CONTROLS & SWITCHGEAR FOR A LARGE LANDFILL

Enercon Engineering custom designed and built controls & switchgear for the Waste Management Saluda, Va. landfill which uses eight Caterpillar G3515 engines powered by methane gas from decomposing waste to operate generators that produce electric power which is sold to the local utility company, Dominion Transmission Power Co.

Waste Management uses air/fuel ratio controllers and programming to allow operation within the variable threshold of landfill gases, as the naturally formed methane fuel content varies.

SPECIFICATIONS

ENGINES

  • Eight Caterpillar G3516
  • 1,148 HP @ 1,200 rpm

GENERATORS

  • 820 kW
  • 4,160 volts, 142 amps
  • 60 hertz, 3 phase
  • 6,520 kW total power

SWITCHGEAR

  • 4.16kV
  • Utility tie breaker (52-T)
  • NEMA 1 for indoor use
  • 95″ high, 85″ deep, 396″ long

EMERGENCY STANDBY POWER FOR MICHIGAN TECH UNIVERSITY

With thousands of students attending classes, working in labs, and living on campus, the need for reliable emergency power is critically important at Michigan Tech University.

To meet this need, Enercon Engineering custom designed a control system & switchgear for four large diesel powered generators. Built around Enercon’s unique Evolution touch screen control system, this medium voltage switchgear controls 9 megawatts of emergency standby power for the entire university.

The switchgear consists of four generator cubicles, one master cubicle and one remote panel to interface with existing switchgear, rated NEMA 1 for indoor use.

The university was able to reduce its energy bill demand costs by reaching a standby agreement with the local utility company.

SPECIFICATIONS

ENGINES

  • Four 2.250 kW engines
  • Diesel powered

GENERATORS

  • 9 MW total power
  • 12,470 total volts

CONTROLS & SWITCHGEAR

  • NEMA 1 Automatic Paralleling Medium Voltage Switchgear
  • 3 phase, 3 wire 1,200 amp main bus
  • Enercon Evolution Touch Screen Controls
  • SCADA Monitoring system
  • Power metering includes 3 phase AC amps, phase to phase AC voltage, frequency, kilowatts (3 phase), power factor, kVARS (3 phase), kilowatt hours (3 phase accum.), kilovar hours (3 phase accum.)

INDUSTRIAL PANELS UL508A CONTROL PANELS

Enercon Engineering designs and builds custom UL508A certified Industrial Control Panels providing integrated solutions for your specific application.

All of our designs incorporate the latest protection and control technologies, advanced connectivity and diagnostics, with world-class industrial software for PLC HMI and SCADA. This allows us to incorporate the absolute highest quality components that are on the market into our Power Control systems.

OUR DESIGN CONCEPTS INCLUDE:

  • Build to Spec or Custom Design
  • Back Plate Design & Layout
  • PLC Programming with Remote Capabilities
  • Customer’s Choice of Equipment
  • Private Labels
  • Custom Paint
  • Full In-House Testing Capabilities
  • Includes Standard 2 Year Warranty

LOW VOLTAGE SWITCHGEAR & CONTROLS

2-section power envelope, UL 1558 Low Voltage Generator switchgear and Controls are housed in a 5-section lineup. There are the two Generator sections, a double door Master section, and a PC/HMI section.

SPECIFICATIONS

  • Woodward EasyGen controllers with color touch displays, per Generator
  • Woodward LS door mount breaker control units
  • Allen-Bradley ControlLogix Redundant PLC arrangement with Device Level Ring Ethernet topology
  • System Main I/O rack and (2) Generator section drop I/O racks
  • 19” viewable color TFT HMI/display System PC with component software and Microsoft Office H&B loaded
  • Front of panel red mimic bus

POWER UPGRADE UTILITY SUBSTATION

Control components removed from the existing switchgear & modified.

SPECIFICATIONS

  • Switchgear and engine controls upgrade in (2) existing power modules leaving the existing switchgear breakers and power envelope
  • Testing and recertification of existing breakers
  • New master control panel and master PLC with integrated SCADA communications – Modbus TCP/IP
  • Manual and Automatic Utility paralleling with Baseload, Import/Export and Standby Island Mode
  • Utility grade protective relaying and generator protection
  • Generator metering, alarm history and trending
  • Factory acceptance testing prior to site installation

PARALLELING SWITCHGEAR

480V switchgear is for indoor service and includes circuit breakers and controls for three (3) combined heat & power (CHP) generator sets, two (2) utility services, two (2) feeders, and two (2) bus ties. All breakers are draw-out design and rated for 65kAIC.

To meet space requirements, some of the breakers are stacked. The engine and synchronizing controls are remote at the generator sets. The system controls allow for standby operation as well as utility paralleling modes.

UL 891 SWITCHBOARD

  • NEMA1 rated switchgear, 79″H X 144″W X 48’D.
  • Modular sections include gasketed doors with lockable handles
  • Painted RAL7035 light gray
  • 2000 ampere main bus braced for 65kA
  • Ground bus

Download PDF Paralleling Switchgear PDF [Size 505 KB]        Back To Top


WASTE WATER TREATMENT CONTROLS & SWITCHGEAR

This Waste Water project was part of a $169M investment by New Water to construct new biosolids treatment facilities within the Green Bay Waste Water Treatment Facility in Wisconsin. The facility, which was built in the 1970’s treats domestic waste in addition to paper mill waste.

The new biosolids treatment facilities included New digestion, reciprocating engine electrical power generation, dewatering and incineration processes, and implementation of nutrient removal and recovery processes.

Enercon’s scope of supply for this project was providing the Switchgear and controls for the New Cogeneration and Emergency Standby Plant which included (2) dual fuel blended digester and natural gas generator sets and (2) diesel standby generators.

ENERCON CUSTOM CONTROLS OPERATE:

  • (2) CG170-20 anaerobic digestion Caterpillar Engines that are employing the Tem Evo Control.
  • Fuel blending between Natural and Bio Gas in 3 modes of operation with multiple utility feeds, including black start operation.
  • Control of heat recovery valves: Jacket Water, exhaust, and after cooler
  • (2) G3516C diesel Caterpillar Engines for both grid relief to the local utility and emergency backup power. The diesels and the gas generators are completely integrated.

ENERCON CUSTOM CONTROLS OPERATE:

  • (2) CG170-20 anaerobic digestion Caterpillar Engines that are employing the Tem Evo Control.
  • Fuel blending between Natural and Bio Gas in 3 modes of operation with multiple utility feeds, including black start operation.
  • Control of heat recovery valves: Jacket Water, exhaust, and after cooler
  • (2) G3516C diesel Caterpillar Engines for both grid relief to the local utility and emergency backup power. The diesels and the gas generators are completely integrated.

Power upgrade of diesel generator enercon switchgear and controls originally Commissioned in 2009.

  • Woodward EasyGen controllers with CAN-to-fiber communication link to controllers in digester building
  • Updated engine controls for the (2) existing Caterpillar 3516C with unit mount EMCP 3.3 controllers
  • Schweitzer SEL-700G protective relays with PT/CT test blocks
  • Allen-Bradley 1756 ControlLogix PLC racks with EN2TR modules connected to plant Ethernet ring
  • Protocol converter/Gateway device for mapping all updated metering and alarm data
  • Integration of new start/stop logic as part of updated plant Sequence of Operations
  • Control and status upgraded and available to overall plant SCADA scheme

15KV ARC FLASH RATED SWITCHGEAR LINEUP

  • Provided power envelope for the Main-Tie-Generator-Bus Tie-Generator-Bus Tie-Main configuration
  • Siemens/Enercon joint design venture to provide Arc flash exhaust plenum routing to building exterior
  • Mains and Generator protection used Schweitzer Engineering Laboratories (SEL) protective relays
  • Mains and Generator sources provided with Allen-Bradley PM 5000 digital multi-function metering Package

The main cogeneration control panel utilizes an Allen-Bradley Plant Automation Controller and includes control logic for monitoring and controlling the new cogeneration units, providing the blending algorithm for the digester and natural gas sources and heat recovery of new cogeneration units to supplement the plant heating system.

The control panels for the biogas generators utilize Woodward Easygen controllers and are configured to interface with the Caterpillar TEMEvo engine controllers for total engine control.

  • Allen-Bradley ControlLogix Plant Automation Controller platform programmed within PlantPAx including door mount Industrial PC
  • Complex PLC rack configuration to accommodate plant P&ID structure with Ethernet ring connected network
  • Control logic included provided blending algorithm of the digester and natural gas sources and Cogeneration heat recovery to supplement plant heating system
  • Mains, Ties, and Bus Ties included with Woodward LS-5 circuit breaker controllers integrated to simplify all control modes of operation
  • Protocol converter/gateway devices utilized to gather all automation data and communicate with plant SCADA network over fiber link
  • CAN-to-fiber converters provided for interconnection between biogas generator building controllers and diesel generator building controllers

INDIVIDUAL COGENERATION PANELS FOR THE (2) CATERPILLAR CG170 BIOGAS GENERATORS

  • Design interface to the Caterpillar TEM-Evo unit controls for total engine control alongside unit Woodward EasyGen controllers
  • Mounting/wiring of PLC drop I/O for serial connection to wall mount CPU unit
  • CAN-to-fiber converters for EasyGen communication to Master Control LS-5 network

This project once again demonstrated Enercon’s expertise in the domain of on-site power generation and capability as a system integrator to deliver a fully integrated, customized solution for a complex cogeneration system.

Download PDF Waste Water Treatment Controls and Switchgear PDF [Size 1.93 MB]        Back To Top


UL508A COGEN CONTROLS WATER & SEWER FACILITY

UL508A COGEN CONTROL PANEL

Water and Sewer Cogen Facility Control panel lineup consisting of 10 bayed cubicles of Rittal TS8 NEMA 12 modular cabinets, overall dimensions of complete lineup approximately 87″H x 207″W x 24″D. Each cabinet has a full length single door with locking handle and painted ANSI 61 light gray.

GENERATOR CONTROL PANEL SECTIONS (QUANTITY 6) TYPICAL:

  • Woodward 2301E governor
  • Woodward DSLC-2 Synchronizing and Load controller
  • Varmeter 4.5″ analog
  • Watt Meter 4.5″ analog
  • Voltmeter 4.5″ analog
  • Voltmeter switchboard type selector switch, 4-position
  • Ammeter 4.5″ analog
  • Ammeter switchboard type selector switch, 4-position
  • Auto/Manual selector switch, switchboard type, 2-position maintained
  • Circuit breaker control, switchboard type switch, OPEN/CLOSE positions
  • Generator load control switch, switchboard type, pistol grip, 3-position spring return to center from left and right
  • 86 lockout relay, 24VDC coil, with orange tripped target indicator
  • 30mm NEMA 4X circuit breaker position indicator lights, push to test, open(green), closed(red), tripped(amber)
  • 30mm NEMA 4X circuit breaker cell position indicator light, push to test, withdrawn(white)
  • Synchronizing Switch with Removable Handle
  • Voltage Raise/Lower control switch, switchboard type, 3-position spring return to center from left and right
  • 30mm NEMA 4X generator start pushbutton, black flush head operator
  • Fault Reset pushbutton, black flush head operator

MAIN AND TIE CONTROL PANEL SECTIONS (QUANTITY 2) TYPICAL:

  • Solid state digital multi-function metering device which includes:
    • LCD Display
    • Ethernet port configured for Modbus TCP/IP
    • RS-485 Modbus RTU serial port
    • Transducer option, four isolated 4-20mA DC analog outputs
    • Four programmable relay outputs
    • Power analysis, harmonics option
    • 8MB of non-volatile memory for storage of waveform, event, and log files
    • Compatible with existing Siemens WinPM.net software
  • Auto/Manual selector switch, switchboard type, 2-position maintained
  • Circuit breaker control, switchboard type switch (quantity 3), OPEN/CLOSE positions
  • 86 lockout relay (quantity 2), 24VDC coil, with orange tripped target indicator
  • 30mm NEMA 4X circuit breaker position indicator lights (quantity 2 sets), push to test, open(green), closed(red), tripped(amber)
  • 30mm NEMA 4X circuit breaker cell position indicator light (quantity 2), push to test, withdrawn(white)
  • Synchronizing Switch with Removable Handle (2- for main circuit breakers and 2- for tie circuit breakers)

SWING PANEL (SHIPPED LOOSE FOR SITE MOUNTING TO TOP OF CONTROL LINE-UP)

Dual swing synchronizing display panel to include the following:
  • Incoming Voltmeter
  • Incoming Frequency Meter
  • Running Voltmeter
  • Running Frequency Meter
  • 4.5″ Synchroscope 120V Analog
  • (2) Synchronizing Indicating Lights
  • Synchronizing Switch w/Removable Handle

ADDITIONAL EQUIPMENT FOR INSTALLATION OUTSIDE OF CO-GEN CONTROL PANEL:

17″ HMI touchscreen mimic panel to be mounted in the existing control panel in the Operator Room. Include all the functions of the Co-Gen Control panel touchscreens. 201 ALTORFER

Download PDF UL508A Cogen Controls Water and Sewer Facility PDF [Size 642 KB]        Back To Top


CONTROL PANELS FOR 1500kW 480V CATERPILLAR GENERATOR SET

GENERATOR CONTROL PANEL:

Woodward EasyGen genset control module with door mounted touch screen display:

  • Generator set status display.
  • Generator set metering and status:
    • Voltage, phase to phase and phase to neutral.
    • Frequency.
    • Amperage in each phase.
    • kW.
    • kVAR.
    • Synchroscope.
    • Bus voltage and frequency.
    • Alarm and shutdown annunciation.
  • Governor biasing for kW control
  • Voltage regulator biasing for kVAR control.
  • Communications Gateway interface to master PLC.

MASTER CONTROL PANEL:

  • Woodward LS5 synchronizing and control module for each main plus tie breakers.
  • Utility and bus Voltage and Frequency display.
  • CANBUS communications between all LS5s and generator EasyGen control module.
  • Allen Bradley Control Logix PLC Platform
  • Master 12” Color Touch Screen includes the following screens:
  • Overall Electrical Oneline with breaker status
  • Generator Status screens
  • System Control Parameters with three levels of password access
  • System Transition selection (Open/Closed Transition)
  • System Timers
  • System Alarms and Warnings screen

The project includes separate control panels for one 1500kW 480 volt Caterpillar generator set and a master control for the customer’s main-tie-main” utility switchgear. Both control panels utilize Woodward generator and utility synchronizing/loading controls.

Download PDF Control Panels for 1500kW 480V Caterpillar Generator Set PDF [Size 293 KB]        Back To Top

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