GENERATORS

INTRODUCTION

Our generator systems skills and experience cover the full spectrum from small single standby generator installations through to large diesel generator power plants generating in excess of 10MVA at 33kV. Smaller installation are handled by Indulec independently, whereas financially significant projects are handled by forming project specific partnerships or joint ventures. We assist our clients to make informed trade-off decisions with regards to real needs and costing considerations. It is our goal to deliver well defined power solutions that will perform according to pre-defined standards/limitations.

EXPERIENCE

Our first standby generator installation was commissioned towards the end of 2005. A long relationship with Superwatt Power Systems commenced 18 months later which saw Indulec offering detail engineering services covering the full spectrum of client liaison, project proposal support, detail design (including the generators, control panels and switchgear), engineering supervision during site construction, system programming, commissioning and training, etc. In June 2011 we got approval from NamPower to synchronize and co-generate (at 33kV) with our new diesel power plant which was delivered to a mine near Swakopmund. This was repeated in 2016 with a 14MVA plant, also to a new mine near Swakopmund.

Experience in MV switchgear specification includes ABB and Schneider. Indulec has experience with several generator controllers and is open to a client’s preferences (if any) when considering single standby generator installations. However, our preferred controller when designing multiple genset power plants is the ComAp range. We use ComAp exclusively for all installations specified for MV (medium voltage). Indulec has significant experience with these controllers.

One of the benefits of the ComAp controllers is the fact that all logic signals between generators in a multi-genset cluster can be transferred as virtual input/output over the inter-controller CAN bus. As a result, Indulec gained experience in utilizing single mode fiber optic systems for all communication between generators and other peripheral equipment when designing a power plant, effectively rendering the control system completely immune to large electromagnetic disturbances typically associated with MV installations and/or lightning activity.

PROJECT GALLERY

TYPICAL PROCESS FOR TURNKEY INSTALLATIONS UP TO 1MVA

  • Determine client’s infrastructure, needs and preferences (“wish list”)
    • Determine nominal and maximum load profile
    • Establish short and medium term expansion/growth profile
    • Identify high power equipment, if applicable
    • Analyze site equipment for generator power sensitivity
    • Establish business profile when operating from standby power (essential and non-essential loads, etc., if applicable)
    • Optimal positioning and installation considerations (including noise and aesthetic impact as well as access and cost implications)
    • Discuss switchgear and generator controller options/requirements
  • Presentation of technical and financial proposals (can be an iterative process)
  • Acceptance of final proposal – receive firm order from client
  • Delivery and installation of equipment as per quotation
  • Commissioning of equipment and verification that the original design performance criteria are met
  • Transfer to client – technical support

Financing can be arranged. Conditions apply.

MULTIPLE GENSET POWER PLANT DESIGN

The complexity and list of features associated with larger site design depends directly on the plant’s duty cycle. Applications where the power plant will be the only source of power will be significantly more complex than a standby power plant with limited run-hours. A brief overview of items to consider:

  • Determine client’s infrastructure, needs and preferences (“wish list”) – same as previous section
  • Identify all non-linear loads and power harmonics associated with these (VFD/VSD drives for example)
    • Ensure high enough fault current level – sizing of project alternators
    • It might be necessary to deploy VFD/VSD drives with active front ends to mitigate harmonics
    • Other options to mitigate load-induced harmonics
  • Define plant fuel intake, storage and distribution
    • Enough fuel reserve to accommodate worst case delivery risks
    • Fuel offloading and metering (for delivery by truck)
    • Fuel distribution manifold, booster pump/s and filtration system
    • Fuel metering per genset for system management
  • Define plant oil intake, storage and distribution
    • Mostly applicable to 24/7 operation
    • Enough oil reserve to accommodate worst case delivery risks
    • Oil offloading (most likely delivered in drums or pallet tanks)
    • Oil distribution manifold, high pressure booster pump/s and filtration
    • Oil metering per genset for system management
  • Used engine oil drainage and recovery system
  • Firefighting strategy and equipment
  • Office space, workshop space, on-site parts storage
  • Site layout within client’s constraints in mind (if any)
  • Site electrical planning including earthing strategy