How does Grupel build up the special projects?Carlos Martins
The production process of Grupel’s special projects is very different from that of a standard generator, in design, development, manufacture, installation and commissioning, because they are created according to the customer's needs and requirements.
But, what does it actually take to get a Special Project done?
When a new special project arrives at the production line, it has already been studied and designed by the engineering department that takes into account the technical and special specifications set by the customer. Then, we started production following the guidelines from the department.
In the first stage, we prepare the container or canopy with the necessary cuts, and then move on to its painting. After painting, we start to soundproof the container with an acoustic sandwich panel, consisting of rock wool.
When the preparation of the container is finished, we start the assembly of the group. That is, the coupling of the engine and the alternator, and the placement of the radiator. In some cases, other components are added, such as the transformer, control panel, anti-fire system, among others.
Then, the electricity team comes to action and assembles the necessary electrical panels and systems.
The last phase includes the assembly of the exhaust system and the testing of our products. The groups are tested as if they were in place, to fulfill the function for which they were designed.
After the projects successfully approve these tests, the exhaust is dismantled so that the container can be easily transported and gets to its destination in perfect condition to be installed.
It is important to guarantee that the interior of the containers is well lit so that, at times when some intervention by the customer or technicians is required, it is easier to access the equipment inside the container.
It is also essential that the projects are at an adequate temperature. Additional cooling systems and fans depend on each project. Some are used to extract hot air from the compartment where the generator is located, and others are used only to freshen the radiator coolant up.
The reinforcement of the container is also worth a mention. We place chocks at the base of the container and columns on the walls, so that it can support the weight of heavy generators, especially in the process of loading for transportation.
The process of making a special project is not easy. More so when the equipment has to be assembled in compact containers, in which there is not much space, such as those of 6m (20ft). But everything is done in partnership with the departments that studied and defined the production process, to ensure that all specifications are met and, in the end, everything goes well, leading to the satisfaction of our customers.
Special Projects Sector
Get to know one of Grupel's Special Projects
Production of a project of 18 MW to Angola
Recently, we had a large production of special projects to Angola, that we are still producing, but in a final phase, in which the process wasn’t easy to manage because it takes its time to build up a special project, but with a motivated team everything becomes possible.
This 18MW project consists of a production of 11 groups for continuous functioning, all with the same requirements, what made the production and the process much easier.
Relatively to the project characteristics, the containers are divided into 3 cabinets, one for the transformer, another for the switchboard and other for the genset group. In the case of other projects, it can have a cabinet with fuel tanks, other with fire protection systems that demand another cabinet for the CO2 tanks.
The fact that this project has a transformer, it isn’t a usual request in the special projects, however, in this case, it was necessary due to the medium tension genset.
Also, I underline the fact that in this project there are 2 ventilators to extract heat, one in the genset cabinet and another in the transformer cabinet, but they only operate when they reach a determined temperature that is defined by the Grupel engineering department.
Regarding to the components, the chosen engines for the customer were MTU, not only because they are reliable engines, since they are going to operate 24/24h, but also because of the operation cost, since the MTU engines have an optimized and economical fuel consumption relation, which means that is possible to reach a point where the initial value in the acquisition of the engine is overcome by the saved value in fuel.
This special project was without a doubt a challenge, and soon it will be a developed project that we can add to our historic, however we still have some containers to end and to deliver to our customer, proceed to the respective installation and commissioning, that we hope it might be soon and that meet the needs and expectations of our client.