Supply of 6.6 MW, 6 kV, commissioning works, installation supervision of DGS for a large industrial enterprise
| Total capacity | 6600 kW |
| Client | Industrial enterprise |
| Фото |
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| Task | Provision of emergency power supply to the needs of a large industrial enterprise in conditions of prolonged complete de-energization. |
| Solution | Supply of three high-capacity mobile diesel power plants and carrying out a full range of installation and commissioning supervision, as well as tests for comprehensive equipment control. |
The main features of the project
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Ahead of schedule: due to strict adherence to delivery dates in accordance with the importance of the project, diesel generator sets in containers were manufactured and shipped ahead of schedule.
Mobility: all containers were placed on wheeled trailers.
Large capacity: the supplied complex is a powerful and fully autonomous 6.6 MW backup power supply source.
To solve the Customer's problems, a mobile container-type diesel generator set with a single capacity of 2.2 MW and a voltage of 6.3 kV was selected. In total, 3 diesel power plants TE.2200P-T6300-3RN produced by Techexpo were supplied as part of this project.
The main characteristics of the MDGS (mobile diesel generator set):
- Degree of automation according to (State Standart (SS) 50783-95) – 3;
- Rated power, MW – 2.2;
- Maximum power in overload mode, MW – 2.32;
- Voltage, V – 6300;
- Current frequency, Hz – 50;
- The idling time at the rated speed is from 10 to 60 minutes;
- Current – alternating;
- Number of phases – 3;
- Type of arousal – AREP;
- Insulation class – H;
- The degree of protection of the generator is IP 43;
- Fuel consumption at rated load, l/h – 594.4;
- Overall dimensions (assembled, mounted on a semi–trailer), mm - 19515x4800x3500;
- The mass of the MDGS, kg, is not more than 61,000.
Operation modes of the TE.2200P-T6300-3RN diesel power plant:
- manual control mode without applying load to the generator;
- manual control mode with dedicated load operation;
- synchronization mode of the control unit with another similar control unit and load supply;
- synchronization mode of the MDGS with the existing MDGS of the Customer based on the DEIF AGC-150 controller;
- stop modes: normal stop and emergency stop;
- the mode of sequential activation of two high-voltage asynchronous electric motors with a capacity of 800 and 600 kW.
The composition of the MDGS
The MDGS includes:
- an electric unit;
- weatherproof shell (MDGS container);
- fuel system;
- oil system;
- gas outlet system;
- cooling system;
- heating system;
- lighting system;
- fire safety system;
- automatic control system of the control unit and load distribution;
- high-voltage switchgear;
- the wheeled semi-trailer of the MDGS.
Electrounit
The electric unit consists of a primary motor and a synchronous generator mounted on shock absorbers on one frame.
The Yuchai YC105TA3600-G31 diesel engine is used as the primary engine in the electric unit.
The high-voltage synchronous generator LSA53.2 XL13 is used as a generator in the electric unit.
MDGS Container
The MDGSs are supplied in containers made using allwelded technology with a degree of protection according to SS 14254-2015 (IEC 60529:2013), not lower than IP44.
Container features:
- Thermal insulation with basalt wool with a thickness of at least 50 mm;
- The floor frame with reinforced construction under the electric unit;
- The floor is made of corrugated metal sheet with a thickness of at least 3 mm;
- The outer skin of the container is made of profiled steel sheets with a thickness of at least 1.2 mm.
All structural elements of the container module, which are subject to corrosion, have a protective white paint coating according to SS 9.104-2018, SS 35094-2024, SS 9.401-2018, taking into account the climatic conditions of the site and operation. The service life of protective coatings is at least 5 years.
The MDGS container module is divided into compartments:
- aggregate;
- electrical engineering;
- fuel tank.
The compartments are separated by a noise-insulated partition.
Auxiliary switchboard
To provide power, control and display of technological and electrical systems of the container, the MDGS provides a shield of its own needs (auxiliary switchboard). The control panel is made in the form of a separate hinged cabinet and is located in the aggregate compartment of the container.
Control unit (Switchgear)
The switchgear is mounted in floor cabinets and consists of two cabinets:
CABINET 1 consists of a vacuum circuit breaker for the generator voltage network with remote and automatic control, and a switch-on lock in case of deviation of the network parameters;
CABINET 2 consists of a switch for the outgoing line and an industrial receiver for connecting the outgoing cable line;
CABINET 3 consists of an in-house transformer for powering the switchgear's own needs.
Automation
The MDGS is equipped with DEIF AGC150 control panels, which have the function of continuous remote monitoring of the state of the MDGS with the display of operating indicators on the screen:
- engine (speed, coolant temperature, cooler temperature, oil temperature, oil pressure, engine on-board generator power, instantaneous fuel consumption, exhaust gas temperature, engine operating time in operating hours);
- generator (line voltage, phase voltage, line power, full power, reactive power, line current, phase current, frequency, cos φ);
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- a switchable emergency warning alarm for deviation of the parameters of the electric unit with storage in the automation memory;
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- automatic check of the electric unit's readiness for start-up;
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- accounting for the amount of electricity generated and the number of starts;
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- manual start and stop of the electric unit;
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- automatic control of pre-start, pre-stop operations and preparation for receiving the load;
- automatic and manual switching on and off of the automatic generator switch (AGS).
The control panel also allows you to synchronize MDGS with other MDGS of a similar design. Synchronization and load balancing functions are included in the control panel along with the necessary protective devices for the systems. In the event of an emergency situation in the operation of nodes, aggregates, DGS systems, a warning signal with a fault code (error) is sent to the control panel screen, or a local emergency stop is automatically performed with the cause (error code) displayed.
Wheeled trailer
The containers of all MDGSs are mounted on four-axle wheeled low-frame semi-trailers with two pivoting self-aligning axles. The design of the container and trailer ensures the secure attachment of the container. The trailer is equipped with additional supports (jacks) for unloading axles, air suspension and parking jacks in the «parking» position.
Complete set of MDGS
The MDGS is equipped with two sets of rechargeable batteries (main working and emergency) with independent chargers to ensure backup of the MDGS after start-up.
The delivery package includes a two-section cable coil located directly in the electrical compartment of the MDGS. Two lengths of 6.3 kV flexible power cable are placed on the coil. The placement of coils with a cable in the electrical compartment ensures the rapid deployment of the control system in any conditions.
The fuel compartment is equipped with its own electric fuel pump and a coil with an oil- and gasoline-resistant hose 30 meters long, which ensures independent replenishment of the fuel tank with diesel fuel from any source.
- an exhaustive supply of spare parts, tools and accessories (spare parts) for a 24-month service life;
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- a set of fuels and lubricants and process fluids for a 24-month service life;
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- a set of lifting equipment for unloading equipment at the site of operation;
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- a complete package of accompanying technical documentation, including design, operational and repair documentation.
Trials
An individual test program and methodology have been developed to verify compliance with Customer requirements. All MDGSs have passed the following types of tests:
— acceptance tests of the head sample according to SS 15.301 at the Techexpo production site;
— acceptance tests of subsequent samples according to SS R 15.309 at the Techexpo production site;
— acceptance tests at the Customer's site.
During the tests, all the declared characteristics of the equipment were fully confirmed and the operability of all MDGS systems was checked.
According to SS R 53176-2008, the following reliability indicators were provided for the MDGSs installed under the project:
- the assigned service life before maintenance is at least 250 hours;
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- the average recovery time is no more than 14 hours;
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- the launch reliability coefficient is not lower than 0.99;
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- comprehensive reliability indicator — not less than 0.99;
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- the assigned full-service life until the first complete diesel bulkhead is at least 30,000 hours;
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- the assigned service life of the MDGS is 30 years;
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- the operating time to failure is at least 2000 hours.
Installation and commissioning supervision
At the Customer's site, Techexpo specialists carried out a full range of installation supervision and commissioning work for the commissioning of the MDGS.
Installation supervision and commissioning were carried out according to an individual program developed for these MDGSs.
During the work, the following tasks were performed:
- Visual inspection of the equipment;
- Inspection of electrical and technological systems of the container;
- Checking and configuring relay protection and automation devices;
- Idling start-up and operation of the control unit;
- Start-up and operation of the MDGS on a dedicated load;
- Start-up and operation of the MDGS in the mode of synchronization of the MDGS with each other with work on the total load;
- Start-up and operation of the MDGS in synchronization mode with similar MDGSs of the Customer with work on the total load.
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Форма заявки
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