2 aggregates and 4 networks - case studyy

One of the first projects of Prototypownia: a dedicated guaranteed power supply system including 2 redundant power generators and 4 independent connections to the electrical network. The design of the power supply system takes into account the special needs of the farm. The power supply system designed and serviced by Prototypownia ensures the safety of approximately 400,000 chickens at any time.

The dedicated power supply system comprising 2 redundant power generators and 4 independent connections to the electrical network was one of the first systems designed and implemented by Prototypownia. Since then, we have regularly carried out service work, and the customer has recommended us to many of his friends.

Location: 8 facilities, each housing 50,000 chickens - some under construction, Poland

State we found: generator set Wola 100 kVA, 1 outdated connection to the electrical network.

 

Assumptions for the power system:

1. Power system guaranteeing power supply to facilities in the event of a lack of power from the mains

2. Maintenance-free starting of power generators in case of lack of power supply from the mains

3. The availability of power also in the event of a failure of the generator set

4. The system itself should inform about any irregularities, lack of fuel and failures

Applied solutions for the power supply system:

As part of the project, a second connection to the electrical network was introduced to supply new facilities. We planned another 2 emergency connections that could take over the power supply from the mains in the event of a failure of professional connections. The 1970s generator set, which did not meet current environmental standards, took too much fuel and gave too little power, was scrapped, instead 2 redundant, almost failproof, economical and pro-ecological power generators appeared in the system. And some other interesting solutions...

Specification of the basic generator set:

1. Generator set with an Iveco engine with a maximum power of 220 kVA (176 kW)

rated power: 200 kVA (160 kW)
rated current: 288 A
voltage: 230/400 V
power factor: cos fi = 0.8
frequency: 50 Hz

dimensions: 1000 x 2800 x 1660 mm (W x L x H), the unit has been mounted in a specially adapted, soundproofed room
weight: 1640 kg
exhaust: routed outside the generator room, thermally protected

engine: Iveco 1500 rpm, straight-six engine, diesel
PRP power: 175 kW
cooling: liquid
rotation regulator: electronic
capacity: 6.7 l
standard tank capacity: 330 l

generator: synchronous, brushless
possible overload: 110% for 1h, 150% for 2 minutes (e.g. machine start-up time)
voltage stabilization: AVR
protection class: IP21
frequency 50 Hz

additional options used:
ATS - about this later in the article
ventilation system discharging air outside the room
enlarged fuel tank
electrical switchboard with wiring (description later in the article)
analogue indicators

the generator set control panel shall provide:
actual motor speed, magnetothermal 3-field switch, safety switch, automatic start, voltmeter, ampere meter, kWh counter, full start-up and operation history, operating fluid indicators, etc.

The generator set described above supplies 8 facilities closely related to poultry farming and is the first emergency power source in the event of a power outage from the grid.

 

Specification of the backup generator set:

1. Generator set with an Iveco engine with a maximum power of 440 kVA (352kW)

rated power: 400 kVA (320 kW)
rated current: 578 A
voltage: 230/400 V
power factor: cos fi = 0.8
frequency: 50 Hz

dimensions: 1250 x 3300 x 1950 mm (W x L x H), the unit has been mounted in a specially adapted, soundproofed room
weight: 2760 kg
exhaust: routed outside the generator room, thermally protected

engine: Iveco 1500 rpm, straight-six engine, diesel
PRP power: 352 kW
cooling: liquid
rotation regulator: electronic
capacity: 12.9 l
standard tank capacity: 600 l

generator: synchronous, brushless
possible overload: 110% for 1h, 150% for 2 minutes (e.g. machine start-up time)
voltage stabilization: AVR
protection class: IP21
frequency 50 Hz

additional options used:
ATS - about this later in the article
ventilation system discharging air outside the room
enlarged fuel tank
electrical switchboard with wiring (description later in the article)
analogue indicators

the generator set control panel shall provide:
actual motor speed, magnetothermal 3-field switch, safety switch, automatic start, voltmeter, ampere meter, kWh counter, full start-up and operation history, operating fluid indicators, etc.

The 440 kVA generator set is a redundant source of electricity (it takes over the load in the event of a failure of the basic generator set) and is a power reserve for the emergency power supply of future facilities.

2 redundant connections to the electrical network
As part of the project, we introduced 2 redundant power lines. This means that each existing connection has its counterpart powered from an independent power line, which will take over the role of the basic power supply in the event of a failure of the constantly used network. This solution is the first protection and - thanks to the use of a dedicated ATS system - it is activated even before the generator set.

 

ATS and electrical switchgear - two in one

The most interesting thing in the project was the combination of all the necessary elements: power generators and 4 networks with the need to provide the customer with such standards as SMS about the upcoming fuel reserve. After  installation, the cabinet took about 2 x 4 m, quite a lot for the initial conditions of Prototypownia... ;-)

Despite various limitations, we have applied the latest and at the same time the most reliable technologies and innovative solutions. We have made the ATS system based on the most reliable switches (i.e. excluding unreliability caused by a lack of electricity...) and taking into account the available protection possibilities.
In the ATS system, we used all possible protections to start the generator set, even in the case of such a serious failure as those caused by a lightning strike.

These solutions make it possible to:

1. Switch between the main network and the backup network on each of the facilities (in the event of a lack of power from the basic network)
2. automatic start-up of the first generator set in case of lack of power supply from the mains
3. automatic start-up of the second generator set (in case where the first generator set does not start or when the first generator set will not be able to generate the appropriate power)
4. electronic start-up of the first generator set by the User (excluding automation, in the event of its failure)
5. electronic start-up of the second generator set by the User (excluding automation, in the event of its failure)
6. manual start-up of the first generator set (excluding automation and electronics, necessary e.g. in the case of a lightning strike)
7. manual start-up of the second generator set (excluding automation and electronics, necessary e.g. in the case of a lightning strike)
8. automatic, electronic and manual switching of power supply between objects (e.g. in case of failure of 1 connection to the network or asymmetrical demand)
9. power distribution - regardless of the source, relative to the priority resources on each of the facilities and between the facilities
10. Automatic SMS or telephone call informing about the need to refuel, add operating fluids, failure, starting the generator, etc. (User configurable). The system has been additionally enriched with a guard module -> ask.