Energy Efficiency

Installation of electric power system for increased energy efficiency in industry

Installation of a cogeneration plant with the use of steam from the catalytic cracking process in tubular reactor to increase the energy efficiency of the industrial unit. Have been installed new demineralization units for water treatment in the inlet pipes of the boilers that are in the Utilities Central. Boilers steam turbogenerators trigger that distributes power to three substations connected to the auxiliary input substation with 4 transformers of 25MVA-138kV / 13.8kV and controlled by EPMS for disposal loads at a time that there is peak demand. Substations are supervised by the IEC 61850 network inside the control room located in the central building of utilities.
It was necessary to replacement of the control and protection of turbines and generators exchange and adequacy of synchronization systems and the replacement and refurbishment of field instrumentation to implement the new system. The contingency analysis algorithm analyzed the consumption of critical loads in the electrical system enabling the load shedding system test. The system has 88 hours under test with the total demand of the plant operation sharing all electrical loads. Several operations were made with medium voltage circuit breakers in substations through the supervisory system in the Operation Control Center. Electromechanical assembly in axial condensers were used to reduce losses at the entrance of the turbines and increase energy efficiency of the cogeneration unit.

Technical Summary

Design, planning, installation and system commissioning for a cogeneration plan with 4 turbo generators to 18 MW of power steam each (110t /h – 95 bar and 460 °C), demineralisation unit for water treatment, 3 medium voltage substations 12MVA each process piping with automated valves government, blocking and retention, automation system with discharge of loads, network IEC 61850 for 178 relay integrated protection EPMS, 1500 meters metal frame for piperack connecting the Boilermaking Utilities Central with production area, 2,530 I / O instrumentation analog control and digital, utility station with two centrifugal turbocompressor full gearing 47000 m3 / h 3500 kW- 8 stages, 4, 80 m3 compensation tanks, air refrigeration dryer, the system pumps industrial water for laser welding cooling, exhaust with integrated electrostatic filters, Digital Control System for all plant.