| Country: | Brazil |
| Industry Sector: | Oil/Gas/Power |
| Product(s): | 576 x P675P5 |
| Application: | Standby |
Aruanã Energia, SA, one of our sub-Dealers in Brazil, installed and commissioned an impressive 576 x P675P5 generator sets over a nine month period to a site in the town of Igarassu, Pernambuco.
When combined these generator sets have the capacity to supply a total output of 236 MW of standby power to the national grid in Brazil. The power plant is expected to operate between 1000 – 2000 hours every year during times of peak demand and to provide additional power during the winter months. Our sub-Dealer, Aruanã Energia, SA, successfully won the contract in June 2006 to supply two power plants, Pau Ferro (94 MW) and Termomanaus (142 MW), which were later merged on to the same site. As part of this contract Aruana Energia, SA, have been appointed to supply power via this installation for the next 15 years.
Aruanã Energia, SA, were contracted to supply and install the following:
- 576 x P675P5 (baseload rated at450 kW, 60 Hz, 440v)
- EasYgen 3200 sync panels
- Industrial silencers
- Battery chargers
- Motorized circuit breakers
- Fuel transfer solenoids
The FG Wilson manufacturing facility in Brazil had to meet these substantial manufacturing requirements within a tight timeframe whilst already operating close to maximum production capacity. All the generator sets were ordered, built and delivered onsite and to schedule, within a seven month period, by 11th December 2008.
In addition to the huge number of generator sets and peripheral equipment, the actual installation of the units also posed a number of challenges. For example, roads leading to the site ran through sugar field plantations, which were impassable during certain times of the rainy season. This presented a major hurdle when managing the logistics of receiving and offloading the hundreds of generator sets, transformers, cable and other site materials during the nine month construction period. As only two generator sets could be transported by truck at any one time, it took over 250 delivery runs for the appointed transport company, who covered a staggering 1.3 million km in carrying out this mammoth task.
The Pau Ferro and Termomanaus Power Plants were designed to be the most cost effective solution for standby/peak shaving applications for the Brazilian power market. These costs savings are gained through the innovative use of highly efficient diesel engines as the main source of power.
Traditionally, larger more expensive industrial, locomotive or ship engines would be used in Brazil for standby/peak shaving applications. This unique design was the most cost-effective solution available and was based on a 15% annual plant utilisation factor. Some of its most impressive features include very low acquisition and installation costs, optimised fuel economy at all dispatch levels and low operations and maintenance costs. The generator sets operate at 440v and step up to 34.5 kV transformers, which again step up to the 230 kV transmission grid line. A single plant operator remotely controls each plant, via a stateof- the-art SCADA system which was developed specifically for this project by our Dealer Aruanã and
FG Wilson Power Solutions Team. This advanced control system dispatches and regulates power from the generator sets as required, allowing the operator to simply input the necessary plant output. This provides tremendous savings in operating and maintenance costs over the lifetime of the power plant. Aruanã Energia, SA, hope to market this type of plant for smaller distributed power stations in the range of 50 MW, with a focus on isolated power systems in developing countries and remote industrial operations such as mining sites.
Aruanã Energia, SA, are an FG Wilson sub-Dealer and independent power producer that has been active in the Brazilian power market since 2002. They have participated in projects that have supplied over 650 MW of power in Brazil.
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