How does Grupel build up the special projects?

special projects

How does Grupel build up the special projects?

The special projects have a way of production and assembling lines that are very distinct from the standard because, in this case, there is nothing standard about it, these genset groups are customized and created according to the customer requirements.

The stages of special projects go through the design ability, development, production, installation and commissioning of projects.

When we receive the directions for a new special project, the first step is to know all the technical and special specifications that the client needs to implement the project, so that when the project is inserted in the production plan, it already has been studied and designed by the engineering department, and at that point, we can start to produce the project following these guidelines.

The first phase of our special projects team is the metal mechanic, in which we prepare the container or canopy with the necessary cuts so that it can move to the next stage, the painting.  After this finishing touch, we move on to the next phase, the soundproof with fiberglass wool, in which the container is coated, including the walls of the cabinets, and then we place a panel to cover this fiber.

When this preparation stage is over, we can initiate the genset group assembly, that usually it is the engine, alternator, and radiator, but it can have other components like transformer, switchboard, fire protection system, among others. Once we finish this process, the electricity team steps in and places the switchboards and other necessary systems.

In a final phase, we proceed to the installation of the exhaust system and to the genset test, in which the groups are tested to the limit as if they were on site, performing the stipulated functioning. After the tests with the group approved, we must disassemble the exhaust so that the container can be easily transported, and well packed for it to arrive in perfect conditions to install in the project location.

Throughout the entire procedure of a special project production, the only stage that I highlight as one of the most complicated, is when the project has a compacted container, as it happens in the container of 6m (20ft), where we don’t have space to assembly engines, and that’s one example of a compact project.

One mandatory step in the production of special projects is to work together with the engineering department and others that created the production process, among other requirements or important specifications of the project, to ensure that everything goes well until the tests of the group, and that the customer turns out very satisfied with our product and with its functioning.

In relation to some specifications, I’d like to point out the illumination that exists in the interior of the container in every special project, that is very important, especially when they are compact and is necessary to perform any intervention by the customer or technicians, and this way the visibility and accessibility become easier. Other point is the cooling system, that in this case is the additional component, the ventilators, that differentiate in every project, because some of them can be to extract the hot air from the genset cabinet, other where their function is just to cooling-liquid of the radiator, and another that refrigerates the genset and the air. Another point is the reinforcement that we do in the containers because of its weight and size of the groups, and for that, we add shims on the container base and columns in the walls so that it can support the weight and not damage, especially in the transporting loading process.

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.

Renato Simões
Team Chief
Special Groups Sector

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