Victoria Sugar Mill - Cogeneration Expansion Project

5MW Steam Turbine Generator Upgrade

IN LATE 2010 ENERGY POWER CONSULTING ENGINEERS WAS ENGAGED BY SUCROGEN AUSTRALIA TO SUPPLY CONTROL EQUIPMENT TO FACILITATE THE EXPANSION OF A COGENERATION SCHEME AT VICTORIA SUGAR MILL AT INGHAM IN NORTH QUEENSLAND AUSTRALIA.

This new control equipment needed to integrate with existing Si-TEC Xtend control equipment installed on the 5MW and 3.6MW steam turbine generators and also an 11kV connection to the grid. The need to maintain the existing 11kV grid connection as a standby, while installing a new 11/66 kV grid connection as part of the cogeneration expansion added to the complexity of the design.

Further consideration was also needed due to the connection across a fault-limiting reactor between the existing 11kV switchboard and the new 11kV switchboard comprising the new 19MW Shin Nippon steam turbine generator that was supplied as the basis of the cogeneration expansion.

The design engineered by Energy Power Consulting Engineers included for grouping control that allowed for the STG’s to be controlled from multiple Si-TEC Xtend master controllers (generator system masters) depending on the status of the existing 11kV mill/ grid interconnector circuit breaker, the status of the new 11/66kV mill/grid interconnector circuit breaker circuit and the status of new bustie circuit breaker connecting the new 11kV switchboard to the existing 11kV switchboard.

The increase in generated MW’s and export to the grid required controlling reactive power in a voltage control mode during periods of high export power dispatch while implementing a power factor control mode during low levels of export power dispatch. In both modes, the reactive power control interfaced with the on-line tap changer on the new 11/66kV power transformer.

Although not directly involved in the 19MW STG supply, Energy Power Consulting Engineers also provided consultancy, design and engineering services with respect to the governing and excitation systems for this new machine.

The design, engineering and commissioning services for the Victoria Mill cogeneration expansion project included:

• Detailed Arrangement and Layout Drawings

• Detailed Schematics

• PLC I/O Drawings

• Cable and Termination Schedules

• Control System Functional Description

• Commissioning of master Powerhouse controllers

• Commissioning of 19MW Steam Turbine Generator

• Factory acceptance testing in India for the AVR system

The Cogeneration expansion project was successfully completed and commissioned in August 2011 and Energy Power Consulting Engineers would like to acknowledge Sucrogen Australia for their assistance during the project.