CONTROL SYSTEM
Turbogenerator Control System Modernization Project
Client: UTE - Punta del Tigre - Uruguay - 2023
We are excited to share the successful execution of the Turbogenerator Control System Modernization Project at the Punta del Tigre Thermal Power Plant for our esteemed client, UTE from Uruguay.
The project encompassed a comprehensive modernization of the operational stations, specifically targeting the Mark VIe control system of the six Aero derivative gas turbines from General Electric, LM60000 Sprint PC model, identified as GT1, GT2, GT3, GT4, GT5, and GT6.
Our commitment extended beyond hardware and software updates, including database and screen migrations, adjustments, report generation, and detailed engineering for the data network of the Punta del Tigre Thermal Power Plant.
In an effort to ensure a seamless transition, we provided a team of specialists for the installation and configuration of systems such as Acronis Backup, Proficy Historian, and Microsoft SQL. Additionally, we delivered specialized training to the plant's operation and maintenance departments, ensuring they are equipped to leverage the new functionalities to their fullest extent.
The project team comprised engineers specialized in General Electric systems with extensive experience. We met the client's quality requirements and achieved successful integration that significantly enhances the existing performance. As an example, we present SCADA schemes similar to those that were updated and integrated with iFix.
This project signifies technological modernization and stands as a testament to our commitment to excellence and customer satisfaction.
We continue to contribute to the operational success of vital facilities like the Punta del Tigre Thermal Power Plant.
Easygen Synchronizer Installation Service
Client/Plant: Jamaica Private Power Company - Jamaica - 2023
We have been consulted by a client with the need to improve the synchronization of the generation unit composed of a steam turbogroup equipped with all its original control systems, including the first-generation Woodward 505 electronic speed regulator for the steam turbine and Brush AS-303/CS-303 synchronizers.
GENERSOL conducted a diagnosis and proposed replacing the synchronization system and installing one from the advanced EasyGen 3200 series by Woodward. In addition, another Woodward EasyGen 3000 control was installed for Sync-check functionality. This change not only modernizes the infrastructure but also significantly improves the efficiency and interoperability of the plant's control system.
The EasyGen 3200 series stands out for its ability to facilitate precise and effective synchronization, seamlessly integrating automatic control systems. Its support for multiple communication protocols, including Ethernet, CAN, J1939, and RS485, allows it to connect with a wide variety of control systems currently available in the market, ensuring exceptional adaptability and functionality.
A crucial aspect of this upgrade is the direct compatibility with the Woodward 505 steam turbine speed controller. This synergy between the EasyGen 3200 and the Woodward 505 ensures smooth communication and seamless integration, thus optimizing the performance and reliability of JPPC operations.
The scope of our service included problem identification, engineering to define the scope of the solution, hardware supply, as well as carrying out all installation and commissioning activities on-site, in addition to updating drawings.
With this advancement, we reaffirm our commitment to innovation and operational excellence, offering technological solutions to the Latin American energy industry.
BRUSH MAINTENANCE AND SERVICES
BEGGING Brush
Brush has designed a robot that allows you to know the status of your generator without removing the rotor and in just 5 to 7 working days.
He makes El Cid, checks the tightness of the wedges while filming the entire interior with high-definition cameras.
Major maintenance 100,000 Hours Brush Generator BDAX7
Client: Ecopetrol - Colombia - 2022
A major maintenance equivalent to 100,000 hours of operation was carried out, as well as a review of the online partial discharge monitoring system in a BDAX7-290ER generator.
We collect electrical and mechanical operating values before shutting down the turbo generator to analyze the running trend and look for signs of abnormality before shutdown.
The disassembly of the unit was carried out, the removal of the rotor to carry out the internal inspection together with the electrical tests of insulation resistance, ohmic resistance, rotor videoscopy, EL CID and RSO test.
The rotor is cleaned and a heating system is installed to raise the external temperature of the forge so as not to lose the insulation resistance values, which must sustain 500V and have values in the order of MOhm.
Like the rotor, the exciter and PMG are cleaned and left ready for reassembly. The stator is also carefully cleaned to remove all possible traces of dirt, oil and other contamination on the core and winding heads.
With the stator ready, the wedge tightening, core imperfections, insulation resistance, and ohmic tests are performed.
Once these stages are completed, the machine is ready for reassembly, tests in maximum speed condition, no-load synchronization and finally tests at 3 load levels 25%, 50% and 100% of its nominal operating capacity.
The vibration and temperature levels in the core, bearings, lubrication system, coolant inlet and outlets, etc. are checked to confirm proper functioning.
The review of the online monitoring system, the configuration and download of data from the last commissioning to include the analysis of the PD values in the final report.
At this point the generator is operational and is left under observation for the next 24 hours to validate the absence of oil leaks, strange noises, overheating or other anomalies.
Rewinding of the DAX8 Generator rotor of the UTI6 Unit.
Client: In the Santa Rosa of ENEL- Peru - 2020.
We carried out the Rewinding of the DAX8 Generator rotor of the UTI6 Unit of the ENEL Santa Rosa plant, as well as the machining of the rotor shaft.
At the same time, a set of new custom bearings was supplied.
Ring Off inspection of the DAX8 Generator rotor of the UTI6 Unit of the ENEL Santa Rosa plant
Client: In Santa Rosa - Peru - 2019
We carried out the Ring Off inspection of the DAX8 Generator rotor of the UTI6 Unit of the ENEL Santa Rosa plant due to an emergency situation.
Genersol personal supply immediately according to the urgent need of our client.
Major maintenance of 5 BRUSH and IDEAL generators
Client: Repsol - Ecuador - Year 2017 - 2019
Repsol Ecuador has its own power generation plant in Block 16, made up of 3 Brush BDAX7 generators and 2 Ideal generators.
In 2017 we obtained the contract to do major maintenance of the 5 units. In addition to that we changed one AVR and did maintenance work on the other AVRs
In the different units you can see the state of the units as they are, after carrying out maintenance and cleaning, and after painting.
UNIT 1
UNIT 2
UNIT 3
UNIT 4
UNIT 5
Major maintenance of 2 Brush DBAX7 generators.
Client Proeléctrica - Mamonal Plant - Colombia
Proelectrica's Mamonal plant has 2 LM5,000 generation units with a Brush DBAX7 generator.
In 2018 we carried out the major maintenance of both generators.
The project included the temporary entry of tools and electrical test equipment, disassembly of the units, cleaning, electrical and mechanical tests, inspection of bearings and seals. Assembly of the generators, one of them with the replacement of the defective rotor, functional tests and final commissioning.
Due to the findings in one of the units, it was necessary to supply a new rotor that must have been manufactured urgently.
The necessary logistics were carried out to transport the rotor by air to Colombia.
Maintenance of 6 Brush generators
CELEC Client - Machala Ecuador Plant
The CELEC Machala plant has 6 TM2500 turbogroups with a Brush DBAX7 generator.
In 2018 we obtained the contract to carry out maintenance of 8,000, 50,000 and 100,000 hours (depending on the hours of each one) of the 6 Brush generators.
The project included the management of permits for personnel, the temporary admission of equipment and tools, as well as the execution of all the tasks pertinent to each maintenance.
Major maintenance Brush Generators DBAX9.
UTE Client - Plant CTR La Tablada - Uruguay
The UTE CTR – La Tablada plant has two Frame 9 turbines with a DBAX 9 Brush Generator.
In 2014, major maintenance was carried out on the generators of both units of 135 MW each.
The project included the disassembly of the units, the extraction of the rotors using large cranes. Cleaning of rotors and stators, electrical and mechanical tests such as wedge tightening, cid, polarization index, etc., assembly of the units, alignment, electrical reconnection, tests and commissioning.
Temporary admission permits for electrical tools and equipment were managed, as well as those of the engineers in charge of the project.
MAINTENANCE OF OTHER GENERATORS
Major maintenance of 16 MVA hydro generator with rotor extraction
Client / plant: COBEE S.A. Cahua Plant, Zongo Valley - La Paz, Bolivia - 2023
We have successfully completed the major maintenance of generator CAH02 with rotor extraction. During this maintenance, GENERSOL had to adapt and successfully resolve unforeseen difficulties such as the discovery that the insulation contained asbestos, which required the implementation of safety measures and work protocols in accordance with NIOSH 7400 and NIOSH 7402 standards, under which Genersol already has work experience, causing a maintenance period of 20 days to extend to more than 45 days.
During the execution of the work, among other activities, the following were carried out:
- Condition tests, pre and post electrical tests: Insulation and Polarization Index, DC Absorption, Power Factor, Tangent Delta, Capacitance, El CID, Wedge Tightening, Non-Linear Current, Partial Discharges, Vibrations, Ultrasound, Pole Voltage Drop Test, Inductance.
- Disassembly of all rotor poles and fans.
- Disassembly of the polar core coil.
- Cleaning of all pole and rotor core components.
- Replacement of insulation between coil and polar core.
- Manufacture and replacement of damaged wedges.
- Repairs with resin and dielectric varnish.
- Verification of pole weights to avoid balancing problems.
- Improvement and replacement of insulation for slip ring pins.
- Grinding of collector rings in the field.
For the execution of the work, Genersol supplied specialized materials to ensure a complete and meticulous maintenance, including everything from wedges and gaskets to conductive varnishes and two-component resins, and all necessary insulating materials.
This achievement highlights not only our technical capability and experience in the field of energy engineering but also our unwavering commitment to quality and excellence in every project we undertake, as well as our ability to adapt and solve problems that arise in the field.
Rotor removal structures
Client: ENEL, San Isidro - Chile - Year 2022 - 2023
The design, manufacture and assembly of four anti-seismic structures with their respective cars was carried out to carry out the removal associated with the major maintenance of the rotors of the MITSUBISHI generators of the 305 MVA model 701 F gas units and the SRT 40.5 model steam units. AX of 163 MVA at the San Isidro plant. As well as the disassembly once the maintenance was completed.
Each structure has an average weight of 12 tons.
The mass of the rotors averaged 42 tons with an average length of 10 meters. The units required that the structure to be installed have a design that saved various interferences such as overhead cranes and other structures to maximize the efficiency of the works.
As it is a major maintenance, work was done under constant coordination with the client - ENEL - and the contractor in charge of maintenance - MITSUBISHI - to achieve the objectives set on time and in accordance with a precisely planned schedule. For this, weekly and daily planning and coordination meetings were held where all the works were adjusted, so that all the on-site tasks that were part of the critical path were executed as planned, without delays.
The importance of this work in the major maintenance of the units implied a strict quality control that ensured the success of the project. From the use of a standards-based design methodology, especially the AISC 360-16 code, to ensuring a supply of top quality materials, stress simulations, seismic deformation simulations, work procedures, quality inspections, reviews and excellent document management that allowed us to trace the entire project.
Siemens 70 MW generator
Client: Montes del Plata - Uruguay - 2022
We have made available 4 of our mechanics for 25 days to provide direct support to the Siemens supervisor in charge of the Overhaul of the 70 MW Siemens generator in Montes Del Plata (Uruguay) carried out in 2022
Specialized maintenance of 100,000 hours of generator group 03GTA (33,500 KVA) of CH Machupichu
Customer: MACHUPICCHU HYDROELECTRIC POWER - Peru -
We have carried out the specialized maintenance service of 100,000 hours of the 03GTA (33,500 KVA) generator set of CH Machupicchu in Peru in 2021.
It included:
- Disassembly of the rotor.Recoiling and changing the wedges of the stator coils.Determine the electrical and mechanical condition of the insulation of the generator stator winding and repair it.General cleaning, wedge slots, winding, terminations, heads and splices.Electrical tests of rotor and stator. Commissioning of the generation group.
TURBINES SERVICES
Design, Supply, and Commissioning of a Double Runner and Shaft for Francis Turbine.
Client: Empresa de Generación Eléctrica de Arequipa (EGASA) - Charcani IV Hydroelectric Power Plant - - Peru - 2021-2023
In 2021, EGASA issued a tender for its Charcani Hydroelectric Power Plant for the design, supply, and installation service of a Double Runner and Shaft for a Francis-brand Turbine.
As a result of this tender, a framework contract was established with GENERSOL, through which the entire delivery and installation was completed.
On this occasion, GENERSOL once again demonstrated its technical capability by working together with EGASA in defining each of the stages to be quoted, as they involved specific materials, size, series, among others.
We deeply thank Empresa de Generación Eléctrica de Arequipa (EGASA) - Charcani IV Hydroelectric Power Plant for trusting in our expertise. This milestone is possible due to the dedication and hard work of our team, which once again demonstrated its ability to meet the highest quality standards.
At Genersol, we consider each project an opportunity to strengthen long-term relationships. This successful collaboration reinforces our position as trusted suppliers and strengthens us as a strategic partner for the sustainable development of Latin America's energy infrastructure.
ASBESTOS REMOVAL
Removal of floors, gutters and cable trays with Asbestos content in Hydroelectric Power Plants
Client: Huinco and Moyopampa Hydroelectric Power Plants - Peru - 2019
In both plants we have carried out the removal of contaminated materials, encapsulating them and preparing them for final disposal.
The works were carried out in confined areas, so the measurement and control of oxygen was carried out throughout them.
Monitoring of asbestos particles was also carried out during the works and at the end of the same under the NIOSH 7400 and 7402 methods.
Work was also carried out with the necessary precautions for the removal of the cable trays in the tunnels, which, in addition to being a confined space, were very small.
All work was carried out in compliance with labor and environmental safety regulations.
Asbestos Removal in Hydroelectric Power Plant.
UTE Client - Gabriel Terra Plant - Uruguay
In 2016, in one of the units of the hydroelectric power plant, the motorization of the generator occurred and a failure in its control system caused the brake pads that contained asbestos to be activated permanently, causing the pad to disintegrate and asbestos particles will be distributed throughout the unit.
Our company, in conjunction with the firm Envirovac of Canada, carried out the decontamination of the unit, cleaning and removing the contaminated materials, complying with all environmental and labor safety regulations.
During the process, samples were taken that were analyzed in the on-site laboratory according to the NIOSH9002 standard.
EPC
Renewal of the fire protection system
Client / plant: EGEMSA Machupichu Hydroelectric Plant - Peru - 2023
The Machupicchu Hydroelectric Plant, located in Peru, carried out the renewal of its fire protection system in Phase I during the year 2023.
Genersol was responsible for carrying out this service by supplying the equipment, technical personnel, and consumables for the execution of this project, which has been crucial to ensuring the safety and protection of the generation facilities and equipment.
The plant has three Pelton-type vertical shaft generation units, each equipped with two fire protection systems: one for the generator and another for the power transformer.
Our previous experience in this field was one of the conditions for being chosen to carry out the design, supply, transportation, installation, assembly, testing, and commissioning of the new fire protection system. This system covered critical areas such as the machine room, cable gallery, and control room of the plant.
The renewal of the fire protection system in Phase I of the Machupicchu Hydroelectric Plant represents a significant milestone in strengthening the plant's safety. The project was executed within the budget and agreed-upon timeframe.
Genersol always demonstrates its commitment and dedication in the execution of projects of this magnitude, actively contributing to the operational improvement of our clients.
XLPE 230kV Power Cables of 800 & 2000 mm2 and Terminals - Supply and Installation
Client / Plant: Termo Caribe SAS ESP. - Colombia - 2023
Termocaribe built a simple cycle thermal generation plant with a Siemens SGT800 unit. As part of the project, they contracted Genersol for the supply and installation of
- Al 800 mm2 and Cu 2000 mm2 cables at 245 kV in existing trenches
- Pfisterer ESS245-C97 aerial terminals, CONNEX 6S
We connected the Power Transformer to the Hitachi GIS and hybrid substations. Once the work was completed, we carried out the underground laying of the cables and installed Pfisterer terminals.
Genersol conducted FAT tests on the materials prior to shipment, as well as inspection in warehouses prior to assembly. Genersol demonstrated its commitment to achieving objectives as the civil works experienced significant delays, in addition to serious problems in the construction of the ducts.
There were floods prior to the execution of the works which slowed down the overall project. Genersol had to add resources and spend more time in the field, managing to deliver the work on time.
Complete substation of 37.5 MVA in 220 kV
Client - EGESUR / Independencia Substation of REP-ISA- Years 2022 - 2023
Engineering, Supply, Installation, Operation and Maintenance of a 37.5 MVA 220 kV substation.
The project that included engineering, procurement of materials, supply and turnkey installation of a complete Substation of 37.5 MVA from 220kV to 60kV with a Power Transformer, connection cells to the 220 KV and 60 KV bars and others. control, protection, measurement and data transmission equipment.
We also had to obtain the environmental and operations permits related to the commissioning and operation of the Transformer
The work included the supply and assembly of:
- TSEA / Toshiba power transformerSwitch / disconnectors / circuit breakers / switches / voltage and current transformers in 220 kV - GESwitch / disconnectors / circuit breakers / switches / voltage and current transformers in 60 kV - GE Laying of power cables of more than 300 meters per phaseLaying of control cable of more than 300 metersProtection relays Battery bankCivil WorksAssembly of the transformer and complete bay in 220 and 60 kVProtection relays and their configuration and integration to the ScadaTests level 1, level 2 and level 3Coordination of the cut for connection with COESSWere carried out FAT and SAT tests of all equipment in the factory and on site.
Some of the major challenges of this project included:
- Carry out basic and detailed engineering during the pandemic without being able to have face-to-face meetings with the other actors involved. Import all supplies from various countries in Europe and Asia during the largest transportation crisis in history, having to move various equipment by air to meet the agreed deadlines.
170kV SF6 Insulated Hitachi / ABB Circuit Breaker
Client - Machupicchu Hydroelectric Power Plant - 2022
We carry out the engineering, supply and installation of a 170kV SF6-insulated tripolar switch.
Supply of 1 tripolar Hitachi / ABB Switch with tripolar and unipolar control, made up of three independent poles (live tank) insulated in SF6.
The project included detailed engineering, assembly, testing and commissioning.
Detail engineering:
- Civil part including anchoring of the structures to the existing bases, Electromechanical part, Electrical part that includes the use of control cables from the centralization box to the new switch boxes. Preparation of functional diagrams and preparation of connection tables.
Disassembly of switch and connections
Switch assembly, connection of control circuits on the board and connections in the Substation of the Machupicchu Hydroelectric Power Plant.
Controls and tests:
- Time tests in ms.Closing and Opening.Free trip.Operation sequence.Phase simultaneity.Closing and opening coil tests.Maximum operating current.Ohmic resistance.Minimum operating voltage. Contact resistance, insulation with 10 Kv., dynamic on opening. Displacement.Travel.Displacement speed.SF6 gas tests. Content of water vapor or Sulfur Dioxide (SO2). Among others.
Terminals and Splices in 170kV cables.
Customer: TEYMA – UTE - Uruguay - Year 2019 and
We supply and install 170kV terminals and splices for the connection to the GIS bay of the UTE Uruguay Substation, located in Punta del Este.
The scope included:
- Study, ampacity, hydraulic and overload calculations. Preparation of dimensional drawings of the junction chambers, layout plans of junctions, tanks, boards and other accessories of the chambers. Supply, factory tests, maritime transport and nationalization. Corresponding installation to HV Cable Splices, GIS Terminals and accessories such as tanks, key boards, pressure gauges, oil supply and connections.
Specialized labor, tools, equipment and necessary instruments were supplied.
All works were carried out under the supervision of an ABB technical supervisor specializing in GIS Substations.
Supply and installation of 2 Transformers of 20 MVA.
Client: UTE - Central Batlle - Uruguay
We have carried out the project in Turnkey condition, which included the supply and installation of 2 power transformers of 20 MVA from 31.5 to 6 kV with their corresponding civil works. The foundations and firewalls were built, as well as the fire-fighting system and the grounding mesh. The supply and laying of new medium voltage conductors was carried out, replacing the existing ones, respecting environmental regulations.
The project included detailed engineering, supplies, installation, commissioning, tests and final disposal of the conductors.
In the main components such as transformers and medium voltage cables, the design of the equipment, control of the production process and execution of the acceptance tests at the factory were carried out.
Our foreign trade department was in charge of the logistics, covering maritime freight to Uruguay and land freight to the plant with its consequent unloading on site.
CNC - Mechanized Center
Customer - ANCAP - Refinery plant La Teja - Uruguay
ANCAP for its La Teja refining plant acquired a double column machining center as well as its tools for the manufacture of heat exchanger plates in turnkey mode.
The engineering of the project was carried out as well as the civil and electromechanical works that included, among others, the foundations of the warehouse for its subsequent erection, the installation of an overhead crane, the CNC foundations with their subsequent positioning and installation, etc.
The commissioning of the same and training courses for Ancap personnel were carried out.
Supply and assembly of a 300 kW generator set
IPEN Client – Peru
The Peruvian Nuclear Energy Institute chose us to supply and install an emergency generator set for the 300 kW RP-10 reactor in a turnkey condition, with the corresponding adaptation of the room, power connection, air intake and exhaust, etc. .
