he Italian manufacturer COELMO is well-known worldwide for producing rugged and highly-reliable generating sets designed and produced for professional applications covering a range from 3 to 4,000 kVA. These robust reliable gensets can be personalised and provided with accessories which allow them to be adapt to a variety of different industry sectors, making them an ideal choice for demanding users.
COELMO was recently involved in the design, supply, installation and commissioning of one 2,000 kVA generating set (model BTD16M33) and three other 1,400 kVA Coelmo generating sets (model BTD12M33) in ESP, 50Hz, 400 V, 1500 rpm. These have been supplied to an important hydrocracking complex located in Assiut, Egypt.
These COELMO gensets are equipped with:
- Baudouin engine 16M33G2000/5 - 12M33G1400/5
- Mecc Alte alternator ECO46 VL4 - ECO46 1L4
- 40 ft container, 85 dB(A) 1 m
- Parallel control panel with remote start (Comap)
- Motorised circuit breaker
- Fire detection and CO2 extinguishing system
- 1,000-litre fuel tank with leakage collection tank
The ECO46 VL4 has many product features designed into the alternator. Self-regulation is obtained through a digital electronic regulator that is fed by an auxiliary winding. The manufacturer, Mecc Alte guarantees an almost constant supply from the generator – under any possible operating condition. In the design a rotating inductor is fitted with a damper cage.
The windings have a 2/3 pitch in order to reduce the harmonic content of voltage. The entire series is manufactured according to, and complies with, the most common specifications such as CEI 2-3, IEC 34-1, EN 60034-1, VDE 0530, BS 4999-5000, CAN/ CSA-C22.2 No14-95- No100-95.
The ECO46 1L4 alternator fitted to the other gensets is also from the ECO46 range - which has many special product features designed into the alternator. Self-regulation is obtained through a digital electronic regulator which is fed by an auxiliary winding. The manufacturer guarantees an almost constant supply from the generator – under any possible operating condition. A rotating inductor is fitted with a damper cage. The windings have a 2/3 pitch in order to reduce the harmonic content of voltage. The entire series is manufactured according to, and complies with, the most common specifications such as CEI 2-3, IEC 34-1, EN 60034-1, VDE 0530, BS 4999-5000, CAN/ CSA-C22.2 No14-95- No100-95.
Looking at the engines
The Baudouin PowerKit 16M33G2000/5 ESP/PRP/DCP/COP Diesel Engine Engine and block features a cast iron cylinder block with inspection door per cylinder, cast iron cylinder liners, wet type and replaceable valves guides and seats. There are separate cast iron cylinder heads with 4 valves. The engine has hardened steel forged crankshaft with induction-hardened journals, crank pins and radius, plus lube oil-cooled light alloy pistons with high-performance piston rings
The cooling systems has radiator and hoses supplied separately and two separate circuits: the high temperature circuit equipped with thermostatically-controlled system with two gear driven coolant pumps, while the low temperature circuit equipped with belt-driven coolant pump.
An advanced lubrication system features full flow screw able oil filters, lube oil purifier with replaceable cartridge and a water-cooled lube oil cooler.
The fuel system incorporates a high-pressure common rail system with one high pressure pump gear driven in the V angle of cylinder block, plus two rails mounted on the sides of the engine, double wall, under inlet manifold. There is a Duplex fine filter and water separation filter assembly with transparent cup for better efficiency and an electric fuel priming pump integrated in the filter support.
The air intake and exhaust system has been designed with two compressors are feeding a single water-air intercooler, mounted over the flywheel housing, with vertical flow. There is a special rear mounted air filter with restriction indicator and an exhaust manifold and turbocharger shield for heat isolating. The electrical system has 2 x 24V DC electric starter motors and n° 1 battery charging alternator. Low oil pressure & high water temperature sensors have also been provided. Lastly, the engine has an SAE 0 flywheel housing and 18” flywheel.
The Baudouin 12M33G1400/5 engine is a mid-sized engine from the 12M33 range. The engines aspiration comes from its turbocharger and air to air after cooler. The 12-cylinder engine is set up to run at 50 Hz and rotates counter-clockwise. The fuel injection system uses an inline fuel injection pump with an electronic governor. This diesel engine is produced in China and France.
The 12M33G1400/5 engine produces 1622.6 horsepower (1210 kWm) when running at 1500 RPM and has a total displacement of 39.2-litres. The engine can be used in a diesel generator at either Prime (PRP) or Standby (ESP) power ratings.
The Baudouin 12M33G1400/5 fuel consumption depends on its load. At 1500 rpm prime power it is has the following fuel consumption (percent of prime power):
At 50% it uses 108.9 litres/hr. At 75% it uses 160.3 litres/hr. At 100% it uses 217.6 litres/hr. At Emergency Standby Power it uses 242.9 litres/hr. The dimensions of this Baudouin Diesel Engine are 3511mm in length, 2192mm in width and 2246mm in height and a (dry) weight of 4395kg (all measurements including the radiator). The cylinders of the engine have a bore of 150mm and stroke of 185mm.
This powerful engine can be coupled with an alternator to create a powerful diesel generator which can be used for power generation in multiple industries and sectors. Syncing the generator with other generators would provide extra power production and increased reliability of power.
Today, COELMO® Generating Sets cover a range from 3 to 4000 kVA and thanks to the possibility of customization they are the best choice for both commercial and industrial applications that allow them to adapt to a variety of industrial and business sectors.
The Assiut oil refinery is located on a 1,037acre-site, approximately 400km south of Cairo, Assiut, Upper Egypt. The Assiut hydrocracking complex (AHC) is a US$2.5-billion hydrocracking complex designed to process 2.5 million tonnes/year of heavy fuel oil (mazut) from ASORC’s nearby 4.5 million-tpy Assiut refinery to produce about 2.8 million tpy of Euro 5-quality diesel and other high-value products. It will be powered through a new 3x75MVA, 220/11/6.6kV substation provided by GE.
The hydrocracking complex design features new process units including vacuum distillation unit (VDU), diesel hydrocracking unit, delayed coking unit, distillate hydrotreating unit (DHU), hydrogen production facility unit, sulphur recovery unit (SRU), and sulphur solidification unit (SSU). This key project is intended to reduce emissions as well as the country’s current reliance on and associated costs for foreign product imports.
A spokesman for COELMO commented: "We are proud to have our high-quality gensets associated with the Assiut hydrocracking complex, part of Egypt's key national energy development programme, and look forward to supporting its power needs for many years to come."