tool kit and instruments for gensets for 4500 hours).

The containers are completed with fuel, oil, cooling, control, lighting, heating, ventilation, fire prevention, gas exhaust systems on a turnkey basis.

The climatic version of the energy complex equipment is a moderately cold climate, location category: I according to GOST 15150-69. Operation temperature range – from -50°С to +40°С, earthquake resistance requirement - 9 scores according to MSK 64.

The diesel gensets are made based on Cummins KTA50G8I, Cummins KTA38-G12 engines and Stamford PI734C, Stamford HCI634V current generators. Proektelectrotekhnika transformers are installed, models TLS-1600/6,3/0,4-UЗ and TLS-800/6,3/0,4-UЗ.

The genset fuel system includes:

• A diesel genset fuel system with diesel fuel filters;
• A filter separator mounted on the fuel supply line;
• A fuel tank with 4 level detectors, coarse-mesh filter and fuel dip stick;
• A pump for automated feeding fuel to the fuel consumed tank from an external tank;
• A redundant manual pump;
• A valve on the supply main (protection against spontaneous tank discharging);
• A fuel flow meter on the line of feeding fuel to the fuel consumed tank;
• Pipeline and shut-off valves, faucets, taps.

When fuel is running out in the tank to the lower level, the low-level indicator generates a signal to the auxiliary power automation system to turn on the electric fuel-feeding pump. Filling the fuel consumed tank is carried out till the high-level indicator response. For switching over to a reserve source, an alarm high-level indicator is installed in the tank body. When it responds, a signal to turn off the electric fuel-feeding pump is generated. When an alarm low-level indicator responds, a signal to stop the diesel gensets is transmitted to the auxiliary power control system. To exhaust the air and fuel vapors, a fuel tank ventilation pipeline with a fire-stop valve is installed. The fuel tank design provides for water holding and discharging. 

The oil system makes it possible to fill up oil manually into the engine case from the oil supply tank and drain it manually. Every container with a diesel genset comes with an oil tank, a manual pump for pumping oil into the container, an automated oil filling-up device with the oil level visualization in the case, a manual pump for pumping oil from the engine case.

A gauge tube for visual control of the oil level, a filling port are assembled on the supply tank. There’s diesel case ventilation with a condensate collector located inside the container unit rooms to exhaust the air and fuel vapors off the container unit. The condensate collector is located below the level of the vent port in the engine case. There’s oil tank ventilation to exhaust the air and fuel vapors off the container.

The cooling system includes an in-service radiator on Cummins diesel gensets, temperature regulators, coolant preheaters.

The exhaust system consists of temperature compensators, industrial dumpers (the noise dumping level is 15 dBA), with bellows and a spark-preventer.

The diesel genset control system automatically supports the genset state being ready to take a load, continuous and parallel operation with an external network with the set power level of the diesel genset in the range of 30-100% of the nominal capacity (manual power setting). The system maintains records of the diesel fuel and power consumption, and instantaneous and average fuel consumption data are represented in Modbus register values. The system provides current and historical data to be analyzed in the operator panel in the control module:

• fuel volume and temperature in the tanks of each diesel genset;
• fuel consumption rate (for leak detection);
• the level of generated capacity of each diesel genset;
• the total power level onsite;
• diesel genset status (performance, temperature conditions, load).

The level of energy complex automation according to GOST 33105-2014 – third. A parallel operation with same-type stations, and continuous operation - with equalizing couples are provided. The distribution of the load between generator units is automatic. The functions of diesel genset systems automatic control:

• engine start heating;
• automatic system of refueling from an exterior capacity;
• charging battery from 220 V network from an external network;
• automatic opening/closing of motorized air inflow and outflow valves.
• generator parameters: voltage between phases, between every phase and neutral, current frequency, strength at every phase; total active power (kW); total reactive power (kVAr); power factor by phases (cos φ); - the meter of active and reactive power, consumed from the generator (kW*h, kVAr*h); genset starts and stops counter.
• engine parameters: oil pressure; coolant temperature; bent shaft rotation rate; starting battery voltage; the level of fuel in the feed tank, %; built-in consumed fuel counter; engine hour meter; instantaneous fuel consumption counter.
• providing the generator protection functions: high/low voltage; high/low current frequency; current overload; power overload; voltage and currency imbalances by phases; incorrect phase sequences; short circuit; generator motorization; generator loss of excitation; a separate diesel genset panic stop;
• providing the engine protection functions: low oil pressure; low coolant level; low/high coolant temperature; low/high rotation rate; the low level of fuel in the feed tank; low/high starter battery voltage.

Technical specification and container design for diesel gensets and a control module

Design - fixed in a Sever container. The container body is vandal-proof, leak-, heat- and noise-proof. Fire resistance rating - II according to Construction code and regulations 21-01-97. The seismic capacity degree - 9 scores on MSK-64 scale. The container is a heat-insulated electrical room, where all facilities including MEP systems (lighting, heating, ventilation, socket network) are installed. Index of protection - IP54, 2 fire resistance rating. An entrance door, the openings of air valves, a louver, foundations (sleds) and supporting structures to install and mount equipment, openings for power and control cable inlet/outlet, openings for genset heating equipment pipelines are built into the container unit. A swinging installation opening (opening sash) for mounting (demounting) the diesel genset and other facilities is made in the station end. There's a welded metal frame, and anti-corrosion coating.

A rust-resistant 2 mm thick steel sheet is used on the outside. A polymer coated 0.5 mm corrugated steel sheet is used on the inside of the wall. The non-inflammable heat-insulation layer thickness is less than 100 mm. The structure of walls, floor and ceiling provides heat insulation, vapor sealing and makes through frost penetration impossible.

All electrical facilities maintain reliable, trouble-free operation at a steady-state voltage value from 0.85 UHOM to 1 UHOM and short-term (to 1 sec.) voltage fluctuations from 0.7 UHOM to 1,2 UHOM.

The automatic transfer switch system provides protection (blocking) against an opposing connection when the diesel genset is powered by an external source. When powered by an external source, the work of all electrical support equipment is ensured. When the diesel genset operates without a power supply from an external source, all electrical support equipment is powered by the diesel genset.

Lighting is not less than 200 lx at the control and services sites according to SP 52.13330.2011. The system is comprised of routine lighting 220V, emergency lighting 24V (using universal lamps with LED light with E27 base), external lighting, maintenance lighting. The lamps are fastened securely, their design makes it possible to transport the diesel set without their dismounting.

The routine lighting lamps can be turned on and off in automatic and manual modes using switches installed next to the doors inside the container unit. In the case of automatic lighting, the internal lighting turns on if there are people in the room;  external lighting is turned on when it gets dark. The routine lighting is powered by automatic differential switches with a current loss preset of 30 mA.

The emergency lighting is powered by lamps with self-contained power sources. The self-contained power sources are charged using automatic differential switches with a current loss preset of 30 mA. The emergency lights are installed inside the container unit above every entrance door. The emergency lighting automatically turns off when there's no 230V voltage in the routine lighting network.

The firefighting system includes:

1) an automatic fire and security alarm unit;

2) an automatic aerosol fire fighting unit;

3) automatic and manual fire detectors;

4) public fire alarm system signal devices and evacuation management devices;

5) a set of emergency fire-fighting equipment (carbon dioxide fire extinguishers OU-5 – 2 pcs.).

The fire security devices are powered by separate automatic switches; redundancy power supply - by its own batteries.

The ‘Fire’ signal automatically turns off the diesel genset electric power supply.

The ventilation system - supply ventilation, with a mechanical draft, provides the automatic control of preset temperature during repair works. The ventilation system automatically turns off in case of fire. The system provides the automatic control of temperature inside the container in the range from +15°С to +40°С.

Air intake valves – with an electrical and mechanical drive, fitted with built-in anti-freezing heating. The air intake valves have safety blinds preventing valve damage during transportation and storage and protecting against the entry of rain and snow inside the genset rooms while operating. Ventilation apertures are fitted with protection louvers.

The control module with an indoor switchgear is necessary for diesel genset remote stop, start, energy complex control, distribution and commutation of power from the diesel genset to the control unit. The container unit of the control module is divided with a partition into two rooms: a 6,3 kV distributing gear and an operator's room.

The 6,3 kV distributing gear room is equipped with a high-voltage switchgear, an operational power cabinet, an auxiliaries board.

There’s a 0,4 kV voltage distribution cabinet, a central control room, a PC for monitoring and control (a laptop with installed monitoring software) in the operator’s room. Communication with a drill operator (phone).

The central control room ensures:

- diesel generator unit start/stop with automatic generator circuit-breaker turn on/off;

- displaying the diesel genset operating conditions and fault signaling;

- the diesel genset microprocessor control system is integrated into the drill automated control system.

The HV distributing gear voltage is 6,3 kV, the number of high-voltage circuit breakers - by 1 unit for every diesel genset + 1 unit. Redundant one according to the diesel genset capacity.